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.

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