All in One PC Power Supply Reference Design Agenda • EPA efficiency requirements • Reference design goals • Topology selection • PFC stage design • LLC stage design • SR design • Standby management and handshaking • Reference design performance • Conclusions • Future work Energy Efficiency: Regulatory Agencies Targets •Standby (no load) Power Reduction • ~25% of total energy passing through power supplies is in standby mode[13] • Concerted effort by worldwide regulatory agencies •Active Mode Efficiency Improvement • ~75% of total energy passing through power supplies is in active mode[13] •Power Factor Correction (or Harmonic Reduction) • Applicable with IEC61000-3-2[11] (Europe, Japan) • Some efficiency specifications also require >0.9 PF. example: computers (ENERGY STAR® rev. 4[12]) Korea e-Standby program[8] China CSC[6] (ex-CECP), Japan Top Runner[9] program Japan Eco Mark[10] program Australia AGO[7] California CEC[5] Europe COC[4] ENERGY STAR®[3] Update on Energy Efficiency Regulations Computing •Desktops: • ENERGY STAR® 5.0 effective on Jul. 1, 2009 • 80 PLUS & Climate Savers Computing Initiative • Tiered efficiency levels •Laptops (More information at ENERGY STAR® 2.0 for External Power Supplies) • Efficiency: ≥ 87% • Standby (no load) power: ≤ 500 mW • PF ≥ 0.9 Set-Top Boxes (STB) Solid State Lighting Luminaires •ENERGY STAR® 1.1 effective on Feb. 1, 2009 • Off-state power: 0 • Minimum efficacy (Lumen/Watt) requirements by applications (downlights, outdoor lights, etc…) • PF ≥ 0.9 for Commercial ≥ 0.7 for Residential •ENERGY STAR® 1.2 effective in 2H2009 •ENERGY STAR® additional requirements for LED bulbs • PF ≥ 0.7 • High system efficacy high efficiency power supply •ENERGY STAR® 2.0 effective on Jan 1, 2009 •Europe Code of Conduct version 7 effective Jan 1, 2009 • Standard is based on maximum allowable TEC (Total Energy Consumption in kWh/year) or allowance • Base Allowance depends on the type of STB (Cable, Satellite, etc…) • Additional functionalities allowance (DVR, etc…) • Annual Energy Allowance (kWh/year) = Base Functionality Allowance + Additional Functionalities Allowance For exhaustive and up-to-date information on agencies and regulations, check the PSMA energy efficiency data base at: www.psma.com Efficiency Targets for Single-output Computing Power Supplies (Servers, Blades, All-in-1) Single-Output Levels Specification Efficiency (%) 20% of 50% of 100% of rated rated rated output output output power power power Effective Date • Single-Output • Non-Redundant • PFC 0.9 at 50% 81% 85% 81% Start June 2007 • Single-Output • Non-Redundant • PFC 0.9 at 50% 85% 89% 85% Start June 2008 All in 1 PC • Single-Output • Non-Redundant • PFC 0.9 at 50% • Single-Output • Non-Redundant • PFC 0.9 at 50% 88% 90% 92% 94% Sources: • 80 PLUS® : http://www.80plus.org/ • Climate Savers® Computing Initiative: http://www.climatesaverscomputing.org/ • ENERGY STAR®: http://www.energystar.gov/index.cfm?c=revisions.computer_spec 88% 91% Start June 2010 Target Target for this reference design Agenda • EPA efficiency requirements • Reference design goals • Topology selection • PFC stage design • LLC stage design • SR design • Standby management and handshaking • Reference design performance • Conclusions • Future work Reference Design Goals • Must meet highest EPA eff. requirements (80+ silver or gold) • Must fit into All-in-1 PC (Apple iMAC – 0.23 dm3) • Input voltage range 90-265 Vac • Single output – 12 V divided into two terminals: => Standby terminal: delivers power all the time - 50 mA in off mode - 100 mA in sleep mode - 5 A maximum in active mode => Power terminal: delivers power in active mode (15 A max.) • Total maximum output power 216 W Agenda • EPA efficiency requirements • Reference design goals • Topology selection • PFC stage design • LLC stage design • SR design • Standby management and handshaking • Reference design performance • Conclusions • Future work PFC Stage Selection • Input power for this application is > 75 W => need a PFC • ON Semiconductor offers solutions for three modes: Operating Mode IL IL IL Tclamp Tclamp Main Feature Continuous Conduction Mode (CCM) Always hard-switching Inductor value is largest Minimized rms current e.g.: NCP1654 Critical conduction Mode (CrM) Large rms current Switching frequency is not fixed e.g.: NCP1606 Frequency Clamped Critical Conduction Mode (FCCrM) Large rms current Frequency is limited Reduced coil inductance e.g.: NCP1605 PFC Stage Selection - FCCrM Efficiency of a 300 W, wide mains PFC has been measured: Efficiency at 100 Vrms NCP1605 (FCCrM) NCP1606 (CrM) 20% 30% 40% NCP1654 (CCM) 50% 60% 70% Output Load 80% 90% 100% Frequency Clamped CrM seems the most efficient solution while keeping reasonable cost PFC Stage Selection – Controller Some features useful in our application: - Frequency Clamped Critical Conduction Mode - Lossless High Voltage Current Source for Startup - Soft Skip Cycle for Low Power Standby Mode - Fast Line / Load Transient Compensation - Signal to Indicate that the PFC is Ready “pfcOK” - VCC range: from 10 V to 20 V - Output Under and Overvoltage Protection - Brown−Out Detection NCP1605 integrates all needed features for all-inone power supply and thus reduces overall cost Power Stage Selection cr n I g n i s ea r e w po & we o P ity s en D r Active clamp forward Forward Flyback Half-bridge LLC Power Stage Selection – LLC Benefits • Series type of resonant converter that allows operation over relatively wide input voltage and output load ranges • Limited number of components: resonant tank can be partially or fully integrated into main transformer • Zero Voltage Switching (ZVS) condition for the primary switches under all load conditions • Zero Current Switching (ZCS) for secondary rectifier under all load conditions • Simple synchronous rectification (SR) implementation Cost effective, highly efficient and EMI friendly solution Power Stage Selection – Controller NCP1397 Features: - High-frequency operation from 50 kHz up to 500 kHz - 600 V high-voltage floating driver - Adjustable minimum switching frequency (3% accuracy) - Adjustable deadtime from 100 ns to 2 us - Startup sequence via an externally adjustable soft-start - Brown-out protection combined with latch input - Timer-based auto-recovery and immediate latched OCP - Disable input for ON/OFF control (skip mode) - Low startup current of 300 µA - 1 A / 0.5 A peak current sink / source drive capability - Common collector or emitter optocoupler connections Benefits for all-in-1 application: • No driver transformer needed => size restrictions • Simple skip mode implementation => needed for standby • Simple OCP implementation => cost impact NCP1397 is cost effective and reliable solution for LLC power stage Power Stage Selection – SR Justification 6 2.33 % of output power 5 4 Losses [W] Losses calculated for one Shottky diode Here should be SR turned off 3 Losses calculated for one SR MOSFET (including driving) 2 2.17 % of output power 1 1.4 % of output power 0 0 3 6 9 12 15 18 Output current [A] Synchronous Rectification can significantly improve efficiency above certain output power Power Stage Selection – SR Controller Some features useful in our application: NCP4303 - Operates in CCM and DCM Applications - True Secondary ZCD with Adjustable Threshold - Automatic Parasitic Inductance Compensation - 50 ns Turn off Delay from CS to Driver - Interface to External Signal for CCM Mode - Trigger Input to enter Standby Mode - Adjustable Min Ton Independent of Vcc Level - Adjustable Min Toff Independent of Vcc Level - 5 A / 2.5 A Peak Current Drive Capability - Voltage range up to 28 V - Gate drive clamp of either 12 V or 5 V - Low startup and standby current consumption - Maximum Frequency of Operation up to 500 kHz NCP4303 is high performance driver for any SR system Secondary SR Turn On/Off • Usage of SR boosts efficiency above certain power only • Operation of SR for low output currents is inefficient SR needs to be turned off based on the output current information OTP for Secondary Rectifiers • Max output current is 18 A. In case of fan or secondary rectification system fail serious damage can occur to data or SMPS itself SMPS needs to be protected against over temperature and provide a signal to PC for fan speed control and to shut down prior the SMPS would fail Standby Management • According to All-in-1 spec the power terminal has to be turned off during standby mode by an external switch NFET provides low Rds on compare to PFET Complete Block Diagram FCCrM maximize eff. of front stage, reduces PFC coil size ZVS maximizes efficiency, LLC topology minimizes dimensions SR improves eff. under medium and high loads Disconnects pwr. output during STBY Agenda • EPA efficiency requirements • Reference design goals • Topology selection • PFC stage design • LLC stage design • SR design • Standby management and handshaking • Reference design performance • Conclusions • Future work NCP1605 Design Worksheet 200 uH PFC inductor keeps low operating frequency => EMI impact PFC Stage Schematic Agenda • EPA efficiency requirements • Reference design goals • Topology selection • PFC stage design • LLC stage design • SR design • Standby management and handshaking • Reference design performance • Conclusions • Future work Resonant Inductance Location? External inductance Internal leakage inductance Benefits: • Greater design flexibility • Lower radiated EMI emission • Transformer winding utilization Benefits: • Primary to secondary insulation is easy to achieve • Better cooling for windings • One component only Drawbacks: • Worse windings cooling • Primary to secondary insulation is more complex to achieve Drawbacks: • Less design flexibility • EMI radiation • Eddy currents in SMPS metal cover due to stray flux • Pure winding window utilization External resonant coil provides more benefits for high power density designs LLC Resonant Tank Parameters Selected solution: Standard transformer + external resonant inductance Transformer: Primary inductance Lm= 430 uH Leakage inductance Llk= 55 uH Turn ratio prim. to sec. n = 17.5 Turn ratio prim. to aux. naux = 11.6 Resonant coil: Ls= 30 uH Resonant capacitor: Cs= 2 x 12 nF LLC Resonant Tank Model • • This design uses transformer leakage and external coil as resonant inductance T model can be used L k = 1 − lk Lm Le1 = Le 2 = (1 − k ) ⋅ Lm Lme = k ⋅ Lm T model reflects the fact that Lm also participates on resonance => transformer gain impact LLC Stage Gain Characteristic 0.100 Full load 0.090 0.080 0.070 f op= 87 kHz@ V bulk=350 Vdc f op= 103 kHz@ V bulk=385 Vdc f op= 124 kHz@ V bulk=420 Vdc Gain [-] 0.060 0.050 0.040 0.030 0.020 0.010 0.000 1.00E+04 1.00E+05 1.00E+06 Frequency [Hz] Selected resonant tank provides narrow operating frequency range LLC Primary Side Schematic NCP1397 simplifies LLC stage design implementing dual OCP and skip mode by Agenda • EPA efficiency requirements • Reference design goals • Topology selection • PFC stage design • LLC stage design • SR design • Standby management and handshaking • Reference design performance • Conclusions • Future work SR Design Vds SR MOSFET losses: - Conduction losses Id π⎞ ⎛ = ⎜ I out ⋅ ⎟ ⋅ Rds _ on 4⎠ ⎝ 2 Pcond => Rds_on selection - Gate drive losses Pdrv = Q g ⋅ Fsw ⋅ Vcc => gate charge selection - Body diode losses I π⎞ ⎛ = out ⋅V f + ⎜ I out ⋅ ⎟ ⋅ Rdyn 2 4⎠ ⎝ 2 SR controllers consumption and gate drive losses in standby would hamper standby efficiency ⇒ It is critical to turn off whole SR system in standby mode Pbody => Affected by diode Vf, dynamic resistance and parasitic inductance, external Shottky to be used SR – Package Parasitic Inductance • TO220 package is mostly used due to cost and also simple soldering process • • • • Parasitic inductances Ldrain and Lsource create voltage drop that is proportional to the secondary current Isec(t) derivative. The Vds voltage reaches zero level prior secondary current SR controller detects zero voltage in the time the secondary current has still significant level => efficiency degradation Higher frequency or dIsec(t)/dt is, higher efficiency drop will be SR Design – Package Parasitic Inductance • This issue becomes really serious when very low Rds_on MOSFET is used SR controller with Vth_zcd= 0 mV SR controller with Vth_zcd= -5 mV SR controller with 0 mV ZCD threshold provides longer conduction period for SR MOSFET NCP4303 Parasitic Inductance Compensation Lcomp can be done on PCB or using ferrite bead Secondary current SR MOSFET gate voltage SR MOSFET conduction period is maximized when NCP4303 implemented with compensation Inductance Note: Parasitic inductance compensation not used in this PCB version Note: Patent pending SR Design – MOSFET Selection • SR MOSFET works under ZVS conditions => Gate charge is given by Ciss capacitance (Cgs+Cgd) and gate voltage MOSFET type Qg @ 5 V [nC] Qg @ 12 V [nC] Rds_on @ 5V [mΩ] Rds_on @ 12V [mΩ] IPP015N04N 101 245 1.9 1.2 FDP047AN 39 96 5.8 4 IRFB3206 55 133 3.3 2.3 SR Design – Gate Voltage Clamp Selection 6 Vclamp= 5 V Vclamp= 12 V Fop=120 kHz FDP047 AN Total power loss [W] 5 4 3 2 1 0 0 3 6 9 12 15 18 Output current [A] NCP4303 with 12 V gate voltage clamp to be used SR Final Schematic with SR Turn On/Off SR on/off switch Schottky Improves efficiency under light loads NCP4303 with min. ton and min. toff adjust resistors SR on/off comparator Secondary current sensing and amplifier Simple and cost effective SR implementation Agenda • EPA efficiency requirements • Reference design goals • Topology selection • PFC stage design • LLC stage design • SR design • Standby management and handshaking • Reference design performance • Conclusions • Future work OTP To All-in-1 PC Either PFC or LLC can be latched-off in case of overtemperature Power Terminal On/Off To All-in-1 PC N MOSFET provides low Rds_on Primary Biasing • HV startup is needed for All-in-1 application NCP1605 simplifies primary biasing X2 Capacitor Discharge Circuitry • It is mandatory to discharge X2 cap after is application unplugged from mains • X2 discharge resistor increases standby consumption Charge pump helps to decrease standby input power by removing X2 cap. discharge resistor Total Board Schematic Full All-in-1 solution from ON semiconductor Reference Design Photo – Top Side PFC stage Secondary capacitor Output connector SR MOSFETs and STBY switch on cooler EMI filter LLC stage Resonant inductor Transformer Reference Design Photo – Bottom Side NCP1397B LLC cnt. NCS1002 regulator LM324 amplifier 2 x NCP4303 SR cnt. NCP1605 PFC cnt. Agenda • EPA efficiency requirements • Reference design goals • Topology selection • PFC stage design • LLC stage design • SR design • Standby management and handshaking • Reference design performance • Conclusions • Future work SMPS Efficiency Charts 94% 91.7% 92% 89% Efficiency 90% 90.5% 90.4% 88% 87.8% 88.5% 86% 84% 82% 230 Vac 110 Vac 80% 0 3 6 9 Output current [A] 12 15 18 Reference design meets 80+ silver specification SMPS Efficiency Charts, Comparison With Original Solution Without SR 94% 92% Efficiency 90% 88% 86% 230 V (ON reference design) 84% 230 V (Original SMPS) 110 V (ON reference design) 82% 110 V (Original SMPS) 80% 0 3 6 9 12 Output current [A] 15 18 Light Load Efficiency 2000 No load 1800 50 mA load Consumption [mW] 1600 1400 1200 1000 800 600 400 200 0 90 115 140 165 190 AC voltage [V] 215 240 265 PF C co il SR r de er ifie di o re ct .& l re ct . PF C an sf or m sw h na nt co i Br id ge Tr itc O SF ET s es o M sw 8 R LL C O ut pu t Pd [W] Detail Losses Distribution 9 Vin=110 Vac Vin=230 Vac 7 6 5 4 3 2 1 0 Future Work • Implement parasitic inductance compensation in SR stage and thus further boost the efficiency. • Use different SR MOSFET(s) and gate clamp voltage to reduce driving losses. • Further optimization of the PFC stage efficiency • Boost efficiency to meet 80+ gold specification ☺ Conclusion • High efficient 80+ silver reference design from ON Semicondcutr is now available!! • FCCrM PFC stage driven by NCP1605 provides excellent efficiency results and minimizes PFC inductor size. PFC OK signal and skip mode featured in this controller simplifies design of All-in-1 PC SMPS • LLC power stage driven by NCP1397 provides high efficiency, skip mode capability and cheap OCP implementation • Synchronous Rectifier driven by NCP4303 maximize the SR MOSFET conduction time – thus maximize efficiency. Voltage clamp on the driver reduces driving losses • ON Semiconductor provides full support on this reference design and mentioned ICs For More Information • View the extensive portfolio of power management products from ON Semiconductor at www.onsemi.com • View reference designs, design notes, and other material supporting the design of highly efficient power supplies at www.onsemi.com/powersupplies