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| Design Idea DI-61 (R) TinySwitch-II 3 W Charger: <200 mW No-load Consumption Application Charger Device TNY264P Power Output 3W Input Voltage 85-265 VAC Output Voltage 5 V, 600 mA Topology Flyback 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 The circuit meets CISPR-22 Class B conducted EMI limits without a Y capacitor, and therefore has very low AC leakage 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. Operation 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. Key Design Points * Minimize secondary circuit bias currents. Use low current 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. * Design transformer with low reflected voltage to minimize clamp losses. A larger device (TNY266) may allow further reduction in VOR. * Wind transformer for lowest leakage inductance. Choose wire gauges to completely fill winding layers. * Winding the transformer with tape between primary layers further reduces intra-winding capacitance and no-load consumption. * Resistor R7 limits the peak current into the optocoupler LED to prevent damage during unusual transients. R3 C5 470 pF 33 D7 11DQ06 C6 470 F 10 V L3 Ferrite Bead 1 L1 1.0 mH D1 1N4005 D2 1N4005 D5 1N4007G R2 330 1/2 W R1 100 k C3 390 pF 1 kV 102T 33 AWG 2 8 5 V, 0.6 A 8T 24 AWG 7 3 15T 2 x 32 AWG R7 4.7 R4 1.5 k RF1 8.2 L 1.0 W 85 - 265 VAC C1 4.7 F 400 V C2 4.7 F 400 V 4 T1 EE13 LP = 1.9 mH Q1 2N3906 C7 100 F 10 V N D TinySwitch-II U1 TNY264P EN BP R5 820 VR3 BZX79B5V1 D3 1N4005 D4 1N4005 U2 C4 0.1 F 50 V U2 PC817A R6 2.4 2W L2 Bead 2.2 H S RTN Figure 1. TinySwitch-II 3.0 W Cell Phone Charger. PI-3681-031204 DI-61 www.powerint.com March 2004 DI-61 PI-3688-082803 80 70 60 (QP) (AV) No-load Consumption (mW) Amplitude (dBV) 50 40 30 20 10 Quasi-Peak Scan 150 100 0 -10 -20 0.15 1 Average Scan 50 0 10 50 80 120 160 200 240 280 Frequency (MHz) Figure 2. Conducted EMI, Full Load, 230 VAC, Grounded to "Artificial Hand" of LISN. PI-3684-082603 Input Voltage (VAC) Figure 3. No-load Input Power vs. Line Voltage. 6 5 4 3 2 1 0 0 TRANSFORMER PARAMETERS Core Material EE13 TDK PC40, or equivalent AL of 128 nH/T2 EE13, 8 pin Primary (1-2), tape, Bias (3-4), tape, Secondary (7-8), 5 V, tape 1.9 mH 10% 500 kHz (minimum) 50 H (maximum) Output Voltage (VDC) 115 VAC 230 VAC Bobbin Winding Order (pin numbers) Primary Inductance Primary Resonant Frequency Leakage Inductance Limits for Output Voltage and Current 100 200 300 400 500 600 700 Output Current (mA) Figure 4. 5.0 VDC, 600 mA CV/CC Curve. Table 1. Transformer Construction Information. For the latest updates, visit www.powerint.com Power Integrations may make changes to its products at any time. Power Integrations has no liability arising from your use of any information, device or circuit described herein nor does it convey any license under its patent rights or the rights of others. POWER INTEGRATIONS MAKES NO WARRANTIES HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. The products and applications illustrated herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. The PI logo, TOPSwitch, TinySwitch, LinkSwitch and EcoSmart are registered trademarks of Power Integrations. PI Expert and DPA-Switch are trademarks of Power Integrations. Copyright 2004, Power Integrations Power Integrations MAIN PHONE NUMBER +1 408-414-9200 B 3/04 5245 Hellyer Avenue APPLICATIONS FAX +1 408-414-9760 San Jose, California 95138 For a complete listing of worldwide sales offices, please visit www.powerint.com APPLICATIONS HOTLINE +1 408-414-9660 www.powerint.com PI-3685-082703 200 |
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