PSB-ICSP-1123-Rev B-ICS-6000 DC Burned Boards

Description: 

The ICSP business unit has received reports of burned PCBs within the ICS-6000 DC module. The most reported symptom is a burning smell and/or minor amounts of smoke released from the instrument. Investigation into the reports identified that the burned components were limited to and contained within the DC module and pose no risk to the user or local environment.

A formal CAPA was opened into the issue and returned modules were subjected to a thorough factory and independent third-party failure analysis. The Quality and Engineering teams determined the containment and safety features built into the ICS-6000 DC module performed as designed preventing any risk or hazard outside of the DC module.

The contract manufacturer (CM) also performed their own investigation, and this led to the determination of root cause to be directly related to stacked tolerances between the faceplate and DC Suppressor power supply board. When each was at the extreme of the tolerance range the screw standoffs were not properly aligned resulting in assemblers overtightening and/or misaligning the DC Suppressor PCB to the faceplate resulting in stress across the PCB and ultimately causing a short circuit. This occurred in a very small number of systems, but the short circuit can manifest itself during power up at install, shortly after install or even many months later.

The CM implemented corrective measures to prevent the shipment of failed DC Suppressor assemblies or out of tolerance faceplates on April 27, 2022. Simultaneously the ICSP BU sustaining engineering team began work on revising the DC Suppressor PCB to remove the chance of future tolerance concerns.

The IC/SP BU will continue to monitor, ensuring the CAPA measures were effective. All ICS-6000 DC burned board events must be reported to the IC/SP PSE team immediately.

Environment:

ICS-6000 DC modules

Recommendations:

In the event of a failure with thermal damage limited to the DC suppressor power supply PCBA, the entire assembly should be replaced. A new part number has been created that contains the DC Suppressor power supply PCB and faceplate already assembled along with two screws to mount it to the rear of the DC module. 

Please order the new P/N: B51000145 (ASSY, PCB BRKT, ICS 6000) and replace only as a full assembly. Picture below is the preassembled part.

Replacement procedure:

·         Set the module atop a lab bench and ensure it is disconnected from AC power.

·         Pull out the DC Suppressor power supply assembly (PCB and faceplate).  Dispose of locally and do not reuse the PCB, nor faceplate.

·         Slide in the new PCB and faceplate assembly, using the two accompanying screws to affix it to the rear of the DC module.