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Industrial Process control Solutions

Industrial Process control Solutions. 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

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Industrial Process control Solutions

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  1. Industrial Processcontrol Solutions

  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. Industrial Process Control Programmable Controller CANopen Master Module LCD Display Unit Power Supply • 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 Servo Drive Servo Drive Distributed I/Os Power Supply Sensors

  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. Industrial Control: Intersil Products Overview

  6. 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 ADC Signal Sensor Amp Amp Filter Precision VREF Power Supply • Input common mode disturbances come from: • Sensor contact with conductive surfaces • External transient sources • Earth ground disturbances

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

  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. How Do You Select the Right Amplifier? Indentify Global Priorities 1. Price, package, performance 2. New requirement or 2nd source? 3. Decision process - timing 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? Sensor Characteristics? Output Voltage Range Output Current Range Sensor Resistance Sensor Capacitance Supply Voltage, Bias Requirements V+ Output Requirements? Accuracy, Noise, Drift Rload, Cload, Vout or Iout Frequency, Amplitude Settling Time, THD Rail to Rail + - Amplifier Input Signal? Voltage or Current Amplitude, Frequency Signal to Noise, Temperature Drift Bias Voltage Ground Sensing Positive Rail Sensing Keys to Success Learn as much possible about the application and amplifier requirements 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/) Identify priority tradeoffs and finalize the selection V-

  10. Broad Portfolio of Precision Op Amps for Sensor Frontends

  11. Typical Application: Photodiode Outstanding Noise Performance Precision Low Noise JFET Op Amp 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 300 fA(typ)

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

  13. Low Noise, High Voltage Instrumentation Amp Using JFET Precision Op Amps Roll Your Own High Performance Instrumentation Amplifier Using High Voltage 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 ISL28210 ISL28207 ISL28127 ISL28117 Hi Z Vout Sensor ISL28210 ISL28207 ISL21090 ISL21009

  14. Micropower, Chopper Stabilized, RRIO Op Amps ISL28233 & ISL28433: Best-in-Class Performance for Precision and Drift on Extremely Low Power Competitive Summary Typical Application: Temperature Measurement • 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 ISL28233 Long Term Drift Zero Drift

  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

  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 Low Voltage Low Drift Op Amps ISL28233 ISL28134 ISL28176 High Voltage ISL28130 Low Drift Op Amps ISL28217 ISL28207 ISL28218 Diode Used for Cold Junction Compensation

  17. ISL28218Precision 40V Single Supply, Low Noise Operational Amplifier ISL28118, ISL28218 has Outstanding Noise Performance at Half the Power . • Typical Application : • Low Side Current Sense Wide 3V to 40V Operating Supply Range Below Ground (V-) Input Capability 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 Vpos + 500mv To Vneg - 500mV Vcm Range extends to -0.5V below Ground Robust 42V Differential Input Range Competitive Summary ISL28218 Rail to Rail Output and Ground Sensing Input are excellent for Low Side Current Sense Applications ISL28218 - V+ + V-

  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 ISL28218 is an excellent choice for Low Side Current Sense applications Vo = IL x Rshunt x ( Rf /Ri + 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

  19. Intersil Power Management in Industrial Control • 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 • 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

  20. ISL684X - Isolated Power Controller Family 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 Fast 40 ns (Max) Peak-Current-Sensing Time Eliminates Short-Circuit Current “Tail Out” ISL6844 40 Best Competitive BiCMOS 3842 Superior performance vs. Competition in every specification 70 Bipolar UC3842A 300 Max Current Sense Propagation Delay (ns) (Shorter is better)

  21. ISL85033 – 28V, 3A:3A Dual Std Buck Regulator • 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 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 Vin1 Vout1: 3A CH1 Vin2 Vout2: 3A CH2 • Dual Buck Regulator - 3A/3A Outputs • Single Parallel Buck – 6A Output Vin1 Vout1: 6A CH1 Vin2 CH2

  22. 2µs Settling 0 to 3A Load Step 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 Fast Transient Response

  23. 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) ISL80101/2/3 Competitive Advantages

  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 Boot Capacitor Inductor Type III Compensation RSEN

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