1 Thermoelectric Cooler Reliability Report RMT Ltd 53 Leninskij prosp Moscow 119991 Russia Phone +7-095-132-6817 Fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru Moscow, February 5th, 2004 RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 2 Contents 1 Introduction ......................................................................................................................................3 1.1 Background.............................................................................................................................3 1.2 Contents of This Report ..........................................................................................................3 1.3 Notice of Confidentiality ..........................................................................................................3 2 Test Program ...................................................................................................................................4 2.1 Test Program Content.............................................................................................................4 2.2 Sampling Plan.........................................................................................................................5 2.3 Test Plan.................................................................................................................................5 3 Methods ...........................................................................................................................................6 3.1 General ...................................................................................................................................6 3.2 Military Standards ...................................................................................................................6 3.3 Telcordia Requirements..........................................................................................................6 4 Thermoelectric Coolers ...................................................................................................................7 5 Variable Frequency Vibration Testing .............................................................................................8 5.1 Purpose of Test.......................................................................................................................8 5.2 Test Method Used...................................................................................................................8 5.3 Test Equipment Details...........................................................................................................8 5.4 Test Parameters .....................................................................................................................8 5.5 Test Data ................................................................................................................................8 5.6 Test Results ..........................................................................................................................10 6 Mechanical Shock Testing.............................................................................................................11 6.1 Purpose of Test.....................................................................................................................11 6.2 Test Method Used.................................................................................................................11 6.3 Test Equipment Details.........................................................................................................11 6.4 Test Parameters ...................................................................................................................11 6.5 Test Data ..............................................................................................................................11 6.6 Test Results ..........................................................................................................................13 7 Temperature Cycling .....................................................................................................................14 7.1 Purpose of Test.....................................................................................................................14 7.2 Test Method Used.................................................................................................................14 7.3 Test Equipment Details.........................................................................................................14 7.4 Test Parameters ...................................................................................................................14 7.5 Test Data ..............................................................................................................................14 7.6 Test Results ..........................................................................................................................17 8 Power Cycle Testing......................................................................................................................18 8.1 Purpose of Test.....................................................................................................................18 8.2 Test Method Used.................................................................................................................18 8.3 Test Equipment Details.........................................................................................................18 8.4 Test Parameters ...................................................................................................................18 8.5 Test Data ..............................................................................................................................18 8.6 Test Results ..........................................................................................................................21 9 Thermoelectric Cooler Qualification Summary Sheet ...................................................................22 RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 3 1 Introduction This Section contains a description of the background of the testing, a brief overview of the contents of this Report, and a Notice of Confidentiality. 1.1 Background RMT Ltd has performed complex qualification testing of TE modules for application is Space program. Thermoelectric cooler type– 1MC06-060-10. 1.2 Contents of This Report Section 2 contains brief description of Qualification Test Program. Section 3 – brief description of produced batch of TE modules. Sections 4 through 9 contain detailed information regarding the multiple types of testing conducted on the selected modules. For each test, the purpose of the test, test methods, test equipment used, test data, test results, and conclusions are described. 1.3 Notice of Confidentiality This Report and all of its contents are to be treated as confidential information. The Report may not be reproduced, or may the information contained within be divulged to third parties, without the prior written consent of RMT Ltd. RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 4 2 Test Program 2.1 Test Program Content Content of the Test Program is the following: Table 2.1-1 Qualification Inspection Sequence No Test 1 Electrical Measurements Test Conditions Per Table 2.1.2 2 Mounting of units to test base With InSb solder (117 °C) 3 4 Performance Test in Nitrogen Vibration 5 6 7 Mechanical Shock Electrical Measurements Life Test 8 9 Performance Test in Vacuum Final electrical Measurement Note 1 MIL-STD-883E, Method 2007.2, Vibration, Variable Frequency MIL-STD-883E, Method 2002.3, Mechanical Shock Per Table 2.1.2 MIL-STD-883E, Method 1006, Intermittent Life Tamb= 85°C Current: Imax=1.65 A Cycle Time: 5 minutes on and 5 minutes off. Number of cycles: 6000 cycles (1000 hrs) Note 1 Per Table 2.1.2, AC Resistance change: < 5% of initial value Note 2 10 External Visual Inspection Notes: 1) Verify that the performance meets the following specification: a. Thot = 30 °C b. Tcold = -42 ±2°C c. Current = Imax=1.65 A ±5% d. Voltage = Umax=7.5 V ±5% 2) The TEC shall be examined to verify that the materials, design and construction, physical dimensions, marking and workmanship are in accordance with the requirements specified herein. They shall be free from cracks, voids, sharp edges and other defects that would be adversely affect life or serviceability. Table 2.1-2 Electrical Measurements at Room Temperature No Characteristics Symbol 1 AC Resistance R 2 Insulation Resistance Ri Test Conditions VDC= 500 ± 50V Limits Min Max Unit 3.40 3.75 Ω 10 - MΩ Note Testing includes the following methods: 1) Vibration 2) Mechanical Shock 3) Life Test (High temperature Burn-In) 4) To this report additional method is included – Temperature Cycling RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 5 2.2 Sampling Plan Sampling Plan for the program is the following: Table 2.2-1 Sampling Plan No 1 2 3 4 2.3 Test Vibration Mechanical Shock Life Test (Power Cycle Test) Temperature Cycling LTPD, % Acceptance Number 0 0 0 0 10 10 2 7 Sample Size, pcs 22 22 116 32 Test Plan Total batch of produced TE modules was divided into lots according to Test Plan: Table 2.3.1 Test Plan No 1 2 3 4 5 6 7 8 9 Test Electrical Measurements Performance Test in Vacuum Vibration Mechanical Shock Life Test (Power Cycle Test) Temperature Cycling External Visual Inspection Performance Test in Vacuum Final Electrical Measurement Lot 22 pcs 100% 2 pcs 100% 100% 2 pcs 100% Lot 22 pcs 100% 2 pcs 100% 100% 2 pcs 100% Lot 116 pcs 100% 6 pcs 100% 100% 6 pcs 100% Lot 32 pcs 100% 2 pcs 100% 100% 2 pcs 100% RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 6 3 Methods 3.1 General Methods used for testing reported herein are based on military standards and Telcordia requirements. 3.2 Military Standards Military standards (abbreviated in the singular as “MIL-STD”) were originally developed for defense and aerospace related organizations, but lately these standards have been adopted by many commercial and industrial companies ranging from those using thermoelectric for telecommunications to those using them for medical applications. Thermoelectric modules, being typically comprised of a small circuit of Peltier elements, are tested using MIL-STD 883 for microcircuits. 3.3 Telcordia Requirements Telcordia, whose requirements are referenced in this report, is a company that provides technical analysis, testing, and consulting services to product suppliers and service providers in the communications market. Telcordia’s GR-468 CORE is their generic reliability assurance requirement. RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 7 4 Thermoelectric Coolers Total batch of 250 TE modules was produced for purposes of current Qualification Test Program. Production Specification # 1157 dated 15.12.2003. The Specification is attached. All TE modules were hot side metallized and pre-tinned by InSn solder (117 deg. C melting point) Hot side – nicked (clear) ceramics, except 12 samples prepared for performance testing in vacuum. Cold side of these 12 TE modules was metallized for thermocouples mounting. The first 192 samples were divided into four lots according to Sampling Plan (Item 2.2). RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 8 5 Variable Frequency Vibration Testing 5.1 Purpose of Test The variable frequency vibration test was performed for the purpose of determining the effect of vibration frequency in the specified frequency range on component parts. 5.2 Test Method Used The basic test method employed was MIL-SDT-883E. Method 2007.2. Vibration. Variable Frequency. All 22 samples have been taken from produced batch # 1157 (Appendix 1). Every TE module has been soldered (solder InSn, 117 deg. C melting point) onto individual flat copper sub-holder. The 22 parts were bolted to the vibration table on three different faces. These parts were then subjected to vibration at a 20 G level from 20 to 2.000 Hz. The frequency sweep up and down was performed in four minutes and repeated four more times. The axis was then changed and the sweep was repeated another four times. The same process was repeated for three axis as well. A measurement of the AC Resistance and Figure-of-Merit of each part was taken before and after each test. Performance pre-test and post-test are compared of selected samples from the lot. Performance pre-test and post-test are compared of selected samples from the lot. 5.3 Test Equipment Details The following test equipment was used to conduct this test. Vibration Machine ВЭДС-200А (Russia), S/N 44-24675. TEC Vacuum Performance Tester DX3085. DX4065 Z-Meter (ACR, Z, Time Constant), S/N 10-0012. Insulation Tester MEG, P/N 690326. Microscope LOMO Stereo-MX-3, S/N TT0009. 5.4 Test Parameters The test was conducted at room temperature with the parts in a non-operational mode. A four-minute sweep up and down was conducted at 20 G’s over a frequency range of 20 to 2.000 Hz in four minutes. Four such sweeps were done on each of three axes. Ambient conditions: temperature 22 oC, humidity 57%, pressure 742 mmHg 5.5 Test Data After testing visual inspection shows no any damaged sample. Insulation resistance measurement before and after testing shows Ri>300 MOhm, close to the upper level of Tester scale. Table with detailed listing of each tested samples did not included into the document. Table 5.1-1 shows the data from the test of the TEC 1MC06-060-10 part. The before and after test Resistances in Ohms and Figure-of-Merit (Z) in 1000/K are shown, as well as the calculated change value. RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 9 3.55 3.50 3.45 3.40 3.35 3.30 3.25 3.20 2.80 2.75 2.70 Z R, Ohm Table 5.5-1. Resistance and Figure-of-Merit Data for TEC 1MC06-060-10 Vibration Test (dated 20/01/04) Before After Before After ΔR ΔZ Sample # Sample # Ohm Ohm 1000/K 1000/K % % A1 3.41 3.47 1.76% A1 1.11% 2.70 2.73 A2 3.43 3.45 0.58% A2 0.00% 2.72 2.72 A3 3.43 3.47 1.17% A3 0.37% 2.73 2.74 A4 3.43 3.50 2.04% A4 -1.82% 2.74 2.69 A5 3.42 3.44 0.58% A5 -0.37% 2.72 2.71 A6 3.36 3.38 0.60% A6 -0.73% 2.75 2.73 A7 3.37 3.40 0.89% A7 0.00% 2.72 2.72 A8 3.40 3.40 0.00% A8 -1.09% 2.75 2.72 A9 3.39 3.38 -0.29% A9 0.00% 2.74 2.74 A10 3.38 3.37 -0.30% A10 -1.86% 2.69 2.64 A11 3.42 3.49 1.95% A11 -0.77% 2.71 2.69 A12 3.37 3.42 1.55% A12 0.40% 2.72 2.73 A13 3.40 3.46 1.67% A13 -0.37% 2.73 2.72 A14 3.29 3.29 0.01% A14 -2.17% 2.72 2.66 A15 3.41 3.41 0.12% A15 -1.75% 2.72 2.67 A16 3.42 3.47 1.60% A16 0.64% 2.72 2.74 A17 3.38 3.39 0.42% A17 -1.11% 2.73 2.70 A18 3.33 3.37 1.13% A18 0.04% 2.71 2.71 A19 3.38 3.38 0.06% A19 0.69% 2.70 2.72 A20 3.26 3.25 -0.22% A20 -1.06% 2.74 2.71 A21 3.36 3.39 0.92% A21 -0.86% 2.71 2.68 A22 3.37 3.42 1.44% A22 -1.28% 2.70 2.67 Average 3.38 3.41 0.80% Average 2.72 2.71 -0.54% Min 3.26 3.25 -0.30% Min 2.69 2.64 1.11% Max 3.43 3.50 2.04% Max 2.75 2.74 -2.17% 2.65 2.60 2.55 2.50 2 3 2 3 Table 5.5-2 Performance of TECs 1MC06-060-10 before and after Vibration Test Sample # A11 A22 ΔTmax K 70.5 70.0 Before test Imax Umax V A 7.3 1820 7.2 1800 ΔTmax K 69.8 69.5 After test Umax V 7.4 7.3 Imax A 1820 1800 RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 10 5.6 Test Results 5.6.1 A total of 22 parts were selected for the purpose of this report. Telcordia provides a suggested passing criterion for such a test in GR-468 CORE of less than 5% change in resistance. All parts tested met the suggested criterion, with maximal change in resistance 2.04%, minimal change -0.37 %. The average change value is of 0.80%. 5.6.2 Figure–of-Merit (Z) was controlled too. All parts showed slight change of TEC performance with maximal change in Z is -2.17%, minimal change 1.11%. The average change value is of -0.54%. Performance testing in vacuum also before and after test of selected samples showed good correlation with Z measurements of all samples of the lot – correspondent only slight reduction of ΔTmax RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 11 6 Mechanical Shock Testing 6.1 Purpose of Test The purpose of this test was to determine the suitability of the thermoelectric modules for use in equipment which may be subject to moderately severe shocks as a result of suddenly applied forces or abrupt changes in motion. 6.2 Test Method Used The basic test method employed was MIL-SDT-883E. Method 2002.3. Mechanical Shock. All 22 samples have been taken from produced batch # 1157 (Appendix 1). Every TE module has been soldered (solder InSn, 117 deg. C melting point) onto individual flat copper sub-holder. The 22 parts were initially prepared by mounting them successively on the test platform. The test platform was impacted by a swing arm to apply the mechanical shock. These parts were then subjected to shock at 1500 G level using a 0.5 msec duration half-sine wave pulse. Each device was shocked a total of 5 times in the first axis. The axis was then changed and the shock was repeated another 5 times. The same process was repeated for each of the remaining four axes as well. A measurement of the AC Resistance and Figure-of-Merit of each part was taken before and after each test. Performance pre-test and post-test are compared of selected samples from the lot. Performance pre-test and post-test are compared of selected samples from the lot. 6.3 Test Equipment Details The following test equipment was used to conduct this test. Single Impact Machine STT, S/N P24/78-13617. TEC Vacuum Performance Tester DX3085. DX4065 Z-Meter (ACR, Z, Time Constant), S/N 10-0012. Insulation Tester MEG, P/N 690326. Microscope LOMO Stereo-MX-3, S/N TT0009. 6.4 Test Parameters The test was conducted at room temperature with the parts in a non-operational mode. A total of five shocks were conducted in each of six axes. Ambient conditions: temperature 22 oC, humidity 56%, pressure 740 mmHg 6.5 Test Data After testing visual inspection shows no any damaged sample. Insulation resistance measurement before and after testing shows Ri>300 MOhm, close to the upper level of Tester scale. Table with detailed listing of each tested samples did not included into the document. Table 6.5-1 shows the data from the test of the TEC 1MC06-060-10 part. The before and after test AC Resistances in Ohms and Figure-of-Merit (Z) in 1000/K are shown, as well as the calculated change value. RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 12 Table 6.5-1. Resistance and Figure-of-Merit Data for TEC 1MC06-060-10 Mechanical Shock Test (dated 27/01/04) Sample # B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 Average Min Max R Before 3.45 3.47 3.47 3.45 3.47 3.44 3.43 3.44 3.47 3.45 3.40 3.44 3.38 3.41 3.42 3.37 3.47 3.40 3.43 3.41 3.39 3.43 3.43 3.37 3.47 R After 3.44 3.44 3.46 3.44 3.59 3.51 3.43 3.49 3.52 3.48 3.43 3.43 3.49 3.47 3.42 3.49 3.52 3.42 3.48 3.48 3.47 3.50 3.47 3.42 3.59 ΔR Sample # -0.29% -0.86% -0.29% -0.29% 3.46% 2.03% 0.00% 1.45% 1.44% 0.87% 0.88% -0.29% 3.23% 1.64% -0.10% 3.33% 1.33% 0.42% 1.38% 2.11% 2.42% 1.90% 1.17% -0.86% 3.46% B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 B22 Average Min Max 3.65 2.80 3.60 2.75 Z After 2.73 2.74 2.74 2.75 2.66 2.68 2.73 2.73 2.74 2.76 2.74 2.63 2.64 2.69 2.69 2.74 2.63 2.61 2.67 2.61 2.65 2.75 2.70 2.61 2.76 ΔZ -0.36% -0.36% 0.00% 0.00% -2.92% -2.55% -0.36% -0.73% 0.00% 0.36% 0.00% -2.78% -1.72% -0.54% -1.82% -0.45% -2.05% -3.17% -0.88% -1.98% -1.52% 0.30% -1.07% 0.36% -3.17% 2.70 3.50 Z R, Ohm 3.55 Z Before 2.74 2.75 2.74 2.75 2.74 2.75 2.74 2.75 2.74 2.75 2.74 2.70 2.69 2.70 2.74 2.75 2.69 2.69 2.69 2.67 2.69 2.74 2.72 2.67 2.75 3.45 2.65 3.40 2.60 3.35 2.55 3.30 2.50 2 3 2 3 Table 6.5-1. Performance of TECs 1MC06-060-10 before and after Mechanical Shock Test Sample # B11 B22 ΔTmax K 71.0 70.5 Before test Imax Umax V A 7.5 1850 7.3 1800 ΔTmax K 70.0 70.5 After test Umax V 7.6 7.4 Imax A 1850 1800 RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 13 6.6 Test Results 6.6.1 A total of 22 parts were selected for the purpose of this report. Telcordia provides a suggested passing criterion for such a test in GR-468 CORE of less than 5% change in resistance. All parts tested met the suggested criterion, with maximal change in resistance 3.46%, minimal change -0.86 %. The average change value is of 1.17%. 6.6.2 Figure–of-Merit (Z) was controlled too. All parts showed slight change of TEC performance with maximal change in Z is -3.17%, minimal change 0.36%. The average change value is of -1.07%. 6.6.3 Performance testing in vacuum also before and after test of selected samples showed good correlation with Z measurements of all samples of the lot – correspondent only slight reduction of ΔTmax RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 14 7 Temperature Cycling 7.1 Purpose of Test The purpose of this test was to determine the resistance of the parts to alternate exposure to extremes of high and low temperatures. 7.2 Test Method Used The basic test method employed was MIL-SDT-883E. Method 1010.7. Condition B. All 32 samples have been taken from produced batch # 1157 (Appendix 1). The ovens were then heated to 125oC and the cold chamber was brought down to -55oC. The TE modules were then placed in the oven for a period of 10 minutes, and then place in the cold chamber. also for a period of 10 minutes. Fast transfer between cold and hot chambers (less then 5 sec) was provided. This cycling was repeated until any sample of the tested lot reaches 5% change in AC Resistance. A measurement of the AC Resistance and Figure-of-Merit of each part was taken before and after each test. Performance pre-test and post-test are compared of selected samples from the lot. Performance pre-test and post-test are compared of selected samples from the lot.. 7.3 Test Equipment Details The following test equipment was used to conduct this test. TABAI Thermal Shock Chamber TSE-10, S/N450118 TEC Vacuum Performance Tester DX3085. DX4065 Z-Meter (ACR, Z, Time Constant), S/N 10-0012. Insulation Tester MEG, P/N 690326. Microscope LOMO Stereo-MX-3, S/N TT0009. 7.4 Test Parameters The hot chamber temperature was set to 125oC. while the cold chamber was set to -55oC. The parts were held at each temperature for a minimum of 10 minutes for each exposure. This cycling was repeated until any sample of the tested lot reaches 5% change in AC Resistance. 7.5 Test Data After testing visual inspection shows no any damaged sample. Insulation resistance measurement before and after testing shows Ri>300 MOhm, close to the upper level of Tester scale. Table with detailed listing of each tested samples did not included into the document. Tables 7.5-1 and 7.5-2 shows the data from the test of the TEC 1MC06-060-10 part. The before and after test AC Resistances in Ohms and Figure-of-Merit (Z) in 1000/K are shown, as well as the calculated change value. RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 15 Table 7.5-1. Resistance Data for TEC 1MC06-060-10 Temperature Cycling Test (finished 25.01.04) Sample # 0 130 270 410 500 630 760 900 3.45 3.48 3.50 3.50 3.49 3.44 3.35 3.36 3.47 3.49 3.43 3.52 3.44 3.44 3.41 3.45 3.47 3.45 3.47 3.41 3.38 3.36 3.36 3.36 3.37 3.36 3.45 3.44 3.43 3.35 3.43 3.39 3.43 3.35 3.47 3.45 3.46 3.49 3.47 3.47 3.41 3.36 3.37 3.45 3.47 3.41 3.48 3.45 3.44 3.41 3.45 3.44 3.43 3.44 3.42 3.39 3.35 3.40 3.37 3.37 3.35 3.45 3.43 3.43 3.37 3.42 3.41 3.42 3.35 3.45 3.54 3.46 3.56 3.49 3.54 3.48 3.42 3.43 3.51 3.47 3.44 3.51 3.51 3.46 3.43 3.48 3.45 3.43 3.46 3.41 3.47 3.38 3.44 3.39 3.37 3.37 3.44 3.43 3.43 3.39 3.45 3.39 3.45 3.37 3.51 3.54 3.48 3.52 3.49 3.56 3.48 3.40 3.44 3.50 3.49 3.42 3.49 3.47 3.45 3.46 3.47 3.47 3.42 3.45 3.41 3.39 3.37 3.45 3.38 3.38 3.38 3.46 3.44 3.47 3.39 3.46 3.42 3.45 3.37 3.47 3.48 3.45 3.49 3.46 3.51 3.42 3.39 3.42 3.55 3.51 3.45 3.52 3.49 3.48 3.51 3.48 3.48 3.42 3.44 3.41 3.40 3.36 3.46 3.39 3.39 3.40 3.48 3.45 3.44 3.44 3.49 3.45 3.45 3.36 3.51 3.53 3.54 3.51 3.52 3.56 3.50 3.43 3.45 3.54 3.54 3.45 3.49 3.46 3.52 3.51 3.47 3.51 3.45 3.44 3.46 3.42 3.38 3.49 3.40 3.39 3.38 3.51 3.48 3.48 3.41 3.51 3.47 3.48 3.38 3.52 3.59 3.51 3.55 3.48 3.55 3.43 3.42 3.44 3.57 3.48 3.44 3.51 3.50 3.46 3.46 3.45 3.46 3.43 3.45 3.50 3.43 3.40 3.38 3.40 3.39 3.39 3.48 3.46 3.46 3.46 3.47 3.42 3.46 3.38 3.50 3.57 3.52 3.55 3.51 3.57 3.47 3.45 3.51 3.53 3.53 3.45 3.51 3.51 3.47 3.46 3.51 3.48 3.46 3.46 3.44 3.43 3.38 3.52 3.41 3.40 3.41 3.48 3.46 3.47 3.41 3.50 3.43 3.48 3.38 3.52 R, Ohm C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 Average Min Max Cycles/R, Ohm ΔR 3.48% 1.15% 1.43% 0.29% 2.29% 0.87% 2.99% 4.46% 1.73% 1.15% 0.58% -0.28% 2.03% 0.87% 1.47% 1.74% 0.29% 0.29% -0.29% 0.88% 1.48% 0.60% 4.76% 1.49% 0.89% 1.49% 0.87% 0.58% 1.17% 1.79% 2.04% 1.18% 1.43% -0.29% 4.76% 3.65 3.60 3.55 3.50 3.45 3.40 3.35 3.30 0 100 200 300 400 500 600 700 800 900 Cycles RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 16 Table 7.5-2. Figure-of-Merit TEC 1MC06-060-10 Temperature Cycling Test (finished 25.01.04) Sample # C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 Average Min Max 0 2.76 2.79 2.73 2.72 2.73 2.70 2.71 2.74 2.75 2.74 2.72 2.77 2.73 2.76 2.71 2.75 2.74 2.66 2.75 2.73 2.70 2.74 2.73 2.74 2.77 2.74 2.74 2.71 2.76 2.77 2.68 2.77 2.74 2.66 2.77 130 2.74 2.79 2.73 2.71 2.72 2.70 2.69 2.72 2.74 2.74 2.72 2.76 2.72 2.75 2.70 2.74 2.74 2.66 2.75 2.73 2.69 2.74 2.71 2.74 2.76 2.73 2.74 2.70 2.75 2.76 2.67 2.77 2.73 2.66 2.77 270 2.75 2.78 2.73 2.71 2.71 2.71 2.70 2.72 2.71 2.74 2.72 2.76 2.76 2.78 2.73 2.78 2.77 2.64 2.73 2.72 2.69 2.74 2.69 2.73 2.75 2.73 2.73 2.70 2.75 2.75 2.66 2.70 2.73 2.64 2.78 Cycles/Z, 1000/K 410 500 2.73 2.73 2.79 2.77 2.73 2.68 2.71 2.69 2.71 2.68 2.70 2.69 2.69 2.64 2.71 2.71 2.73 2.74 2.73 2.73 2.71 2.72 2.75 2.76 2.72 2.72 2.74 2.74 2.70 2.71 2.74 2.73 2.74 2.73 2.65 2.64 2.73 2.72 2.72 2.71 2.68 2.68 2.73 2.73 2.69 2.68 2.72 2.72 2.75 2.75 2.72 2.72 2.73 2.73 2.69 2.70 2.74 2.75 2.75 2.75 2.65 2.66 2.75 2.76 2.72 2.71 2.65 2.64 2.75 2.76 630 2.73 2.80 2.72 2.71 2.70 2.70 2.69 2.70 2.73 2.73 2.71 2.75 2.72 2.73 2.71 2.73 2.74 2.65 2.73 2.72 2.68 2.73 2.68 2.71 2.75 2.71 2.73 2.70 2.75 2.74 2.65 2.76 2.72 2.65 2.76 760 2.73 2.77 2.72 2.70 2.70 2.69 2.68 2.70 2.72 2.72 2.70 2.75 2.72 2.73 2.71 2.73 2.73 2.64 2.72 2.67 2.71 2.68 2.73 2.72 2.74 2.71 2.72 2.69 2.74 2.75 2.64 2.69 2.71 2.64 2.75 900 2.73 2.78 2.73 2.70 2.70 2.69 2.68 2.71 2.72 2.71 2.71 2.75 2.71 2.71 2.72 2.73 2.73 2.64 2.72 2.71 2.67 2.72 2.67 2.71 2.74 2.70 2.72 2.69 2.74 2.74 2.65 2.69 2.71 2.64 2.74 ΔZ -1.09% -0.36% 0.00% -0.74% -1.10% -0.37% -1.11% -1.09% -1.09% -1.09% -0.37% -0.72% -0.73% -1.81% 0.37% -0.73% -0.36% -0.75% -1.09% -0.73% -1.11% -0.73% -2.20% -1.09% -1.08% -1.46% -0.73% -0.74% -0.72% -1.08% -1.12% -2.89% -0.94% -2.89% 0.37% 2.85 2.80 Z 2.75 2.70 2.65 2.60 0 100 200 300 400 500 600 700 800 900 Cycles RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 17 Table 7.5-3. Performance of TECs 1MC06-060-10 before and after Temperature Cycling Test Sample # C11 C22 7.6 ΔTmax K 70.2 70.5 Before test Imax Umax V mA 7.3 1800 7.3 1850 ΔTmax K 70.0 70.3 After test Umax V 7.4 7.4 Imax mA 1800 1850 Test Results 7.6.1 A total of 32 parts were selected for the purpose of this report. Telcordia provides a suggested passing criterion for such a test in GR-468 CORE of less than 5% change in resistance. All parts tested met the suggested criterion, with maximal change in resistance 4.76%, minimal change -0.29 %. The average change value is of 1.43%. 7.6.2 Figure –of-Merit (Z) was controlled too. All parts showed slight change of TEC performance with maximal change in Z is -2.89%, minimal change 0.37%. The average change value is of -0.94%. 7.6.3 Performance testing in vacuum also before and after test of selected samples showed good correlation with Z measurements of all samples of the lot – correspondent only slight reduction of ΔTmax 7.6.4 The tested samples withstood 9 times longer testing than required by Telcordia GR-468 CORE. RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 18 8 Power Cycle Testing 8.1 Purpose of Test The purpose of this test was to determine the resistance of the parts to thermal/electrical stresses generated by sudden cycling between “on” and “off” conditions. 8.2 Test Method Used The basic test method employed was MIL-SDT-883E, Method 1006, Intermittent Life, Condition B. It is required to confirm reliability of selected TE modules of 50 FIT. That is why sample size increased to 116 samples (LTPD 2%) is applied. All 116 samples have been taken from produced batch # 1157 (Appendix 1). Every TE module has been soldered (solder InSn, 117 deg. C melting point) onto individual flat copper sub-holder. Prior to the test, the AC Resistance and Insulation Resistance of each TE module were recorded. Measurement of Performance in vacuum of 6 selected samples has been made prior the test. Every TE module mounted onto sub-holder has been mounted onto common heat sink using thermally conductive grease as an interface material. The wires from the test TE modules were run to a power supply controlled by a programmable controller. The heat sink with mounted TE modules was placed into oven. The oven temperature was then set to keep the parts at 85oC. The programmable controller cycled the thermoelectric modules between the “on” and “off” conditions for 1000 hours. 8.3 Test Equipment Details The following test equipment was used to conduct this test. HERAEUS Power Controller КRGU.UI-45-7785 HERAEUS Oven HEP 2, S/N 8903510 DX2050 Programmable Time Controller TEC Vacuum Performance Tester DX3085. DX4065 Z-Meter (ACR, Z, Time Constant), S/N 10-0012. Insulation Tester MEG, P/N 690326. Microscope LOMO Stereo-MX-3, S/N TT0009. 8.4 Test Parameters The TE modules were run at maximum current (Imax) according to specification on the TE modules, which was specified as 1.65 Amps at a duty cycle of 5 min on and 5 min off. The ambient temperature was set at 85oC, and the parts were tested for 1000 hrs (6000 cycles) to meet the requirements of the intermittent life test. 8.5 Test Data After testing visual inspection shows no any damaged sample. Insulation resistance measurement before and after testing shows Ri>300 MOhm, close to the upper level of Tester scale. Table with detailed listing of each tested samples did not included into the document. RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 19 Tables 8.5-1 and 8.5-2 shows the data from the test of the TEC 1MC06-060-10 part. The before and after test AC Resistances in Ohms and Figure-of-Merit (Z) in 1000/K are shown, as well as the calculated change value. Table 8.5-1. Resistance (Ohm) Data for TEC 1MC06-060-10 Power Cycling (finished 24.01.04) Before After 3.43 3.37 3.42 3.39 3.38 3.39 3.38 3.38 3.38 3.42 3.40 3.42 3.40 3.40 3.39 3.38 3.42 3.40 3.42 3.42 3.40 3.41 3.40 3.42 3.41 3.42 3.40 3.40 3.37 3.42 3.44 3.42 3.38 3.43 3.40 3.42 3.39 3.41 3.42 3.41 3.37 3.40 3.40 3.44 3.49 3.47 3.46 3.44 3.42 3.51 3.51 3.45 3.43 3.48 3.43 3.48 3.50 3.52 3.44 3.45 3.49 3.46 3.50 3.50 3.49 3.45 3.49 3.52 3.54 3.52 3.46 3.47 3.47 3.46 3.50 3.53 3.45 3.54 3.46 3.51 3.50 3.51 3.51 3.54 3.44 3.46 3.52 3.53 ΔR 1.54% 2.88% 1.17% 1.47% 1.15% 3.57% 3.76% 2.10% 1.48% 1.75% 0.76% 1.77% 2.98% 3.50% 1.49% 1.93% 2.07% 1.81% 2.33% 2.30% 2.73% 1.23% 2.87% 3.01% 3.95% 2.91% 1.60% 2.19% 2.87% 1.31% 1.94% 3.28% 1.89% 3.32% 1.60% 2.70% 3.14% 2.71% 2.63% 3.53% 2.05% 1.81% 3.50% 2.66% Samples # D45 D46 D47 D48 D49 D50 D51 D52 D53 D54 D55 D56 D57 D58 D59 D60 D61 D62 D63 D64 D65 D66 D67 D68 D69 D70 D71 D72 D73 D74 D75 D76 D77 D78 D79 D80 D81 D82 D83 D84 D85 D86 D87 D88 Before After 3.40 3.42 3.42 3.38 3.42 3.37 3.44 3.40 3.40 3.38 3.44 3.40 3.39 3.39 3.38 3.40 3.42 3.43 3.40 3.37 3.39 3.39 3.44 3.40 3.42 3.38 3.41 3.40 3.43 3.38 3.39 3.37 3.41 3.43 3.39 3.40 3.41 3.39 3.39 3.42 3.40 3.39 3.43 3.42 3.50 3.49 3.52 3.47 3.52 3.41 3.52 3.49 3.50 3.51 3.50 3.45 3.48 3.44 3.45 3.53 3.47 3.49 3.48 3.48 3.51 3.43 3.57 3.46 3.48 3.44 3.51 3.49 3.54 3.46 3.44 3.49 3.46 3.50 3.47 3.46 3.52 3.44 3.49 3.51 3.45 3.44 3.52 3.54 ΔR 2.83% 1.93% 2.90% 2.61% 2.78% 1.20% 2.47% 2.75% 2.85% 3.70% 1.65% 1.60% 2.72% 1.57% 2.11% 3.66% 1.56% 1.69% 2.10% 3.24% 3.40% 1.41% 3.65% 1.95% 2.04% 1.71% 2.98% 2.63% 3.38% 2.42% 1.41% 3.57% 1.69% 2.17% 2.31% 1.70% 3.43% 1.73% 3.16% 2.65% 1.58% 1.59% 2.75% 3.42% Samples # D89 D90 D91 D92 D93 D94 D95 D96 D97 D98 D99 D100 D101 D102 D103 D104 D105 D106 D107 D108 D109 D110 D111 D112 D113 D114 D115 D116 Average Min Max Before After 3.40 3.37 3.38 3.38 3.41 3.43 3.39 3.40 3.40 3.45 3.40 3.42 3.41 3.42 3.38 3.39 3.41 3.44 3.42 3.39 3.36 3.42 3.40 3.43 3.42 3.40 3.41 3.39 3.40 3.37 3.44 3.48 3.50 3.49 3.45 3.48 3.48 3.51 3.50 3.47 3.56 3.51 3.48 3.47 3.54 3.48 3.49 3.52 3.56 3.48 3.47 3.47 3.47 3.48 3.49 3.47 3.51 3.50 3.50 3.48 3.42 3.54 ΔR 2.46% 3.75% 3.38% 2.12% 2.08% 1.46% 3.53% 3.02% 2.20% 3.22% 3.03% 1.63% 1.65% 3.61% 2.97% 2.84% 3.13% 3.41% 1.68% 2.15% 3.05% 1.54% 2.24% 1.54% 1.58% 3.29% 2.61% 3.37% 2.35% 0.76% 3.95% 3.60 3.55 R, Ohm Samples # D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 D16 D17 D18 D19 D20 D21 D22 D23 D24 D25 D26 D27 D28 D29 D30 D31 D32 D33 D34 D35 D36 D37 D38 D39 D40 D41 D42 D43 D44 3.50 3.45 3.40 3.35 2 3 RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 20 Table 8.5-2. Figure-of-Merit (1000/K) for TEC 1MC06-060-10 Power Cycling (finished 24.01.04) After 2.64 2.66 2.72 2.66 2.69 2.62 2.70 2.60 2.72 2.72 2.68 2.66 2.71 2.61 2.66 2.65 2.67 2.71 2.68 2.68 2.71 2.58 2.69 2.68 2.65 2.67 2.66 2.69 2.64 2.65 2.59 2.70 2.61 2.71 2.62 2.66 2.64 2.68 2.66 2.64 2.65 2.69 2.68 2.69 ΔR Samples Before # 2.73 -4.00% D45 -1.48% D46 2.75 -0.37% D47 2.73 -1.12% D48 2.73 -1.47% D49 2.72 -2.53% D50 2.72 -0.48% D51 2.69 -3.70% D52 2.71 -0.44% D53 2.73 -0.37% D54 2.72 -1.47% D55 2.68 -2.13% D56 2.72 -1.63% D57 2.74 -4.40% D58 2.70 -1.65% D59 2.71 -1.85% D60 2.73 -2.34% D61 2.73 -0.95% D62 2.69 -0.78% D63 2.71 -1.18% D64 2.68 -0.81% D65 2.71 -3.87% D66 2.73 -0.41% D67 2.73 -1.87% D68 2.73 -2.79% D69 2.71 -1.22% D70 2.69 -1.19% D71 2.69 -1.18% D72 2.73 -3.83% D73 2.69 -3.07% D74 2.67 -3.68% D75 2.72 -0.74% D76 2.68 -2.94% D77 2.73 -0.73% D78 2.70 -3.53% D79 2.74 -1.44% D80 2.74 -3.40% D81 2.69 -0.85% D82 2.73 -1.37% D83 2.76 -2.62% D84 2.70 -2.50% D85 2.68 -0.66% D86 2.74 -1.69% D87 2.69 -0.88% D88 2.72 After 2.67 2.66 2.70 2.64 2.67 2.66 2.60 2.69 2.65 2.63 2.58 2.64 2.70 2.60 2.61 2.63 2.63 2.66 2.68 2.64 2.61 2.63 2.68 2.63 2.61 2.64 2.64 2.68 2.66 2.60 2.66 2.67 2.69 2.66 2.71 2.71 2.66 2.67 2.65 2.68 2.59 2.72 2.60 2.70 ΔR Samples Before # -2.09% D89 2.72 -3.20% D90 2.68 -1.10% D91 2.71 -3.26% D92 2.69 -1.77% D93 2.73 -2.13% D94 2.75 -3.27% D95 2.74 -0.81% D96 2.73 -3.00% D97 2.70 -3.38% D98 2.72 -3.70% D99 2.73 -2.76% D100 2.73 -1.35% D101 2.73 -3.74% D102 2.69 -3.55% D103 2.73 -3.56% D104 2.70 -3.70% D105 2.71 -0.93% D106 2.68 -1.18% D107 2.74 -1.46% D108 2.70 -3.55% D109 2.71 -3.66% D110 2.75 -1.83% D111 2.70 -3.66% D112 2.69 -3.73% D113 2.68 -1.79% D114 2.70 -1.68% D115 2.73 -1.90% D116 2.73 -1.23% Average 2.72 Min 2.68 -2.77% 2.76 -2.13% Max -0.34% -1.54% 2.80 -1.44% 2.75 -0.95% 2.70 -1.20% 2.65 -1.26% -2.34% 2.60 -3.85% 2.55 -0.78% 2.50 -3.39% 2.45 -0.55% 2.40 -3.38% 2 -0.63% After ΔR 2.66 2.64 2.65 2.64 2.66 2.66 2.65 2.65 2.62 2.69 2.63 2.66 2.65 2.64 2.71 2.65 2.64 2.64 2.65 2.61 2.63 2.71 2.65 2.62 2.59 2.66 2.72 2.69 2.67 2.58 2.72 -2.28% -1.35% -2.21% -1.79% -2.60% -3.10% -3.14% -2.79% -2.82% -1.03% -3.66% -2.42% -2.89% -1.93% -0.84% -1.96% -2.73% -1.42% -3.28% -3.44% -2.95% -1.38% -1.74% -2.71% -3.43% -1.37% -0.33% -1.47% -1.85% -0.37% -4.40% Z Samples Before # D1 2.75 D2 2.70 D3 2.73 D4 2.69 D5 2.73 D6 2.69 D7 2.71 D8 2.70 D9 2.73 D10 2.73 D11 2.72 D12 2.72 D13 2.76 D14 2.73 D15 2.70 D16 2.70 D17 2.73 D18 2.74 D19 2.70 D20 2.71 D21 2.73 D22 2.68 D23 2.70 D24 2.73 D25 2.73 D26 2.70 D27 2.69 D28 2.72 D29 2.75 D30 2.73 D31 2.69 D32 2.72 D33 2.69 D34 2.73 D35 2.72 D36 2.70 D37 2.73 D38 2.70 D39 2.70 D40 2.71 D41 2.72 D42 2.71 D43 2.73 D44 2.71 3 RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 21 Table 8.5-3. Performance of TECs 1MC06-060-10 before and after Power Cycling ΔTmax K 71.0 70.5 71.0 71.0 71.0 71.5 Sample # D1 D22 D44 D66 D88 D110 Before test Umax V 7.4 7.3 7.3 7.2 7.2 7.2 Imax mA 1850 1850 1830 1800 1800 1820 ΔTmax K 69.5 69.0 70.0 70.0 70.5 70.0 After test Umax V 7.4 7.4 7.5 7.3 7.5 7.3 Imax mA 1850 1850 1830 1810 1830 1820 80 8 70 7 60 6 50 5 40 4 30 3 20 2 10 1 U, V T, deg.C Fig. 8.5-1. Example of Performance Test in vacuum (sample # D22, before) 0 0 8.6 500 1000 1500 Current, mA 2000 0 2500 Test Results 8.6.1 A total of 116 parts were selected for the purpose of this report. Telcordia provides a suggested passing criterion for such a test in GR-468 CORE of less than 5% change in resistance. All parts tested met the suggested criterion, with maximal change in resistance 3.95%, minimal change 0.76%. The average change value is of 2.35%. 8.6.2 Figure–of-Merit (Z) was controlled too. All parts showed slight change of TEC performance with maximal change in Z is -4.40%, minimal change - 0.37%. The average change value is of -1.85%. 8.6.3 Performance testing in vacuum also before and after test of selected samples showed good correlation with Z measurements of all samples of the lot – correspondent only slight reduction of ΔTmax RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru 22 9 Thermoelectric Cooler Qualification Summary Sheet TEC MODEL Cold Side Dimensions Hot Side Dimensions Height ΔTmax Qmax Imax Umax No of Couples Element Cross-Section Element Height End Plates Ceramics Assembly Solder Barrier Connection 1MC06-060-10 10 x 12 mm2 12 x 12 mm2 2,1 mm 72 deg. 6.6 W 1.65 A 7.5 V 60 0.6x 0.6 mm2 1.0 mm Al2O3 (100%) PbSn (187 deg. C) Ni Horizontal wires QUALIFICATION TESTS Power Cycling Specification No A10-DJO-TS-0005, Table 8-1 MIL Sdt 883 Method 1006 Telcordia GR-468 CORE. R4-94 Complete Temperature Cycling MIL Std 883. method 1010 Condition B Teclcordia GR-468 CORE. R-93 Complete Mechanical Shock Specification No A10-DJO-TS-0005, Table 8-1 MIL STD 883 Method 2002. Condition B Telcordia GR-468 CORE R4-89 Complete Vibration Test Specification No A10-DJO-TS-0005, Table 8-1 MIL STD 883 Method 2007. Condition A 2 Telcordia GR-468 CORE. R4-90 Complete Quality Manager Date Y.V. Zakhartsev 06.02.2004 RMT Ltd 53 Leninskij prosp Moscow 119991 Russia phone +7-095-132-6817 fax +7-095-132-5870 e-mail [email protected] http://www.rmtltd.ru