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1 September 2005
As the world of process control becomes increasingly complex, control and measurement signals that make or break the process application become more important. A stray signal can cause system inefficiencies, product contamination, and system failure. Consider several design parameters to maintain the accuracy and integrity of the overall system. Isolation and conditioning of signals have become top priorities. Related trends in process automation include more distributed measurement and control and smaller and lower cost input/output (I/O) modules. In order to meet these requirements, isolation and conditioning are sometimes left out of the I/O function, resulting in future problems, such as ground loops and noise, and therefore requiring external signal conditioners.
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Isolators
All isolation devices, regardless of their design or technology, perform the same function: they interrupt common mode currents while preserving information flow. Isolation also permits separating (and accurately measuring) small normal mode signals that ride on large common mode carrier (unwanted) signals. It's this function that breaks the ground loop. In a perfect world, an isolation circuit would allow information to flow across an isolation barrier with no signal degradation, no power consumption, no size or cost penalty, and infinite protection against common mode voltage differential (otherwise called ground loops) and transients. This type of isolator doesn't exist, but does serve as a benchmark to evaluate isolation technologies. Isolation can be analog or digital. Both analog and digital isolation can use components, such as transformers and opto couplers, for the separation of unwanted signals.
Optical isolation
Optical isolation uses a light emitting diode (LED) and a photodiode to convey information across an isolation barrier. Optocouplers, which see use in almost every branch of the electronic industry, are an effective low-cost method of isolating digital signals. However certain limitations exist in pure opto isolation circuits. These limitations are due to the time associated with the charging and discharging of the photodiode. When the energy from the LED strikes the photodiode, it immediately starts converting photons to electrons. When the LED turns off, the photodiode stops converting photons to electrons, but the existing charge needs to dissipate. There is a propagation delay associated with this process, which can distort input pulse widths. This affects the throughput rate of an optocoupler, which limits its use to slower applications.
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Even at slower speeds, optos can experience problems. The photodiode, a semi-conductor, is very sensitive to electro-static discharge (ESD) and common mode transients, which can produce unwanted distortions to the output. Despite the limitations, optos offer high isolation levels and low cost in a wide variety of low-speed applications.
Magnetic isolation
Magnetic isolation (DC/DC isolation) designs are based on transformers within the circuit. A magnetic isolator consists of a transformer with a driver at the primary and a receiver at the secondary. The driver encodes the input signal into an AC waveform that then couples from the primary to the secondary. The receiver then decodes the waveform and reconstructs the signal at the output. Constructing transformer-based digital isolators involves using high-speed CMOS devices with slow propagation delays, which can thus see use at high speeds and low speeds, maintaining high accuracy. The disadvantage of this type design is it requires a hybrid construction and enough space on the board (or vented housing designs) for heat dissipation. A few have been introduced to the market recently that are cost effective and require less PCB real estate. These devices, however, cost more than optos but provide high integrity signal conversion in a compact design.
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