Design Idea DI-61
TinySwitch®-II 3 W Charger:
<200 mW No-load Consumption
Input Voltage
Topology
Device
Power Output
Output Voltage
Application
Flyback
Charger
3 W
85-265 VAC
TNY264P
5 V, 600 mA
The circuit meets CISPR-22 Class B conducted EMI limits
without aYcapacitor,andthereforehasverylowACleakage
current. This EMI performance is achieved via the
TinySwitch-II internal jitter, use of a shield winding, an
output RC snubber, and the primary RCD clamp.
Design Highlights
• Less than 200 mW no-load power consumption (for
115 or 230 VAC input)
• Meets CISPR-22 Class B without Y capacitor
• Low cost, low component count solution
Key Design Points
Operation
• Minimizesecondarycircuitbiascurrents. Uselowcurrent
feedback Zeners for best tolerance. The very low Zener
bias current in this design will provide approximately
10% output voltage tolerance. A precision reference
(e.g. TL431) can be used if higher precision is required.
• Designtransformerwithlowreflectedvoltagetominimize
clamplosses.Alargerdevice(TNY266)mayallowfurther
reduction in VOR.
• Wind transformer for lowest leakage inductance. Choose
wire gauges to completely fill winding layers.
• Windingthetransformerwithtapebetweenprimarylayers
further reduces intra-winding capacitance and no-load
consumption.
The TinySwitch-II flyback converter in Figure 1 generates a
constant voltage, constant current (CV/CC) 5 V, 600 mA
output. Typical applications include wall-mounted chargers
for cell phones, PDAs and other battery powered portable
equipment.
The key performance characteristic of the circuit shown is the
extremely low no-load consumption of <200 mW. A linear
transformer charger of similar rating will typically consume
1 W to 4 W at no-load. At $0.12/kWh, the TinySwitch-II can
therefore reduce energy costs by $1 to $4 per year.
The no-load performance is achieved by use of TinySwitch-II,
and by careful transformer design.
• Resistor R7 limits the peak current into the optocoupler
LED to prevent damage during unusual transients.
C5
R3
470 pF 33 Ω
D7
11DQ06
5 V, 0.6 A
1
8
C6
470 µF
10 V
L1
L3
C3
8T
1.0 mH
R1
Ferrite
Bead
390 pF
1 kV
24 AWG
100 kΩ
R7
R4
4.7 Ω
1.5 kΩ
7
3
D1
D2
102T
33 AWG
RF1
8.2 Ω
1.0 W
1N4005 1N4005
15T
2 x 32 AWG
C7
D5
1N4007G
L
100 µF
2
Q1
2N3906
10 V
4
R2
T1 EE13
LP = 1.9 mH
330 Ω
1/2 W
C1
4.7 µF
400 V
C2
85 - 265
VAC
4.7 µF
400 V
VR3
BZX79B5V1
TinySwitch-II
U1
TNY264P
R5
820 Ω
N
D
S
EN
BP
U2
D3
1N4005
D4
1N4005
L2
Bead
2.2 µH
C4
0.1 µF
50 V
R6
2.4 Ω
2 W
U2
PC817A
RTN
Figure 1. TinySwitch-II 3.0 W Cell Phone Charger.
PI-3681-031204
March 2004
DI-61
www.powerint.com