Capabilities Brochure

V ish ay I n tertech n olo g y, I n c .
AND TEC
INNOVAT
I
N
O L OGY
Vishay Dale
O
HN
POWER METAL STRIP RESISTORS
®
19
62-2012
Resistors - Optimized for Current Sensing
Power Metal Strip ® Optimized
for Current Sensing
INTRODUCTION
Vishay’s Power Metal Strip® resistors are optimized for current sensing in a wide range of
electronic systems. Their low ohmic resistance, in combination with low RTC and low
thermal EMF, makes Power Metal Strip products the resistor of choice for high-current and
high-power applications in all market segments.
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•
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Resistance from 0.00005 ohm to 1 ohm
Resistance tolerance down to 0.5 %
Very low inductance of < 5 nH
Low thermal EMF (< 3 μV/°C)
Lead (Pb)-free available
Low RTC metal resistive element (< 20 ppm/ºC)
Operating temperature range of – 65 ºC to + 275 ºC
In addition to the standard case sizes, Vishay offers nonstandard product sizes and
terminal configurations to support emerging applications. This brochure provides
n overview of Power Metal Strip product capabilities to support the needs of designers.
Resources
• For technical questions contact ww2bresistors@vishay.com
• Sales Contacts: http://www.vishay.com/doc?99914
One of the World’s Largest Manufacturers of
Discrete Semiconductors and Passive Components
Capabilities
1/6
VMN-PL0022-1204
This document is subject to change without notice. THE PRODUCTS DESCRIBED HEREIN AND THIS DOCUMENT ARE SUBJECT TO
SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V ish ay I n tertech n olo g y, I n c .
AND TEC
INNOVAT
I
N
O L OGY
Vishay Dale
O
HN
POWER METAL STRIP RESISTORS
®
19
62-2012
High-Current, Standard, Power Metal Strip® Resistors
Product
Power
Rating
Features
Dimensions
Resistors - Optimized for Current Sensing
WSR2
•DC-DC converter in switching
power supplies
L =0.455 in. [11.56 mm]
•VRM’s in notebook/desktop PC’s
W=0.275 in. [6.98 mm]
•Instrumentation
H=0.095 in. [2.41 mm]
•Automotive controls for body
and powertrain
•DC-DC converter in switching
power supplies
L =0.394 in. [10.0 mm]
•VRM’s in notebook/desktop PC’s
W=0.205 in. [5.20 mm]
•Instrumentation
H = 0.117 in. [3.00 mm]
•Automotive controls for
EHPS/EPS/EPAS
2.0 W
•0.001 Ω to 1.000 Ω
•± 0.5 %, ± 1.0 % •TCR down to ± 75 ppm/°C
3.0 W
•0.0003 Ω to 0.004 Ω
•± 1.0 % •Low TCR resistance element
(< 20 ppm/ºC)
3.0 W
•0.0003 Ω to 0.005 Ω
•± 1.0 % •Low TCR resistance element
(< 20 ppm/ºC)
L =0.272 in. [6.90 mm]
W=0.260 in. [6.60 mm]
H = 0.117 in. [3.00 mm]
3.0 W
•0.0003 Ω to 0.005 Ω
•± 1.0 % •Low TCR resistance element
(< 20 ppm/ºC)
•DC-DC converter in switching
L =0.400 in. [10.10 mm]
power supplies
W=0.260 in. [6.60 mm] •Instrumentation
H = 0.117 in. [3.00 mm] •Automotive controls for
EHPS/EPS/EPAS
3.0 W
•0.0005 Ω
•± 1.0 % •Low TCR resistance element
(< 20 ppm/ºC)
L =0.788 in. [20.02 mm] •Instrumentation
W=0.453 in [11.50 mm] •Automotive controls for body
H=0.026 in. [0.66 mm]
and powertrain
3.0 W
•0.0005 Ω
•± 1.0 % •Low TCR resistance element
(< 20 ppm/ºC)
L =0.746 in. [18.95 mm] •Instrumentation
W=0.493 in [12.52 mm] •Automotive controls for variable
H=0.086 in. [2.18 mm]
speed motor control
3.0 W
•0.002 Ω
•± 1.0 % •Low TCR resistance element
(< 20 ppm/ºC)
L =0.455 in. [11.56 mm] •Instrumentation
W=0.216 in. [5.49 mm] •Automotive controls for variable
H=0.011 in. [0.28 mm]
speed motor control
3.0 W
•0.001 Ω to 0.200 Ω
•± 0.5 %, ± 1.0 % •TCR down to ± 75 ppm/°C
•DC-DC converter in switching
power supplies
L =0.455 in. [11.56 mm]
•VRM’s in notebook/desktop PC’s
W=0.275 in. [6.98 mm]
•Instrumentation
H=0.095 in. [2.41 mm]
•Automotive controls for body
and powertrain
5.0 W
•0.001 Ω to 0.300 Ω
•± 0.5 %, ± 1.0 % •TCR down to ± 75 ppm/°C
•DC-DC converter in switching
power supplies
L =0.455 in. [11.56 mm]
•VRM’s in notebook/desktop PC’s
W=0.275 in. [6.98 mm]
•Instrumentation
H=0.095 in. [2.41 mm]
•Automotive controls for body
and powertrain
5.0 W
•0.0002 Ω to 0.003 Ω
•± 1.0 % •Low TCR resistance element
(< 20 ppm/ºC)
L =0.591 in. [15.0 mm]
W=0.305 in. [7.75 mm]
H = 0.020 in. [0.50 mm]
WSL3921
WSL2726
WSL4026
WSR2-1
WSR2-6
WSR2-14
WSR3
WSR5
WSL5931
Capabilities
Application
2/6
•DC-DC converter in switching
power supplies
•Instrumentation
•Automotive controls for
EHPS/EPS/EPAS
•DC-DC converter in switching
power supplies
•VRM’s in notebook/desktop PC’s
•Instrumentation
•Automotive controls for
EHPS/EPS/EPAS
VMN-PL0022-1204
This document is subject to change without notice. THE PRODUCTS DESCRIBED HEREIN AND THIS DOCUMENT ARE SUBJECT TO
SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V ish ay I n tertech n olo g y, I n c .
AND TEC
INNOVAT
I
N
O L OGY
Vishay Dale
O
HN
POWER METAL STRIP RESISTORS
®
19
62-2012
High-Current, Custom, Power Metal Strip® Resistors
Product
Maximum
Current
Features
Dimensions
Application
Resistors - Optimized for Current Sensing
SPR4000
•0.0007 Ω
•± 5 %
•Multi-terminal
L =0.708 in. [18 mm]
W=0.264 in. [6.7 mm]
H=0.732 in. [18.6 mm]
•Instrumentation
•Automotive controls
for EHPS/EPS/EPAS
•300 μΩ to 660 μΩ
•±5%
• 3-W Power
• Power Metal Strip® construction
L = 1.142 in. [29.0 mm]
W = 0.748 in. [19.0 mm]
•Power meter shunt
• Instrumentation
• Power supplies
•
•
•
•
50 μΩ to 1000 μΩ
±5%
3-W Power
Power Metal Strip® construction
L = 1.142 in. [29.0 mm]
W = 0.315 in. [8.0 mm]
•Power meter shunt
• Instrumentation
• Power supplies
•
•
•
•
100 μΩ
±5%
3-W Power
Power Metal Strip® construction
L = 1.195 in. [30.4 mm]
W = 0.973 in. [24.7 mm]
H = 0.040 in. [1.0 mm]
•Power meter shunt
• Instrumentation
• Power supplies
•
•
•
•
50 μΩ to 1000 μΩ
±5%
3-W Power
Power Metal Strip® construction
L = 2.165 in. [55.0 mm]
W = 0.590 in. [15.0 mm]
H = 0.059 in. [1.5 mm] max
• Power meter shunt
• Instrumentation
• Power supplies
600 A
•
•
•
•
50 μΩ to 1000 μΩ
±5%
36-W Power
Power Metal Strip® construction
L = 3.346 in. [85.0 mm]
W = 0.708 in. [18.0 mm]
H = 0.118 in. [3.0 mm]
• Automotive/industrial
battery monitor shunt
• Power supplies
100 A
•0.00038 Ω
•± 5 %
•Power Metal Strip® construction
•Manganin element
L =3.937 in. [100.0 mm]
W=0.787 in. [20.0 mm]
H=0.060 in. [1.5 mm]
•Instrumentation
•Automotive battery
monitor shunt
187 A
•0.0002 Ω
•± 5 %
•Power Metal Strip® construction
•Manganin element
L =0.590 in. [15.0 mm]
W=0.512 in. [13.0 mm]
H=0.049 in. [1.24 mm]
•Instrumentation
•Automotive controls
for EHPS/EPS/EPAS
1000 A
•0.00005 Ω
•± 5 %
•Power Metal Strip® construction
•Manganin element
L =9.450 in. [240 mm]
W= 3.937 in. [100 mm]
H=0.190 in. [4.7 mm]
•High-current meter
shunt
95 A
WSMS2906
WSMS2908
WSMS3124
175 A
WSMS5515
WSBS8518
SPR3004
WSL5931-xx
SPR4001
Capabilities
3/6
VMN-PL0022-1204
This document is subject to change without notice. THE PRODUCTS DESCRIBED HEREIN AND THIS DOCUMENT ARE SUBJECT TO
SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V ish ay I n tertech n olo g y, I n c .
AND TEC
INNOVAT
I
N
O L OGY
Vishay Dale
O
HN
POWER METAL STRIP RESISTORS
®
19
62-2012
Resistors - Optimized for Current Sensing
Applications
Current sensing Power Metal Strip resistors allow control circuitry to monitor the level of current in a circuit by translating
current into a voltage that can be easily measured. The devices work by resisting the current flow in a circuit to a calibrated
level, thus allowing a voltage drop to be detected and monitored by control circuitry. The low resistance of Power Metal
Strip devices allow this function to be carried out with exceptional accuracy.
Current shunting is another application suitable for the low-ohmic Power Metal Strip resistor technology. When shunting,
a resistor is used to divert most of the current in an electric circuit. Power shunts are used for electric motor starting,
braking, and speed control. Loading, neutral grounding, preheating, and capacitor loading are applications in which a
resistor shunts large amounts of current. A two- or four-terminal resistor with low ohmic resistance and high-current
capability is the best solution for a shunt.
Current sensing and shunting are functions common to all market segments with many applications. Automotive
electronics, industrial and medical equipment, mobile telecom, and notebook computers are among the diverse
environments in which Power Metal Strip resistors deliver exceptional performance.
Power Management
Brushless DC Motor
Control
Torque
The use of brushless DC motors is increasing
in motion control applications. The motor’s
high efficiency and small size are important
for automotive, industrial, military, aircraft, and
communications equipment.
Speed
IM
Typical RS = 0.01 Ω
Capabilities
Driver
Motor
Rs
Feedback
Sensors
* Speed
* Shaft Position
* Rotation Direction
Figure A
(DC Motor Current Monitoring)
emissions. The brushless DC motor cools the engine block or
radiator to reduce temperature variation while high-power current
sense resistors are used for fan speed control.
+
RS
PICmicro®
Microcontroller
Direction
Automotive engine fan controls utilize brushless
DC motors to improve engine temperature
management. Accurate air flow and temperature
control in the engine compartment are needed
to allow the engine to run at a constant higher
temperature for better fuel efficiency and lower
Battery Bus
Input
+
–
Diff
AMP
Electronic power steering and electric vehicle traction drives also
use brushless DC motors. A current sense resistor is used to
control the peak value of the motor winding current (load current).
This Is an application that requires low-inductance and highcurrent capabilities. See Figure A.
Current sensing resistors are also used in the feedback circuit
as replacements for Hall effect sensors. Figure B shows use of
current sense resistor “Rs” in an H-bridge motor control.
Figure B
(H-Bridge Current Monitoring)
4/6
VMN-PL0022-1204
This document is subject to change without notice. THE PRODUCTS DESCRIBED HEREIN AND THIS DOCUMENT ARE SUBJECT TO
SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V ish ay I n tertech n olo g y, I n c .
AND TEC
INNOVAT
I
N
O L OGY
Vishay Dale
O
HN
POWER METAL STRIP RESISTORS
®
19
62-2012
Resistors - Optimized for Current Sensing
Automotive Battery Management
Accurate current sensing is becoming an increasingly important capability as the demands being placed on automotive
batteries are growing. Electrical Hydraulic Power Steering (EHPS) / Electrical Power Steering (EPS) / Electrical Power
Assistance Steering (EPAS), electronic-hydraulic braking, electric and hybrid vehicles, and power doors, all require the
battery to provide additional current above and beyond what the alternator can deliver.
For proper battery management, a low-ohmic current sensing resistor is used to sense the amount of current flowing
into the vehicle’s electrical system. The current sensing resistor must be capable of handling high currents (up to 1000 A)
while offering a low temperature coefficient of resistance, low thermal EMF, and high stability in extreme environments.
Resistance values of 50 μΩ to 125 μΩ are typically required for these applications.
Figure C illustrates use of current sense resistor in a high-current battery management circuit.
GRD
Rs
Electrical
Load
+
–
Figure C
(Automotive Battery Sensor)
Battery
Typical RS = 0.0001 Ω
Utility Power Meters Shunt
The utility industry is seeing a new generation of multifunction power meters. The new meters are more accurate in
measuring and reporting actual utility usage and peak usage times, providing the power company with more accurate
data to determine customer usage and to adjust billing terms.
In this application, a current sense resistor supports the microcontroller to determine power usage. A current shunt
converts the current through the meter to a small, millivolt-level voltage. The voltage across the shunt must remain small
to minimize the power dissipation by the shunt. A shunt with a resistance of 100 μΩ will provide a signal of 20 mV and
dissipate 1 W of power at 100 A.
Figure D shows the current channel of an electric meter using a current shunt to convert the load current to a
millivolt-level voltage.
Load
Rs
Line
1 kΩ
Current Sense Hi
1 kΩ
Current Sense Lo
Figure D
(Current Channel of
an Electric Meter)
1 µF
Typical Rs = 350 µΩ
Capabilities
5/6
VMN-PL0022-1204
This document is subject to change without notice. THE PRODUCTS DESCRIBED HEREIN AND THIS DOCUMENT ARE SUBJECT TO
SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V ish ay I n tertech n olo g y, I n c .
INNOVAT
I
N
AND TEC
O L OGY
Vishay Dale
O
HN
POWER METAL STRIP RESISTORS
®
19
62-2012
New Product Application Sheet
Resistors - Optimized for Current Sensing
Design Engineer: To help us support your new product requirements, please complete the information below.
Application Summary:
Resistance Value = Ohms
Temperature Coefficient =
ppm/ºC
Load Current: I peak =
Amps
I continuous =
Amps
Environmental Conditions: Temperature Range:
Moisture:
Other:
Product Size:
L=
Resistance Tolerance =
Duration =
sec_
ºC to
ºC
ºC at
mm
%
W=
% Rh
mm
H=
mm
Product Sketch:
(Please note current and voltage terminals)
Mounting Type:
q Welded
Project Timing:
Initial Samples:
Month
Year
Design Validation:
Month
Year
Production Start:
Month
Year
Project EAU:
pcs
q Bolted
q Soldered
Target Cost:
USD
Name:
Email:
Title: Company: Terminal Coating
Phone:
Fax:
Email this form to: ww2bresistors@vishay.com
Capabilities
6/6
VMN-PL0022-1204
This document is subject to change without notice. THE PRODUCTS DESCRIBED HEREIN AND THIS DOCUMENT ARE SUBJECT TO
SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000