BCS Series AEC-Q200 Chip Shunt Resistors

What are the BCS Series AEC-Q200 Chip Shunt Resistors?

The BCS series is a family of surface-mount chip shunt resistors designed for precision current sensing in power electronics and automotive applications. Each resistor is constructed from a precision resistive alloy element electron beam welded to copper electrodes, a joining method that produces a metallurgically sound, repeatable bond at the alloy-to-copper interface without the thermal distortion or contact resistance variation associated with conventional soldering or mechanical clamping. The electron beam welding process enables the BCS series to achieve a maximum initial tolerance of ±0.5% after stamping and without trimming, preserving the integrity of the resistive element while meeting tight resistance accuracy requirements straight from manufacture.

Three package footprints are offered to cover a wide range of current and power requirements. The BCS02 measures 6.30 × 3.00 mm and handles up to 57 A with resistance values from 1.5 mΩ to 5 mΩ. The BCS03 measures 10.00 × 5.20 mm, extends the lower resistance boundary to 0.2 mΩ, and supports continuous currents up to 244 A at its lowest resistance value. The BCS05 measures 15.00 × 7.75 mm and delivers up to 273 A at 0.2 mΩ, with a maximum power rating of 15 W at 70°C. Across all three sizes, the TCR performance is maintained over an operating temperature range of −55°C to +170°C, with TCR grades of ±25, ±50, ±100, ±150, and ±200 ppm/°C available depending on the variant selected. The tightest grade, ±25 ppm/°C, is specified over −55°C to +125°C for the BCS02C and BCS03C variants.

The BCS series is qualified to AEC-Q200, the automotive passive component stress test standard, and all reliability tests are conducted in accordance with AEC-Q200 and MIL-STD-202 methods. Qualification testing covers high-temperature storage at +170°C for 1000 hours, thermal shock across −55°C to +155°C for 1000 cycles, bias humidity at 85°C and 85% RH for 1000 hours, load life at rated power for 2000 hours, mechanical shock at 100 g peak acceleration, vibration from 10 Hz to 2 kHz, and substrate bending to 2 mm deflection. Short-time overload testing is performed at five times the rated voltage for five seconds. Maximum resistance change limits are defined for each test condition, confirming stability under the thermal, mechanical, and electrical stresses characteristic of automotive and industrial deployment environments. Components are supplied in tape and reel format — 4000 pieces per reel for the BCS02 series and 2000 pieces per reel for the BCS03 and BCS05 series — compatible with standard automated pick-and-place assembly.

Model: BCS
Resistor type: AEC-Q200 Chip Shunt
Description: Precision, E-beam welded
Power Rating: 2.5W~15W
Resistance (Ω): 0.2~5m
Tolerance (%): ±0.5, ±1, ±5
TCR (ppm/C): 25-200

Model: TCS8536
Resistor type: AEC-Q200 E-beam
Description: E-beam welded shunt
Power Rating: 36W
Rated Current: 600~1200A
Resistance (Ω): 0.1m, 0.05m, 0.025m
Tolerance (%): ±1, ±2, ±5
TCR (ppm/C): 100

Model: TCS8440T
Resistor type: AEC-Q200 E-beam
Description: E-beam welded shunt
Power Rating: 36W
Rated Current: 840A
Resistance (Ω): 0.05m
Tolerance (%): ±1, ±2, ±5
TCR (ppm/C): 100

Model: ECS
Resistor type: AEC-Q200
Description: Chip shunt
Power Rating: 1W~15W
Resistance (Ω): 0.2~10m
Tolerance (%): ±1, ±2, ±5
TCR (ppm/C): 100-200

Model: TCS
Resistor type: AEC-Q200 E-beam
Description: Shunt
Power Rating: 12W~36W
Rated Current: 200~350A
Resistance (Ω): 0.05~0.5m
Tolerance (%): ±1, ±2, ±5
TCR (ppm/C): 100