www.fairchildsemi.com Deep Burst Mode Operation with Feedback Impedance Modulation for Reducing Standby Power Consumption of Switched-Mode Power Supplies Abstract – Many electric appliances operate in standby mode when not performing their main function. These appliances consistently consume electric power and the environmental impact of this power consumption has attracted public attention. This paper presents “deep” burst mode operation with feedback impedance modulation as a technique to minimize standby power consumption. The proposed method is verified with a 19V/65W prototype converter. I. INTRODUCTION There are roughly 10 billion units of AC-DC power supplies globally.[1] When an AC-DC power supply is plugged to a power outlet without loading, known as standby mode, it still consumes energy to maintain its output voltage. As power supplies are pervasive, the total power consumption in standby mode is a considerable portion of domestic energy consumption[2-3]. Consequently, regulatory agencies have started to set standards for no-load power consumption for these power supplies[4-5] and the regulations will become stricter in the future. There have been several attempts to reduce standby power consumption of AC-DC switchedmode power supplies (SMPS), such as reviewing industrial-available techniques of SMPS controllers[6], optimizing passive components[7], applying additional circuitry[8], and modifying the power converter topology[9]. The first two do not change circuit topology, so are in favored by SMPS manufacturers. The third and fourth possibilities need variation on circuit topology or additional part count, which takes time for industrials to implement. © 2012 Fairchild Semiconductor In this paper, a novel method called “deep burst mode” is introduced. With this method, the conventional topology can be used without additional circuitry. The next section analyzes standby power consumption in typical AC-DC SMPS. Deep burst mode is introduced in Section III and an experiment result of a 19V/65W prototype follows in Section IV. Section V provides the conclusion of this paper. II. STANDBY POWER CONSUMPTION OF SWITCHEDMODE POWER SUPPLIES Figure 1 shows the typical structure of an AC-DC SMPS with rated output power under 70W. The AC-DC SMPS mainly generates a DC voltage output from universal AC inputs (90~264Vrms). The SMPS is composed by following parts: an electromagnetic interference (EMI) filter used for meeting the EMI requirements, a bridge rectifier rectifying AC input voltage into a DC voltage on CBULK, a flyback converter converting the DC voltage on CBULK into specified DC output voltage, a PulseWidth Modulation (PWM) controller applied to control the flyback converter, and a feedback circuit taking the output-voltage information from the secondary side into the PWM controller in the primary side for regulation. For applying currentmode control, current information is sensed by a current-sense resistor, RSENSE. Deep Burst Mode Operation with Feedback Impedance Modulation for Reducing Standby Power Consumption of Switched-Mode Power Supplies Flyback Converter Universal AC Inputs LLPF NP NS CX Bridge Rectifier EMI Filter LP Feedback Circuit cont. SENSE 6 4 HV RT 5 PWM Controller CFB Primary Side VDD 7 3 NC NA Secondary Side Photo coupler GATE 8 2 FB CLPF - MOSFET 1 GND COUT DC Output CBULK RSENSE Feedback Circuit + Shotcky Diode Photo Coupler cont. Shunt Regulator Figure 1 General Structure of AC-DC SMPS under 70W The SMPS operates in standby state when the device connected to the DC output of the SMPS does not perform its main function or when the DC output is disconnected from any device. In standby state, although outputs requires very low or even no power, the SMPS still consumes some power for maintaining its operation and the output voltage. The major power losses are caused by: Power Consumption in PWM Controller Even when there is no load connected to the output, the power supply should keep operating to respond to the load variation of the output. To keep the power supply operating, the PWM controller should be properly biased, which results in power consumption. Power Consumption in Feedback Circuit A typical feedback circuit for isolated SMPS is shown in Figure 2. Because the primary side and secondary side of the circuit need to be properly biased for their operation, both of them consume some power. ZFB FB To PWM VOUT Primary Secondary Side Side VBIAS IC IF RD R1 Switching Loss Every time the power MOSFET switches, switching losses occur. The loss comes from changing the state of the MOSFET from ON to OFF or from OFF to ON. Generally, these power losses are proportional to switching frequency. Modern PWM controllers employ burst mode operation to reduce switching loss. Figure 3 gives typical operation of burst mode, where the GATE signal is alternatively enabled and disabled according to the feedback voltage. tburst=1/fburst VFB VFB-ZDC trest GATE Npulse Time Figure 3 Burst Mode Operation of PWM Controllers In conventional AC-DC SMPS, there are continuous losses in the startup circuit and X-Cap (CX in Figure 1) bleeder circuit. With a state-ofthe-art PWM controller, these losses can be reduced or eliminated by circuit integration.[10-11] RF CF VFB PC817 Controller IC KA431 R2 Figure 2 Typical Feedback Circuit of Isolated SMPS © 2012 Fairchild Semiconductor 2 Deep Burst Mode Operation with Feedback Impedance Modulation for Reducing Standby Power Consumption of Switched-Mode Power Supplies III. DEEP BURST MODE OPERATION PRINCIPLES To lower the standby power consumption, the power consumptions mentioned in Section II must be reduced. Deep burst mode is an innovative designed feedback-control mechanism. It is aimed at reducing standby power losses in the feedback circuit and switching process by modulating internal parameters of the PWM controller; nothing needs to change for other SMPS parts. Varying feedback configuration can cause negative effects on operation of the SMPS, so deep burst mode activates only when the loading is quite small. Figure 4 shows a conceptual flow of deep burst mode to avoid negative impact. Is loading extra light? B. Linear Operating Region of Shunt Regulators Figure 5 shows circuitry around the shunt regulator (KA431) in the feedback circuit. The operation principle of shunt regulators is to adjust IKA by monitoring VREF; higher VREF means larger IKA. According to datasheets of shunt regulators; for operating in linear range, VKA should be higher than the internal reference voltage (2.5V in typical) and IKA should be larger than minimum the regulation current (IKA(MIN), 0.45mA in typical)[12]. As a result, the linear operating range can be drawn as Figure 6. VOUT VF IKA Activate deep burst mode operation YES RD VKA VREF Figure 5 Circuit Around a Shunt Regulator IKA NO Normal Operation NO Switch MOSFET to keep the controller IC working YES VOUT VF 2.5 RD Modulate ZFB to be larger and clamp VFB internally (VKA<VREF) Linear Region Supply voltage of controller is nearing its lower boundary? I KA( MIN ) Cut-off Region NO Go back to normal operation YES Deep Burst Mode Operation Figure 4 Conceptual Flow of Deep Burst Mode Operation A. Activate Deep-Burst Mode Operation To activate deep burst mode, the PWM controller must ensure that loading of the SMPS is very low. In no-load condition, most PWM controllers operate in burst mode, as shown in Figure 3, where GATE stops when VFB is lower than VFB-ZDC. The non-switching time, trest, increases as load decreases, thus trest is used as an indicator for very light-load condition. The dynamic load change might activate deepburst mode operation, which can lead to oscillation of the output. Therefore, a delay is introduced to avoid prematurely entering deep burst mode. To explain the operation principle of deep burst mode, characteristics of shunt regulator should be explained. Then the configuration inside the feedback-pin (FB-pin) of the PWM controller needs to be discussed. With this background understandings, the whole operation principle can be described step-by-step. © 2012 Fairchild Semiconductor ~ 2.5V VREF Figure 6 Characteristics of Shunt Regulator Detect loading being increased? C. Configuration and Operation of PWM Controller for Deep Burst Mode In deep-burst mode, a new feedback impedance (ZFB) modulation technique is employed. Configuration of FB-pin internal circuitry is shown in Figure 7. Once activated, the deep-burst mode logic does the following manipulations . Switch ZFB to a larger value Connect RCLAMP between FB-pin and ground VBIAS VOUT Deep-Burst Logic ZFB FB To PWM IC IF VFB RCLAMP VDD Controller IC RD R1 RF CF PC817 VREF KA431 R2 Figure 7 FB-Pin Configuration and Feedback Circuit of Deep Burst Mode The objectives of deep burst mode operation are: Reduce power consumption in feedback circuit by increasing ZFB impedance 3 Deep Burst Mode Operation with Feedback Impedance Modulation for Reducing Standby Power Consumption of Switched-Mode Power Supplies Prevent UVLO of PWM controller by modulating ZFB impedance actively Reduce switching loss by rising VFB-ZDC With the controller cycling through these steps, the supply voltage of controller is kept higher than its allowable minimum level and output voltage is regulated around its specified value. Reducing Power Consumption in Feedback Circuit With the RCLAMP between FB-pin and ground, VFB is essentially clamped as: VFB CLAMPED RCLAMP VBIAS Z FB RCLAMP VOUT Step 3 Step 2 Step 4 Step 1 time (1) Once VFB-CLAMPED is lower than VFB-ZDC, GATE output is essentially terminated. Meanwhile, due to GATE output stopping, output voltage drops and the VREF of the shunt regulator drops. As a result, IF drops to IKA(MIN) and the shunt regulator works in the cut-off region (Figure 6). The large ZFB reduces IC. These manipulations reduce power consumption in the feedback circuit. VDD VDD-ZFBR time VFB rise due to Modulating ZFB VFB VFB-ZDC (normal mode) VFB fall due to VOUT rising VFB-ZDC (deep-burst mode) VFB drop due to abruptly switching ZFB time VGATE time Large-ZFB state Modulating-ZFB state Large-ZFB state Figure 8 Key-Waveform Diagram of Deep-Burst Mode Operation Preventing UVLO of PWM Controller Under no-load condition, power consumption of the controller itself is a dominant factor of the total power consumption of the power supply. Therefore, maintaining the supply voltage of the controller (VDD) as low as possible is critical to reducing the standby power consumption. As shown in Figure 4, as long as the load remains at its minimum level, deep-burst mode operation detects VDD to control the GATE output, preventing UVLO. The procedure is implemented by the following steps (corresponding waveforms are shown in Figure 8): Step 1: Once deep burst mode is activated, ZFB switches to large impedance, RCLAMP connects to the FB-pin, and VFB-ZDC is heightened. VFBCLAMP is always lower than VFB-ZDC, so there should be no GATE output. Step 2: Once VDD drops to VDD-ZFBR, which is near the minimum operation voltage for the controller, deep burst mode starts modulating ZFB to smaller impedance. Step 3: Once ZFB is modulated to smaller impedance, VFB-CLAMP and VFB both rise. When VFB rises above VFB-ZDC, the GATE signal starts to output. At this moment, both VDD and VOUT get the required energy. Step 4: Rising output voltage causes VFB to drop. Once VFB drops below VFB-ZDC, the GATE signal stops and deep burst mode logic switches ZFB to large impedance immediately. © 2012 Fairchild Semiconductor Reducing Switching Loss Raised VFB-ZDC causes burst mode operation to occur at higher VFB value. For peak-current mode control, the peak value of primary-side current (IPEAK) is proportional to VFB. Figure 9 shows waveform of primary-side current of a flyback converter operating in deep burst mode, where the average switching frequency is equivalent to: f SW . AVG f burst N pulse (2) The relationship between IPEAK and the average switching frequency (fSW.AVG) can be represented as: 1 PIN LPRI I PEAK 2 VBULK f SW . AVG 2 (3) where LPRI is the primary-side inductance, VBULK is the voltage on CBULK, and PIN is input power of the flyback converter. For a specified PIN, higher IPEAK leads to lower fSW.AVG. Thus, the increased VFB-ZDC reduces average switching loss. tburst=1/fburst IPRI K VFBZDC K VFB Npulse I PEAK time Figure 9 Primary-Side Current of Flyback Converter Operating in Deep Burst Mode 4 Deep Burst Mode Operation with Feedback Impedance Modulation for Reducing Standby Power Consumption of Switched-Mode Power Supplies D. Exiting Deep Burst Mode Modifying the FB-pin configuration can affect the feedback stability of SMPS since it can change the location of the pole of the compensation network. To minimize stability issues, changing the feedback impedance only occurs in standby state. As a result, the control algorithm to exit deep burst mode needs to be carefully designed. To exit deep burst mode, all the modifications to the feedback impedance and control circuit should be reset: recovering ZFB back to normal value, disconnecting RCLAMP from the FB pin, and turning VFB-ZDC to normal-mode value. According to status of ZFB impedance through the steps in Figure 8, the process can be categorized into two states: large-ZFB state and modulating-ZFB state. Two conditions for exiting deep-burst mode are implemented in the deepburst mode logic: 1) When loading gradually increases from noload, the increased power requirement extends the duration of modulating-ZFB state. This time duration can be an indicator of increased load. As the duration increases beyond a specific designed threshold, the controller exits deep-burst mode. 2) If a drastic load transient occurs during large-ZFB state, the PWM controller should modulate ZFB immediately to start MOSFET switching. In this situation, VFB rises quickly even if clamped. Sudden rise of VFB can indicate a load step change to exit deep burst mode during largeZFB state. IV. EXPERIMENTAL RESULTS The deep burst mode operation discussed in this paper was implemented in Fairchild’s mWSaver™ PWM controller FAN6756[10] and applied to a 19V/65W adaptor for laptop computers, whose schematic is shown in Figure 1 and Figure 7. Major parameters of the experimental prototype are listed in Table 1. With this PWM controller, the no-load power consumption of a 19V/65W adaptor can be as low as 30mW. Figure 10 Photograph of the Experiment Prototype TABLE 1. PARAMETERS OF EXPERIMENT PROTOTYPE Category Power Stage Passives Semiconductor Devices Feedback components © 2012 Fairchild Semiconductor Parameter Value Parameter Value LP 510µH COUT 1000µF NP 38 LLPF 1.6µF NS 8 CLPF 470µF NA 7 Controller FAN6756 Photo Coupler PC817A Shunt Regulator KA431 MOSFET FQPF7N65C Schottky Diode MBR20150CT R1 200kΩ RD 1.2kΩ R2 30kΩ CFB 1nF RF 4.7kΩ RSENSE 0.176Ω CF 2.2nF 5 Deep Burst Mode Operation with Feedback Impedance Modulation for Reducing Standby Power Consumption of Switched-Mode Power Supplies Figure 11 shows waveforms of FAN6756 in deep burst mode operation. In area I, the flyback converter operates in full-load condition. In area II, loading is decreased to no load, so the IC operates in burst mode. The controller assures that loading is quite low by checking tREST > 10ms. After waiting for the 900ms delay, the controller activates deep burst mode operation, shown in area III. Where the VDD-ZFBR is 7V, VFB-ZDC is 2.55V (outside deep-burst mode, it is 2.0V). Large ZFB value is 90kΩ, normal ZFB value is 8.5kΩ. In the last area of the figure, loading is changed back to full load, so the controller exits deep burst mode and resumes normal operation. I II III IV Full Load No Load VRD≈0.574V IF≈0.478mA VRD≈0.5V IF≈0.417mA VRD≈0.934V IF≈0.778mA ZFB=8.5kΩ ZFB=90kΩ (most of the time) Figure 12 Deep Burst Mode and Voltage across VRDOperation ≈0.574V ≈0.478mA RD (C1: GATE, C2:IFV FB, C3: VRD, 500ms/div) The measured power consumption under noload condition of the experiment prototype is shown in Table 2. For universal AC inputs from 90 to 264Vrms, the no-load power consumptions are all below 30mW, which can meet most international regulations and standards for standby power consumption with enough margin. TABLE 2. NO-LOAD POWER CONSUMPTION OF THE EXPERIMENT PROTOTYPE AC Input (Vrms) No-Load Power Consumption (mW) 90 18 115 19 230 24 264 27 Figure 11 Deep Burst Mode Operation of FAN6756 PWM Controller (C1: GATE, C2: VFB, C3: VDD, C4: VOUT, 1s/div) To get the IF of the photo coupler, voltage across RD in Figure 7 is measured. During burst mode, IF is around 0.778mA in this system. With ZFB switched to a larger value, IF is reduced to ~0.417mA, which is almost the minimum regulation current of the applied shunt regulator. As IF is reduced, the coupled current IC decreases; that is, power consumption in both primary and secondary side of the feedback circuit is reduced. © 2012 Fairchild Semiconductor V. CONCLUSIONS This paper has proposed deep burst mode operation, where the standby power consumption of an AC-DC SMPS is dramatically reduced by changing feedback circuit configuration and adding a dedicated logic circuit. The experimental prototype of a 19V/65W flyback converter confirms the feasibility and effectiveness of deep burst mode operation. Therefore, the mechanism is suitable for reducing the standby power consumption of AC-DC SMPS. 6 Deep Burst Mode Operation with Feedback Impedance Modulation for Reducing Standby Power Consumption of Switched-Mode Power Supplies REFERENCES [1] [2] [3] [4] [5] [6] [7] Calwell, C.; Mansoor, A.; Keefe, R., “Active Mode Power Supply Efficiency: Key Issues, Measured Data, and the Design Competition Opportunity,” Applied Power Electronics Conference and Exposition, 2004. APEC '04. Nineteenth Annual IEEE , vol.1, no., pp. 323- 328 Vol.1, 2004. Clement, K.; Pardon, I.; Driesen, J.; “Standby Power Consumption in Belgium,” Electrical Power Quality and Utilisation, 2007. EPQU 2007. 9th International Conference on , vol., no., pp.1-4, 9-11 Oct. 2007. 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Young-Bae Park; Moon, S.C., “Minimizing Standby Power by Optimizing Passive Components,” Fairchild Semiconductor Power Seminar 2010-2011. © 2012 Fairchild Semiconductor Hang-Seok Choi; Huh, D.Y. , “Techniques to Minimize Power Consumption of SMPS in Standby Mode,” Power Electronics Specialists Conference, 2005. PESC '05. IEEE 36th , vol., no., pp.2817-2822, 16-16 June 2005. [9] Byoung-Hee Lee; Young-Do Kim; Gun-Woo Moon , “SingleSwitching Double-Powering Converter for Reducing Power Consumption of AC/DC Adapter in Standby Mode,” Power Electronics and ECCE Asia (ICPE & ECCE), 2011 IEEE 8th International Conference on , vol., no., pp.199-204, May 30 2011-June 3 2011. [10] Fairchild Datasheet, “FAN6756 – mWSaver™ PWM Controller,” rev. 1.0.4, 2011. [11] Shao-Chun Huang, “AX-CAP™ Technology,” Fairchild Semiconductor White Paper, 2011. [12] Fairchild Datasheet, “KA431/KA431A/KA431L Programmable Shunt Regulator,” rev. 1.0.9, 2011. [8] Walter Chiu received B.S. and M.S. degrees in electrical engineering from National Taiwan University, Taipei, Taiwan, in 2008 and 2010. He is currently an application engineer in the Power Conversion group of Fairchild Semiconductor Taiwan, where he is involved in SSR flyback power management ICs and the development of mWSaver™-technology PWM controllers. 7