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TELEFUNKEN Semiconductors ANT018

Optocouplers in Switching Power Supplies

Issue: 12. 95
ANT018 TELEFUNKEN Semiconductors

Table of Contents
Introduction .................................................................................................................................................................... 1

VDE 0884 – Facts and Information............................................................................................................................... 1

Layout Design Rules ...................................................................................................................................................... 2

TEMIC Optocoupler Program ...................................................................................................................................... 4

Construction ................................................................................................................................................................ 4
Overview .................................................................................................................................................................... 4
6-PIN STD Isolators.................................................................................................................................................... 5

Appendix ......................................................................................................................................................................... 6

Approvals List............................................................................................................................................................. 6
Certified Optocouplers for Switchmode Power Supplies ........................................................................................... 6
Certifications............................................................................................................................................................... 7

Issue: 12. 95
TELEFUNKEN Semiconductors ANT018
Introduction
This report should give the designer a full understanding If design engineers work with TEMIC optocouplers, they
on how to use optocouplers which provide protection will find some terms and definitions in the data sheets
against electric shock for designs. which relate to VDE 0884. These will now be explained:
Safety standards for optocouplers are intended to pre- Rated isolation voltages: VIO is the voltage between the
vent injury or damage due to electric shock input terminals and the output terminals.
Two levels of electrical interface are normally used: Note: All voltages are peak voltages!
Reinforced, or safe insulation is required in an opto- • VIOWM is a maximum rms. voltage value of the
coupler interface between a hazardous voltage circuit optocouplers assigned by TEMIC. This characterizes
(like an AC line) and a touchable Safety Extra Low the long-term withstand capability of its insulation.
Voltage (SELV) circuit.
• VIORM is a maximum recurring peak (repetitive)
Basic insulation is required in an optocoupler interface voltage value of the optocoupler assigned by TEMIC.
between a hazardous voltage circuit and a non-touchable This characterizes the long-term withstand capability
Extra Low Voltage (ELV) circuit. against recurring peak voltages.
The most widely used insulation for optocouplers in • VIOTM is an impulse voltage value of the optocoupler
switch-mode power supply is reinforced insulation (class assigned by TEMIC. This characterizes the long-term
II). The following information enables the designer to withstand capability against transient over voltages.
understand the safety aspects, the basic concept of the Isolation test voltage for routine tests is at factor 1.875
VDE 0884 and the design requirements for applications. higher than the specified VIOWM/ VIORM (peak).
A partial discharge test is a different test method to the
VDE 0884 – normal isolation voltage test. This method is more sen-
sitive and will not damage the isolation behavior of the
Facts and Information optocoupler like other test methods probably do.

Optocouplers for line-voltage separation must have The VDE 0884 therefore does not require a minimum
several national standards. The most accepted standards thickness through insulation. The philosophy is that a
are: mechanical distance only does not give you an indication
of the safety reliability of the coupler. It is more
• UL/ CSA for America recommendable to check the total construction together
with the assembling performance. The partial discharge
• BSI for Great Britain test method can monitor this more reliably.
• SETI, SEMKO, NEMKO, DEMKO for Nordic The following tests must be done to guarantee this safety
countries (Europe) requirement.
• VDE for Germany 100% test (piece by piece) for one second at a voltage
Today, most manufacturers operate on a global scale. It is level of specified VIOWM/VIORM (peak) multiplied by
1.875 - test criteria is partial discharge less than 5 pico
therefore mandatory to perform all approvals.
coulomb.
The VDE 0884 is now becoming a major safety standard
A lotwise test at VIOTM for 10 seconds and at a voltage
in the world, partly due to German experts having a long
level of specified VIOWM/ VIORM (peak) multiplied by
record of experience in this field. It is therefore
1.5 for 1 minute – test criteria is partial discharge less
worthwhile understanding some requirements and
than 5 pico coulomb.
methods of the VDE 0884.
At the moment there are two drafts which are being Design example:
circulated to set the VDE 0884 to an international IEC The line AC voltage is 380 V rms. Your application class
standard. is III ( DIN/VDE 0110 Part 1/1.89). According to table 1,
The IEC 47 (CO) 1042 describes the terms and defini- you must calculate with a maximum line voltage of 600 V
tions – IEC 47 (CO) 1175 the test procedure, while the and a transient over voltage of 6000 V.
test method itself is already incorporated in IEC 747-5.

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ANT018 TELEFUNKEN Semiconductors

Table 1. Recommended transient overvoltages related to AC/ DC line voltage ( peak values )

VIOWM/VIORM Appl. Class I Appl. Class II Appl. Class III Appl. Class IV
up to

50 V 350 V 500 V 800 V 1500 V

100 V 500.V 800.V 1500.V 2500.V

150 V 800 V 1500 V 2500 V 4000 V

300 V 1500 V 2500 V 400 V 600 V

600.V 2500 V 4000 V 6000 V 800 V

1000 V 4000 V 6000 V 8000 V 1200 V

Now select the CNY75 from our TEMIC coupler temperature for at least a weekend. The test time is
program. The next voltage step of 380 V is 600 V actually 72 hours. This is a simulated space of time
(V IOWM ).The test voltages are 1600 V for the CNY75 where failures may occur.
for the routine test and 6000 V/ 1300 V for the sample
test. It is the designer’s task to create his design inside of the
maximum safety ratings.
The VDE 0884 together with the isolation test voltages
also require very high isolation resistance, tested at an Optocouplers – approved to the VDE 0884 – must
consequently pass all tests undertaken. This then enables
ambient temperature of 100°C. you to go ahead and start your design.
Apart from these tests for the running production, the
VDE Testing and Approvals Institute also investigates the
total construction of the optocoupler. The VDE0884 Layout Design Rules
requires life tests in a very special sequence; 5 lots for 5
different subgroups are tested. The previous chapter described the important safety
requirements for the optocoupler itself; but the knowledge
The sequence for the main group is as follows:
of the creepage distance and clearance path is also
• Cycle test important for the design engineer if the coupler is to be
mounted onto the circuit board. Although several different
• Vibration creepage distances referring to different safety standards,
like the IEC 65 for TV or the IEC 950 for office
• Shock
equipment, computer, data equipment etc. are requested,
• Dry heat there is one distance which meanwhile dominates
switching power supplies: This is the 8-mm spacing
• Accelerated damp heat requirement between the two circuits: The hazardous
input voltage (AC 240 power-line voltage) and the safety
• Low temperature storage (normally -55°C) low voltage.
• Damp heat steady state This 8-mm spacing is related to the 250-V power line and
• Final measurements. defines the shortest distance between the conductive parts
(either from the input to the output leads) along the case
Finally there is another chapter concerning the safety of the optocoupler, or across the surface of the print
ratings. This is described in VDE 0884. board between the solder eyes of the optocoupler input/
output leads, as shown in figure 1. The normal distance
The maximum safety ratings are the electrical, thermal
and mechanical conditions that exceed the absolute input to output leads of an optocoupler is 0.3 ″. This is
maximum ratings for normal operations. The philosophy too tight for the 8-mm requirement. The designer now has
is that optocouplers must withstand a certain exceeding of two options: He can provide a slit in the board, but then
the input current, output power dissipation, and the airgap is still lower; or he can use the „G“

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optocoupler from TEMIC. „G“ stands for a wide-spaced terial of the optocoupler itself and the material of the
lead form of 0.4″ and obtains the-8 mm creepage, clear- board must provide a specified creeping-current resis-
ance distance. The type designation for this type of „G“ tance. The behavior of this resistance is tested with
coupler is, for example: CNY75G. special test methods described in the IEC 112. The term
is "CTI" (Comparative Tracking Index).
The spacing requirements of the 8 mm must also be taken
into consideration for the layout of the board. The VDE 0884 requires a minimum of a CTI of 175. All
TEMIC optocouplers have a CTI of 275.
Figures 2 and 3 provide examples for your layout.
The creepage distance is also related to the resistance of
the tracking creepage current stability. The plastic ma-

Creepage
path

Clearance path

Figure 1. Isolation creepage/ clearance path

(The creepage path is the shortest distance between conductive parts along the surface of the isolation material.
The clearance path is the shortest distance between conductive parts.)

0.4 "/ 10.16 mm

0.332 "/ 8.2 mm

Figure 2. Optocoupler mounting on a board (side view)

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ANT018 TELEFUNKEN Semiconductors

Power interface area

G = 0.322 " / 8.2 mm

G

Layer

SELV control circuit area

Power interface area

G G
G

SELV control circuit area

Figure 3. Top view of optocoupler mounting on a board

(clearance on PC board: 0.322 ″/ 8.2 mm, creepage path on PC board is 0.322 ″/ 8.2 mm)
Not only the solder eyes of the coupler itself on the board must have the 8-mm distance,
but also all layers located between the SELV areas and the power interface areas.

Deviations of this distance during the production process

TEMIC Optocoupler are also excluded. These two features are the specific
reasons why TEMIC opto-couplers are well-accepted by
Program manufacturers of power supplies.

Construction
An optocoupler is comparable with a transformer or a
mechanical relay; but its advantages are smaller dimen-
sions, shorter switching time, no contact bounces, no
interference caused by arcs and the possibility of adapt-
ing a signal already in the coupler for the following stage
of the circuit.
0.75 mm
This combination together with the safety aspects pro-
vides outstanding advantages for use in power supplies. Figure 4. Cut through of a TEMIC optocoupler (thickness
Safety factors in particular depend on the design, con- through insulation)
struction and selected materials. TEMIC optocouplers
are designed with a coplanar lead frame, where the die
are mounted side by side. A semi-ellipsoid with even Overview
better reflection capabilities is fitted over each dice. The
entire system is then casted in a plastic material The information given in this brochure enables the
impermeable to the infrared range and of high di-electric designer to select the right optocoupler for his appli-
strength. The whole system is now molded with a special cation. The previous chapters focused only on safety
mold compound to ensure that no external influences such aspects. Apart from this there are other characteristics for
as light or dust etc. interfere with the functioning of the the optocoupler. Table 2 enables the designer to select
coupler (see figure 4). This design has several the optocoupler to suit his own needs. This selection
advantages: The "thickness through insula-tion", the should be done using the most important characteristics
clearance (internally) between the input and the output like CTR (Current Transfer Ratio) and devices with or
side is fixed at 0.75 mm and is thus mecha-nically stable without base connection. The designer may ask for our
even under thermal overloads, i.e. the possibility of a data sheets for detailed information.
short circuit caused by material defor-mation is excluded.

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TELEFUNKEN Semiconductors ANT018
n.c. C E B C E
6 5 4 6 5 4

95 10805
94 9222

1 2 3 1 2 3
A (+) C (-) n.c. A (+) C (-) n.c.

Figure 5. Without base connection Figure 6. With base connection

6-PIN STD Isolators

Table 2. Devices offering (VDE 0884-tested)

CTR VCE > 32 V VCE > 32 V VCE > 90 V

IC/ IF Ungrouped CTR Grouped CTR Grouped CTR

Base With Without With Without With Without

Connection

> 20% 4N25(G)V

> 50% CQY80N(G) TCDT1100(G) TCDT1120(G)

> 100% 4N35(G)V TCDT1110(G)

40 - 80% CNY17(G)-1 TCDT1101(G)

63 - 125% CNY17(G)-2 TCDT1102(G) CNY75(G)A TCDT1122(G)

100 - 200% CNY17(G)-3 TCDT1103(G) CNY75(G)B TCDT1123(G)

160 - 320% CNY75(G)C TCDT1124(G)

G = wide space 0.4″ lead form, for 8-mm PC board spacing requirements

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Appendix
are many agreements between national institutes, e.g., UL
Approvals List for USA is also accepted by CSA/Canada.
TEMIC divides optocouplers into "coupling systems".
As mentioned before, as long there is no equivalent IEC- Each coupling system represents the same technology,
standard to the VDE 0884, optocouplers must still fulfill materials etc. The coupling systems are indicated with
all other national safety standards. The enclosed copies capital letters and each coupler is marked with this
of documents present all certificates the designer needs coupling system indicator letter. The certificates at least
for worldwide acceptance of his power supply. All the also refer to the systems and list all subtypes to the
approvals below are most important. If the designer related coupling system. The user is able to track his
needs any others, he must be aware that there selected coupler on the certificate.

Certified Optocouplers for Switchmode Power Supplies

Coupling System Coupling System
G, H, I, K A, C, S

German Standard
VDE 0884 CNY64
CQY80N, CQY80NG
File No: CNY65
CNY17(G)1-3
System S: 70753 CNY66
CNY75(G)A-C
System A: 68301 CNY21N
TCDT1101(G)A-C
System G: 70902 TCDT1101(G)-1103(G)
System H: 70977 TCDT1110(G)
System J: 70977 TCDT1120-1124(G)
System K: 70977
American (USA)
Test Institute CNY64
UL CNY65
CNY66 4N25(G)V
1577
CNY21N 4N35(G)V
File No:
E76222
Nordic Approvals CNY64
CNY65 K3010P(G)-K3012P(G)
(SETI)
CNY21N K3020P(G)-K3023P(G)
British Std
BS415 CNY65
BS7002

Internal Structure

Case

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Certifications
Note: The certificates have been left out because of resolution problems. If you need the original application note,
please contact TEMIC.

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