IPC-9592 Final Draft - April 2007

1 IPC- 9592 Performance Parameters for Power Conversion Devices Final Draft April 2007 IPC- 9592 Final Draft April 2007 2 IPC- 9592 , Performance Parameters for Power Conversion Devices 1 SCOPE Statement of Scope This document standardizes the performance parameters for power conversion devices including but not limited to the computer and telecommunications industries. The phrase power conversion devices refers to AC to DC and DC to DC modules, converters and printed circuit board assemblies.

2 This specification sets the requirements for design; qualification testing; conformance testing; manufacturing quality processes; and regulatory requirements but does not include the functional requirements of the specific equipment. Description Power Conversion Devices addressed in this document are used in the electronics industry to provide conversion of mains power sources, usually AC, to lower DC voltages either for direct use of electronic circuits, or as a secondary source for additional DC to DC power conversion devices to provide several DC voltage levels for various electronic devices in a product. Performance Parameters are comprised of mechanical , electrical , environmental, quality/reliability, and regulatory requirements: mechanical requirements include form and size, connector and wiring configurations, and cooling needs.

3 electrical requirements define the electrical interface, including power source (AC or DC), input voltage, frequency and current needs, output voltages and current capabilities, and, where applicable, logic controls. Environmental requirements entail both operating and shipping temperatures, humidity, shock and vibration limits. Quality/Reliability Assurance requirements include definitions and requirements for the design and testing of the quality and reliability of power conversion devices. Regulatory requirements are international standards for safety, electronic interference, and environmental impact of power conversion devices. Methods This document describes specific methods to meet the defined performance parameters. These methods are Design for Reliability, Design Qualification Testing, Manufacturing Conformance Testing, and Quality Processes.

4 In addition, this document specifies key Regulatory Requirements pertaining to power conversion devices. Purpose The purpose of this document is to create a set of consistent specifications and methods to assure suitability, quality, safety and reliability of power conversion devices for the electronics industry. These specifications will apply to suppliers of power conversion devices, including their design and testing, and will provide guidelines for the end user to ensure adequate specifications for use in their products. All of the specifications and requirements defined in this document are intended to be part of suppliers Power Conversion Devices Certifications outlined by the customers and will ship with first article and any design changes to the power conversion device.

5 Order of Precedence When Purchasing In the event of conflict when this document is utilized for purchasing a product addressed by this IPC standard, the following order of precedence shall apply: a. Purchase order b. Master drawing c. This standard d. Applicable documents (see 2) IPC- 9592 Final Draft April 2007 3 2 APPLICABLE DOCUMENTS AND TERMS AND DEFINITIONS IPC IPC J-STD-001 Requirements for Soldered electrical and Electronic Assemblies IPC/EIA/JEDEC J-STD-002 Solderability Tests for Component Leads, Terminations, Lugs, Terminals and Wires IPC-A-610 Acceptability of Electronic Assemblies IPC-9701 Performance Test Methods and Qualification Requirements for Surface Mount Solder Attachments INTERNATIONAL CANADIAN STANDARDS ASSOCIATION (CANADA) CAN/CSA No.

6 60950-1 Safety of Information Technology Equipment, Including electrical Business Equipment INTERNATIONAL ORGANIZATION FOR STANDARDIZATION ISO 3741 Determination of Sound Power Levels of Noise Sources - Precision Methods for Broad-Band Sources in Reverberation Rooms (Equivalent to ANSI/NAIS ) ISO 3744 Determination of Sound Power Levels Noise Sources Using Sound Pressure - Engineering Method in an Essentially Free Field Over a Reflecting Plane (Equivalent to ANSI/NAIS ) ISO 10302 Method for the Measurement of Airborne Noise Emitted by Small Air-Moving Devices (Equivalent to ANSI ) GB CHINA GB 4943-2001 Safety of Information Technology Equipment (Including electrical Business Equipment) INTERNATIONAL ELECTROTECHNICAL COMMISSION IEC 60529 Degrees of Protection Provided by Enclosures (equivalent to EN 60529) IEC 60950-1 Safety of Information Technology Equipment, Including electrical Business Equipment, including all national deviations as specified in the current CB Bulletin IEC 61000 Electromagnetic Compatibility (EMC) consists of over 30 documents covering electromagnetic and radio interference, power line interference, ESD, immunity and ground (earth connection) testing IEC 61000-3-2 Electromagnetic Compatibility (EMC) Part 3-2 Limits Limits for Harmonic Current Emissions (Equipment Input Current 16A per Phase) IEC 61000-4-2 Electromagnetic Compatibility (EMC)

7 Part 4-2 Testing and Measurement Techniques Electrostatic Discharge Immunity Test IEC 62040-1-1 1st edition and IEC 62040-1-2 1st edition Components and Subassemblies used in Uninterruptible Power Systems (and their equivalent adapted standards such as EN 62040-1-1 or UL 1778, etc. in different countries) NORMA OFICIAL MEXICANA NOM-019-SCFI Safety requirements for Information Technology Electronical Devices EUROPEAN UNION EN 50116 Information Technology Equipment. Routine electrical Safety Testing in Production EN 55022 Information Technology Equipment Radio Disturbance Characteristics Limits and Methods of Measurement EN 55024 Electrostatic Discharge Requirements UNITED STATES TELCORDIA SR332-1 Reliability Prediction Procedure for Electronic Equipment IPC- 9592 Final Draft April 2007 JEDEC EIA/JESD22-A101 Steady State Temperature Humidity Bias Life Test JESD22-A108 Temperature, Bias and Operating Life JESD22-A114 Electrostatic Discharge (ESD) Sensitivity Testing - Human Body Model (HBM) TERMS AND DEFINITIONS The definition of all terms used herein shall be as specified in IPC-T-50 and as defined below.

8 AABUS - (As an Acronym): As Agreed Between User and Supplier - (As a Term): Indicates additional or alternate requirements to be decided between the user and the supplier in the procurement documentation. Examples include contractual requirements, modifications to purchase documentation, and information on the drawing. Agreements can be used to define test methods, conditions, frequencies, categories or acceptance criteria within a test, if not already established. ARRHENIUS RELATIONSHIP Mathematical model for relation of failure rate to temperature see Appendix E. BOM - Bill of Material BMP - Board Mount Power: Refers to encapsulated and open PWB power converters that are mounted on larger PWBs. Cp - Process Capability: An indicator of process capability using the ratio of specification width to process variation.

9 Cpk - Process Capability Index: Adjustment of Cp for the effect of a non-centered distribution. Measures how close a process is running to its specification limits, relative to the natural variability of the process and center of the distribution. DFMEA - Design Failure Modes and Effects Analysis DL - Destruct Limit: The stress level at which product will fail. When the stress level is reduced, the failure will not recover ( , This is a hard failure). DMTBF - Demonstrated Mean Time Between Failure: The value of MTBF determined from a life test. This test does not measure the actual reliability. DoC - Declaration of Conformity: The proof of compliance provided by a manufacturer or importer that the information technology equipment being imported into those countries requiring said compliance, meets the requirements.

10 DVT - Design Verification Test: a qualification test to assess if design specifications are met. EDVT - electrical Design Verification Test: a qualification test to assess electrical design specifications are met EMC - Electro-Magnetic Compatibility EMI - Electro-Magnetic Interference ESD Electro-Static Discharge FET - Field Effect Transistor: includes power MOSFETS commonly used in power converters Grms - Root Mean Square value of G, where G is acceleration due to gravity a measure of dynamic acceleration used in vibration testing. HALT - Highly Accelerated Life Test: Design test used to improve the robustness/reliability of a product through test-fail-fix process where applied stresses are beyond the specified operating limits. HASA - Highly Accelerated Stress Audit; performed via sample testing as opposed to 100% that is done with HASS.