integrating speed and flexibility isolating industrial control
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Integrating Speed and Design Flexibility with the Si838x
Industrial Automation - Applications & Challenges
Introduction - Isolation Products
Industrial Product Portfolio – Products That Solve Problems
Si838x – PLC input modules isolators
Si88xx – Isolators with integrated dc/dc
Si82xx – Industrial MOSFET & IGBT drivers
Si892x – Analog isolators
Product Tools to Accelerate Design
Agenda
Industrial Automation Applications
Industrial Automation - Challenges
No Compromise on Safety
Safety features are critical
Products should have stable performance under high stress
High Noise Environment
High noise immunity to external electrical/magnetic fields
High immunity to high voltage noise transients
Long Product Lifetimes
Key parameters should be stable over temp, VDD and age
Products should have long lifetime under high stress
High Performance
Product performance levels should be world class
Low latency & skew ensure high efficiency and throughput
Bottom Line
High performance isolation products provide safety and high noise
immunity with long lifetimes
Introduction – Isolation Products
6 Silicon Labs ConfidentialSilicon Laboratories Confidential
Why Isolate?
Common isolation usage examples
Safety Isolation protects electronics systems & people
Here, 400V is isolated from a 3.3V MCU
Level Shifting VDD1 and VDD2 can be different levels
Noise elimination Ground currents do not disturb sensitive circuit
IN
GND1 GND2
OUT
VDD1 VDD2
CM
OS
Iso
lati
onMCU
Low Voltage3.3V
High voltage400 V
2x FET driver
3.3V
Safety from high voltages
Power MOSFETs
2.7V 5.5V
2.7V
GND1
5.5V
GND2
Level Shifting
IN
GND1 GND2
OUT
VDD1 VDD2
CM
OS
Iso
lati
on
Noise sensitive input
IN
GND1 GND2
OUT
VDD1 VDD2
CM
OS
Iso
lati
onMCU
Eliminates noise by cutting ground loop
ADCHigh
current I/O
High noise on GND2
7 Silicon Labs Confidential
Traditional Isolation Used Optical Coupling
Poor reliability
Key parameters drift over temperature, VDD and age
Poor timing characteristics
Long delay times slow system throughput
Key parameters (e.g. jitter) often not specified
Marginal common mode transient immunity
(CMTI)
Fast common mode transients can corrupt data
Additional BOM required to meet CMTI requirements
Energy inefficient
Requires high current – increases overall energy consumption
8 Silicon Labs Confidential
Isolation using non-optical (CMOS) capacitive coupling CMOS based design uses On-Off Key Modulation
Uses differential capacitive coupling
High voltage components are capacitors
High reliability
Inherent stability over temperature, VDD and age
CMOS isolator reliability is 10x that of optos
Excellent timing characteristics
Low propagation delay
Low skew – excellent part to part matching
High common mode transient immunity (CMTI)
High performance digital isolators achieve 200 kV/µs
Low power
Highly efficient digital isolators require a fraction of the power
compared to optos
Application Specific Challenges
Programmable Logic Controllers (PLC)
Industrial I/O modules
CNC machines
Servo motor control
Process Automation Controllers (PAC)
Process control using distributed control systems
PLC - Industrial Machine Control & Process Automation
Transceiver forCommunication
PLC OutputDriver
P
Pressure sensor
Proximity switch
Limit switch Si838x
FIRE
Pump motor
Flow valve
Fire alarm
Relay/Solenoid
FET
PLCController
Unit
Si88xx
11 Silicon Labs Confidential
PLC systems may have 128 channels
Field inputs can be sourcing or sinking
Optos are not fast enough for servo motor control
Optos performance is poor over temp and age
Si838x solves this problem
Huge board area savings
Up to 8x channels in QSOP-20 package
Up to 16x Si838x can be daisy chained for 128 channels
One SPI interface to processor
Bipolar input capability (sourcing or sinking)
2 Mbps data rates possible for reliable servo control
High noise immunity
Problem: PLC needs fast & multiple isolated inputs
PLC board
24 V Digital Inputs
Channel 1Proximity sensor
Channel 2Pressure sensor
Channel 8
Embedded processor
24 V Digital Outputs
PLC board
Channel 1
Channel 2
Channel 8
Embedded processor
CM
OS
Iso
lati
on
1x Si838x
SPI
8x
inp
uts
12 Silicon Labs Confidential
APPLICATIONS
FEATURES
Programmable Logic Controllers (PLC)
CNC Machines
Distributed I/O
Process Automation Controllers (PAC)
Servo Motor Control
Si838x: PLC Input Isolator
8x bipolar inputs, interface to 24V digital field inputs
2 Mbps high speed channels for servo control
Parallel interface option also available
Integrated 2.5kVrms safety rated isolation
De-bounce filter
2.25 -5.5 V VDD capability for low power controller interface
Low EMI due to dithering technique used in design
IEC 61131-2 compliant, Type 1,2,3
Iso
lati
on
Bar
rier
Si8380S
e
e
e
e
e
e
e
e
SPI
VDD
GND
MISO
MOSI
SCLK
NSS
SDITHRU
A1
A2
A3
A4
A5
A6
A7
A8
COM
CM
OS
Iso
lati
on
Bar
rier
24V field side switches are connected to Si838x input through simple R network (R1, R2)
R1, R2 values ensure IEC 61131-2 compliance to Type 1,2,3 switches
App note AN 970: PLC Inputs Design Guide explains how to calculate R1, R2
Si838x: Application Diagram
Si838xP
2.2nF
Low-sideResistor
High-sideResistor AHx
InputBHx
Output
COM GND
VDD
R1
R2
VD
Field
Potential
IIN
ID
C1
24V DC
uController
Input
GND
VDDVIN
Field PLC Digital Input Module PLC
High Speed Channels Only
SensorOr Switch
Isol
atio
n B
arri
er
Current Limit
Resistor
Status Lamp LED
R3
D2
The Si8380S can be daisy chained for 128 total channels
Max SCLK frequency will be reduced based on number of devices
Daisy Chain Capability: 128 Channels
Si8380S_0M
OSI
SCLK
NSS
MIS
O
SDIT
HR
U
SPI Master
MO
SI
SCLK
NSS
MIS
O
Si8380S_1
MO
SI
SCLK
NSS
MIS
O
SDIT
HR
U
Si8380S_2
MO
SI
SCLK
NSS
MIS
O
SDIT
HR
U
Si8380S_15
MO
SI
SCLK
NSS
MIS
O
SDIT
HR
U
. . .
Real-time hierarchical control network from control room to factory floor
Connects sensors and actuators in machines and across modules
Each connecting node is a transceiver (physical layer or “PHY”), for example: RS-485
Transceiver needs to be signal and power isolated
Factory Automation - Isolating Interfaces (PHY)
ADC
ADC
ADC
Embedded processor
Power Supply
Si88xx
Temp sensor
Flow sensor
F
P
Pressure sensor
RS-485 Transceiver
CM
OS
Iso
lati
on
DCDCregulator
Digital isolationChannels
Rx/Tx
DCDCControl &
switch
Rx
Tx
VOUT
VCC
ENDigital
isolationChannels
Rx/TxA
B
16 Silicon Labs Confidential
Signal isolators solve key system issues
Provide safety from high voltages
Enable level shifting
Reduce noise
A total solution needs power isolation
Si88xx Solves the Problem
Total solution for signal & power isolation
Quad digital isolators, 100 Mbps data rate
Up to 5W dc-dc converter, 83% peak efficiency
Plug-n-play solution
Power Isolation is Difficult
Othercircuits
CM
OS
Isol
atio
n
Rx
Tx A
B
ENDigital
isolationChannels
Rx/Tx
Embedded processor
Digital isolationChannels
Rx/Tx
VDDB
VOUTVIN
VINPower Supply
Signal isolator
+
-
Power Switch
PWM Controller Opto-coupler Error Amp & Loop Compensation
VOUTTransformer
Isol
atio
n
MCU
B
A
Si88xxOther
circuits
CM
OS
Iso
lati
on
DCDCregulator
Digital isolationChannels
Rx/Tx
DCDCControl &
switch
Rx
Tx
VOUT
VCC
ENDigital
isolationChannels
Rx/TxA
B
Embedded processor
VINPower Supply
MCU
17 Silicon Labs Confidential
APPLICATIONS
FEATURES
VOUT
A1
HFRCVR
HFRCVR
HFRCVRA2
A3
A4
B1
B2
B3
B4
VDDB
VSNS
VDDA
VDD
VSW
HFRCVR
HFRCVR
UVLO
SH_FC
SS
FET
FETUVLO
Error amp &Compensation
GNDA GNDB
Si88240: 100Mbps quad digital isolator with 2W DCDC converter
UTB02185s
COMP
DC/DCcontroller
Frequency control &Shutdown ZCOMP
HFXMTR
CM
OS
Iso
lati
on
HFXMTR
HFXMTR
HFXMTR
HFXMTR
Factory automation
Automotive battery management systems (BMS)
Process & motor control
PLCs & distributed control systems
Si88xx: Multi Channel Isolator with Integrated dc-dc
Integrated dc-dc converter with secondary sensing & feedback
Internal switch: 2 W of power & 78 % efficiency
External switch: 5 W, 83% efficiency
Full featured with soft start, frequency control, shutdown options
Robust Isolation
5 kVRMS reinforced
Unmatched noise immunity of 100 kV/ms
Up to four high speed digital channels, multiple configurations
Low prop delay of 18 ns
Target Application: Power Supply Solutions
Isolated ac/dc or dc/dc basic topology: Power stage and sync FET’s need gate drivers to control switching
Critical needs Highest noise immunity to support fast switching for higher efficiency
Safety is always important
Full wave rectifier
IsolatedGate Driver
SyncFETs
Secondary Side
Controller
Power switch
DC Output Voltage
Gate Driver
AC Input Voltage
Isolated Transformer
19 Silicon Labs Confidential
Loss of VDDA/B can lead to flux imbalance
Controller needs to know output power status
Power systems need a safe initialization time
Guarantee of no unintended switching
Si8239x solves this problem
Internal UVLO feedback ensures output OFF &
status feedback to controller
EN pin ensures safe default state
Safe 1 ms startup time for initialization
Special ESD circuit prevents power up through
EN pin
Problem: Switching power safely 400 V
GND
ON
OFF
VDDAON
VDDBOFF
Controller
Iso
lati
on
Flux imbalance
400 V
GND
OFF
VDDAON
VDDBOFF
No flux imbalanceU
VLO
& s
afet
y co
ntr
ol
CM
OS
Iso
lati
on
OFF
Si8239x: Enhanced safety driver
Controller
2.5V – 5.5VVDDI
EN
RDY
20 Silicon Labs Confidential
APPLICATIONS
FEATURES
IsoDriver
Driver
UVLO
UVLO
Driver
VDDI
VIA
VIB
RDY
DT
VDDA
VOA
VOB
VDDB
UVLO
Input logic & control
Deadtime control
CM
OS
Iso
lati
on
Si8239x
Power supply
ac/dc converters
dc/dc converters
Si8239x: Drivers with UVLO Safety
UVLO safety feature – prevents flux imbalance
UVLO status feedback to controller
Optional shutdown feature on UVLO fault
2.5 V VDDI capability
1ms safe start-up delay: Allows safe system start-up
EN (active high) instead of DIS for added safety
High CMTI: 50kV/µs
21 Silicon Labs Confidential
Improves system efficiency and BOM
Reduces size, cost of capacitor and magnetics
Improves transient response
The risk is Increased switching transients: dv/dt
Skipped pulses or permanent latch-up
Si827x solves this problem High noise immunity (CMTI) of 200 kV/µs to avoid
skipped pulses
High latch-up immunity of 400 kV/µs to prevent
permanent damage from latch-up
Low 2.5 V VDDI
EN pin for safe default
Problem: Faster switching desiredTypical power converter application with
half bridge topology
VDDA
VDDB
UV
LO &
saf
ety
con
tro
l
CM
OS
Iso
lati
on
Si827x: High Noise Immunity Driver
Controller
2.5V – 5.5VVDDI
EN
Protected to 400 kV/µs
Controller
Iso
lati
on
0 V – 600 V in 5 ns
= 120 V/ns
120 kV/µs transient can cause problems
Driver
600 V
GND
High side MOSFET
Low side MOSFET
600 V
GND
High side MOSFET
Low side MOSFET
22 Silicon Labs Confidential
APPLICATIONS
FEATURESCM
OS Iso
lati
on
Driver
Control
UVLOVDDI
VIA/PWM
VIB/DT
GNDA
VOA
UVLO VDDA
GNDA
VOB
UVLO VDDB
GNDB
Enable
Power supplies
Class-D audio amps
dc/dc converters
Si827x: Drivers with high CMTI
High CMTI (dV/dt immunity)
200kV/us for data & 400kV/us for latch-up
Low jitter and skew
1ns max jitter, 5ns max output skew
2.5V VDDI capability, 30V VDDA/B
Optional separate outputs for pull-up/down on single channel
CM
OS
Isola
tion
Driver
Control
UVLOVDDI
VI
GNDI
VO+
VO+
UVLO VDDA
GNDA
Enable
Drive stage for AC induction motor has multiple stages to provide power to motor through IGBTs
Current/voltage feedback is provided for control loop
Critical needs for drivers
Integrated IGBT protection features, low latency, high noise immunity & wide temp range supported
Critical needs for current sensing
High noise immunity, low delay, accuracy over temperature
Motor Control
DC LINK(+)
DC LINK(-)
Si8920
3xSi8920
Si828x
Si828x
Si828x
Si828x
Si828x
Si828x
24 Silicon Labs Confidential
APPLICATIONS
FEATURESCM
OS Iso
lati
on
DESAT
Detection
Fault and
Reset
Miller
Clamp
Input
Control
UVLO UVLOVDDA
RDY
IN+
IN-
GNDA
RST
VDDB
CLMP
VH
VL
GNDB
VMID
DSAT
FLT
dc/dc
Controller
and
Switches
VDDP
VSW
GNDP
dc/dc
Regulator COMP
VSNS Motor drive inverters
Solar inverters
High power converters
Si8281: Isolated IGBT driver with dc-dc converter
Integrated isolated dc/dc controller
Orderable option to use higher voltage power rail (> 5.5 V)
Options for frequency and soft-start control
IGBT driver only option with no dc/dc also available
Unique integrated DC/DC significantly simplifies layout
A single power bus routed across system – no complicated spacing concerns
Each driver creates its own power supply - supplies kept local to each driver
Local power reduces inductance, improves noise, and removes transients
Results in more compact and smaller PCB
Si828x Simplifies PCB Layout
26 Silicon Labs Confidential
Sensor has to be electrically isolated from controller
Systems are noisy
Sensors have large delays limiting response time
Accuracy over temperature difficult to maintain
Si8920 iso amp is the solution… Robust galvanic isolation keeps controller safe
Low signal delay; controller can respond quickly
Tiny offset/gain drift insures accuracy
Excellent transient noise immunity
Problem: Current Measurement in HV Systems
System
Controller
600V
Isolation
Si8920
System
Controller
600V
I?
27 Silicon Labs Confidential
APPLICATIONS
Benefits
Motor drive inverters
Solar inverters
High power converters
Si8920 : Isolated analog amplifier for current sense
Low voltage, differential input connects directly to shunt resistor
±100mV (16x gain) or ± 200mV (8x gain), ±1% max gain error
Low group delay allows fast response
0.75 µs
High bandwidth, low noise – allows wide usage with high accuracy
0.03mVrms over 400kHz, 0.2% non-linearity
High working voltage allows connection to high voltage bus
1200V working voltage, 20+ years lifetime at working voltage
CM
OS Iso
lati
on
Mod
UVLO UVLOVDDB
AIP
AIN
GNDB
VDDA
AOP
AON
GNDA
DeMod
Industrial Product Portfolio
Silicon Labs Industrial Portfolio
Si86xx
• 1-6 ch, 5kVrms
• Pin matched - ADI, TI
• Faster, less noise
Si88xx
• Si86xx + dc/dc
• 5W power, 80% eff
• Low noise
Si86xxT
• Si86xx + 10kV surge
• Reinforced VDE 0884
• Robust isolation
Si838x
• For PLC inputs
• 8 ch high speed
• Sinking/sourcing
Si823x
• Drives MOSFET based systems
Si826x
• Replaces Opto-drivers
Si828x
• Drives IGBT systems
Si827x
• Fast MOSFETs
• GaN FETs
Si8239x
• For 2.5 V VDD systems
Si8920
• Analog isolator
• Differential I/O
• Current sensing using shunt
Digital Isolator
Analog Isolator
Isolated Gate Driver
Evaluation kits
• Si838xISO-KIT: Hook up eight isolated PLC inputs on one board with Si838x
• Si88xxxISO-KIT: Experience plug-n-play signal & power isolation with the Si88241ED-IS
• Si8281-KIT: Fire up an IGBT using an Si8281CD-IS
• Si86xxTISO-KIT: Quick eval for the 10kV surge capable Si8642ET-IS
• Si8920ISO-KIT: Measure current on a high voltage rail easily with the Si8920BC-IP
Application notes and white papers
• AN970: PLC Inputs Design Guide
• AN892: Design Guide for Isolated DC/DC Using the Si882xx/883xx
• AN901: Design Guide for Isolated DC/DC using the Si884xx/886xx
• AN486: High-Side Bootstrap Design Using ISOdrivers in Power Delivery Systems
• Pin-Compatible Digital Isolated Gate Drivers Make Life Easy for Power Designers
Online tools
• Bootstrap Calculator
Development Tools for Isolation Products
Thank You! Any questions?
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