Data and Power IsolationAdvanced Techniques of Higher Performance Signal Processing

2

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3

Today’s Agenda

What Problem Are We Solving?

Insulation Characteristics and Isolation Requirements

Discussion of Safety Certifications System Level Component Level

Advantages of iCoupler Products over Optocouplers

Application Examples Isolated DC-to-DC Converters Isolated Half-Bridge Gate Drivers

4

Problem to Be Solved

Hazardous voltages exist at many points within industrial and consumer locations

People and equipment must be protected from long-term potential differences and temporary overvoltage conditions (faults)

Local and global regulations mandate safety

5

Problem to Be Solved

Example: Industrial motors often switched with hundreds of volts

Low voltage control system must interact with high voltage mains to safely operate the motor

IEC standard 61800-5-1 governs safety requirements for adjustable speed electrical power drive systems

6

What Is Isolation? Why Is it Needed?

Electrical isolation required in many applications Safety

Protect users from shock Protect equipment from shock

Performance Eliminate ground loops Provide fault tolerance Segregate noise

Circuitry must communicate and/or provide power across an isolation barrier Maintain Isolation

No current flow (or very little) High Performance

Voltage ratings, power, timing, reliability

Insulation Characteristics and Isolation Requirements

8

Types of Isolation

Functional Isolation Circuit Functionality only, not for protection Elimination of Ground Loops and Noise Fault Tolerance

Safety Isolation Protects People or Other Equipment from Shock Basic Insulation – protection from electric shock Supplemental Insulation – independent insulation in a system to protect from

faults Double Insulation – both basic and supplemental applied together Reinforced Insulation – a single insulation system demonstrated to be

equivalent to double insulation

9

Reinforced Insulation

Double insulation is created with independent basic and supplemental insulation applied to the same interface This is not always practical when high precision or high speed signals need to

pass across the isolation barrier Analog degradation and digital timing errors accumulate with each barrier

crossing

Reinforced insulation allows a single insulation system to be classified as robust as double insulation Components may need to meet additional structural requirements

Minimum thickness of solid insulation Multiple layers of film insulation Increased creepage and clearance

Additional type testing during qualification Thermal cycling Surge

Additional assembly line tests Partial discharge

10

Parameters that Characterize Isolation

Insulation Grade• Basic • Supplementary• Reinforced

Working Voltage Across a Barrier• Distance along surface to protect from tracking (creepage)• Insulation lifetime

Transient Voltage• Distance through air that would prevent arcing (clearance)• Distance through Insulation (internal clearance)• Distance along material boundaries• Breakdown threshold of the insulation

Environment of the Application• Type of contamination at the isolation barrier• Air pressure range (altitude of operation)

20um

PolyimideIsolation

11

Creepage and Clearance for IC Packages

Wide SO-16 Package Creepage 7.6mm Clearance >8mm

Creepage Shortest distance across a

surface between conductive parts Package limitation is the end

Clearance Shortest distance through the air

between conductive parts Board limited by pads < package

7.6mm

Board and Package Have Different MeasurementsWhen Combined the Minimum Sets the System Limit

12

Insulation Lifetime

Testing Is Time Consuming Accelerated testing (above maximum working voltage) must be used Models are used to extrapolate lifetime from shorter term data

None of the Standards Effectively Addresses Coupler Lifetime Only VDE has something that is intended to simulate a life test and it is a pass

fail under a set of test conditions Not useful for real verification of lifetime

Manufacturers Test Their Own Parts Digital isolators use 2 types of insulating materials (polyimide and SiO2)

Understand the wear out mechanisms for both materials Continue to test to better understand wear out and lifetime characteristics

Safety Certifications

14

Goals of a Safety Standard

Application of a safety standard is intended to reduce the risk of injury or damage due to the following Electric shock Energy related hazards Fire Heat related hazards Mechanical Hazards Radiation Chemical hazards

15

Standards Bodies and Agencies

Standards Bodies Develop the Master Standard for a System or Component IEC – International Electrical Commission – Worldwide UL – Underwriters Laboratories – North America VDE – in Europe For electrical safety, rules seem to be harmonizing with IEC

Regional Standards Bodies Interpret worldwide standards for application to the local region

Local line voltage requirements Infrastructure specific modifications (power quality) Environmental differences (altitude in China, humidity in Brazil) Political leverage

Test Agencies Provide testing and certification services

16

Types of Standards

Most Common Systems Level Standards Determine components specs based on system requirements

IEC 60664-1: Insulation Coordination IEC 60950-1: Information Systems IEC 60601-1: Medical Equipment IEC 61010-1: Instrumentation IEC 61800-5: Motor Drives and Inverters

Piece Part Level Standards Certify that components meet the manufacturers safety specifications, not

certify to application requirements UL 1577: Used for All Isolators IEC 60747-5: Optocoupler Isolators VDE 0884-10: Nonoptocoupler Isolators – Reinforced Only

17

System and Component Standards

All system level standards address safety isolation so that requirements for the system can be used to evaluate components

System level specs can put unrealistic requirements on the internal construction of components

If a component standard exists, it supersedes the requirements of the system standard Certified components can be treated as black boxes

internally

IEC61010-1 System Level

VDE-0884-10 Component Level

18

CB Certifications and China (CCC)

Each IEC Standard Is Tailored to Its Market Segment For the safety standards the world is harmonizing quickly In most parts of the world if you have a certification for the end product at one of

the larger testing organizations like TUV it will be applicable over most of the world

There are still testing and regulatory differences

CB Certification Reviews Your Certification Against All of the Other Flavors of the Same Standard and Reconciles the Differences At the piece part level it was optional to get a CB cert until recently China has issued their own set of standards, which are nearly identical to IEC

standards with a few local differences such as high altitude requirements. The CB certification allows a manufacturer to get the CCC version of the

certification with little or no test. CCC does not recognize external versions of the standards CCC also requires direct inspection of manufacturing facilities periodically This is costly to set up, but is required for all CCC certifications

19

iCoupler Products Meet Many System and Component Standards

www.analog.com/icoupler Safety and Regulatory Compliance

Advantages of iCoupler Products over Optocouplers

Optocoupler Technology

Signal Isolator of Choice for Decades The standard for low-cost isolation

GaAs or GaAlAs LEDs Emit Light When Current Passes Through It 5‒20mA typically used Speed is directly correlated to current

Photodetector Absorbs Light and Turns It into Current

Current Transfer Ratio (CTR) Defines Performance

21

LED

Photodetector

Additional Isolation for Higher Performance

22

Advantages of iCoupler Technology over Optocouplers Performance

4× improvement in data rate and timing specifications

Integration Multiple isolation channel integrated with other functions reduces size and cost

Power Consumption Operates at levels up to 90% lower than optocouplers

Ease of Use Standard digital CMOS interfaces means no external components needed to

connect to other digital devices

Reliability Eliminate LEDs used in optocouplers

23

Performance Benefits – Data Rate and Timing

High Speed

Medium Speed

ParameterAnalog DevicesADuM128xCR

iCouplerOptocoupler 1 Optocoupler 2

Max. Data Rate (Mbps) 100 25 50

Prop. Delay (ns) 24 40 22

Part to Part Match (ns) 9 20 16

Pulse Width Distortion (ns) 2 6 2

ParameterAnalog DevicesADuM128xBRDual iCoupler

Dual Optocoupler

Max. Data Rate (Mbps) 25 10

Prop. Delay (ns) 35 100

Part to Part Match (ns) 12 40

Channel-to-Channel Match (ns) 6 Unspecified

Pulse Width Distortion (ns) 3 35

24

Integration Benefits – 30%–60% Cost/Size Reduction vs. Optocoupler Solution

Component Count: 3Board Area: 160 sq. mmTotal Cost: $2.55

ADuM1401B: $2.40Discretes (2): $0.03Placement Costs: $0.12

Component Count: 3Board Area: 160 sq. mmTotal Cost: $2.55

ADuM1401B: $2.40Discretes (2): $0.03Placement Costs: $0.12

Component Count: 18Board Area: 425 sq mmTotal Cost: $5.75

Opto (2): $2.50Dual Opto: $2.50Discretes (15): $0.21Placement Costs: $0.54

Component Count: 18Board Area: 425 sq mmTotal Cost: $5.75

Opto (2): $2.50Dual Opto: $2.50Discretes (15): $0.21Placement Costs: $0.54

C2C1

10

mm

16 mm

DataConverter Data

Converter

R5

R6

R7

R8

D1

D2

C2

C3

25

mm

17 mm

D4

R7

R1

R2

R3

R4

D3

C1

Vendor-recommended Interface Circuit

ADuM1401

DualOpto

Opto

Opto

(10K OEM pricing)

iCoupler Solution Optocoupler Solution

Wide Array of Integration Possibilities

25

Isolated Data Channels 1–6 channels Options for speed, temp, and ACQ-100

isoPower Isolated dc-to-dc power and data in 1 package Up to 500 mW isolated power

Communications USB I2C SPI RS-485 RS-232 CAN

Gate Drivers Half-bridge MOSFET drivers Gate drivers with isoPower

Isolated - ADCs 16-bit

Isolated Energy Metering

26

Over a Decade of Innovation and Reliability

27

1

10

100

1000

0.01 0.1 1 10 100

Po

we

r C

on

su

mp

tio

n (

mW

)

Data Rate (Mbps)

Optocouplers

iCoupler®

Power Consumption Benefits –Up to 90% Reduction vs. Optocouplers

Reduced Heat Dissipation

Improved Reliability

Reduced Performance Variation

Reduced Cost

28

Ease of Use Advantages

Perceived Strength of Optocouplers Is Low Cost Inexpensive components don’t mean an inexpensive solution

Design Constraints Downside of Optocouplers Upside of iCoupler Tech.

Board Layout Multiple components needed Single component

Interface to Other Components

Complex application circuits for each instance

Standard TTL or CMOS

Power SupplyIncreases need for more expensive

power suppliesPower supply flexible to budget

Timing/Bandwidth Requirements

Pay for higher performing components OR can’t meet

requirements

Components flexible to meet requirements

TemperatureDesign considerations needed to account for current transfer ratio

(CTR)

No CTR; stable operation over temperature

System CostLack of integrated features drives up

system costComplete, integrated solutions

limit overall BOM cost

Reliability and Quality BenefitsSingle Digit ppm and Automotive Qualification

29

iCoupler Products Have the Same Safety Approvals asHigh Quality Optocouplers (UL, CSA, VDE)

100% Production Testing Is Performed at up to 6 kV rms

Parameter

Optocouplers

Analog Devices

iCoupler Products

iCoupler Technology Benefits

Active Devices LEDs, Photodiodes, (Silicon Transistors)

0.6 micron CMOS No LED Wearout

FIT Rate <10

Insulation Discrete,

Assembly-Level Polyimide,

Wafer-Level

Semiconductor clean-room environment, control, and consistency

Thermal Dissipation 50 mW to 200 mW

per channel

1mW to 10 mW per channel

(data rates < 10 Mbps)

Increased lifetime

Negligible heating of adjacent components

Safety reports available at: www.analog.com/iCoupler

Application Example:Isolated DC-to-DC Converter

31

Design of an Isolated DC-to-DC Power Supply

Low power (<2.5 W) isolated DC-to-DC power is used in many applications: Isolated USB interface Smart sensor

For most of these applications, the typical technical requirements are: High isolation voltage: 2.5 kV rms to

5.0 kV rms Low output voltage ripple: 1% of output voltage Excellent output voltage regulation: 1% over

line and load Small size Long-term reliability: 20 to 50 years

32

Design of a 2.5 W Isolated DC-to-DC Power Supply

The Function of an Isolated DC-to-DC Converter: Provide a stable dc power supply to the secondary side Provide good load regulation and load transient response Closed-loop control is required to provide good load regulation and transient

response

Two Main Topologies: Primary-side control: Output voltage information must be transferred from the

secondary side to the primary side. Secondary-side control: Output voltage is divided down and connected to a

secondary-side controller. The switching control signals are then sent to the primary side to control the switches.

33

Primary-Side Controller with an Optocoupler for Isolated Feedback from Secondary to Primary

Optocoupler for feedback has many limitations CTR degradation over time can destabilize the loop Optocoupler added components waste power, add size and cost Slow loop response due to limited dynamic range of optocoupler

A complicated multiorder RC network is needed to compensate the loop

Control Logic

VIN

SW

VOUT

GND1

GND2

VREF

Type II or III Network

Shunt Regulator (with Error Amp)

Opto-Coupler

Controller

34

Limitations of a Primary-Side Sensing Flyback Regulator

The output voltage information can be derived from the flyback voltage, but the secondary diode voltage and its temperature dependence can affect the output regulation

Need to design an external compensation network for the primary-side sensing controller, which adds complexity, size, and cost

VIN

GND1

GND2

VREF

Control Logic

Controller

CompensationNetwork

VFLYBACK ~= (VOUT + VDIODE)*(NPRI/NSEC)

VDIODET1NPRI/NSEC

VOUT

35

New Technology: Primary- and Secondary-Side Control for Isolated DC-to-DC Switching Regulator

Optimizes Control with Integrated Feedback Secondary-side controller sends PWM signal to primary-side controller

Easier to Design with than Optocoupler-Based Solutions All loop compensation is internal All feedback is internal with no optocoupler CTR degradation issues

Faster More Accurate Output Output voltage is sensed on the output side

VIN

FB

VOUT

GND1 GND2

VREF

X1X2

Primary Control Logic

Secondary Control Logic

CompensationNetwork

ADuM3070

36

ADuM3070 Isolated Switching Regulator

2.5 W Isolated DC-to-DC Converter 80% Efficiency

Integrated Secondary-Side andPrimary-Side Controllers Secondary-side sensing Isolated feedback to improve

light load efficiency

Integrated Transformer Driver

Soft Start and Thermal Shutdown

Regulated Output Voltage Between 3.3 V to 30 V

Adjustable Internal Oscillator Between 200 kHz and 1 MHz

2500 V rms 1 Minute Withstand Isolation Rating

16-Lead QSOP package

–40°C to +105°C

ADuM3070

1043

7-00

1

PRIMARYCONVERTER/

DRIVER SECONDARYCONTROLLER

INTERNALFEEDBACK

VDD2

OC

FB

VREG

VDD1 VISO

VDDA

X2X1

GND1 GND2

REG

RECT

5V

37

Comparing ADuM3070 with Primary-Side Sensing Flyback Regulator

The larger output ripple of the primary sensing flyback regulator is due to the DCM (discontinuous conduction mode) control while the ADuM3070 uses CCM (continuous conduction mode).

The DCM mode allows the voltage on the output capacitor of the primary sensing flyback to droop when the secondary current is zero in discontinuous mode.

40 mV p-p 500 kHz ripple 100 mV p-p 200 kHz ripple

38

Accuracy of iCoupler Switching Regulator vs. Primary-Side Sensing Flyback

0 50 100 150 200 250 300 350 400 450 5000

10

20

30

40

50

60

70

80

90Efficiency

Flyback

ADuM3070

Load Current (mA)

Eff

icie

ncy

(%

)

50 100 150 200 250 300 350 400 450 5004.95

4.96

4.97

4.98

4.99

5.00

5.01

5.02

5.03 Load Regulation

Flyback Solution

ADuM3070 Solu-tion

Load Current (mA)

Ou

tpu

t V

olt

age

(V)

-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 1004.90

4.92

4.94

4.96

4.98

5.00

5.02

5.04Temperature Performance

Flyback Solution

ADuM3070 Solution

Ambient Temperature (°C)

Ou

tpu

t V

olt

age

(V)

39

Isolated DC-to-DC Switching Regulator Portfolio

Isolation Rating Functionality Package Status

ADuM347x 2.5 kV rms 4 Channel + Switching Regulator SSOP-20 Released

ADuM3070 2.5 kV rms Switching Regulator Only QSOP-16 Released

ADuM4070 5 kV rms Switching Regulator Only WSO-16 Released

ADuM447x 5 kV rms 4 Channel + Switching Regulator WSO-20 Released

Isolated Switching Controllers Are Available with Digital Isolators – ADuM347x

5 kV rms Reinforced Isolators in Certified 8 mm Creepage With and Without Quad Digital Isolators Also Available

40

Benefits of iCoupler Isolated Switching Regulators

Versus Discrete Optocoupler-Based Regulated Solutions Less complicated design with internal feedback compensation Faster response Stable operation over lifetime

Versus Primary-Side Sensing More accurate Better response over temperature Faster response

Versus Discrete Power and Data Isolation Smaller size through higher levels of integration Higher efficiency than open loop designs with output regulators

Application Example:Isolated Half-Bridge Gate Drivers

42

Fundamentals of Implementing an IsolatedHalf-Bridge Gate Driver

Typical Application Secondary power supply for high voltage power supplies and inverters:

Strings of PV Panels

~ AC Grid

DC/DC Boost

==

DC/AC Inverter

=~

43

Function of an Isolated Half-Bridge Gate Driver

To drive the gates of high- and low-side N-channel MOSFETs (or IGBTs)

To provide a low output impedance to reduce the conduction losses

Have a fast switching time to reduce the switching losses

The high- and low-side drivers need very close matching of the timing characteristics to allow accurate and efficient switching

This reduces the dead-time from one switch of the half bridge turning off before the second switch turns on

44

Approaches

High Voltage Half-Bridge Gate Driver

Optocoupler Half-Bridge Gate Driver

Pulse Transformer Half-Bridge Gate Driver

Digital Isolator Gate Driver

45

High Voltage Half Bridge Gate Driver

Limitation #1: Only one isolated input channel, relying on the high voltage driver to have the needed matching in the timing between channels, but the level shifter adds time delay between the channels

Limitation #2: High voltage gate drivers do not have galvanic isolation and rely instead on junction isolation to separate the high-side drive voltage from the low-side drive voltage in the same IC Parasitic inductance in the circuit can cause the output voltage, VS, to go below ground

during a low-side switching event When this happens, the high side driver can latch-up and become permanently damaged

46

Optocoupler Half-Bridge Gate Driver

2 optocouplers + 2 gate drivers = large solution size

Optocouplers are discrete devices with limited in channel-to-channel matching Dead-time increases, adding to switching losses and reduced efficiency

Increased optocoupler speed is based on increasing LED current, which reduces lifetime and consumes power

47

Pulse Transformer Half-Bridge Gate Driver

An advantage of using a pulse transformer is that it does not require isolated power supplies to drive the secondary side MOSFETs

A potential problem in this application can occur when large transient gate drive currents flow in the inductive coils, causing ringing Can switch the gate on and off when not intended, leading to damage of the

MOSFETs

Magnetic core and isolated windings of the pulse transformer require a relatively large package

48

Digitally Isolated Gate Driver

Uses a standard CMOS integrated circuit process with metal layers to form transformer coils separated by 20 µm of rugged polyimide insulation Use in reinforced applications > 5 kV rms Isolation 50 year lifetime with 400 V rms working voltage and 700 V peak between the

outputs

ADuM3223 (3 kV rms) and ADuM4223 (5 kV rms)Half-Bridge Gate Drivers

49

Fast Timing <50 ns total propagation delay <5 ns delay matching

High Reliability 50 year lifetime for 400 V rms

working voltage 125ºC Operation

Integral Features Up to 5 kV rms input-output isolation 700 V galvanic isolation between

outputs 4 A peak current drive 4.5 V to 18 V output range Disable pin UVLO on VDDA and VDDB Thermal shutdown

Improves the Performance and Efficiency of: AC/DC power supplies DC/DC power supplies Solar inverters Motor control

VOB

VOA

VDDB

VSSA

VDDA

VSSB

VIA

VIB

VDis

50

Importance of Common-Mode Transient Immunity (CMTI) in High Voltage Gate Drivers

In half-bridge gate driver applications for high voltage power supplies, very fast transients can occur across the switching MOSFETs

A large dV/dt across the isolation barrier has the potential to cause logic transition errors

Optocouplers have very sensitive receivers to detect the light transmitted across their isolation barrier, and their outputs can be upset by large common mode transients

Optocouplers are only immune up to 25 kV/µs

51

Capacitor-Based Digital Isolator with CMTI< 25 kV/µs

With a 2-terminal device the signal frequencies need to be well above the expected frequency of the noise so that the barrier capacitance presents low impedance to the signal and high impedance to the noise When the common-mode noise level becomes large enough to overwhelm the

signal, it can cause a data upset at the isolator output

Capacitor-based digital isolator with CMTI of < 25 kV/µs

2-terminal device:capacitor-based digital isolator

52

Transformer-Based Digital Isolator with CMTI> 50 kV/µs

Digital isolators with transformer isolation can deliver higher signal levels to their receivers and withstand >50 kV/µs without data errors Transformer-based isolators are 4-terminal devices with low differential

impedance to the signal and high common-mode impedance to the noise, which can yield excellent CMTI

Transformer-based digital isolator with CMTI of >50 kV/µs

4-terminal device:transformer-based digital isolator

53

Benefits of Isolated Half-Bridge Gate Drivers

The solution size and design complexity are dramatically reduced through integration

This leads to improved timing performance

Robustness is also improved through galvanic isolation of the output drivers and higher CMTI

54

What Did We Cover Today?

Discussed the need for galvanic isolation to provide safety and/or performance benefits

Reviewed insulation characteristics and physical characteristics of isolators that are impacted by voltage requirements

Examined the differences between system level and component level safety certifications

Highlighted the advantages of iCoupler digital isolators over optocouplers

Detailed two applications that benefit from the performance characteristics offered by digital isolators

55 Tweet it out! @ADI_News #ADIDC13

Design Resources Covered in This Session

Design Tools and Resources:

Ask technical questions and exchange ideas online in our EngineerZone™ Support Community Choose a technology area from the homepage:

ez.analog.com Access the Design Conference community here:

www.analog.com/DC13community

Name Description URL

IBIS Models Input-Output Buffer Interface Standard (IBIS) Models for Signal Integrity Simulations

iCoupler IBIS Models

Circuitsfrom theLab

H-Bridge Driver Circuit Using Isolated Half-Bridge Drivers

CN0196

Low Cost, 16-Bit, 250 kSPS, 8-Channel, Isolated Data Acquisition System

CN0254

Universal Serial Bus (USB) Cable Isolator Circuit CN0159

Videos iCoupler Digital Isolator Video Library Video Library

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Selection Table of Products Covered Today

Part number Description

ADuM3070 2.5 kV rms Isolated Switching Regulator with Integrated Feedback

ADuM347x 2.5 kV rms Isolated Switching Regulator with Quad-Channel Isolators

ADuM4070 5.0 kV rms Isolated Switching Regulator with Integrated Feedback

ADuM447x 5.0 kV rms Isolated Switching Regulator with Quad-Channel Isolators

ADuM3223 3.0 kV rms Isolated Precision Half-Bridge Driver, 4 A Output

ADuM4223 5.0 kV rms Isolated Precision Half-Bridge Driver, 4 A Output

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Visit the ezLINX Demo in the Exhibition Room

Design Tool to Help Customers Design with ADI’s Isolated Transceiver Products

Rapid Design and System Evaluation Isolated communication networks

Open-Source Hardware and Software Environment 8 different isolated physical layer

communication standards Isolated USB, RS-485, RS-422,

CAN, RS-232, SPI, I2C and LVDS

Demo Showing Live Isolated CAN Network This demo board is available for purchase:

www.analog.com/DC13-hardware