Avaya 3305 : Avaya Aura Experience Portal with POM Implementation and Maintenance Exam
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Test Number : 3305
Test Name : Avaya Aura Experience Portal with POM Implementation and Maintenance
Vendor Name : Avaya
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Avaya with testing
I as soon as designed a product for Avaya, a 1U x 19" rack with an open-framed OEM vigor provide. Yields had been good in the beginning. Later, HIPOT (excessive-talents) trying out began to fail on random contraptions at a ten p.c cost, which changed into an awful lot greater than I expected, on account that the agency Checked
The product presented energy for Avaya's VOIP phones in a distribution field with 10 watts for every gadget inline on RJ45 ports which ran at T1 or 1.544Mbps charges. i was head of design at C-MAC in Winnipeg very nearly 10 years in the past. i was accountable for examine method and fault isolation.
I chose two suppliers for the 180W 1U open-body power provide gadgets (PSUs). They had a contract to provide Avaya with 10,000 gadgets within the first yr. Then the PSUs begun failing in HIPOT trying out. After many emails and make contact with calls to the company, it refused to trust its product might have one of these excessive failure price. I discovered it had these days transferred the production from California to Mexico. I began to investigate the foundation reason for the disasters.
no longer handiest did the 1.5kV DC HIPOT verify fail, but many devices grew to become nonfunctional after the verify. Some handed firstly, then failed later in practical testing. To figure out what might trigger such screw ups, I decided to current limit the HIPOT tester with a excessive-voltage series resistor. despite the fact that it became designed for a 2mA latest limit, the capacitance within the tester become satisfactory to create high-present impulse if low-impedance arcing took place. continuously, it gives a gradual-rising output to 1.5kV for one second and then shuts off.
That avoided PSU disasters from catastrophic failure of arc discharge, but 1.5 mA overcurrent nonetheless occurred on 10 percent of the units.
Then I examined the root cause of the screw ups and discovered terrible method strategies in meeting with arcing. I highlighted all of the areas of the PSU the place insulation gaps had to enhance and insufficient silicone or PU cloth had been utilized.
The standard manager of the enterprise supplying the PSUs failed to accept as true with his design group in California and his production team in Mexico could not detect the identical problems of their amenities. The service provider blamed us for breaking the product. I couldn't consider it both, so i was determined to work out why there became such a major discrepancy in yield and catastrophic failure quotes.
I concluded that they have been testing it incorrect. after I asked how they carried out the test with DC excessive-voltage enter, it turned into good enough. but once I asked how they terminated the outputs, they explained they did it with outputs loaded however floating, whereas they tested with DC output grounded open circuit.
Eureka! I demanded they check the equal approach they had been testing, and they started to see the same issues. My reasoning turned into that the increased insulation on the floating secondary facet became enough to make their check circulate and their verify fail. a niche raise of handiest 1mm or 2mm made it circulate.
The PSUs had been not being produced with enough insulating paste on exposed passive gadget leads. details... particulars... tsk, tsk. They on no account did make an apology, however i'm bound they discovered their lesson. also, the polarity of the HIPOT test could have an effect on failure modes, considering the fact that the passive materials had been connected to lively parts.
constantly, impartial and line (hot) are shorted collectively, and the excessive-voltage input is utilized between them and the floor wire. but when the secondary is also floating, any arcing between primary (AC) and secondary (DC) may still pass if the DC insulation breakdown were ample. but a positive DC HIPOT arcing to ground would put a reverse spike on the DC output by means of capacity of nice pulse going from floor to DC-terrible output.
the chances of a excessive-competencies spike on the power line are excessive in Florida, where they verified, and they can also be as a good deal as the meter 6kV suppressor. that is always between scorching and neutral and less possible between hot and neutral and ground, unless there is a floor fault, due to the fact that neutral is grounded on the main transformer. HIPOT is supposed to be a leakage to floor look at various. The noise enter caps are chosen for 60Hz on the rated voltage to ground to evade an unsafe leakage existing, nonetheless it is established with an impulse for line ingress on an ungrounded unit. If the DC output is grounded externally in an software, for protecting or something motive, it must be tested in this manner with DC-poor output grounded for HIPOT.
remember to current restrict your probes just above the verify failure threshold to prevent capacitor discharge on short. how many PSU HIPOT escapes have you ever viewed?
This entry was submitted with the aid of Anthony Stewart and edited via Rob Spiegel.
Anthony begun existence as knowledgeable engineer after his EE commencement in 1975 at the college of Manitoba in Winnipeg. He contributed 30 years in R&D industries similar to aerospace, telemetry, SCADA, telecom, disk pressure, nuclear instrumentation, and contract manufacturing.
tell us your event in solving a knotty engineering problem. ship to Rob Spiegel for Sherlock Ohms.