UltraFlo FDB (UFF)

TM

Failure Analysis

06-25-2012

Nidec
Nidec Corporation
Philippines Corporation - NCFL
Central
MED Technical
Engineering Laboratory
– Ronalyn Lucero
Shiga Technical
Production – JeromeCenter
Tumpang

Nidec confidential 1/11

Objective:

Learn the IC terminal pin assignment and it’s



connections.

Learn how to conduct Failure Analysis for



NO ROTATION NG.

Impart the findings found during Failure



Analysis.
Nidec confidential 2/11
CC120K02 IC
4 3 2 1
5 16
6 15
7 14
8 13
9 10 11 12

Pinmark

Terminal Name NG Terminal Results Terminal Name NG Terminal Results

1. Tach Signal Fan rotates but No signal 9. RNF No resistance or 0 ohm

2. PWM Fan rotates in full speed rotation 10. COM Phase No rotation
3. 5V No rotation 11. GND
4. No Connection 12. TOSC Fan will not start
5. Pole 13. Set 4 IC resistance NG
Select
6. U Phase No rotation 14. Set 3 IC resistance NG
7. V Phase No rotation 15. Set 2 IC Resistance NG
8. W Phase No rotation 16. Set 1 IC Resistance NG

Nidec confidential 3/11

CC120K03 IC

1 10
2 9
3 8
4 7
5 6

Pinmark

Terminal Name NG Terminal Results Terminal Name NG Terminal Results

1. FG / Tach Fan rotates but No signal 9. POLE

2. COM Phase No Rotation 10. W Phase No rotation

3. VCC No rotation 11. GND

4. U Phase No rotation 12. TOSC Fan will not start

5. V Phase No rotation 13. PWM Fan rotates in full speed rotation

Nidec confidential 4/11

Failure Analysis
NO ROTATION NG

Abnormal conditions of a unit that can be IC related NG

- IC generates hot temperature. - Not start up at Low duty.
- Rotor continue to rotate and stop. - Abnormal Current Wave Form.

FAILURE ANALYSIS FLOW PHOTO AND IMPORTANT INFORMATION

F~Tester Check.

F~Tester
Judgement
OK
NG A

Check rotation by hand.

Rotational Condition
NG
OK B

C
Nidec confidential 5/11
Failure Analysis
FAILURE ANALYSIS FLOW PHOTO AND IMPORTANT INFORMATION

Visual check connector pad.

Visual Condition
NG OK NG
D
OK

Remove IC Mold

Visual Check

Visual Condition
NG
D
OK

IC Resistance Check

Handy Type Tester

Findings MT-3210

IC Related B
D SA Related

Nidec confidential 6/11

Failure Analysis Findings
Fig. 1

Floated IC

PROBLEM
 Motor have rotation but Current Value is HIGH.
ROOTCAUSE
 Floated IC – IC Pin 15 (Set 2) and Pin 16 (Set 1) is floated.

ANALYSIS

 Motor change max speed since Pin 15 and Pin 16 has no connection.
RECOMMENDATION

 Immediately feedback to PIC for them to coordinate to CT/L and FPC supplier.

Nidec confidential 7/11

Failure Analysis Findings
Fig. 2

OK

Removed Capacitor / Soldering NG

PROBLEM

 No Rotation
ROOTCAUSE
 Removed stability capacitor due to Soldering NG.
ANALYSIS
 No capacitor opens circuit result to No Rotation.
RECOMMENDATION

 Immediately feedback to PIC for them to coordinate to CT/L and FPC supplier.
Nidec confidential 8/11
Failure Analysis Findings
Fig. 3

Shorted PWM and 5V

PROBLEM
 High speed rotation of a rotor even in 16% duty.

ROOTCAUSE

 Shorted PWM and 5V.

ANALYSIS

 Fan speed cannot change since PWM is equal to 5V.

RECOMMENDATION

 Immediately feedback to PIC for them to coordinate to CT/L and FPC supplier.

Nidec confidential 9/11

Failure Analysis Findings
Fig. 4

Shorted COM and GND

PROBLEM
 No Rotation

ROOTCAUSE

 Shorted COM and GND.

ANALYSIS

 Shorted COM phase to GND will result to COM phase equal to 0V.

RECOMMENDATION

 Immediately feedback to PIC for them to coordinate to CT/L and FPC supplier.

Nidec confidential 10/11

Failure Analysis Findings
Fig. 5

No connection

COM PHASE
COM PHASE

connected

Shorted RNF and COM

PROBLEM
 No Rotation

ROOTCAUSE

 IC COM phase is not connected with the Stator COM phase.

ANALYSIS

 No connection on IC and Stator phase results to NO ROTATION defects.

RECOMMENDATION

 Immediately feedback to PIC for them to coordinate to CT/L and FPC supplier.

Nidec confidential 11/11

Failure Analysis Findings

Scratch

Scratch

PROBLEM
 No Rotation

ROOTCAUSE

 Rubbing between pillow and impeller.

ANALYSIS

Scratch result to unbalanced positioning of the impeller due to improper docking of the rotor to pillow

RECOMMENDATION
Recommend to hand rotate the docked rotor before screw attachment process.

Nidec confidential 12/11

Failure Analysis Findings
Not
connected
V Phase

Insufficient
Soldering

PROBLEM
 No Rotation

ROOTCAUSE

 Insufficient soldering on common phase terminal on the FPC.

ANALYSIS

 Insufficient soldering on common phase will lead to no connection.

RECOMMENDATION

 Immediately check soldering process in line.

Nidec confidential 13/11

 Thank you
is a registered trademark or a trademark of Nidec Corporation in Japan, the United States and/or certain other countries.
　 is a registered trademark of Nidec Corporation in Japan, and a trademark in the United States and/or certain other countries.
is a registered trademark of Nidec Corporation in Japan, and a trademark in the United States and/or certain other countries.

Nidec confidential 14/11

Failure Analysis

FAILURE ANALYSIS FLOW

Check Production in Line

(Machine / Process)

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Failure Analysis

FAILURE ANALYSIS FLOW

Check Production in Line

(Machine / Process)

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Failure Analysis

FAILURE ANALYSIS FLOW

Check Production in Line

(Machine / Process)

Nidec confidential 17/11

Failure Analysis

FAILURE ANALYSIS FLOW

Check Production in Line

(Machine / Process)

Nidec confidential 18/11

Failure Analysis
FAILURE ANALYSIS FLOW

Separate Cover and Rotor

Visual Check
Cover Rotor
Cover & Rotor
Visual Condition
NG
OK A

Separate rotor

Visual Check
Bearing Impeller
Rotor
Visual Condition
NG
Cap Hub
OK A
Magnet
Teardown Bearing
Housing
Bearphite
NKT
Visual Check
Bearing

Nidec confidential 19/11

Failure Analysis
FAILURE ANALYSIS FLOW

Separate Cover and Rotor

Visual Check
Cover Rotor
Cover & Rotor
Visual Condition
NG
OK A

Separate rotor

Visual Check
Bearing Impeller
Rotor
Visual Condition
NG
Cap Hub
OK A
Magnet
Teardown Bearing
Housing
Bearphite
NKT
Visual Check
Bearing

Nidec confidential 20/11

Failure Analysis
FAILURE ANALYSIS FLOW

Make report

Send report to CT/L

Nidec confidential 21/11

Different Waveform
 F~Tester machine can determine the abnormality of a unit through it’s display on Current Wave
and FG Signal Wave.
F~TESTER SAMPLE DISPLAY OF DIFFERENT WAVE FORM

Fig. 1 Fig. 2 Fig. 3 Fig. 4

OK CURRENT WAVE NG CURRENT WAVE NG CURRENT WAVE NG CURRENT WAVE

Fig. 5 Fig. 6 Fig. 7

OK FG SIGNAL WAVE NG FG SIGNAL WAVE NO ROTATION

 Upon Failure analysis, if we encounter this kind of abnormality, we should report immediately
to production PIC’s. Then they are the one to coordinate with the supplier or to CT/L. Also we wil
l send this motor to CT/L.
Nidec confidential 22/11
IC Issue
Resistance checking through Handy Type Tester

U,V,W~COM Checking COM~GND Checking TACH~GND Checking

IC Resistance Value
Model
U,V,W ~ COM COM~GND Tach~GND
D1 5.2~5.5 ohms 10~12 M ohms 0.F
D2 3.2~3.5 ohms 10~12 M ohms 0.F

 If the value of U,V,W~COM is abnormal, there is problem in Stator.

 If the value of COM~GND is abnormal, IC is broken.
 If Tach~GND has value, FG signal is NG.

Nidec confidential 23/11