CCFL Lamp Sample Quality Control Manual

Description

The product CCFL I26-350, is designed as the light source for backlight module of a 7" LCD monitor, and its color chromaticity are set at X=0.30±0.0 1; Y=0.285±0.01.

Lighting Principles

BriteView's CCFL is made of miniature hard-glass tube, which is spread with high-performance tri-color fluorescent powder on its inner surface and filled in idle-gad & less of mercury vapor. When powered it on, the gas was dissociated to stimulate the mercury vapor and emission out 253.7nm ultra-violet rays, and then changed to visible light when passed through fluorescent coating layer.

Product Characteristics

• High luminance & efficiency, low power consumption, compact size and long life.
• Good impact absorbability, start ability & repeatability
• Ability to be instantly started on under 0.1 Lx illuminations.
• Color temperature tri-colors can be adjusted to customer's requirements.

Applications

LCD monitor backlight source.

Ambient conditions for applications

• For operation:
• Temperature: 0~60°C
• Relative humidity: 20~90%
• No condensation or iced on lamp surface.
• For storage:
• Temperature: -30~70°C
• Relative humidity: 5~90%
• No condensation or iced on lamp surface.

Notices

• Do not bend both-ends electrodes, or it may influence vacuum characteristics and break-down the lamp.
• Do not bend, curve, or shock on lamps or it may be broken.
• The average life may be shortened when using lamps in low temperature (<0°C) environments.
• To prevent electric-shock, do not touch both-ends electrodes of lamps while it is powered on.
• The welding of wires to electrode should be finished in a short time in order to prevent the overheating and breakage of lamps.
• Do not look at lamp for a long time when lighting; doing so may hurt eyes.

Testing Instruments & Conditions

Testing Instruments

• Milli-ampare meter: INSTEK GDM-8246A
• RMS meter: INSTEK GDS820C
• High-voltage probe: TEK P6015A
• Luminance meter; TOPCON BM-7

Testing Conditions

• Temperature:25±2°C
• Relative humidty:65%±20%(no wind)
• Start testing after lighting 5 minutes.

Notices

• Do not misconnect the positive/negative poles of inverter.
• Do not touch instruments while on or testing

Basic Specifications

Size and Dimensions Materials List

No.	Part Names	Materials	Remarks
1	Electrode guide-pin	Ni	-
2	Glass tube	Hard-glass	-
3	Fluorescent Powder	Tri-Colors Fluorescent Powder	-
4	Filling gas	Ne+Ar	-
5	Electrode	Ni	-
6	Degasnater	Al-Zr	-
7	Rubber cap	-	-
8	Connector	-	-
9	Wire assy	-	-

Initial Characteristics

No.	Items	Specifications	Remarks
1	Color temperature	8000k(ref.)	Tube current at 5mA
2	Color chromaticity	X=0.300±0.01 Y=0.285±0.01	Checking the central section of lamps with TOPCON BM-7
3	Main ray wave length	R=611 G=544 B=453	Checking the central section of lamps at tube current 5mA
4	Tube current	5mA	Measured with GDM-8246
5	Tube voltage	690V±10%ms	Measured with TOPCON BM-7
6	Power (ref.)	3.45W	At input voltage 12VDC
7	Surface luminance	33000±10%cd/m2	Measured with TOPCON BM-7
8	Effective lighting length	300mm	Total length of lamp which luminance over 80% of it at central section
9	Startup voltage	1050 Vrms max.	At ambient temp. 25±2°C
10	Startup time	500ms max.	Testing after lain in room temp. 25±2°C for 2 hrs later
11	Stable discharging time	3min	100% luminance at lamp central section after power on 5 minutes
12	Life	25000hrs	Ambient without wind
13	Dimension	OD=2.6±0.1mm ID=2.0mm	Lamp length 350±1.0mm

Testing Schematics

Lamp Current Testing

• Wire length of A-B: 150±10mm
• Wire length of C-D:300±10mm
• Measurement item: Lamp current
• Instruments: Lamp current milli-ampare meter GDM-8246

Lamp Voltage Testing

• Wire length of A-B: 150±10mm
• Wire length of C-D:300±10mm
• Measurement item: Lamp voltage
• Instruments: RMS meter GDS-820C & high voltage probe TEK P6015A

Brightness & Chromaticity

Life Testing

Judging conditions

If one of the following conditions occurred, the lamp life is over:

• The luminance of lamp central section becomes less than 50% of initial value.
• Starting voltage is higher than the rated voltage.

Testing Items

Test		Rated Life
Rated Life
Ambient temperature:	normal(25°C)	≥ 25,000 hrs
Current:	5rnA
Power on frequency:	continuous
Low Temperature Life
Ambient temperature:	0°C±1°C	≥ 500 hrs
Current:	5rnA
Power on frequency:	continuous
On-off life
Ambient temperature:	normal(25°C)	≥ 200,000 hrs
Current:	5mA
Power on frequency:	l0 sec. on and 10 sec. off

Application Environments

Items	Specifications	Remarks
Operation temperature	0°C~60°C	No Condensation
Storage temperature	-30°C~70°C	No Condensation
Relative humidity	90%	No Condensation

Reliability Testing

Lamps need to fulfill the following reliability tests items:

No.	Items	Conditions	Specifications
1	Impact testing	6.3.1	C,E
2	vibration testing	6.3.2	C,E
3	Terminal tensil strength testing	6.3.3	C,E
4	Heat-cycle testing	6.3.4	A,C,D,E
5	High temperature & humidity testing	6.3.5	A,B,C,D,F
6	High temperature testing	6.3.6	A,C,D,F
7	Low temperature testing	6.3.7	A,B,C,D,F
8	High temperature & humidity operation testing	6.3.8	A,B,C,D,F
9	Seal up testing	6.3.9	C,D,E
10	Snaking testing	6.3.10	G
11	Low temperature operation testing	6.3.11	A,B,C,D,F

Judging conditions

After reliability testing, the characteristics of testing lamps must meet the following requirements:

• Startup voltage: No over 10% of initial value.
• Luminance: At least 50% of initial value.
• No mechanical or physical damage (e.g. nickel guide pin broken)
• No visible distortion, color changing, etc.
• No lamp can light up.
• The luminance should be up to 95% of it stability, after it has been powered on 3 minutes.
• No darken or color changing in appearance, or lighting is not normal (such as flicking, smacking, etc.)

Testing Conditions

• Impact testing:
• Pulse wave of 30G, llm/sec2 should be applied three times each in X,Y,Z directions. The lamp should be held on the testing fixture.
• Vibration test:
• Acceleration 19.6m/sec2, frequency 20-500-20Hz be applied in 3 minutes each time, and each In X,Y,Z directions for l hour. Be careful to prevent resonant point.
• Terminal wire intensity test:
• Tube axial load: l kg
• Time: 5 sec.
• Heat-cycle test:
• Operating 10 cycles as following condition
• 
• High-temperature & humidity storage test:
• Temperature: 70±2°C
• Humidity: 90±5%R.H
• Time: 500 hrs
• The lamps should be preserved at room temperature for 2 hrs before doing function testing.
• High temperature storage test:
• Temperature: 70±2O°C (Dry)
• Time: 1000hrs
• The lamps should be preserved at room temperature for 2 hrs before doing function testing.
• Low temperature storage test:
• Temperature: -30°C ±2O°C
• Time: 1000hrs
• The lamps should be preserved at room temperature for 2 hrs before doing function testing.
• High-temperature & humidity operating test:
• Temperature: 40±°C
• Humidity: 90%R.H
• Time: 5mA
• Current: 5mA
• Current: 5mA
• Sealed test:
• Sampling 40pcs dipped in the boiling water(>95°C) for 10 sec, then dipped in 4°C water for 10 sec. Doing cycle 3 times. All samples should be passed, if there is one fail, do the Next test again.
• Snaking test:
• Temperature: 50±2°C
• Time: 24hrs
• Current: 5mA
• The lamps should be preserved at >0°C ±2 temperature for 2 hrs before doing function testing.
• Low-temperature operation test:
• Temperature: 0±1°C Time: 5mA The lamps should be preserved at room temperature for 2 hours before doing function testing.

Inspections & AQL (Acceptable Quality Level)

Lamp Quality Control

In order to control the lamp's quality, according to CNS 2779 Z4006 table II -A ~single sampling plans of normal inspection to do the quality control.

• Bad quality: Snaking, flicker, crack (No external force)
• Light bad quality: Fluorescent coating cracked & peeled off

Remark:

• Hg stuck on inner wall of tube is normal.
• Light black color of two end-sides of glass tube is normal.
• Fluorescent coating peeled off in 15mm from two end-sides is not counted.

Inspection Items	AQL	Inspection Methods
Appearance of Lighting	Bad quality AQL<0.4 Light bad quality AQL<0.5	Vision
Mechanical dimensions	N=5, C=0	Measuring tools
Initial characteristics	N=5, C=0 (AQL 0.4)	According to 3,4 paragraph

Packing & Marking

According to the packing requirement standards of BriteView Technologies Inc.