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. • • • • • • • 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 [email protected] • 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: [email protected] 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