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Programmable Power Resistor

A SCPI programmable power resistor

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After building my programmable precision resistor I needed a simple 20 Ohm power resistor capable of dissipating 400W peak power (over a few seconds). Long story short, I ended up with another fun project, recycling much of the code I've written for the programmable precision resistor.

Introduction

For the performance checks of my Agilent 6811B AC Power Source/Analyzer (375VA) I needed a 20 Ohm resistor with a ton of power handling capability. The original plan was to mount 8 wire wound 50W resistors on a heat sink and be done with it. Then I thought: Why not reuse all the code I've already written for the programmable resistor and build a programmable high power resistor that can complement my DC load for AC applications...

Features and preliminary specs

Parameter Value / Description
Resistance range (nominal, Ohm) short circuit, 1.25 to 80 Ohm, open circuit:

0, 1.25, 1.429, 1.538, 1.667, 1.818, 2, 2.143, 2.222, 2.273, 2.308,
2.353, 2.5, 2.727, 2.857, 2.941, 3, 3.077, 3.158, 3.333, 3.448,
3.529, 3.636, 3.750, 4, 4.167, 4.286, 4.444, 4.615, 5, 5.263, 5.455,
5.714, 5.833, 6, 6.5, 6.667, 7.143, 7.333, 7.5, 8, 8.333,
8.571, 9, 9.167, 9.375, 10, 10.667, 10.909, 11.111, 11.667, 12,
12.5, 13.333, 13.636, 14, 15, 15.385, 16.667, 17.143, 17.5, 18.333,
19, 20, 21.667, 22.5, 23.333, 24, 25, 26.667, 27.5, 28.333,
29, 30, 31.667, 32.5, 33.333, 34, 35, 36.667, 40, 42.5,
43.333, 44, 45, 46.667, 50, 55, 60, 65, 70, 80
Setpoint resolution settable to 1 mOhm, selects closest supported resistance value
Short-term setpoint accuracy estimate <= 1% of nominal value + 0.2 Ohm
Display resolution three decimal places (fixed)
Thermal drift
(estimate based on design)
<=50ppm/K
Power/current rating Depends on resistance setting. Limiting values are calculated and displayed.
Up to ~150 W continuous (400W peak) or 6A, whichever is lower
Bandwidth unspecified
Calibration modes - Uncalibrated: Switches are activated according to entered setpoint, display shows setpoint
- Two-wire (2W), Four-wire (4W): The resistance value closest to the entered setpoint is selected
Operating modes Fixed: On trigger, no change
Step: On trigger, step to trigger setpoint value
Up: On trigger, increase setpoint (auto, linearly, 1-2-3-4-5-6-7-8-9, 1-2-5, 1-3)
Down: On trigger, decrease setpoint (linearly, 1-2-3-4-5-6-7-8-9, 1-2-5, 1-3)
List: See list mode
List mode Up to 100 values with individual dwell times
- Start: on trigger; or immediately after mode selection
- Step:
  - Auto: Advance index automatically, solely based on dwell time
  - Trigger: Advance index on each trigger event, ignoring the dwell time
  - Once: Advance index on each trigger event, only after dwell time elapsed
Switching - fast (default)
- break-before-make
Protection Over temperature protection (OTP)
Trigger Source: Bus, Immediate, Manual, Timer
Mode: Continuous, Single
Parameter:
- Delay,
- Holdoff,
- Time (0.01 s .. 10^7 s; Source: Timer)
Command and trigger execution 10ms loops

User interface - 16x2 Dot Matrix display:
- Primary display: Resistance setpoint, (max.) heatsink temp.
- Secondary display:
- limiting values (voltage, current, power)
- trigger state
- uncalibrated resistance value
User presets 0-9 (0 is restored on power-up)
Interface - Input and Sense: 4mm safety banana jacks
- USB (Virtual COM port)
Fans Two temperature controlled 60mm fans (12V, 4500 rpm)
Power supply Switch mode

Typical applications

  • (AC) Power supply tests
  • Audio amplifier tests

Note

All information is provided "as is" without any warranty whatsoever. Although I have compiled the information to the best of my knowledge, there might be errors. You use the information at your own risk.

  • Topology (1)

    Sebastian04/18/2024 at 20:15 0 comments

    In this application the focus is on power handling capability, not so much a high resolution (high number of resistance values) or precision. This is why the topology used in the Programmable Precision Resistor is not as suitable for this application as it has been before. Also my ELMA cases are really small (and I mean really small, so thermal considerations will be challenging), so I can’t simply increase the number of power resistors and relays in the process. That’s why I’ll stick to the original plan of using 8 power resistors.

    Three of a total of eight power resistors used in this project

    Instead the idea is to find a topology where I can select different resistance values by either connecting the resistors in series or in parallel. Let’s first have a look at a circuit for only two resistors.


    A simple circuit allowing to switch between a series and parallel connection of two resistors. It requires one single throw and one dual throw switch.

    For this design I assume that both resistors are identical, both in their resistance value R as well as their power rating P. It’s very obvious how this circuit works, but here are the current paths for the different switch states anyway:

    Switch states of the presented topology

    Since the math behind this is really simple, here are the results without any further explanation.

    S0aS0bR0P0I0U0
    002R2P√(P/R)
    2R√(P/R)
    01RP√(P/R)R√(P/R)
    100unlim.unlim.0
    11R/22P2√(P/R)R√(P/R)
    Switch states and the associated electrical parameters

    And now we have our basic building block that we’ll use in the next post of this series.

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