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Ms 2443 final

  1. 1. Technical ArticleMS-2443.www.analog.comPage 1 of 10 ©2013 Analog Devices, Inc. All rights reserved.Safeguard Your RS-485Communication Networksfrom Harmful EMC Eventsby James Scanlon, Senior Evaluation Engineer, AnalogDevices, Inc., and Koenraad Rutgers, Senior FieldApplications Engineer, Bourns, Inc.IDEA IN BRIEFIn real industrial and instrumentation (I&I) applications,RS-485 interface links must work in harsh electromagneticenvironments. Large transient voltages caused by lightningstrikes, electrostatic discharge, and other electromagneticphenomenon can damage communications ports. To ensurethat these data ports can survive in their final installationenvironments, they must meet certain electromagneticcompatibility (EMC) regulations.These requirements include three main transient immunitystandards: electrostatic discharge, electrical fast transients,and surge.Many EMC problems are not simple or obvious, so they mustbe considered at the start of the product design. Leavingthese considerations to the end of the design cycle can leadto overruns in engineering budget and schedule.This article describes each of these main transient types andpresents and demonstrates three different EMC compliantsolutions for three different cost/protection levels on RS-485communication ports.Analog Devices, Inc., and Bourns, Inc., have partneredto extend their offering of system oriented solutions byco-developing the industry’s first EMC compliant RS-485interface design tool that provides up to Level 4 protectionlevels for IEC61000-4-2 ESD, IEC61000-4-4 EFT, andIEC61000-4-5 surge. It gives designers the design optionsdepending on the level of protection required and availablebudgets. These design tools allow designers to reduce risk ofproject slippage due to EMC problems by considering themat the start of the design cycle.RS-485 STANDARDI&I applications require data transmission between multiplesystems, often over very long distances. The RS-485 electricalstandard is one of the most widely used physical layerspecifications in I&I applications, such as industrialautomation, process control, motor control, and motioncontrol; remote terminals; building automation, such asheating, ventilation, and air conditioning (HVAC); securitysystems; renewable energy.Some of the key features of the RS-485 that make it ideal foruse in I&I communications applications are:• Long distance links—up to 4000 feet• Bidirectional communications possible over a singlepair of twisted cables• Differential transmission increases common-modenoise immunity and decreases noise emissions• Multiple drivers and receivers can be connected on thesame bus• Wide common-mode range (–7 V to +12 V) allows fordifferences in ground potential between the driver andreceiver• TIA/EIA-485-A allows for data rates of up to 10’sof MbpsTIA/EIA-485-A describes the physical layer of the RS-485interface and is normally used with a higher-level protocol,such as Profibus, Interbus, Modbus, or BACnet. This allowsfor robust data transmission over relatively long distances.In real applications, however, lightning strikes, powerinduction and direct contact, power source fluctuations,inductive switching, and electrostatic discharge can damageRS-485 transceivers by generating large transient voltages.Designers must ensure that equipment does not only workunder ideal conditions but that it will also work in the “realworld”. To ensure that these designs can survive in electricallyharsh environments, various government agencies andregulatory bodies have imposed EMC regulations. Compliancewith these regulations gives the end user assurance thatdesigns will operate as desired in these harsh environments.
  2. 2. MS-2443 Technical ArticlePage 2 of 10ELECTROMAGNETIC COMPATIBILITYAn electromagnetic environment is composed of bothradiated and conducted energy, so EMC has two aspects:emission and susceptibility. Thus, EMC has the ability of anelectronic system to function satisfactorily in its intendedelectromagnetic environment without introducing intolerableelectromagnetic disturbances to that environment. Thisarticle deals with increasing the protection level for EMCsusceptibility of RS-485 ports against the three main EMCtransients.The International Electrotechnical Commission (IEC) isthe world’s leading organization that prepares and publishesinternational standards for all electrical, electronic, andrelated technologies. Since 1996, all electronic equipmentsold to or within the European Community must meet EMClevels as defined in specifications IEC61000-4-x.The IEC61000 specifications define the set of EMC immunityrequirements that apply to electrical and electronic equipmentintended for use in residential, commercial, and light industrialenvironments. This set of specifications includes three typesof high voltage transients that electronic designers need tobe concerned about for the data communication lines:• IEC 61000-4-2 electrostatic discharge (ESD)• IEC 61000-4-4 electrical fast transients (EFT)• IEC 61000-4-5 surge immunityEach of these specifications defines a test method to assessthe immunity of electronic and electrical equipment againstthe defined phenomenon. The following sections summarizeeach of these tests.ELECTROSTATIC DISCHARGEESD is the sudden transfer of electrostatic charge betweenbodies at different potentials caused by near contact orinduced by an electric field. It has the characteristics of highcurrent in a short time period. The primary purpose of theIEC61000-4-2 test is to determine the immunity of systemsto external ESD events outside the system during operation.IEC61000-4-2 describes testing using two coupling methods.These are known as contact discharge and air-gap discharge.Contact discharge implies a direct contact between thedischarge gun and the unit under test. During air dischargetesting, the charged electrode of the discharge gun is movedtoward the unit under test until a discharge occurs as an arcacross the air gap. The discharge gun does not make directcontact with the unit under test. A number of factors affectthe results and repeatability of the air discharge test, includinghumidity, temperature, barometric pressure, distance, andrate of approach to the unit under test. This method is abetter representation of an actual ESD event but is not asrepeatable. Therefore, contact discharge is the preferred testmethod.During testing, the data port is subjected to at least 10 positiveand 10 negative single discharges with a one second intervalbetween each pulse. Selection of the test voltage is dependenton the system end environment. The highest specified test isLevel 4, which defines a contact discharge voltage of ±8 kVand an air discharge voltage of ±15 kV.Figure 1 shows the 8 kV contact discharge current waveformas described in the specification. Some of the key waveformparameters are rise times of less than 1 ns and pulse widthsof approximately 60 ns. This equates to a pulse with a totalenergy in the range of 10s of mJ.Figure 1. IEC61000-4-2 ESD Waveform (8 kV)ELECTRICAL FAST TRANSIENTSElectrical fast transient testing involves coupling a numberof extremely fast transient impulses onto the signal lines torepresent transient disturbances associated with externalswitching circuits that are capacitively coupled onto thecommunication ports, which may include relay and switchcontact bounce or transients originating from the switchingof inductive or capacitive loads—all of which are verycommon in industrial environments. The EFT test definedin IEC61000-4-4 attempts to simulate the interferenceresulting from these types of events.Figure 2 shows the EFT 50 Ω load waveform. The EFTwaveform is described in terms of a voltage across 50 Ωimpedance from a generator with 50 Ω output impedance.The output waveform consists of a 15 ms burst of 2.5 kHzto 5 kHz high voltage transients repeated at 300 ms intervals.Each individual pulse has a rise time of 5 ns and pulse durationof 50 ns, measured between the 50% point on the rising andfalling edges of the waveform. The total energy in a singleEFT pulse is similar to that in an ESD pulse. The total energyin a single pulse is typically 4 mJ. Voltages applied to the dataports can be as high as 2 kV.
  3. 3. Technical Article MS-2443Page 3 of 10Figure 2. IEC61000-4-4 EFT 50 Ω Load WaveformsThese fast burst transients are coupled onto the communicationlines using a capacitive clamp. The EFT is capacitivelycoupled onto the communication lines by the clamp ratherthan direct contact. This also reduces the loading caused bythe low output impedance of the EFT generator. The couplingcapacitance between the clamp and cable depends on cablediameter, shielding, and insulation on the cable.SURGE TRANSIENTSSurge transients are caused by overvoltage from switchingor lightning transients. Switching transients can result frompower system switching, load changes in power distributionsystems or various system faults such as short circuits.Lightning transients can be a result of high currents andvoltages injected into the circuit from nearby lightningstrikes. IEC61000-4-5 defines waveforms, test methods, andtest levels for evaluating immunity against these destructivesurges.The waveforms are specified as the outputs of a waveformgenerator in terms of open circuit voltage and short circuitcurrent. Two waveforms are described. The 10/700 µscombination waveform is used to test ports intended forconnection to symmetrical communication lines: forexample, telephone exchange lines. The 1.2/50 µs combinationwaveform generator is used in all other cases, in particularshort distance signal connections. For RS-485 ports, the1.2/50 µs waveform is predominantly used and will bediscussed in this section. The waveform generator has aneffective output impedance of 2 Ω; hence, the surge transienthas high currents associated with it.
  4. 4. MS-2443 Technical ArticlePage 4 of 10Figure 3 shows the 1.2/50 µs surge transient waveform. ESDand EFT have similar rise times, pulse widths, and energylevels; however, the surge pulse has a rise time of 1.25 µs andthe pulse width is 50 µs. Additionally, the surge pulse energycan reach up to almost 90 J, which is three to four orders ofmagnitude larger than the energy in an ESD or EFT pulse.Therefore, the surge transient is considered the most severeof the EMC transients. Due to the similarities between ESD andEFT, the design of the circuit protection can be similar, butdue to its high energy, surge must be dealt with differently.This is one of the main issues in developing protection thatimproves the immunity of data ports to all three transientswhile remaining cost effective.Resistors couple the surge transient onto the communicationline. Figure 4 shows the coupling network for a half-duplexRS-485 device. The total parallel sum of the resistance is 40 Ω.For the half-duplex device, each resistor is 80 Ω.During the surge test, five positive and five negative pulsesare applied to the data ports with a maximum time intervalof one minute between each pulse. The standard states thatthe device should be set up in normal operating conditionsfor the duration of the test.Figure 3. IEC61000-4-5 Surge 1.2/50 µs WaveformFigure 4. Coupling/Decoupling Network for a Half-Duplex RS-485 Device
  5. 5. Technical Article MS-2443Page 5 of 10PASS/FAIL CRITERIAWhen transients are applied to the system under test, theresults are categorized into four pass/fail criteria. Followingis a list of the pass/fail criteria giving examples of how eachone might relate to an RS-485 transceiver:• Normal performance; no bit errors would occur duringor after the transient is applied• Temporary loss of function or temporary degradationof performance not requiring an operator; bit errorsmight occur during and for a limited time after thetransient is applied• Temporary loss of function or temporary degradationof performance requiring an operator; a latch up eventmay occur that could be removed after a power on resetwith no permanent or degradation to the device• Loss of function with permanent damage to equipment;the device fails the testCriteria A is the most desirable with Criteria D beingunacceptable. Permanent damage results in system downtime and the expense of repair and replacement. For missioncritical systems, Category B and Category C will also beunacceptable, as the system must operate without errorsduring transient events.TRANSIENT PROTECTIONWhen designing circuitry to protect against transients, thedesigner must consider a few main items:1. The circuitry must prevent or limit damage caused bythe transient and allow the system to return to normaloperation with minimal impact on performance.2. The protection scheme should be robust enough to dealwith the type of transients and voltage levels the systemwould be subjected to in the field.3. The length of time associated with the transient is animportant factor. For long transients, heating effectscan cause certain protection schemes to fail.4. Under normal conditions, the protection circuitryshould not interfere with system operation.5. If the protection circuitry fails during overstress, itshould fail in such a way as to protect the system.Figure 5 shows a typical protection scheme, which can becharacterized as having primary and secondary protection.Primary protection, which diverts most of the transientenergy away from the system, is typically located at theinterface between the system and the environment. It isdesigned to remove the majority of the energy by divertingthe transient to ground.Secondary protection protects various parts of the systemfrom any transient voltages and currents let through by theprimary protection. It is optimized to ensure that it protectsagainst these residual transients while allowing normaloperation of these sensitive parts of the system. It is essentialthat both primary and secondary designs are specified to worktogether in conjunction with the system I/O to minimize thestress on the protected circuit. These designs typicallyinclude a coordinating element such as a resistance or anonlinear overcurrent protection device between theprimary and secondary protection devices to ensure thatcoordination occurs.Figure 5. Protection Scheme - Block DiagramRS-485 TRANSIENT SUPPRESSION NETWORKSBy nature, EMC transient events vary in time, so the dynamicperformance and the matching of the dynamic characteristicsof the protection components with the input/output stageof the protected device leads to successful EMC design.Component data sheets generally only contain dc data,which is of limited value given that the dynamic breakdownsand I/V characteristics can be quite different from the dcvalues. Careful design, characterization and an understandingof the dynamic performance of the input/output stage of theprotected device and the protection components is requiredto ensure that the circuit meets EMC standards.
  6. 6. MS-2443 Technical ArticlePage 6 of 10The circuits shown in Figure 6 illustrate three different fullycharacterized EMC compliant solutions. Each solution wascertified by an independent external EMC compliance testhouse, and each provides different cost/protection levels forthe Analog Devices ADM3485E 3.3 V RS-485 transceiverwith enhanced ESD protection using a selection of Bournsexternal circuit protection components. The Bourns externalcircuit protection components used consist of transientvoltage suppressors (CDSOT23-SM712), transient blockingunit (TBU-CA065-200-WH), thyristor surge protectors(TISP4240M3BJR-S), and gas discharge tubes (2038-15-SM-RPLF).Each solution was characterized to ensure that the dynamicI/V performance of the protection components protects thedynamic I/V characteristics of the ADM3485E RS-485 buspins such that the interaction between the input/output stageof the ADM3485E and the external protection componentsfunction together to protect against the transient events.Figure 6. Three EMC Compliant ADM3485E Circuits (Simplified Schematic, All Connections Not Shown)
  7. 7. Technical Article MS-2443Page 7 of 10PROTECTION SCHEME 1As described earlier, the EFT and ESD transient have similarenergy levels, while the surge waveform has energy levelsthree to four magnitudes greater. Protecting against ESDand EFT is accomplished in a similar manner, but protectingagainst high levels or surge requires more complex solutions.The first solution described here protects up to Level 4 ESDand EFT and Level 2 surge. The 1.2/50 μs waveform is usedin all surge testing described in this article.This solution uses the Bourns CDSOT23-SM712 transientvoltage suppressor (TVS) array, which consists of twobidirectional TVS diodes optimized to protect RS-485systems with minimal overstress while allowing the fullrange of RS-485 signal and common mode excursions(–7 V to + 12 V) on the RS-485 transceiver. Table 1 showsthe voltage levels protected against for ESD, EFT, and surgetransients.Table 1. Solution 1 Protection LevelsESD (-4-2) EFT (-4-4) Surge (-4-5)Level Voltage (contact/air) Level Voltage Level Voltage4 8 kV/15 kV 4 2 kV 2 1 kVA TVS is a silicon based device. Under normal operatingconditions, the TVS has high impedance to ground; ideally,it is an open circuit. The protection is accomplished byclamping the overvoltage from a transient to a voltage limit.This is done by the low impedance avalanche breakdown ofa PN junction. When a transient voltage larger than thebreakdown voltage of the TVS is generated, the TVS clampsthe transient to a predetermined level that is less than thebreakdown voltage of the devices that it is protecting. Thetransients are clamped instantaneously (< 1 ns), and thetransient current is diverted away from the protected deviceto ground.It is important to ensure that the breakdown voltage of theTVS is outside the normal operating range of the pinsprotected. The unique feature of the CDSOT23-SM712 isthat it has asymmetrical breakdown voltages of +13.3 V and–7.5 V to match the transceiver common mode range of+12 V to –7 V, therefore providing optimum protectionwhile minimizing overvoltage stresses on the ADM3485ERS-485 transceiver.Figure 7. CDSOT23-SM712 I/V CharacteristicPROTECTION SCHEME 2The previous solution protects up to Level 4 ESD and EFTbut only to Level 2 surge. To improve the surge protectionlevel, the protection circuitry gets more complex. The followingprotection scheme will protect up to Level 4 surge.The CDSOT23-SM712 is specifically designed for RS-485data ports. The next two circuits build on the CDSOT23-SM712 to provide higher levels of circuit protection. TheCDSOT23-SM712 provides secondary protection while theTISP4240M3BJR-S provides the primary protection. Co-ordination between the primary and secondary protectiondevices and overcurrent protection is accomplished usingthe TBU-CA065-200-WH. Table 2 shows the voltage levelsprotected against for ESD, EFT, and surge transients withthis protection circuit.Table 2. Solution 2 Protection LevelsESD (-4-2) EFT (-4-4) Surge (-4-5)Level Voltage (contact/air) Level Voltage Level Voltage4 8 kV/15 kV 4 2 kV 4 4 kVWhen a transient is applied to the protection circuit, theTVS will break down, protecting the device by providing alow impedance path to ground. With large voltages andcurrents, the TVS must also be protected by limiting thecurrent through it. This is done using a transient blockingunit (TBU), which is an active high speed overcurrentprotection element. The TBU in this solution is the BournsTBU-CA065-200-WH.A TBU blocks current rather than shunting it to ground. Asa series component, it reacts to current through the devicerather than the voltage across the interface. A TBU is a highspeed overcurrent protection component with a presetcurrent limit and a high voltage withstand capability. Whenan overcurrent occurs and the TVS breaks down due to thetransient event, the current in the TBU will rise to the current
  8. 8. MS-2443 Technical ArticlePage 8 of 10limiting level set by the device. At this point, the TBUdisconnects the protected circuitry from the surge in lessthan 1 µs. During the remainder of the transient, the TBUremains in the protected blocking state, with very lowcurrent (<1 mA) passing through to the protected circuit.Under normal operating conditions, the TBU exhibits lowimpedance, so it has minimal impact on normal circuitoperation. In blocking mode, it has very high impedance toblock transient energy. After the transient event, the TBUautomatically resets to its low impedance state and allowsresumption of normal system operation.Like all overcurrent protection technologies, the TBU hasa maximum breakdown voltage, so a primary protectiondevice must clamp the voltage and redirect the transientenergy to ground. This is commonly done using technologiessuch as gas discharge tubes or solid-state thyristors, such asthe totally integrated surge protector (TISP). The TISP actsas a primary protection device. When its predefined protectionvoltage is exceeded, it provides a crowbar low impedancepath to ground, hence diverting the majority of the transientenergy away from the system and other protection devices.The nonlinear voltage-current characteristic of the TISPlimits overvoltage by diverting the resultant current. As athyristor, a TISP has a discontinuous voltage-currentcharacteristic caused by the switching action between highand low voltage regions. Figure 9 shows the voltage currentcharacteristic of the device. Before the TISP device switchesinto a low voltage state, with low impedance to ground toshunt the transient energy, a clamping action is caused bythe avalanche breakdown region. In limiting an overvoltage,the protected circuitry will be exposed to a high voltage forthe brief time period that the TISP device is in the breakdownregion before it switches into a low-voltage protected on-state. The TBU will protect the downstream circuitry fromhigh currents resulting from this high voltage. When thediverted current falls below a critical value, the TISP deviceautomatically resets allowing normal system operation toresume.As described, all three components work together inconjunction with the system I/O to protect the system fromhigh voltage and current transients.Figure 9. TISP Switching Characteristic and Voltage Limiting Waveshape
  9. 9. Technical Article MS-2443Page 9 of 10PROTECTION SCHEME 3Protection levels above Level 4 surge are often required.This protection scheme will protect RS-485 ports up to andincluding 6 kV surge transients. It operates in a similarfashion to protection scheme 2, but in this circuit, a gasdischarge tube (GDT) is used in place of the TISP to protectthe TBU, which is, in turn, protecting TVS, the secondaryprotection device. The GDT will provide protection tohigher overvoltage and overcurrent stress than the TISPdescribed in the previous protection scheme. The GDT forthis protection scheme is the Bourns 2038-15-SM-RPLF. TheTISP is rated at 220 amps versus the GDT rating of 5 kA perconductor. Table 3 shows the protection levels provided bythis design.Table 3. Solution 3 Protection LevelsESD (-4-2) EFT (-4-4) Surge (-4-5)Level Voltage (contact/air) Level Voltage Level Voltage4 8 kV/15 kV 4 2 kV X 6 kVPredominately used as a primary protection device, a GDTprovides a low impedance path to ground to protect againstovervoltage transients. When a transient voltage reaches theGDT spark-over voltage, the GDT will switch from a highimpedance off-state to arc mode. In arc mode, the GDTbecomes a virtual short, providing a crowbar current path toground and diverting the transient current away from theprotected device.Figure 10 shows the typical characteristics of a GDT. Whenthe voltage across a GDT increases, the gas in the tube startsto ionize due to the charge developed across it. This is known asthe glow region. In this region, the increased current flowwill create an avalanche effect that will transition the GDTinto a virtual short circuit, allowing current to pass throughthe device. During the short circuit event, the voltagedeveloped across the device is known as the arc voltage. Thetransition time between the glow and arc region is highlydependent on the physical characteristics of the device.Figure 10. GDT Characteristic WaveformCONCLUSIONThis article described the three IEC standards of interest thatdeal with transient immunity. In real industrial applications,RS-485 communication ports subjected to these transientscan be damaged. EMC problems discovered late in a productdesign cycle may require expensive redesign and can oftenlead to schedule overruns. EMC problems should, therefore,be considered at the start of the design cycle and not at alater stage where it may be too late to achieve the desiredEMC performance.The key challenge in designing EMC compliant solutions forRS-485 networks is matching the dynamic performance of theexternal protection components with the dynamic performanceof the input/output structure of the RS-485 deviceThis article demonstrated three different EMC compliantsolutions for RS-485 communication ports, giving thedesigner options depending on the level of protectionrequired. The EVAL-CN0313-SDPZ is the industrys firstEMC compliant RS-485 customer design tool, providing upto Level 4 protection levels for ESD, EFT, and surge. Theprotection levels offered by the different protection schemesare summarized in Table 4. While these design tools do notreplace the due diligence or qualification required at thesystem level, they allow the designer to reduce risk of projectslippage due to EMC problems at the start of the designcycle, hence reducing design time and time to market. Formore information, please visit: 4. Three ADM3485E EMC Compliant SolutionsESD (-4-2) EFT (-4-4) Surge (-4-5)Protection Scheme Level Voltage (contact/air) Level Voltage Level VoltageTVS 4 8 kV/15 kV 4 2 kV 2 1 kVTVS/TBU/TISP 4 8 kV/15 kV 4 2 kV 4 4 kVTVS/TBU/GDT 4 8 kV/15 kV 4 2 kV X 6 kV
  10. 10. MS-2443 Technical ArticlePage 10 of 10REFERENCES:ADM3485E Data Sheet.Analog Devices Interface and Isolation. Telecom Protection Compatibility (EMC) Part 4-2: Testing andMeasurement Techniques—Electrostatic DischargeImmunity Test (IEC61000-4-2:2008 (Ed. 2.0)).Electromagnetic Compatibility (EMC) Part 4-4: Testing andMeasurement Techniques—Electrical Fast Transient/BurstImmunity Test (IEC61000-4-4:2012 (Ed. 3.0)).Electromagnetic Compatibility (EMC) Part 4-5: Testing andMeasurement Techniques—Surge Immunity Test(IEC61000-4-5:2005 (Ed. 2.0)).EVAL-CN0313-SDPZ. First, Hein. Application Note AN-960. RS-485/RS-422Circuit Implementation Guide, April, this article onOne Technology Way • P.O. Box 9106 • Norwood, MA 02062-9106, U.S.A.Tel: 781.329.4700 • Fax: 781.461.3113 • www.analog.comTrademarks and registered trademarks are the property oftheir respective owners. TA11306-0-1/©2013 Analog Devices, Inc. All rights reserved.