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SIMPLY SMARTER ™ INDUSTRIAL PROCESS CONTROL SOLUTIONS.

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Presentation on theme: "SIMPLY SMARTER ™ INDUSTRIAL PROCESS CONTROL SOLUTIONS."— Presentation transcript:

1 SIMPLY SMARTER ™ INDUSTRIAL PROCESS CONTROL SOLUTIONS

2 2 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

3 3 Industrial Process Control Basic Process Control PLC: Programmable Logic Controller PAC: Programmable Automation Controller Networked Control System DCS: Distributed Control System SCADA: Supervisory Control and Data Acquisition Integrated Process Control PAS: Process Automation System CPAS: Collaborative Process Automation System 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 Power Supply Programmable Controller Power Supply Sensors Servo Drive Distributed I/Os CANopen Master Module LCD Display Unit Servo Drive

4 4 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 Common Analog Needs High Precision Low Drift, Low Noise’ High Resolution High Density/Low Power High channel count Small Packaging Flexible Power Sources

5 5 Industrial Control: Intersil Products Overview

6 6 Sensor Amplifier Electrical Environment ADC Signal Sensor Amp Filter Amp Input common mode disturbances come from: Sensor contact with conductive surfaces External transient sources Earth ground disturbances Power Supply Input differential disturbances come from: Electrical imbalances within the sensor External transient sources Externally coupled and internal sensor noise sources Precision VREF Get more useful ADC bits by: Minimizing output noise Minimizing output DC offset and drift Maximizing output voltage swing

7 7 100MHz 1MHz 10KHz 20kHz - 2MHz Piezo Ultrasound Sonar Ranging Fetal Imaging High Speed Photodiode Bar Code Scanner Photo- diode Smoke Detection Position Magnetic Stripe Transducer Card Readers 100Hz 1Hz 0.1Hz Skin Electrode ECG/EEG Frequency Piezo Absolute Pressure Sensors Weigh Scale Infusion Pump Electro Chemical pH Probes DC Piezo Pressure Sensors Blood Pressure Muscle/Bone injury Temperature PTC Thermo- couple Sensor Amplifier Bandwidth Range

8 8 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

9 9 How Do You Select the Right Amplifier? + - V+ V- 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 Output Requirements? Accuracy, Noise, Drift Rload, Cload, Vout or Iout Frequency, Amplitude Settling Time, THD Rail to Rail 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? 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/)http://www.intersil.com/products/odst/ 3.Identify priority tradeoffs and finalize the selection Indentify Global Priorities 1. Price, package, performance 2. New requirement or 2 nd source? 3. Decision process - timing

10 10 Broad Portfolio of Precision Op Amps for Sensor Frontends End Application SensorSensor CharacteristicsOp Amp RequirementsRecommended 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 - 5000  ) 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 ChemicalPh ElectrodeMedium signal voltage High impedance (500M  ) 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 MagneticHall Effect Magneto Resistive Low signal voltage Low impedance (100 -5000  ) 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

11 11 Precision Low Noise JFET Op Amp Typical Application: Photodiode Outstanding Noise Performance ISL28210: Superior Ibias and Noise Performance Competitive Summary Applications Flow sensors and other high impedance applications Medical instrumentation Active filter blocks Precision instruments 10x Better MfgMax Ibias (pA) Differential Input Capacitance (pF) Noise @ 1kHz (nV/  Hz) Noise 0.1 – 10Hz (nV P-P ) BW (MHz) Min SR (V/µs) Max V OS (µV) Max I S (mA) ISIL28.3658012.5203002.9 Comp A7512.5824008209002.3 Comp B5041321008206002.5 Comp C1086180025401003 Comp D5018**5145004.8 300 fA (typ)

12 12 pH Sensor Equivalent Circuit 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 ~ 400M  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 + - ISL28210 is an excellent op amp for high impedance sensor applications Very High Input Impedance Reference Electrode Measurement Electrode Potassium Chloride Solution Silver Chloride Tip

13 13 Low Noise, High Voltage Instrumentation Amp Using JFET Precision Op Amps Process control applications in noisy environment often require differential measurements For high impedance sensors it is desirable to maintain the input characteristics of high end amplifiers 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 The disadvantage is CMRR is limited by the matching of the resistors Intersil’s new 40V precision amplifiers are excellent choices for these applications ISL21090 ISL21009 ISL28210 ISL28207 ISL28127 ISL28117 Hi Z Vout Sensor Roll Your Own High Performance Instrumentation Amplifier Using High Voltage Precision Op Amps

14 14 Zero Drift ISL28233 Long Term Drift Micropower, Chopper Stabilized, RRIO Op Amps Competitive Summary MfgMax Is (µA) Max Vos (µV) TCVos (nV/C) Max Ibias (pA) Noise 0.1 to 10Hz (µVp-p) Min BW (kHz) ISL28233256501801.0400 Comp A2510502001.1350 Comp B1715100501.96115 ISL28233 & ISL28433: Best-in-Class Performance for Precision and Drift on Extremely Low Power 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 Low Noise at Low Power Typical Application: Temperature Measurement

15 15 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 SensorsThermocoupleRTDTermistorIntegrated Silicon Temp Range (°C) -270 to +1800-250 to +900-100 to +450-55 to +150 Typical Applications High temperatureBridge temperatureBridge TemperatureComputers Chemical reactionsCalibrationPyrometer calibrationHVAC Bio physicsProcess controlFlow metersCell phones Gas ghromatographyInstrumentationAnemometers manometers Battery management Internal combustion engines Cold junction reference temp AdvantagesSimple, low cost, self- powered, rugged, wide temp range Most accurate, most stable, good linearity High sensitivity, fast response, 2-wire ohm measurement Most linear, highest output, inexpensive Dis- advantages 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

16 16 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 ANSIMaterialTemp Range ( °C) Sensitivity (µV/C) BPlatinum (6%)/Rhodium – Platinum (30%)/Rhodium 38 to 18007.7 CTungsten (5%)/Rhenium – Tungsten (26%)/Rhenium 0 to 230016 EChomel – Constantan0 to 98276 JIron – Constantan0 to 76055 KChromel – Alumel-184 to 1260 39 RPlatinum (13%)/Rhodium – Platinum 0 to 159311.7 SPlatinum (10%)/Rhodium – Platinum 0 to 153810.4 TCopper – Constantan-184 to 40045 Low Voltage Low Drift Op Amps ISL28233 ISL28134 ISL28176 High Voltage ISL28130 Low Drift Op Amps ISL28217 ISL28207 ISL28218

17 17 Vcm Range extends to -0.5V below Ground ISL28218 Precision 40V Single Supply, Low Noise Operational Amplifier Typical Application : Low Side Current Sense Features Single or Dual Supply, Rail-Rail Outputs Below Ground (V-) Input Capability 42V Abs Max Differential Input Range Wide Supply Range3V to 40V Low Current Consumption1100 μA Low Voltage Noise5.6nV/rtHz Temperature Range-40°C to +125°C ISL28118, ISL28218 has Outstanding Noise Performance at Half the Power. ISL28218 Rail to Rail Output and Ground Sensing Input are excellent for Low Side Current Sense Applications ISL28218 V+ V- + - Vpos + 500mv To Vneg - 500mV Robust 42V Differential Input Range Competitive Summary Below Ground (V-) Input Capability Wide 3V to 40V Operating Supply Range

18 18 Low Side Current Sense Amp Advantages Simplicity and low cost Low Common Mode Voltage Ground Sensing Input and Output Disadvantages Ground Path disturbances / Transients Limited dynamic range Load is lifted from ground due to Shunt Resistor No short circuit detection Key amplifier requirements 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 Vo = I L x R shunt x ( R f /R i + 1 ) Input Characteristics Low Sensor Impedance Low Signal voltage (100’s uV to 10’s mV) Depending on load current Low Inductance Low TC Rshunt ISL28218 is an excellent choice for Low Side Current Sense applications

19 19 Keys to success  Understand your full power chain, Vin –> Vout  Understand what is your biggest concern, Efficiency, Size, etc. Intersil Power Management in Industrial Control Under stand your power needs  Size, Efficiency, or a particular spec  What Power Source  Is Isolation needed  What are you powering Industrial Power Power is needed on all boards In general, the power chain looks like the one shown Vin -> Typ 24V, can go to 36V. Isolation will be required for some rails 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

20 20 ISL684X - Isolated Power Controller Family Max Current Sense Propagation Delay (ns) (Shorter is better) ISL6844 300 70 40 Fast 40 ns (Max) Peak-Current-Sensing Time Eliminates Short-Circuit Current “Tail Out” Bipolar UC3842A Best Competitive BiCMOS 3842 Features 1A MOSFET Gate Driver 60μA Start-up Current, 100μA Maximum 25ns Propagation Delay Current Sense to Output Fast Transient Response with Peak Current Mode Control 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

21 21 ISL85033 – 28V, 3A:3A Dual Std Buck Regulator CH1 CH2 Vin1 Vin2 Vout1: 3A Vout2: 3A CH1 CH2 Vin1 Vin2 Vout1: 6A Dual Buck Regulator - 3A/3A Outputs Single Parallel Buck – 6A Output Dual Output, Standard Buck Regulator with Integrated High Side MOSFET Vin range 4.5V to 28V Vout range 0.8V to 24V 3A/Channel guaranteed output current Selectable 180 o 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

22 22 ISL80101/2/3 High Current PMOS LDOs LDOs capable of 1A, 2A, and 3A current drive Designed for fast load transient response Tight ±2% V OUT accuracy over -40ºC < T J < 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 FeaturesBenefits 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

23 23 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)

24 24 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 Inductor R SEN Type III Compensation Boot Capacitor

25 www.intersil.com


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