Programmable resistor modules provide a simple solution for voltage handling up to 1.2kV

Pickering Interface has released a new family of high-voltage programmable resistor modules in a compact single-slot PXI and PXIe form factor, model 40-230 (PXI) and 42-230 (PXIe), supplying a simple solution for applications requiring voltage handling up to 1.2kV. Part of its expanding range of programmable resistor modules, the new module is available in 70 standard builds, including four single-channel builds that offer a wide variety of resistance ranges and resolution capabilities, playing a pivotal role in simulating real-world resistive loads and fault conditions for high-voltage DUTs across automotive, aerospace, and energy sectors.

The 40/42-230 high-voltage programmable resistor module plays a vital role in simulating real-world resistive loads and fault conditions for high-voltage DUTs such as EV power inverters, BMSs (battery management systems), and some aerospace components. Engineers can use these modules for critical tasks, including voltage isolation check testing, which ensures the safe functionality of high-voltage systems and compliance with safety standards such as ISO 6469 and IEC 60664.

The module enables engineers to emulate resistance sensor values, such as those from thermistors and RTDs, in high-voltage environments, enabling safe testing without needing the actual sensor hardware. For added test coverage, when used in the HIL simulation testing of ECUs, each channel of the 40/42-230 can be set to short and open circuit conditions to verify the controller's response to a faulty sensor or connection.

"Building on Pickering's ongoing investment in sensor and battery simulation, this new range is one of a few PXI or PXIe modules that can handle voltages up to 1.2 kV, making it suitable for high-voltage environments like EVs, aerospace, or power electronics test benches," said Stephen Jenkins, simulation product manager at Pickering. "With the proliferation of high-voltage systems, engineers face significant challenges ensuring that high-voltage subsystems can safely function alongside low-voltage electronics. This module serves as an invaluable tool in meeting such demands."

With up to four channels available from a single slot, the module delivers multi-channel flexibility and a wide resistance range from 1Ω to 76.8MΩ in a compact single-slot PXI or PXIe form factor, and resistance resolution down to 0.125Ω. The module's hardware interlock and simulation features ensure safety and facilitate diagnostics. Key applications range from high-voltage test environments, including automotive EV and aerospace systems, to applications needing rapid reconfiguration of resistance, or test systems with limited PXI slots (requiring multi-channel modules), as well as HIL simulation platforms needing fault insertion.

The 40/42-230 is available in 70 standard builds, including four single-channel builds that suit the most common configurations:

• Narrow resistance range version, available in 2 or 4 channel variants.
• Medium resistance range version, available in 1 or 2 channel variants.
• Wide resistance range version, available in 1-channel variants.

Software control is simplified by using resistor value calls. The module calculates the resistance setting closest to the requested value and sets that value. The user can then interrogate the module to find the exact setting used. To help ensure long-term accuracy, an optional cable assembly may be attached to the module in place of the DUT, enabling simple calibration using a DMM to verify the resistor channels.

The 40/42-230 high-voltage modules are fitted with a hardware interlock, which provides greater safety than typical software protection. When activated, the interlock will return all relays to their default unpowered state (assuming the switches are fully functional) and provide error notification via the software interface. The interlock feature can be daisy-chained between additional hardware interlock-enabled modules, allowing one signal to disable multiple cards.

Drivers are supplied for Windows, Linux and real-time operating systems. All standard products manufactured by Pickering Interfaces include a three-year warranty and guaranteed long-term product support.