Isolation is an integral part of many modern applications from medical to instrumentation to industrial. Most applications require the designer to integrate isolation in the design while improving performance, saving board space, increasing reliability levels, reducing power consumption, and, of course, cutting cost. This session provides an understanding of various isolator technologies, and offers suggestions on how to address such stringent design objectives.
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
3
4. Problem to Be Solved
4
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
5
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
6
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
8
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
9
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)
10
20um
Polyimide
Isolation
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
11
7.6mm
Board and Package Have Different Measurements
When 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
12
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
14
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
15
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
16
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
17
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
18
19. iCoupler Products Meet Many System and
Component Standards
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www.analog.com/icoupler Safety and Regulatory Compliance
21. 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
22
23. Performance Benefits – Data Rate and Timing
23
High Speed
Medium Speed
Parameter
Analog Devices
ADuM128xCR
iCoupler
Optocoupler 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
Parameter
Analog Devices
ADuM128xBR
Dual 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
25. 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
27. 1
10
100
1000
0.01 0.1 1 10 100
PowerConsumption(mW)
Data Rate (Mbps)
Power Consumption Benefits –
Up to 90% Reduction vs. Optocouplers
27
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
28
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 Supply
Increases need for more expensive
power supplies
Power supply flexible to budget
Timing/Bandwidth
Requirements
Pay for higher performing components
OR can’t meet requirements
Components flexible to meet
requirements
Temperature
Design considerations needed to
account for current transfer ratio
(CTR)
No CTR; stable operation over
temperature
System Cost
Lack of integrated features drives up
system cost
Complete, integrated solutions
limit overall BOM cost
29. Reliability and Quality Benefits
Single Digit ppm and Automotive Qualification
29
iCoupler Products Have the Same Safety Approvals as
High 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
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
31
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.
32
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
33
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
34
VIN
GND1
GND2
VREF
Control
Logic
Controller
Compensation
Network
VFLYBACK ~= (VOUT + VDIODE)*(NPRI/NSEC)
VDIODE
T1
NPRI/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
35
VIN
FB
VOUT
GND1 GND2
VREF
X1
X2
Primary
Control
Logic
Secondary
Control
Logic
Compensation
Network
ADuM3070
36. ADuM3070 Isolated Switching Regulator
2.5 W Isolated DC-to-DC Converter
80% Efficiency
Integrated Secondary-Side and
Primary-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
36
ADuM3070
10437-001
PRIMARY
CONVERTER/
DRIVER SECONDARY
CONTROLLER
INTERNAL
FEEDBACK
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.
37
40 mV p-p 500 kHz ripple 100 mV p-p 200 kHz ripple
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
39
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
40
42. Fundamentals of Implementing an Isolated
Half-Bridge Gate Driver
Typical Application
Secondary power supply for high voltage power supplies and inverters:
42
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
43
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
45
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
46
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
47
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
48
49. 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
50
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
51
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
52
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
53
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
54
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
55
Name Description URL
IBIS Models Input-Output Buffer Interface Standard (IBIS) Models for
Signal Integrity Simulations
iCoupler IBIS
Models
Circuits
from the
Lab
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
56. Tweet it out! @ADI_News #ADIDC13
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
56
57. Tweet it out! @ADI_News #ADIDC13
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
57
This demo board is available for purchase:
www.analog.com/DC13-hardware