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Avaya 6401-1 : Avaya IP Office Implementation Exam

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Test Number : 6401-1
Test Name : Avaya IP Office Implementation
Vendor Name : Avaya
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Avaya testing

The Case of the HIPOT examine screw ups | 6401-1 question bank and Questions and Answers

I as soon as designed a product for Avaya, a 1U x 19" rack with an open-framed OEM energy deliver. Yields have been good at first. Later, HIPOT (high-abilities) testing all started to fail on random devices at a 10 p.c expense, which turned into a great deal larger than I expected, for the reason that the agency tested earlier than transport.

The product provided power for Avaya's VOIP phones in a distribution field with 10 watts for each and every equipment inline on RJ45 ports which ran at T1 or 1.544Mbps quotes. i used to be head of design at C-MAC in Winnipeg very nearly 10 years in the past. i used to be liable for examine technique and fault isolation.

I chose two suppliers for the 180W 1U open-frame vigour supply gadgets (PSUs). They had a contract to deliver Avaya with 10,000 gadgets in the first yr. Then the PSUs all started failing in HIPOT trying out. After many emails and phone calls to the organization, it refused to consider its product could have this type of high failure rate. I found out it had recently transferred the creation from California to Mexico. I started to investigate the root explanation for the screw ups.

no longer only did the 1.5kV DC HIPOT check fail, however many contraptions grew to become nonfunctional after the look at various. Some passed initially, then failed later in useful checking out. To work out what may trigger such screw ups, I determined to existing limit the HIPOT tester with a excessive-voltage sequence resistor. despite the fact that it became designed for a 2mA present limit, the capacitance within the tester was adequate to create excessive-present impulse if low-impedance arcing befell. continually, it gives a gradual-rising output to 1.5kV for one second after which shuts off.

That avoided PSU failures from catastrophic failure of arc discharge, but 1.5 mA overcurrent nonetheless occurred on 10 % of the instruments.

Then I examined the root explanation for the screw ups and found poor process methods in meeting with arcing. I highlighted all of the areas of the PSU the place insulation gaps needed to increase and inadequate silicone or PU cloth had been applied.

The well-known supervisor of the company presenting the PSUs failed to believe his design crew in California and his creation team in Mexico could not discover the same problems of their amenities. The corporation blamed us for breaking the product. I could not agree with it both, so i used to be determined to work out why there became such an important discrepancy in yield and catastrophic failure prices.

I concluded that they have been testing it wrong. after I asked how they performed the check with DC high-voltage enter, it became adequate. but after I asked how they terminated the outputs, they defined they did it with outputs loaded but floating, whereas they demonstrated with DC output grounded open circuit.

Eureka! I demanded they examine the identical approach they have been checking out, and that they started to look the same problems. My reasoning changed into that the elevated insulation on the floating secondary side become adequate to make their look at various pass and their verify fail. a niche boost of only 1mm or 2mm made it flow.

The PSUs have been now not being produced with sufficient insulating paste on exposed passive equipment leads. particulars... details... tsk, tsk. They in no way did express regret, but i'm bound they learned their lesson. also, the polarity of the HIPOT verify could affect failure modes, on account that the passive elements were related to active parts.

consistently, impartial and line (hot) are shorted collectively, and the high-voltage enter is utilized between them and the ground wire. but when the secondary is also floating, any arcing between primary (AC) and secondary (DC) could still move if the DC insulation breakdown had been sufficient. but a good DC HIPOT arcing to floor would put a reverse spike on the DC output through skill of high quality pulse going from floor to DC-terrible output.

the chances of a excessive-abilities spike on the vigour line are excessive in Florida, where they verified, and that they can be as a good deal as the meter 6kV suppressor. this is constantly between hot and impartial and fewer likely between scorching and impartial and floor, until there is a ground fault, given that neutral is grounded on the leading transformer. HIPOT is supposed to be a leakage to ground verify. The noise input caps are chosen for 60Hz at the rated voltage to ground to steer clear of an hazardous leakage existing, nevertheless it is validated with an impulse for line ingress on an ungrounded unit. If the DC output is grounded externally in an software, for protecting or whatever thing purpose, it must be validated during this method with DC-terrible output grounded for HIPOT.

do not forget to latest limit your probes simply above the examine failure threshold to prevent capacitor discharge on brief. what number of PSU HIPOT escapes have you ever seen?

This entry was submitted by Anthony Stewart and edited through Rob Spiegel.

Anthony begun life as an expert engineer after his EE commencement in 1975 on the tuition of Manitoba in Winnipeg. He contributed 30 years in R&D industries corresponding to aerospace, telemetry, SCADA, telecom, disk power, nuclear instrumentation, and contract manufacturing.

tell us your journey in fixing a knotty engineering difficulty. ship to Rob Spiegel for Sherlock Ohms.

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