Thermal Stress Test

There are three types of stress tests in general to evaluate the reliability or output stability in power supplies, which are thermal stress tests, voltage stress tests, and current stress tests. In order to unravel its mystery, this article will introduce about thermal stress testing. Additionally, other than specific customer demands, FSP conducts tests on our products based on the testing conditions and results of the thermal stress tests and the key component items listed below:

Device	Type	Category	Derating Thermal
Capacitor	–	–	90%
MOSFET	–	Main Switch	85%
		Small Signal
Diode	–	–
IC	–	–
Photo Coupler	–	–
Inductor	Transformer	–	85%
	Choke	–	90%

The reliability and output stability are always important in choosing a power supply. However, most manufacturers are unable to provide reliable data as proof that their products have an advantage over others in reliability and output stability, creating a gray area for many unorthodox manufacturers to have control over the choice of components for their power supplies. Most consumers would not always run computer equipment with the power supply on full load, nor use it beyond the ambient temperature exceeding 40 or even 50 degrees (heat-resistance setting of high-end products). Therefore, unorthodox manufacturers usually use low quality parts, or use them beyond the rated conditions of 100%. We mentioned that most consumers wouldn’t use power supplies under a full load, and the products usually wouldn’t break down within the year, which allowed the unorthodox manufacturers room to maneuver. When issues arise after a period of time or the warranty has expired, the consumers also just take it as bad luck without pursuing further.

In addition to the testing standards of key components, our testing conditions are also stringent. The components and parts of our products are required to be tested at the maximum heat-resistant conditions and under different loads as the conditions for passing safety specification certifications. Below are the internal testing conditions of our 80 Plus Gold 650W product:

² AC Input: 90Vac/115Vac/230Vac/264Vac

² Frequency: 47Hz/60Hz/50Hz/63Hz

² Ambient Temperature: 40℃

Loading	+5V	+12V	-12V	+3.3V	+5Vsb
FL1	20A	42.85A	0.3A	6.05A	2.5A
FL2	10.8A	43.9A	0.3A	20A	0A
FL3	0.1A	54.16A	0A	0A	0A
SB Mode	*	*	*	*	2.5A

After all, the input and output conditions are set, it is internally specified by the company to use the fan reported with the least cooling capabilities for testing. If the worst one could satisfy company standards, then the best one would definitely excel in test results. The fan setting of this same 650W gold product is as follows:

Fan Type	Input Voltage	Load	Fan Voltage(Vdc)
FAN, MIDDLE,0.3A,12V,120*25,27dB,   55-68cfm,1800rpm,SLEEVE,2PIN, 150mm,CONNECT,D12SM-12,YATE LOON/NICE FULL	90Vac/47HZ	FL1	11.44
		FL2	11.44
		FL3	11.44
	115Vac/60Hz	FL1	11.44
		FL2	11.44
		FL3	11.44
	230Vac/50Hz	FL1	11.44
		FL2	11.44
		FL3	11.44
	264Vac/63Hz	FL1	11.44
		FL2	11.44
		FL3	11.44

The following tables are all test results under the conditions set by the FSP Group. All testing items conform to internal standards. We also specify that all new models from R&D must go through this stage for the product to proceed to test production. Only if the test production is without issues, may the product go into mass production.

(UNIT:℃)

Location	SPEC	FL1								Result
		90V	Derating (%)	115V	Derating (%)	230V	Derating (%)	264V	Derating (%)
QS203	175	77.99	44.6	77.41	44.2	77.3	44.2	77.26	44.1	Pass
QS201	175	87.51	50	86.5	49.4	86.24	49.3	85.97	49.1	Pass
QS103	175	63.66	36.4	62.68	35.8	62.23	35.6	62.21	35.5	Pass
CS106	105	64.21	61.2	63.85	60.8	63.56	60.5	63.53	60.5	Pass
FL1	130	77.59	59.7	60.32	46.4	49.28	37.9	48.38	37.2	Pass
FL3	130	92.86	71.4	70.85	54.5	56.33	43.3	54.95	42.3	Pass
BD1	150	93.11	62.1	80.44	53.6	62.55	41.7	60.59	40.4	Pass
C6	105	51.19	48.8	48.73	46.4	46.11	43.9	45.47	43.3	Pass
L1	130	107.93	83	89.45	68.8	67.99	52.3	61.32	47.2	Pass
Q201	150	79.39	52.9	71.7	47.8	65.54	43.7	65.39	43.6	Pass
Q202	150	72.11	48.1	65.43	43.6	60.07	40	59.98	40	Pass
D6	175	73.18	41.8	65.5	37.4	57.97	33.1	57.41	32.8	Pass
Q1	150	85.02	56.7	70.03	46.7	57.85	38.6	57.26	38.2	Pass
L201	130	75.28	57.9	71.72	55.2	68.93	53	68.48	52.7	Pass
T3	130	44.16	34	43.56	33.5	43.15	33.2	43.35	33.3	Pass
T201	130	80.97	62.3	80.1	61.6	79.7	61.3	78.98	60.8	Pass
T101	130	72.37	55.7	71.41	54.9	70.92	54.6	70.37	54.1	Pass
LS801	130	62.76	48.3	62.34	48	62.26	47.9	62.45	48	Pass
LS802	130	52.46	40.4	52.18	40.1	52.05	40	52.26	40.2	Pass
CS202	105	66.64	63.5	66.27	63.1	66.49	63.3	66.57	63.4	Pass
CS805	105	53.19	50.7	52.8	50.3	52.81	50.3	53.06	50.5	Pass
CS213	105	47.14	44.9	46.77	44.5	46.85	44.6	47.09	44.8	Pass
QS805	175	62.19	35.5	61.81	35.3	61.73	35.3	62.09	35.5	Pass
QS806	175	52.54	30	52.19	29.8	52.18	29.8	52.37	29.9	Pass
QS803	175	64.34	36.8	64.01	36.6	63.89	36.5	64.2	36.7	Pass
QS804	175	61.74	35.3	61.19	35	61.32	35	61.45	35.1	Pass
IC101	125	67.15	53.7	66.45	53.2	66.18	52.9	66.3	53	Pass
IC801	150	53.59	35.7	53.25	35.5	53.23	35.5	53.42	35.6	Pass
D2	150	60.55	40.4	55.08	36.7	49.38	32.9	48.58	32.4	Pass
LS101	130	50.76	39	50.2	38.6	50.01	38.5	50.04	38.5	Pass
LS201	130	65.48	50.4	65.1	50.1	65.05	50	65.24	50.2	Pass
R36	150	84.77	56.5	69.52	46.3	53.97	36	52.35	34.9	Pass
L2	130	77.61	59.7	67.27	51.7	57.03	43.9	55.85	43	Pass
CT201	130	50.93	39.2	48.85	37.6	47.2	36.3	47.28	36.4	Pass
AMB	—	40	—	40	—	40	—	40	—	—

 

Location	SPEC	FL2								Result
		90V	Derating (%)	115V	Derating (%)	230V	Derating (%)	264V	Derating (%)
QS203	175	79.41	45.4	79.03	45.2	78.73	45	78.86	45.1	Pass
QS201	175	88.37	50.5	87.54	50	87.17	49.8	87.22	49.8	Pass
QS103	175	59.64	34.1	58.84	33.6	58.37	33.4	58.38	33.4	Pass
CS106	105	61.44	58.5	61.02	58.1	60.86	58	60.86	58	Pass
FL1	130	76.77	59.1	59.75	46	48.71	37.5	48.16	37	Pass
FL3	130	92.52	71.2	70.34	54.1	56.15	43.2	54.83	42.2	Pass
BD1	150	93.03	62	80.51	53.7	62.52	41.7	60.7	40.5	Pass
C6	105	50.95	48.5	48.62	46.3	46.06	43.9	46.07	43.9	Pass
L1	130	107.97	83.1	89.5	68.8	68.01	52.3	64.82	49.9	Pass
Q201	150	80.11	53.4	72.34	48.2	66.01	44	65.77	43.8	Pass
Q202	150	72.65	48.4	65.95	44	60.47	40.3	60.33	40.2	Pass
D6	175	73.35	41.9	65.6	37.5	58.09	33.2	57.5	32.9	Pass
Q1	150	85.31	56.9	70.33	46.9	58.03	38.7	57.39	38.3	Pass
L201	130	75.88	58.4	72.32	55.6	69.61	53.5	69.67	53.6	Pass
T3	130	44.05	33.9	43.5	33.5	43.19	33.2	43.24	33.3	Pass
T201	130	82.14	63.2	81.25	62.5	80.84	62.2	80.87	62.2	Pass
T101	130	63.03	48.5	62.14	47.8	61.41	47.2	61.6	47.4	Pass
LS801	130	56.12	43.2	55.85	43	55.62	42.8	55.73	42.9	Pass
LS802	130	66.42	51.1	66.13	50.9	66.04	50.8	66.06	50.8	Pass
CS202	105	68.07	64.8	67.94	64.7	67.92	64.7	68.03	64.8	Pass
CS805	105	59.86	57	59.65	56.8	59.55	56.7	59.63	56.8	Pass
CS213	105	47.51	45.2	47.39	45.1	47.35	45.1	47.49	45.2	Pass
QS805	175	68.06	38.9	67.84	38.8	67.7	38.7	67.8	38.7	Pass
QS806	175	62.14	35.5	61.9	35.4	61.79	35.3	61.95	35.4	Pass
QS803	175	63.75	36.4	63.59	36.3	63.46	36.3	63.56	36.3	Pass
QS804	175	58.38	33.4	58.09	33.2	58	33.1	58.12	33.2	Pass
IC101	125	60.24	48.2	59.55	47.6	59.21	47.4	59.34	47.5	Pass
ICS801	150	54.02	36	53.79	35.9	53.78	35.9	53.91	35.9	Pass
D2	150	60.45	40.3	55	36.7	49.32	32.9	48.88	32.6	Pass
LS101	130	49.03	37.7	48.69	37.5	48.44	37.3	48.52	37.3	Pass
LS201	130	67.69	52.1	67.44	51.9	67.3	51.8	67.29	51.8	Pass
R36	150	84.79	56.5	69.72	46.5	53.95	36	52.71	35.1	Pass
L2	130	77.65	59.7	67.32	51.8	56.93	43.8	56	43.1	Pass
CT201	130	51	39.2	48.91	37.6	47.2	36.3	47.22	36.3	Pass
AMB	—	40	—	40	—	40	—	40	—	—

 

Location	SPEC	FL3								Result
		90V	Derating (%)	115V	Derating (%)	230V	Derating (%)	264V	Derating (%)
QS203	175	77.13	44.1	76.79	43.9	76.67	43.8	76.84	43.9	Pass
QS201	175	85.24	48.7	84.51	48.3	84.19	48.1	84.33	48.2	Pass
QS103	175	56.88	32.5	56.26	32.1	55.73	31.8	55.88	31.9	Pass
CS106	105	57.92	55.2	57.54	54.8	57.4	54.7	57.51	54.8	Pass
FL1	130	71.32	54.9	57.97	44.6	47.19	36.3	46.85	36	Pass
FL3	130	86.15	66.3	68.78	52.9	54.61	42	53.84	41.4	Pass
BD1	150	91.41	60.9	79.81	53.2	61.92	41.3	60.31	40.2	Pass
C6	105	50.78	48.4	48.52	46.2	45.97	43.8	46.05	43.9	Pass
L1	130	106.33	81.8	88.71	68.2	67.78	52.1	64.74	49.8	Pass
Q201	150	78.58	52.4	71.33	47.6	65.26	43.5	65.13	43.4	Pass
Q202	150	71.55	47.7	65.25	43.5	60.02	40	59.86	39.9	Pass
D6	175	72.37	41.4	65.17	37.2	57.73	33	57.28	32.7	Pass
Q1	150	83.64	55.8	69.57	46.4	57.58	38.4	57.16	38.1	Pass
L201	130	74.85	57.6	71.52	55	68.74	52.9	68.95	53	Pass
T3	130	43.84	33.7	43.35	33.3	42.97	33.1	43.21	33.2	Pass
T201	130	80.35	61.8	79.64	61.3	79.06	60.8	79.56	61.2	Pass
T101	130	60.38	46.4	59.55	45.8	58.94	45.3	59.15	45.5	Pass
LS801	130	48.3	37.2	48.02	36.9	47.91	36.9	48.01	36.9	Pass
LS802	130	47.17	36.3	47.01	36.2	46.88	36.1	47.06	36.2	Pass
CS202	105	66.52	63.4	66.32	63.2	66.19	63	66.49	63.3	Pass
CS805	105	48.42	46.1	48.37	46.1	48.17	45.9	48.4	46.1	Pass
CS213	105	46.76	44.5	46.7	44.5	46.52	44.3	46.74	44.5	Pass
QS805	175	49.46	28.3	49.31	28.2	49.19	28.1	49.35	28.2	Pass
QS806	175	46.58	26.6	46.47	26.6	46.27	26.4	46.49	26.6	Pass
QS803	175	49.06	28	48.92	28	48.74	27.9	48.93	28	Pass
QS804	175	48.23	27.6	48.08	27.5	47.8	27.3	48	27.4	Pass
IC101	125	54.92	43.9	54.4	43.5	54.03	43.2	54.25	43.4	Pass
IC801	150	49.17	32.8	49.02	32.7	48.86	32.6	49.01	32.7	Pass
D2	150	59.86	39.9	54.85	36.6	49.13	32.8	48.82	32.5	Pass
LS101	130	46.19	35.5	45.81	35.2	45.56	35	45.74	35.2	Pass
LS201	130	66.39	51.1	66.16	50.9	66	50.8	66.18	50.9	Pass
R36	150	83.47	55.6	69.2	46.1	53.74	35.8	52.59	35.1	Pass
L2	130	76.59	58.9	66.89	51.5	56.69	43.6	55.82	42.9	Pass
CT201	130	50.53	38.9	48.6	37.4	46.93	36.1	47	36.2	Pass
AMB	—	40	—	40	—	40	—	40	—	—

 

Location	SPEC	SB mode				Result
		90V	Derating (%)	264V	Derating (%)
QS203	175	41.14	23.5	41.08	23.5	Pass
QS201	175	42.77	24.4	42.72	24.4	Pass
QS103	175	48.31	27.6	48.29	27.6	Pass
CS106	105	50.28	47.9	50.32	47.9	Pass
FL1	130	42.83	32.9	42.8	32.9	Pass
FL3	130	43.44	33.4	43.45	33.4	Pass
BD1	150	42.6	28.4	42.55	28.4	Pass
C6	105	41.03	39.1	41.05	39.1	Pass
L1	130	40.42	31.1	40.44	31.1	Pass
Q201	150	40.46	27	40.46	27	Pass
Q202	150	40.41	26.9	40.43	27	Pass
D6	175	40.67	23.2	40.68	23.2	Pass
Q1	150	40.46	27	40.48	27	Pass
L201	130	40.66	31.3	40.69	31.3	Pass
T3	130	40.37	31.1	40.3	31	Pass
T201	130	41.47	31.9	41.49	31.9	Pass
T101	130	60.12	46.2	60.14	46.3	Pass
LS801	130	42.22	32.5	42.24	32.5	Pass
LS802	130	41.3	31.8	41.29	31.8	Pass
CS202	105	41.64	39.7	41.64	39.7	Pass
CS805	105	41.46	39.5	41.48	39.5	Pass
CS213	105	40.96	39	40.99	39	Pass
QS805	175	41.85	23.9	41.85	23.9	Pass
QS806	175	41.53	23.7	41.56	23.7	Pass
QS803	175	41.96	24	41.98	24	Pass
QS804	175	42.35	24.2	42.36	24.2	Pass
IC101	125	58.77	47	58.83	47.1	Pass
IC801	150	41.54	27.7	41.55	27.7	Pass
D2	150	42.43	28.3	42.45	28.3	Pass
LS101	130	47.09	36.2	47.1	36.2	Pass
LS201	130	41.58	32	41.58	32	Pass
R36	150	41.05	27.4	41.04	27.4	Pass
L2	130	40.36	31	40.37	31.1	Pass
CT201	130	40.41	31.1	40.45	31.1	Pass
AMB	—	40	—	40	—	—

 

Everyone knows the operating temperature for electric components is, the lower the better, as usually, the operating temperature and lifespan of the component is inversely related to each other. Are you more at ease and safe with FSP products after reading this report? Because most components still have a ways to go from operating temperature to rated derating under different loads, therefore we can be sure of the product’s standard in reliability and output stability. Are you curious of FSP’s testing equipment in our laboratories? What equipment do we have to test new products? Below are some pictures for you to learn about our laboratories.