integrating speed and flexibility isolating industrial control

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


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


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


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


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


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


Rx/Tx

DCDCControl &

switch

Rx

Tx

VOUT

VCC

ENDigital

isolationChannels

Rx/TxA

B

Embedded processor

VINPower Supply

MCU


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


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


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


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


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


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


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?


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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integrating speed and flexibility isolating industrial control

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