High Potential Stress Test Procedure (HI-POT)
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High Potential Stress Test Procedure (HI-POT) |
TABLE OF CONTENTS
PARA. TITLE
1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCE DOCUMENTS
4.0 PRECAUTIONARY INSTRUCTIONS
5.0 EQUIPMENT REQUIRED
6.0 TEST REQUIREMENTS
7.0 GROUND CONTINUITY
8.0 HIGH POTENTIAL STRESS
9.0 RECORD KEEPING REQUIREMENTS
10.0 UNIT IDENTIFICATION
1.0 PURPOSE
THE PURPOSE OF THIS PROCEDURE IS TO PROVIDE THE INSTRUCTIONS NEEDED TO
PERFORM A COMPLETE AND THOROUGH HIGH POTENTIAL STRESS TEST AND A GROUND
CONTINUITY VERIFICATION IN ORDER TO INSURE COMPLIANCE WITH THE SYSTEM
REQUIREMENTS.
2.0 SCOPE
THIS PROCEDURE DEFINES THE METHOD FOR CHECKING THE GROUND CONTINUITY, THE
HIGH POTENTIAL STRESS CAPABILITY AND THE ASSOCIATED RECORD KEEPING THAT IS
REQUIRED TO BE PERFORMED ON THE EAGLE POWER SUPPLY SUB-ASSEMBLY.
3.0 REFERENCE DOCUMENTS
500713 PRODUCT SPEC BASE UNIT P/S
502046 SYSTEM SPEC DESK TOP COMPUTER
502077 DESIGN SPEC BASE P/S
503132 TEST SPEC BASE P/S
907472 POWER SUPPLY ASSY DTC
903394 PCBA P/S CONTROL MODULE
903404 LD P/S CONTROL MODULE
903443 PCBA P/S INPUT MODULE
903444 LD P/S INPUT MODULE
903445 PCBA P/S OUTPUT MODULE
903446 LD P/S OUTPUT MODULE
QA00-50002 UL/CSA COMPLIANCE
4.0 PRECAUTIONARY INSTRUCTIONS
4.1 DANGEROUS VOLTAGES WILL BE PRESENT DURING THESE TESTS! IT IS
IMPERATIVE THAT THE TEST OPERATOR BE ALERT, PAY CLOSE ATTENTION AND
REMAIN FREE FROM ANY DISTRACTION DURING THE PERFORMANCE OF THESE
TESTS.
4.2 UNAUTHORIZED PERSONNEL SHOULD BE RESTRICTED FROM THE AREA WHEN
THESE TESTS ARE IN PROCESS.
4.3 EQUIPMENT, CABLES AND ACCESSORIES SHOULD BE CHECKED AT FREQUENT
INTERVALS FOR WEAR, DAMAGED INSULATION OR ANY CONDITION THAT COULD
BE CONSIDERED UNSAFE.
4.4 THE TEST AREA SHOULD BE KEPT CLEAR AND UNCLUTTERED. ALL UNNESSARY
EQUIPMENT AND TOOLS SHOULD BE REMOVED FROM THE TEST AREA.
4.5 IT IS IMPORTANT THAT ALL CABLES AND CONNECTORS ARE PROPERLY
IDENTIFIED AND CONNECTED CORRECTLY PRIOR TO THE APPLICATION OF
POWER, OTHERWISE DAMAGE, ERRONEOUS INDICATIONS OR EVEN INJURY COULD
RESULT.
5.0 EQUIPMENT REQUIRED
5.1 A HIGH POTENTIAL STRESS TESTER WITH THE CAPABILITY OF:
A) DELIVERING AND SUSTAINING THE SPECIFIED VOLTAGE FOR THE
REQUIRED LENGTH OF TIME.
B) A METER THAT INDICATES THE VOLTAGE AT THE OUTPUT CONNECTIONS.
C) AN INDICATOR, EITHER VISUAL OR AUDIBLE, TO INDICATE A
BREAKDOWN.
D) ABLE TO BE CALIBRATED.
5.2 AN ADAPTER CABLE TO CONNECT THE HI-POT TESTER TO THE DEVICES UNDER
TEST, WITH THE FOLLOWING:
A) AN OUTPUT CONNECTOR THAT WILL MATE DIRECTLY WITH THE AC INPUT
RECEPTACLE OF THE UNITS UNDER TEST.
B) A HIGH VOLTAGE INSULATED WIRE CONNECTING THE GROUND SIDE OF
THE TESTER TO THE GROUND PIN OF THE OUTPUT CONNECTOR.
C) A HIGH VOLTAGE INSULATED WIRE CONNECTING THE OUTPUT SIDE OF
THE TESTER TO BOTH THE AC LINE AND AC NEUTRAL PINS OF THE
OUTPUT CONNECTOR.
5.3 A GROUNDING CONNECTOR THAT WILL BE CAPABLE OF CONNECTING SIGNAL
GROUND TO CHASSIS GROUND.
5.4 A CLOCK OR WATCH CAPABLE OF DISPLAYING SECONDS.
5.5 AN OHMMETER CAPABLE OF MEASURING AS LOW AS 0.1 OHMS.
6.0 TEST REQUIREMENTS
6.1 ALL EAGLE POWER SUPPLIES MUST BE TESTED AND PASS THE GROUND
CONTINUITY AND HIGH POTENTIAL STRESS (HI-POT) TESTS BEFORE BEING
INSTALLED IN A SYSTEM, SENT TO STOCK OR SHIPPED AS A SPARE UNIT.
6.2 ANY UNIT THAT FAILS EITHER THE GROUND CONTINUITY TEST OR THE HIGH
POTENTIAL STRESS TEST MUST HAVE ALL DEFECTS IDENTFIED AND REPAIRED.
AFTER REPAIR, THE UNIT MUST BE RETESTED AND PASS BOTH TESTS.
6.3 ANY POWER SUPPLY ASSEMBLY THAT HAS HAD UPDATING, REPAIR,
MODIFICATION OR CHANGES OF ANY KIND TO THE INTERNAL COMPONENTS,
SHALL REQUIRE RETESTING FOR BOTH GROUND CONTINUITY AND HI-POT.
7.0 GROUND CONTINUITY
7.1 VERIFY THAT THE UNIT UNDER TEST IS CLEAR OF ANY EQUIPMENT, CABLES OR
OTHER MATERIALS ON THE TEST STATION AND THAT THERE ARE NO ELECTRICAL
CONNECTIONS TO THE UNIT.
7.2 USING A METER CAPABLE OF MEASURING OHMS AS LOW AS 0.1 OHMS, SET THE
METER TO THE OHMS FUNCTION AND TO THE LOWEST SCALE AVAILABLE.
7.3 CONNECT THE COMMON PROBE OF THE METER SECURELY TO ANY CONVENIENT
POINT ON THE SHEET METAL CHASSIS OF THE UNIT UNDER TEST.
7.4 CONNECT THE OTHER PROBE OF THE OHMMETER TO THE GROUND PIN OF THE AC
POWER INPUT CONNECTOR.
7.5 TO PASS, THE RESISTANCE MEASURED BETWEEN THE GROUND PIN OF THE POWER
INPUT CONNECTOR AND THE METAL CHASSIS MUST BE 0.2 OHMS OR LESS.
7.6 IF THE UNIT UNDER TEST FAILS THE GROUND CONTINUITY TEST, DO NOT RUN
THE HI-POT TEST.
8.0 HIGH POTENTIAL STRESS (HI-POT TEST)
8.1 VERIFY THAT THE UNIT UNDER TEST IS CLEAR OF ANY EQUIPMENT, CABLES OR
OTHER MATERIALS ON THE TEST STATION AND THAT THERE ARE NO ELECTRICAL
CONNECTIONS TO THE UNIT.
8.2 TURN ON THE HI-POT TESTER.
8.3 SET THE OUTPUT VOLTAGE OF THE HI-POT TESTER TO 1450 VOLTS DC.
8.4 TURN OFF THE HI-POT TESTER.
8.5 PLACE THE POWER SWITCH OF THE UNIT UNDER TEST TO THE ON POSITION.
8.6 CONNECT THE HI-POT TESTER ADAPTER CABLE TO THE AC INPUT RECEPTACLE
OF THE UNIT UNDER TEST.
8.7 CONNECT THE GROUNDING CONNECTOR TO P1 OF THE POWER SUPPLY UNDER
TEST. THEN, FIRMLY CONNECT THE ALLIGATOR CLIP OF THE GROUNDING
CONNECTOR TO ANY CONVENIENT POINT ON THE METAL CHASSIS OF THE UNIT
UNDER TEST, THAT WILL PROVIDE A SOLID GROUND CONNECTION.
8.8 TURN ON THE HI-POT TESTER AND ALLOW TO RUN FOR 60 SECONDS.
8.9 AFTER THE 60 SECONDS, TURN OFF THE HI-POT TESTER.
8.10 DISCONNECT THE UNIT UNDER TEST FROM THE TESTER.
8.11 DISCONNECT THE GROUNDING CONNECTOR FROM THE UNIT UNDER TEST.
8.12 TO PASS, THE UNIT UNDER TEST MUST BE EXPOSED TO A MININUM STRESS OF
1414 VDC FOR 60 SECONDS WITHOUT ANY INDICATION OF BREAKDOWN.
9.0 RECORD KEEPING REQUIREMENTS
A LOG MUST BE KEPT ON ALL EAGLE POWER SUPPLY UNITS TESTED FOR GROUND
CONTINUITY AND HIGH POTENTIAL STRESS. THIS LOG MUST BE CONTAIN THE
FOLLOWING INFORMATION:
9.1 THE COMPLETE SERIAL NUMBER OF THE UNIT TESTED WHICH INCLUDES THE
FACTORY ORDER AND SERIAL NUMBER.
9.2 GROUND CONTINUITY PASS OR FAIL CHECK-OFF.
9.3 HIGH POTENTIAL STRESS PASS OR FAIL CHECK-OFF.
9.4 THE DATE THE TEST WAS PERFORMED.
9.5 THE NAME OR IDENTIFYING STAMP OF THE TECHNICIAN THAT PERFORMED THE
TEST.
A SAMPLE OF A RECOMENDED LOG SHEET IS SHOWN BELOW
__________________________________________________________________________ | | | SERIES 2000 POWER SUPPLY HI-POT & GROUND CONTINUITY LOG SHEET | | | | | | UNIT |GND CONT | HI-POT | PARTS |RETEST | DATE | TEST | | SERIAL # | (check) | (check) | REPLACED | OK | PASSED | OPERATOR | | (COMPLETE) |PASS|FAIL|PASS|FAIL| |(check)| | | |==========================================================================| | | | | | | | | | | |--------------------------------------------------------------------------| | | | | | | | | | | |--------------------------------------------------------------------------| | | | | | | | | | | |--------------------------------------------------------------------------| | | | | | | | | | | |--------------------------------------------------------------------------|
10.0 UNIT IDENTIFICATION
10.1 ALL POWER SUPPLY ASSEMBLIES THAT HAVE PASSED THE GROUND CONTINUITY
AND HI-POT TESTS SHALL BE MARKED SO THAT THEY CAN BE READILY
IDENTIFIED.
10.2 THE MARKING MAY BE IN THE FORM OF AN ADHESIVE LABEL WITH PRINTING,
SUCH AS "HIPOT OK".
10.3 THE LABELS SHALL BE PLACED ON THE SHEET METAL SURFACE OF THE REAR
PANEL OF THE POWER SUPPLY WITHIN AN AREA THAT WILL NOT BE COVERED
BY THE SYSTEM'S REAR COVER.