element14 Learning Center

Optoelectronics I: Optocouplers
Sponsored by

1. Introduction | 2. Objectives | 3. Scope | 4. Basic Concepts | 5. Analysis |

6. Glossary | Related Components | Test Your Knowledge

1. Introduction

Should a production line halt because of a failure, millions of dollars and countless
opportunities may be lost. Two potential causes of breakdowns are electromagnetic
interference and high voltage surges. Does your environment require high voltage
isolation, enabling a safe interface between high and low voltage circuits? Do you have
a need to protect sensitive low-voltage components?

Optocouplers permit electrical circuits and highly diverse voltage levels to work together
as a system and interface with each other, while remaining electrically isolated or
galvanically separated. This learning module covers the concepts, design, and
implementation of optocouplers, a light emitting diode integrated with a photodetector in
one package to provide electrical insulation and signal isolation.

2. Objectives

After completing this module, you will be able to:

Discuss the basic concepts of an optocoupler

Explain how optocouplers work
Understand isolation technologies
Describe the different types of optocouplers

3. Scope

Optocouplers, sometimes referred to as opto-isolators or photo-couplers, are

semiconductor devices that isolate unwanted signals by physically separating high-
voltage circuits from low-voltage circuits.

Optocouplers are used in an array of isolation applications, ranging from data

communications and digital logic interface circuits, to power supply and motor control
circuits. They are suitable for use in industrial spaces, automotive markets, renewable
energy, and mission critical applications such as military and aerospace. They even
have a place in electronic hobbyist projects.
The scope of this learning module covers the fundamental of optocouplers, including
their construction, operation, design considerations, and types.

4. Basic Concepts

Optocouplers provide physical separation while still transferring signals between high
and low voltage circuits using a light source. An LED emits infrared light and a
photodetector device detects the light. Assembling these two components into an
integrated circuit (IC) package gives us a basic optocoupler.

Before investigating commercially manufactured optocouplers, let's explore what is

happening inside an optocoupler IC, by assembling our own home made optocoupler
isolation circuit, using discrete components from our electronics parts bins.

Figure 1: How to build your own Optocoupler

Using a piece of heatshrink tubing, physically connect an LED and a photoresistor.

Changes in light from the LED circuit will be seen by the photoresistor side of the circuit
as changing resistance. The LED side of the circuit is physically isolated from the
photoresistor by an air gap, and the signal is then transferred across the gap with light.
 Figure 2: Isolation insulation

Transferring a signal across a physical separation using light is represented in the block
diagram A in Figure 2. Tx is the transmitting light source and Rx is the receiver detector.
In block diagram B, there is a slot between the LED and the photodetector light sensor.
If the slot is blocked with an opaque object, the light transfer is inhibited. In this
application, the components could be used for end of tape detection or to signal the
level of a liquid. In block diagram C, the components are in a reflective configuration.
Light from the source is reflected onto the light sensor. This arrangement could be
employed to determine tape-position, shaft rotation, or to detect the amount of smoke in
the air.

A commercial optocoupler consists of an infrared emitting diode and a photodetector

separated by an optically transparent, electrically insulating film or dielectric. When a
current flows through the diode, light is emitted, which passes through the dielectric and
is coupled to the photodetector. The photodetector generates a current that is
proportional to the light received. This current can be manipulated by various circuitry to
perform specific functions. The major function of an optocoupler is to prevent high
voltages or rapidly changing voltages on one side of the circuit from damaging
components or distorting transmissions on the other side. This is done by optically
passing desired signals, while maintaining electrical isolation between two systems.

Optocouplers provide both electrical insulation and signal isolation. The ability of an
optocoupler to protect surrounding circuitry against damage from different voltage levels
is determined by its physical construction. The physical construction is also what
determines the desired isolation voltage.

Figure 3: Physical construction

Optocouplers (refer to Figure 3) with a vertical construction have the emitter diode
separated from the photodetector in a sandwich configuration. In vertical assemblies,
the optics (Tx & Rx) are separated by glass or a transparent polymer dielectric sheet.
Breakdown voltages are dependent on the thickness of the dielectric sheet and the
specifications of connections with external pins.

In horizontally constructed optocouplers, the emitter diode and the photodetector have a
gap between them enclosed in a bubble of silicon. The silicon is designed to trap and
reflect the light to the photodetector. Horizontal constructed optocouplers are rated for
voltages of < 2.4kV, with vertical devices rated for voltages of > 2.4kv to 6kV.

5. Analysis

Figure 4: Basic circuit analysis

The optocoupler isolates the input circuit from the output circuit. This means there can
be two separate power supplies, one for the input circuit and one for the output. In this
simple circuit, the input is 5VDC and output is Vcc. There is a voltage shift from the
input to the value of Vcc. In a circuit where the power supplies for both sides are using
the same voltage and current capabilities, the optocoupler is providing isolation without
any major shift in voltage or current levels.

In the optocoupler circuit provided in Figure 4, the resistor R1 provides current limiting
for the emitter diode (red). Its value is set to limit the maximum forward input current (IF)
through the infrared diode in the optocoupler. The values of the forward input current for
different types of optocouplers are detailed in their respective data sheets. For the
Avago® technologies 4N25, the IF is 10ma and for the HCPL-817 it is 50ma. The
resistor R2 in the circuit is the load resistor for the photodetector (green). Using the data
sheet values, you can calculate the value of R1.

Drop Voltage = Input Voltage - Input Forward Voltage (VF)

R1 = Drop Voltage / Input Forward Current (IF)

HCPL-817 Recommended Operating Conditions
Parameter Symbol Min. Max. Units
Power Supply Voltage VCC 4.5 18 V
Forward Input Current (ON) IF(ON) 0.5 12.0 mA
Forward Input Voltage (OFF) VF(OFF) 0 0.8 V
Operating Temperature TA 0 70 °C

Figure 5: HCPL-817 graph

The ratio of input current (IF) to output current (IC), called the Current Transfer Ratio
(CTR), is expressed as a percentage, and it can be found in the manufacturer’s data
sheet. The value of CTR will depend on the type of optocoupler, the value of
photodetector collector voltage (VC), and the ambient temperature. The CTR may
degrade over time. By starting with an IF that is lower than the maximum, it will extend
the device's performance over the intended lifetime of the circuit.

Isolation vs Insulation

In electrical circuits, isolation is required when transmitting signals between high and
low voltage systems. The end equipment standards define which level of isolation is
needed to ensure safe operation. The threshold of human safety standards requiring
reinforced protection starts at 42V DC or 60V AC, and for some sensitive integrated
circuits, the voltage level for desired protection may be even lower.
Isolation refers to the separation between two systems or voltage levels, while insulation
refers to the actual medium being used to do the separation. For example, an
optocoupler is an isolation device with a silicon insulation barrier between the infrared
emitter and photodetector.

Circuit designers can encounter three types of isolation-related issues:

Voltage Transients: These are brief and intense surges between two circuits or
systems. They are potentially high current or voltage surges that might damage
components, causing electric shock that can endanger human life.

Ground Loop Currents: These are unwanted signals between circuits of different
ground potentials, which result in ground loops. They are usually found in
communication networks having different grounds at various connecting nodes. The
potential difference in grounds for an alternating current (AC) or direct current (DC)
circuit can generate noise. In order to ensure reliable information exchanges, and to
prevent current flow between different ground reference voltages, there is a need to use
isolation.

High-Voltage Level Shifting: Using digital ICs results in lower operating voltages.
The need for devices to separate sensitive electronics from high power electronics is
growing. If the voltage potential is large enough, it can cause damage to equipment,
transmission error, or degradation of data signals. Long-term exposure results in the
heating and burning of circuit boards, which damages components and causes electric
shocks, some potentially deadly to human beings.

For example, in a motor control application the electronic system of a motor consists of
2 stages: the low voltage controller and the power module. Within such a system, it is
important to protect and insulate the two stages from switching transients and common
mode voltage fluctuations. At the same time, it is necessary to provide level shifting and
signal isolation of interface control and feedback circuits.

There are three main levels of insulation, called functional, basic, and reinforced.
Functional insulation is needed for correct operation between different potentials in a
system. Basic insulation provides protection for users from electrical shock, as long as
the insulation barrier remains intact. Reinforced or double insulation provides fail safe
operation in that, should one level of insulation fail, a second level will continue to
protect the user.

The level of insulation required is very much dependent on the failure mode of a
component under fault conditions. Reinforced insulation is only approved for a fail safe
component. This means that reinforced insulation not only provides protection from
electric shock, it has a failsafe design with a user's accessibility permissible.

In the market today, isolation devices based on optical technology (optocouplers) are
mainly still being used. However, alternative isolation devices based on magnetic,
capacitive, and Radio Frequency (RF) technologies are available and becoming more
prominent.

Electrostatic Discharge
One of the primary causes of component failure in high speed logic circuits is
Electrostatic Discharge (ESD). ESD can occur from improper device or board handling,
improperly designed interfaces, or some other phenomenon that causes a large voltage
spike on a device interface. When devices are damaged by ESD, the affected devices
might cease to function, exhibit parameter degradation, or demonstrate high failure
rates. The only solution is the replacement of the damaged component.

Optocouplers are excellent devices for protecting against ESD problems, especially in
situations where two systems are being linked together in electrically demanding
environments. Optocouplers allow for ground isolation, making it possible for systems to
remain electrically neutral within themselves, even though they may be floating in an
electrically noisy environment. These environments can include motor control, switching
power supplies, industrial networks, and medical applications.

Electromagnetic Interference (EMI)

Electromagnetic interference (EMI) can be defined as any electromagnetic disturbance
that disrupts, degrades, or otherwise interferes with authorized electronic emissions,
limiting the effective performance of electronics and electrical equipment.

It can be induced unintentionally, as a result of spurious emissions, inter-modulation

products, atmospheric disturbances (including lightning), extra-terrestrial sources (such
as sunspots), or intentionally, as in some forms of electronics warfare.

Radio Frequency Interference (RFI) is a special class of EMI in which radio frequency
transmissions result in problems in equipment operation. Radio frequency interference
can originate from a wide range of sources, such as mobile phones, power lines,
transformers, medical equipment, electro-mechanical switches, and devices that
transmit RF energy.

Developers explore two aspects of isolation devices when evaluating their EMI
performance: the amount of EMI the device itself generates, and the device's immunity
from radiated EMI. The utilization of optical, rather than electronic, pathways gives
optocouplers the advantage over other technologies.

Optocouplers provide the highest levels of protection and reliability from EMI in
electrical systems. They generate the least EMI and are the most resistant to EMI of all
the isolation technologies. Similarly, they are the most resistant to damage or disruption
by high-voltage transients.

Optocouplers also have a well-defined safety specification that allows them to receive a
reinforced rating for safety in critical applications.
Safety Standards for Isolation
International Safety Standards for devices are published to ensure equipment and
products are used at a basic standard level of safety. This ensures safety for both the
equipment and the people using it. These standards are focused on public safety in the
areas of electrical shocks, mechanical hazards, fire, and electromagnetic interference.
At the system and component levels, isolation safety standards vary within equipment
applications and geographically.

In the industrial market, the system-level safety standards international standards are
IEC 6043 (International Electrotechnical Commission), with UL5084 (Underwriters
Laboratories) for the United States and EN 624775 (European Union) for Europe. At the
component level for optocouplers, the safety standards are IEC 60747-5-5 for
International, UL 1577 for the United States, and EN 60747-5-5 for Europe.

To receive an IEC 60747-5-5 approval, optocoupler components undergo a stringent set

of qualification tests that includes environmental, mechanical, isolation, and electrical
testing. For future optocoupler standards and maintenance, the IEC will become the de-
facto standard worldwide.
The criteria for passing the component is the Partial Discharge (PD) test, with a rigorous
upper limit of 5 pC. Insulation, as a resistor to current flow, is an important factor in
product safety design.

The fundamental principle of designing for product safety is the separation of circuits
that present a danger of electrocution from other circuits, or certain parts of the
equipment that a user might come into contact with, or that connect to other equipment.
The circuit must be safe, not only during normal usage, but also under fault conditions.
Two main levels of insulation with clear distinction of safety are:

Basic Insulation Standards

Since January 2004, the standard certification for optocouplers has been IEC/EN/DIN
EN 60747-5-58. Although this standard specifically pertains to optical isolators only,
devices using other isolation technologies, such as magnetic or capacitive isolation
barriers, have obtained certifications to this optocoupler safety standard. This
recognition is limited to Basic Insulation only. This level of insulation might not provide
failsafe operation.

Devices that are certified and approved under IEC/EN/DIN EN 60747-5-5 with
recognition for Basic Insulation only provide basic protection against electrical shock.
They cannot be considered as fail safe. Such devices should not be accessible to a
user.

Reinforced Insulation
The level of insulation required is very much dependent on the failure mode of a
component under fault conditions. Reinforced Insulation is only approved for a failsafe
component. This means that Reinforced Insulation not only provides protection from
electric shock, it has a failsafe design and it is acceptable for users to have access.
Reliability of High Voltage Insulation
Optocouplers are often used in environments where high voltages are present. Though
many safety standard regulations have been established to provide guidelines to the
industry on the application of high voltages, the concern with this insulation is the
uncertainty of its reliability, due to poorly understood aging and failure mechanisms
under electrical and thermal stress.

Another measure of isolation barrier integrity is the high-voltage life test. This is
accomplished by simply applying a high-voltage across the isolation barrier and
measuring how long it takes for failure to occur in a high temperature environment. RF
isolation devices have fared somewhat better than optocouplers, but still only lasted a
few hundred hours.

Applications
Optocouplers are used in industrial communication applications, including industrial
input-output systems, sensors and temperature controlling systems, power supplies and
regulation systems, electric motor control and drive systems, and instrumentation and
medical systems.

They can also be found in Industrial Drives, Industrial Networking, Motor Control, PLC
Input/Output Isolation, Power Distribution Systems, Robotics, and Switching Power
Supplies designs. Optocouplers were initially proven in the first commercial hybrid
electrical vehicle (HEV), the Toyota® Prius. Optocouplers are being used in recently
released models of HEVs and Electrical vehicles (EVs) from Japan, Korea, China,
Europe, and the United States. In addition, more than 40 automotive companies,
including car manufacturers and tier one suppliers, are using or evaluating isolation
products.

Optocoupler Types

Optocoupler Types Functional Diagram

Darlington Output Optocouplers

Part Numbers: 6N139, 6N138,
HCPL-0701, HCPL-0700, HCNW139,
HCNW-138
These high gain series couplers use
a Light Emitting Diode and an
integrated high gain photodetector to
provide extremely high current
transfer ratio between input and
output. Separate pins for the
photodiode and output stage result in
TTL compatible saturation voltages
and high speed operation.
Optocoupler Types Functional Diagram
Digital Output Optocouplers
Part Numbers: 6N137, HCNW137,
HCNW2601, HCNW2611,
HCPL-0600, HCPL-0601,
HCPL-0611 Optically coupled gates
that combine a GaAsP light emitting
diode and an integrated high gain
photo detector. An enable input
allows the detector to be strobed. The
output of the detector IC is an open
collector Schottky clamped transistor.

Truth Table (Positive Logic)

LED Enable Output
ON H L
OFF H H
ON L H
OFF L H
ON NC L
OFF NC H
NOTE: A 0.1-µF bypass capacitor must be connected as
close as possible between pins 5 and 8.

Gate Drive Output Optocouplers

Part Numbers: HCPL-3180
GaAsP LED for high frequency
driving of power IGBTs and
MOSFETs. The LED is optically
coupled to an integrated circuit with a
power stage.
Optocoupler Types Functional Diagram
Linear Optocouplers
Part Numbers: HCNR200 and
HCNR201
High linearity analog optocoupler that
consists of a high-performance
AlGaAs LED that illuminates matched
photodiodes. The input photodiode
can be used to monitor, and therefore
stabilize, the light output of the LED.

Optically Isolated Amplifiers

Part Numbers: HCPL-7840
The optocoupler designed for current
sensing in electronic motor drives.

Optocouplers - Miscellaneous
Part Numbers: HCPL-3120/J312,
HCNW3120
The AlGaAs LED is optically coupled
to an integrated circuit with a power
output stage. These optocouplers are
ideally suited for driving power IGBTs
and MOSFETs used in motor control
inverter applications. The high
operating voltage range of the output
stage provides the drive voltages
required by gate controlled devices.
Optocoupler Types Functional Diagram

Transistor Output Optocouplers

Part Numbers: HCPL-817
Optocoupler for general purpose
applications. It contains a light
emitting diode optically coupled to a
photo-transistor.

6. Glossary

Galvanic isolation: a design technique that separates electrical circuits to eliminate

stray currents. Signals can pass between galvanically isolated circuits, but stray
currents, such as differences in ground potential or currents induced by AC power, are
blocked. Refers to a design or material technique that guarantees voltage and noise
isolation across an insulating barrier.

IEC 604: Industrial international standard for equipment and machinery

(http://www.iec.ch).

UL 508: US Industrial standard for machines (http://www.ul.com/).

EN 62477: Safety requirements for power electronic converter systems and

equipment (https://www.cenelec.eu).
 Basic Insulation: Insulation applied to live parts to provide basic protection against
electric shock (http://www.601help.com/Disclaimer/glossary.html)
Reinforced Insulation: Single insulation system applied to live parts, which provides
a degree of protection against electric shock equivalent to double insulation under the
conditions specified in IEC 60601-1 (http://www.601help.com/Disclaimer/glossary.html).

IEC/EN/DIN EN 60747-5-5: International safety standards (http://www.cenelec.org/).

Failsafe: A mode of system termination that automatically leaves system processes

and components in a secure state when a failure occurs or is detected in the system.

*Trademark. Broadcom is a trademark of Broadcom Inc. Other logos, product and/or company names
may be trademarks of their respective owners.

Take the Quiz