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INDUSTRIAL PROCESS CONTROL SOLUTIONS SIMPLY SMARTER™ Industrial Solutions: Introduction Purpose • Introduce Intersil solutions for industrial control applications Objectives • Overview of industrial control systems • Review typical industrial control block • Overview of industrial sensors • Present Intersil feature products with select application circuits 2 Industrial Process Control Programmable Controller Basic Process Control • PLC: Programmable Logic Controller • PAC: Programmable Automation Controller Networked Control System CANopen Master Module LCD Display Unit Power Supply • DCS: Distributed Control System • SCADA: Supervisory Control and Data Acquisition Integrated Process Control • PAS: Process Automation System • CPAS: Collaborative Process Automation System Servo Drive Servo Drive Broad coverage across Intersil’s product portfolio • • • • • • • • • • Op amps Data converters Switches and multiplexers RS-485/422 interfaces Voltage references Digital potentiometers (DCPs) Real time clocks Switching and linear regulators Isolated power Voltage monitoring Distributed I/Os Power Supply Sensors 3 PLC/DCS Industrial Control Elements I/O intensive • 1 to 256 digital or analog input and output cards per control module Analog input sensor modules • Temperature, pressure, flow, vibration, position, torque, motion, power, motors, lighting Output modules • Valves, switches, process control set-points, motor drives velocity and position, power and safety controls, lighting Communication • Fieldbus, Profibus, HART, Modibus, Ethernet, BACnet, and more • RS485, RS422 built ports common to most systems Power • Core micro and digital I/O power • Multiple voltage sources – analog modules, subsystem 4 Common Analog Needs High Precision • Low Drift, Low Noise’ • High Resolution High Density/Low Power • High channel count • Small Packaging Flexible Power Sources Industrial Control: Intersil Products Overview Intersil Solutions for Industrial Control Applications Sensor Modules Temperature Sensors Gain Amplifiers Active Filters +V Force or Strain Sensors Current 1 of n ADC +V Pressure Flow Sensors Precision Amps -V MUX Precision Amps -V Instrumentation DG408 8:1 MUX 40V Op Amps Amps 5V Op Amps DG409 Diff 4:1 MUX ISL28210 EL8170/8173 ISL28276 ISL28217 ISL28133 / 233 ISL28210 ISL28207 ISL28217 ISL28134 ISL28127 (3 amps discrete) ISL28214 ISL28218 ISL28208 Microcontroller ADC VOLTAGE REFERENCE ISL21009 ISL21090 V System Power Digital Potentiometers ISL223x4 ISL224x4 ISL223x6, ISL22317 ISL96017, ISL95811 Actuators Motors Control loops 4-20mA FET drive V ANALOG SIGNAL OUTPUT MODULE Precision Amps ISL28133, ISL28217 5 LDO Buffer, Filters, Span Drivers +V Precision Amps -V 40V Op Amps ISL28217 ISL28207 ISL28127 ISL28218 ISL28208 FET Drivers +V Precision Amps -V 5V Op Amps ISL28276 ISL28133/233 /433 ISL28134 ISL28214 PWM Control 1 of n DAC MUX 4:1 MUX DG408 DG409 V Switching Regulator SW Controller PWM Controllers ISL8107, ISL6420, ISL8112 & ISL6441 LDO ISL80101, ISL80111 Power monitor ISL88011, ISL88041 Power sequencer ISL8700, ISL8705A DAC Voltage Reference ISL21009 ISL21090 Isolated Controllers ISL6842, ISL6721 Switching Regulators ILS85033, ISL8022, ISL8088 System Power Compensation Voltage Reference ISL21060, ISL21009 ISL60002, ISL21090 Voltage Monitors & Watchdog Core & I/O Power Vibration Sensor RS232 / RS485 RS-485 ISL317xE, 3.3V Dual Protocol ISL314xE, 5V ISL81334, 5V 2 ch Interface ISL41334, 5V 2 ch RS-232 RS-232 RS-485 ISL4221EIRZ ISL81387, 5V 1 ch ISL3232EIRZ ISL41387, 5V 1 ch ISL3330, 3.3V 1 ch ISL4243EIRZ ISL3331, 3.3V 1 ch RTC ISL3332, 3.3V 2 ch ISL3333, 3.3V 2 ch RTC ISL12022, ISL12023 ISL12020M. ISL12022M ISL12057 , ISL12058, ISL12059 CONTROL MODULE ANALOG SIGNAL INPUT MODULE Power Isolated Power Isolated Power Sensor Amplifier Electrical Environment Get more useful ADC bits by: • Minimizing output noise • Minimizing output DC offset and drift • Maximizing output voltage swing Input differential disturbances come from: • Electrical imbalances within the sensor • External transient sources • Externally coupled and internal sensor noise sources Signal Sensor Amp Filter Amp ADC Precision VREF Power Supply Input common mode disturbances come from: • Sensor contact with conductive surfaces • External transient sources • Earth ground disturbances 6 Sensor Amplifier Bandwidth Range 100MHz 20kHz - 2MHz Piezo Ultrasound Sonar Ranging Fetal Imaging 1MHz High Speed Photodiode Bar Code Scanner Magnetic Stripe Transducer Card Readers Frequency 10KHz 100Hz 1Hz 0.1Hz DC 7 Skin Electrode ECG/EEG Temperature PTC Thermocouple Electro Chemical pH Probes Photodiode Smoke Detection Position Piezo Absolute Pressure Sensors Weigh Scale Infusion Pump Piezo Pressure Sensors Blood Pressure Muscle/Bone injury Sensor Module Overview Sensor modules measure a wide range of physical phenomenon Sensor and application accuracy requirements can vary significantly Amplifier selection is critical to achieving performance Physical Sensor Type Measure Impedence Amplifier Technology Physical Sensor Type Measure Impedence Amplifier Technology Thermocouple Voltage Low Bipolar Current Hi / Lo Current Shunt Voltage Low Bipolar Resistance Resistance Voltage Low to Med Bipolar Low to High JFET, CMOS Bipolar Low Low High Low Bipolar JFET, CMOS Bipolar IR Thermal Sensor Current High JFET, CMOS Low Bipolar Thermo Pile Voltage Low Bipolar AC Voltage Charge, Voltage Voltage Voltage, Current Resistance Voltage Low Bipolar Resistance Resistance Voltage, Resistance Charge, Voltage Low Low to Med Low to Med High Bipolar Bipolar Bipolar JFET, CMOS Charge Resistance Charge, Voltage Charge High Med High High JFET, CMOS JFET, CMOS JFET, CMOS JFET, CMOS Colorimeter (Photodiode) Charge High JFET, CMOS Charge High JFET, CMOS RTD Thermister Temperature Silicon Load Cell / Bridge Force /Weight Strain Guage Mechanical Diaphram Pressure Piezeo Electric Flow 8 Motion, Vibration LVDT Piezeo Electric Microphone Motor Sensor Accelorometers Ph Electrode Solution Conductivity Chemical CO Sensor Turbidity (Photodiode) Differential Pressure Voltage, Resistance Low to Med Bipolar Mass Flow (Temp) Resistance Low Bipolar Light / IR Photodiode Hot Wire Annometer Magnetic Flow Resistance AC Voltage Low Low Bipolar Bipolar Humidity Moisture / Capacitance Infrared detector Capacitance Charge High High JFET, CMOS JFET, CMOS Ultrasound Doppler Mechanical Turbine Frequency Voltage Med Low Bipolar Bipolar Magnetic Hall Effect Magneto Resistive Voltage Resistance Low Low, Med Bipolar Bipolar How Do You Select the Right Amplifier? Indentify Global Priorities 1. Price, package, performance 2. New requirement or 2nd source? 3. Decision process - timing Sensor Characteristics? Output Voltage Range Output Current Range Sensor Resistance Sensor Capacitance Supply Voltage, Bias Requirements Amplifier Input Signal? Voltage or Current Amplitude, Frequency Signal to Noise, Temperature Drift Bias Voltage Ground Sensing Positive Rail Sensing 9 V+ + V- Supply Voltage Requirement? Dual Supply ±2.5V, ±5V, ±10V, ±15V, ±20V? Single Supply 1.8V, 3V, 5V, 10V, 15V, 30V? Power Level Battery, Line Power, Micro Power? Output Requirements? Accuracy, Noise, Drift Rload, Cload, Vout or Iout Frequency, Amplitude Settling Time, THD Rail to Rail Keys to Success 1. Learn as much possible about the application and amplifier requirements 2. Use the offline selector tool or the selection guide to narrow the selection to a small list of 3-5 amplifiers (http://www.intersil.com/products/odst/) 3. Identify priority tradeoffs and finalize the selection Broad Portfolio of Precision Op Amps for Sensor Frontends End Application Sensor Sensor Characteristics Op Amp Requirements Recommended Amplifiers Temperature Measurement Thermocouple Resistance Thermometer (RTD) Thermo PIle Low signal voltage Low impedance Low signal bandwidth Low Vos and drift High open loop gain Moderate input Impedance Slew rate & bandwidth not critical ISL28133, ISL28233 Low Power 5V Chopper ISL28134 Low Noise 5V Chopper ISL28176, ISL28276 5V Op Amps ISL28107, ISL28207 Low Ibias 40V Op Amps ISL28117, ISL28217 Low Power 40V Op Amps ISL28108, ISL28208 Rail-Rail Out 40V Op Amps Pressure, Force, Flow Measurement Strain Gage, Load Cell Low signal voltage Low impedance (100 - 5000W) Low signal bandwidth (~ 1kHz) Low Vos and drift High open loop gain, CMRR Moderate bandwidth ISL28118, ISL28218 Rail-Rail Out 40V Op Amps ISL28127, ISL28227 Low Noise 40V Op Amps ISL28117, ISL28217 Low Power 40V Op Amps EL8171/72, ISL28270/72 5V Rail-Rail In-amps Ultrasonic Vibration Measurement Motion , Vibration Piezo-electric Sensor Medium signal voltage AC coupled, high impedance Signal bandwidth (~100kHz) High input impedance Low input Ibias, low noise Low input capacitance, Cin High bandwidth Moderate open loop gain ISL28210 Low Noise JFET Op Amp ISL28107, ISL28207 Low Ibias 40V Op Amps ISL28138 High BW CMOS Op Amp ISL28114, ISL28214 Low Cost CMOS Op Amps Position Measurement Light Photodiode (Photovoltaic) Low signal voltage High impedance Signal bandwidth (~10kHz) Very high input impedance Low input Ibias, low noise Low input capacitance, Cin High bandwidth ISL28210 Low Noise JFET Op Amp ISL28138 High BW CMOS Op Amp Chemical Ph Electrode Medium signal voltage High impedance (500MW) Low signal bandwidth High input impedance Low input Ibias, low noise Low input capacitance, Cin Moderate open loop gain ISL28210 Low Noise JFET Op Amp ISL28107, ISL28207 Low Ibias 40V Op Amps ISL28138 High BW CMOS Op Amp ISL28114, ISL28214 Low Cost CMOS Op Amps Magnetic Hall Effect Magneto Resistive Low signal voltage Low impedance (100 -5000W) Moderate signal bandwidth Low Vos and drift High open loop gain, CMRR Moderate bandwidth ISL28118, ISL28218 Rail-Rail Out 40V Op Amps ISL28127, ISL28227 Low Noise 40V Op Amps ISL28117, ISL28217 Low Power 40V Op Amps EL8171/72, ISL28270/72 5V Rail-Rail In-amps 10 Precision Low Noise JFET Op Amp ISL28210: Superior Ibias and Noise Performance Competitive Summary Mfg Max Ibias (pA) Differential Input Capacitance (pF) Noise @ 1kHz (nV/Hz) Noise 0.1 – 10Hz (nVP-P) BW (MHz) Min SR (V/µs) Max VOS (µV) Max IS (mA) ISIL 2 8.3 6 580 12.5 20 300 2.9 Comp A 75 12.5 8 2400 8 20 900 2.3 Comp B 50 4 13 2100 8 20 600 2.5 Comp C 10 8 6 1800 25 40 100 3 Comp D 50 1 8 ** 5 14 500 4.8 ISL28210 Input Bias Current (Max) Ibias (pA) 10000 ISL28210 Input Bias Current (Max) Applications • Flow sensors and other high impedance applications • Medical instrumentation • Active filter blocks • Precision instruments Outstanding Noise Performance 10x Better 1000 100 10 1 Competitor A Competitor B 25C 11 Typical Application: Photodiode 60C 85C Competitor C 125C ISL28210 300 fA (typ) pH Sensor Equivalent Circuit Reference Electrode + Potassium Chloride Solution Silver Chloride Tip Very High Input Impedance ISL28210 is an excellent op amp for high impedance sensor applications - Measurement Electrode Sensor Sensitivity & Range • pH range 1 to 14 • Voltage output: 59.16mV/pH • pH neutral (7) = 0V • Sensor output range: -414mV to +414mV • Source impedance ~ 400MW Amplifier Requirements • Gain = VOUT swing/818mV (~ 12 for 10V output) • Input bias current of 10pA or less = 1% measurement error • VOS < 0.5mV < 0.1% • OPA best for 2-terminal integrated sensor or INA • INA best for 3-terminal remote sensor w/ground shield In spite of simplicity, pH sensor probes have many sensitivities including temperature, contamination and aging 12 Low Noise, High Voltage Instrumentation Amp Using JFET Precision Op Amps Roll Your Own High Performance Instrumentation Amplifier Using High Voltage Precision Op Amps ISL28210 ISL28207 For high impedance sensors it is desirable to maintain the input characteristics of high end amplifiers ISL28127 ISL28117 Hi Z Vout Sensor ISL28210 ISL28207 Process control applications in noisy environment often require differential measurements This often results in a “roll their own” instrumentation amplifiers using select high performance precision amplifiers The advantage is the user has a great deal of flexibility in achieving the desired performance and cost tradeoffs ISL21090 ISL21009 The disadvantage is CMRR is limited by the matching of the resistors Intersil’s new 40V precision amplifiers are excellent choices for these applications 13 Micropower, Chopper Stabilized, RRIO Op Amps ISL28233 & ISL28433: Best-in-Class Performance for Precision and Drift on Extremely Low Power Competitive Summary Mfg Max Is (µA) Max Vos (µV) TCVos (nV/C) Max Ibias (pA) Noise 0.1 to 10Hz (µVp-p) Min BW (kHz) ISL28233 25 6 50 180 1.0 400 Comp A 25 10 50 200 1.1 350 Comp B 17 15 100 50 1.96 115 Features • 1.65V to +6.0V single supply range • -40°C to +125°C temperature range • Rail-to-Rail inputs and output Applications • Pressure measurement • Electronic weigh scales • Precision/strain gauge sensors • Precision regulation • Low ohmic current sense • Bi-directional current sense • High gain analog front ends ISL28233 Long Term Drift Zero Drift 14 Typical Application: Temperature Measurement Low Noise at Low Power Temperature Sensors Temperature is the most widely measured parameter in Industrial Controls • The four most common types are Thermocouple, RTD, Thermistor and Integrated Circuits • Each sensor has different characteristics and care must be taken to select the appropriate sensor for a given application • In all cases calibration is needed and the accuracy will be dependent on the sensor conditioning circuit Sensors Temp Range (°C) Typical Applications 15 Thermocouple RTD Termistor -270 to +1800 -250 to +900 Integrated Silicon -100 to +450 -55 to +150 High temperature Bridge temperature Bridge Temperature Computers Chemical reactions Calibration Pyrometer calibration HVAC Bio physics Process control Flow meters Cell phones Gas ghromatography Instrumentation Anemometers manometers Battery management Internal combustion engines Cold junction reference temp Cold junction reference temp Cold junction reference temp Advantages Simple, low cost, selfpowered, rugged, wide temp range Most accurate, most stable, good linearity High sensitivity, fast response, 2-wire ohm measurement Most linear, highest output, inexpensive Disadvantages Non-linear, low voltage, cold junction required, least sensitive & stable Expensive, slow response, excitation required, low sensitivity, 4-wire ohm measurement Poor linearity, more limited temp range, fragile, excitation required, self-heating issues Limited temp range, power supply needed, slow, self-heating issues, limited package Thermocouple or Thermopile Sensors Thermocouples are the most popular temperature sensor • Low cost and package flexibility Signal levels are near DC and non-linear • Very small (10s of µV) Cold junction compensation is required • Accurate absolute measurements Precision amplifiers work best • Low offset, low drift, with high gain minimize errors • High voltage and low voltage requirements Diode Used for Cold Junction Compensation 16 Low Voltage Low Drift Op Amps ISL28233 ISL28134 ISL28176 ANSI High Voltage ISL28130 Low Drift Op Amps ISL28217 ISL28207 ISL28218 Material Temp Range ( °C) Sensitivity (µV/C) B Platinum (6%)/Rhodium – Platinum (30%)/Rhodium 38 to 1800 7.7 C Tungsten (5%)/Rhenium – Tungsten (26%)/Rhenium 0 to 2300 16 E Chomel – Constantan 0 to 982 76 J Iron – Constantan 0 to 760 55 K Chromel – Alumel -184 to 1260 39 R Platinum (13%)/Rhodium – Platinum 0 to 1593 11.7 S Platinum (10%)/Rhodium – Platinum 0 to 1538 10.4 T Copper – Constantan -184 to 400 45 ISL28218 Precision 40V Single Supply, Low Noise Operational Amplifier ISL28118, ISL28218 has Outstanding Noise Performance at Half the Power . Features Single or Dual Supply, Rail-Rail Outputs Below Ground (V-) Input Capability 42V Abs Max Differential Input Range Wide Supply Range 3V to 40V Low Current Consumption 1100 μA Low Voltage Noise 5.6nV/rtHz Temperature Range -40°C to +125°C Wide 3V to 40V Operating Supply Range Below Ground (V-) Input Capability V+ Vpos + 500mv To Vneg - 500mV + V- Vcm Range extends to -0.5V below Ground Robust 42V Differential Input Range Typical Application : Low Side Current Sense ISL28218 Rail to Rail Output and Ground Sensing Input are excellent for Low Side Current Sense Applications ISL28218 17 Competitive Summary Max Is Mfg (uA) ISL28218 1100 Comp A 2250 Comp B 2200 Noise Noise Max .1 to 10Hz @ 1kHz GBP Max Vos Ibias nVp-p nV/rt Hz (MHz) (uV) TcVos (nA) 300 5.6 4 230 1.4 575 300 3.9 3.25 175 2 450 400 12 10.5 475 2.5 650 Low Side Current Sense Amp Advantages • Simplicity and low cost • Low Common Mode Voltage • Ground Sensing Input and Output Disadvantages ISL28218 is an excellent choice for Low Side Current Sense applications • Ground Path disturbances / Transients • Limited dynamic range • Load is lifted from ground due to Shunt Resistor • No short circuit detection Key amplifier requirements Input Characteristics Low Sensor Impedance Low Signal voltage (100’s uV to 10’s mV) Depending on load current Low Inductance Low TC Rshunt 18 Vo = IL x Rshunt x ( Rf /Ri + 1) • • • • • • • Ground Sensing Input Rail to Rail Output Low Offset (Dynamic Range) Low Voltage Noise Good response time (PWM) Single op amp configuration for low cost Differential 2 amp configuration for remote sensors Intersil Power Management in Industrial Control Industrial Power • Power is needed on all boards Control ISL80101 1.8V Memory In general, the power chain looks like the one shown • Vin -> Typ 24V, can go to 36V. • Isolation will be required for some rails • 5V ISL85033 Embedded Power Controller 2.5V FPGA/ uProcessor 3.3V +15V 24V ISL6844 Gnd Gnd Analog I/O module To Sensors -15V Buck to low voltage non-isolated rails • LDO – Cleans up the noise from the switchers • • Power monitor, Sequencers Reliability, Easy to use, Efficient & re-usable • 19 Keys to success Understand your full power chain, Vin –> Vout Understand what is your biggest concern, Efficiency, Size, etc. Under stand your power needs Size, Efficiency, or a particular spec What Power Source Is Isolation needed What are you powering ISL684X - Isolated Power Controller Family Features Fast 40 ns (Max) Peak-Current-Sensing Time Eliminates Short-Circuit Current “Tail Out” • 1A MOSFET Gate Driver ISL6844 • 60μA Start-up Current, 100μA Maximum • 25ns Propagation Delay Current Sense to Output • Fast Transient Response with Peak Current Mode Control Best Competitive BiCMOS 3842 Bipolar UC3842A 40 70 300 Max Current Sense Propagation Delay (ns) (Shorter is better) • Adjustable Switching Frequency to 2MHz • 20ns Rise and Fall Times with 1nF Output Load • Trimmed Timing Capacitor Discharge Current for Accurate dead-time/Maximum Duty Cycle Control • High Bandwidth Error Amplifier • Tight Tolerance Voltage Reference Over Line, Load, and Temperature • Tight Tolerance Current Limit Threshold Superior performance vs. Competition in every specification 20 Feature Smallest package option Industrial operating temp range Oscilator max frequency Max current sense propagation delay 5 V reference accuracy over line, load, temp 2.5 V error amp reference total accuracy Error amp unity gain bandwidth Max operating supply current (no switching) Max startup current GATE output rise/fall times (1 nF load) ISL6842 DFN-8 -40 ~ +105 C 2 MHz 40 ns 1.0% 1.0% 5 MHz 3 mA 100 uA 40 ns/40 ns UC2842A SOIC-8 -40 ~ +85 C 500 kHz 300 ns 2.0% 2.0% 1 MHz 17 mA 500 uA 150 ns/150 ns UCC28C42 MSOP-8 -40 ~ +85 C 1 MHz 70 ns 3.6% 2.0% 1.5 MHz 3 mA 100 uA 50 ns/40 ns MIC38C42A MSOP-8 -40 ~ +85 C 1 MHz 250 ns 3.6% 3.2% 1 MHz 6 mA 230 uA 80 ns/60 ns ISL85033 – 28V, 3A:3A Dual Std Buck Regulator Dual Output, Standard Buck Regulator with Integrated High Side MOSFET Vin1 Vin2 CH1 CH2 Vout1: 3A Vout2: 3A • Vin range 4.5V to 28V • Vout range 0.8V to 24V Dual Buck Regulator - 3A/3A Outputs • 3A/Channel guaranteed output current • Selectable 180o Out of Phase operation or In Phase operation modes • Current Mode Control • Output Current Sharing capability • Fsw 500KHz (default) or 300KHz to 2MHz Adj. • Synchronization to external clock – 360KHz to 2MHz • Independent EN and PGOOD for both channels • Independent Sequential ratio-metric or absolute tracking between outputs • Internal 5mS Soft-Start or Externally Adjustable Soft-Start 21 Single Parallel Buck – 6A Output Vin1 Vin2 CH1 CH2 Vout1: 6A ISL80101/2/3 High Current PMOS LDOs LDOs capable of 1A, 2A, and 3A current drive • Designed for fast load transient response • Tight ±2% VOUT accuracy over -40ºC < TJ < 125ºC • 70dB PSRR over full-rated load current • 90μVrms low output noise from 300Hz to 300kHz • Less than 1µA shutdown current • 7 industry-standard fixed & adjustable Vout options: • PGOOD, Enable, Short-Circuit & Reverse Current Protection, & Over-Temperature Shutdown Capability Features Fast Transient Response Helps to ensure that output voltage is properly regulated even under varying load current step changes ±2% Total DC Accuracy Tight accuracy will help guarantee a reliable POL voltage supply in critical application fields such as Medical, Industrial, Telecommunications, etc. Low Dropout Voltage VDO must be low to minimize power dissipation and maintain sufficient VOUT levels in spite of lower VIN due to aging batteries Enable, PG, IRSET, OCP Protection, Thermal Shutdown Added key features help LDOs be more dependable and customizable in different applications 2µs Settling 0 to 3A Load Step Fast Transient Response 22 Benefits ISL80101/2/3 Competitive Advantages Advantages on Key Specs • Leading class fast load transient response and total AC regulation band for LDOs in this category • Best in class ±0.3% Initial Accuracy & ±1.8% Total DC Accuracy – Guaranteed for full junction temp (TJ) -40°C to +125°C – Over full rated load current capability – Includes line & load regulation • Best in class package power density (i.e. Up to 3A per 9mm2) Key Differentiators Over Competition • Enable & PGOOD are standard features • Ability to set Inrush Current Limit via IRSET pin • <1V EN Threshold for decreasing voltage applications • Option for user-programmable Current Limit (*Contact Factory) 23 Other Power Parts Full Power chain available • Sequencers to power the rails up in a particular order – Highlighted in brochure • Power Monitors – to give early detection if a rail goes down • Power Modules – Complete system in chip ISL8201M Block Diagram MOSFETs Boot Capacitor Inductor Type III Compensation RSEN 24 www.intersil.com