RP-21200
STAR
Series
®
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Card you purchase
®
has...
SOLID-STATE ADVANCED REMOTE
POWER CONTROLLERS
FEATURES
•
Low Cost
•
Continuously Programmable and
Preset Ranges
•
EMI Tolerant
•
I
2
T & Instant Trip Protection
•
MIL-STD-704 Compliant
•
Opto-Isolated Control Circuitry
•
No Thermal Derating
•
Low Power Dissipation
•
Thermal Memory
•
Coordinated Tripping Characteristics
DESCRIPTION
The RP-21200 STAR Series of 28 Vdc Solid-State Power Controllers
(SSPCs) replace electromagnetic circuit breakers and solid-state relays rated
from 1 through 25 amperes. These SSPCs provide status outputs and
logic input control so that they may be remotely located near the load.
The 28 Vdc SSPCs are available in three programmable current ranges;
1-3 amperes, 3-9 amperes, and 8.3-25 amperes. Each of these ranges
offer four preset current settings and allow the user to set other ranges.
The primary function of the SSPC is to protect the wire from I²R heat-
ing. The SSPC uses standard logic I/O, “on/off” logic input controls,
provides isolation between the control side and power side, and has
status outputs. The device is contained in a non-flammable housing
and is electrically shock proof. It has self contained SSPC functions
including thermal memory. The RP-21200 STAR Series are PC board
through-hole or surface-mountable lightweight encapsulated devices
that are impervious to moisture.
Using power MOSFET switches, these power controllers offer low
“ON” resistance, low voltage drop, high “OFF” impedance, and low
power dissipation. Built using the latest plastic and epoxy technolo-
gies, they offer small size, low power, and high reliability.
APPLICATIONS
Designed to replace circuit breakers in land, air, and sea vehicles,
these SSPCs provide status outputs, which show switch state and
minimum load current. An optional analog current monitor can report
load current. Fault tolerant systems can be configured using these
SSPCs with a remote or local CPU.
Data Device Corporation
105 Wilbur Place
Bohemia, New York 11716
631-567-5600 Fax: 631-567-7358
www.ddc-web.com
FOR MORE INFORMATION CONTACT:
Technical Support:
1-800-DDC-5757 ext. 7771
©
2000 Data Device Corporation
Data Device Corporation
www.ddc-web.com
HIGH SIDE
SWITCH CONFIG.
OR
POWER IN
LOAD
+28 Vdc
POWER IN
MOSFET
DRIVER,
TRANSFORMER
ISOLATION
Vcc
LOW SIDE
SWITCH CONFIG.
+28 Vdc
VBIAS SUPPLY
INPUT
R
SENSE
POWER OUT
SLEW
CONTROL
LOAD
INTERNAL
POWER
SUPPLY
OPTO-
ISOLATION
SHORT
CIRCUIT
CONTROL,
POWER OUT
SYSTEM
GND
SLEW
CONTROL
2
AND
LATCHES
STATUS1
STATUS2
CONTROL
CMD
LOCK-OUT
ISOLATED
CONTROL
CIRCUIT
STATUS
CIRCUIT,
VBIAS SUPPLY
COMMON
I
3
I
2
RANGE PROGRAM (R
1
)
LOAD DETECTION PROGRAM (R
2
)
V ref
INSTANT TRIP PROGRAM (R
3
)
PROGRAM REFERENCE
OPTIONAL BATTLE SHORT CONTROL
CHASSIS (BASE)
GROUND
OPTIONAL
ANALOG
CURRENT
OUTPUT
RP-21200
E-10/06-0
FIGURE 1.
STAR
Series BLOCK DIAGRAM
TABLE 1. ABSOLUTE MAXIMUM RATINGS
PARAMETER
Power In to Power Out
Power Out to Slew Control
Control Input to Signal Ground 1
Lock-Out Input to Signal Ground 1
Power Out to Signal Ground
VBias voltage
Lead Temperature (soldering)
Junction Temperature
UNIT
Vdc
Vdc
Vdc
Vdc
Vdc
Vdc
°C
°C
VALUE
70 continuous
90 transient
100 continuous
-0.5 to 7.0
-0.5 to 7.0
-100 to +100
-0.5 to +6.0
+260 (within 10 sec.)
125
TABLE 3. RP-212XX SPECIFICATIONS (CONT.)
PARAMETER
Power Input Leakage
Current to Power Out
RP-21209
Power Input Leakage
Current to Power Out
RP-21225
Load Capacitance
RP-21203
Load Capacitance
RP-21209
Load Capacitance
RP-21225
Control to Power Output
Isolation Resistance
Output Capacitance
RP-21203
Output Capacitance
RP-21209
Output Capacitance
RP-21225
Trip Reset Time
Rupture Capacity
CONDITIONS
Power In = 0-40 V
-55°C to +100°C
See Note 5
Power In = 0-40 V
-55°C to +100°C
See Note 5
See Note 3
-55°C to +100°C
See Note 3
-55°C to +100°C
See Note 3
-55°C to +100°C
Control to Power
Output = 50V
Power in to Power
Output = 28V
Power in to Power
Output = 28V
Power in to Power
Output = 28V
See Note 4
UNIT
mA
VALUE
2 max.
mA
µF
µF
µF
Ω
pF
pF
pF
ms
A
4 max.
700 min.
1400 min.
6800 min.
108 min.
900 typ.
3300 typ.
6600 typ.
1 max.
Unlimited
1x max.
rated current
4x max.
rated current
Note: 1. This input shall not exceed VBias by more than 0.5V.
TABLE 2. RECOMMENDED OPERATING CONDITIONS
PARAMETER
Power In to Power Out
Control Input to Signal Ground1
Lock-Out Input to Signal Ground 1
Power Out to Signal Ground
VBias voltage
UNIT
Vdc
Vdc
Vdc
Vdc
Vdc
VALUE
+0.0 to +40.0
+4.5 to +5.5
+4.5 to +5.5
-40 to +40
+4.5 to +5.5
Note: 1. This input shall not exceed VBias by more than 0.5V.
TABLE 3. RP-212XX SPECIFICATIONS
PARAMETER
Logic Type
CONDITION
See FIGURE 2
See Note 2
V
Bias
=4.5-5.5 V
DC
RP-212XXF0
V
Bias
=4.5-5.5 V
DC
RP-212XXF1
Control Turn-On Voltage2
Control Turn-Off Voltage2
Lockout Disable Voltage2
Lockout Enable Voltage2
Control/Lockout Input
Current2
Control/Lockout Input
Current2
Status Output Voltage
Low
Status Output Voltage
High
Status Truth Table
‘On’ Resistance
Power Dissipation
Power Input Leakage
Current to Power Out
RP-21203
-55°C to +100°C
-55°C to +100°C
-55°C to +100°C
-55°C to +100°C
Control = 5 V
Lockout = 0 V
-55°C to +100°C
Control = 0 V
Lockout = 5 V
-55°C to +100°C
V
Bias
= 4.5 V
I
OL
= 2.5 mA
-55°C to +100°C
V
Bias
= 4.5 V
I
OH
= -0.4 mA
-55°C to +100°C
See TABLE 6
See TABLE 4
See TABLE 4
Power In = 0-40 V
-55°C to +100°C
See Note 5
UNIT
—
mA
mA
V
V
V
V
µA
µA
µA
µA
VALUE
TTL/CMOS
Compatible
20 typ.
30 max.
50 typ.,
75 max.
2.0 min.
0.8 max.
2.0 min.
0.8 max.
100 max.
-100 min.
1.0 max.
-1.0 min.
Output Reverse
Continuous Current
All Models
Output Reverse Pulsed
Current All Models
Output Reverse Voltage at
Rated Current
Output Voltage Drop at
25°C
Output Voltage Drop at
100°C
Trip Characteristics
Response Time
Power Out Voltage
>
Power In Voltage
Pulse Width
≤
100
µs
Power Out Voltage
>
Power In Voltage
See Note 3
See TABLE 4
See Note 3
See TABLE 4
See FIGURE 5
-55°C to +100°C
See FIGURE 6
-55°C to +100°C
Instant Trip=3000%
See FIGURE 5
A
A
Vbias Supply Current8
V
1.8 max.
V
V
—
—
A2-
sec
A2-
sec
A2-
sec
% of
Rated
Current
0.2 max.
0.3 max.
—
—
10.6 x Irated
current
2
4.2 x Irated
current
2
1.4 x Irated
current
2
190 min.
210 max.
V
0.4 max.
I2t Max Rating
Calculation
Instant Trip=1000%
See FIGURE 5
Instant Trip=200%
See FIGURE 5
V
—
—
—
mA
3.5 min.
—
—
—
0.3 max.
Instant Trip Level Without
External Programming
Resistor
See Figures
3 and 4
Data Device Corporation
www.ddc-web.com
3
RP-21200
E-10/06-0
TABLE 3. RP-212XX SPECIFICATIONS (CONT.)
PARAMETER
Instant Trip Level With
External Programming
Resistor Shorted
Load Detection Level
Without External
Programming Resistor
Load Detection Level With
Ext. Programming
Resistor Shorted
Thermal Resistance
Junction-to-Case
RP-21203
Thermal Resistance
Junction-to-Case
RP-21209
Thermal Resistance
Junction-to-Case
RP-21225
Thermal Resistance
Base-to-Sink RP-21203
Thermal Resistance
Base-to-Sink RP-21209
Thermal Resistance
Base-to-Sink RP-21225
Thermal Resistance
Base-to-Ambient
RP-21203
Thermal Resistance
Base-to-Ambient
RP-21209
Thermal Resistance
Base-to-Ambient
RP-21225
Size
Weight RP-21203
Weight RP-21209
Weight RP-21225
Operating Case
Temperature Range
Storage Temperature
Mounting Torque
CONDITIONS
See Figures
3 and 4
See Figures
3 and 4
See Figures
3 and 4
Hottest die
to base
Hottest die
to base
Hottest die
to base
—
—
—
UNIT
% of
Rated
Current
% of
Rated
Current
% of
Rated
Current
°C/W
VALUE
8. During initial power-on @ Vbias
~
3.5Vdc, a transient current pulse of up to
100mA above the Vbias Supply Current may be observed.
FUNCTIONAL DESCRIPTION
2845 min.
3155 max.
89 min.
101 max.
5 min.
15 max.
The RP-21200
STAR
Series of programmable Solid-State Power
Controllers (SSPCs) are electronic circuit breakers and, as such,
are primarily intended to protect the wiring between the power
source and the load. They are designed to replace electro-
mechanical or thermal circuit breakers while providing the relia-
bility of solid-state electronics. Unlike circuit breakers, SSPCs
can easily interface with TTL/CMOS signals associated with
solid-state controllers, such as embedded microprocessors.
The Block Diagram in FIGURE 1 shows the various functional
blocks within the RP-212XXF1 series. The control side employs
buffers for the logic signals, which are isolated and level shifted
from the power side by optical isolation. On the power side are
the analog and digital circuits which drive the power MOSFET
switch, sense the switch’s current and provide programmability.
An internal DC-DC converter, powered by the control side 5 Volt
bias supply provides isolated power to the power side circuitry.
An optional analog Current Monitor output uses optical isolation,
and provides an analog voltage signal on the control side which
is proportional to the switch’s (load) current.
The
STAR
Series has two TTL/CMOS compatible inputs. One
input is the Control Command. A logic high on the Control
Command will turn on the power switch and a logic low will turn
it off. The other input is a Lockout Input which can be used to
provide safety during system maintenance. When the Lockout
Input is at a logic high, the SSPC is disabled and always off,
regardless of the state of the Control Command input. When the
Lockout input is at a logic low, the SSPC follows the state of the
Control Command.
The two TTL/CMOS compatible outputs, Status 1 and Status 2,
provide status information on the switch current (load current)
and switch state, respectively. Status 1 will be at a logic high
when the switch current is less than the programmed Load
Detection value - see FIGURE 4 for programming information.
When the switch current is greater than the programmed Load
Detection value, Status 1 will be at a logic low. Status 2 reflects
the state of the switch. When the switch is closed, Status 2 will
be at a logic high and when the switch is opened, Status 2 will
be at a logic low. The combination of the states of the Control
Command, Lockout Input, Status1 and Status 2 outputs provide
Built-In-Test (BIT) capability. TABLE 6 shows the possible status
combinations.
As in a circuit breaker, the SSPC will carry continuous current up
to a certain level without tripping. For the RP-21200 series, the
SSPC will not trip as long as the continuous current is less than
110% of the programmed current - see FIGURE 4 and TABLE 5
for programming information. The
STAR
Series are guaranteed
to trip if the continuous current is greater than 145% of the pro-
grammed value. Again, like a circuit breaker, the RP-21200
series can handle short duration overloads without tripping. The
I
2
t curve shows that time to trip is inversely proportional to the
square of the current. This means that short overloads can be
large without tripping but longer overloads must be small to avoid
tripping. FIGURE 5 shows a typical set of I
2
t curves. Operation
4
RP-21200
E-10/06-0
3 max.
°C/W
1 max.
°C/W
0.5 max.
°C/W
°C/W
°C/W
1.8 max.
0.9 max.
0.5 max.
Free Air
°C/W
25 max.
Free Air
°C/W
20 max.
Free Air
See Figure 8
—
—
—
—
—
—
°C/W
—
oz (g)
oz (g)
oz (g)
°C
°C
in-lbs
15 max.
—
1.24 (35)
1.59 (45)
2.12 (60)
-55 to +100
-55 to +125
5
TABLE 3 notes:
1. All specifications are at 25°C unless otherwise specified. Maximum Rated
Current is defined as the current when the R1 current range programming pin is
shorted to the programming reference pin.
2. Control and Lockout operate the input optocoupler. They may be interchanged
which will invert their function. See FIGURE 2 for a schematic of this input structure.
3. Limits are shown when programmed to maximum instant trip level, and at the
maximum current rating setting. Limits are 33% of those shown when there are
no connections to R1, I2, and I3 programming pins (when at minimum current
range, but maximum instant trip range).
4. This means that the SSPC may be reset 1 ms after a trip has occurred.
However, if the cause of the trip has not been removed, the second trip will occur
faster than the first trip. This is an example of how the internal ‘thermal memory’
protects the wire. Also, repeated resetting and tripping must not occur faster than
30 ms after the first reset in order to prevent overheating of the SSPC.
5. DDC recommends using an external bleed resistor in situations that may not
tolerate leakage currents that will permit power-in VDC at the load.
6. Analytical Radiation Tolerance Estimate.
7. The STAR Series design incorporates series power supply resistors to protect
against latch-up damage.
Data Device Corporation
www.ddc-web.com
TABLE 4. POWER DISSIPATION
PART
NUMBER
RP-21203
RP-21209
RP-21225
“ON”
RESISTANCE
(OHMS)
0.100
0.033
0.012
MIN. RATED CURRENT
VOLTAGE
DROP
(V)
0.1
0.1
0.1
POWER
DISSIPATION
(W)
0.25
0.45
0.98
MAX. RATED CURRENT
VOLTAGE
DROP
(V)
0.3
0.3
0.3
POWER
DISSIPATION
(W)
1.05
2.85
7.65
TABLE 4 notes:
1. Values shown are maximum over the case temperature range of -55°C to +100°C; typical values at
25°C are typically 67% of the maximums shown above.
2. Voltage drop is approximately 0.6% per °C improved below the100°C limit.
3. Power Dissipation data includes 150 mW contribution of VBIAS, but doesn’t include the analog current
monitor (see TABLE 3). “F1” is another 45 mA maximum.
in the area between the minimum and maximum curves is
ambiguous; the SSPC may or may not trip.
A hot wire cannot withstand as great an overload as a cool wire.
The
STAR
Series of SSPCs incorporate ‘Thermal Memory’ to
protect a wire that is hot from a previous overload.
The Instant Trip Characteristic ranges shown in FIGURE 5 are pro-
grammable as detailed in FIGURE 4. If the overload exceeds the
upper Instant Trip level, the SSPC will trip regardless of the dura-
tion of the overload. The main reason for an Instant Trip level is to
protect the switch from excessive short-term power dissipation but
can be programmed for system considerations, if necessary.
The RP-21200
STAR
Series are available in three current
ranges. As shown in TABLE 5, they are programmable over a
three-to-one range. The ranges are: 1 - 3 Amps, 3 - 9 Amps and
8.3 to 25 Amps. TABLE 4 shows the Maximum “on” resistance
and voltage drops over the temperature range.
The rise and fall times of the output voltage are controlled to be
approximately 500µS. Fast rise times minimize the power dissi-
pation in the switch during turn-on and turn-off. Slow rise times
minimize EMI, voltage spiking due to line inductance and allow
starting up into higher capacitive loads. The 500µS rise and fall
times in the
STAR
Series represent a compromise. While the
switch can handle the power dissipation during occasional
changes of state, rapidly switching the SSPC on and off will lead
to overheating. These SSPCs should not be cycled at greater
than a 30ms rate.
To control the rise and fall time, the Slew Control Input must be
returned to Chassis Ground. The load return is the ideal Chassis
Ground; the Chassis Ground can also be used as a ground but,
if there is noise between Chassis Ground and load return, some
of this noise may appear on the output. An alternative Chassis
Ground is the Power In but, if the Power In is turned on abruptly,
such as through a switch or contactor, the output may exhibit a
small transient although the SSPC is commanded off.
I
3
Control Command
100K
R
BiasGnd
I
2
R
1
R
2
R
3
Current Range Programming
Load Detection Programming
Instant Trip Programming
Program Reference
Vbias
100K
Lockout Command
RP-212XX
BiasGnd
RP-212XX
Internal Preset Programming Options
FIGURE 2. RP-212XX SERIES CONTROL/LOCKOUT
FUNCTIONAL SCHEMATIC
Data Device Corporation
www.ddc-web.com
5
FIGURE 3. RP-212XX SERIES PROGRAMMING
CONNECTIONS
RP-21200
E-10/06-0
DIY/Open Source Hardware
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