® ® INNOVATION and EXCELLENCE DTL5A-LC 100 Watt, Serial-Input Electronic Load Low Compliance Version Features DATEL's DTL5A-LC is a serial-input controlled electronic loads featuring a low compliance voltage operation (down to 0.6 Volts)! Similar to DATEL's DTL3A, the DTL5A-LC also offers a loading current range of 0 to 2.0A full scale range with a loading voltage to 50V. The DTL5A-LC's ability to operate down to 0.6 Volts, allows this device to be used with next-generation, low-voltage output power supplies. The DTL3A's compliance voltage operates from 2.5 Volts to 50 Volts, sufficient for today's 2.5V, 3.3V, 5 Volt, etc., power product voltages, with improved gain specifications. · Serial-input controlled · 100 watts maximum load capacity · 0.6 to 50V, 0 to 2.0A capability · Parallel load capability for higher current and power applications · Dynamic loading to 20 kHz · Compliance Voltage down to 0.6 Volts Applications · Power supply test and characterization · Dynamic power supply burn-in · Battery capacity testing · Current source testing · Capacitor discharge testing · Power resistor substitution The small but efficient heat transfer package allows up to 100W of power dissipation by using external heatsinking. The devices are packaged in a small 2" x 2" x 0.4" metal package, providing easy mounting capability for external heatsinks. A monitor circuit makes sure a compliance voltage is present, before biasing the DTL5A-LC's output stage. A Fault line goes active, should the device-under-test go below its compliance voltage. These loads feature fast current step response times, settling a full scale step in 100 µsec to ±1% Full Scale Range (FSR). Dynamic loading is up to 20kHz, and a current resolution of ±0.025% is achieved. Opto-isolators are utilized on the digital input lines, with 500 Volts of isolation provided from the load outputs to input ground. The optoisolators are internally buffered, making the DTL5A-LC easy to drive, with any digital I/O board. Isolation from any pin to case is 500 Volts. · Real-time load simulation +5V Supply Ground 3 2 Isolated DC/DC Converter 11 7 Control Strobe (CS) Clock (CLK) Serial Data In (SDI) Latch Data (LD) 10 6 5 Buffers/ 4 Opto Isolators Power Supply Under Test 9 4 1 +Load Input Amplifier/ Current Sensor D/A Converter 8 Fault +Load Input –Load Input –Load Input Error Detection Figure 1. Simplified Schematic DATEL, Inc., Mansfield, MA 02048 (USA) • Tel: (508)339-3000, (800)233-2765 Fax: (508)339-6356 • Email: [email protected] • Internet: www.datel.com 100 Watt DTL5A-LC Performance Specifications and Ordering Guide Serial-Input Electronic Loads ➀ Output Model Compliance Voltage (Volts) DTL5A-LC 0.6 to 50 Loading Curent (Amperes) Current Resolution mA 0 to 2.0 0.5 Accuracy (%FSR) Offset Error (%FSR) ±3 ±0.05 Gain Error (mA) Gain Error (% of Setting) Package (Case Pinout) ±0.25 C1 50 ➀ Typical at TA = +25°C under nominal line voltage and full-load conditions unless otherwise noted. Mechanical Specifications Case C1 Part Number Structure DTL A - LC 5 Prefix: DTL = DATEL product #4-40 CLEAR THRU (TYP 4 PL ) A-Series High Reliability Voltage Range/Current: 5 = 2.5 to 50V, 0 to 2A Metal Shell LC = Low Compliance: Voltage Range of 0.6 to 50V DTL5A-LC model only Aluminum Header .±0.001 Pins ±0.20 Min ±0.001 Pins The warranty period is one year 2.02 Max. A 1.800 B A ± .0 1 0 1.640 Temperature Derating 7 8 60 Load Capacity in Watts 40 1.640 4 3 1 0 2 1 1 1 .200 80 9 .220 100 5 1.200 1.000 .800 .600 .400 2.02 Max. 6 7 B 8 6 5 20 0 10 20 25 30 40 50 60 70 80 90 100 9 4 BOTTOM VIEW 3 (Label/pin side) 10 2 Base Plate Temperature in °C 11 1 I/O Connections Note: The DTL5A-LC electronic load packaging has been designed to allow for use with external heatsinking for high wattage applications. The DTL5A-LC can dissipate up to 100 Watts with external cooling (heatsink or fan) observing the base plate temperature requirements above. The loads are capable of dissipating 5 Watts at room temperature without any external cooling. The devices can also be connected in parallel for additional loading capability. 2 Pin Function Pin Function 1 Fault 8 - Load Input 2 Ground 9 - Load Input 3 +5 Volts Supply 10 + Load Input 4 Latch Data (LD) 11 + Load Input 5 Serial Data In (SDI) 6 Clock (CLK) 7 Control Strobe (CS) ± .0 1 0 DTL5A-LC 100 Watt Serial-Input Electronic Loads Performance/Functional Specifications Typical @ TA = +25°C under nominal line voltage and full-load conditions unless noted. Input Digital Inputs (pins 4, 5, 6, 7): VIL VIH IIL Min. Typ. Timing Max. Units 0.8 CLK -0.6 Volts Volts mA 20 µA t Min. Typ. Max. Units 200 kHz Refer to timing diagram: 2.0 IIH t =t cl 1 µsec 1 µsec 1 µsec 2 µsec 2 µsec 2 µsec 0.5 µsec 0.5 µsec ch css t Output csh Loading Current t See Ordering Guide Current Resolution ±0.025 ld1 % FSR t t Offset Error ±0.05 % FSR Gain Error DTL5A-LC ±0.3 % FSR ld2 ldw t ds t dh Compliance Voltage Range Output Impedance See Ordering Guide 10 Mohm Absolute Maximum Ratings Dynamic Characteristics Dynamic Loading to: 20 kHz Settling Time (Full Scale Step) 100 usec Slew Rate 10 A/µsec These are stress ratings. Exposure of devices to any of these conditions may adversely affect long-term reliability. Proper operation under conditions other than those listed in the Performance/Functional Specifications Table is not implied. Power +5 Volts Supply (pin 3) +4.75 Current (pin 3) +5.0 +5.25 Volts +110 +150 mA Power Supply Voltage (pin3): 5.5 Volts Digital Input Voltage (pins 4,5,6,7): 5.5 Volts Output Reverse-Polarity Protection: No protection Output Overvoltage Protection: No protection Storage Temperature –40 to +105°C Lead Temperature (soldering, 10 sec.) +300°C Environmental Operating Ambient Temperature Ta, where no derating required. Natural Convection, vertical mount Storage Temperature –40 +105 Humidity (Non-condensing) 95 Altitude Above Sea Level 10,000 °C % feet Physical Dimensions 2" x 2" x 0.52" (51 x 51 x 12.7mm) Pin Length 0.2 inches Shielding Case Material 6-sided Tin-plated Steel Shell Heat-sink side: Aluminum Pin Material Brass, solder coated Isolation, ± Load to Input Ground 500 Volts Isolation, any pin to case 500 Volts Isolation, resistance 100 Mohm Mounting Through-hole spacer, #4-40 clearance Weight 1.9 ounces (55 grams) 3 DTL5A-LC 100 Watt Serial-Input Electronic Loads Overview Software: C Language The DTL5A-LC is a serial-input controlled current sink. Powered by a single +5V power supply, the DTL5A-LC provides a compliance voltage range from 0.6 Volts to 50 Volts, with loading currents to 2.0 Amperes. Refer to the Table of the basic "Mapping of the Serial-Input Data Word to the Loading Current for the devices transfer function. Utilizing external heatsinking, the device handles loads to 100 watts with a base-plate temperature of 25°C, derating thereafter (only 5 Watts without external heatsink/cooling. Refer to the "Temperature Derating" curve figure herein that illustrates the load capacity in Watts, as a function of the base plate temperature. The following steps describe a typical timing sequence when using four lines of a parallel digital I/O port and a programming language such as C. Using 4 bits of an 8-bit port, assign BIT_0 (LSB) to the Control Strobe (CS, pin 7), BIT_1 to Latch Data (LD, pin 4), BIT_2 to Serial Data In (SDI, pin 5) and BIT_3 to the Clock (CLK, pin 6). 1. Initialize with Latch Data, Clock, and Control Strobe HIGH. BIT_0 = 1, BIT_1 = 1, BIT_2 = X (don’t care), BIT _3 = 1 2. Place the Control Strobe LOW. The Device Under Test (DUT) outputs are hooked up to the +Load Input (pins 10 & 11) and the - Load Input (pins 8 & 9). An input serial data stream (Pin 5) and clock (Pin 6) are opto-isolated internally. These isolated inputs are gated through to a 12-bit serial input D/A, where the input word can be latched using the Latch Data input (Pin 4). A Fault ouput pin (Pin 1) indicates excessive heat or operation outside the compliance range. BIT_0 = 0 3. Place D11 (MSB) of the Data Word into Serial Data In. BIT_2 = 0 or 1 4. Toggle the Clock HIGH-LOW-HIGH BIT_3 =1-to-0-to-1 Operation Overview 5. Place D10 of the Data Word into Serial Data In. BIT_2 = 0 or 1 Programming is easily accomplished by utilizing four lines of a parallel digital I/O port. The four digital outputs will be used to control the Control Strobe (CS, pin7), the Latch Data (LD, pin 4), the Serial Data In (SDI, pin 5) and the Clock (CLK, pin 6) functions of the DTL5A-LC Series. 6. Toggle the Clock High-LOW-HIGH. BIT_3 = 1-to-0-to-1 Initialization 7. REPEAT this process (steps 5 and 6) for the remaining data bits (D9-D0). Initialization of the device is accomplished by first setting the Control Strobe, Clock and Latch Data pins to a Logic High ("1") state. The Serial Data In state at this time is "Don’t Care". Next, bring the Control Strobe pin to a Logic Low ("0") state. The load is now prepared to accept a serial input word. 8. Set the Control Strobe High. Bit_0 = 1 9. Toggle the Latch Data High-LOW-HIGH BIT_1 = 1-to-0-to-1 Input of Serial Data After initialization, a serial-input data word representing the desired load current is input to the load. This is accomplished with a data stream that begins with the Most Significant Bit (MSB). With the MSB present on the Serial Data In (pin 5), toggle the Clock (pin 6) through a High-Low-High state sequence. Similarly, proceed from the MSB to the LSB bits, toggling the Clock (pin 6) through a High-Low-High state for each bit. The timing specifications shown in the "Timing Diagram" should be observed in transitioning the clock states. Serial-Input Data Word MSB Latching the Data Word Upon entering the final, Least Significant Bit (LSB), the serial-input data word is latched, by bringing the Control Strobe (pin 7) high and then toggling the Latch Data (pin 4) through a High-Low-High state sequence. LSB Load Current (Amperes) DTL5A-LC 1111 1111 1111 1.9995 1100 0000 0000 1.5000 1000 0000 0000 1.000 0111 1111 1111 0.9995 0100 0000 0000 0.5000 0010 0000 0000 0.2500 0000 0000 0001 0.0005 0000 000 0000 0.000 Mapping of the Serial-Input Data Word to Load Current 4 100 Watt Serial-Input Electronic DTL5A-LC Loads tdh SDI D10 D 11 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 tds CLK tcss tcl tcsh tch CS tld2 tld1 LD tldw Timing Diagram Load Regulation 5 DTL5A-LC 1 0 0 Wa t t Serial-Input Quality and Reliability The DTL5A-LC is one of the first Electronic Loads to emerge from DATEL’s new, company-wide approach to designing and manufacturing the most reliable power products available. The five-pronged program draws our Quality Assurance function into all aspects of new-product design, development, characterization, qualification and manufacturing. Design for Reliability Design for Reliability is woven throughout our multi-phased, new-productdevelopment process. Design-for-reliability practices are fully documented and begin early in the new-product development cycle with the following goals: 1. To work from an approved components/vendors list ensuring the use of reliable components and the rigorous qualification of new components. 2. To design with safety margins by adhering to a strict set of derating guidelines and performing theoretical worst-case analyses. 3. To locate potential design weaknesses early in the product-development cycle by using extensive HALT (Highly Accelerated Life Testing). 4. To prove that early design improvements are effective by employing a thorough FRACA (Failure Reporting Analysis and Corrective Action) system. Electronic Load stepped up again and the cycle is repeated until the "fundamental limit of the technology" is determined. DATEL has invested in a Qualmark OVS-1 HALT tester capable of applying voltage and temperature extremes as well as 6-axis, linear and rotational, random vibration. A typical HALT profile (shown above) consists of thermal cycling (–55 to +125°C, 30°C/minute) and simultaneous, gradually increasing, random longitudinal and rotational vibration up to 20G’s with load cycling and applied-voltage extremes added as desired. Many devices in DATEL’s new A-Series could not be made to fail prior to reaching either the limits of the HALT chamber or some previously known physical limit of the device. We also use the HALT chamber and its ability to rapidly cool devices to verify their "cold-start" capabilities. Qualification For each new product, electrical performance is verified via a comprehensive characterization process and long-term reliability is confirmed via a rigorous qualification procedure. The qual procedure includes such strenuous tests as thermal shock and 500 hour life. Qual testing is summarized below. Qualification Testing HALT Testing Qualification Test Method/Comments The goal of the accelerated-stress techniques used by DATEL is to force device maturity, in a short period of time, by exposing devices to excessive levels of "every stimulus of potential value." We use HALT (Highly Accelerated Life Testing) repeatedly during the design and early manufacturing phases to detect potential electrical and mechanical design weaknesses that could result in possible future field failures. HALT DATEL in-house procedure During HALT, prototype and pre-production electronic loads are subjected to progressively higher stress levels induced by thermal cycling, rate of temperature change, vibration, power cycling, product-specific stresses (such as dc voltage variation) and combined environments. The stresses are not meant to simulate field environments but to expose any weaknesses in a product’s electro/mechanical design and/or assembly processes. The goal of HALT is to make products fail so that device weaknesses can be analyzed and strengthened as appropriate. Applied stresses are continually stepped up until products eventually fail. After corrective actions and/or design changes, stresses are Marking Permanency DATEL in-house procedure End Point Electrical Tests Per product specification Typical HALT Profile High Temperature Storage Max. rated temp., 1,000 hours Thermal Shock 10 cycles, –55 to +125°C Temperature/Humidity +85°C, 85% humidity, 48 hours Lead Integrity DATEL in-house procedure Life Test +70°C, 500 hours* * Interim electrical test at 200 hours. In-Line Process Controls and Screening A combination of statistical sampling and 100% inspection techniques keeps our assembly line under constant control. Parameters such as solder-paste thickness, component placement, cleanliness, etc. are statistically sampled, charted and fine tuned as necessary. Visual inspections are performed by trained operators after pick-and-place, soldering and cleaning operations. Units are 100% electrically tested prior to potting. All devices are temperature cycled, burned-in, hi-pot tested and final-electrical tested prior to external visual examination, packing and shipping. Rapid Response to Problems DATEL employs an outstanding corrective-action system to immediately address any detected shortcomings in either products or processes. Whenever our assembly, quality or engineering personnel spot a product/ process problem, or if a product is returned with a potential defect, we immediately perform a detailed failure analysis and, if necessary, undertake corrective actions. Over time, this system has helped refine our assembly operation to yield one of the lowest product defect rates in the industry. Test Time (minutes) ® ® INNOVATION and EXCELLENCE ISO 9001 DATEL, Inc. 11 Cabot Boulevard, Mansfield, MA 02048-1151 Tel: (508) 339-3000 (800) 233-2765 Fax: (508) 339-6356 Internet: www.datel.com Email: [email protected] Data Sheet Fax Back: (508) 261-2857 DATEL DATEL DATEL DATEL DS-DTL005 Rev_A 1/2000 (UK) LTD. Tadley, England Tel: (01256)-880444 S.A.R.L. Montigny Le Bretonneux, France Tel: 01-34-60-01-01 GmbH München, Germany Tel: 89-544334-0 KK Tokyo, Japan Tel: 3-3779-1031, Osaka Tel: 6-354-2025 DATEL makes no representation that the use of its products in the circuits described herein, or the use of other technical information contained herein, will not infringe upon existing or future patent rights. The descriptions contained herein do not imply the granting of licenses to make, use, or sell equipment constructed in accordance therewith. Specifications are subject to change without notice. The DATEL logo is a registered DATEL, Inc. trademark.