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(R)
INNOVATION and EXCELLENCE
DTL5A-LC
100 Watt, Serial-Input Electronic Load Low Compliance Version
Features
* 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
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. 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 sec 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.
Applications
* Power supply test and characterization * Dynamic power supply burn-in * Battery capacity testing * Current source testing * Capacitor discharge testing * Power resistor substitution * Real-time load simulation
+5V Supply Ground 3 Isolated DC/DC Converter 7 Control Strobe (CS) Clock (CLK) Serial Data In (SDI) 6 5 4 Buffers/ 4 Opto Isolators D/A Converter Amplifier/ Current Sensor 9 8 1 Fault Error Detection -Load Input -Load Input 2
11 10
+Load Input +Load Input
Power Supply
Under Test
Latch Data (LD)
Figure 1. Simplified Schematic
DATEL, Inc., Mansfield, MA 02048 (USA) * Tel: (508)339-3000, (800)233-2765 Fax: (508)339-6356 * Email: sales@datel.com * Internet: www.datel.com
DTL5A-LC
100 Watt
Serial-Input
Electronic
Loads
Performance Specifications and Ordering Guide
Compliance Voltage (Volts) 0.6 to 50
Output
Model DTL5A-LC Loading Curent (Amperes) 0 to 2.0 Current Resolution mA 0.5 Accuracy (%FSR) 3 Offset Error (%FSR) 0.05 Gain Error (mA) 50 Gain Error (% of Setting) 0.25 Package (Case Pinout) C1
Typical at TA = +25C under nominal line voltage and full-load conditions unless otherwise noted.
Mechanical Specifications
Case C1
Part Number Structure
DTL
Prefix: DTL = DATEL product
5
A - LC
A-Series High Reliability LC = Low Compliance: Voltage Range of 0.6 to 50V DTL5A-LC model only
#4-40 CLEAR THRU (TYP 4 PL )
Metal Shell
Aluminum Header
Voltage Range/Current: 5 = 2.5 to 50V, 0 to 2A
.0.001 Pins
0.001 Pins
0.20 Min
The warranty period is one year
B
2.02 Max. 1.800 1.640
A A .0 1 0
Temperature Derating
7 8 9 4 3 2 1 11 10 6
2.02 Max.
5
1.200 1.000 .800 .600 .400
100 80 60 Load Capacity in Watts 40 20
1.640
7 6 5 4 3
.200
8
9
BOTTOM VIEW
(Label/pin side) 10
0
10
20 25 30
40
50
60
70
80
90
100
2 1 11
Base Plate Temperature in C
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.
I/O Connections
Pin 1 2 3 4 5 6 7 Function Fault Ground +5 Volts Supply Latch Data (LD) Serial Data In (SDI) Clock (CLK) Control Strobe (CS) Pin 8 9 10 11 Function - Load Input - Load Input + Load Input + Load Input
2
.220
B
.0 1 0
100 Watt Serial-Input Electronic Loads
DTL5A-LC
Performance/Functional Specifications
Typical @ TA = +25C under nominal line voltage and full-load conditions unless noted.
Input
Digital Inputs (pins 4, 5, 6, 7): VIL VIH IIL IIH
Min.
Typ.
Max.
0.8
Units
Volts Volts mA A
Timing
Refer to timing diagram: CLK t =t
cl ch
Min.
Typ.
Max.
200
Units
kHz sec sec sec sec sec sec sec sec
2.0 -0.6 20 See Ordering Guide 0.025 0.05 0.3 See Ordering Guide 10 20 100 10 +4.75 +5.0 +110 +5.25 +150
1 1 1 2
t
css
Output
Loading Current Current Resolution Offset Error Gain Error DTL5A-LC Compliance Voltage Range Output Impedance
t
csh
t
ld1
% FSR % FSR % FSR
t
ld2
2 2
ldw
t t
ds
0.5 0.5
dh
t
Mohm kHz usec A/sec Volts mA
Dynamic Characteristics
Dynamic Loading to: Settling Time (Full Scale Step) Slew Rate
Absolute Maximum Ratings 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) Current (pin 3) Power Supply Voltage (pin3): Digital Input Voltage (pins 4,5,6,7): Output Reverse-Polarity Protection: Output Overvoltage Protection: Storage Temperature -40 +105 95 10,000 2" x 2" x 0.52" (51 x 51 x 12.7mm) 0.2 6-sided Tin-plated Steel Shell Heat-sink side: Aluminum Brass, solder coated 500 500 100 Through-hole spacer, #4-40 clearance 1.9 ounces (55 grams) Volts Volts Mohm inches C Lead Temperature (soldering, 10 sec.) % feet +300C 5.5 Volts 5.5 Volts No protection No protection -40 to +105C
Environmental
Operating Ambient Temperature Ta, where no derating required. Natural Convection, vertical mount Storage Temperature Humidity (Non-condensing) Altitude Above Sea Level
Physical
Dimensions Pin Length Shielding Case Material Pin Material Isolation, Load to Input Ground Isolation, any pin to case Isolation, resistance Mounting Weight
3
DTL5A-LC
Overview
100 Watt
Serial-Input
Electronic
Loads
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 25C, 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 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. Operation Overview 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. Initialization 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. 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. 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.
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. 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 5. Place D10 of the Data Word into Serial Data In. BIT_2 = 0 or 1 6. Toggle the Clock High-LOW-HIGH. BIT_3 = 1-to-0-to-1 7. REPEAT this process (steps 5 and 6) for the remaining data bits (D9-D0). 8. Set the Control Strobe High. Bit_0 = 1 9. Toggle the Latch Data High-LOW-HIGH BIT_1 = 1-to-0-to-1
Serial-Input Data Word
MSB 1111 1100 1000 0111 0100 0010 0000 0000 1111 0000 0000 1111 0000 0000 0000 000 LSB 1111 0000 0000 1111 0000 0000 0001 0000
Load Current (Amperes)
DTL5A-LC 1.9995 1.5000 1.000 0.9995 0.5000 0.2500 0.0005 0.000
Mapping of the Serial-Input Data Word to Load Current
4
100 Watt
Serial-Input
Electronic
Loads
DTL5A-LC
tdh
SDI
D 11
D10
D9
D8
D7
D6
D5
D4
D3
D2
D1
D0
tds
CLK
tcss
tcl tch
tcsh
CS
tld1
tld2
LD
tldw
Timing Diagram
Load Regulation
5
DTL5A-LC
Quality and Reliability
1 0 0 Wa t t
Serial-Input
Electronic
Load
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. HALT Testing 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. 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
Typical HALT Profile
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 +125C, 30C/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
Qualification Test HALT High Temperature Storage Thermal Shock Temperature/Humidity Lead Integrity Life Test Marking Permanency End Point Electrical Tests
* Interim electrical test at 200 hours.
Method/Comments DATEL in-house procedure Max. rated temp., 1,000 hours 10 cycles, -55 to +125C +85C, 85% humidity, 48 hours DATEL in-house procedure +70C, 500 hours* DATEL in-house procedure Per product specification
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)
(R) (R)
ISO 9001
REGISTERED
INNOVATION and EXCELLENCE
DS-DTL005 Rev_A
1/2000
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: sales@datel.com Data Sheet Fax Back: (508) 261-2857
DATEL DATEL DATEL DATEL
(UK) LTD. Tadley, England Tel: (01256)-880444 S.A.R.L. Montigny Le Bretonneux, France Tel: 01-34-60-01-01 GmbH Munchen, 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.

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