QP045000-AB Condensate Pump Quality Procedure

Quality Procedure

QP045000 QUALITY PROCEDURE FOR CP-22-120V, CP-NL20, CP-22-230V, CP-NL20T AND CP-22T CONDENSATE REMOVAL PUMPS

CONDENSATE REMOVAL PUMP REFERENCE PHOTO

I. TitleQP045000 QUALITY PROCEDURE FOR CP-22-120V, CP-NL20, CP-22-230V, CP-NL20T AND CP-22T CONDENSATE REMOVAL PUMPS

II. Document NumberQP045000-AB

III. Reference Documents

DW045000 Condensate Pump AssemblyDW045100 230 V Condensate Pump Final AssemblyDW045200 Condensate Pump Assembly (EWI)TL045000 Test and calibration procedure for Condensate Pump Automated

TesterDW045265 PVC Tubing (EWI)FA045288 CP-22T and CP-NL20T Master Carton Assy (EWI)FA045090 Inner Packaging Box AssyFA045290 Inner Packaging Box Assy (EWI)QP000003 Packaging Drop Test Quality ProcedureQP000006 Quality Procedure for PackagingIPC-A-610 Acceptability of Electronic AssembliesIPC/EIA J-STD-001 Requirements for Soldered Electrical and Electronic Assemblies

Copyright East West LLC Page 1 of 22 rev. 11/24/2008

Quality Procedure


IV. Tools Required Dial Caliper or Ruler capable of measuring 460 mm Decibel Meter True RMS Watt Meter Low ohm meter or Digital Millivolt Meter and Regulated Power Supply. Quick Check 200 Barcode Verifier Spring Scale Manometer capable of 30’ with graduations of 0.5 in. Clear vinyl tubing of various lengths Pantone Color Chart Torque Wrench Measuring Cup capable of measuring 350mL to 2500mL Hi-Pot Tester 35 lb Weight 25 lb Weight 25mm diameter polished stainless steel ball Shore A Hardness Tester

V. Procedure Use attached Inspection form at the end of this document for the inspection If any of the points below are FALSE about the sample being inspected, please record

the failure type associated with that section on the Inspection Form No more than 15% of the sample must come from the same carton, unless the total

number of boxes is less than 7. If there are less than 7 cartons, be sure to select randomly from different layers within the same carton.

All Sampling is per MIL 105E General Inspection Level II unless specified otherwise All cartons containing samples pulled for testing must be marked with an

“Inspected by QC” or similar identification label.

A. Visual Inspection – Packaging (MIL STD Level I)

1. Compare the flute of the inner carton with an approved sample and verify that they are the same. (Major)

2. Verify that the POP boxes are free from dents or scratches. (Minor, Any cartons that are open and unable to be sealed are Major)


Quality Procedure


B. Visual Inspection – Product (MIL STD 105 Level I)

1. Verify that all pads are fully inserted into the base of the tub. Rock tub back and forth to ensure tub is level. Tub must not rise more than 1mm. (Major)

2. Verify that wire colors, wire gage, and UL file No. match correct motor drawing or wire specification. Wires must not be pinched, or insulation torn. (Major)

3. Inspect plug and verify that prongs are straight, not bent, and evenly spaced and free of corrosion. All wire markings must match drawing. (Major)

4. Use pantone chart to verify that the colors of the tub, deck, lens, top cover, and tablet housing match the drawing spec or limit sample. (Minor)

5. Verify that all components are present and assembled according to the drawing. (Major, Missing strain relief clamp is Critical)

6. Verify that all surfaces are free from dents, cracks, scratches or flash visible from 1 Meter. Verify that motor laminates are free or dents, rust or corrosion visible from 1 Meter. Pump must be free of contaminants like tape, packing material, flash trimming. (Minor)

7. Verify that there are no sink marks on the top cover. (Minor)

8. Verify that all wire terminals are tightly connected. Verify quality of soldered connections. The solder nuggets must be completely formed with no 2 touching each other. Reference IPC-A610 or JSTD-001 for manufacturing guides. (Major)

9. Verify that the motor impeller spins freely when turned by hand with no noise or resistance. (Major)

10. Verify that the top label is applied squarely and centered. There must be no bubbles or tears. Printing must match artwork. (Minor)

11. Verify that all labels are clean and free of tears or wrinkles. The label printing must be legible from 1 meter, and match the artwork file. Use pantone chart to verify colors match. (Minor)

12. Verify that the insulation seal is firmly attached to the plastic boss and seated in the housing. (Major)

13. Ensure that the valve is screwed tightly into the plastic housing with a minimum torque as specified on the drawing. (Major)

14.Verify that the plastic lock tabs on the deck fitting are properly assembled in the deck. Using a spring scale, verify that the check valve assembly does not come free


Quality Procedure


when pulled with 10lbs of force. Remove the check valve and inspect the assembly. Assembly must match the drawing spec. (Major)

15. Verify that the deck fits flush onto the tub; there must be no gaps larger than 1 mm. Turn the device upside down only holding the tub at the corners. Ensure that the deck remains firmly attached to the tub. (Major)

16. Verify that cord safety label matches artwork file. (Major)

17. Verify that there is no factory contact info or other identifying markings on the braided hose. Hose must be free of kinks, holes or damage. Location and rotation of hose clamp crimp must match the drawing spec. (Major)

18. Remove the cover from the deck and verify that none of the screw posts are broken or stripped. (Major)

19. Verify that the motor is secured to the condensate pump and that none of the screws or assembled components are loose. (Major)

20. Verify shading pole is properly welded (see Figures 1a and 1b). (Critical if loop is open)

Figure 1a. Loop is closed. Sample passes inspection. Figure 1b. Loop is open. Sample fails inspection


Quality Procedure


21. Verify switch manufacture against UL File. Reference Figure 2. (Critical)

Figure 2. Accepted switches with manufacturer’s logos.

22. Verify the Deck Lid is secured to the Tank while it is in the packaging. (Minor)

23. CP-22T (CP-NL20T): Verify the hose included in the inner carton matches PVC Tubing drawing. (Major)

24. CP-22T (CP-NL20T): Verify that there are no more than three bends (kinks) per 20 feet of tubing for the CP-22T according to the PVC tube drawing.(Major)

C. Dimensional Inspection (Sample Size per MIL 105E S-4)

1. Verify the length and alignment of the float assembly. Length must match the drawing spec. (Major)

2. Verify that the wire lengths match the drawing requirements. (Minor)

3. CP-22T (CP-NL20T): Verify the included hose’s dimensions match the PVC Tubing drawing. (Major)

D. Functional Inspection – Product (Special Sample Size MIL 105 Special Level S-4)

1. Carton Drop Test Perform drop testing on 1 export carton (with straps) before completing the remainder

of the functional testing. See QP000003 for Drop Test procedure. Test must be performed from 460mm drop height.

Pumps which may have sound output issue should also be tested according to the Sound Output Test Procedure.

Once functional testing complete, remove pump cover and perform visual inspection of all components.

Submit separate data report for Drop Test results using table in QP000003.

Note: Pumps with any functional or visual issues after drop testing should NOT be shipped.


Quality Procedure


2. Pump Activation, Alarm, and Safety Switch Function Tests Apply power to pump. Connect the outside Alarm and Safety Switch channels to

a multimeter, LED, or other indicator (Figures 3a and 3b). Verify that the reading is open.

Figure3a. Activation Test Station and Setup. Figure3b. Connect voltage indicator to two outer leads.

Prevent the output hose from discharging water by attaching a hose and routing it into the drain hole (Figures 4a and 4b).

Figure 4a. Route end of output hose through drain hole. Figure 4b. Close-up of output hose in drain hole.

Slowly fill tub with water until the pump activates (see Figure 5).

Figure 5. Add water to tub to activate pump.


Quality Procedure


Record amount of water required to activate pump. The amount of water required to activate the pump must within the specified values according to the drawing. (Major)

Verify that the pump activates before the Red LED activates. Record amount of water required to activate Red LED. The amount of water required to activate the alarm must be within the specified values according to the drawing (Major)

Verify that the pump activates before the Safety (Cut-Off) Switch activates. Record amount of water required to activate Safety switch. (Critical)

Water must not leak out of the overflow holes before the Safety Switch activates. (Critical)

Water must not leak out of the overflow holes before the Red LED activates. (Major)

Record amount of water left in the tub after the pump shuts off. Total water remaining in pump must meet the values in to avoid “slurping” sound of air being suctioned into pump housing. (Major) Pump does not shut off. (Critical)

3. Sound Output Test Place the condensate pump on a flat level surface. Test chamber ambient noise

must be <50dB. Attach a hose to route expelled water into pump drain hole (see Figures 4a and

4b). Apply power to the pump. Slowly add water until pump motor activates. Use the decibel meter to determine the sound output of the pump action of the

condensate pump. Decibel meter should be set to “A” Weighting. Hold the meter 30cm above the top cover, facing the fan. Record the maximum sound output. Sound output must not exceed the drawing

specification. (Major) When running pump in full flow condition, excessive noise may results from the

flow of water back into the pump tank. To reduce this noise, pinch output tubing slightly so that this noise is reduced to a minimum (see Figure 6).

Figure 6. Pinch output tubing to reduce noise.

Listen for any abnormal sounds including impeller or fan rubbing against housing, foreign material or debris circulating through pump. Abnormal noise defects must be re-worked prior to shipment. (Major)


Quality Procedure


4. Pressure Test

Tube Method (Static Head) Set up test according to the diagram below. Ensure that the tube is straight and

level. Note: Performing the test in an empty tube will create inertial forces that will aid

in pump height. Allow 7-8 feet of hose to rest on the ground when setting up the test. Fill the hose resting on the ground with water prior to pumping the water to the specified height.

Turn on pump and record the maximum head pressure in inches of water. Measurement must be taken in less than 1 minute of operation.

Figure 7. Pressure Test Setup

Pressure must match the drawing specification. (Major)

Pressure Test using Automated Tester Method – See TL045000. (Major)

5. Current Draw Test

During Static Head testing, determine current and power draw within 1 minute of operation once maximum pump head is achieved.

Ensure tub is filled with water so that red LED and Safety Switch are activated during testing.

Record current and power draw for each pump in data table. Current and power must not exceed drawing spec (DW045000 for 120V Pump, DW045100 for 230V Pump). (Major)


Test must begin with 8 ft of water in the tube

Quality Procedure


6. Power Cord Test Activate the condensate pump. Bend and twist the power cord in 3 random locations to verify that the cord is free

of opens or broken wire. Pump must not stop or lose function. (Major)

7. Valve Water Backflow Test Use pressure tester to verify sealing ability of the check valves. Connect hose to check valve and fill with water as shown in Figure 8.

Figure 8. Backflow Test Setup

Apply 0 psi of pressure to the check valve hose by filling tube with approximately 30 cm (12 in) of water. Observe hose for 90 seconds to ensure that the water does not decrease or backflow into the tub. (Major if >6mm leakage is observed)

Apply 5psi of pressure to the check valve hose. Observe hose for 90 seconds to ensure that the water does not decrease or backflow into the tub. (Major)

8. Dielectric Withstanding Test Use a hi-pot tester to apply continuously 1500V @ 50 Hz for 2 seconds between

any live parts and grounded dead metal. The pump must have no physical damage or mechanical breakdown for the

application. (Major) Maximum leakage cannot exceed 0.5mA for a 3-wire (grounded) portable pump.

(Major)

9. CP-22T (CP-NL20T): Verify the included hose’s hardness matches PVC Tubing drawing. (Major)


Quality Procedure


E. Functional Inspection – Product (Special Sample Size MIL 105 S-2)

1. Terminal Pull Test Secure pump in place and attach a spring scale to the quick connect motor

leads. Pull on terminal until it detaches from the motor.

Figure 10. Pull spring scale away from motor leads ontil the terminal detaches from motor.

Pull force must be > 2.5lbs. (Major)

F. Functional Inspection – Product (Special Sample Size MIL 105 S-1)

1. Wire Pull Test Mark electrical cord near top cover, and measure the distance between mark and

top cover. (Figure 11)

Figure 11. Mark cord near top cover.


Quality Procedure


Mount condensate pump vertically, and hang a 35 lb weight from wire for 1 minute (Figure 12). With weight attached, measure the distance that the wire is displaced. The cord must not move greater than 2mm. See UL 778 Section 45. (Major)

Figure 12. Wire Pull Test Setup

2. Load Test Add 25 lbs to the top cover shown in Figure 13. No portion of the pump or container should deform or bow outwards. No piece

shall crack or break. Top cover must not collapse into the tub. (Major)

Figure 13. Load Test Setup

3. Pull Test for Check Valve Attach spring scale to check valve. Apply 10 lbs of pull force for 5 seconds. The check valve must remain fully seated in plastic housing. (Major)


35 lbLoad

Quality Procedure


4. Plastic Impact Test Remove cover and pump from the plastic tub. Turn plastic tub face down

(bottom surface facing up) on a flat, level surface. Drop a 25mm diameter polished steel ball onto the tub from a height of 24 inches

from the top of the tub. Repeat 3 times. Tub must not crack or break. (Major)

G. Supporting Data - Required Attachments (Critical)

1. Export Carton Data and Lot Numbers. Record the lot number and carton text from each carton where samples were taken. Attach a photo or written copy of the exact text to the inspection form. Attach Export Carton Inspection Report from QP000006.

2. Submit Drop Test Inspection Report from QP000003.

3. Submit Data Trend report with Inspection Tables to for review.

4. Pallet Fumigation Stamp (if Applicable) - Wood packaging materials must be either:

a. Heat treated to a minimum wood core temperature of 56ºC for a minimum of thirty minutes; or

b. Fumigation with methyl bromide

Certified Treatments must be marked with the following International Plant Protection Convention (IPPC) Logo.

Figure 14. International Plant Protection Convention (IPPC) Logo

5. Daily Production Testing Data. Verify that factory is performing routine in-line daily tests as described in this quality procedure. Attach copies of daily production records.

The following tests must be performed in-line on 100% of products produced unless otherwise specified.


Quality Procedure


Ground Continuity Test – (See UL 1004 section 22A.1) Determine the resistance between points specified in Figures 15a and 15b. The measured resistance must be less than 0.25 Ω.

Figure 15a. Attach one end of resistance meter Figure 15b. Attach opposite end of resistance meterto lead ground terminal. to ground lead plug.

Low ohm measurement - between the grounding wire and any other point required to be grounded.

Leakage Current Test described above Life Cycle Testing – ensure that 2 motors from each batch are tested and that

they meet the > 1,000 hr life cycle requirement. Motor decibel level must be measured during incoming inspection. Motor must

be placed on a 0.5” thick min rubber pad or held in the hand when sound is measured. Sound must be measured with meter facing the shaft at distance specified in the drawing.

Motor supplier must verify that they are performing 100% coil testing for pinhole and surge testing. Documents must be disclosed as evidence of testing.

A. Pinhole Test Procedure - Cut two 6m length magnet wire from the production line. Strip one end of the magnet wire and connect 20VDC power. Place into the tub with salt and phenolphthalein acid. Strip the other end of the magnet wire and place into the tub. If Phenolphthalein turns red, holes are present. See Figure 16.

Figure 16. Pinhole test set up.

Motor supplier must provide records of destructive testing of enamel defects.


Quality Procedure


Check Valve Backflow Test must be performed in process according to this quality procedure at a minimum sampling rate of S-2.

Pressure test using automated tester – Data must be collected in sequential order and provided in a tabelized report. Products must contain a serial number matching the corresponding test data. See drawing for serial number placement. 100% sampling must be performed for the first 5000 units shipped. Minimum 5% sampling must be performed thereafter.

Pump Activation Test (100% Inspection) Alarm Activation Test (100% Inspection) HiPot Test (100% Inspection) Motor Resistance Test using High Voltage Multimeter (100% Inspection) Duckbill IQC Inspection Records Report the Serial Number for ALL pumps included in the order using provided

form.6. Material Certification. Verify that all components match the drawing and UL file.

Factory must provide valid documentation for each component.

7. UL Verification Form – Fill out UL Verification Form and have Factory Manager provide signature.

-OR-

Obtain documentation from the factory that includes: Factory Name Material Name and/or Number Statement that EW’s product was made from identified material Signature of Factory Manager or designate (i.e. Quality Manager)

H. Shipment Quantity

1. Count every export carton for each size and total the quantities. Total quantities must match the quantities on the Inspection Report. (Critical)

End of Procedure


Quality Procedure


Inspection Plan: Mil. Std. 105-E EW Part #:

General Inspection Level II Inspection Date:

Minor AQL: 2.5 Major AQL: 1.0 Critical AQL: 0.0 Shipment Size:

Sample Lot Size:

Section Inspection Item Minors Majors Criticals

A. Visual Inspection – Export

1. Inner Carton Flute X X

2. Inner Carton and POP Box Appearance X X

B. Visual Inspection – Product

1. Tub rise X X

2. PCB (components, LEDs, solder connections) X X

3. Wire & Plug appearance X X

4. Pantone check X X

5. Components present X

6. No dents, cracks, scratches, or flash X X

7. No sink marks X X

8. Wire terminals tightly connected X X

9. Impeller spins freely X X

10.Top cover applied squarely and center X X

11.Labels clean and wrinkle free X X

12.Insulation seal attached X X

13.Valve screwed tightly X X

14.Plastic lock tabs fit X X

15.Deck is flush on tub X X

16.Cord safety label X X

17.No factory contact info X X

18.No broken or stripped screws X X

19.Motor is secured X X

20.Welding of shaded pole X X

21.Switch manufacturer X X

22.Deck Lid Secure X X

23.CP-22T (CP-NL20T): Hose Appearance X X

24.CP-22T (CP-NL20T): Kinks per tube ≤ 3 X X

G. Supporting Data – Required Attachments

1. Export Carton Data X X

2. Pallet Fumigation Stamp (if applicable) X X

3. Daily Production Data X X

- Motor IQC records X X

- Pump Activation X X

- Alarm Activation X X

4. Material Certification X X


Quality Procedure


5. UL Certification X X

H. Shipment Quantity

1. Shipment Quantity X X

Total Defects from Inspection

Lot Acceptance Criteria < < * See Note

Results of this Inspection (circle one) Pass Fail Conditional

Comments:

Note: Critical Failures must be re-worked, reinspected and approved by EW before the shipment can be released,Inspector:

Factory:


Quality Procedure


Inspection Plan: Mil. Std. 105-E S-4 EW Part #:

Special Inspection Level S-4 Inspection Date:


Sample Lot Size:


C. Dimensional Inspection –Product (MIL-105E S-4)

1. Float length X X

2. Wire Length X X

3. CP-22T (CP-NL20T): Hose Dimension X X

D. Functional Inspection –Product (MIL-105E S-4)

1. Carton Drop Test X X X

2. Pump Activation, Alarm, and COM Test X X X

a. Activation Water Level X X

b. Red LED Activation Sequence X X

c. Safety Switch Activation Sequence X X

d. Water Overflow X X

e. Deactivation Water Level X X

3. Sound Output X X

a. Maximum Sound Output X X

b. Abnormal Sound Defects X X

4. Pressure Test (Static and Automated) X X

5. Current Draw Test X X

6. Power Cord Test X X

7. Valve Backflow Test X X

8. Dielectric Withstanding X X

9. CP-22T (CP-NL20T): Hose Hardness X X




Comments: *Carton drop test results should be included with Pump Activation & Sound Output results where applicable.

Note: Critical Failures must be re-worked, reinspected and approved by EW before the shipment can be released,Inspector:


Quality Procedure





Sample Lot Size:


E. Functional Inspection - Product (Sample Size per Mil 105E S-2)

1. Terminal Pull Test X X




Comments:

Note: Critical Failures must be re-worked, reinspected and approved by EW before the shipment can be released,

Inspector:

Factory:


Quality Procedure





Sample Lot Size:


F. Functional Inspection - Product (Sample Size per Mil 105E S-1)

1. Wire Pull Test X X

2. Load Test X X

3. Pull Test for Check Valve X X

4. Plastic Impact Test X X




Comments:

Note: Critical Failures must be re-worked, reinspected and approved by EW before the shipment can be released,

Inspector:

Factory:

Please complete the inspection form and email it to EW’s Atlanta office.


Quality Procedure


Material CertificationInstructions: The inspector must certify that the material used in this shipment matches the product assembly drawing and each material UL file number listed matches the material used.

This page must be signed and included with each inspection. A signature on this form certifies the inspector verifies that UL listed materials have been used in the construction of this lot of the product.

NO. FUNCTION INSULATION MATERIAL MANUFACTURER UL FILE NO.Inspector Verified (Check)

1 DW045000 Condensate Main Assy See Bill of Materials and Associated Drawings

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Inspector

English Name

Date

Lot #

Comments:

Please complete the inspection form and email it to the Atlanta office


Quality Procedure


UL Verification Form

This form must be signed by the Factory Manager and included with each inspection report. A signature on this form certifies that the listed materials meet the UL specified requirements and that they have been used in the manufacturer of this lot of product.

Factory Name and Address: Date:

Material Purchase Date:

EW Project No. and Product Name:

Material Name Material Description

Material Manufacturer

Number or CodeRaw Material Manufacturer

Power Supply Cord (120 V and 230V)

6 ft min., 3 conductors, 105oC temp rating, AWG No. 18, Attachment Plug molded on grounding type rated 125 Vac 15 A, CSA Certified; 6-15 NEMA Plug for 230V SJTW

Pump Motor Enclosure (120 V and 230V)

R/C (QMFZ2) thermoplastic, rated 94-5VB. Type No. AF-342. LG Chemicals

Motor Mounting Plate (120 V and 230V) Tin Plated Copper Pump Housing (120 V and 230V)

Any R/C (QMFZ2) thermoplastic rated 94 HB min.

Impeller (120 V only)6 curved vanes, 1L x 3H” OR 1.2L x 0.4H”.

Float (120 V and 230V) ThermoplasticOutlet Fitting (120 V and 230V) Thermoplastic, 0.18 in IDFan (120 V and 230V) Thermoplastic, 3.0D x 0.5H”Tank (120 V and 230V)

Any R/C (QMFZ2) thermoplastic material rated 94HB min.

Deck (120 V and 230V)

R/C (QMFZ2) thermoplastic, rated 94-5VB. Type No. AF-342 LG Chemicals

On-Off Float Switch (120 V and 230V)

Rating 5 A, 125/250 Vac OR any R.C (WOYR2/8, rated min. 5 A, 125/250 Vac

TTS2-3N-15, KW4A, MFS-01, SM5-03D-6-C5.

Trantek, Yueging Dong Nan Electronic, Talismanic Electronic Co., Dicgu Electronics.

Light Switch (120 V and 230V) R/C (WOYR2), Rated 125-250 Vac, 5 A U.83133169 Crouzet


Quality Procedure


Internal Wiring (120 V and 230V)

R/C (AVLV2) AWM and CSA Certified, Rated 105oC, 300 V min. No. 18 AWG

Printed Circuit Board

R/C (QMST2 or ZPMV2), rated 94V-2 min., with the following components: Resisters (39K Ohm), Diode (1N4007), Terminals.

MotorR/C (XEWR2, OBJY2, PRGY2), rated 120V, 2.0 A, 60 Hz, Class B insulation.

EWM 63/33-12-18 or 131.

EW Mfg, or A.O. Smith

Impeller (230V only)Thermoplastic, seven vanes, 2.6”D. Or curved vanes 1.2Lx 0.4H”

Printed Circuit Board (230V only)

R/C (QMST2 or ZPMV2), rated 94V-2 min., with the following components: Resisters (78K Ohm), Diode (1N4007), Terminals.

Motor (230V only)R/C (XEWR2/8, OBJY2/8, PRGY2/8), rated 1.0 A, 230 Vac, Class B insulation

EWM 63/33-22-18, or 131

EW Mfg or A.O. Smith

Serial Number Report

Lot # Inspection Date:

Serial # Serial # Serial # Serial # Serial # Serial # Serial # Serial # Serial #


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