MIXED SIGNAL ASIC IN GAS INSTANTANEOUS BOILER · PDF fileMIXED SIGNAL ASIC IN GAS INSTANTANEOUS BOILER CONTROLLER 15% cost reduction and improved safety are achieved with Mixed Signal

24656 Demo.doc Version: 04.10.1999 10:10

FUSE Application Experiment N° 24656 Page 1 of 31

MIXED SIGNAL ASIC IN GAS INSTANTANEOUSBOILER CONTROLLER

15% cost reduction and improved safety are achieved with Mixed SignalASIC in a Gas Instantaneous Boiler Controller

Application Experiment n. 24656

24656 Demo.doc Version: 04.10.1999 10:10


Abstract

THERMOWATT is an Italian Company employing 303 persons. It produces electric and electroniccomponents for the industrial sector of house appliances in its plants in Arcevia. Electric Department is aworld-wide market leader in design, production and commercialisation of electrical heating elements andthermostats for boilers, washing machines, etc.

THERMOWATT markets its products on the European Countries and in the Far East

Total THERMOWATT production is composed by more than 100 different codes: burner controls units,dedicated diagnosis instrumentation and complete temperature and burner control circuits.

The Company experiences are on discrete electronic components and small PLD, up to 400 combinatorialgates, on micro-controller applications, on programmable logic device and on Gate Arrays

The THERMOWATT products are utilised as industrial components to be applied as electronic controls forgas appliances like instantaneous boilers.

The product to be improved is a gas instantaneous boiler controller. The existing production is realised onPCB boards using a Gate Array (collecting functions from three different PLDs), a lot of discrete digital,analogue, high voltage components and some large EMC filters.

The boards are installed inside the boiler for water temperature control acting on the gas burner and thewater flow.

Although all the functions were correctly responding to all the system needs (the product is certified EN298EMC), its overall costs were too high: the board mounts roughly 300 electronic components and the test tasktakes about 3' per piece. The Company decided to develop a new Mixed ASIC contains all the functions ofthe old one, cut down the mounted component of 60% in a unique board smaller 20% than before) andreducing the test time of 50%; as well, the Mixed ASIC accords to EN298 European norm.

The reduction of production cost is estimated in 20% (average 18.5 ECU against 22.75 ECU) allowing theCompany to increase its position on the market share.

The Application Experiment actual duration was 16 months. The ASIC project has been developed with acost of 95.42 KECU

The payback period of the FUSE investment is anticipated in about 17 months, and the ROI, calculated on a4 years product life, is 1476%.

Although the Company is using some microelectronic solutions (µP, PLD, GA), it was the first time that it

managed, developed, tested and started a high volume production based on MIXED ASIC. Many issueswere for the first time faced by the Company. It is now ready, not only to manage and assess correctly ahigh technological level project, but to exploit this knowledge in all the other Company products.

Keyword and signature

Keywords:Thermal control, gas heater boiler, electric equipment, MIXED ASIC, Safety Critical, Safety Certification, CE.

Signature:5-01415550310-3-2971-2-31-I

24656 Demo.doc Version: 04.10.1999 10:10


1. Company name and address

2. Company size

THERMOWATT is a company of MTS Group (Merloni Termo Sanitari).The Company turnover was 55.730 KECU in 1997 with 303 employees

MTS Group, already defined as a European company, is today known throughout the world, thanks to themanufacturing and commercial presence of subsidiaries in many countries.

The Group turnover in 1997 was 360 MECU with 2.500 employees and 25 MECU of technical investments.

The group is described in next diagram, where the THERMOWATT position is indicated by the arrow:

THERMOWATT S.p.A.Via S.Giovanni Battista, 21ARCEVIA (AN)60011 ITALY

- 1 – Thermowatt factory in Arcevia

24656 Demo.doc Version: 04.10.1999 10:10


The Company employees' breakdown within the Electronic Dept., that specifically has been involved in theApplication Experiment, is reported here after:

Thermowatt S.p.A. size within theGroup

MTS Group (2500 employees)

Thermowatt (303) others (2197)

Company departments (Electric/Electronic):employees breakdown

Thermowatt S.p.A. (303 employees)

Electric sector (274) Electronic sector (29)

Merloni Termosanitari S.p.A.

Branche commercial office consociated

MTS Benelux sa MTS International sa SMIR srl

Amalga sa

APT Service sa

Neotherme sa

MTS Pte ltd

MTS (Hong Kong) ltd

Argos srl

Thermowatt SpA

New Far srlSABELINVEST sa

MTS GmbH

MTS sa

Fleck sl

MTS (GB) ltd.

MTS Polska Sp z o.o.

MTS (Wuxi) ltd

MTS TermoSanitarios sa MTS Ceska Rep. Sr.o.

MTS (India) Ltd

24656 Demo.doc Version: 04.10.1999 10:10


3. Company business description

THERMOWATT develops, manufactures and markets electrical heating elements for boilers, washingmachines, etc., and electronics controls for instantaneous, storage and combi-gas boilers (the combi-gasboilers are able to produce hot water for both sanitary and heating aims).

Inside the factory, THERMOWATT carries out the following activities:- Establishment and production equipment management;- Products developing and engineering;- On-work safety and Environment defence;- Product-test laboratories management;- Business-marketing management.

The Company is a subsidiary company of MTS group. In fact, THERMOWATT was found to supply the groupthe "strategic" components as thermostats, cuirass power resistor, electronic board, etc.

For all these components, all the effort was spent to give the correct answer to the group needs; in a secondphase, these components are offered to the "external" market. Although the THERMOWATT is orientedtoward the "internal" market, it respects the same rules of the whole market as economical competitiveness,high product quality, etc. So, these issues allow the Company to face the whole market.

Thermowatt is involved in the industrial sectors of Tools and Machinery (29) in particular for ElectricDomestic Appliances (PCCOM 2971) and Non-electric Domestic Appliances (PCCOM 2972)

Thermowatt Products

Main line of products are:- Electric water heaters (European leader)- Industrial water heaters (European leader)- Boilers (European leader)- Gas water heaters (European leader)- Electric water heaters (European leader)- Sinks, Steel baths and shower trays, Acrylic and hydro-massage baths (20% European market)- Combi boilers (16% European market)- Electric Components (thermostats, electrical heating elements, pumps, electronic boards)

Thermowatt - Employees in Electronic sector

14

8

4

1

2

Production

Design & Development

Material Managing

Lab & Certification

Quality Assurance

24656 Demo.doc Version: 04.10.1999 10:10


Samples of Thermowatt products are shown below:

Considering detailed electronic production, at this moment there are more than 100 codes for it that aredivided in 5 families for typology, complexity and cost:

THERMOWATT ELECTRONIC PRODUCT LINESCAME: Single board in plastic box used in low-cost combi boilers. Temperature modulation by

external mechanical thermostats, with diagnosis interface; no special functions.GOVE: Single board in plastic box used in electronic combi boilers. Temperature modulation by PID

(Proportional Integral Derivative) electronic circuit, with diagnosis interface; no specialfunctions.

SERIE E: Power board and control board installed directly into the boiler control panel without plasticbox, used in new series of electronic combi boilers. Temperature modulation by PIDelectronic circuit, with diagnosis interface and led thermometer; special electronic functions:ice protection, pump protection, interface for remote user control unit.

SERIE ES: Power board and control board installed directly into the boiler control panel without plasticbox, used in new series of electronic combi boilers. Temperature modulation by STEPLEVELS electronic circuit, with diagnosis interface; special electronic functions: iceprotection, pump protection, interface for remote user control unit.Application area:

- 2 – MTS gas combi boiler - 3 – MTS storage

- 4 - One model of currentThermowatt electronic controlboards

24656 Demo.doc Version: 04.10.1999 10:10


- Electronic burner controls for combi-gas boilers, instantaneous boilers- Control systems for standing gas boilers

CA-CB: Single boards in plastic box only for burning sequence control. Thefamily is composed of standard products (dimensions andconnections) for gas appliances like gas fan heaters, instantaneousand combi gas boilers.Application area:- Electronic burner controls for combi-gas boilers, instantaneous

boilers and gas fan heaters;- Control systems for standing gas boilers- Control systems for air conditioning- Electronic control systems for electrical storage system- Electronic control systems for instantaneous electrical boilers

Specifically, electronic control that was object for FUSE Application Experiment is relevant to SERIE-E andSERIE-ES products, (highlighted in the table) which covered a volume production of 11,000 pieces in 1996(9% of electronic components production) and 40,000 pieces in 1997 (27% of yearly electronic production).

Total Company electronic production shares onto different product lines as it is shown in the following barchart:

The series E realised with the ASIC, the AE object, has a very good prospective in term of market, since thecompetitiveness and quality reached are very high and these will allows the company to face with the wholemarket.

- 5 – Thermowatt CA control unit

24656 Demo.doc Version: 04.10.1999 10:10


The table shows the share of the whole THERMOWATT production of the electronic boards. The figures arepieces.

THERMOWATT CLIENTSYears MTS Group External Client 1 External Client 2 TOTAL1995 91.000 5.000 96.0001996 110.000 7.000 8.000 125.0001997 130.000 10.000 10.000 150.000

4. Company markets and competitive position at the start of the AE

Characteristic of the market and evolution

The market of electrical and gas boilers (either for home application, as for Hospitals, Industries, and all thehuman Communities) is very large and in continuous evolution following the world’s increase energyconsumption. Therefore the same evolution of the energy consumption may be applied to the evolution ofboiler controls.

In particular in the Industrial Countries, but with a very impressive acceleration also in Emerging Countries.The forecasted exploitation of alternative energy may have an impact on this kind of products. Is possibletoday to foreseen a decrease of the market in the medium/long term and this is one of the main reason toinnovates the product with a reduction of costs and better versatility. Today the Thermostat products are in alarge part furnished to the other Companies of the Group (acting as a OEM manufacturer – the product isconsidered however “sold”) and in part sold in the market by distributors on the industrial sector of Tools andMachinery.

Company potential markets

The company delivers to the European market segment of electronic controls for gas boilers; the table showsthe European potential market. Other countries market were evaluated; for example, the Far East one needsproducts that are not safety designed and tested as European appliances; this market could be absorb up to2.000.000 Pcs/year.

Market Pcs/year PercentageItaly 1.200.000 34.3

Germany 800.000 22.9U.K. 600.000 17.1

France 400.000 11.4The Netherlands 350.000 10

Spain 100.000 2.9Others 50.000 1.4

Europe (Total) 3.500.000 100

A comparison between the Electronic Boiler Controls turnover respect to the other Thermowatt products isfurnished in the following table.

Product Turnover 1997 PercentageElectronic Boiler controls 4.280 13Other components 49.800 87

Total (KECU) 55.730 100

Market opportunity of AE product

24656 Demo.doc Version: 04.10.1999 10:10


The reduction of cost of the AE product associated to better characteristics and reduced dimensions of theboars is considered, by the company, the very interesting opportunity to increase the percentage of sales ofthe “external” market, i.e. that part do not absorbed by the Group, and the possibility to widen the number ofproduct with different degree of characteristics and prices.

It is also foreseen a better penetration in Emerging Countries, particularly in South America (Brazil) wherethe Management is negotiating the opportunity to produce “in loco” our product because the Politics of thisCountry that avoid the importation of finite products in order to maintain under control the inflation rate.

Current competitive positionThe company delivers to the European market segment of electronic controls for gas boilers. The figureshows the Company competitive position in the European market, where it covers the sixth position; theCompany is present on the domestic market with a share of 10%. THERMOWATT produces about 150 KPcs/Years of electronics controls for boilers.

Note that in a boiler, the electronic control is the item with the biggest value.

The European market analysis shows the trend to produce controls for combi-gas boilers on 1998. This trendis the same in the domestic market: in fact, focusing only on the combi-gas control production, the reductionof the product industrial costs could be reached.

As well, the entire market suffers of a critical situation due to the competitor coming from Far East. Their verystrong competition led then THERMOWATT to increase strongly the product competitiveness, especially incost reduction, since all the function are correctly carried out by the products.

These are the reason of the improvement that has been worked out on the control "SERIE E" type, followingthe THERMOWATT marketing department indication. In fact, it has been evaluated as the better item toimprove, since all the return both in economical and technical terms, should be the better ones on this type.

The major competitors, shown in the graph, are in Germany, Netherlands and France and they are presenton the market with products very similar to Thermowatt for what that concern the overall functionality but insome case they are already utilising very advanced techniques and technology as Fuzzy control, taking into

24656 Demo.doc Version: 04.10.1999 10:10


consideration a series of other variables. Thermowatt considers the AE as a first step that will be followed bysome other applications utilising the gained experience.

Excluding the more advancer application, all the other competitors are at the same technical level ofThermowatt and no weaknesses nor strengths are prevalent between them inside this scenario.

Economic data of AE product

The economic data of the E-series electronic boiler controller are shown in the following. The cost and priceare furnished as average data up-dated to 1997:Average manufacturing cost of products 22.75 ECUAverage sell price of products 28.59 ECU

Company total production during past three years is shown in table below, both in figures of quantity andrelated turnover. Electronic components, among which the FUSE target is, are highlighted.

TURNOVER 1995-1996-19971995 1996 1997

PRODUCT PCS/Y KECU PCS/Y KECU PCS/Y KECUELECTRONIC COMPONENTS 96.000 3.278 125.000 4.461 150.000 4.288

OTHERS COMPONENTS(THERMOSTATS…)

14.096.000

28.110 14.800.000

41.230 15.000.000

49.800

TOTAL COMPONENTS 14.192.000

31.388 14.925.000

45.691 15.130.000

55.730

5. Product to be improved

General description

Among all THERMOWATT products, the “SERIE E” is an electronic control board for gas instantaneousboiler appliances.

Essentially the electronic control receive command from the user (program or commands), measure thetemperature (water and external) and, when the water begins to flow at the user’s demand, the circuitoperates immediately to furnish the water at the imposed temperature activating pump, ignition, valve, fanmotor etc. The proper elaboration is described more in detail in the following.

In its essentially composed by two boards, which are shown in the pictures, devoted respectively to theelaboration and control of signals and the power actuation.

- 6 – Thermowatt SERIE-E control board - 7 – Thermowatt SERIE-E power board

24656 Demo.doc Version: 04.10.1999 10:10


The technology utilised for the boards are:• PCB with discrete components• Gate Array for logic functions• Electromechanical and HV components for spark-gap and power control

Functional description of product to be improved

The "SERIE E" control is installed directly into the boiler control panel without plastic box and is used in newseries of electronic combi boilers.

The control performs temperature modulation by a PID (Proportional Integral Derivative) electronic circuit,with diagnosis interface and led thermometer.

The product general control functions can be group into four main categories:

1. Control and Safety2. Regulation3. Temperature control4. Diagnosis - Visualisation

It worth to mention some special electronic functions performed that are:

• ice protection,

• pump protection

• interface for remote user control unit.The complete set is made by one Supply Control Board (EA), with a Temperature/Temperature Board (TTB)control module, and one Logic Control Board (EC) as showed with following functional block diagram.

The most important components used are:

• “CA90” GATE ARRAY : digital IC for burning control by logic equations.• DISCRETE COMPONENTS : for main controls (as safety timers, EMC filters, etc.).• TRANSFORMER : for DC supply and flame sensor circuit.

BLOCK DIAGRAM OF EXISTING PRODUCT TO BE IMPROVED

TTB MODULE

SUPPLY CONTROLBOARD (EA)

LOGIC CONTROLBOARD (EC)

CA90GATE

ARRAY

CONTROL CIRCUITSBY STANDARD ICsDISCRETE DEVICESAND PASSIVECOMPONENTS

GASMODULATOR

MAIN SUPPLYFLAME SENSOR

CARRY-OUTCIRCUITS

TTB SENSOR

MAINSUPPLY

GASPUMPSPARKVALVEFAN

USERSELECTIONS

TEMPSENSORS

BOILERSENSORS

24656 Demo.doc Version: 04.10.1999 10:10


• RELAYS : for high voltage carrying out and non-volatile lock-out.

Reason to improve the existing product

The product is on the market since several years and hence they came to the mature phase of their lifetime,presenting several drawbacks.

Actually, the pretty old conception of the boards, mainly using discrete off-the-shelf components, severelyaffected the manufacturing cost of these products. Their improvement mainly had been required foreconomic reasons of manufacturing costs saving.

The analysis for cost reduction on the control family "type E SERIES" highlighted the necessity to find a newtechnology that would have:

• Reduced the quantity of used components, saving space and improving product reliability• Better answered to EN 298 safety requirements in terms of EMC immunity as mandatory for safety

control gas appliances.

In fact current E-Series controls present the following problems to be resolved or improved:1. PCBs are very large: they take too much space inside the appliance;2. For EMC approval need a big external extra-filter;3. Need many components (more than 300) those cause production and component management

problems;4. Functional tests take a long time;5. Reliability must be improved.6. Introduction of new functions as a double safe circuit for gas control

24656 Demo.doc Version: 04.10.1999 10:10


6. Description of the technical product improvements

Detailed functional Block Diagram of product to be improved

SANITARYWATERFLOW

HEATINGWATERFLOW

ROOMTHERMOSTATTIMER

SANITARYWATERNTC SENSOR

HEATINGWATERNTC SENSOR

DIAGNOSYSINTERFACE

REMOTE CONTROLINTERFACE CIRCUIT

DIVERTOR VALVE CONTROL CIRCUIT

PUMP CONTROL CIRCUIT

PUMP SAFETY CIRCUIT

SANITARY WATER FLOW SWITCHDEBOUNCEING CIRCUIT

RUN MODE SELECTION CIRCUIT

ADJUSTABLE DELAY RESTART FORHEATING TEMP CONTROL CIRCUIT

MAX HEATING TEMP STOP CIRCUIT

BOILER LIMIT TEMP CONTROL

MAX SANITARY TEMP STOP CIRCUIT

PID SANITARY TEMP CONTROL

CHIMNEYSWEEPER CIRCUIT

ANTIFREEZE CIRCUIT

PID HEATING TEMP CONTROL

HEATING MAX POWER

SLOW IGNITION REGULATION C.

HEATING WATER LEDS-THERMOMETER

LEDS-THERMOMETER

TEMP CONTROLSIGNALS

GASMODULATION

CA90GATE

ARRAY

SAFETYTIMERS

LOCK-OUT

CONTROLS

LOGIC CONTROL BOARD (5033) SUPPLY CONTROL BOARD (5004)

FLAME SENSOR

TTB CONTROL CIRCUIT(PROT. FUMI)

CARRY OUT CIRCUIT

MAIN SUPPLY CIRCUITMAIN SUPPLY

DIVERTORVALVE

PUMP

GAS VALVE

SPARKER

IONIZATIONCURRENTELECTRODE

TTB NTC SENSOR

GASMODULAT

FUSE Application Experiment N° 24656 Version: 04.10.1999 10:10


General description

The new product substantially has the same functions as the existing one (SERIE-E and SERIE ES controlsystems), but a lot of components have been replaced with the single chip mixed ASIC. Next diagrams shows in details which functions were integrated into the new ASIC:

A comparison between the block diagram of the new product vs. the old one, immediately shows how theCA90 Gate Array has been integrated, as well as TTB module that was external on the old version.

DIVERTOR VALVE CONTROL CIRCUIT

PUMP CONTROL CIRCUIT

PUMP SAFETY CIRCUIT

SANITARY WATER FLOW SWITCHDEBOUNCEING CIRCUIT

RUN MODE SELECTION CIRCUIT

ADJUSTABLE DELAY RESTART FORHEATING TEMP CONTROL CIRCUIT

MAX HEATING TEMP STOP CIRCUIT

BOILER LIMIT TEMP CONTROL CIRCUIT

MAX SANITARY TEMP STOP CIRCUIT

CHIMNEYSWEEPER CIRCUIT

ANTIFREEZE CIRCUIT

HEATING MAX POWER REGULATION C.

SLOW IGNITION REGULATION C.

HEATING WATER LEDS-THERMOMETERCONTROL CIRCUIT

TEMP CONTROL SIGNALSMULTIPLEXER CIRCUIT

CA90GATE ARRAY

SAFETYTIMERS

LOCK-OUTCONTROLS

ACOBIGSTANDARD CELL A/D

(CCSE)

TTB CONTROL CIRCUIT(PROT. FUMI)

Fig.8 – New ASIC Engineering Samples

ASIC descriptionProcess: 1,2 _m, double poly, double metalDie size: 11mm_

Package type: ceramic CLCC 52



In addition, from the detailed block diagram shown in previous page, it can be seen how the CCSE chipincludes also:• safety functions (safety timers, lock-out controls);• temperature controls (max heating sanitary and boiler temperature stops);• regulations (diverter valve control, pump control, run mode selection, slow ignition regulation and others),• special functions (chimneysweeper and antifreeze controls).

The carried out integration generated the following benefits:

Economical benefits

Since the total number of components has been sharply reduced, as showed in next tables, components andproduct management had an important cost reduction (2,2 ECU for FFI version and 3,5 ECU for M/MIversions, where is integrated also the FUMI-TTB control circuit).Hence:• reduction of manufacturing costs

SERIE E family cost saving analysis comparing old and new product

Version OLD PRODUCT NEWPRODUCT

DIFFERENCE

MI 23,5 18,5 -5FFI 22 18,5 -3,5

Note: unitary cost for new SERIE E family is 18.5 ECU against average 22.75 ECU of the old familyproducts.

This means that by introducing ASIC, the Company is saving from 15% up 20% on unitary manufacturingcosts reducing the number of components and hence significant reduction in testing time and cost.

BLOCK DIAGRAM OF IMPROVED PRODUCT WITH THE NEW COMPONENT

SUPPLY CONTROL BOARD

LOGIC CONTROL BOARD

CCSE

ANALOG -DIGITAL

ASIC

GASMODULATOR

MAIN SUPPLYFLAME SENSOR

CARRY-OUTCIRCUITS

TTBSENSOR

MAINSUPPLY

GASPUMPSPARKVALVEFAN

USERSELECTIONS

TEMPSENSORS

BOILERSENSORS

CONTROL CIRCUITSBY STANDARD ICsDISCRETE DEVICESAND PASSIVECOMP.ONENTS



SERIE E family component utilisation and testing time: comparison between old and new product

COMPONENTEXISTINGPRODUCT

NEWPRODUCT

DIFFERENCE

GATE ARRAY 1 - -1STANDARD CELL - 1 +1

IC LM 358 1 - -1IC LM 324 5 1 -4

IC 4066 1 - -1IC 74HC14 1 - -1

TRANSISTORS 20 10 -10DIODES/ZENER 48 7 -41

RESISTORS 182 83 -99CAPACITORS 30 15 -15

PCB ( cm_ TOT EA+EC) 406 322 -84Production test time (in-circuit and

functional)3 min 20

Sec2 Min -1 min 20 sec

Technical benefits

The A/D Standard Cell technology solution allows integrating all typology of functions: only variable parts willremain external by discrete devices.

A double-safety circuit for gas control has been integrated and it has been verified with certifying EuropeanBody GASTEC collaboration in order to obtain CE certification.

This characteristic is the greater improvement of Thermowatt product relative to the competitors because it isabsolutely the first time it is applied to these kind of products, no other having this on the market.

This improvement increases the EMC immunity (new product has an internal special noiseless cell), so it willbe possible and easy to obtain EN298 EMC approval and remove many external filters, actually used in theexisting product.

The new Boile r mounting the ASIC objec t of the AEThe new circuit mounting the ASIC object of the AE



7. Choices and rationale for the selected technologies, tools and methodologies

TechnologyThe technology to use must be optimised according to the following main requirements:

- Costs Reduced manufacturing costReduced time for factory testReduced time for field testHandling of materials, immobilisation of capitalsWarehouse cost due to material codes

- EMC immunity Requirement of very low emission- Size of board The minimum as possible- Reliability The higher as possible- Time to market The shorter as possible

A methodology for the selection of the right technology is summarised in the following table

TECHNOLOGIES COSTS IMMUNITY SIZE RELIABILITY

TIME TOMKT

PCB

Components cost higher thennormal circuitHigh soldering costRedesign cost due toobsolescenceHigh manufacturing costSensible cost of handling andwarehouse materialsAutomatic assembly with pick-and-place SMD machines withreduction of timeWaste time in production andfield test because the spreadcomponents

Poorimmunity leveleither witheffort in lay-out design

Small sizeusing SMDcomponents

Low Low

Microprocessor

Needs external components asADC/DAC, Voltage referenceetc with a negative impact oncostSensible to obsolescenceMedium handling andwarehouse costsAutomatic assembly with pick-and-place SMD machines withsensible cost reductionProduction and field testsevaluated in minutes

Goodimmunity levelbut with lay-out designeffortsMinor effortson lay-outdesign

Small sizeusing SMDcomponents

Medium High(dependingby the SW)

ASIC

Very low cost of the componentfor high volumeNo redesign due toobsolescenceLow manufacturing costLow handling and warehousecostsProduction and field testsevaluated in seconds

Very highimmunity levelNo lay-outdesign efforts

Very small sizeusing SMDASIC

High Low



The first solution examined was using SMD (Surface Mounted Devices) components. The analysis showedthat there were no cost reductions for the SMD components (diodes, SMD transistors, SMD IC, op-amps,and gates); mounting, soldering components on PCB should cost more than traditional components; anywayPCB dimension would be shorter than in traditional technology. The conclusion is that SMD didn't lead tocost savings in the SERIE-E product.

In a conventional or SMD PCB is very hard to design an efficient lay-out, specially in presence of HighVoltage produced by the spark ignition. Filtering the noise that the spark generates is very expensive.

The second solution examined was Microcontroller 40 pin with A/D and PWM. The technical analysisshowed two important matters for which microcomputer was not a suitable solution:

- The first is the digital analogue conversion: the boiler needs an analogue output for temperaturecontrolling made by way of a coil in the gas valve.The SERIE-E control units makes this control in a simple way by a PID control current feedback and thefinal result is good with a final temperature output accurate to ± 1 C°.The resolution of the current control is 3 ma /C°.Using a microcontroller would lead to accuracy loss for D/A troubles and noise.

- The second reason is noise immunity: it is possible of frequent latch-up inside the control PCBs or in thesurrounding area of a few centimetres, specially in presence of the spark ignition that generates HighVoltage of the order of 20.000 Volts to ignite the aria/gas moisture. This can creates spikes on the signalground. The frequency for sparking is 10 Hz and the rise time for the HV pulses is about 50 ns, withassociated spectrum of frequency of the order of 20 and more MHz.

From the cost point of view, a microcomputer masked for big quantities is roughly 3,4 ECU more externalhardware, whereas new ASIC would cost about 2,7 ECU.

Hence a mixed signal ASIC revealed to be the most suitable trade-off between technical and economicalrequirements stated above.

ToolsThermowatt designers have developed the ASIC in the AMS labs, using Mentor software tools, collaboratingdirectly with AMS technicians. The use of the standard AMS libraries and methodologies allowed avoidingsoftware translation between different developing tool, optimising then all the results.The development has been carried out defining the digital and analogue components schematic andtranslating them in VHDL language. A sample has been realised producing an FPGA for the digital part andan analogue standard circuit, in order to test the correctness of the implemented functions.



8. Expertise and experience in microelectronics of the company and the staff allocated to theproject

Thermowatt's technical staff had no experience of ASICs, both from the technical and managerial points ofview.

Despite the complete “ignorance” in the specific sector, the Company has a large experience in hw and swdesign and the basic knowledge of the methodology and the ASIC technology in general.

Main expertise prior this Application experiment was on discrete electronic components and "small PLDs", upto 400 combinatorial gates.

The Company had expertise also in systems based on micro-controllers and on programmable logic device.Actually, micro-controllers used are Texas Instruments TMS370 and SGS Thomson ST6, and PLD used areALTERA Classics family (EP320, EP900) .

Three years before starting the experience of realising the mixed signal ASIC, the Company produced a gatearray, integrating a 400 gates PLD for saving cost reasons. But all the activities relevant to that integrationproject had been done by the silicon foundry, without any contribution from Thermowatt.

The people who took part in the Application are hereafter shown:

System Manager leader of the group of techniciansDesigner 1 With experience in water temperature and gas control electronic systems based on

Gate Array.Designer 2 With experience in water temperature electronic control systemsApproval Manager With experience in electronic software design for gas control appliancesTesting Manager With Testing and Quality Assurance experiences

9. Workplan and rationale

The original workplan, showed in the following table, was divided in 5 work-packages: Main objectives and activities conducted within each workpackage are reported hereafter:

1. ManagementGuide and co-ordination of the activities and of the people involved in the AE (first user and subcontractors):create plan, monitoring activities, organising and collecting data, negotiate with the suppliers, organiseconferences and dissemination actions.

2. TrainingAssure improvement in know how for managing of mixed ASIC.Design of gas boiler controls using ASIC particularly for safety questions and knowledge acquisition abouttesting methods of PCBs equipped with mixed signals by means of on job training for all the activities;special course for software simulation languages.

3. DesignTo transform the specifications in technical solutions written in form of schematics before and then indescriptive language (HDL) for ASIC implementation: specifications definition of a logical schematics andtheir translation to HDL for ASIC simulation and creation of test pattern.Multi-Product Wafer certification and final documentation for production mask.

4. FabricationSilicon foundry activities for MPW prototypes production.

5. Testing Functional and on board samples testing by field-test of 20 complete samples of new E-SERIE systemequipped with new ASIC.

An overview of the whole workplan is reported in table, were exact tasks conducted under workpackages 1-5are highlighted



WorkplanWORKPACKAGES TASK 1 TASK 2 TASK 3 TASK 4

WP1 MANAGEMENT PROJECTMANAGEMENT

DISSEMINATION

WP2 TRAINING MANAGEMENTTRAINING

CADTRAINING

DESIGNTRAINING

TESTTRAINING

WP3 DESIGN SPECIFICATIONS

DESIGN TESTAPPROVALSCHEMATICS

PRE-SAMPLESBREADBOARDVERIFICATION

WP4 FABRICATION M.P.W.PROTOTYPEPRODUCTION

WP5 TESTING TEST SET UP FUNCTIONALTESTING

PROTOTYPETESTING

FIELDTESTING

The following figure shows the budgeted Gantt in comparison with the actual one. The latter has had somevariations due to design-review activity.



Differences among the two charts are clearly evident but the plan has not suffered serious delays (it hasbeen necessary only an additional month to complete the program of the activities, having not considered atthe start the summer Company holiday time). This results was also thanks to the fact that during the AE,CESVIT has continuously supported THERMOWATT in documentation managing and in technical training bymeetings and specific training sessions.

Initially, we started defining a feasibility evaluation and following we carried out a balanced workplan.

In the first part of the AE, THERMOWATT staff was mainly involved in training activity to acquire knowledgein project managing and in CAD managing and design.

During all the on going phases of the activities, in order to realise the necessary documentation, it has beenvery important for WP1 conduction, the continual contact with CESVIT. Same for managing the contacts withFoundry AMS and for organising a presentation of the project in an important international seminar of thesector ("electronic controls for gas appliances" 24-25 November 1997 The Hague- Netherlands, organisedby GASTEC).

After the closure of the AE it will be then possible also to organise other meetings for the diffusion activity,particularly toward Italian companies, to transfer the acquaintances obtained from the experience of ourmixed ASIC first user.

At the beginning, WP2 training activity had been advised like a continual support during all the duration ofthe project. Instead, on going work, intense specific short and very practical training has been organised tofurnish at the THERMOWATT staff the adequate knowledge before facing each new phase of the project.CESVIT took care with attention of this part of the activities, always granting all the THERMOWATTrequests. This solution has allowed not dispersing the efforts of the involved persons. CESVIT contributionabout the aspects of technological management has revealed to be more important than any specificallytechnical contribution that they could have also furnished.

At WP3 start, the specification definition activity has been carried out. It was not very difficult for the completesystem (very similar at the existent product), but it was very important to define the ASIC specifications andtechnical solutions written in form of schematics before and then in descriptive language (HDL).

Within this design workpackage, AMS and GASTEC collaboration has been very important to define thecircuit realisation.

Thanks to GASTEC collaboration at this stage of the project, the CE certification activity of the ASIC device,used in all the different control boards versions of SERIE-E family, was started, and completed successfully.

It was very important to validate all steps of integration into a single chip of the safety circuit, because thiswas also a very first experience for GASTEC. Many technical solutions were defined together during specificmeetings with AMS technician and the GASTEC test engineer involved in this project.

AMS subcontractor collaborated to realise the ASIC internal circuitry, especially for the analogue cells, thepower supply and power ON/OFF reset controls; after the design definition it was fundamental the commonactivity in Multi-product Wafer prototypes production and their certification by simulations and lab tests.

GASTEC has participated in the various technical meetings to understand the criteria of the projectdevelopment and verify that each aspect pit in accord with the safety norms. That has been very importantfor avoiding to devote time and facilities to a project not compliant with CE norms: duty operate revisionswould have required additional costs and serious delays in the completion time of the plan.

This activity has required more time than expected and a big employment of human THERMOWATTresources, with the continual collaboration of AMS and GASTEC, but, when the verification of the design hasbeen completed, immediately AMS realised the samples of MPW with functional and safety specificationscompletely defined.

The final activity of samples verification (WP3) and test definition (WP5) has again involved Thermowatt,AMS and GASTEC, especially in the last three months of the project.



In this last phase it was necessary to do some modifications of the circuit and inside the layout of the deviceto overcome few problems that appeared on the MPW samples.

In the final period of the AE, THERMOWATT has completed the ASIC final documentation for productionmasks by simulation and creation of test pattern for the silicon foundry.

Last step, using the complete new PCB board with ASIC samples, was to realise functional and on boardtesting by field-test of complete combi-gas boiler samples.

As stated before, the complexity of the design and the difficulty of affecting all the conditions of operation ofan A/D ASIC would have required a big work of set-up on prototypes realisation. Lot of functional tests havebeen carried out by using at first PCB prototypes with programmable devices (XILINX) and after with MPWsamples.

Actually these tasks caused an increase of expenses with respect to the budget, due to the increase of theworking hours and the development costs for the certification phase of the samples.

Anyway, at the end of the AE, it was immediately transferred in production.

Awareness of these requested efforts is essential for a First User to avoid problems that can cause seriousdelays in the times of time production and considerable increases of expense.In Thermowatt's experience, it was also very important the choice of a silicon vendor like AMS, leader in thesector of the A/D ASIC, very available to furnish a continual technical collaboration in the realisation of thecircuit design and layout definition by simulations and functional tests. The following table shows the companies involved in this AE, their role and the percentage of their sustainedcost in front of the overall project costs:

% Cost on the overall projectCompany Roleplanned actual

THERMOWATT First User – all task 64.7 65.1CESVIT ASIC training and design support 12.2 11.5

AMS Silicon foundry and design 32.1 23.4 The next table explains the percentage of the cost sustained by subcontractors in front of each single task:

% of subcontractors cost per taskCompanyTraining Design Fabrication

planned actual planned actual planned actualCESVIT 37,9 37,9 9.1 8.5 0 0

AMS 0 0 30.9 31 100 100TOTAL 37.9 37.9 40.0 39.5 100 100



SUMMARY OF ACTUAL COSTS AT THE END OF THE PROJECT

Labour (p/d) Labour Cost(KECU

AMS Cost(KECU)

Cesvit Cost(KECU)

Other costs(1) (KECU)

Total(KECU)

Origin.

Actual Origin.

Actual Origin.

Actual Origin.

Actual Origin.

Actual Origin.

Actual

WP1

Management.

40 40 10.8 10.8 10.8 10.8

WP2

Training 64 64 9.03 9.03 5.51 5.51 14.54 14.54

WP3

Design 270 294 35.71 38.88 18.61 20.14 5.51 5.51 0.45 0.45 60.28 64.98

WP4

Fabrication

2.2 2.2 2.2 2.2

WP5

Testing 16 20 2.18 2.9 2.18 2..9

TOTAL 389 418 57.72 61,61 20.81 22.34 11,02 11.02 0.45 0.45 90 95.42

(1) PLEASE NOTE: purchase of a new PC

Risk analysis and contingency plan

At the beginning of the project was formulated an analysis of the possible risks and, at the occurrence, take adecision to reduce their effects.

The risk for the overall project was not considered high, because the Subcontractor experiences in the fieldwas a warranty for a success. The main individual risks are concerning the design for obvious reasons.

The risk of resources’ turnover was considered low because, in the geographical region where the Companyis located, this is not a true problem. Besides the Company can move resources within the group.In the following table are summarised the results described:

Risk Level Contingency planeManagementPersonnel change Low Periodic review concerning the work status

Substitution of personTrainingInsufficient designer’s skill Very low Additional trainingDesignComplexity underestimationChange in specification

MediumMedium

Additional person; modification of workplanDesign review; negotiation with the SystemManager;

FabricationDelay in prototype low Modification of workplan with anticipation and/or

paralleling phasesTestingDesign deficiencyFabrication defects

LowVery low

Redesign of partsNew prototype

Dissemination No risks

10. Subcontractor information

Considering the poor experience of the Company in the specific field of application (ASIC) it was a priorityneed to choice subcontractors with a very important capability to supports the Company in its learningprocess, other than to have a practical and consolidated experience in the field.



The subcontractors must provide the expected services with an excellent professional level and assistance indesign and test of new device.

Besides they must provide to THERMOWATT the skills needed to mix digital and analogue in one single chipand to define the ASIC internal layout according to safety norms and support THERMOWATT in thedevelopment and debug of the prototype.

The subcontractors have been selected in conformity with the following factors:• Relevant Expertise & Experience regarding the design and realisation of ASICs• References of previous project conducted providing "on job training" to the committing Company• Existing links with silicon foundries• Costs of the order of 50 ECU per hour• Accessibility and flexibility to get assistance at the need Two subcontractors whose experiences are reported below, were chosen because they matched theprevious requirements. SUBCONTRACTOR 1Name: AMS Austria Mikro Systeme International GmbHSize: 750Business: Development and production of application –specific integrated circuits.

Relevant Expertise & Experience: AMS is specialised in the development and production of application-specific integrated circuit. The company provides a continuum of custom and semi-custom MOS/VLSIcapabilities, including full custom circuits, standard-cell, high performance analogue and digital cell in CMOS,gate arrays and silicon foundry facilities for customer-designed circuits.

Services provided: AMS, the No.1 in the European market of analogue/digital ASICs, offers its customersfull custom circuits, standard cells and silicon foundry services for customers seeking the joint developmentof their circuits with the company and its “all under one roof” service – research and development, designengineering, mask lithography, wafer fabrication, assembly and test.

In this application, this foundry had a very important role, not only for the chip fabrication, but also for itsfundamental contribution in training Company's staff in mixed signal ASIC design, as well as in approachingwith them the problem of designing a layout suitable for EN safety regulations.

Costs: average hourly cost of 50-60 ECU

Rationale for choosing / evaluation of the subcontractor: The presence of an Italian AMS design centrein Milan, the experience and the cost competitiveness in analogue/digital ASIC design and fabrication are themain reasons for the choice of this partner.

AMS, during the AE, has continually furnished a technical support to Thermowatt. This support has allowedto define the circuit using the AMS certified libraries for the choice of the analogue standard cells and of thepower reset circuits control and of generation of internal clocks; in this way the certification and test activity ofthe device has been very simple and right.

For have this type of support it’s essential to choose a partner like AMS for have rights contacts with theinvolved people directly in factory and the availability of the of simulation and test tools.

General assessment with regards to the conducted AE: The subcontractor provided the expectedservices with an excellent level of support. It provided assistance in design and test of new device.It transferred to THERMOWATT the skills needed to mix digital and analogue in one single chip and to definethe ASIC internal layout according to safety norms.AMS has also supported THERMOWATT in the development and debug of the prototype.



Personnel and operative interface: AMS supported company in choosing technology and transforming thespecifications in technical solutions written in form of schematics before and then in descriptive language forASIC implementation. Then AMS had produced the prototype.

The AMS Italian office is in Milano and is very important to have a direct technical and commercial interfaceduring the development activity. Here tree persons have been involved in the project.

In AMS Graz (Austria), two designers have been involved in this project, as well as a layout engineer and atest engineer during the different steps of the ASIC development.

Contract and compliance: The Company stipulated a contract including clauses that guarantee Company'sintellectual property rights on developed project.

THERMOWATT has concluded with AMS a standard development and production agreement of integratedMOS circuit. The parties set out to develop the contractual circuit in two steps:

• Engineering samples production• Prototypes production after THERMOWATT approval

To start the production, THERMOWATT commitment was to advise AMS within 4 weeks after receiving theprototypes, writing to AMS about the samples correspondence to the requirements defined in the ASICspecification.

SUBCONTRACTOR TTN CESVIT

Name: Centro di Microelettronica of CESVIT (CESVIT-CM)Size: 36Business: High technology agency

Relevant Expertise & Experience: Microelectronics centre of CESVIT S.p.A. has a strong experience inPCB, FPGA, and ASIC design. The Centre is qualified to provide training and assistance to companies whodo their first design using a new technology and the Centre’s facilities, competencies as well as state of arttools, are available to companies.

It provides also training courses on VHDL languages test and to manufacturing services.

Services provided: On Job Training, Design Review and Management and an excellent accessibility andFlexibility was demonstrated. Besides, the subcontractor have a lot of links with different foundries.

Costs: average hourly cost of 50-60 ECU

Personnel:1 Senior Engineer1 Junior Engineer1 Market and business analyst

Rationale for choosing / evaluation of the subcontractor: CESVIT is the ideal partner forTHERMOWATT in this project for its strong experience in ASIC design.

Personnel and operative interface: Cesvit carried and training action which assured our technicians(electronic department Manager, design and testing Manager) the improvement in know-how managing ofmixed ASIC.

Technical training has been conducted on job, related with:- VHDL language- Development EDA tool used by foundry that was selected to realise the prototype- Testing methods of mixed ASICMoreover Cesvit, in quality of TTN, supported THERMOWATT also in managerial activity.



Contract and compliance:

The contract was a simple one based on a standard offer describing the cost and time allocated to the workand then on the respective order. The subcontractor role was mainly devoted to provide on job training to theCompany.

This kind of contract has demonstrated its effectiveness and adequacy with respect to the projectcharacteristics. CESVIT carried out activities within time and costs as reported in the offer/order, bothrelating with the technical and managerial aspect of the project.

The IP (Intellectual Property) concerning the implementation of the ASIC (it was the Application Experimentobject) was covered with a non-disclose agreement between the First User and the TTN CESVIT.

11. Barriers perceived by the company in the first use of the AE technology

The main barrier encountered by the Company was the management resistance to make a full integration inone chip.

Company's management usually approached innovative solutions trying to minimise the risks and withshortest time to market, avoiding any revolutionary design. Company development philosophy was that ofkeeping, as far as possible, near at the present solutions.

This cultural barrier was also related to a lack of detailed technical information about the effects of theintroduction of new technology in order to integrate, in only one chip, the main safety functions. This wasperceived as a problem for the standard safety requirements because GASTEC, centre for CE certification,had never considers this new solution before our Application Experiment. So it would be necessary to definenew verification criteria, similar at the standard for the existent products, but applied also directly at the ASICinternal layout.

Same barrier of lack of detailed technical information generated problems about the specific project of boilerfunctions: in the old project many function specifications were flexible using standard devices anddiscrete/passive components. Could an ASIC guarantee the same?

The problem was to define a small-size Integrated Circuit with many external hardware set-up selections likepump running mode, boiler version (M, MI or FFI and with or without storage boiler, etc.), just to get the sameflexibility. These problems have been very evident in the past because the SERIE E electronic control boardshad required continual changes of specifications to optimise the new product. Only when the project hadbecome more stable, it has been possible to appraise which THERMOWATT actions could do for reduce thecosts and increase the reliability of its products.

Another technology barrier was about the new approach to the use of XILINX devices necessary forprototyping and its software design tool.

THERMOWATT staff was accustomed to define directly by schematic entry the digital circuitry becauseexistent products are very simply but not optimised. Logic programmable device was too expensive forproduction utilisation, but they were an excellent support during the ASIC development activity. For thisreason was a problem the approach at the project definition and design using different languages and tools.

Few risks was perceived at the beginning of the project; they was concerning the personnel turnover and thealways possible cold acceptance of an innovative product by the market.

12. Steps taken to overcome the barriers and arrive at an improved product

The Company was actually able to overcome the cultural barrier since a well-structured work plan wascarried out. This has leading all the activities described, although they were not followed exactly. As well, thewhole ASIC development divided task by task makes THERMOWATT more confidants about the project,allowing then more flexibility in managing any single task. For these reasons, for THERMOWATT was veryimportant to characterise the companies that could furnish a particular support for overcoming all thetechnological and cultural barriers that the new project presented.



Then, THERMOWATT, with the CESVIT support, was applied the AE co-ordinating the relations with thesubcontractors and defining a correct workplan. About CESVIT, its main activity was to transfer toTHERMOWATT staff new project management criteria, organise support activities in design (VHDL training),and test definition. In fact, these were for the Company a very hard step to overcome, since different toolsand design methods experienced it.

AMS has guarantee specific technical support initially in ASIC design definition (internal cells and physicallayout) and analogue and digital simulations, too. After the Multi-product wafer samples production, the AMSsupport was in lab test analysis and final test patterns generation.

GASTEC has followed all the design activities to verify all the technical solutions according to CE norms. Itslabs in Apeldoorn (Netherlands) have allowed to make all the necessary tests for the verification of the safetyEuropean norms and the Immunity and Emission tests for EMC verifications. It was the first time thatGASTEC carried out these kinds of tests, so it was established a relationship that allowed to carry outsuccessfully all the activities.

13. Knowledge and experience acquired

The experience and knowledge transferred to THERMOWATT management staff is mainly on plan definitionand activity monitoring, and handling as well on co-operation with partners. This was more or less what thecompany had expected when it started the experiment.

The positive collaboration between partners permitted to THERMOWATT to acquire experience onstrategies, co-operation ways, and interaction necessary to exploit innovation within its commercial products.For this purpose during the development, when it was clear what potentiality would have the product, theCompany has carried out a market survey in order to investigates the better opportunity to exploit the results.This survey formulates a market plane in order to allows the management to apply new strategy concerning:price, distribution network, standardisation of the product within the group, an advertising campaign offeringa reduced price for retrofits and powering of service.

THERMOWATT technicians have trained to be able to design and test mixed analogue/digital ASIC usingVHDL description and XILINX EDA tools.

The collaboration with GASTEC Centre for CE certification permitted also to gain knowledge and experienceabout design and testing criteria according to the safety requirements for gas appliance controls.

So it is possible to summarise the gained Knowledge and expertise after the AE as follows:- Project managing and documentation;- Project specifications definition;- Design methodologies and High Level language tools utilisation;- Simulation tools;- CE certification criteria for mixed A/D ASIC;- Testing rules and tools for ASIC-based control systems.

14. Lessons learned

This AE showed THERMOWATT the importance of keeping up with technology advances to remaincompetitive and also revealed the importance of good project management and design methods that will bestrategic for future projects.

The success of the AE project strongly depends on the quality of the planning which goes into the originalworkplan. The THERMOWATT plan was inadequate at the beginning because to many “TBD” (to bedefined) and misunderstood activities were identified. It was changed and negotiated during the work with avery effective contribution of the partners.

One of the most important operation to do at the beginning is to evaluate the risks associated with eachmilestone and to define the time and the steps (like the prototype board using XILINX device and after theMulti product wafer samples production) to avoid problems related to functionality and technology in the finalproduction.



Concerning the delay on the scheduled plan, it was reduced because the fundamental intervention ofsubcontractors specially when some modifications of the circuit, inside the layout of the device, wasnecessary to overcome few problems that appeared on the MPW samples.

The most important lesson learned is related to the criteria to make a full integration in one chip of safetyfunctions required for gas appliance controls. Some misunderstanding encountered during the design wasresolved when it was clear the importance of the internal physical layout definition, not only the VHDLdescription.

However, the technical approach required in VHDL description, is a new experience for Thermowatt’stechnicians: using XILINX EDA tools, they have learned the new concepts for the circuitry description and allthe problems related to this activity (are necessary continuous hardware and software updating).

The choice of subcontractors is also very important for the success of the AE, where was fundamental thetraining and the samples fabrication activities.

Then the choice of the project partners must be a fundamental aspect of the AE. First user must select acompany that could furnish a continual and right technical support, like AMS, and it is main point collaboratewith contingent corporate body of project certification (like GASTEC) until from the beginning of the specificsdefinition activities and of the design realisation.

15. Resulting product, its industrialisation and internal replication

Industrialisation

In following table are showed the steps for the new E-SERIE control boards production.Starting with the experience acquired by the AE it is possible to industrialise this product with a minimumnumber of modification.

In order to produce a component with the larger versatility is possible THERMOWATT decided to apply anexternal hardware settings (jumpers or resistor values) of the parameters.In this way it is possible to change the temperature modulation system and the timings for pump and burnercontrol to permit to use the ASIC on many different applications. In fact, the new versions of CAME, GOVE,SERIE ES will be realisable using only the same integrated circuit.

The volume production will be carried out with the same foundry (AMS) utilised as a partner during the AEand the Mentor software tools used during the development will be still utilisedConcerning the resources employed in the development, THERMOWAT retain to change the team becausethe skill acquired may be distributed within the Company, utilising the more skilled person to become focalpoints for other technicians, in order to distributes the knowledge.

The industrialisation phases are scheduled as shown in the table.

PHASE ACTIVITY

FORESEENDEADLINE

Cost(KECU)

1. New ASIC production (10.000 pcs) October ‘98 30

2. New PCB production October ‘98 1.5

3. Internal samples certification November ‘98 0.75

4. CE (GASTEC) certification November ‘98 1.5

5. Boards automatic assembly definition November ‘98 2

6. Boards in-circuit testing definition November ‘98 1.5

7. Boards functional testing definition November ‘98 2.5

8. Start series production December ‘98 2

41.75



Internal replication

The replication of this experiment could be exploited in the same control boards for gas appliances field: itdepends by the market request, the production cost, and others variables that the Company is not actuallyable to evaluate. THERMOWATT will wait for one year for the results from the application field: whether anyproblem will rise from the field, the Company will start with a new ASIC development.

In any case, THERMOWATT is now skilled and experienced to carry out new ASIC for safety criticalproducts.

16. Economic impact and improvement in competitive position

SERIE E, the product which is the object of the AE is a product consolidated in the market. It is the results ofyears of experiences collected by the Company in the instantaneous gas boilers. In fact, some little boilerfunction can generate big problems; for example, it is a very big problem to protect the circuit from the over-voltage generated by the 20 KVolts spark: it requires to mount in the circuit big and expansive EMC filters.Then, although the circuit uses advanced technology components as the GA, its costs both fixed andvariable are too high. Only a high integration figure allows saving costs.

The new boiler controller design with the high level of integration, surmounts most of the issues with thecurrent boiler and provides added value to the customer in the reliability, safety and thermal accuracy (whichimplies energy saving). No known competitors today have such features and so the Company expects to bevery competitive particularly as the cost reduction adds some flexibility to pricing. An aggressive marketingposition will be employed.

The following table shows the sales values anticipated if the FUSE project were or were not undertaken

Return of Investment and Payback Period

The payback period based on the Fuse investment of 95.42K is anticipated in 17 months while the ROIassuming a 4 year product life is estimated at 1476%.

Sales with and without FUSE

0

5001000

1500

20002500

3000

3500

4000

1997 1998 1999 2000 2001

Year

Tu

rnov

er (

K?)

0

100

200

300

400

500

600

700

Pro

fit

Imp

rove

men

t (K

?)

Turnover with FUSE

Turnover without FUSE

Profit Improvement

Payback of 90K?



17. Target audience for dissemination throughout Europe

The experience of THERMOWATT will be useful for medium firms that, pushed by the market competition,must reduce the industrial cost of mature products, introducing a new technology able to reduce the quantityof components, to save space, to improve reliability and EMC immunity. It could be useful also for thosecompanies who have a management approaching innovative solutions trying to minimise the risks and withshortest time to market, avoiding any revolutionary design. And wherever Company development philosophyis that of keeping, as far as possible, near at the present solutions.

The following table shows the possible fields interested in the application:

Sectors PRODCOM DescriptionTools & Machines

Electric Domestic AppliancesNon-electric Domestic Appliances

29712972

The technology used optimises the following mainfactors:• product cost reduction• strong EMC immunity and very low emission• minimising factory costs: space for material stock,

easy testing, few material codes• improve reliability• short time to market with short time for field test

Precision InstrumentsIndustrial Process Control

Equipment3330 The safety functions, performed through the ASIC

Mixed with the “second fault tolerant” design, can beapplied in the Industrial process control equipment.

Many of the medium European enterprises developing electronics could repeat the experience ofTHERMOWATT, in particular all that Companies realising products where the control must match safetyrequirements.

In order to better focus the company to reach in dissemination activity, the following table states the Companycharacteristics:

Management: Conservative and following the "minimum risk" strategy.Starting technology: P CB ; µP digi tal and anal ogue di screte components techniques

Applications: Precision Instruments: Industrial Process Control Systems ,Tools & Machines: Domestic Appliances

Development Methodology: CAD tools; SW development tools, “second fault tolerant” designBarriers: Cultural and managerial

Company Size: 50-400Company turnover: 15-100 MECU

The Company would underline how all the obstacles to the introduction of the new technology were bounded byprejudices. They reveal their groundlessness during the project development and the use of new methodologies.In this sense, the utility of their experience was not only technical, and it could represent an invitation to deepenthe possibility to use new project methods, technologies and techniques without permitting that prejudices orsuperficial examinations mislead. The positive collaboration with the partners permitted First User acquiringexperience on strategies, co-operation ways and interaction necessary to exploit innovation within its commercialproducts.

MIXED SIGNAL ASIC IN GAS INSTANTANEOUS BOILER · PDF fileMIXED SIGNAL ASIC IN GAS INSTANTANEOUS BOILER CONTROLLER 15% cost reduction and improved safety are achieved with Mixed Signal

Documents