SENSITRON SEMICONDUCTOR SPDP50D375-503 TECHNICAL DATA DATASHEET 5065, A DC Solid State Power Controller Module Description: This product is a Solid State Power Controller (SSPC) Modules; the electronic equivalent to electromechanical circuit breakers with isolated control and status. It is designed to operate with minimal heatsink requirements. It is a microcontroller-based Solid State Relays rated up to 50A designed to be used in high reliability 375V DC applications. These modules have integrated current sensing with no derating over the full operating temperature range. This product is programmable with a simple jumper configuration connector in steps as 30A / 40A / 50A. The product series also allows programming the Instant Trip level at three different levels: 150A, 200A and 250A.The Battle Override that allows the protection to be turned off is a standard option. Compliant Documents & Standards: MIL-STD-704F MIL-STD-217F, Notice 2 Aircraft Electrical Power Characteristics, 12 March 2004 Reliability Prediction of Electronic Equipment, 28 Feb 1995 Module Features: • • • • • • • • • Minimal heat sinking or external cooling required Extremely Low Power Loss, No Derating Over the Full Temperature Range IMS Base Plate construction Solid State Reliability High Power Density Silver plated contacts for buss bars Gold over nickel plated base plate Sub D connector shell is steel with 30u” gold plated socket contacts Passivated Steel hardware on power terminals Electrical Features: • • • • • • • • • • • • • • • • • • • 375VDC Input with Very Low Voltage Drop; 400mV, typ. @ 50A, 250C True I2t Protection up to 6X rating with Nuisance Trip Suppression I2t Protection level externally programmable Instant Trip Protection level externally programmable Reports Loss of Line Voltage Reports Over Temperature condition and turns off during this condition Output Leakage Sink for safe output voltage when SPDP50D375 turned off No trip operation upto 1000µF of output capacitance Instant Trip Protection (40 μsec typ) for Loads Above programmed Instant Trip level Unlimited Interrupt Capability; Repetitive Fault Handling Capability Thermal Memory Internally Generated Isolated Supply to Drive the Switch Low Bias Supply Current: 20 mA typ @ 5V DC High Control Circuit Isolation: 750V DC Control to Power Circuit Soft Turn-On to Reduce EMC Issues EMI Tolerant Module Reset with a Low Level Signal; Reset Circuit is Trip-Free TTL/CMOS Compatible, Optically Isolated, Input and Outputs Schmitt-Trigger Control Input for Noise Immunity • 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 • • World Wide Web - http://www.sensitron.com • E-Mail Address - [email protected] • Page 1 SENSITRON SEMICONDUCTOR SPDP50D375-503 TECHNICAL DATA DATASHEET 5065, A Table 1 - Electrical Characteristics (at 25 oC and Vbias = 5.0V DC unless otherwise specified) Control & Status (TTL/CMOS Compatible) BIAS (Vcc) BIAS (Vcc) Current S1 and S2 Status Signals CONTROL and Battle Short Signals VT+ (Positive-going input threshold voltage) VT− (Negative-going input threshold voltage) ΔVT Hysteresis (VT+ VT−) Reset 5.0V DC Nominal, 7.0V DC Absolute Maximum 4.5V to 5.5 VDC 21 mA typ 30 mA max Voh=3.7V, min, at Ioh=-20mA Vol=0.4V, max, at Iol=20mA 2.0V, min, 3.5V, max 1.2V, min, 2.3V, max 0.6V, min, 1.4V, max Cycle CONTROL Signal Power Input Voltage – Continuous – Transient Power Dissipation Max Voltage Drop Trip Level 0 to 425V DC, 500V DC Absolute Maximum +600V or –600V Spike (< 10 uS) See Table 4 See Table 4 See Figures 1 - 3, Trip Curves See Table 4 220% of rating Trip time Output Rise Time (turn ON) Output Fall Time under normal turn-off Output Fall Time under Fault Min Load Requirement See Figures 1 - 3, Trip Curves 2 msec typ 250 usec typ 50 usec typ Nil Current Protection Short Circuit Protection Instant Trip 600 A 150A, 200A and 250A programmable Table 2 - Physical Characteristics Temperature Operating Temperature Storage Temperature TA = -55 °C to +100 °C TA = -55 °C to +125 °C Environmental Altitude Case Dimensions Operating Orientation Weight MTBF (Estimate: MIL STD 217F) Up to 30,000 ft Can be installed in an unpressurized area 4.96” x 2.60” x 2.04” Any 650 g 200 Khrs at 25°C Full load • 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 • • World Wide Web - http://www.sensitron.com • E-Mail Address - [email protected] • Page 2 SENSITRON SEMICONDUCTOR SPDP50D375-503 TECHNICAL DATA DATASHEET 5065, A Figure 1 - Trip Curve (Unit programmed for 50A rated current) Figure 2 - Trip Curve (Unit programmed for 40A rated current) • 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 • • World Wide Web - http://www.sensitron.com • E-Mail Address - [email protected] • Page 3 SENSITRON SEMICONDUCTOR SPDP50D375-503 TECHNICAL DATA DATASHEET 5065, A Figure 3 - Trip Curve (Unit programmed for 30A rated current) Table 3 - Signal Timing – (-55 oC to 100 oC @ LINE = 375V DC) Parameter Turn ON Delay Load Current Rise Time Turn OFF Delay Load Current Fall Time t0 t1 t2 t3 Min 300 1.5 300 150 Max 800 3 800 300 Units μs ms μs μs Note: Current Fall Time from trip dependent on magnitude of overload Figure 4 – Timing Diagram CONTROL t2 LOAD CURRENT t1 t3 t0 • 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 • • World Wide Web - http://www.sensitron.com • E-Mail Address - [email protected] • Page 4 SENSITRON SEMICONDUCTOR SPDP50D375-503 TECHNICAL DATA DATASHEET 5065, A Figure 5 - Mechanical Dimensions and Pin Assignments All dimensions are in inches Table 4 – Individual Power Dissipation Data (includes Vbias Power) SPDP50D375 Set for SPDP50D375 Set for 30 Amp Rating 40 Amp Rating SPDP50D375 Set for 50 Amp Rating 30A O 2.8W typ @ 18A 25 C O 7.8W max @ 30A 25 C 13.1W max @ 30A 100OC O 155mV typ @ 18A 25 C O 261mV max @ 30A 25 C 435mV max @ 30A 100OC 50A 7.8W typ @ 30A 25OC O 22.0W max @ 50A 25 C 36.5W max @ 50A 100OC O 261mV typ @ 30A 25 C O 440mV max @ 50A 25 C 730mV max @ 50A 100OC Current Rating @ 100OC Power Dissipation Max Voltage Drop 40A 5.0W typ @ 24A 25OC O 14.0W max @ 40A 25 C 23.3W max @ 40A 100OC O 208mV typ @ 24A 25 C O 350mV max @ 40A 25 C 582mV max @ 40A 100OC Table 5 – PIN-OUT Information Connector Pin 1 2 3 4 5 6 7 8 9 DB1 (COMMAND) BATTLE SHORT S2 STATUS S1 STATUS CONTROL +5V BIAS PWR RTN NC (NO CONNECTION) BIAS RTN TEMPERATURE DB2 (SELECT) 30A (Current Rating) PROG RET 40A (Current Rating) PROG RET NC (NO CONNECTION) 150A (Instant TRIP) PROG RET 200A (Instant TRIP) PROG RET Power (E1 – E4) E1- Line E2- Load E3- PASSTHRU Return E4- PASSTHRU Return • 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 • • World Wide Web - http://www.sensitron.com • E-Mail Address - [email protected] • Page 5 SENSITRON SEMICONDUCTOR SPDP50D375-503 TECHNICAL DATA DATASHEET 5065, A Figure 6 - Electrical Block Diagram Description Figure 3 shows the block diagram of the SPDP50D375 SSPC Series. It uses a SN74LVC14A device for digital I/O. This TTL compatible device has a Schmitt-Trigger input to minimize the effects of noise on the input. Its outputs can each drive more than 10 standard TTL loads. It’s also compatible with CMOS inputs and outputs. The SN74LVC14A is isolated from the remainder of the module circuitry by three optocouplers. The block labeled “Control & Protection Circuitry” gets power from the DC-DC converter and is referenced to the output of the SSPC. This block contains an amplifier to gain up the voltage developed across the sense resistor. It also contains a microcontroller with on-board timers, A/D converter, clock generator and independent watchdog timer. The microcontroller implements a precision I2t protection curve as well as an Instant Trip function to protect the wiring and to protect itself. It performs all of the functions of multiple analog comparators and discrete logic in one high-reliability component. The code programmed in the microcontroller acquires the output of the internal A/D converter, squares the result and applies it to a simulated RC circuit. It checks the output of the simulated circuit to determine whether or not to trip (turn off the power Mosfets). Because the microcontroller simulates an analog RC circuit, the SSPC has ‘thermal memory’. That is, it trips faster if there had been current flowing prior to the overload than if there hadn’t been current flowing. This behavior imitates thermal circuit breakers and better protects the application’s wiring since the wiring cannot take as much an overload if current had been flowing prior to the overload. • 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 • • World Wide Web - http://www.sensitron.com • E-Mail Address - [email protected] • Page 6 SENSITRON SEMICONDUCTOR SPDP50D375-503 TECHNICAL DATA DATASHEET 5065, A The watchdog timer operates from its own internal clock so a failure of the main clock will not stop the watchdog timer. The code programmed in the microcontroller will periodically reset the watchdog timer preventing it from timing out. If the code malfunctions for any reason, the watchdog timer is not reset and it times out. When the watchdog timer times out, it resets the microcontroller. Since the code is designed to detect levels and not edges, the output of the module, and therefore the output of the SPDP50D375, immediately reflects the command on its input. The “Control & Protection Circuitry” block also has the ability for the user to adjust the current rating by varying the trip point with depending on the configuration jumper used on the connector; this jumper shorts a resistor divider chain. This method is used to select 2 lower current ratings for the product, viz. 30A, 40A; not connecting the jumper leaves the product configured to 50A. To adjust the Instant Trip current level, the same method is used; 2 different jumpers select Instant Trip level at 150A, 200A; not connecting the jumper selects the maximum level of 250A. When setting the current rating, select a configuration that is at least 15% above the full load rating. Example: if the max load is 33A, the product shall be configured to 40A. The Power Mosfets used in the SPDP50D375 Series have been selected for very low Rds(on) and result in low voltage drop and low power dissipation. In most applications, the SPDP50D375 will be operated at 50 – 80% of rated current to provide a safety margin. As can be seen in Table 4, when the SPDP50D375 is operated at 30 Amps, 60% of rated current, it dissipates same amount of energy at room temperature. Minimal heat sinking is required for this condition. However, if the SPDP50D375 is to be operated at maximum rating and/or at elevated temperatures, the dissipation warrants heatsinking. Mounting the product on a plate with some airflow is usually sufficient. The product has a baseplate temperature sensor that is calibrated for 10mV / 0C. TMP36 from Analog Devices is used as the sensor IC. This IC has a 750mV output at 00C, thus allowing temperature below zero to be measured. This IC operates from the 5V Bias supply. This sensor can be used by customer to determine heatsink size and other cooling, if necessary. Another identical temperature is used to measure and trip the switch in case of over temperature. An independent sensor is used to avoid grounding issues. For temporary overloads, no additional heatsinking is required provided the SPDP50D375 is allowed some time to cool down. The SPDP50D375 has sufficient thermal mass that the temperature will rise only a few degrees under the worst-case overload. Repetitive overloads should be avoided. When the SPDP50D375 reports a trip condition, the controller driving the SPDP50D375 should allow no more than four repetitions and then allow thirty seconds to cool down before trying to turn on again. The SPDP50D375 will trip on overloads in the ALWAYS TRIP region shown in Figure 1 and will never trip when in the NEVER TRIP region. The SPDP50D375 can be reset by bringing the CONTROL pin to a logic low. When the “CONTROL” pin is brought back to logic high, the SPDP50D375 will turn back on. If the overload is still present, the SPDP50D375 will trip again. Cycling the “5 Volt BIAS” power will also reset the SPDP50D375. If the “CONTROL” pin is at logic high when the “5 Volt BIAS” power is cycled, the SPDP50D375 will turn back on when the “5 Volt BIAS” power is re-applied. Battle Short input allows the customer to override the TRIP function keeping the device turned on exceeding current limitations. Assertion of Battle Short command while the Control is High is interpreted as valid Battle Short command. In this case, the Output will be turned ON and TRIP detection disabled. This mode shall only be used when absolutely necessary since this overrides all the protection features (I2t, Instant Trip, Over temperature) and may allow the product to fail, if any faults were to occur. Status Outputs The “S1” and “S2” status outputs of the SPDP50D375 show whether or not there is an over temperature condition and whether or not the line voltage is present. When an unsafe temperature condition is present, the “S2” status goes to a logic high state and the output of the SPDP50D375 is turned off. When the temperature • 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 • • World Wide Web - http://www.sensitron.com • E-Mail Address - [email protected] • Page 7 SENSITRON SEMICONDUCTOR SPDP50D375-503 TECHNICAL DATA DATASHEET 5065, A drops about 15 oC to a safe condition, the “S2” status output goes back low and the output of the SPDP50D375 is turned back on. Both “S1” and “S2” status outputs go to a high level when line voltage drops below 5 volts. Table 6 shows the states of the “S1” and “S2” status outputs. Table 6 – Control and Status High Voltage Considerations The SPDP50D375 series is designed for 375VDC systems. The SPDP50D375 contains an Output Leakage Sink to ensure that the output is at a safe voltage when the SPDP50D375 is off (whether the SPDP50D375 is turned off or is off due to loss of 5V BIAS Power). This circuitry absorbs the leakage current from the main switch and keeps the output voltage less than 1.5VDC over the temperature range. Figure 3 shows the Output Leakage Sink as a simple switch. However, the Output Leakage Sink is a transistor operating as a current source with a value of 83 mA. When the current into the output leakage sink is less than 83 mA, the transistor saturates and the output leakage sink looks like a resistor of about 36 Ohms. 83 mA can be used to determine how long it takes to discharge a particular load capacitance if the load is a pure capacitance. If the load is a combination of resistance and capacitance, it’s likely that the RC time constant will discharge the capacitance faster than the output leakage sink. Sufficient spacing should be allowed for on the user’s PCB between the 375VDC line supply and the 375VDC power return and between the CONTROL and 5VDC Bias circuits and the 375VDC circuit to prevent arcing. Due to the small size of the SPDP50D375 series, the spacing between pins is small so conformal coating should be used to prevent arcing, especially if transient voltages above 375VDC are possible. Conductor Size MIL-W-5088L has a chart the shows wire size as a function of wire temperature and current. This chart is for a single copper wire in free air. For an ambient temperature of 70 oC, the chart allows a 24-gauge wire to handle 10 Amps continuously at a wire temperature of 200 oC – a wire temperature rise of 130 oC. For a wire temperature limited to 150 oC, the chart requires a 22-gauge wire and for a wire temperature of 105 oC, the chart requires a 20-gauge wire. Amendment 1 of MIL-W-5088L has a table for copper wire in a bundle, group or harness with condition on the number of wires, percent of total harness capacity, etc. This table shows that an 18 gauge wire is necessary for 200 oC operation, 16-gauge for 150 oC and 14-gauge for 105 oC. MIL-W-5088L has various figures showing derating for harnesses as a function of the number of current carrying conductors for different altitudes. MIL-W5088L only specifies wire for DC or RMS AC conditions, not for transient or overload conditions. MIL-W-5088L and its amendment should be consulted to determine minimum wire sizes for other currents and conditions. • 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 • • World Wide Web - http://www.sensitron.com • E-Mail Address - [email protected] • Page 8 SENSITRON SEMICONDUCTOR SPDP50D375-503 TECHNICAL DATA DATASHEET 5065, A For transient or overload conditions, the transient or overload happens so quickly that heat is not transferred from the wire to the surroundings. The heat caused by the I2R heating of the wire causes the temperature to rise at a linear rate controlled by the heat capacity of the wire. The equation for this linear rise in temperature, with respect to time, can be solved as: I2t = constant. Every wire has an I2t rating that’s dependent on the temperature rise allowed and the diameter of the wire. If the I2t rating of the SSPC or circuit breaker is less than the I2t rating of the wire, then the SSPC or circuit breaker can protect the wire. The maximum I2t rating for the SPD50D375 is TBD Amp2-Seconds. Every wire size in the paragraphs above has an I2t rating that exceeds the SPDP50D375 I2t rating for the temperature rises stated. Therefore, to select a wire size, it’s simply a matter of determining the maximum temperature rise of the application and deciding whether or not the wire will be in a bundle and use the information above. Application Connections Due to the presence of the circuitry that keeps the output at safe voltage when the SPDP50D375 series are off, the SPDP50D375 Series may only be configured as a high-side switch as shown in Figure 3. Rise Time & Fall Time The rise and fall times of the SPDP50D375 are pre-set at the factory for a nominal 2mS rise time and 250µS fall time with a LINE supply of 375VDC (see Table 1 for min/max limits). The rise and fall times will vary linearly with supply voltage. The “PWR RTN” pin is used to control the rise and fall times. If the “PWR RTN” pin is left open, the rise and fall times will be less than 25uS. Leaving the “PWR RTN” pin open can be useful when a faster rise or fall time is desirable; however, the Output Leakage Sink will not be functional with the “PWR RTN” pin open. With the “PWR RTN” pin connected as in Figures 3, the SPDP50D375, when set for a 50 Amp rating, can turn on into a capacitive load of 1.2mF, typ, without tripping for any power supply voltage within the ratings. The capacitive load capability is proportional to current rating and can be therefore easily calculated for each model and setting in the SPDP50D375 Series. Wiring and Load Inductance Wiring inductance can cause voltage transients when the SPDP50D375 is switched off due to an overload. Generally, these transients are small but must be considered when long wires are used on either the “LINE” or “LOAD” pins or both. If longer wire lengths are used, a transient suppressor may be used at the “LINE” pin so that the total voltage between the “LINE” and “LOAD” pins is less than 500 Volts. The SPDP50D375 series includes a reverse biased diode from the “LOAD” to “PWR RTN” pins to prevent damaging transients on the output due to inductive loads. Paralleling Do not parallel different models of this series as the current sharing will not be predictable. For example, putting two SPDP50D375s in parallel will not double the rating to 100 Amps. Due to differences in the Rds(on) of the Power Mosfets in the SSPCs, the current will not share equally. In addition, there are unit-to-unit differences in the trip curves so that two SPDP50D375s in parallel may possibly trip at 70 Amps. Also, both SPDP50D375s will not trip together; the SPDP50D375 carrying the higher current will trip first followed by the other SPDP50D375. Multiple SPDP50D375s may be used in parallel as long as these complexities are appreciated. Connectors Busbars are typically used to make the power connections. The product has 2 terminals for input and 2 for output. This RETURN bus bar connections are shorted together inside the module using a copper strap. This configuration allows the customer to run the bus in parallel on both the input and output sections. • 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 • • World Wide Web - http://www.sensitron.com • E-Mail Address - [email protected] • Page 9 SENSITRON SEMICONDUCTOR SPDP50D375-503 TECHNICAL DATA DATASHEET 5065, A The 9-pin D-Sub connector DSUB1 is used for control; we recommend using a standard cable of no more than 3 ft. This will ensure that the noise and other interference are kept to a minimum. The DSUB2 is used for setting the current levels and instant trip levels. We expect the customer to configure this connector locally; any cables attached to this connector may cause nuisance trip or malfunction of the unit since the internal control points are brought out of the pins. As a general rule, current-carrying power circuit should be kept well away from the control circuit and other low-level circuits in the system. It’s unlikely, but possible, that magnetic coupling could affect the control circuit when turning normal loads on and off. However, in the case of an overload, the magnetic coupling could be 10 times greater than with normal loads. Effects of such coupling could cause ‘chattering’ when turning on and off, oscillation, and the possibility of turning the SPDP50D375 back on after an overload. The SPDP50D375 Series is a Trip-Free device. Once tripped it will not turn back on until reset and commanded on again. Reset is accomplished by bringing the “CONTROL” pin low and turning the SSPC back on is accomplished by bringing the “CONTROL” pin high. Sufficient magnetic coupling between the currentcarrying power circuit and the control circuit can negate the Trip-Free characteristic. MIL-STD-704F This standard covers the characteristics of the electrical systems in Military Aircraft. The SPDP50D375 Series meets all of the requirements of MIL-STD-704F including Normal, Emergency, Abnormal and Electric Starting conditions with the Ripple, Distortion Factor and Distortion Spectrum defined in the standard. In addition, the SPDP50D375 Series can withstand + 600 V spikes for 10µS. This capability is beyond that required by MILSTD-704F. DISCLAIMER: 1- The information given herein, including the specifications and dimensions, is subject to change without prior notice to improve product characteristics. Before ordering, purchasers are advised to contact the Sensitron Semiconductor sales department for the latest version of the datasheet(s). 2- In cases where extremely high reliability is required (such as use in nuclear power control, aerospace and aviation, traffic equipment, medical equipment , and safety equipment) , safety should be ensured by using semiconductor devices that feature assured safety or by means of users’ fail-safe precautions or other arrangement . 3- In no event shall Sensitron Semiconductor be liable for any damages that may result from an accident or any other cause during operation of the user’s units according to the datasheet(s). Sensitron Semiconductor assumes no responsibility for any intellectual property claims or any other problems that may result from applications of information, products or circuits described in the datasheets. 4- In no event shall Sensitron Semiconductor be liable for any failure in a semiconductor device or any secondary damage resulting from use at a value exceeding the absolute maximum rating. 5- No license is granted by the datasheet(s) under any patents or other rights of any third party or Sensitron Semiconductor. 6- The datasheet(s) may not be reproduced or duplicated, in any form, in whole or part, without the expressed written permission of Sensitron Semiconductor. 7- The products (technologies) described in the datasheet(s) are not to be provided to any party whose purpose in their application will hinder maintenance of international peace and safety nor are they to be applied to that purpose by their direct purchasers or any third party. When exporting these products (technologies), the necessary procedures are to be taken in accordance with related laws and regulations. • 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 • • World Wide Web - http://www.sensitron.com • E-Mail Address - [email protected] • Page 10