SPDP03D270 - Sensitron Semiconductor

SENSITRON

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PART NUMBER: SPDP03D270/SPDP03D375

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COMPETITION SENSITIVE

Page 1

SPDP03D270

SPDP03D375

DC Solid State Power Controller Module

Description:

The SPDP03D375 Solid State Power Controller

(SSPC) Module is designed to operate without

any heat sink requirements. It is a

microcontroller-based Solid State Relay rated up

to 3A, designed to be used in high reliability

375V DC applications. This module has an

integrated current sensing with no de-rating over

the full operating temperature range, and works

as an electronic equivalent to an

electromechanical circuit breaker with isolated

control and status.

This module is programmable from 0.9A to 3A,

and also allows programming the Instant Trip

level from 400% to 700% of maximum rating.

Compliant Documents & Standards:

MIL-STD-704F Aircraft Electrical Power Characteristics, 12 March 2004

MIL-STD-217F, Notice 2 Reliability Prediction of Electronic Equipment, 28 Feb 1995

Features:

• No additional heat sinking required.

• No derating Over the Full Temperature Range

• Low Weight (40 gms)

• Epoxy Shell Construction

• Solid State Reliability

• High Power Density

• Survives short circuit

• Battleshort input

Benefits:

Sensitron‟s SSPC technology and products combine functionalities of electro-mechanical breakers, solid state

relays and system monitors and provide the following benefits to our customers:

• Electrical load protection and monitoring - current, voltage and temperature measurements

• Operational improvements by allowing for diagnostics, prognostics and condition-based configuration

• Life cycle cost savings and reduced cost of ownership

• Increased radius of operation through power budgeting and load shedding

• Crew offloading and intelligent load management

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Page 2

SPDP03D270

SPDP03D375

Electrical Features (SPDPXXD375 Series):

• 375VDC Input with Very Low Voltage Drop; 110mV, typ. @ 3A for SPDP03D375

• True I2t Protection up to 7X rating with Nuisance Trip Suppression

• I2t Protection level externally programmable to 30% of the maximum rating

• Instant Trip Protection level externally programmable from 400% to 700% of maximum rating

• Reports Loss of Line Voltage

• Reports Over Temperature condition and turns off during this condition

• Output Leakage Sink for safe output voltage when SPDP03D375 turned off

• No trip operation up to 40 µF of output capacitance,

• Instant Trip Protection (250 sec 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: 75 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

Table 1 - Electrical Characteristics (at 25 oC and Vbias = 5.0V DC unless otherwise specified)

Power

Input Voltage – Continuous

– Transient

0 to 425V DC, 500V DC Absolute Maximum

+600V or –600V Spike (< 10 µsec)

Power Dissipation

See Table 4

Current

See Table 4

See Figure 1, Trip Curve

Max Voltage Drop

See Table 4

Trip time

See Figure 1, Trip Curve

Output Rise Time (turn ON)

2000 sec typ

Output Fall Time under normal turn-off

500 µsec typ

Output Fall Time under short

50 µsec typ

Min Load Requirement

Nil

Protection

Short Circuit Protection

Unlimited

Instant Trip

400% - 700%, programmable

Control & Status (TTL/CMOS Compatible)

BIAS (Vcc)

5.0V DC Nominal, 5.5V DC Absolute Maximum

4.5V to 5.5 VDC

BIAS (Vcc) Current

75 mA typ

100 mA max

S1 and S2 Status Signals

Voh=4.6V min, at Ioh=-4mA

Vol=0.4V max, at Iol=4mA

CONTROL, Battle Short Signal Input

VIL = 0V to 0.8V measured w.r.t Bias Rtn

VIH = 2.0V to 5V measured w.r.t Bias Rtn

Reset

Cycle CONTROL Signal

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SPDP03D270

SPDP03D375

Table 2 - Physical Characteristics

Temperature

Operating Temperature

TA = -40 C to +100 C

Storage Temperature

TA = -55 C to +125 C

Environmental

Altitude

Up to 30,000 ft.

Can be installed in an unpressurized area

Case Dimensions

2.50”L x 1.00”W x 0.50”H

Operating Orientation

Any

Weight

40 gms

MTBF (Estimate: MIL STD 217F)

TBD hrs at 25 C Full load

Pin Descriptions

+5V BIAS: Power supply for the SPDP unit

+5V RTN: Power return for the SPDP unit

BATTLE SHORT: Battle short command. The SPDP will be forced on when this pin has been

commanded high

S1 STATUS: Status indication output

S2 STATUS: Status indication output

CONTROL: Controls the SPDP on and off, active high

INSTANT TRIP ADJ: This pin programs the instant trip level from 400% to 700% of the rating by putting

a resistor between this pin to LOAD.

I2T TRIP ADJ: This pin programs the I2T trip level from 30% to 100% of the rating by putting a

resistor between this pin to the LOAD

LOAD: Connect LOAD to this pin

LINE: Connect Input Line voltage to this pin

POWER RTN: This pin controls the turn on/off speed, and also discharges the LOAD when the

SPDP is off, while it has been connected to Power Return.

I2T TRIP curve

I2T current trip is guaranteed to happen when the input current is higher than 145% of the configured

rating, and guaranteed not to happen when the input current is below 115% of the programed rating. Trip

time is described in Figure 1.a and Figure 1.b. Please notice that if the instant trip level has been configured

lower than 700%, any current above the instant trip point will cause a immediately turn off. In both figures,

the Y axis is referenced to the programed current rating. For example, in Figure 1.b, 100% on Y axis means

30% of 3A.

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SPDP03D270

SPDP03D375

Figure 1.a - Trip Curve for 100% configuration

Figure 1.b - Trip Curve for 30% configuration

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SPDP03D270

SPDP03D375

Table 3 - Signal Timing – (-40 oC to 100 oC @ LINE = 375V DC)

Parameter

Symbol

Min ( s)

Max ( s)

CONTROL to GATE Status Delay for Turn On

t0

100

450

Turn ON Delay

t1

150

600

Load Current Rise Time

t2

1000

2500

CONTROL to GATE Status Delay for Turn Off

t3

1200

2000

CONTROL to current start to decrease

t4

1200

2000

Load voltage Fall Time

t5

200

700

Note: Current Falling Time from trip dependent on magnitude of overload

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SPDP03D270

SPDP03D375

Figure 2 - Mechanical Dimensions and Pin Assignments

All dimensions are in inches

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SPDP03D270

SPDP03D375

Table 4 – Individual Power Dissipation Data (includes Vbias Power)

SPDP03D375

SPDP03D375 Set for

0.9 Amp Rating

SPDP03D375 Set for

3 Amp Rating

Current Rating

0.9A

3A

Power Dissipation

0.42W typ @ 0.6A 25OC

0.47W max @ 0.9A 25OC

0.51W max @ 0.9A 100OC

0.56W typ @ 1.8A 25OC

1.2W max @ 3A 25OC

1.90W max @ 3A 100OC

Max Voltage Drop

44mV typ @ 0.6A 25OC

77mV max @ 0.9A 25OC

140mV max @ 0.9A 100OC

100mV typ @ 1.8A 25OC

260mV max @ 3A 25OC

490mV max @ 3A 100OC

Figure 3 - Electrical Block Diagram

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SPDP03D270

SPDP03D375

Description

Figure 3 shows the block diagram of the SPDP03D375 SSPC. It uses a digital isolator for digital I/O. The

block labeled “Control (µC)” 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.

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 SPDPXXD375,

immediately reflects the command on its input.

The Control block also has the ability for the user to adjust the current rating by varying the trip point with a

resistor between the “I2t TRIP ADJ” pin and the “LOAD” pin, to adjust the Instant Trip current level with a

resistor between the “INSTANT TRIP ADJ” pin and the “LOAD” pin. See Equation (1) to select the

appropriate resistor for adjusting the current rating. See Equation 2 to select the appropriate resistor for

adjusting the Instant Trip current.

Select RI2T to program the current rating between 0.9A and 3A. Please notice the actual I2t trip level is

between 115% and 145% of the programed current according to the I2T trip curve.

Equation (1)

Select RINST to program the instant trip level between 400% and 700% of the rated current.

Equation (2)

Note: I0 is rated current for the SSPC unit 3A.

The Power MOSFETs used in the SPDP03D375 have been selected for very low Rds (on) and result in

low voltage drop and low power dissipation. As can be seen in Table 4, when the SPDP03D375 is

operated at 3 Amps, 100% of rated current, it dissipates less than 1.9 Watt in the whole temperature range.

When operates at extreme temperature, some heat sink can be accomplished by adding copper area to the

“LINE” and “LOAD” pins, a heat sink can be epoxy attached to the surface of the module or a flat copper or

RI2T 3.24 103I0Ii2t_trip

Ii2t trip 0.3 I0

RINST 18.2 1037 I0Iinst_trip

Iinst_trip 4 I0

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SPDP03D270

SPDP03D375

aluminum heat sink can be sandwiched between the SPDP03D375 and the printed circuit board using a

thermal pad to maximize heat transfer. Each application should be evaluated at maximum expected

constant current.

The SPDP03D375 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 SPDPXXD375 reports a trip

condition, the controller driving the SPDPXXD375 should allow no more than four repetitions and then allow

thirty seconds to cool down before trying to turn on again.

The SPDP03D375 will trip on overloads in the ALWAYS TRIP region and will never trip when in the NEVER

TRIP region. It can be reset by bringing the CONTROL pin to a logic low. When the “CONTROL” pin is

brought back to logic high, the SPDP03D375 will turn back on. If the overload is still present, it will trip

again. Cycling the “5 Volt BIAS” power will also reset the SPDP03D375. If the “CONTROL” pin is at logic

high when the “5 Volt BIAS” power is cycled, the SPDP03D375 will turn back on when the “5 Volt BIAS”

power is re-applied.

Status Table

Table 5 shows the states of the “S1” and “S2” status outputs.

BS

CONTROL

INPUT

OUTPUT

STATUS

S1

STATUS S2

SSPC STATUS

1

0

OFF

0

Normal Off

2

0

OFF

0

1

Over Temp

3

0

OFF

1

No Line Voltage

4

0

1

ON

0

Normal On

5

0

1

OFF

0

1

Over Temp

6

0

1

OFF

1

0

Tripped

7

1

X

ON

0

Battle short On

8

1

X

ON

0

1

Over Temp observed

9

1

X

ON

1

0

Trip condition observed

Table 5 – Control and Status

Normal Off – The SSPC is functioning normally and the channel is off. Both “S1” and “S2” status

outputs go to a low level

Over Temperature – An unsafe operating temperature (116oC typical) is detected.

a. During normal operation (2, 5), the channel will be turned off. When the temperature drops to

about 101oC, the “S2” status output goes back low and the output of the SPDP03D375 is

turned back on

b. During BS, the condition will only be reported.

No Line Voltage - Both “S1” and “S2” status outputs go to a high level when the line voltage drops

below 5 volts or when the load has not been discharged to 5V lower than the line voltage after turn off

command. This status has higher priority than over temperature status.

Normal On – The SSPC is functioning normally and the channel is on.

a. Tripped – The channel current surpassed the programmed I2t/instant trip point of the

SPDP03XD375.

b. During normal operation the channel will turn off and “S1” will be high and “S2” will be low until

reset.

c. During BS, and “S1” will be high and “S2” will be low to indicate the condition has been

detected.

Battleshort On - The BS mode has priority over all status conditions that would turn off the channel.

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SPDP03D270

SPDP03D375

High Voltage Considerations

The SPDP03D375 is designed for 375VDC systems. It contains an Output Leakage Sink to ensure that the

output is at a safe voltage when it is off (whether it 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 80 mA. When the current

into the output leakage sink is less than 80 mA, the transistor saturates and the output leakage sink looks

like a resistor of about 60 Ohms. 80 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 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 SPDP03D375, the spacing between pins is small so conformal coating should

be used to prevent arcing, especially if transient voltages above 375VDC are possible.

Wire Size

MIL-W-5088L has a chart that 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 26-gauge wire

to handle 3 Amps continuously at a wire temperature of 100 oC – a wire temperature rise of 30oC.

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 a 22 gauge wire is

necessary for 105 oC operation.

MIL-W-5088L has various figures showing derating for harnesses as a function of the number of current

carrying conductors for different altitudes. MIL-W-5088L 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.

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 SPD03D375 is 11.7 Amp2-Seconds. Every wire size in the paragraphs

above has an I2t rating that exceeds the SPDP03D375 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 SPDP03D375 is off, it

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 SPDP03D375 are pre-set at the factory for a nominal 2mS rise time and 500µS

fall time with a LINE supply of 375VDC (see Table 1 for min/max limits). The rise and fall times will vary

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SPDP03D270

SPDP03D375

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 time will be around 400µS, and the fall time will be around 50µS (control to

gate change delay will stay the same). 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. And fault may be tripped by capacitive load.

With the “PWR RTN” pin connected as in Figures 3, the SPDP03D375, when set for a 3 Amp rating, can

turn on into a capacitive load of 40µF, typ. without tripping for any power supply voltage within the rating.

Short circuit definition

With the “PWR RTN” pin connected as in Figures 3, SPDPxxD375 can survive at short circuit condition

which has been defined by 0.1Ohm resistor in series with 1.35uH inductance cross the LOAD and

LOAD_RTN. At 25 C, short circuit trip level has been defined as current larger than 21.2A (typical). And

this short circuit trip level will decrease with temperature linearly at a rate of 0.1A/ C (typical). So the unit will

trip at lower current level when at higher temperature to protect itself, which means at high temperature,

short circuit trip level may be lower than the set instant trip level.

Wiring and Load Inductance

Wiring inductance can cause voltage transients when the SPDP03D375 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. A 30 foot length of wire in free air will cause a transient voltage of about 10 Volts

when the SPDP03D375 trips at an Instant Trip level of 21 Amps. At the rated load current of 3 Amps, the

voltage transient will be less than 1 Volt. A transient suppressor is recommended at the “LINE” pin so that

the total voltage between the “LINE” and “LOAD” pins is less than 500 Volts. The SPDP03D375V unit

includes a reverse biased diode from the “LOAD” to “PWR RTN” pins to prevent damaging transients on the

output due to inductive loads.

Paralleling

For example, putting two SPDP03D375s in parallel will not double the rating to 6 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 SPDP03D375s in parallel may possibly trip at 5 Amps.

Also, both SPDP03D375s will not trip together; the SPDP03D375 carrying the higher current will trip first

followed by the other SPDP03D375. Multiple units may be used in parallel as long as these complexities

are appreciated.

Board Layout

The 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 SPDP03D375 back on after an overload. The SPDP03D375

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 then turning the SSPC back on by bringing the

“CONTROL” pin high. Sufficient magnetic coupling between the current-carrying 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 SPDP03D375

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 SPDP03D375 can withstand + 600 V spikes for 10µS. This capability is beyond that

required by MIL-STD-704F.

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SPDP03D270

SPDP03D375

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.

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6- The datasheet(s) may not be reproduced or duplicated, in any form, in whole or part, without the expressed written permission of

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