Capabilities

V i s h ay I n t e r t e c h n o l o g y, I n c .
WIREWOUND RESISTORS
Vishay Dale
Resistors - Solutions for Your Application
Pulse Handling Capabilities of
Vishay Dale Wirewound Resistors
INTRODUCTION
Power wirewound resistors have steady-state power and voltage ratings which indicate the
maximum temperatures that the units should attain. For short durations of 5 seconds or less,
these ratings are satisfactory; however, the resistors are capable of handling much higher
levels of power and voltage for short periods of time (less than the cross-over point). For
instance, at room temperature the RS005 has a continuous rating of 5 W, but for a duration
of 1 ms the unit can handle 24 500 W, and for 1 μs the unit can handle 24 500 000 W. The
reason for this seemingly high power capability is the fact that energy, which is the product
of power and time, is what creates heat; not just power alone. Vishay Dale can provide
solutions for your application if provided with information detailed on page three.
Resources
• Datasheet: RS style wirewound fuse resistor - www.vishay.com/doc?30232
• 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
VMN-PL0396-1302
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 i s h ay I n t e r t e c h n o l o g y, I n c .
WIREWOUND RESISTORS
Vishay Dale
Resistors - Solutions for Your Application
Short Pulses (Less Than the Cross-Over Point Time Duration)
For short pulses, it is necessary to determine the energy applied to the resistor. For pulses less than the cross-over
point, Vishay Dale engineering assumes all of the pulse energy is dissipated in the resistance element (wire). In order
for the resistor to maintain its performance characteristics over the life of the product, Vishay Dale bases analysis and
recommendations on the amount of energy required to raise the resistance element to + 350 ºC with no heat loss to the
core, coating, or leads. The cross-over point is the time where significant energy starts to be dissipated not only in the wire
itself but is now being dissipated into the core, leads, and encapsulation material. This is the point where the pulse is no
longer considered a short pulse, but is now considered a long pulse.
The pulse handling capability is different for each resistor model and value, as it is based on the mass and specific heat of
the resistance element. Once the power and energy have been defined, Vishay Dale can determine the best resistor choice
for the application.
Cross-Over Point
An example of an RS005 500 Ω resistor at room temperature:
Required information:
ER = Energy rating of a given model, resistance value, and ambient temperature. Provided by Vishay Dale, ER = 6.33 J.
PO = The overload power capability of the part at 1 s. The overload power capability of an RS005 for
1 s, 10 x 5 W x 5 s = 250 Ws/1 s = 250 W
Cross-over point (s) = ER (J)/PO (W)
6.33 J/ 250 W = 0.0253 s.
The cross-over point for the RS005 500 Ω resistor at room temperature is approximately 25.3 ms.
Long Pulses (Cross-Over Point to 5 Seconds)
For long pulses, much of the heat is dissipated in the core, leads, and encapsulation material. As a result, the calculations
used for short pulses are far too conservative. For long pulse applications, the short time overload ratings from the
datasheets are used. Note that repeated pulses consisting of the short time overload magnitude are extremely stressful
and can cause some resistor styles to fail.
• To find the overload power for a 5 s pulse, multiply the power rating by either 5 or 10 as stated on datasheet
• To find the overload power capability for 1 s to 5 s, convert the overload power to energy by multiplying by 5 s, then
convert back to power by dividing by the pulse width in seconds
• For pulse durations between the cross-over point and 1 s, use the overload power computed for 1 s
Example
1. What is the overload power for an RS005resistor?
From the datasheet, the RS005 is rated at 5 W and will take 10 times rated power for 5 s: 10 x 5 W = 50 W
2. What is the energy capability of the RS005 for 5 s?
For 5 s, the energy capability is: 50 W x 5 s = 250 W·s or J
3. What is the overload power capability of the RS005 for 1 s?
For 1 s, the overload power capability is 250 W·s / 1 s = 250 W
4. What is the energy capability of the RS005 for 0.5 s?
For 0.5 s, the energy capability is 250 W x 0.5 s = 125 W·s or J
Capabilities
2/8
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V i s h ay I n t e r t e c h n o l o g y, I n c .
WIREWOUND RESISTORS
Vishay Dale
Information Required to Determine Pulse Capability
Resistors - Solutions for Your Application
Type of Pulse
• Single Square Wave
–– Resistor value and tolerance?
–– Voltage or current?
–– Duration?
–– Repeated?
–– Maximum ambient temperature?
–– Is there any other power applied during the pulse?
• Capacitor Discharge
–– Resistor value and tolerance?
–– Capacitance?
–– Charge voltage?
–– Repeated?
–– Maximum ambient temperature?
–– Is there any other power applied during the pulse?
• Exponential Decay/Lightning Surge
–– Resistor value and tolerance?
–– Rise time?
–– Peak voltage?
–– Time to ½ voltage?
–– Maximum ambient temperature?
–– Is there any other power applied during the pulse?
• Repetitive Pulse
–– Resistor value and tolerance?
–– Voltage or current?
–– On time - off time?
–– Number of repetitions?
–– Maximum ambient temperature?
–– Is there any other power applied during the pulse?
Pulse applications often fall into one of three categories: square wave, capacitive charge/discharge, or exponential decay.
An example of the pulse energy calculation for each of these will be shown in the following sections.
Square Wave
A constant voltage or current is applied across a resistor for a given pulse duration.
E = Pt
2
P = V or I2R
R
V or I
Where:
E =Energy (watt-seconds,
W·s, or Joules, J)
P = Pulse power (watts, W)
t = Pulse duration (seconds, s)
V = Pulse voltage (volts, V)
R = Resistance (ohms, Ω)
I = Pulse current (amps, A)
Example
A single square wave pulse with an amplitude of 100 VDC for 1 ms is applied to a 10 Ω
resistor. What is the pulse energy?
t
P=
V2 = (100 V)2
= 1 kW
10 Ω
R
E = Pt = 1 kW x 1 ms = 1 W·s or J
Capacitive Charge/Discharge
A capacitor is charged to a given voltage and then discharged through a wirewound resistor.
E=
CV2
2
Where:
E =Energy (W·s or J)
C =Capacitance (farads, F)
V = Peak voltage (V): VDC or VRMS × 2
V
Example
A 2 µF capacitor is charged to 400 VDC and discharged into a 1 kΩ resistor. What is the pulse energy this will produce?
2
E = CV =
2
Capabilities
2 µF x (400 V)2
2
= 0.16 W·s or J
3/8
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V i s h ay I n t e r t e c h n o l o g y, I n c .
WIREWOUND RESISTORS
Vishay Dale
Exponential Decay/Lightning Surge
Resistors - Solutions for Your Application
The application reaches a peak voltage and decreases at a rate proportional to its value. This is typically modeled by
DO-160E WF4 or IEC 6100-4-5 and represents a lightning surge.
Peak
E=
V
) ((
+
V2 x τ
-2xR
) (
x
e
-
2 x (t3 - t1)
τ
))
-1
Where:
E =Energy (W·s or J)
V = Peak voltage (V): VDC or VRMS × 2
R = Resistance (Ω)
t1= Time to peak voltage (s)
t2= Time to 50 % of peak voltage (s)
t3= Time to negligible voltage (s)*
τ =Exponential rate of decay
50 %
0
(
1 x V2 x t
1
3
R
t1
t2
..t3
t
*N
ote that if no t3 is provided, it is assumed to be greater than
20 times t2
Example
Following DO-160E WF4, the peak voltage is 4 kV over a 100 Ω resistor, with the corresponding times:
t1 = 1.2 µs
t2 = 50 µs
t3 = not provided; for the calculation it will be 20 x 50 µs = 1 ms
τ=-
E=
(t2 - t1)
(50 µs - 1.2 µs)
== 70.4 µs
ln (0.50)
ln (0.50)
(
1
(4 kV)2
x
x 1.2 µs
100 Ω
3
Capabilities
) ((
+
(4 kV)2 x 70.4 µs
- 2 x 100 Ω
) (
x e
-
2 x (1 ms - 1.2 µs)
70.4 µs
4/8
))
-1
= 5.51 W·s, or J
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SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V i s h ay I n t e r t e c h n o l o g y, I n c .
WIREWOUND RESISTORS
Vishay Dale
Resistors - Solutions for Your Application
Equally Spaced Repetitive Pulses
When calculating pulse handling capability for repetitive pulses, the average power as well as the individual pulse energy
must be considered. This is because the average power establishes some average heat rise on the part, which uses up
some percentage of the part’s energy capability. That portion of the energy not used by average power is then available
to handle the instantaneous pulse energy. When the two percentages (average power to rated power and pulse energy to
pulse handling capability) are added together, they must not exceed 100 % of the part’s overall rating.
Example
The following example is provided based upon an equally spaced repetitive square wave pulse.
Where:
V = Pulse voltage (V)
l
= Pulse current (A)
t
= Pulse width (s)
T =Cycle time (s)
P = Pulse power (W)
PAvg =Average power (W)
E =Energy (W∙s or J)
V or l
t
T
2
1. The pulse power, P = V or I2R, is calculated for a single pulse
R
Pt
2. The average power is calculated as follows: PAvg =
T
3. Calculate the pulse energy: E = Pt
4. Calculate the percentage of average power to rated power (PR):
Percentage (power) =
PAvg
x 100
PR
5. V
ishay Dale engineering can provide the pulse handling capability (ER) given a resistor model, resistance value, and
ambient temperature
6. Calculate the percentage of pulse energy to pulse handling capability:
Percentage (energy) = E x 100
ER
7. Add the percentages in (4) and (6). If the percentage is less than 100 %, the resistor chosen is acceptable. If the
percentage is greater than 100 %, a resistor with a higher power rating or higher pulse handling capability should be
selected. Contact Vishay Dale engineering to determine the best resistor choice for your application.
Example
A series of equally spaced square wave pulses with an amplitude of 200 VDC, a pulse width of 20 ms, and a cycle time of
20 s, is applied to an RS007 100 Ω resistor at an ambient temperature of 25 °C.
2
2
1. The pulse power is: P = V = (200 V) = 400 W
R
100 Ω
400 W x 0.02 s
Pt
2. The average power is: PAvg =
=
= 0.4 W
20 s
T
3. The pulse energy is calculated: E = Pt = 400 W x 0.02 s = 8.0 W∙s, or J
4. The RS007 resistor has a rated power (PR) of 7 W. The percentage of average power to rated power is calculated:
PAvg
0.4 W
X 100 =
X 100 = 5.7 %
7.0 W
PR
5. The pulse handling capability (ER) provided by Vishay Dale engineering at an ambient temperature of 25 °C is 15.3 J
6. The percentage of pulse energy to pulse handling capability is calculated:
E x 100 = 8.0 J x 100 = 52.3 %
15.3 J
ER
7. The percentages calculated in (4) and (6) are added: 5.7 % + 52.3 % = 58 %
Since this percentage is less than 100 % of the overall rating, the RS007 style resistor will sufficiently handle the pulse.
Capabilities
5/8
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V i s h ay I n t e r t e c h n o l o g y, I n c .
WIREWOUND RESISTORS
Vishay Dale
Resistors - Solutions for Your Application
Non-Inductive Resistors
Non-inductive power resistors consist of two windings, each of which is twice the finished resistance value. For this
reason, the energy capability will nearly always be greater than a standard wound unit. To calculate the energy capability
needed for non-inductive styles, compute the energy per ohm (J/Ω) by dividing the energy by four times the resistance
value.
Example
What is the energy per ohm pulse handling capability required to handle a 0.2 J pulse applied to a 500 Ω resistor?
The energy per ohm needed is:
0.2 J
E
=
= 100 x 10 -6 J/Ω
4R 4 x 500 Ω
This can be provided to Vishay Dale engineering in order to find the best product for the application.
Voltage Limitations
Short pulses – No overload voltage rating has ever been established for wirewound resistors when pulsed for short
durations. Sandia Corporation has performed a study on our NS and RS resistors using 20 µs pulses. This study indicates
that this type of unit will take about 20 kV per inch as long as the pulse handling capability is not exceeded.
Long pulses – For pulses between the cross-over point to 5 s, the recommended maximum overload is √10 times the
maximum working voltage for the 4 W size and larger, and √5 times the maximum working voltage for sizes smaller than 4 W.
Fusible Resistors
If the goal of the application is for the resistor to fuse open under a specific condition, Vishay Dale offers
fusible resistors. Reference page seven for common RS fuse resistor types, or click the following link for the entire
datasheet: www.vishay.com/doc?30232.
Capabilities
6/8
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SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V i s h ay I n t e r t e c h n o l o g y, I n c .
WIREWOUND RESISTORS
RS Style Wirewound Fuse
Resistor
Vishay
Dale
Dale
RS Style Wirewound Fuse Vishay
Resistor
Vishay Dale
Fast-Acting,
MoldedStyles,
Styles, Custom
Custom Designed
Designed For
Fast
Acting, Molded
For Your
Your Application
Application
Resistors - Solutions for Your Application
Features
Fast Acting, Molded Styles, Custom
Designed For Your Application
•
•
•
•
•
•
•
TYPICAL ELECTRICAL SPECIFICATIONS
Low temperature coefficient (down to 30 ppm/°C)
FEATURES
High temperature silicone molded package
•FEATURES
Low temperature
(derated
to 200 °C)coefficient (down to 30 ppm/°C) Available
• High temperature silicone molded package Available
• (derated
Low temperature
coefficient
to 30 ppm/°C)
Performs
function
of resistor(down
and series
fuse and provides
to 200 °C)
Available
High temperature
silicone
molded
package
predictable
fusing
times
•• Performs
function
of
resistor
and
series
fuse
and provides
(derated to 200 °C)
predictable
fusing
times
Complete
• Performswelded
functionconstruction
of resistor and series fuse and provides
• Complete
construction
predictablewelded
fusing times
No
flaming
oror
distortion
of
conditions
•• No
flaming
distortion
ofunit
unitunder
under fusing
fusing conditions
Complete welded construction
Ideal
squib
applications
and
protection
of of
•• Ideal
for
Squib
circuit
and
protection
No for
flaming
or circuit
distortion
ofapplications
unit under
fusing
conditions
devices
semiconductor
devices
• semi-conductor
Ideal for Squib
circuit applications and protection of
semi-conductor
devices
• Negligible
noiseand
andvoltage
voltagecoefficient
coefficient
Negligible
noise
• Negligible noise and voltage coefficient
TYPICAL ELECTRICAL SPECIFICATIONS
The following are offered as examples of reliable designs. Hundreds of possible combinations are available for meeting your requirements.
Thefactory
following
offered
asaddress
examples
reliable
Hundreds
of possible combinations
are available
for meeting your requirements.
Contact
byare
using
email
inof
the
footerdesigns.
of this page,
for assistance.
Higher wattages
available.
Contact factory by using email address in the footer of this page, for assistance. Higher wattages available.
1.0 W CONTINUOUS POWER (1)
FUSING PARAMETERS
1.0 W CONTINUOUS POWER (1)
FUSING PARAMETERS
TOLERANCE
GLOBAL
HISTORICAL
RESISTANCE
TYPICAL
CONTINUOUS
CROSSOVER
TOLERANCE
GLOBAL
HISTORICAL FUSING
RESISTANCE
±%
MODEL
MODEL
RANGE Ω
FUSING FUSING
TYPICAL
CONTINUOUS
CROSSOVER
TIME
CURRENT
VALUE
±%
MODEL
MODEL CURRENT
RANGE Ω
CURRENT
FUSING
CURRENT
VALUE
A
ms TIME
A
Ω
A
ms
A
Ω
RS01A...209
RS-1A-209
0.5
4
49
500
5,
10
0.10
100.0
RS01A...209
RS-1A-209
0.5
4
49 - 500
5, 10
0.10
100.0
RS01A...118
1.01.0
99
6.8
5, 10
10
0.25
16.0
RS01A...118 RS-1A-118
RS-1A-118
6.8--185
185
5,
0.25
16.0
RS01A...212
1.25
88
4.7
5, 10
10
0.30
11.11
RS01A...212 RS-1A-212
RS-1A-212
1.25
4.7--107
107
5,
0.30
11.11
RS01A...213
1.51.5
1515
3.5
5, 10
10
0.35
8.16
RS01A...213 RS-1A-213
RS-1A-213
3.5--68
68
5,
0.35
8.16
RS01A...143
2.02.0
1515
2.2
5, 10
10
0.40
6.25
RS01A...143 RS-1A-143
RS-1A-143
2.2--35
35
5,
0.40
6.25
RS01A...214
2.52.5
2323
1.7
5, 10
10
0.45
4.94
RS01A...214 RS-1A-214
RS-1A-214
1.7--23
23
5,
0.45
4.94
RS01A...162 RS-1A-162
RS-1A-162
1.1--12
12
5,
0.55
3.31
RS01A...162
3.03.0
4848
1.1
5, 10
10
0.55
3.31
RS01A...208 RS-1A-208
RS-1A-208
0.72--6.44
6.44
5,
0.75
1.78
RS01A...208
4.04.0
4747
0.72
5, 10
10
0.75
1.78
RS01A...207 RS-1A-207
RS-1A-207
0.35--2.17
2.17
5,
1.0
1.01.0
RS01A...207
6.06.0
7070
0.35
5, 10
10
1.0
RS01A...215 RS-1A-215
RS-1A-215
0.29--1.61
1.61
5,
1.25
0.64
RS01A...215
8.08.0
4848
0.29
5, 10
10
1.25
0.64
RS01A...173 RS-1A-173
RS-1A-173
10.0
0.23--1.16
1.16
5,
1.50
0.44
RS01A...173
10.0
5050
0.23
5, 10
10
1.50
0.44
RS01A...216 RS-1A-216
RS-1A-216
15.0
0.19--0.82
0.82
5,
1.75
0.33
RS01A...216
15.0
3535
0.19
5, 10
10
1.75
0.33
RS01A...217
RS-1A-217
20.0
46
0.12 - 0.42
5, 10
2.0
0.25
RS01A...217
RS-1A-217
20.0
46
0.12 - 0.42
5, 10
2.0
0.25
Note
Note (1) The Continuous Current Rating applies only to values equal to or less than the Crossover Value. The Continuous Power Rating applies only
(1) The Continuous Current Rating applies only to values equal to or less than the Crossover Value. The Continuous Power Rating applies only
to values equal to or higher than the Crossover Value.
to •values
equal that
to orthe
higher
thancompromise
the Crossover
Value.between resistive and fusing functions sometimes makes certain exact combinations
Be aware
inherent
involved
• Be aware
that the However,
inherent in
compromise
involved
between
resistive
fusing of
functions
sometimes
makes
certain
exact combinations
unattainable.
nearly all cases,
this does
not prevent
the and
production
a functional,
reliable fuse
resistor
thoroughly
capable of
unattainable.
However, in
nearly all cases, this does not prevent the production of a functional, reliable fuse resistor thoroughly capable of
meeting application
requirements.
meeting application requirements.
GLOBAL PART NUMBER INFORMATION
GLOBAL
PART
NUMBER
INFORMATION
Global Part
Numbering
example:
RS01A402R0JS70209
Global PartRNumbering
example:
S
0
1 RS01A402R0JS70209
A
4
0
R
S
0
1
GLOBAL MODEL
(See Typical
Electrical
GLOBAL
MODEL
Specifications Global
A
4
VALUE
0
2
2
R
R
TOLERANCE
R = Decimal
VALUE
15R00 = 15 Ω
J = ± 5.0 %
TOLERANCE
K = ± 10.0 %
Historical PartRS-1A-209
Numbering example: RS-1A-209 402
402ΩΩ 5 % S70
RS-1A-209
J
J
S
S
7
7
0
0
PACKAGING
R = Decimal
J = ± 5.0 %
(See Typical
ModelElectrical
column for
15R00 = 15 Ω
K = ± 10.0 %
Specifications
Global
options)
Model column for
options) Part Numbering example: RS-1A-209 402 Ω 5 % S70
Historical
HISTORICAL MODEL
0
0
RESISTANCE VALUE
402 Ω
E70 = Lead
(Pb)-free, tape/reel
PACKAGING
E12 = Lead (Pb)-free, bulk
E70 = Lead (Pb)-free, tape/reel
S70==Lead
Tin/lead,
tape/reel
E12
(Pb)-free,
bulk
B12 = Tin/lead, bulk
S70 = Tin/lead, tape/reel
B12 = Tin/lead, bulk
2
2
0
0
9
SPECIAL
(DashSPECIAL
Number)
(up to 3 digits)
(Dash
From
1 -Number)
999
to 3 digits)
as(up
applicable
From 1 - 999
as applicable
5%
S70
TOLERANCE CODE
PACKAGING
5%
9
S70
If a MODEL listed in TYPICAL ELECTRICAL SPECIFICATIONS table does not meet your requirements, then please include the following
HISTORICAL
RESISTANCE
VALUE
information. ItMODEL
will enable us to choose
the best design
for your application.TOLERANCE CODE
PACKAGING
1. Operating wattage or current, ambient temperature and required resistance stability. (% ΔR/1000 h)
If a MODEL
listed
in TYPICAL
ELECTRICAL
SPECIFICATIONS
does “blow”
not meet
your
requirements, then please include the following
2. Fusing
wattage
or current
and maximum
“blow” time. Also,table
minimum
time,
if applicable.
information.
It will
enable us
choose the
best design
for your
application.
3. Nominal
resistance
andtomaximum
allowable
resistance
tolerance,
(5 % to 10 % preferred).
1. Operating
wattage
or
current,
ambient
temperature
and
required
resistance
stability.
(%
ΔR/1000 h)
4. Maximum allowable physical size.
2. Fusing
wattage
or interrupted.
current and maximum “blow” time. Also, minimum “blow” time, if applicable.
5. Voltage
to be
3. Nominal
resistance
and maximum
allowable
resistance
tolerance,
% application.
to 10 % preferred).
6. Frequency
of power
source, wave
form and
a brief description
of (5
your
4. Maximum allowable physical size.
5. Voltage to be interrupted.
6. Frequency of power source, wave form and a brief description of your application.
Document Number: 30232
Capabilities
Revision: 12-Jan-11
For technical questions, contact: [email protected]
7/8
www.vishay.com
VMN-PL0396-1302
1
Document Number: 30232
For technical questions, contact: [email protected]
www.vishay.com
This
document
is subject to change without notice. THE PRODUCTS DESCRIBED HEREIN AND THIS DOCUMENT ARE SUBJECT TO
Revision:
12-Jan-11
1
SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V i s h ay I n t e r t e c h n o l o g y, I n c .
WIREWOUND RESISTORS
Resistors - Solutions for Your Application
Vishay Dale
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