Power Roadshow 2013
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Insultion and Isolation.
Technology Solutions
Page 1
Avago Technologies Confidential
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Agenda
Page 2
Isolatori
Magnetici
Isolatori
Capacitivi
Isolatori
Ottici
Isolatori
RF
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Safety Isolation is regulated by IEC standards
• High voltage is life threatening
• Safety isolation is regulated by international standards and
compliance to standards must be certified
• Standards are established by experts in the field and based on
rigorous engineering experiments and test data
• Equipment connected to high voltages must comply to equipment
standards
• Isolation components used in equipment must be certified to
standards required by the equipment
• IEC 60747-5-5 is a standard ONLY for optocouplers
• Not for alternative isolators such as magnetic and capacitive isolators
Page 3
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Basic, Double and Reinforced Insulation Definitions
• Voltage greater than 30 VAC or 60 VDC is defined as a hazardous
voltage
• Two levels of protection are required between hazardous voltages
and safe voltages
• The first layer is basic insulation and the second layer is
supplementary insulation
• The combination of basic insulation and supplementary insulation is
known as double insulation
• If a single layer of insulation has the same insulation property as
double insulation, this is known as reinforced insulation
Page 4
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Overview of Equipment Safety Standards
Safety
Standard
Scope
IEC60664,
UL840
Insulation Coordination For
Equipment Within Low Voltages
(<1000Vac or <1500Vdc) Systems
IEC61800
Adjustable Speed Electrical Power
Drive Systems
EN50178
Electronic Equipment for use in power
installations
Construction Requirements for
Reinforced Insulation
High Voltage Test Method
Equipment
Examples
Impulse, AC/DC Hipot, partial
discharge
Solid Insulation DTI ≥ 0.75 mm
Thin sheet ≥ 0.2 mm 1 layer
Thin sheet < 0.2 mm; 3 layers
Impulse, AC/DC Hipot, partial
discharge
Motor Drives
Impulse, AC/DC Hipot, partial
discharge
Motor Drives
Solid Insulation > 0.4 mm
> 2 layers for thin sheet insulation
Optocoupler
Semiconductor Isolator
Impulse, AC/DC Hipot
Networking Power
Supply, POE,
Router
IEC60950-1
Information Technology Equipment
Safety
•
•
•
•
IEC60601-1
Medical Electrical Equipment – Part
1: General requirements for basic
safety and essential performance
• Solid Insulation > 0.4 mm
• > 2 layers for thin sheet insulation
• Optocoupler
Impulse, AC/DC Hipot
ECG, Endoscope
IEC61010-1
Safety requirements for electrical
equipment for measurement, control,
and laboratory use
• Solid Insulation > 0.4 mm
• > 2 layers for thin sheet insulation
• Optocoupler
Impulse, AC/DC Hipot
Power Analyzer,
Industrial Scope
UL508
Industrial Control Equipment
Impulse, AC/DC Hipot
PLC, Lighting
Dimmer
UL2202
Electrical Vehicle Charging System
Impulse, AC/DC Hipot
EV Charger
Page 5
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Overview of Component Safety Standards
Isolation
Devices
Norm
Scope
Key Requirements
Transformer
EN61558
(VDE0570)
Safety of Transformers and General
Requirements
Hipot Test,
Specify constructions.
Capacitor
EN 132400
Harmonized system of quality assessment for
electronic components. Sectional specification. Fixed
capacitors for electromagnetic interference
suppression and connection to the supply mains
(Assessment Level D)
Optocoupler
IEC 60747-5-5
Semiconductor Devices – Discrete Devices
– Part 5: Photo-couplers
Impulse Test: 10 kV
Partial Discharge
Optocoupler
UL1577
Standard for Optical Isolators
Hipot Test up to 5 kVrms 1 minute
Semiconductor
Isolator
VDE0884-10 (in
draft status)
Magnetic Digital Isolator
Similar to obsolete optocoupler standard
VDE0884-5.
Impulse Test: up to 8 kV for 250 Vac (Y1)
Specify constructions
Status of Optocoupler Standard
IEC 60747-5-5 Official Released in 2007,
DIN EN60747-5-5 Based on IEC 60747-5-5, Officially Released in Nov’2011
IEC 60747-5-2 To be withdrawn and replaced by IEC 60747-5-5 in 2012.
DIN EN 60747-5-2 based on IEC 60747-5-2, to be withdrawn and replaced by DIN EN 60747-5-5 in 2014.
VDE 0884-5 has been replaced by DIN EN 60747-5-2
Page 6
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Isolation Technology Overview
Optocoupler
Magnetic or Capacitive Isolators
DTI (Distance through Insulation): 80um to 1000um
DTI: 8um to 17um
Number of Layers: 3
Number of Layers: 1
Insulation Material: Polyimide Tape + Silicone
Insulation Material: SiO2 or Polyimide
Electric Field Stress: Vbias / 80 um
Electric Field Stress: Vbias / 8 um
Page 7
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Optocoupler Safety Standard IEC 60747-5-5
(That’s what Avago optocoupler certified)
Test Type
Test Method
Test Condition
Passing Criteria
Type Test
(20 Samples)
Environmental Stress
Rapid Change of Temp : 10cycles, dwell time – 3hrs
Vibration: Axis – 3, 10cycles, amplitude -75mm/98m/s2
Shock : Axis -3, acceleration – 980m/s2
No insulation
degradation.
Transient Test
60s
Viotm
X 1.875
Vpd,b
Vpd,a
Partial discharge < 5pC
X 1.6
Viorm
10s, PD < 5pC
Method a), TYPE Test
Surge Test
RIO>109W at VIO=500V
10kVpeak
50us
1.2us
Routine Test
(100%
Production)
Partial Discharge
Partial discharge < 5pC
Viotm
1s, PD < 5 pC
Vpd,b
X 1.875
X 1.6
Vpd,a
Viorm
Method b3), ROUTINE Test
Page 8
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Environmental and Dielectric Strenght Test
Environmental
Test
Rapid Change of Temp :
10cycles, dwell time – 3hrs
Vibration: Axis – 3, 10cycles,
amplitude -75mm/98m/s2
Shock : Axis -3, acceleration
– 980m/s2
Dielectric
Strenght Test
3.75kVac or 5kVac for 1 min
Optocoupler
Pass
Page 9
Magnetic Isolator Capacitive Isolator
Pass
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Pass
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Surge Test
Surge test per Optocoupler Standard IEC 60747-5-5, passing criteria ≥ 10 kV
XX8441B
Supplier S
RF
XXX7240M
Supplier A
Magnetic
XXXX1400W
Avago
Optocoupler
XXXX2400C
20
18
16
14
12
10
8
6
4
2
0
ACPL-36JT
Passing Voltage (kV)
Surge Test
Supplier T
Capacitive
• Optocoupler passed 10 kV surge test by wide margin
• Magnetic isolators: Random samples of barely passed 10 kV however failed at 12 kV
• RF and capacitive isolators: With SiO2 as isolation failed 8 kV and 6 kV respectively
Page 10
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Partial Discharge Test
Step 1. Select 5 samples of optocouplers, magnetic and capacitive
isolators each in same SOIC package with 8 mm creepage
High Voltage and
High Temperature
Stress Test Setup
Step 2. For 8 mm creepage select 1.6 kVrms as continuous
working voltage as solid insulation is good for 200 Vrms/mm
Step 3. Perform partial discharge on all units at 3 kVrms (1.875 x
1.6 kVrms), indicating partial discharge free for 1.6 kVrms.
Step 4. Perform 1.6 kVrms stress under 125º C. Measure time to
failure based on continuous leakage monitoring.
Isolation
Technology
Insulation
DTI (mm)
Partial Discharge
Test Voltage
Working Voltage
Capability per
standard
Aging Mechanism / Life
Expectancy Prediction
Model
Life time
Prediction
Time to Failure
under 1.6 kVrms
Bias at Ta=125º C
Optocoupler
Polyimide Tape + Silicone
0.4
3 kVrms
1.6 kVrms
Partial Discharge
No Degradation
> 4000 hrs
Magnetic
Polyimide
0.017
3 kVrms
1.6 kVrms
Space Charge Degradation /
Thermodynamic Model
80 hrs
12 hrs
Capacitive
SiO2
0.008
3 kVrms
1.6 kVrms
TDDB / E-Model
2500 hrs
21 hrs
1. Optocoupler lifetime is consistent with partial discharge result.
2. For magnetic and capacitive isolators partial discharge results predict a far more optimistic lifetime than actual results. It
is not a suitable test for isolators using thin layer insulation.
Page 11
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Conclusion on IEC Standards
• Safety standard for optocouplers is well established and proven effective in
predicting optocoupler’s lifetime.
• Optocoupler standard, IEC 60747-5-5, does not apply to magnetic and capacitive
isolators, due to differences in construction and insulation material. High working
voltage life stress has shown partial discharge predicting overly optimistic for
lifetime of magnetic and capacitive isolators.
• Equipment safety standard is based on assumptions of solid insulation or
multilayer thin sheet insulation. Ultra thin layer insulation used by magnetic and
capacitive isolators introduces large electric field stress compared to
conventional insulation. Its aging and defect screening needs to be studied for
safe and reliable application.
• Test compliance to optocoupler and equipment standards can be obtained by
magnetic and capacitive isolators. However it is ultimately designer’s and
manufacturer’s responsibility to ensure safety and reliability of the equipment by
applying the right insulation.
Page 12
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Safety plus Superior Performance Compared to
Capacitive and RF Technology Based Isolators
• High common mode rejection
• High EMI immunity
• Low radiated emissions
• Negligible LED degradation over time
Page 13
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Avago Optocouplers provide extra advantages in harsh industrial and automotive environments.
• Common Mode Rejection
Avago ACPL-M72T Optocoupler
dV/dt = 45kV/us
Vcm = 1 kV, Frequency = 12.5 MHz
Supplier S XX8441B RF
dV/dt = -4kV/us
Page 14
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Optocoupler provided added advantages in harsh industrial and automotive environment.
Avago Optocoupler
• EMI Immunity
CH1: Vo1
CH3: 1060 A/µs
CH2: Vo2
CH3: ESD Current
Magnetic Isolator
CH1: Vo1
CH2: Vo2
Avago Optocoupler
Page 15
Supplier A Magnetic
XXX5500
XXXX2400C
CH3: 130 A/µs
XXXX1410B
1800
1600
1400
1200
1000
800
600
400
200
0
ACPL-M71T
Susceptibility -dI/dt - A/us
EMI Test - ESD Method (HBM)
Supplier T
Capacitive
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Optocoupler provided added advantages in harsh industrial and automotive environment.
• EMI Immunity (Machine Model, MM)
Communication OK
EMI noise current: 15 A
Avago Optocoupler --- No missing bits seen
at 15A of loop current nearby.
30
25
Communication Error
20
15
EMI noise current: 2.8 A
10
Avago Optocoupler
Page 16
Supplier A
Magnetic
XXXX2400C
0
XXXX1410B
5
ACPL-M71T
EMI Noise Current - A
EMI Test - ESD Method (MM)
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Magnetic Isolator --- Missing bits seen at
2.8 A of loop current nearby.
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Optocoupler provided added advantages in harsh industrial and automotive environment.
• Low Radiated Emissions
Avago:
Optocoupler
ACPL-M72T
34.5 dBµV
Input Frequency: 1 MHz, 1-channel ON
Radiated Emission
Noise Level - dBuV
50
45
Supplier S :
40
RF Isolator
XX8441B
35
45.2 dBµV
Page 17
XXX7520C
(G4)
XX8220DD
(952)
Avago: Supplier A:
Optocoupler Magnetic
XX8441BB
(1012)
XXXX2400C
(849)
XXXX1400C
(851)
ACPL-M71T
(NR)
30
Supplier S: RF
Supplier T
Capacitive
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Negligible LED Degradation
LED for ACPL-x6xL 10 MBd ultra low power digital optocouplers
Mean data at varying IF
Page 18
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PhotoIC vs Phototransistor
Page 19
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SOCKET 1 : GATE DRIVE
Your Imagination, Our Innovation
SOCKET 2: CURRENT/VOLTAGE SENSE.
+HVDC
+5V
IGBT1
IGBT Gate Drive
Avago OC #2
IGBT2
SHUNT
IGBT Gate Drive
Avago OC #1
-HVDC
SOCKET 3 : DIGITAL BUS APPLICATIONS
MCU
Page 20
TRANSCEIVER
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+5V
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Technology Development Trend
Compact SMD Package
Enhancement Insulation Performance
Enhancement Isolation Performance (CMR)
Ultra Low power consumption
Page 21
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Packages
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Gate Drivers
• Rail-to-Rail IGBT / MOSFET
Integrated Optocouplers Gate
Drivers
• Smart IGBT / MOSFET
Optocouplers Gate Drivers
• High Speed / High CMR Interface
(Optocouplers or Fibers)
Page 23
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Isolation Amplifiers – The Technology
Optically
Transparent
Dielectric
Input Signal
Processing
Input
Voltage
Regulator
Clock
Generator
Σ-Δ
Modulator
Encoder
Output Signal
Processing
Packaged products
Voltage
Regulator
LED Drive
Circuit
Detector
Circuit
Decoder
and D/A
Filter
Output
• The Isolation Amplifier/Σ-Δ modulator converts the analog input
signal into a high-speed serial bit stream; the time average of the bit
stream is directly proportional to the input signal.
• This stream of digital data is encoded and optically transmitted to
the detector circuit.
• The detected signal is decoded and converted back into an analog
signal, which is filtered to obtain the final output signal.
Page 24
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Simplified block diagram
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Isolation Amplifier for Current & Voltage Sensing
Page 25
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Isolation Amplifiers Sweet Spot
Shunt R (Ω)
Power Dissipation & Shunt R vs Current Range
0,015
35 Power
0,013
30
0,011
Dissipation
(W)
25
0,009
20
0,007
R100
R50
15
0,005
10
0,003
5
0,001
-0,001
R200
1
10
20
30
40
Isolation Amplifiers
Sweet Spot
Page 26
50
60
70
80
90
100
110
120
130
140
150
RMS Current
Power Dissipation on Shunt Resistor may be too high. On One
method is to connect shunts in parallel to split the power
handling. The other method is to use a smaller input range.
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0
200mV
100mV
50mV
Trend
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Ultra Low Power Consumption
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Thank You
www.avagotech.com
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