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Data and Power Isolation
Advanced Techniques of Higher Performance Signal Processing
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2
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
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
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
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
Insulation Characteristics and
Isolation Requirements
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
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
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
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
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
Safety Certifications
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
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
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
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
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
iCoupler Products Meet Many System and
Component Standards
19
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
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
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
Integration Benefits – 30%–60% Cost/Size
Reduction vs. Optocoupler Solution
24
Component Count: 3
Board Area: 160 sq. mm
Total Cost: $2.55
ADuM1401B: $2.40
Discretes (2): $0.03
Placement Costs: $0.12
Component Count: 18
Board Area: 425 sq mm
Total Cost: $5.75
Opto (2): $2.50
Dual Opto: $2.50
Discretes (15): $0.21
Placement Costs: $0.54
C2C1
10mm
16 mm
Data
Converter Data
Converter
R5
R6
R7
R8
D1
D2
C2
C3
25mm
17 mm
D4
R7
R1
R2
R3
R4
D3
C1
Vendor-recommended
Interface Circuit
ADuM1401
Dual
Opto
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
Over a Decade of Innovation and Reliability
26
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
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
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
Application Example:
Isolated DC-to-DC Converter
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
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
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
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
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
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
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
Accuracy of iCoupler Switching Regulator vs.
Primary-Side Sensing Flyback
38
0
10
20
30
40
50
60
70
80
90
0 100 200 300 400 500
Efficiency(%)
Load Current (mA)
Efficiency
Flyback
ADuM3070
4.97
4.98
4.99
5.00
5.01
5.02
5.03
50 100 150 200 250 300 350 400 450 500
OutputVoltage(V)
Load Current (mA)
Load Regulation
Flyback Solution
ADuM3070
Solution
4.90
4.92
4.94
4.96
4.98
5.00
5.02
5.04
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100
OutputVoltage(V)
Ambient Temperature ( C)
Temperature Performance
Flyback Solution
ADuM3070 Solution
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
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
Application Example:
Isolated Half-Bridge Gate Drivers
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
=
~
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
Approaches
High Voltage Half-Bridge Gate Driver
Optocoupler Half-Bridge Gate Driver
Pulse Transformer Half-Bridge Gate Driver
Digital Isolator Gate Driver
44
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
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
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
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
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
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
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
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
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
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
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
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
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

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Data and Power Isolation (Design Conference 2013)

  • 1. Data and Power Isolation Advanced Techniques of Higher Performance Signal Processing
  • 2. Legal Disclaimer  Notice of proprietary information, Disclaimers and Exclusions Of Warranties The ADI Presentation is the property of ADI. All copyright, trademark, and other intellectual property and proprietary rights in the ADI Presentation and in the software, text, graphics, design elements, audio and all other materials originated or used by ADI herein (the "ADI Information") are reserved to ADI and its licensors. The ADI Information may not be reproduced, published, adapted, modified, displayed, distributed or sold in any manner, in any form or media, without the prior written permission of ADI. THE ADI INFORMATION AND THE ADI PRESENTATION ARE PROVIDED "AS IS". WHILE ADI INTENDS THE ADI INFORMATION AND THE ADI PRESENTATION TO BE ACCURATE, NO WARRANTIES OF ANY KIND ARE MADE WITH RESPECT TO THE ADI PRESENTATION AND THE ADI INFORMATION, INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF ACCURACY OR COMPLETENESS. TYPOGRAPHICAL ERRORS AND OTHER INACCURACIES OR MISTAKES ARE POSSIBLE. ADI DOES NOT WARRANT THAT THE ADI INFORMATION AND THE ADI PRESENTATION WILL MEET YOUR REQUIREMENTS, WILL BE ACCURATE, OR WILL BE UNINTERRUPTED OR ERROR FREE. ADI EXPRESSLY EXCLUDES AND DISCLAIMS ALL EXPRESS AND IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE AND NON-INFRINGEMENT OF ANY THIRD PARTY INTELLECTUAL PROPERTY RIGHTS. ADI SHALL NOT BE RESPONSIBLE FOR ANY DAMAGE OR LOSS OF ANY KIND ARISING OUT OF OR RELATED TO YOUR USE OF THE ADI INFORMATION AND THE ADI PRESENTATION, INCLUDING WITHOUT LIMITATION DATA LOSS OR CORRUPTION, COMPUTER VIRUSES, ERRORS, OMISSIONS, INTERRUPTIONS, DEFECTS OR OTHER FAILURES, REGARDLESS OF WHETHER SUCH LIABILITY IS BASED IN TORT, CONTRACT OR OTHERWISE. USE OF ANY THIRD-PARTY SOFTWARE REFERENCED WILL BE GOVERNED BY THE APPLICABLE LICENSE AGREEMENT, IF ANY, WITH SUCH THIRD PARTY. ©2013 Analog Devices, Inc. All rights reserved. 2
  • 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 19 www.analog.com/icoupler  Safety and Regulatory Compliance
  • 20. Advantages of iCoupler Products over Optocouplers
  • 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
  • 24. Integration Benefits – 30%–60% Cost/Size Reduction vs. Optocoupler Solution 24 Component Count: 3 Board Area: 160 sq. mm Total Cost: $2.55 ADuM1401B: $2.40 Discretes (2): $0.03 Placement Costs: $0.12 Component Count: 18 Board Area: 425 sq mm Total Cost: $5.75 Opto (2): $2.50 Dual Opto: $2.50 Discretes (15): $0.21 Placement Costs: $0.54 C2C1 10mm 16 mm Data Converter Data Converter R5 R6 R7 R8 D1 D2 C2 C3 25mm 17 mm D4 R7 R1 R2 R3 R4 D3 C1 Vendor-recommended Interface Circuit ADuM1401 Dual Opto Opto Opto (10K OEM pricing) iCoupler Solution Optocoupler Solution
  • 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
  • 26. Over a Decade of Innovation and Reliability 26
  • 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
  • 38. Accuracy of iCoupler Switching Regulator vs. Primary-Side Sensing Flyback 38 0 10 20 30 40 50 60 70 80 90 0 100 200 300 400 500 Efficiency(%) Load Current (mA) Efficiency Flyback ADuM3070 4.97 4.98 4.99 5.00 5.01 5.02 5.03 50 100 150 200 250 300 350 400 450 500 OutputVoltage(V) Load Current (mA) Load Regulation Flyback Solution ADuM3070 Solution 4.90 4.92 4.94 4.96 4.98 5.00 5.02 5.04 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 OutputVoltage(V) Ambient Temperature ( C) Temperature Performance Flyback Solution ADuM3070 Solution
  • 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
  • 44. Approaches High Voltage Half-Bridge Gate Driver Optocoupler Half-Bridge Gate Driver Pulse Transformer Half-Bridge Gate Driver Digital Isolator Gate Driver 44
  • 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