TM IPC01 SERIES BY MICROPAC Micropac Industrial Power Controller IPC01 AC and DC ISOLATED OUTPUT Features: UL508 and CSA C22.2 NO. 14-10 Recognized, (File number E354703) Patent Pending – Power Control, Monitoring, and Load Protection All solid-state circuitry, with no moving parts to wear, ensures a long life. Soft start for reduced EMI. High efficiency with less than 0.8V drop at full load. Compact panel mount “Hockey Puck” style package. No Output current de-rating is required for base plate temperatures of -40ºC to +80ºC. SPST, normally open power controller. UL94V-0 approved clear IP20 touch safe protection cover. MIL-STD-704A through E and MIL-STD-1760E I2t compliant. TTL / CMOS compatible Switch Status. AC devices designed for inductive load power factors to 0.75. AC devices designed with integrated load switching transient suppression. Description: The IPC combines both relay and circuit breaker functions. The Isolated IPC is mechanically similar to the standardized industrial Solid State Relay. The functions include Soft Start load switching, I2t overload / fault protection that provides circuit breaker function to MIL-STD-1760E and load status signaling indicating switch output conditions of ON, OFF and Overload. Inductive and optical coupling between the input circuits and output provides isolation of 1,500 VRMS. Power MOSFET output switches provide soft start and low ON voltage drop for improved thermal characteristics. The input Control logic operates from a VDD of 5 to 32VDC. (See Figure 5) Applications: Aerospace Ground Support Equipment. Industrial and Commercial Lighting Systems. Commercial Test Equipment. Manufacturing Equipment. Energy Exploration Systems and Equipment. Communications Systems and Plants. Aircraft and Avionics Systems. Automation Equipment. Fabrication Equipment. Vending Machines. Selective Power Distribution. Laboratory Test Systems. Food Processing. Output current is monitored to control outputs during overcurrent conditions (see the I2t trip curves). Over-current conditions include Over-Load and Shorted Output during TurnOn. Open-collector Output Status indicates the state of the Output Switch MOSFET load driver. The output remains OFF until the short is removed and the unit’s control line is toggled OFF and back ON. Locking the output OFF on an error condition prevents damage to the controller and further system damage caused by the short circuit. Output Status is an Active Low (Open Collector) for Controller OFF or Tripped conditions and High (pull up resistor) for a normally ON output state. The IPC is designed for rated current over a Baseplate Temperature Range of -40ºC to +85ºC. This includes the operations of Soft Start at Command ON and Trip OFF on Over Load or Fault Conditions. Micropac Industries cannot assume any responsibility for any circuits shown, or represent that they are free from patent infringement. Micropac reserves the right to make changes at any time in order to improve design and to supply the best product possible. Micropac Industries, Inc. 905 E. Walnut St., Garland, TX 75040 (972) 272-3571 Fax (972) 494-2281 www.micropac.com E-MAIL: [email protected] 12/18/2013 Rev G ©March 2013 Pg. 1 of 9 TM BY MICROPAC Industrial Power Controller ABSOLUTE MAXIMUM RATINGS Description DC IPC Isolation Voltage AC IPC 1,500 VDC 1,500VDC 1,2 Load Voltage 75 / 400V VDC 40 / 280VAC RMS Less Than 8 Times Rated Operating Current / Self Protecting3 Load Current Bias supply voltage, VDD Self Protecting to MIL-STD-1760E3 -0.6 to 32 VDC Control Voltage -0.6 to 32 VDC 1 Volt above VDD / 1 Volt below Return 1 Volt above VDD / 1 Volt below Return Operating Temperature, Case -40ºC to +80ºC -40ºC to +80ºC Storage Temperature -55ºC to +85ºC -55ºC to +85ºC 1. External snubbing may be required for Power Controller protection. 2. Reversing output polarity on DC units may cause permanent damage. 3. The I2t circuit breaker function terminates AC overloads and fault currents per Figures 1 or 2 and DC overloads and fault currents per Figures 3 or 4. AC ELECTRICAL OUTPUT CHARACTERISTICS: TC = -40 to 80° C Description1 Units Rated Operating Voltage Device 40VAC / 10A 280VAC / 5A VRMS 0 – 40 0 - 280 Overvoltage (Maximum) VRMS 45 310 Transients (Maximum) VPEAK 64 424 Hz 50 – 450 50 - 450 Operating Frequency Current Rating ARMS 10 5 2,3 APEAK 100 50 4 mSec 8 8 mSec 12 12 µSec 35 35 µA 500 500 Maximum On-State Voltage Drop @ Rated Current VRMS 0.75 0.75 Maximum On-State Resistance @ Rated Current Ohms 0.15 0.30 Interrupt Current Rating Turn-On / Turn-Off Time Turn-On / Turn-Off Delay6 Trip Shutdown Time 3,5 Maximum Off-State Leakage @ Rated Voltage 1. This is not a “zero crossing Turn-On” IPC. Turn-On at other than zero-crossing will experience a “soft-start” voltage and current equal to the typical Turn-On Rise Time of 8msec. At 60 Hz this is ½ sin of the normal voltage rise and is 2.5 cycles for 400 Hz. 2. Steady state trip current is between 120% and 160% of rated current. See Figures 1 and 2. 3. I2t trip current is time dependent. See Figures 1 and 2. 4. Output of 10 to 90% / 90 to 10%. 5. Output current measured from fault onset to 10% rated load. 6. “ON” command period is 1 sec minimum with a duty cycle of 10%. Micropac Industries cannot assume any responsibility for any circuits shown, or represent that they are free from patent infringement. Micropac reserves the right to make changes at any time in order to improve design and to supply the best product possible. Micropac Industries, Inc. 905 E. Walnut St., Garland, TX 75040 (972) 272-3571 Fax (972) 494-2281 www.micropac.com E-MAIL: [email protected] 12/18/2013 Rev G ©March 2013 Pg. 2 of 9 TM BY MICROPAC Industrial Power Controller DC ELECTRICAL OUTPUT CHARACTERISTICS: TC = -40 to 80° C Description Units Rated Operating Voltage Transient Overvoltage 1 Current Rating Interrupt Current Rating 2,6 Device 75VDC / 10A 400VDC / 5A V 0 – 75 0 - 400 VPEAK 95 475 A 10 5 % 120 160 5,7 mSec 6 6 Turn- On/Turn-Off Delay5 mSec 10 10 µSec 35 35 Maximum Off-State Leakage @ Rated Voltage µA 500 500 Maximum On-State Voltage Drop @ Rated Current V 0.75 0.75 Ohms 0.08 0.16 Turn-On/Turn-Off Time Trip Shutdown Time 3,4 Maximum On-State Resistance @ Rated Current 1. Transient overvoltage exceeding this voltage may result in damage to the device. 2. Steady state trip current is between 120% and 160% of rated current. See Figures 3 and 4. 3. I2t trip current is time dependent. See Figures 3 and 4. 4. Output current measured from fault onset to 10% rated load. 5. “ON” command period is 1 sec minimum with a duty cycle of 10%. 6. Inductive loads must be suppressed. Fault shutdown can be ≤ 5µs. 7. Output of 10 to 90% / 90 to 10%. Micropac Industries cannot assume any responsibility for any circuits shown, or represent that they are free from patent infringement. Micropac reserves the right to make changes at any time in order to improve design and to supply the best product possible. Micropac Industries, Inc. 905 E. Walnut St., Garland, TX 75040 (972) 272-3571 Fax (972) 494-2281 www.micropac.com E-MAIL: [email protected] 12/18/2013 Rev G ©March 2013 Pg. 3 of 9 TM BY MICROPAC Industrial Power Controller AC AND DC CHARACTERISTICS: TC = -40 to 80° C Description Units AC and DC Devices Maximum Bias supply, VDD VDC 32 Maximum Bias current mA 35 1 VDC -0.5 to ≤ VDD 2 VDC 3.9 Maximum Turn-off voltage (VIL) 2 VDC 2.0 3 Seconds 100 Status Supply Voltage (open Collector) VDC 32 Status off leakage current µADC 4 Status on voltage VDC 0.4 ºC 150 ºC/W 5 Output Capacitance pF 3,000 Input to Output Capacitance pF 25 Maximum Control voltage range (CMOS Configuration) Minimum Turn-on voltage (VIH) Trip Reset Time Junction temperature Thermal resistance, JC 1. Input transitions should be “bounce-less contact” with transitions of <1 msec. 2. TTL Logic may require a pull-up resistor to ensure a “high” input condition. 3. The IPC has load current memory. A period of 100 seconds between an overload, or shorted load restart allows for full current startup. Table 1: Short circuit and Status Sequence Shorted at Turn On Input Control Load Current Switch Status Output Shorted while On 0 1 1 0 1 1 1 1 0 1 0 0 0 0 1 1 0 0 0 1 0 0 0 0 1 1 0 0 0 1 Short Applied Short Applied Short Removed Load Load Load Short Applied Short Removed Load Load Notes: 1. Unit Powers up in the OFF condition with application of VDD . However, it is highly recommended that Control be held low (Off) during the initiation of Power to ensure there is no transient reset / start signaling. 2. Fault Status reports only when VDD is present. 3. An OFF Control to ON Control transition is required to first turn the Unit On. 4. A loss of VDD will return the output state to OFF. 5. Truth Table Power sequencing: Output Status open collector pull-up resistor is assigned a separate and always on voltage producing a “1” when “Open”. Micropac Industries cannot assume any responsibility for any circuits shown, or represent that they are free from patent infringement. Micropac reserves the right to make changes at any time in order to improve design and to supply the best product possible. Micropac Industries, Inc. 905 E. Walnut St., Garland, TX 75040 (972) 272-3571 Fax (972) 494-2281 www.micropac.com E-MAIL: [email protected] 12/18/2013 Rev G ©March 2013 Pg. 4 of 9 TM BY MICROPAC Industrial Power Controller PACKAGE DIMENSIONS (Inches) 6 5 LOAD Industrial Power Controller IPC01-75VDC10A-ST STATUS 5-32 VDC 1 2 Made In the USA GND CNTRL 3 4 Pin Designation Pin 1 Pin 2 Pin 3 Status + 5 to 32 VDC Input GND Pin 4 Pin 5 Pin 6 Control Output (+ DC) (~AC) Output (- DC) (~AC) Micropac Industries cannot assume any responsibility for any circuits shown, or represent that they are free from patent infringement. Micropac reserves the right to make changes at any time in order to improve design and to supply the best product possible. Micropac Industries, Inc. 905 E. Walnut St., Garland, TX 75040 (972) 272-3571 Fax (972) 494-2281 www.micropac.com E-MAIL: [email protected] 12/18/2013 Rev G ©March 2013 Pg. 5 of 9 TM BY MICROPAC Industrial Power Controller 100A MAY TRIP CURRENT (Amps RMS) 80A 65A 60A MUST TRIP 40A 20A 20A MUST NOT TRIP 10A 10A 0.01 0.1 1 TIME (Seconds) 10 100 1000 FIGURE 1: TRIP CURVE for IPC01-40VAC10A 50A 40A CURRENT (Amps RMS) MAY TRIP 30A MUST TRIP 25A 20A MUST NOT TRIP 10A 10A 5A 5A 1000 0.01 0.1 1 TIME (Seconds) 10 100 FIGURE 2: TRIP CURVE for IPC01-280VAC5A Figure 1 & 2 Notes: 1. Output currents are interrupted in the Must Trip / May Trip / Must Not Trip regions similar to MIL-STD-1760E. 2. Load fault current from the “ON” operating condition is limited by the source and load impedance. Micropac Industries cannot assume any responsibility for any circuits shown, or represent that they are free from patent infringement. Micropac reserves the right to make changes at any time in order to improve design and to supply the best product possible. Micropac Industries, Inc. 905 E. Walnut St., Garland, TX 75040 (972) 272-3571 Fax (972) 494-2281 www.micropac.com E-MAIL: [email protected] 12/18/2013 Rev G ©March 2013 Pg. 6 of 9 TM BY MICROPAC Industrial Power Controller 100A 90A CURRENT (Amps) 80A MAY TRIP MUST TRIP 70A 65A 60A 50A 40A 30A MUST NOT TRIP 20A 20A 10A 10A 0.01 0.1 1 TIME (Seconds) 10 100 1000 FIGURE 3: TRIP CURVE for IPC01-75VDC10A. CURRENT (Amps) 70A 60A 50A MAY TRIP MUST TRIP 40A 30A 20A MUST NOT TRIP 10A 0.01 0.1 10A 5A 1 TIME (Seconds) 10 100 1000 FIGURE 4: TRIP CURVE for IPC01-400VDC5A. Figure 3 & 4 Notes: 1. Output currents are defined in the Must Trip / May Trip / Must Not Trip regions. Load fault current in the “ON” operating condition is limited by the source and load impedance. 2. Over current and fault trip currents terminate abruptly and may require external “snubbing” or clamping to prevent damage to the IPC. Micropac Industries cannot assume any responsibility for any circuits shown, or represent that they are free from patent infringement. Micropac reserves the right to make changes at any time in order to improve design and to supply the best product possible. Micropac Industries, Inc. 905 E. Walnut St., Garland, TX 75040 (972) 272-3571 Fax (972) 494-2281 www.micropac.com E-MAIL: [email protected] 12/18/2013 Rev G ©March 2013 Pg. 7 of 9 TM BY MICROPAC Industrial Power Controller LOW SIDE SWITCH HIGH SIDE SWITCH DC or AC BUS V+ DC or AC BUS V+ OPTOCOUPLER VDD 5 2 OPTOCOUPLER CONTROL CENTRAL DIGITAL CONTROL UNIT TRIP STATUS GND 4 LOAD 5 5 I²t & OVERCURRENT PROTECTION CIRCUIT DC CIRCUIT SNUBBER DC CIRCUIT SNUBBER 1 TRANSFORMER ISOLATED CONTROL CIRCUIT 6 3 6 6 LOAD ISOLATION FIGURE 5: Block Diagram and Function. High side (5) or low side (6) switch connections are facilitated by full isolation between Input Logic, Base Plate and Output Switch Connects. Logic level Control input circuit drives an Opto-Coupler across the isolation to the switch circuits and a second Opto-Coupler returns a signal for the Open-collector Status Output. Control (4), Status (1), VDD Input Power 5-32VDC (2) and GND (3) make up the Input isolation group. A filtered DC to DC converter is driven from the input VDD to power the secondary side circuits. The Output circuit consists of Output MOSFETs connected at their sources through a current sense resistor and their Drains offered as the output switch. In the DC version, the sense resistor is monitored by the I2t detection circuit. A Fault Latch receives inputs from the I2t detection circuit, the power supply and the control Opto-Coupler. Based on these inputs the Gates of the output MOSFETs are controlled. The Fault Latch also provides the Status signal. In the AC version, an absolute amplifier rectifies the output current (voltage) of the sense resistor by the I2t detection circuit. As in the case of the DC version, a Fault Latch receives inputs from the I2t detection circuit, the power supply and the control Opto-Coupler. Based on these inputs the Gates of the output MOSFETs are controlled. The Fault Latch also provides the Status signal. Micropac Industries cannot assume any responsibility for any circuits shown, or represent that they are free from patent infringement. Micropac reserves the right to make changes at any time in order to improve design and to supply the best product possible. Micropac Industries, Inc. 905 E. Walnut St., Garland, TX 75040 (972) 272-3571 Fax (972) 494-2281 www.micropac.com E-MAIL: [email protected] 12/18/2013 Rev G ©March 2013 Pg. 8 of 9 TM BY MICROPAC Industrial Power Controller Ordering / Part Number Structure Example Part Number I PC 0 1 - 7 5 VDC 1 0 A - ST I PC 0 1 - # # # # V * C # # # A - * * Industrial Power Control #### - Maximum Switching Voltage Do Not Use Leading Zeros Series 01 - MosFET switch, I²t trip, status ... XX - Other options TBD Notes: 1) D - Direct A - Alternating (1) Max Volts ### - Maximum Switched Current Do Not Use Leading Zeros Output Switch Voltage Max Current 75 V DC D 10 400 V DC D 5 40 V RMS A 10 280 V RMS A 5 Options* ST - Standard Version (-40°C to 80°C) ... XX - Other options TBD * All modules are acrylic conformal coated Voltage range is from “0” volts to maximum volts specified. Micropac Industries cannot assume any responsibility for any circuits shown, or represent that they are free from patent infringement. Micropac reserves the right to make changes at any time in order to improve design and to supply the best product possible. Micropac Industries, Inc. 905 E. Walnut St., Garland, TX 75040 (972) 272-3571 Fax (972) 494-2281 www.micropac.com E-MAIL: [email protected] 12/18/2013 Rev G ©March 2013 Pg. 9 of 9