NO.

motoalt 2005

MATERIAL or METHODS Specification

TITLE:

MotoALT/CALT 2005 Test Procedure

REVISION DATE:

ISSUE: MEMO:
O

30-DEC-04

PRELIMINARY

MEMO:

ISSUE:

PAGE:

1 of 40

ORIGINATOR:

DETAIL SPEC CHANGES:

DATE:

Kenneth McKillip

Initial Spec Release

Dec 04

_________________________________________________________________________________________________________________________________________________________

CONTENTS
1. Scope
2. Product Submission
3. Responsibility
3.1 ALT Reliability Manager
3.2 ALT Engineer/Technician
3.3 Responsible Motorola Engineer/OEM Engineer
4. Reference Documents
5. Definitions and Acronyms
6. Marking the Product
7. Testing
7.1 Allocation of Units to Modules
7.2 Overview of Testing
7.2.1 Parametric, Cameras, SPL, Blue Tooth and Desense Test
7.2.2 Power On Test
7.2.3 Module Description
7.2.4 Tests Between Stresses to Capture Failures
7.3 Functional Test
7.4 Signaling Test
7.5 Parametric, SPL, Blue Tooth and Desense Test Specifications
7.6 Camera Testing
8. Environmental and Mechanical Stresses and Finish Testing
8.1 Module I (Electrical/Physical Reliability Test) -- Thermal Environmental Sequence
8.1.1 Thermal Shock
8.1.2 First Drop Sequence
8.1.3 First Parallel Shaker Table Vibration and ESD Sequence
8.1.3.1 First Electrostatic Discharge (ESD)
8.1.3.2 First Shaker Table Vibration
8.1.4 Dust
8.1.5 Temperature Cycling
8.1.6 Temperature Humidity (+65OC/90%RH, 88 88hrs)
8.1.7 Second Drop Sequence
8.1.8 Second Parallel Shaker Table Vibration and ESD Sequence
8.1.8.1 Second Electrostatic Discharge (ESD)
8.1.8.2 Second Shaker Table Vibration
8.1.9 Final Parametric & Signaling
8.1.10 Initial & Final Desense Test Procedure
8.1.11 Initial & Final SPL Test Procedure
8.1.12 Initial & Final Blue Tooth Test Procedure
8.1.13 Initial & Final Embedded Camera Test Procedure
8.1.14 Initial & Final Embedded GPS Test Procedure
8.2 Module II (Mechanical Durability/Life Cycle Module) Mechanical Sequence
8.2.1 Thermal Shock
8.2.2 Temperature Humidity +65C/90% RH
8.2.3 Keypad Actuation
8.2.4 Chemical Exposure and Dry
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8.2.5 Squeeze Test

8.2.6 Flip Cycling
8.2.6.1 Flip Cycling (Hyperextension)
8.2.6.2 Flip Cycling
8.2.7 Final Parametric and Signaling test
8.3 Module III (Finish Module) Finish / Paint performance
8.3.1 Thermal Shock
8.3.2 Temperature Humidity +65C/90% RH
8.3.3 Box of Rocks Test
8.3.4 Dry Tests
8.3.4.1 Flip Cycling
8.3.4.2 Crosscut Tape Adhesion
8.3.4.3 Abrasion
8.3.4.4 Pencil Hardness
8.3.4.5 Edge Test
8.4 Module IV (DTF) Proto Cert Verification / Module 1 Drop Test Judgment
8.4.1 Worst Case Side Determination
8.4.2 DTF
9. Repair and Replacement Policy
9.1 Aborting ALT
9.2 Lost Hours (in ALT failure rate calculations)
APPENDIX
A. MotoALT Module I Sequence
B. MotoALT Module II Sequence
C. MotoALT Module III Sequence
D. MotoALT Module IV Sequence
E. MotoCALT Module I Sequence
F. MotoCALT Module II Sequence
G. MotoCALT Module III Sequence
H. MotoCALT Module IV Sequence
I. Unit Flow through MotoALT and MotoCALT Module I
J. Power Cycling Routine
K. Temperature Cycling Chamber Profile
L. Temperature Cycle Programming
M. Unit Orientations in Shaker
N. Portable Drop Checklist
O. Shaker Orientation Checklist
P. ESD Checklist
Q. DTF Checklist
R. Minimal Parametric Test Set
S. Desense Test (GSM Only)
T. MotoALT Failure Rate Formula
U. MotoALT/CALT Percent Complete Chart
V. Glossary of terms

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1. Scope
1.1 This specification provides the proper procedures for successfully conducting both the MotoALT Motorola
Accelerated Life Test and MotoCALT "Motorola Continuous Accelerated Life Test" process audit on OEM
portable wireless products. Refer to Appendix A, B, C, and D for MotoALT flows and Appendix E, F, G, and
H for MotoCALT flows. Reference will be made to other supporting 12M specifications to further define
specific steps in this process.
1.2 The purpose of the MotoALT is to provide an assessment of product quality, reliability, and design
robustness prior to product shipment to customers. The purpose of the MotoCALT is to demonstrate that
the current product being shipped has maintained the product quality and reliability demonstrated by the
MotoALT goal for ship authorization. Both are accomplished by exposing the product to various
environmental and mechanical stresses and measuring the effect on product functionality and finish. These
environments have been designed to age and fatigue the product within acceptable limits based on material
specifications, historical performance, and known customer expectations. The results are then used to
estimate product failure rates.
1.3 It is not the purpose of the MotoALT/CALT to certify that the product meets all required specifications or to
verify software feature performance. MotoALT/CALT testing is conducted to detect customer perceivable
failures as the result of exposure to accelerated field stresses. Full compliance testing is the responsibility of
Development Engineering.
1.4 Engineering judgment has been used to align the process with what the customer would most likely
consider a product failure or flaw. Either soft and hard malfunction or degradation of the product may be
considered failures. The focus of the test structure is failure precipitation; not on definitively isolating what
stresses caused what failures.
2

Product Submission
Products may be submitted by Motorola Development Engineering, OEM Engineering, or at the request of
Reliability Engineering. Typical submission quantities are shown in the table below. The sample should be
homogeneous in nature and be fully flexed as a customer would receive the product. Products must include
ancillary components such as antennas, batteries, back covers, and SIM cards. The latest operating software and
RSS is to be supplied by appropriate Development Engineering. For Pilot and Production Vintage MotoALTs, the
product should be delivered in the condition a customer would receive it in. Hence, product labels should be
included and installed, even though these additions are normally made in distribution, and the product might
never have been there. Omissions to the above submission items may be waived by approval from the Reliability
Engineering Manager. Each submission will be assigned a tracking number by the ALT Reliability Manager.
Tracking numbers are generated sequentially as ALT submissions are made.
TEST
SUBMISSION QUANTITY

MotoALT
56

MotoCALT
22

Responsibility
3.1 ALT Reliability Manager
3.1.1

The ALT Reliability manager shall insure compliance to this document.

3.1.2

The manager shall assign each MotoALT/CALT to a specific Engineer and or Technician to perform
the necessary testing listed in this document in the order as specified.

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The manager shall review the final results and either approve or disapprove the results of the
MotoALT/CALT. When approval is merited, conditionally or unconditionally, the ALT Reliability
Manager will issue an Approval Notice or demonstrate approval by other equivalent means as
required. To disapprove the results the ALT Reliability Manager will communicate directly with the
responsible Engineer in a manner that is mutually satisfactory

3.2 ALT Engineer/Technician

3.2.1

The Engineer/Technician shall perform the required testing as given in this document.

3.2.2

The Engineer/Technician shall fill in the electronic ALT Engineering Report form as given in the
Global Database at the Reliability website. Information and results shall be kept up to date as the
data is taken.

3.2.3

The Engineer/Technician shall keep the ALT Manager informed of any issues as they arise.

3.3 Responsible Motorola Engineer/OEM Engineer

3.3.1

The engineer responsible for the MotoALT submission shall insure that all deliverables are met as
given in this document.

3.3.2

The Responsible Engineer shall review, perform failure analysis, determine corrective action, and act
upon all reported failures and defects. This shall be documented by the engineer filling in the failure
analysis and corrective action fields in the ALT Engineering Report form.

3.3.3

The Responsible Engineer shall be responsible for the implementation of all corrective actions and
close out of the MotoALT.

Reference Documents
ED00102
12M09158A58
12M09170A79
12M09174A85
12M09175A65
12M09175A68
12M09175A70
12M09176A22
12M09176A66
12M09176A72
12M09181A10
12M09182A40
12M09193A75
12M09193A59
ED00230
ED00144
12M09193A72
00R09188T25

Product Dust Test

Electrostatic Discharge Test Procedure
Abrasion Resistance of Coatings/Printing
Vibration Induced Power Down Faults with Shaker Table
SIT Test for Pocket and Wearable Products
Keypad Actuation Test
Chemical Susceptibility of Consumer Products
Impact Testing Exterior Surfaces of Consumer Products
Lens Scratch Test
Decorated Surfaces Reliability Requirements
Antenna Tip Cycling Tests for Wearable Product
Mechanical Cycling Test for Flips
Stubby Sideload
Camera Testing
Autocycle Functionality Requirements
Painted Surface Abrasion Test Procedure
Cellular Phone Testing Requirements
ALT 2000/CALT 2000 Test Procedure

_______________________________________________________________________________________________________________________________________________________

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Definitions and Acronyms

ALT
AMPs
CALT
CDMA
DTF
ESD
GSM
NPLC
OEM
PCS
SIM
TDMA
GPS

30-DEC-04

PRELIMINARY

Accelerated Life Testing

Advanced Mobile Phone Service
Continuous Accelerated Life Testing
Code Division Multiple Access
Drop to Failure
Electro-Static Discharge
Global System for Mobile Communication
New Product Launch Center
Outsourced Equipment Manufacturer
Personal Communication Sector
Subscriber Identity Module chip and contains the subscriber's billing
information, Call Lists and service information
Time Division Multiple Access
Global Positioning System

Marking The Product

It is recommended that the product be marked (either by the submitting engineer, or the assigned ALT
engineer/technician) using the following convention so that it may be accurately tracked. The marking scheme
aids the technician by providing an easier way to remember which units go in which environment. All units are
labeled with the last 3 digits of the ALT sequence number assigned at submission, followed by a hyphen and a
unit number from 1 to 56 for MotoALTs and 1 to 22 for MotoCALTs.

Testing
7.1 Allocation of Units to Modules
The units are divided up between the modules as shown in the table below.
Module
I. Electrical & Physical Module
II. Mechanical Durability
III. Finish Module
IV. DTF

MotoALT
Units #1 - #24
Units #33 - #48
Units #49 - #56
Units #25 - #32

MotoCALT
Units #1 - #10
Units #11 - #16
Units #17 and #18
Units #19 - #22

7.2 Overview of Testing

7.2.1

Parametric, Camera, SPL, Blue Tooth and Desense Test

Parametric, SPL, Blue Tooth and desense (GSM) performance is only measured at the end of the
ALT test on the 7th day, under normal circumstances. However, at various times during the
ALT/Design cycle for a product, initial parametric, SPL, Blue Tooth and desense (GSM) data must be
taken at room temperature before any environmental stresses are applied to the units in Module I.
Depending upon the verification needs of the submitting Development Engineering group, parametric,
camera, SPL, Blue Tooth, and Desense testing may always be required. Camera testing is defined on
Section 7.6. Initial room temperature parametrics, SPL, Blue Tooth and desense (GSM) are always
taken on MotoCALT's. In cases where the initial room temperature parametrics, SPL, Blue Tooth and
desense (GSM) are measured, the cycle time increases approximately 1 day per band per mode. The

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"Power On" test is done on all units to be put through Module I before being placed into the
Temperature Shock.
7.2.2

Power On Test
The Power On Test consists of applying power to each unit by the easiest method possible and
verifying some level of functionality of the unit. In the case of a cellular phone, application of external
power should cause the phone to turn on, the vibrator or speaker to activate, the display and keypad
backlighting to light up, and all pixels of the display to turn on.

7.2.3

Module Description
All three modules go through the thermal shock environment. After thermal shock, the three modules
separate. Module I (Electrical/Physical Reliability Test) is the thermal environmental sequence and
subjects units to approximately seven (7) days of temperature, humidity, vibration, and drop
environments. Module II (Mechanical Durability/Life Cycle Module) is the mechanical sequence and
subjects units to temperature, humidity, chemical, fatigue, and mechanical stress environments. The
mechanical stresses used are intended to simulate actual customer usage. Module III (Finish Module)
is used to evaluate finish/paint performance. Module IV (DTF) is used as a check to ensure that the
prototype certification results are still valid and also to help judge what is observed during the Module
I drop tests (especially Drop1).

7.2.4

Tests Between Stresses to Capture Failures

Testing of the product between environmental and mechanical stresses is divided into three
categories; functional, signaling, and parametric. It is at these steps that failures are detected from
the stresses and are then noted. Since this specification is intended to cover many different products,
it is only possible to specify the functionality to be verified in fairly general terms. Some examples for
each category of functionality are provided, but since features and parameters may be unique to the
product being tested, others that are undocumented will probably be tested as well. Personnel
performing the testing should be fully trained in the use and operation of the specific product. This will
facilitate a more robust test coverage and add confidence in the ultimate results. In the event that new
batteries or accessories are submitted for test with the units, perceived failures of the batteries or
accessories should be logged as observations in the ALT database. Such failures could include
intermittent behavior, turn offs, battery detachments, or capacity failures. The ideal is to capture and
address customer perceivable faults and insure consistent product and ALT process
performance.

7.3 Functional Test

Functional testing consists of all of the steps required to determine if the product and all its indicators are
electrically and mechanically functioning properly. This testing includes but is not limited to the following:

Actuating buttons and switches to provide the correct visual and audible feedback with consistent
motion and tactile feel
Displays and back-lighting are functional and uniform
Mechanical features such as flips and antennas maintain electromechanical function and freedom
of movement
Transducers should be checked for adequate levels and distortion
Interface connections for charging, headsets, boom mics should be verified to be functioning
properly, if supplied.
Internal circuits such as internal chargers perform properly and provide proper visual and audible
responses

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Inspecting for plastic housing and lens deformation or cracking

Human testing of cameras, Infrared Data Association device (IrDa), Blue tooth device, Secure
Data (SD) card, Tri Flash reader (TFR) card and Touch screen display, if applicable.

A complete description of the attributes to be tested on cellular phones is given in 12M09193A72.

7.4 Signaling Test
Signaling test requires the use of equipment capable of establishing a phone call and being able to simulate
basic system functions. Testing should include but is not limited to:

Call origination, paging and termination in each communications mode

Call origination, paging, dispatch and termination
Ability to perform intra- and inter-band handoffs
Ability to perform power level changes
Ability to change modes and back again

Proper operation of visual indicators, audio quality, and accurate data transmission are to be verified.
Testing should be performed under radiated conditions if possible. A complete description of the attributes
to be tested on cellular phones is given in 12M09193A72.
7.5 Parametric, SPL, Blue Tooth and Desense Test Specifications
Parametric, SPL, Blue Tooth and desense (GSM) testing is conducted to insure that the product has
maintained specified performance with respect to major electrical parameters. Parametric, SPL, Blue Tooth
and desense (GSM) testing at the end of each MotoALT is to be performed at the specification limits set out
in the controlling specifications for the product or technology. Appendix R lists the minimal parametric test
set for AMPs, GSM, CDMA, TDMA and Appendix S lists desense levels that are to be measured as a
minimum for cell phones over the indicated ranges of variables. These parameters , SPL desense (GSM)
and their ranges are minimal and are not intended to limit parametric, SPL, Blue Tooth and desense (GSM)
testing but to insure that all PCS sites perform a set of tests that can be used to correlate data between the
sites. Additional testing may be performed by each test site.
7.6 Camera Testing
Camera Testing shall be performed in accordance with 12M09193A59. This testing is conducted to insure
that product has maintained specified performance with respect to major camera performance parameters.
Specific parametric requirements shall be provided by Development Engineering for the product to be
tested.

Environmental and Mechanical Stresses and Finish Testing

8.1 Module I (Electrical/Physical Reliability Test) -- Thermal Environmental Sequence
8.1.1

Thermal Shock
Procedure:
T/S: Thermal Shock should be completed in a chamber consisting of two compartments, one set to 40 C. and the other set to +75 C. Product is un-powered and started in either the Cold or Hot side of
the chamber for 45 minutes. Cycling is from one temperature extreme to the other, and the transition
time between extremes shall be 8 seconds or less. This complete cycle is repeated 27 times and
should end in the hot side of the chamber. Product is to be placed in the chamber in multiple

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configurations such as antenna up, antenna down, flip open, flip closed, etc. All units are to be placed
face up in the chamber. Do not allow product to lie on top of a unit with its flip open.
Requirement:
Functional testing as defined in paragraph 7.3 is to be conducted after this test. No malfunction or
physical deformation should be evident.
8.1.2

First Drop Sequence

Procedure:
The units #1 through #12 (#1 through #5 for MotoCALT) are to be dropped by hand at room
temperature. Log the sequence of drops using the table in Appendix N. Drop testing is to be
conducted with a battery attached and the unit turned on. If the units under test have extending
features such as a flip and/or antenna, the samples under test should be evenly distributed to cover
all potential configurations. Each units drop is to be documented as to which drop type and product
plane was performed, and what configuration and battery type was used. The units will be dropped by
hand, six times, once on each plane. The drop by hand will attempt to cause the unit to impact on the
side held downward and parallel to the floor at the time of release. For the purposes of record
keeping the side held parallel to the floor is the plane of drop. It should be noted that the release by
hand will often impart some rotation to the product. This rotation causes the drop to be somewhat
random and incidental impact of corners and edges to occur. Drop height is to be 5ft. The drop
surface will be a tiled concrete.
Requirement:
Batteries and covers may detach during drop, but the units must power on once the batteries and
covers have been replaced. At each drop plane the product is given a cursory check of operation.
This cursory check should include powering on the radio and verifying as much functionality as
possible in the time provided. Post drop functional testing per section 7.3 is conducted to insure no
electrical degradation is evident and no mechanical failures such as cracking, chipping, separation,
bent or broken contacts, etc. have occurred. Electrical and mechanical integrity should be maintained.

8.1.3

First Parallel Shaker Table Vibration and ESD Sequence

This parallel test sequence divides the 24 units (10 units for MotoCALT) of Module I into 3 units (1
unit for MotoCALT) for ESD and 21 units (9 units for MotoCALT) for Shaker Table Vibration. Of the 21
units (9 for MotoCALT) for Shaker Table Vibration, 7 apiece are vibrated on each of the X, Y, and Z
axis (3 apiece for each axis for MotoCALT). Each of these axes are described in Appendix M. Note
that the first shaker table vibration environment is done with the units oriented such that the side
facing toward the positive axis is facing the plane of the shaker table. If it is not practical to shake on
one or more of the positive axes, then the associated negative axis may be used instead. An example
of this would be the positive Z axis of most cellular phones. The protruding external antenna makes it
nearly impossible to shake the phone on the Z axis without it falling over or coupling to other axes.
For ESD, the 3 units are chosen so that 2 of the 3 units from ESD eventually go to the Temperature
Cycling environment and 1 goes to the Temperature Humidity environment. (N/A for MotoCALT)

8.1.3.1 Electrostatic Discharge (ESD)

Procedure:
Static discharge is to be performed at +/-5kV and +/-15kV, air discharge, on the specified units. The
units are to be subjected to 10 discharges at each voltage and polarity in all defined locations (10
maximum locations) to which a discharge will occur. Discharge locations are defined early in the
design cycle. Development and Reliability Engineering will determine discharge locations utilizing
historical data and actual product ESD data taken during Proto Certification or Hardware Design
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Certification Testing. The discharge locations are to be illustrated per product to insure test to test
consistency. The locations are subject to change if new data presents itself. If applicable, add
information to the products address book, store messages in memory and set the time/date prior to
testing. Log the sequence of testing using the table in Appendix P. Record which units were used and
what results were obtained. If it is apparent that the unit for test has lost mechanical housing, then
consult Appendix I for alternate radios to use for this test. Refer to 12M09158A58 (class 1C and class
3) for more specific detail on conducting the testing. The discharge to the unit should be in both
standby (turned on only) and transmit mode (unit placed into a call, if possible). If the phone
possesses multiple mode and band capability, then tests should be conducted with calls placed in
each mode and in each band applicable to that mode. The units for this test are chosen as described
in the table below.
Unit number
ESD unit #1
ESD unit #2
ESD unit #3

MotoALT Unit #s
9
11
15

MotoCALT Unit #s
3
n/a
n/a

Requirement:
Generally speaking, no soft failures are allowed at +/-5kV and no hard failures are allowed at 15kV.
All functional and signaling tests per sections 7.3 and 7.4 are to occur periodically during the test to
determine whether a hard or soft failure has happened and to provide the failure location,
configuration and discharge polarity. Re-power up's are allowed at 15kV but are counted as failures at
+/-5kV. LOSS of address book, messages and/or time/date information is counted as a failure at both
+/-5 or and +/-15kV. If the product(s) exhibit loss of address book, messaging or time/date information
then the product(s) shall be reconfigured and testing continued. This is to allow full testing of the
defined test locations. Conversely, if a lock up condition occurs, the product must NOT be altered or
reconfigured. Rather, it should be submitted for analysis unchanged. Finally, one should be sure to
check for full functional operation of the RF front-end circuitry by measuring the units sensitivity.
8.1.3.2 First Shaker Table Vibration
Procedure:
The shaker table (Lab model BRVD-48 or equivalent) is to be preset to 30Hz with a displacement of
0.06. The test duration is 60 minutes. All units to be subjected to this environment are placed in a
box that is rigidly attached to the shaker. Separator inserts are to be used to maintain the units
orientation during the test. Units are to be powered by fresh fully charged batteries. If more than one
battery size is to be used, mix the sizes randomly among the phones. Units are to be marked by a
strip on the intended housings plane facing down using a paint pen. That will be designated the
defined plane. Units should be vibrated for 5 minutes, then checked to see if they are still on, address
book/messages and time/date still in memory, then vibrated for the remaining 55 minutes.
Continuous monitoring for the first 5 minutes is recommended but not required. Refer to
12M09174A85 for further information. The distribution of the units by orientation is given in the table
below. There will be 9 units vibrated in the X plane and 10 apiece vibrated in the Y and Z planes (3 in
each plane for MotoCALT).

X plane
Y plane
Z plane

MotoALT Unit #s
1, 6, 12, 13, 14, 19, 20
2, 3, 7, 8, 10, 21, 22
4, 5, 16, 17, 18, 23, 24

MotoCALT Unit #s
5, 8, 9
1, 4, 7
2, 6, 10

Requirement:
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Units should remain on and address book/messages still in memory, during the first 5 minutes under
test, but may turn off during the next 55 minutes. Units should be free of functional and signaling
failures per testing specified in sections 7.3 and 7.4 after the stress. Cosmetic degradation to lenses
and keypads protected by flips should be counted as failures if they occur with the flip closed. Paint
wear through should be noted as an observation.
8.1.4

Dust
The dust test is to be completed on 16 units (8 units for MotoCALT). This test is done in parallel with
the functional and signaling testing on the 2nd 16 units (other 2 for MotoCALT) in Module I. This
parallel path increases the speed with which the overall sequence of environments can be
accomplished. None of the ESD units from 8.1.3.1 should be included in this test.
Procedure:
Place the units specified below in the dust chamber for 1 hour. Randomly have half with flip open, half
with antenna extended and units evenly dispersed in orientation between, face up, face down and a
mixture of four 90-degree rotations on supporting surface. If it is apparent that the unit for test has lost
mechanical housing integrity do not select it for this test. For further information refer to Dust
12M05019A87 procedure.
MotoALT Unit #s
1, 2, 3, 4, 5, 6, 10, 13, 14, 16,
17, 18, 19, 21, 22, 24

MotoCALT Unit #s
1, 2, 4, 5, 6, 7, 9, 10

Requirement:
All moving parts should retain freedom of movement and the display shall remain unobstructed.
Functional and Signaling performance per sections 7.3 and 7.4 is completed.
8.1.5

Temperature Cycle (-40 C to +75 C , 45 minute dwell, 17 C/min ramp, 88hrs)

Procedure:
Units # 1 through #16 (#1 through #5 for MotoCALT) are to be placed on a shelf inside the chamber
allowing an equivalent product space around them. Product should be fixtured in such a way as to
prevent water accumulation on its surfaces during the test. The units are to have the proper nominal
product voltage applied and the internal auto power-cycling software active throughout the exposure.
In some cases, the product may need to be flashed with software specially designed for this stage of
ALT. Each product is different, so refer to the product 12M. Use power-cycling cables for this
purpose. An example of a PCS power-cycling routine is given in the chart below:
Power-Cycle
Routine
Tx time

Meaning

Indicators Active

Transmit on for 1.5 min

Rx time
Standby time

Receive on for 0.5 min

Idle for 4.0 min

Transmit light or display; vibrator

on
Display active
Display idle

Suggestions for power cycling routine are defined more formally in Appendix J. Also, the T/C profile is
attached in Appendix K. A minimum temperature ramp rate of 17 degrees C. per minute is required.
Requirement:
All functional and signaling tests per sections 7.3 and 7.4 are to be conducted after this test to insure
electrical and mechanical integrity remains.
8.1.6

Temperature Humidity (+65C/90% RH, 88hrs)

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Procedure:
Units #17 through #32 (#6 through #10 for MotoCALT) are to be placed on a shelf inside the chamber
without piling them up on each other. Product should be fixtured in such a way as to prevent water
accumulation on its surfaces during the test. The units are to have the proper nominal product voltage
applied and the internal auto power-cycling software active throughout the exposure. The auto powercycling sequence will be the same here as above in the Temperature Cycling environment.
Requirement:
All functional and signaling tests per sections 7.3 and 7.4 are to be conducted after this test to insure
electrical and mechanical integrity remains.
8.1.7

Second Drop Sequence

The 2nd drop repeats the process flow in 8.1.2 using units #17 through #32 (#6 through #10 for
MotoCALT).
Requirement:
The requirements are the same as those previously stated for the first drop sequence.

8.1.8

Second Parallel Shaker Table Vibration and ESD Sequence

The parallel Shaker Table Vibration and ESD sequence is here repeated with some modifications.
Once again, 29 units are placed in Shaker Table Vibration, distributed by axis with 9 on the x-axis and
10 apiece on the y- and z-axes (3 units on each axis for MotoCALT). Each of these axes are
described in Appendix M and the distribution of radios between axes is described in Appendix I. Note
that the second shaker table vibration environment is done with the units oriented such that the side
facing toward the negative axis is facing the plane of the shaker table. If it is not practical to shake on
one or more of the negative axes, then the associated positive axis may be used instead. For ESD, 3
units (1 unit for MotoCALT) will again be tested, but all should have been through dust in 8.1.4, and 2
should have been through Temperature Humidity per 8.1.6 and 1 through Temperature Cycling per
8.1.5. Because the units tested with ESD here are different from those tested in 8.1.3.1, they must
have gone through Shaker Table Vibration in 8.1.3.2. Units should be chosen for ESD here so that 8
of the 9 units on each axis of the Shaker Table Vibration will be repeats from 8.1.3.2 and the other 1
will not be, it will be an ESD unit from 8.1.3.1.

8.1.8.1 Electrostatic Discharge (ESD)

Procedure:
Static discharge is to be performed at +/-5kV and +/-15kV on the specified units as done previously in
8.1.3.1. Choose 3 units (1 unit for MotoCALT) for this ESD test as prescribed in the table below.

Unit number
ESD unit #1
ESD unit #2
ESD unit #3

MotoALT Unit #s
12
20
23

MotoCALT Unit #s
9
n/a
n/a

Requirement:
The requirements are the same as those previously stated for the first ESD sequence.
8.1.8.2 Shaker Table Vibration
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Procedure:
The shaker table test conducted here is the same as that conducted in 8.1.3.2. The distribution of
units within the test is as specified in the Table below. The table below describes the distribution of
units between vibration axes.

X plane
Y plane
Z plane

MotoALT Unit #s
1, 6, 10, 11, 13, 14, 19
2, 3, 7, 8, 15, 21, 22
4, 5, 9, 16, 17, 18, 24

MotoCALT Unit #s
5, 8, 4
1, 3, 7
2, 6, 10

Requirement:
The requirements are the same as those previously stated for the first shaker table vibration
sequence.
8.1.9

Final Parametric & Signaling

Final Parametric & Signaling Procedure: The units from both Module I (Electrical/Physical Reliability
Test) and Module II (Mechanical Durability/Life Cycle Module) are split evenly so that half are in the
cold chamber and the other half are in the hot chamber. The units are placed inside the chamber
without piling them up and left without power applied for one hour minimum to reach temperature
equilibrium. A longer period may be required for larger mass product in order to reach product
temperature stabilization. Then power and voltage is applied as given in Appendix R and the
parametric test performance measured at the indicated channels for each band in each mode of
operation possessed by the product. The distribution of the units between the temperatures is as
given in the table below. After completing this testing per Appendix R, refer to Appendix S regarding
desense measurement requirements.
Temperature
advertised lower limit of
product temperature
specification
advertised upper limit of
product temperature
specification

Final Parametrics
ALT2000 units

Final Parametrics
CALT2000 units

odd numbered units

odd numbered units

even numbered
units

even numbered units

Requirement: All parametric, functional and signaling tests are to be conducted during this test and all
product specifications are to be met.

8.1.10 Initial & Final Desense Test Procedure:

For MotoALT, units 1, 6, 17, 24 and optional 33 are used for desense testing.
For MotoCALT, units 1, 2, 6, 7 and optional 11 are used for desense testing.
*if defined unit not available then use the next sequential unit as a replacement.
See Appendix S for details.
8.1.11 Initial & Final SPL Test Procedure:
A minimum of 12 units from MotoALT (units 1, 2, 3, 5, 9, 13, 15, 16, 17, 21, 23, and 24) are to be
used for SPL testing. (For MotoCALT, units 1, 2, 3, 5 and 11 are used for SPL testing.)

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The minimal requirements for SPL testing will utilize the standard ring tone against a requirement of
95dB SPL at 5 cm utilizing A weighting. The UUT ringer port shall be aligned with the SPL meter
mic.
*if defined unit not available then use the next sequential unit as a replacement.
8.1.12 Initial & Final Blue Tooth Test Procedure:
Blue Tooth Minimum Parametric Test Requirements:
a)Tx Power Out
b) Tx Freq
c) Sensitivity
d) Audio Loop back
e) BT Link Indicator verification (fun lighting or other indicator)
f) Blue Wake and Host Wake verification
8.1.13 Initial and Final Embedded Camera Test Procedure:
All tests shall be conducted per 12M09193A59. Test limits shall be specified by Development
Engineering. Minimum parametric test requirements will require color and focus testing.
8.1.14 Initial and Final Embedded GPS Test Procedure:
Testing shall be conducted per section 7.5 with parametric requirements per Appendix R.
8.2 Module II (Mechanical Durability/Life Cycle Module) Mechanical Sequence
The purpose of this portion of the test is to demonstrate the product maintains minimum performance levels.
It does not replace product certification requirements. The following stresses are performed on the units #33
through #48 (#11 through #16 for MotoCALT).
8.2.1

Thermal Shock
Procedure:
T/S: Thermal Shock should be completed as referenced in para. 8.1.1.
Requirement:
Functional testing as defined in paragraph 7.3 is to be conducted after this test. No malfunction or
physical deformation should be evident.

8.2.2

Temperature Humidity +65C/90% RH, 48 hours

Procedure:
Units #33 through #48 (#11 through #16 for MotoCALT) are to be placed, unpowered, and face up, in
a chamber capable of maintaining +65C/90% relative humidity for a period of 48 hours.
Requirement:
This is for the most part an aging environment, one that will not generally precipitate failures on its
own. However, a cursory inspection should not reveal any obvious degradation, either functional or
cosmetic.

8.2.3

Keypad Actuation
Procedure:

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Units #45 through #48 (#11 through #14 for MotoCALT) are to be placed on a fixture capable of
applying a 3lb force to each key in sequence, 30,000 cycles/key over the total entire test. The units
will be powered externally during the test, but depending on the product, batteries may be required for
support. Refer to 12M09175A68 for proper set-up and procedure.
Requirement:
Full functional and signaling tests per sections 7.3 and 7.4 are to be conducted after this test. Unit
status will be monitored manually or by automated test equipment so that added information about
product information may be obtained. A unit that powers down or has significant unexpected current
variation over time will be regarded as a failure, and logged as such. There should be no outwardly
visible signs of electrical or mechanical failure.
8.2.4

Chemical Exposure and Dry

Procedure:
Units #33 through #40 (#11 through #14 for MotoCALT) are to be exposed to a chemical stress
simulating the effects of biochemicals and facial oil components per 12M09175A70. Each unit (#33
through #40 for MotoALT and #11 through #14 for MotoCALT) will be wiped with a wipe moistened
with Oleic Acid and then be rubbed dry with a dry wipe. Squeeze test (para. 8.2.5) and Flip
hyperextension test (para. 8.2.6.1) should proceed within 1 hour of when chemical exposure is
completed.
Requirement:
Full functional and signaling tests per sections 7.3 and 7.4 are to be conducted after this test. In
addition, a cursory inspection should not reveal any cracked plastic, lifted or delaminating coatings or
labels, or paint degradation if the units are painted.

8.2.5

Squeeze Test
Procedure:
Units (33-36), which have been subjected to chemical stress (para. 8.2.4), are to be subjected to
2,000 cycles. The units need not be powered during test but batteries should be in place along with a
battery door if applicable. The thinnest and lightest battery should generally be used. Refer to
12M09175A65 for proper set-up and procedure. Units should be divided by orientation as follows: unit
33, 34-flip/face up, length parallel to tampo head length (perpendicular to hammock length), unit 35,
36-flip/face down, length parallel to tampo head length (perpendicular to hammock length). For
MotoCALT units #11 through #14 should be cycled like MotoALT units #33 through #36 respectively.
Flip Hyper-extension testing should commence within 2 hours of Squeeze test completion.
Requirement:
Full functional and signaling tests per sections 7.3 and 7.4 are to be conducted after this test. There
should be no outwardly visible signs of electrical or mechanical failure. Refer to 12M09175A65 for
information about a simple 1 cycle squeeze test that can be used to determine if units have failed in
the squeeze test.

8.2.6

Flip Cycling

8.2.6.1 Flip Cycling (Hyperextension)

Procedure:
Units #37 through #40 (#11 through #14 for MotoCALT) which have been subjected to chemical
stress (para. 8.2.4), are to be placed on a fixture capable of simulating normal flip hyper-extension
cycles. These cycles simulate typical usage of a phone with a clam form factor by loading the flip as
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it would be when the phone is pressed against the users head to form an acoustic seal. The units are
to be subjected to a total of 2500 cycles per 12M09182A40.
Requirement:
Full functional and signaling tests per sections 7.3 and 7.4 are to be conducted after this test. All
mechanics are expected to maintain functionality, with no loss of detent, cracked or broken plastic.
8.2.6.2 Flip Cycling
NOTE: THESE UNITS ARE NOT SUBJECTED TO ANY ENVIRONMENTAL STRESSING
PRIOR TO STARTING THIS TEST.
Procedure:
Units #41 through #44 (#15 and #16 for MotoCALT) are to be placed on a fixture capable of
simulating normal flip cycles. These cycles simulate typical usage of a phone with a clam form factor
by opening and closing the flip as it would be in normal use. The units are to be subjected to a total of
100,000 cycles per 12M09182A40.
Requirement:
Full functional and signaling tests per sections 7.3 and 7.4 are to be conducted after this test. All
mechanics are expected to maintain functionality, with no loss of detent, cracked or broken plastic.
8.2.7

Final Parametric & Signaling

All units are combined with the main flow for final parametrics, refer to 8.1.9 thru 8.1.13 for
procedures.

8.3 Module III (Finish Module) Finish / Paint performance

The purpose of this portion of the test is to demonstrate the products finish/paint maintains minimum
performance levels. It does not replace product certification requirements. The following stresses are
performed on the units #49 through #56 (#17 and #18 for MotoCALT). The units utilized for this module can
be non-functional. In other words the units do not have to work, they just need to be complete units.
8.3.1

Thermal Shock
Procedure:
T/S: Thermal Shock should be completed as referenced in para. 8.1.1.
Requirement:
Functional testing as defined in paragraph 7.3 is to be conducted after this test. No malfunction or
physical deformation should be evident.

8.3.2

Temperature Humidity (+65C/90% RH, 88hrs)

Procedure:
Units #49 through #56 (#17 and #18 for MotoCALT) are to be placed on a shelf inside the chamber
without piling them up on each other. Product should be fixtured in such a way as to prevent water
accumulation on its surfaces during the test.
Requirement:
This is for the most part an aging environment, one that will not generally precipitate failures on its
own. However, a cursory inspection should not reveal any obvious cosmetic degradation.

8.3.3

Box of Rocks Test

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Procedure:
Units #49 through #52 (#17 for MotoCALT) are wiped with oleic acid, soaked in temperature/humidity
for 2 hours, then vibrated with an abrasive material. Detailed procedures can be found in ED00144
Requirement:
Painted surfaces should not show excessive wear, or chipping.
8.3.4

Dry Tests
The following tests are accomplished in order on units that are dry or have not been exposed to
chemicals, oils, etc.

8.3.4.1 Flip Cycling

Procedure:
Units #53 through #56 (#18 for MotoCALT) are to be placed on a fixture capable of simulating
normal flip cycles. These cycles simulate typical usage of a phone with a clam form factor by
opening and closing the flip as it would be in normal use. The units are to be subjected to a total
of 5,000 cycles per 12M09182A40.
Requirement:
All mechanics are expected to maintain functionality, with no loss of detent, cracked or broken
plastic.
8.3.4.2 Crosscut Tape Adhesion
Procedure:
Units #53 through #56 (#18 for MotoCALT) are used for this test per 12M09176A72. Using a
razor, scalpel, other sharp knife, cross hatches (# #) are cut into the finish on the various
painted/finished pieces. A piece of tape is stuck onto the grid area, pressed down, then removed
at as close to a 180 degree angle as possible. The grid area is then examined under microscope
to review the paint flaking.
Requirement:
Painted surfaces should not show excessive wear, or chipping.
8.3.4.3 Abrasion
Procedure:
Units #53 through #56 (#18 for MotoCALT) are used for this test per 12M09176A72. Using a
Norman Abrasion Wear Tester, various painted/finished pieces are exposed to abrasion tape
running across the surface.
Requirement:
Tested surfaces are required to withstand 50 cycles in continuous mode with a 175 gram normal
force.
8.3.4.4 Pencil Hardness
Procedure:
Units #53 through #56 (#18 for MotoCALT) are used for this test per 12M09176A72. Using
various hardness pencils, the painted/finished surfaces are tested to see at what hardness the
substrate or second layer is compromised.
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Requirement:
Pieces should pass up to at least a hardness level of 5H.
8.3.4.5 Edge Test
Procedure:
Units #53 through #56 (#18 for MotoCALT) are used for this test. The various painted/finished
pieces are exposed to a physical bend of 90 degrees. The edge along the bend is then examined
for the paint/finish reactions to the sharp bend.
Requirement:
Pieces should not have the paint/finish peeling off.
8.4 Module IV (DTF) Proto Cert. Verification / Module 1 Drop Test Judgment
The main purpose of this portion of the test is to demonstrate that the results from the products DTF
Prototype certification testing are valid. A secondary purpose is that the results from this module can assist
in the judgment of failures from the Module I drop test. MODULE IV SHOULD NOT BE STARTED UNTIL
COMPLETION OF MODULE I DROP 1.
8.4.1

Worst Case Side Determination

Worst case side is determined by reviewing the Prototype Certification DTF results for the units under
test. (This will be the sides that had the most and earliest failures.) If the results show more than one
set of alternating sides that were bad, the units to be tested should be distributed to cover all the
bad sides. Worst Case Side will be used for the DTF unless Module I drop 1 shows failures. In this
case, units can be split up to cover all the problem areas. This does not matter for MotoCALT, as the
units are dropped on all 6 sides (2 units with flip open and 2 with flip closed if applicable).

8.4.2

DTF
Procedure:
The units #25 through #39 (#19 through #22 for MotoCALT) are to be dropped by hand at room
temperature. Log the sequence of drops using the table in Appendix Q. Drop testing is to be
conducted with a battery attached and the unit turned on. The units will be dropped by hand, in
alternating planes as determined in para. 8.4.1 (for example: drop1 -> bottom drop, drop2 -> top drop,
drop3 -> bottom drop, ). One cycle is equal to dropping twice (6 times for MotoCALT), once in each
of the alternating planes. The drop by hand will attempt to cause the unit to impact on the side held
downward and parallel to the floor at the time of release. For the purposes of record keeping the side
held parallel to the floor is the plane of drop. It should be noted that the release by hand will often
impart some rotation to the product. This rotation causes the drop to be somewhat random and
incidental impact of corners and edges to occur. Drop height is to be 4ft. The drop surface will be a
tiled concrete.
A functional check (per para. 7.3) should be accomplished after each drop cycle.
A complete call processing (per para. 7.4) should be accomplished after every 5 cycles (after every 2
cycles for MotoCALT).
Requirement:
The average drop to failure should be calculated by using a Weibull distribution. The minimum
specification is 46 drops to pass (MotoALT) and 45 drops to pass (MotoCALT). The results from
Module IV should also be compared to the results from Module I drop 1 to see if similar failures were
seen.

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Repair and Replacement Policy

Calculation of a failure rate for a product requires that one know the number of device hours of operation elapsed
during the test. To maximize the number of device hours in a MotoALT/CALT, product that fails must be repaired
and placed back under test as soon as possible. However, the urgency with which repair is pursued will vary with
the type of failure. Catastrophic failure modes that can mask other less severe failure modes should be fixed first,
while failures that would merely annoy the customer without impeding usage or further testing may not be fixed at
all. In some cases these may be fixed as well, in order to capture the defective material for failure analysis and
corrective action.
9.1 Aborting MotoALT/CALT
If more than 25% of the product in an MotoALT/CALT is out of test for repair at any one time the test should
be placed on hold until a sufficient number of units can be returned to the MotoALT/CALT to provide an
adequate sample size, or terminated, at the discretion of the ALT site manager.
9.2 Lost days (in ALT failure rate calculations)
When a unit is out of the test, the number of lost device days should be calculated and subtracted from the
total device days in the MotoALT/CALT for the purposes of calculating the failure rate. For small numbers of
units missing for a short time this turns out to be inconsequential to the predicted failure rate. If a unit
remains in the MotoALT/CALT with significantly reduced functionality, i.e., no display, can not make or
receive calls/pages, or can not turn on, then it shall be counted as a missing unit and information derived
from it will be for For Your Information only use. Therefore, making such corrections is left to the discretion
of the ALT site manager.

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Appendix A: MotoALT Module I Sequence

Electrical/Physical Reliability Test (MotoALT)
Thermal Shock
(Para 8.1.1)
Units #1 thru #24

Parametrics and Functional

(Para. 7.2.1 & 7.3)
Units #1 thru #24
AND
Power On Test
(Para 7.2.2)
Units #1 thru #24

Functional Test
(Para 7.3)
Units #1 thru #24

Sample : 24EA working units

Allowable failures :
10EA((No more than 2EA
failure w/same mechanism is
allowed)

Random Drop
(Para. 8.1.2)
Room Temp, 5ft, 6x,
1x/plane, to vinyl tile,
Units #1 thru #12

Functional Test
(Para 7.3)
Units #1 thru #24

Shaker Table Vibration

(Para. 8.1.3.2)
60min, 30Hz, .060
21 units per above Para

Functional Test and Signaling Test

(Para 7.3 & 7.4)
Units #1 thru #32

Dust
(Para. 8.1.4)
2sec agitation, 15min dwell, 30
min test time, 30 min settling
time
16 units per above Para.

ESD
(Para 8.1.3.1)
+/-5,15kV
3 units-9,11,15

Temperature Cycling
(Para 8.1.5)
40/75C, 88hrs
Units #1 thru #12

Temperature Humidity
(para 8.1.6)
65C/90%RH, 88hrs
Units #13 thru #24

Functional Test
(Para 7.3 & 7.4)
Units #1 thru #24

Random Drop
(Para. 8.1.7)
Room Temp, 5ft, 6x, 1x/plane,
to vinyl tile,
Units #13 thru #24

Functional Test
(Para 7.3)
Units #1 thru #24

ESD
(Para 8.1.8.1)
+/-5,15kV
3 units--12,20,23

Shaker Table Vibration

(Para. 8.1.8.2)
60min, 30Hz, .060
21 units per above Para

Functional Test and Signalling Test

(Para 7.3 & 7.4)
Units #1 thru #24

Parametrics
advertised cold or -10C
(Para. 8.1.9)
Odd numbered units

Parametrics
advertised hot or 55C
(Para. 8.1.9)
Even numbered units

Analyze Data and Report

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Appendix B: MotoALT Module II Sequence

Mechanical Durability /Life cycle Module (MotoALT)

Sample : 16EA working units

1 failure is allowed.
If one item failed from test. It
can be tested separately later.

Parametrics and Functional

(Para. 7.2.1 & 7.3)
Units #33 thru #48

Thermal Shock
(para 8.2.1)
75C/-40, 27 cycles, 40HR
Units #33 thru #48

Temperature Humidity
(para 8.2.2)
65C/90%RH, 48hrs
Units #33 thru #48

Chemical Exposure and Dry

(Para. 8.2.4)
Units #33 thru #40

Squeeze Test
(Para. 8.2.5)
2K cycles
Units #33 thru #36

Keypad Actuation,
(Para. 8.2.3)
30K cycles,
Units #45 thru #48

Hyperextension flip
(Para. 8.2.6.1)
2.5K cycles,
Units #37 thru #40

Flip cycling
(Para. 8.2.6.2)
100Kcycles,
Units #41 thru #44

Parametrics and Functional

(Para. 7.2.1 & 7.3)
Units #33 thru #48

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Appendix C: MotoALT Module III Sequence

Finishing Test module (MotoALT)

Thermal Shock
(para 8.3.1)
75C/-40, 27 cycles, 40HR
Units #49 thru #56

8 units of non-working phone

required.
1ea failure is allowed.

Temperature Humidity
(para 8.3.2)
65C/90%RH, 88hrs
Units #49 thru #56

Box of Rocks
(para 8.3.3)
Units #49 thru #52

Flip cycling
(Para. 8.3.4.1)
5Kcycles,
Units #53 thru #56

Cross Cut
(Para. 8.3.4.2)
Units #53 thru #56

Abrasion
(Para. 8.3.4.3)
Units #53 thru #56

Pencil Hardness
(Para. 8.3.4.4)
Units #53 thru #56

Edge Test
(Para. 8.3.4.5)
Units #53 thru #56

_______________________________________________________________________________________________________________________________________________________

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Appendix D: MotoALT Module IV Sequence

DTF

Sample : 8ea
working units

Average DTF needs

to be 46 to pass.

Functional Test and Signaling Test

(Para 7.3 & 7.4)
Units #25 thru #32

Worst Case Side Determination

(Para. 8.4.1)
Review DTF results from Proto Cert
MODULE I , Drop 1 COMPLETION
BEFORE CONTINUING.

2 drops = 1 cycle

Functional testing done

after each cycle.
Functional testing and
Signaling test after every
5 cycles.

DTF
(Para. 8.4.2)
Room Temp, 4ft, 1x, on each
assigned plane (worst case
sides) , to vinyl tile,
Units #25 thru #32

Functional Test
(Para 7.3)
after each cycle

Functional Test and Signalling Test

(Para 7.3 and 7.4)
after every 5 cycles

Average DTF Calculation

Weibull distribution

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Appendix E: MotoCALT Module I Sequence

Electrical/Physical Reliability Test (MotoCALT)

Thermal Shock
(Para 8.1.1)
Units #1 thru #10

Parametrics and Functional

(Para. 7.2.1 & 7.3)
Units #1 thru #10
AND
Power On Test
(Para 7.2.2)
Units #1 thru #10

Sample : 10EA working units

Allowable failures : No more
than 4EA failures

Functional Test
(Para 7.3)
Units #1 thru #10

Random Drop
(Para. 8.1.2)
Room Temp, 5ft, 6x,
1x/plane, to vinyl tile,
Units #1 thru #5

Functional Test
(Para 7.3)
Units #1 thru #10

Shaker Table Vibration

(Para. 8.1.3.2)
60min, 30Hz, .060
9 units per above Para

Functional Test and Signaling Test

(Para 7.3 & 7.4)
Units #1 thru #10

Dust
(Para. 8.1.4)
2sec agitation, 15min dwell, 30
min test time, 30 min settling
time
8 units per above Para.

ESD
(Para 8.1.3.1)
+/-5,15kV
Unit #3

Temperature Cycling
(Para 8.1.5)
40/75C, 88hrs
Units #1 thru #5

Temperature Humidity
(para 8.1.6)
65C/90%RH, 88hrs
Units #6 thru #10

Functional Test
(Para 7.3 & 7.4)
Units #1 thru #10

Random Drop
(Para. 8.1.7)
Room Temp, 5ft, 6x, 1x/plane,
to vinyl tile,
Units #6 thru #10

Functional Test
(Para 7.3)
Units #1 thru #10

ESD
(Para 8.1.8.1)
+/-5,15kV
1 units-9

Shaker Table Vibration

(Para. 8.1.8.2)
60min, 30Hz, .060
9 units from Groups A-J per
above Para

Functional Test and Signalling Test

(Para 7.3 and 7.4)
Units #1 thru #10

Parametrics
advertised cold or -10C
(Para. 8.1.9)
Odd numbered units

Parametrics
advertised hot or 55C
(Para. 8.1.9)
Even numbered units

Analyze Data and Report

_______________________________________________________________________________________________________________________________________________________

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Appendix F: MotoCALT Module II Sequence

Mechanical Durability /Life cycle Module (MotoCALT)

Sample : 6EA working units

Allowable failures : No failures
allowed.

Parametrics and Functional

(Para. 7.2.1 & 7.3)
Units #11 thru #16

Thermal Shock
(para 8.2.1)
75C/-40, 27 cycles, 40HR
Units #11 thru #16

Temperature Humidity
(para 8.2.2)
65C/90%RH, 48hrs
Units #11 thru #16

Keypad Actuation,
(Para. 8.2.3)
30K cycles,
Units #11 thru #14

Chemical Exposure and Dry

(Para. 8.2.4)
Units #11 thru #14

Squeeze Test
(Para. 8.2.5)
2K cycles
Units #11 thru #14

Flip cycling
(Para. 8.2.6.2)
100Kcycles,
Units #15 and #16

Hyperextension flip
(Para. 8.2.6.1)
2.5K cycles,
Units #11 thru #14

Parametrics and Functional

(Para. 7.2.1 & 7.3)
Units #11 thru #16

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Appendix G: MotoCALT Module III Sequence

Finishing Test module (MotoCALT)

Thermal Shock
(para 8.3.1)
75C/-40, 27 cycles, 40HR
Units #17, #18

Temperature Humidity
(para 8.3.2)
65C/90%RH, 88hrs
Units #17, #18

Box of Rocks
(para 8.3.3)
Unit #17

2 units of non-working phone

required.
Allowable failures : No failures
allowed.

Flip cycling
(Para. 8.2.6.2)
40Kcycles,
Unit #18

Cross Cut
(Para. 8.3.4.2)
Unit #18

Abrasion
(Para. 8.3.4.3)
Unit #18

Pencil Hardness
(Para. 8.3.4.4)
Unit #18

Edge Test
(Para. 8.3.4.5)
Unit #18

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Appendix H: MotoCALT Module IV Sequence

DTF

Sample : 4ea
working units

Average DTF needs

to be 45 to pass.

Functional Test and Signaling Test

(Para 7.3 & 7.4)
Units #19 thru #22

Worst Case Side Determination

(Para. 8.4.1)
MODULE I , Drop 1 COMPLETION
BEFORE CONTINUING.

6 drops = 1 cycle

Functional testing done

after each cycle.
Functional testing and
Signaling test after every
2 cycles.

DTF
(Para. 8.4.2)
Room Temp, 4ft, 1x, on each
side (6 total) , to vinyl tile,
Units #19 thru #22

Functional Test
(Para 7.3)
after each cycle

Functional Test and Signalling Test

(Para 7.3 and 7.4)
after every 2 cycles

Average DTF Calculation

Weibull distribution

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Appendix I: Unit Flow Through MotoALT and MotoCALT Module I

MotoALT
RADIO

INITIAL DATA

TEMP. SHOCK

DROP 1

SHAKER ESD
1

Open

Yes

+X

Closed

Yes

+Y

Open

Yes

+Y

Closed

Yes

+Z

Open

Yes

+Z

6
7
8
9

R
R
R
R

Closed
Open
Closed
Open

Yes
Yes
Yes
Yes

+X
+Y
+Y
ESD

10

Closed

Yes

+Y

11
12

R
R

Open
Closed

Yes
Yes

ESD
+X

13

Open

No

+X

14

Closed

No

+X

15

Open

No

ESD

16

Closed

No

+Z

17

Open

No

+Z

18

Closed

No

+Z

19
20

R
R

Open
Closed

No
No

+X
+X

21

Open

No

+Y

22

Closed

No

+Y

23

Open

No

+Z

24

Closed

No

+Z

INITIAL DATA

TEMP. SHOCK

DROP 1

Closed

Yes

SHAKER ESD
1
+Y

Open

Yes

+Z

Closed

Yes

ESD

Open

Yes

+Y

Closed

Yes

+X

Open

No

+Z

7
8

R
R

Closed
Open

No
No

+Y
+X

Closed

No

+X

10

Open

No

+Z

MotoCALT
RADIO
1

DUST
Closed Face
Down
Open Face
Down
Open Face Up
Closed Face
Up
Closed Face
Up
Open Face Up

Closed Face
Down

Open Face
Down
Closed Face
Up
Closed Face
Down
Open Face Up
Closed Face
Up
Open Face Up
Open Face
Down
Closed Face
Down

88 HOUR

DROP 2

SHAKER ESD
2

P-mets

Cycle

No

-X

Cold

Cycle

No

-Y

Hot

Cycle

No

-Y

Cold

Cycle

No

-Z

Hot

Cycle

No

-Z

Cold

Cycle
Cycle
Cycle
Cycle

No
No
No
No

-X
-Y
-Y
-Z

Hot
Cold
Hot
Cold

Cycle

No

-X

Hot

Cycle
Cycle

No
No

-X
ESD

Cold
Hot

65 / 90

Yes

-X

Cold

65 / 90

Yes

-X

Hot

65 / 90

Yes

-Y

Cold

65 / 90

Yes

-Z

Hot

65 / 90

Yes

-Z

Cold

65 / 90

Yes

-Z

Hot

65 / 90
65 / 90

Yes
Yes

-X
ESD

Cold
Hot
Cold

65 / 90

Yes

-Y

65 / 90

Yes

-Y

Hot

65 / 90

Yes

ESD

Cold

Open Face
Down

65 / 90

Yes

-Z

Hot

DUST

88 HOUR

DROP 2

Open Face Up
Closed Face
Up

Cycle

No

SHAKER ESD
2
-Y

Cycle

No

-Z

Hot

Cycle

No

-Y

Cold

Closed Face
Down
Open Face
Down
Closed Face
Up
Open face Up
Open Face
Down
Closed Face
Down

P-mets
Cold

Cycle

No

-X

Hot

Cycle

No

-X

Cold

65 / 90

Yes

-Z

Hot

65 / 90
65 / 90

Yes
Yes

-Y
-X

Cold
Hot

65 / 90

Yes

ESD

Cold

65 / 90

Yes

-Z

Hot

Approved alternate ESD radios:

1rst ESD

MotoALT: 3,4,14 may replace 9 or 11; 19,20,23,24 may replace 15

MotoCALT: 5 may replace 3

2nd ESD

MotoALT: 17,18,21 may replace 20 or 23; 1,2, 10 may replace 12

MotoCALT: 6 may replace 9

_______________________________________________________________________________________________________________________________________________________

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Appendix J: Power Cycling Routine

Cellular Products: The auto-cycle routine is intended to simulate product operation and provide additional electrical
and thermal stress to components while undergoing ALT thermal environments. Since the unit is typically in a test
mode while this cycle is active, the unit under test is technically not operating as it would in the field.
Historically, the time of the cycle has been 6 minutes. The historical routine is discussed below. Due to changes in
product over time, most importantly the larger number of output devices and bands, compliance of the autocycle
function to ED00230 is now preferred. The preferred autocyle functionality described therein differs fairly significantly
from the historical routine. Only products that have previously been ship authorized, and therefore have field proven
hardware, should continue to use the historical routine.
Historical Note(s) about Autocycle: The cycle has historically consisted of three segments referred to as Transmit,
Receive and Standby. These intervals are not currently equal in time, this was done for factory efficiency. Since this
feature is no longer used in production for burn-in an equal interval of 2 minutes per segment is now preferred.
TX cycle: The transmit cycle should have the carrier on at the highest rated power step for the duration of the cycle.
Some products have more than one final device, in this case the cycle should split this time between the devices. If
the device is operated in different modes efforts should be made to operate the device equally in all modes.
Frequency selection should be made to avoid standard test channels while in cycling mode. Operating at various
frequencies, in the case of multiband phones, is not required unless the above statements are applicable.
Stand-by cycle: In this mode the product is expected to be in the lowest power state possible while remaining
operational.
RX cycle: This cycle should have most functions of the unit awake but carrier off.
Indicators/transducers: Indicators and transducers should be turned on during either the TX or RX cycle. Which ones
get turned on in which cycle is not dictated. The audio paths should be opened with the volume step set at nominal
value. Vibrators should be operated at the default vibration interval. Displays should have all indicators turned on or
cycling. Keypad and display backlighting should be turned on. Alert transducer should be active at a nominal level.
Implementation: while it is desirable to have the ability to enter this mode without the use of a computer it is not
mandatory. If implemented by computer command the implementation should be such that the auto-cycle can be set
and the unit will enter auto-cycle on the next power-up or at the application of B+. Some specifications require that the
unit default back to non-auto-cycle after subsequent loss of power or power down to prevent illegal operation.

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Appendix K: Temperature Cycling Chamber Profile

Temperature Cycle Profile

Condensation Cycle
90%

RH

Chamber Set Temp.

95
+75
70
50
30
10
Temp (deg C)
-10
-30
-40
-50

+75OC/85

1
+75OC

+75OC

17 C/min
O

-40OC

+75OC

+50OC/90%

+17OC/mi
n ramp

-10OC
-30OC

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Appendix L: Temperature Cycle Programming

Intvl #

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

Initia l
Initia l
Fina l
Fina l
Interva l Tem p era ture Hum id ity Tem p era ture Hum id ity Next
# of
Tim e
(Chn. 1)
(Chn. 2)
(Chn. 1)
(Chn. 2) Interva l Loop s

0:00:01
1:00:00
0:00:01
0:40:00
0:00:01
0:40:00
0:00:01
1:00:00
0:00:01
0:40:00
0:00:01
0:40:00
0:00:01
1:00:00
0:00:01
0:20:00
0:00:01
0:10:00
0:00:01
0:10:00
0:00:01
0:20:00
0:00:01
0:10:00
0:00:01
1:49:15
0:00:01
0:40:00
0:00:01
0:40:00
0:00:01
0:40:00
0:00:01

40
40
40
75
75
-40
-40
40
40
75
75
-40
-40
40
40
75
75
75
75
-30
-30
-10
-10
50
50
75
75
-40
-40
75
75
-40
-40

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
75
75
0
0
0
0
90
90
0
0
0
0
0
0
0
0

40
40
75
75
-40
-40
40
40
75
75
-40
-40
40
40
75
75
75
75
-30
-30
-10
-10
50
50
75
75
-40
-40
75
75
-40
-40
40

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
85
85
0
0
0
0
90
90
0
0
0
0
0
0
0
0
0

2
3
4
5
6
7
3
9
10
11
12
13
9
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
27
32
33
1

0
0
0
0
0
0
5
0
0
0
0
0
5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
0
0
255

Ac c ess Point
Tem p era ture
Cyc le/ Shoc k

Ac c ess Point
Tem p era ture
Cyc le/ Shoc k

Ac c ess Point

Hea t Wa ter
Cond ensa tion
Cyc le

Dry-Out
Tem p era ture
Cyc le/ Shoc k

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Appendix M: Unit Orientations in Shaker

Y
-Z

-X

-Y

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Appendix N: Portable Drop Checklist

DROP TEST DATA

PRODUCT:
DROP: 1 OR 2
UNIT #

BATTERY
SMALL LARGE

ANTENNA
IN
OUT

FLIP
OPEN CLOSED

FRONT

BACK

RIGHT

LEFT

TOP

BOTTOM

COMMENTS

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

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Appendix O: Shaker Orientation Checklist

SHAKER TEST DATA

PRODUCT:
SHAKER:
UNIT #

1 OR 2

FRONT (+Z) BACK (-Z)

RIGHT (+X)

LEFT (-X)

TOP (+Y)

BOTTOM (-Y)

COMMENTS

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

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Appendix P: ESD Checklist

ESD DATA SHEET

TEST
CLASS

PRODUCT
DATE
UNITS
VOLTAGE APPLICATION
LEVEL
POINT

COMMENTS AFTER +ESD POLARITY

TESTS

COMMENTS AFTER -ESD POLARITY

TESTS

NOTE: 1st ESD units should be 9, 11, 27; 2nd ESD units should be 12, 26, 28
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Appendix Q: DTF Checklist

DTF Recording Sheet

Tester:
Job #:
Product ID:
Top / Left / Front / Front /Back
Worst Case Orientation: Bottom Right Back with Flip Open
(TB)
(LR)
(FB)
(FBo)
1 Cycle
Orientation Unit Number

Orientation Unit Number

11

6 Cycle
12

2 Cycle
3

7 Cycle
13

14

3 Cycle
5

8 Cycle
15

16

4 Cycle
7

9 Cycle
17

18

5 Cycle
9

10

Signaling
Test

Failure Description

Signaling
Test

Failure Description

10 Cycle
19

20

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Appendix R: Minimal Parametric Test Set

Minimal Parametric Test Set

PARAMETRIC
TESTING (Use closest
usable channel)
TDMA
TXD power out
TXD Frequency Error
TXD Max Current Draw
under highest power level
(2)
TXD EVM
TXD Phase Error
TXD Magnitude Error
TXD Origin Offset
RXD Fast BER @ -107 dB
at extremes -110 dB at
room
RXD RSSI Level
CDMA
Tx Power output at Min
and Max level (set to eighth
rate
vocoder)
CDMA Phase Error
CDMA Frequency Error
CDMA Rho
CDMA Time Offset
RXD Dynamic range FER
@ -25 dB
CDMA RX Sensitivity @104 dBm
AMPS
Power on/off, standby and
max. current drain
TXA power out
TXA Frequency Error
TXA Distortion
TXA Hum and Noise
TXA SAT/DESAT
RXA SINAD @-116dB
input limit
RXA Hum and Noise
RXA Distortion
GSM
Power on/off and standby
current drain
Mobile initiated call
processing
Tx power out
Tx Frequency Error
Peak & RMS phase error
Time Mask measurements
RX Bit Error Rate for RES
II
RX Frame Erasures for
RES II

Cellular
Channel

Cellular
Power
Steps

PCS
Channels

PCS
Power
Steps

799, 991
799, 991

2, 5, 8
2

2, 1989
2, 1989

2, 5, 8
2

n/a
n/a

799

n/a

799, 991
799, 991
799, 991
799, 991

2
2
2
2

2, 1989
2, 1989
2, 1989
2, 1989

799, 991

n/a

799, 991

DCS
Power
Steps

EGSM
Channels

EGSM
Power
Steps

Batt.
Lvl.s

n/a
n/a

n/a
n/a

n/a
n/a

Nom
Nom

n/a

n/a

n/a

n/a

Nom

2
2
2
2

n/a
n/a
n/a
n/a

n/a
n/a
n/a
n/a

n/a
n/a
n/a
n/a

n/a
n/a
n/a
n/a

Nom
Nom
Nom
Nom

2, 1989

n/a

n/a

n/a

n/a

n/a

Nom

n/a

2, 1989

n/a

n/a

n/a

n/a

n/a

Nom

1013, 777

n/a

25, 1175

n/a

n/a

n/a

n/a

n/a

Nom

1013, 777
1013, 777
1013, 777
1013, 777

n/a
n/a
n/a
n/a

25, 1175
25, 1175
25, 1175
25, 1175

n/a
n/a
n/a
n/a

n/a
n/a
n/a
n/a

n/a
n/a
n/a
n/a

n/a
n/a
n/a
n/a

n/a
n/a
n/a
n/a

Nom
Nom
Nom
Nom

1013, 777

n/a

25, 1175

n/a

n/a

n/a

n/a

n/a

Nom

1013, 777

n/a

25, 1175

n/a

n/a

n/a

n/a

n/a

Nom

DCS
Channels

n/a

n/a

n/a

n/a

n/a

n/a

n/a

n/a

Nom

799, 991
799, 991
799
799, 991
799, 991

2, 4, 7
2
2
2
2

n/a
n/a
n/a
n/a
n/a

n/a
n/a
n/a
n/a
n/a

n/a
n/a
n/a
n/a
n/a

n/a
n/a
n/a
n/a
n/a

n/a
n/a
n/a
n/a
n/a

n/a
n/a
n/a
n/a
n/a

Nom
Nom
Nom
Nom
Nom

799, 991

n/a

n/a

n/a

n/a

n/a

n/a

n/a

Nom

799
799

n/a
n/a

n/a
n/a

n/a
n/a

n/a
n/a

n/a
n/a

n/a
n/a

n/a
n/a

Nom
Nom

n/a

n/a

n/a

n/a

n/a

n/a

n/a

n/a

Nom

62

n/a

660

n/a

700

n/a

38

n/a

Nom

1, 124

5, 10, 15

0, 8, 15

512, 700,885

0, 8,
15

975, 38, 124

5, 10,
19

Nom

1, 62, 124

512, 700,885

975, 38, 124

Nom

1, 62, 124

512, 700,885

975, 38, 124

Nom

1, 62, 124

512, 700,885

975, 38, 124

Nom

1, 62, 124

n/a

n/a

512, 700,885

n/a

975, 38, 124

n/a

Nom

1, 62, 124

n/a

n/a

512, 700,885

n/a

975, 38, 124

n/a

Nom

512, 660,
810
512, 660,
810
512, 660,
810
512, 660,
810
512, 660,
810
512, 660,
810

_______________________________________________________________________________________________________________________________________________________

The information contained in this in document is PROPRIETARY to Motorola Inc. and shall not be reproduced
or used in part or whole without Motorolas written consent.

NO.

motoalt 2005

MATERIAL or METHODS Specification

TITLE:

MotoALT/CALT 2005 Test Procedure

REVISION DATE:

PRELIMINARY

MEMO:

30-DEC-04

ISSUE:

PAGE:

37 of 40

Appendix S: Desense Test (GSM only)

Desense Test (GSM Only)

1.0 The following procedure should be followed to conduct desense for GSM products.
1.1 Equipment requirements.
1.1.1 RF enclosure with dipole antenna fitted.
1.1.2 GSM Test Set
1.2 Perform the following.
1.2.1 Set expected input to 25 dbm and amplitude according to applicable 12M.
1.2.2 Connect the dipole antenna in the RF enclosure to the GSM Test Set.
1.2.3 Place a powered phone inside the RF enclosure.
1.2.4 Establish a mobile terminated call.
1.2.5 Reduce the RF amplitude until RX Quality level equals 4.
1.2.6 Read the RX Level Error, This represents the antenna desense.
1.2.7 By reducing the RF amplitude until RX Quality equals 4 you are effectively searching for the
declared sensitivity point of the receiver, which is 102 dbm. This then means that the RX
level error must be 8 or less to pass.
1.3 For channels to be tested, refer to the following matrix, based on the recommendations of 12M09171A30:
P-GSM
1
5
62
70
124

E-GSM
975
5
37
70
124

DCS
512
521
586
651
716
781
846
885

PCS
512
546
611
676
741
806

For additional information and procedures please see ED00130.

_______________________________________________________________________________________________________________________________________________________

The information contained in this in document is PROPRIETARY to Motorola Inc. and shall not be reproduced
or used in part or whole without Motorolas written consent.

NO.

motoalt 2005

MATERIAL or METHODS Specification

TITLE:

MotoALT/CALT 2005 Test Procedure

REVISION DATE:

MEMO:

30-DEC-04

PRELIMINARY
ISSUE:

PAGE:

38 of 40

Appendix T: MotoALT Failure Rate Formula

MotoALT FAILURE RATE FORMULA

SIMPLIFIED FORMULA FAILURE RATE %

PFFR (%/month)

(.68 / SAMPLE SIZE) x (NUMBER OF FAILURES)

# OF FAILURES x 30.3 DAYS PER MONTH

FAILURE RATE = -----------------------------------------------------------------------------------------------------((# OF RADIOS) x (# OF TEST DAYS) DAYS LOST ) x ACC. FACTOR

EXAMPLE:
# OF FAILURES = 1
# OF RADIOS = 24 (10 FOR MotoCALT)
TEST DAYS = 7
ACCELERATION FACTOR = 645
DAYS LOST = 0

1 x 30.3
FAILURE RATE = -------------------------------- = .00017 or (0.017% PER MONTH)
((40 * 7) 0) x 645

_______________________________________________________________________________________________________________________________________________________

The information contained in this in document is PROPRIETARY to Motorola Inc. and shall not be reproduced
or used in part or whole without Motorolas written consent.

NO.

motoalt 2005

MATERIAL or METHODS Specification

TITLE:

MotoALT/CALT 2005 Test Procedure

REVISION DATE:

30-DEC-04

MEMO:

PRELIMINARY
ISSUE:

PAGE:

39 of 40

Appendix U: MotoALT/CALT Percent Complete Chart

Percent complete describes the percentage of the total ALT stress applied to date. In other words, the amount of the
stress to be seen in the whole ALT that the product has seen as of the date in question. This estimate is stress
based not time based.

Point in ALT Flow (after completion of

stress)
initial parametrics
temperature shock
1rst drop, dust, and ESD
temperature cycle, humidity & shaker
2nd drop and ESD
final parametrics
final inspection

Percent complete
0%
5%
25%
45%
75%
94%
99%

_______________________________________________________________________________________________________________________________________________________

The information contained in this in document is PROPRIETARY to Motorola Inc. and shall not be reproduced
or used in part or whole without Motorolas written consent.

NO.

motoalt 2005

MATERIAL or METHODS Specification

TITLE:

MotoALT/CALT 2005 Test Procedure

REVISION DATE:

30-DEC-04

MEMO:

PRELIMINARY
ISSUE:

PAGE:

40 of 40

Appendix V: Glossary of Terms

1. Auto power-cycling - The Auto Cycle is intended to be a 33% duty cycle between STAND-BY, TX, and RX.
- Most products are using 1.5 minutes TX, 2.25 minutes RX, and 2.25 minutes STAND-BY. In the stand-by
mode the product should be in as low current condition as possible. However since the products are typically
in the test mode to accomplish this, they are not as in as low a current state as they might be in stand-by in
the field.
- In TX mode we try to simulate call conditions, the transmitter should be ON and in the case of digital
products with 2 modes part of the cycle is usually spent in each mode.
- In the RX cycle audio paths should be opened and generally noise is heard in the speaker at a nominal
volume step.
- Vibrators, alerts, displays, back light, should all be exercised during the cycle (approx. 1x/minute). Usually
performed during Receive or Stand-by due to higher current drains during the Tx mode.
2. Failure - The definition of what a failure is can be subject to interpretation or be subjective at times.
- Hard failure is permanent loss of function in the product.
- Soft failure is temporary inoperative state of function in the product. Requires some human intervention to
restore operation.

_______________________________________________________________________________________________________________________________________________________

The information contained in this in document is PROPRIETARY to Motorola Inc. and shall not be reproduced
or used in part or whole without Motorolas written consent.