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Avaya 3101-1 : Avaya Aura Communication Manager and CM Messaging - Embedded Maintenance and Troubleshooting Exam

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Test Number : 3101-1
Test Name : Avaya Aura Communication Manager and CM Messaging - Embedded Maintenance and Troubleshooting
Vendor Name : Avaya
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Avaya test

The Case of the HIPOT look at various failures | 3101-1 Test Prep and Latest Questions

I as soon as designed a product for Avaya, a 1U x 19" rack with an open-framed OEM power give. Yields had been decent initially. Later, HIPOT (high-potential) testing started to fail on random instruments at a 10 percent rate, which become tons higher than I anticipated, when you consider that the agency tested before transport.

The product provided energy for Avaya's VOIP phones in a distribution box with 10 watts for every equipment inline on RJ45 ports which ran at T1 or 1.544Mbps quotes. i was head of design at C-MAC in Winnipeg well-nigh 10 years in the past. i used to be responsible for test technique and fault isolation.

I selected two suppliers for the 180W 1U open-body vigour deliver devices (PSUs). They had a contract to provide Avaya with 10,000 contraptions within the first yr. Then the PSUs begun failing in HIPOT testing. After many emails and phone calls to the supplier, it refused to consider its product might have this sort of high failure rate. I found it had recently transferred the construction from California to Mexico. I all started to examine the foundation reason for the disasters.

not only did the 1.5kV DC HIPOT test fail, but many units grew to be nonfunctional after the test. Some passed firstly, then failed later in practical checking out. To figure out what might trigger such failures, I decided to latest restrict the HIPOT tester with a excessive-voltage sequence resistor. although it turned into designed for a 2mA present limit, the capacitance in the tester changed into satisfactory to create high-current impulse if low-impedance arcing happened. always, it offers a gradual-rising output to 1.5kV for one 2d after which shuts off.

That avoided PSU disasters from catastrophic failure of arc discharge, however 1.5 mA overcurrent nevertheless happened on 10 % of the devices.

Then I examined the basis reason behind the failures and discovered poor system strategies in assembly with arcing. I highlighted the entire areas of the PSU the place insulation gaps had to boost and inadequate silicone or PU fabric had been applied.

The ordinary supervisor of the company offering the PSUs failed to consider his design crew in California and his creation group in Mexico couldn't observe the identical issues of their amenities. The organization blamed us for breaking the product. I could not accept as true with it either, so i was decided to work out why there become such a massive discrepancy in yield and catastrophic failure charges.

I concluded that they had been checking out it incorrect. once I asked how they performed the examine with DC excessive-voltage input, it changed into adequate. however after I requested how they terminated the outputs, they defined they did it with outputs loaded but floating, whereas they validated with DC output grounded open circuit.

Eureka! I demanded they verify the equal approach they had been testing, and they began to peer the same complications. My reasoning became that the extended insulation on the floating secondary facet changed into satisfactory to make their check circulate and their verify fail. a spot boost of most effective 1mm or 2mm made it circulate.

The PSUs were no longer being produced with enough insulating paste on uncovered passive equipment leads. details... details... tsk, tsk. They by no means did express regret, however i am sure they discovered their lesson. additionally, the polarity of the HIPOT look at various may affect failure modes, on account that the passive elements had been linked to energetic elements.

invariably, neutral and line (scorching) are shorted together, and the high-voltage enter is applied between them and the floor wire. but if the secondary is additionally floating, any arcing between fundamental (AC) and secondary (DC) could nevertheless circulate if the DC insulation breakdown had been satisfactory. however a good DC HIPOT arcing to floor would put a reverse spike on the DC output via means of high quality pulse going from floor to DC-bad output.

the chances of a high-advantage spike on the energy line are high in Florida, the place they tested, and they can also be as much because the meter 6kV suppressor. it truly is always between hot and impartial and less doubtless between sizzling and neutral and floor, until there is a ground fault, because impartial is grounded at the leading transformer. HIPOT is meant to be a leakage to ground check. The noise input caps are chosen for 60Hz on the rated voltage to ground to keep away from an unsafe leakage existing, nevertheless it is proven with an impulse for line ingress on an ungrounded unit. If the DC output is grounded externally in an utility, for safeguarding or something rationale, it ought to be confirmed in this method with DC-bad output grounded for HIPOT.

don't forget to current limit your probes just above the examine failure threshold to avoid capacitor discharge on short. how many PSU HIPOT escapes have you ever considered?

This entry changed into submitted by way of Anthony Stewart and edited by means of Rob Spiegel.

Anthony begun life as knowledgeable engineer after his EE graduation in 1975 at the university of Manitoba in Winnipeg. He contributed 30 years in R&D industries such as aerospace, telemetry, SCADA, telecom, disk power, nuclear instrumentation, and contract manufacturing.

inform us your event in fixing a knotty engineering issue. ship to Rob Spiegel for Sherlock Ohms.

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