Re: Tantalum Capacitor Reliability

2002-08-02 Thread Ron Pickard


To all,

This discussion has so far pointed to voltage and ripple current as being the 
main causes for
tantalum capacitor mortality. There is, however, another feature of these caps 
that so far has not
been discussed. That is one of temperature, soldering temperature to be exact. 
We have learned over
the last few months that tantalum caps, when subjected to high temperatures 
(soldering, especially
hand soldering), tend to change internally on a physical basis. A few capacitor 
manufacturers have
verified this. After soldering, when a voltage is applied across the tantalum 
cap, the tantalum cap
tries to self-heal itself. In doing so, the tantalum cap appears to re-rate its 
voltage rating to
the applied voltage. The cause of the self-healing appears to be a function of 
the soldering
temperature and the length of time that the temperature is applied. This is 
greatly egaserbated
(sp?) when a soldering iron actually touches a terminal on the tantalum cap. 
For example and after
very hot soldering, a 15V rated tantalum cap could conceivably be re-rated to 
about 5V if 5V is
applied. We learned this the hard way.

We are now actively looking for a suitable alternative to the tantalum cap 
application (buck filter
needing low ESR).

I wanted to throw in my 2 cents.

Best regards,

Ron Pickard
rpick...@hypercom.com





  
  emcconsult...@yahoo.co
  
  m To:   
72146@compuserve.com, chris.maxw...@nettest.com, emc-p...@ieee.org  
  Sent by:  cc: 
  
  owner-emc-pstc@majordoSubject:  Re: Tantalum 
Capacitor Reliability  
  mo.ieee.org   
  

  

  
  07/29/02 01:35 PM 
  
  Please respond to 
  
  emcconsultant 
  

  

  





Nonetheless, inrush current aside, a 20V Tantalum is considered marginal for a 
12V
circuit if reliability is desired. A 60% derating factor was and is a typical 
max
for reliability circuits, i.e a 30V min rated cap is recommended. Tantalums 
require
additional derating than Al-electrolytics. Furthermore, switchers are notorious 
for
destroying Tantalums due to the large and fast V-swings. I don't recall seeing 
too
many Tantalums on switcher designs.

--- Cortland Richmond 72146@compuserve.com wrote:

 Chris,

 The issue isn't voltage rating; low-ESR caps such as these are susceptible
 to excessive charging current at turn-on.  At a former employer, we saw
 REALLY GOOD, expensive caps used on a computer's 5V bus exploding at
 turn-on, even ones rated at 50 volts. Replacing them with cheaper
 electrolytics (TEN volts!) took care of that.  You might be able to
 alleviate turn-on stress by using a power-on monitor circuit to slow down
 the initial charge. But it'd be far cheaper to go to electrolytics.


 Cortland


  One of my colleagues is testing a new design.  He has designed
  a buck-boost switching converter which has tantalum output capacitors.
  We have looked at his design and gone through the calculations.
  His output current is 4 A maximum.  His output voltage is 12 VDC  His
  caclulated ripple current is 800 mA.  He needed a 120 mV ripple voltage,
  so he put 8 each of 68 uF, 20 V tantalum capacitors (with 150 mOhm ESR)
  in parallel on the output.   Each cap is rated for approximately 800mA
 of
  ripple current.
 
  He has seen two failures of these capacitors during initial testing and
  demonstrations.  Meanwhile, many initial units run fine.   From what I
 can
  gather, he hasn't violated any design rules.  He has 20V rated caps on a
 12V
  circuit.  He has a ripple current rating

Re: Tantalum Capacitor Reliability

2002-07-30 Thread John Barnes

Chris,
You may want to look at some of the polymer aluminum electrolytic
capacitors from:
*  Cornell Dubilier.
*  Elna.
*  Jaro Components.
*  Kemet.
*  Matsushita.
*  NIC Components Corporation.
*  Nichicon.
*  Panasonic.
*  Samchung.
*  SDK.
*  etc.

I've used them on the last two controller cards that I designed for my
previous employer, for the DC-DC converters and general bypassing, with
very good results:
*  Equivalent series resistance (ESR) down to 0.015 ohms.
*  No worry about the capacitors catching fire in low-impedance 
   circuits.
*  Priced about 1/3 of equivalent tantalums.
*  Readily available in quantity- no worry about being on allocation.

They do tend to be a little taller than equivalent tantalums, if you are
height-limited.  But you don't have to derate them nearly as much as
tantalums to be safe.  I used the 105C-rated capacitors to ensure a
longer lifetime than the more commonly available 85C capacitors.  The
pin-through-hole (PTH) radial versions had about 2/3 the ESR of the
surface mount technology (SMT) versions when I did my last design.  So
we laid out my cards to use either style, with the SMT bulk capacitors
turned 90 degrees from the PTH bulk capacitors, and their footprints
overlaying one another for compactness.  

If you want to stick with tantalums, we have a bibliography for Power
Distribution on Printed Circuit Boards at
   http://www.dbicorporation.com/pwr-bib.htm

I just added Ken Javor's report to the bibliography, [215a], so out of
the 380+ references, the following ones apply directly to the proper use
of tantalum capacitors:

[91] Precautions and guidelines for users (Tantalum), Nippon
Chemi-con. (download from
http://www.chemi-con.co.jp/english/support/tantal_note_e.html) 

[92] Precautions in Using Tantalum Capacitors. (download from
http://www.bostonaic.com/tantalum/precautions4.html) 

[107] Tantalum Capacitors With Solid Electrolyte (Chip Type), Mectron.
(download from
http://www.mectron.co.kr/components/tan-2.html) 

[145] Cain, Jeffrey, Comparison of Multilayer Ceramic and Tantalum
Capacitors. (download from
http://www.avxcorp.com/docs/techinfo/mlc-tant.pdf) 

[180] Franklin, R. W., Equivalent Series Resistance of Tantalum
Capacitors. (download from
http://www.avxcorp.com/docs/techinfo/eqtantcp.pdf) 

[181] Franklin, R. W., Ripple Rating of Tantalum Chip Capacitors.
(download from
http://www.avxcorp.com/docs/techinfo/rpleinfo.pdf) 

[190] Gill, John, Surge in Solid Tantalum Capacitors. (download from
http://www.avxcorp.com/docs/techinfo/solid_ti.pdf) 

[215a] Javor, K., Investigation Into the Effects of Microsecond Power
Line Transients on Line-Connected Capacitors, NASA/CR-2000-209906, NASA
Marshall Space Flight Center, AL 35812, February 2000.  (download from
http://mtrs.msfc.nasa.gov/mtrs/2000/cr209906.pdf)

[271] Loh, Eugene, Physical Interpretation of the Tantalum Chip
Capacitor Life-Test Results, IEEE Transactions on
Components, Hybrids, and Manufacturing Technology, vol. CHMT-3 no. 4,
pp. 647-654, Dec. 1980. 

[280] Mattingly, David, Increasing Reliability of SMD Tantalum
Capacitors in Low Impedance Applications. (download from
http://www.avxcorp.com/docs/techinfo/rel_ti.pdf) 

[283] Mogilevsky, Boris and Shirn, George A., Surge Current Failure in
Solid Electrolyte Tantalum Capacitors, IEEE
Transactions on Components, Hybrids, and Manufacturing Technology, vol.
CHMT-9 no. 4, pp. 475-479, Dec. 1986. 

I wrote design guidelines for, and gave a couple of informal seminars on
this subject, at my former employer in 2000.  My boss there has given me
permission to publish the design guidelines on dBi's web site after I
remove the proprietary information (about 10% of the document) and get
his approval.  So far I haven't had time to work on that task, but it is
in my queue.
John Barnes
dBi Corporation
http://www.dbicorporation.com/

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Re: Tantalum Capacitor Reliability

2002-07-30 Thread T.Sato

On Mon, 29 Jul 2002 15:41:32 -0400,
  Chris Maxwell chris.maxw...@nettest.com wrote:

 One of my colleagues is testing a new design.  He has designed a
 buck-boost switching converter which has tantalum output capacitors.
 We have looked at his design and gone through the calculations.  His
 output current is 4 A maximum.  His output voltage is 12 VDC His
 caclulated ripple current is 800 mA.  He needed a 120 mV ripple
 voltage, so he put 8 each of 68 uF, 20 V tantalum capacitors (with
 150 mOhm ESR) in parallel on the output.  Each cap is rated for
 approximately 800mA of ripple current.
 He has seen two failures of these capacitors during initial testing
 and demonstrations.  Meanwhile, many initial units run fine.  From
 what I can gather, he hasn't violated any design rules.  He has 20V
 rated caps on a 12V circuit.  He has a ripple current rating of 8 X
 800mA (8 caps in parallel).
 
 It is tempting to just increase the voltage rating to 25V or
 35Vbut why?  Even if he does, how do you prove that the problem
 is fixed.  It would take months of testing the new capacitors to get
 the history that we have on the existing design.
 
 I guess what I'm looking for is some tantalum capacitor wisdom...
 Should we just go ahead and use 25 V or 35V caps in this 12 V
 application?  Are tantalum caps that flaky?  What is the possibility
 that we don't have a design problem; but just a couple of bad
 capacitors?  Is there some piece of knowledge out there that would
 help us tell the difference?

Tantalum capacitors tend to short-circuited and can cause fire
when used in low impedance circuit.
I think many capacitor manufacturers suggest not to use their
tantalum capacitors in low impedance circuit.

Well, changing 25V to 35V will decrease the failure rate, but
it may not enough.

Low ESR aluminum electrolytic capacitors are available these days,
and I think they are easier to use in such case.
Yet another possible choice may organic-semiconductor capacitors,
such as OS-CON from Sanyo.
(http://www.sanyo.com/industrial/components/oscon_home.html)

Regards,
Tom

--
Tomonori Sato  vef00...@nifty.ne.jp
URL: http://member.nifty.ne.jp/tsato/

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Re: Tantalum Capacitor Reliability

2002-07-30 Thread Doug McKean

Been a while, but the voices from a former life in my 
head are reminding me of something to the effect that 
rated ripple current of cap is based on a perfect sine 
wave of ripple. Any other type of waveform can 
drastically effect that rating.  

SuperLo ESR caps were used one time to solve such 
a problem. Not sure if that applies here.  

The voices are pulling back, now.   

Regards, Doug McKean 



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Re: Tantalum Capacitor Reliability

2002-07-30 Thread Cortland Richmond


When we started seeing 50 volt caps blowing up on a 5 volt output it became
evident that the problem _we_ had, instant mortality (grin), was
over-current, not over-voltage. We didn't actually see a voltage transient
- a 'scope had in fact ruled that out - but someone in management had
apparently thought it would be quicker to assume there WAS one. 


Cortland


Hans Mellberg wrote:

 Nonetheless, inrush current aside, a 20V Tantalum is considered marginal
for a 12V
circuit if reliability is desired. A 60% derating factor was and is a
typical max
for reliability circuits, i.e a 30V min rated cap is recommended. Tantalums
require
additional derating than Al-electrolytics. Furthermore, switchers are
notorious for
destroying Tantalums due to the large and fast V-swings. I don't recall
seeing too
many Tantalums on switcher designs. 

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Re: Tantalum Capacitor Reliability

2002-07-30 Thread Scott Douglas


Chris,

I've had this same problem over the years with many man hours spent looking 
for why. We changed to 35 and 50 V parts to good effect in some cases. 
Other cases were not so easy. I like Cortland's idea the problem is charge 
current at turn-on. We had a 5 output 350 watt supply and there were 
definitely some heavy currents flowing at turn-on. In fact, that is when we 
saw most of the failures, turn it on and blow the caps clean across the 
test floor. Started a small fire once.


We incorporated soft start into our power supplies at some point in time 
and this problem seemed to go away too. Coincidence? Never did know for 
sure. Anyway, good luck!


Scott

At 04:10 PM 7/29/02 -0400, Cortland Richmond wrote:


Chris,

The issue isn't voltage rating; low-ESR caps such as these are susceptible
to excessive charging current at turn-on.  At a former employer, we saw
REALLY GOOD, expensive caps used on a computer's 5V bus exploding at
turn-on, even ones rated at 50 volts. Replacing them with cheaper
electrolytics (TEN volts!) took care of that.  You might be able to
alleviate turn-on stress by using a power-on monitor circuit to slow down
the initial charge. But it'd be far cheaper to go to electrolytics.


Cortland


 One of my colleagues is testing a new design.  He has designed
 a buck-boost switching converter which has tantalum output capacitors.
 We have looked at his design and gone through the calculations.
 His output current is 4 A maximum.  His output voltage is 12 VDC  His
 caclulated ripple current is 800 mA.  He needed a 120 mV ripple voltage,
 so he put 8 each of 68 uF, 20 V tantalum capacitors (with 150 mOhm ESR)
 in parallel on the output.   Each cap is rated for approximately 800mA
of
 ripple current.

 He has seen two failures of these capacitors during initial testing and
 demonstrations.  Meanwhile, many initial units run fine.   From what I
can
 gather, he hasn't violated any design rules.  He has 20V rated caps on a
12V
 circuit.  He has a ripple current rating of 8 X 800mA (8 caps in
parallel).

 It is tempting to just increase the voltage rating to 25V or 35Vbut
why?
 Even if he does, how do you prove that the problem is fixed.  It would
take
 months of testing the new capacitors to get the history that we have on
the
 existing design.

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Re: Tantalum Capacitor Reliability

2002-07-29 Thread Ken Javor

I don't think you can use this directly, but I ran hours of tests on a 
tantalum cap at full rated potential while applying large amplitude
microsecond spikes with no hiccups, no heating until I got quite extreme.
The cap was rated at 30 WVDC and I biased it at 28 Vdc, while applying all
kinds of nasty spikes.  The report accounts for at least seven hours of
applied bias potential and spikes, with no failure until after several hours
of a multi-kilovolt, 20 us long spike finally destroyed it.

The reference is:

K. Javor, Investigation Into the Effects of Microsecond Power Line
Transients on Line-Connected Capacitors, NASA/CR-2000-209906, NASA Marshall
Space Flight Center, AL 35812, February 2000, pp. 33.

and it can be found at:

http://see.msfc.nasa.gov/see/ee/eepub.html  

--
From: Chris Maxwell chris.maxw...@nettest.com
To: EMC-PSTC Internet Forum emc-p...@majordomo.ieee.org
Subject: Tantalum Capacitor Reliability
Date: Mon, Jul 29, 2002, 2:41 PM



 Hi all,

 By the way,  thank you to the various group members for the responses
 regarding the hazardous atmosphere classifications.

 One of my colleagues is testing a new design.  He has designed a buck-boost
 switching converter which has tantalum output capacitors.  We have looked
 at his design and gone through the calculations.  His output current is 4 A
 maximum.  His output voltage is 12 VDC  His caclulated ripple current is
 800 mA.  He needed a 120 mV ripple voltage, so he put 8 each of 68 uF, 20 V
 tantalum capacitors (with 150 mOhm ESR)  in parallel on the output.   Each
 cap is rated for approximately 800mA of ripple current.

 He has seen two failures of these capacitors during initial testing and
 demonstrations.  Meanwhile, many initial units run fine.   From what I can
 gather, he hasn't violated any design rules.  He has 20V rated caps on a
 12V circuit.  He has a ripple current rating of 8 X 800mA (8 caps in
parallel).

 It is tempting to just increase the voltage rating to 25V or 35Vbut
 why?  Even if he does, how do you prove that the problem is fixed.  It
 would take months of testing the new capacitors to get the history that we
 have on the existing design.

 I guess what I'm looking for is some tantalum capacitor wisdom...  Should
 we just go ahead and  use 25 V or 35V caps in this 12 V application?  Are
 tantalum caps that flaky?What is the possibility that we don't have a
 design problem; but just a couple of bad capacitors?  Is there some piece
 of knowledge out there that would help us tell the difference?

 Chris Maxwell | Design Engineer - Optical Division
 email chris.maxw...@nettest.com | dir +1 315 266 5128 | fax +1 315 797 8024

 NetTest | 6 Rhoads Drive, Utica, NY 13502 | USA
 web www.nettest.com | tel +1 315 797 4449 |




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Re: Tantalum Capacitor Reliability

2002-07-29 Thread Hans Mellberg

Nonetheless, inrush current aside, a 20V Tantalum is considered marginal for a 
12V
circuit if reliability is desired. A 60% derating factor was and is a typical 
max
for reliability circuits, i.e a 30V min rated cap is recommended. Tantalums 
require
additional derating than Al-electrolytics. Furthermore, switchers are notorious 
for
destroying Tantalums due to the large and fast V-swings. I don't recall seeing 
too
many Tantalums on switcher designs.

--- Cortland Richmond 72146@compuserve.com wrote:
 
 Chris,
 
 The issue isn't voltage rating; low-ESR caps such as these are susceptible
 to excessive charging current at turn-on.  At a former employer, we saw
 REALLY GOOD, expensive caps used on a computer's 5V bus exploding at
 turn-on, even ones rated at 50 volts. Replacing them with cheaper
 electrolytics (TEN volts!) took care of that.  You might be able to
 alleviate turn-on stress by using a power-on monitor circuit to slow down
 the initial charge. But it'd be far cheaper to go to electrolytics.
 
 
 Cortland
 
 
  One of my colleagues is testing a new design.  He has designed
  a buck-boost switching converter which has tantalum output capacitors.
  We have looked at his design and gone through the calculations.
  His output current is 4 A maximum.  His output voltage is 12 VDC  His
  caclulated ripple current is 800 mA.  He needed a 120 mV ripple voltage,
  so he put 8 each of 68 uF, 20 V tantalum capacitors (with 150 mOhm ESR)
  in parallel on the output.   Each cap is rated for approximately 800mA
 of
  ripple current.
 
  He has seen two failures of these capacitors during initial testing and
  demonstrations.  Meanwhile, many initial units run fine.   From what I
 can
  gather, he hasn't violated any design rules.  He has 20V rated caps on a
 12V
  circuit.  He has a ripple current rating of 8 X 800mA (8 caps in
 parallel).
 
  It is tempting to just increase the voltage rating to 25V or 35Vbut
 why?
  Even if he does, how do you prove that the problem is fixed.  It would
 take
  months of testing the new capacitors to get the history that we have on
 the
  existing design.
 
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=
Best Regards
Hans Mellberg
Regulatory Compliance  EMC Design Services Consultant
By the Pacific Coast next to Silicon Valley,
Santa Cruz, CA, USA
office:831-454-9450, cell:408-507-9694, fax:831-454-0755

__
Do You Yahoo!?
Yahoo! Health - Feel better, live better
http://health.yahoo.com

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Re: Tantalum Capacitor Reliability

2002-07-29 Thread Cortland Richmond

Chris,

The issue isn't voltage rating; low-ESR caps such as these are susceptible
to excessive charging current at turn-on.  At a former employer, we saw
REALLY GOOD, expensive caps used on a computer's 5V bus exploding at
turn-on, even ones rated at 50 volts. Replacing them with cheaper
electrolytics (TEN volts!) took care of that.  You might be able to
alleviate turn-on stress by using a power-on monitor circuit to slow down
the initial charge. But it'd be far cheaper to go to electrolytics.


Cortland


 One of my colleagues is testing a new design.  He has designed
 a buck-boost switching converter which has tantalum output capacitors.
 We have looked at his design and gone through the calculations.
 His output current is 4 A maximum.  His output voltage is 12 VDC  His
 caclulated ripple current is 800 mA.  He needed a 120 mV ripple voltage,
 so he put 8 each of 68 uF, 20 V tantalum capacitors (with 150 mOhm ESR)
 in parallel on the output.   Each cap is rated for approximately 800mA
of
 ripple current.

 He has seen two failures of these capacitors during initial testing and
 demonstrations.  Meanwhile, many initial units run fine.   From what I
can
 gather, he hasn't violated any design rules.  He has 20V rated caps on a
12V
 circuit.  He has a ripple current rating of 8 X 800mA (8 caps in
parallel).

 It is tempting to just increase the voltage rating to 25V or 35Vbut
why?
 Even if he does, how do you prove that the problem is fixed.  It would
take
 months of testing the new capacitors to get the history that we have on
the
 existing design.

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