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Exam Number : 2D00056A
Exam Name : APSS Avaya Networking OnlineTest
Vendor Name : Avaya
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The Case of the HIPOT verify failures | 2D00056A genuine Questions and exam Questions
I as soon as designed a product for Avaya, a 1U x 19" rack with an open-framed OEM potheyr supply. Yields had been first rate originally. Later, HIPOT (excessive-abilities) trying out begun to fail on random gadgets at a 10 p.c expense, which become an awful lot bigger than I expected, in view that the organization proven earlier than shipping.
The product supplied energy for Avaya's VOIP telephones in a distribution box with 10 watts for each and every gadget inline on RJ45 ports which ran at T1 or 1.544Mbps rates. i was head of design at C-MAC in Winnipeg basically 10 years in the past. i used to be chargeable for examine technique and fault isolation.
I selected two suppliers for the 180W 1U open-frame vigtheir provide contraptions (PSUs). They had a contract to supply Avaya with 10,000 units within the first yr. Then the PSUs all started failing in HIPOT checking out. After many emails and phone calls to the organisation, it refused to consider its product may have the sort of high failure cost. I discovered it had lately transferred the construction from California to Mexico. I all started to investigate the root explanation for the failures.
not most effective did the 1.5kV DC HIPOT test fail, but many instruments grew to be nonfunctional after the look at various. Some passed at the start, then failed later in purposeful testing. To figure out what might trigger such failures, I decided to existing restrict the HIPOT tester with a high-voltage collection resistor. hotheyver it turned into designed for a 2mA existing restrict, the capacitance in the tester became satisfactory to create excessive-existing impulse if low-impedance arcing befell. always, it gives a sluggish-rising output to 1.5kV for one second and then shuts off.
That averted PSU disasters from catastrophic failure of arc discharge, but 1.5 mA overcurrent nonetheless took place on 10 percent of the instruments.
Then I examined the root explanation for the failures and found negative procedure strategies in assembly with arcing. I highlighted all the areas of the PSU the place insulation gaps had to boost and inadequate silicone or PU material had been applied.
The frequent manager of the company presenting the PSUs did not accept as true with his design crew in California and his construction crew in Mexico couldn't become aware of the same problems of their facilities. The provider blamed us for breaking the product. I couldn't consider it both, so i used to be determined to work out why there turned into such an enormous discrepancy in yield and catastrophic failure charges.
I concluded that they had been checking out it wrong. when I requested how they carried out the examine with DC high-voltage input, it become ok. but once I asked how they terminated the outputs, they explained they did it with outputs loaded but floating, whereas they Checked with DC output grounded open circuit.
Eureka! I demanded they examine the equal manner they theyre trying out, and they all started to look the identical issues. My reasoning turned into that the extended insulation on the floating secondary aspect became satisfactory to make their examine move and their check fail. a spot boost of most effective 1mm or 2mm made it move.
The PSUs had been no longer being produced with ample insulating paste on uncovered passive machine leads. particulars... particulars... tsk, tsk. They by no means did make an apology, but i am certain they realized their lesson. additionally, the polarity of the HIPOT verify might have an effect on failure modes, in view that the passive elements theyre related to active elements.
always, neutral and line (sizzling) are shorted collectively, and the high-voltage input is applied bettheyen them and the floor wire. but if the secondary is additionally floating, any arcing bettheyen simple (AC) and secondary (DC) could nonetheless flow if the DC insulation breakdown had been sufficient. hotheyver a positive DC HIPOT arcing to floor would put a reverse spike on the DC output by way of potential of high-quality pulse going from floor to DC-bad output.
the percentages of a excessive-advantage spike on the energy line are excessive in Florida, where they validated, and they may also be as plenty as the meter 6kV suppressor. it really is usually bettheyen scorching and impartial and less seemingly bettheyen hot and impartial and floor, except there is a ground fault, when you consider that neutral is grounded on the leading transformer. HIPOT is supposed to be a leakage to floor look at various. The noise enter caps are chosen for 60Hz at the rated voltage to ground to prevent an dangerous leakage existing, nonetheless it is Checked with an impulse for line ingress on an ungrounded unit. If the DC output is grounded externally in an application, for protecting or some thing reason, it ought to be Checked in this manner with DC-poor output grounded for HIPOT.
remember to present restrict ytheir probes just above the examine failure threshold to avoid capacitor discharge on short. how many PSU HIPOT escapes have you ever considered?
This entry became submitted via Anthony Stewart and edited via Rob Spiegel.
Anthony all started life as an expert engineer after his EE commencement in 1975 at the university of Manitoba in Winnipeg. He contributed 30 years in R&D industries akin to aerospace, telemetry, SCADA, telecom, disk drive, nuclear instrumentation, and contract manufacturing.
tell us ytheir adventure in solving a knotty engineering problem. ship to Rob Spiegel for Sherlock Ohms.
