DI-13 Design Idea

®
TinySwitch-II

3 W Universal Adapter

Application Device Power Output Input Voltage Output Voltage Topology

3 W Adapter TNY264PN 3W 85 – 265 VAC 9V Flyback

Design Highlights
• No-load consumption less than 250 mW at 230 VAC
• Compact design: 2.0” × 1.2” × 0.75”
• Minimum parts count and single sided PC board ensures cost-
effective solution
• High frequency operation allows compact EF12.6 transformer
• Enhanced ON/OFF control allows simple Zener reference and
eliminates the need for loop compensation
• Built-in circuitry practically eliminates audible noise with
standard varnished transformer
• No-load regulation achieved without pre-load resistor
• Well defined frequency jitter feature reduces EMI–simple input
π filter meets CISPR22 Class B/EN55022B
• Self-protecting hysteretic thermal shutdown: power supply
automatically recovers when fault is removed
This 3 W single output, universal input power supply is available as
a Design Accelerator Kit (DAK-14) including samples and docu-
mentation. With 71% minimum efficiency at full load, compliance to
CISPR22 Class B, small size, and low parts count, the DAK-14
showcases the significant advantages of TinySwitch-II in low power
adapter applications.
Operation
The digital ON/OFF control scheme of TinySwitch-II allows tight
regulation using a low cost secondary Zener reference and
eliminates the need for loop compensation. In addition, no pre-load
is required to maintain regulation at light load, helping to reduce
measured no-load consumption to <250 mW at 265 VAC – see
Figure 3. TinySwitch-II also provides auto-restart to reduce output
overload current during fault conditions.

C5 2200 pF Y1

2
10T D6 L2
x2 11DQ06 Bead 9 V, 330 mA
1 8

C6 C9
D1 & D3 96T 10T 330 MF 220 MF
C3 R4 25 V RTN
1N4007 2.2 nF 330 k7 33 AWG 28 AWG 16 V
1 kV 1/2 W 5
3
RF1
L 8.2 7

C1 & C2 VR2
4.7 MF D5
85 - 265 1N4937 BZX79-B8V2
400 V
VAC

N
D
R2 TinySwitch-II EN/UV
4.7 k7 U1 BP
D1 & D4 1/8 W
1N4007 TNY264PN U2
S LTV817A

C4
L1 0.1 MF
1 mH

PI-3074-092908
Figure 1. TinySwitch-II 3 W Universal Adapter.

www.powerint.com October 2008

Key Design Points 250

PI-3374-091402
• Design transformer for low leakage inductance.

Power Consumption (mW)

• Varnish transformer to practically eliminate acoustic noise –
gluing not required. 200
• Maximum flux density of main transformer should be no more
than 3000 gauss.
150
• Use primary RCD clamp that allows no more than
600 V across the TinySwitch-II DRAIN and SOURCE pins.
• Provide adequate copper area on PCB at the connection to the 100
TinySwitch-II SOURCE pin, for heatsinking.

50

78%

PI-3075-080902
0
75 95 115 135 155 175 195 215 235 255 275

76% Input Voltage (VAC)

Figure 3. Efficiency vs. Input Voltage.
Efficiency (%)

74%

72% Transformer Parameters

Core Material EF 12.6, gapped for ALG of 135 nH/t²
70% Bobbin Hical EF 12.6, 8 pin
Primary (3–1), Shield Winding (1–2),
Winding Order
68% Secondary (8–5)
85 135 185 235 285 Primary Inductance 1.25 mH
Input Voltage (VAC) Primary Resonant 700 kHz (minimum)
Frequency
Figure 2. Efficiency vs. Input Voltage.
Leakage
Inductance 50 μH (maximum)

Table 1. Transformer Parameters.

Power Integrations Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power
5245 Hellyer Avenue Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS
San Jose, CA 95138, USA. MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED
Main: +1 408-414-9200 WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS.
Customer Service The products and applications illustrated herein (transformer construction and circuits external to the products) may be covered by
Phone: +1-408-414-9665 one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations.
Fax: +1-408-414-9765 A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants
Email: usasales@powerint.com its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm.
The PI logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET,
On the Web PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies.
www.powerint.com ©2002, Power Integrations, Inc.

B
10/08 DI-13
DI-28 Design Idea
®
TinySwitch-II

3 W Charger: <30 mW No-load Consumption

Application Device Power Output Input Voltage Output Voltage Topology

Charger TNY264PN 3W 85 – 265 VAC 5 V, 600 mA Flyback

Design Highlights
• Less than 30 mW no-load power consumption (for
115/230 VAC input)
• Meets CISPR-22 Class B without Y capacitor
• Low cost, low component count solution
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 <30 mW. A linear trans-
former 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 using a transformer bias
winding as a low voltage source for TinySwitch-II operating
current. Even without this winding, a TinySwitch-II circuit will
consume <300 mW at no-load. However, by providing external
bias, the internal high voltage current source, which normally
powers the IC from the DRAIN pin, is disabled and a further
reduction in consumption is therefore achieved.
The bias winding should provide enough current to fully disable
the internal current source at no-load. Other load conditions are
not important as the device will be powered from the DRAIN pin if
bias is lost, allowing a simple flyback winding to be used. Figure 2
shows that the bias winding and choice of R2 should provide
approximately 550 μA at no-load to minimize consumption.
The circuit meets CISPR-22 Class B conducted EMI limits without
a Y capacitor and therefore has very low AC leakage current.
TinySwitch-II frequency jitter, use of the bias winding as a shield
and capacitor C3 to soften leakage inductance spikes combine to
provide the EMI performance.
Key Design Points
• Design bias winding circuit to provide approximately 550 μA at
no-load. Figure 2 shows the details.
• Minimize secondary circuit bias currents. Use low current
feedback Zeners for best tolerance. The very low bias current in
this design will provide approximately ±10% output voltage
tolerance. A precision reference (e.g. TL431) can be used to
reduce this if required.
• Design transformer with low reflected voltage to minimize clamp
losses. A bigger device (TNY266) may help to further reduce VOR.
• Wind transformer for lowest leakage inductance. Choose wire
gauges to completely fill winding layers.
• Winding transformer with tape between primary layers further
reduces intra-winding capacitance and no-load consumption.

D7 11DQ06 5V
1 8
L1 C6 L3
1.0 mH C3 8T 470 MF Ferrite
2.2 nF 24 AWG 10 V R3 Bead
VR1
BZY97C200 1 kV 7 D6 1N4148 1.5 k7
D1 D2 105T 3
RF1 1N4005 1N4005
8.2 7 33 AWG
D5 13T x2 C5 R2 C7
1.0 W 1N4937 31 AWG 47 MF 100 MF
2 5.1 k7 Q1
4 16 V 10 V
L 2N3906

85 - 265 C1 C2
VAC 4.7 MF 4.7 MF
400 V 400 V
TinySwitch-II VR3
U1 R4 BZX79B5V1
N TNY264PN 820 7
D
EN

BP
U2
D3 D4
1N4005 1N4005 L2 S C4 R5
Bead 0.1 MF U2 2.7 7
2.2 MH 50 V PC817A 2W RTN

Figure 1. TinySwitch-II 3 W Cell Phone Charger. PI-3079-10140

www.powerint.com October 2008

 80 6

PI-3298-091402

PI-3080-091402
70
5
No Load Consumption

Output Voltage (VDC)

60
115 VAC 4
50 115 VAC
230 VAC
230 VAC
40 3

30
2
20
1
10

0 0
300 400 500 600 700 800 900 0 100 200 300 400 500 600 700
BYPASS Pin Current (μA) Output Current (mA)
Figure 2. No-load Input Power vs. BYPASS Pin Current. Figure 4. 5.0 VDC, 600 mA CV/CC Curve.

30 PI-3081-090402

Transformer Parameters
25 EE13 TDK PC40, or equivalent
No Load Consumption

Core Material
ALG of 128 nH/t²
20 Bobbin EE13, 8 pin
Winding Order Primary (1–2), tape, Bias (3–4), tape,
15 (pin numbers) Secondary (7–8), tape, 5 V, tape

Primary Inductance 1.9 mH ±10%

10
Primary Resonant 500 kHz (minimum)
5 Frequency
Leakage
Inductance 50 μH (maximum)
0
85 110 135 160 185 210 235 260 Table 1. Transformer Parameters.
Input Voltage (VAC)
Figure 3. No-load Input Power vs. Line Voltage.

Power Integrations Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power
5245 Hellyer Avenue Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS
San Jose, CA 95138, USA. MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED
Main: +1 408-414-9200 WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS.
Customer Service The products and applications illustrated herein (transformer construction and circuits external to the products) may be covered by
Phone: +1-408-414-9665 one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations.
Fax: +1-408-414-9765 A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants
Email: usasales@powerint.com its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm.
The PI logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET,
On the Web PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies.
www.powerint.com ©2002, Power Integrations, Inc.

B
10/08 DI-28
DI-61 Design Idea
®
TinySwitch-II

3 W Charger: <200 mW No-load Consumption

Application Device Power Output Input Voltage Output Voltage Topology

Charger TNY264PN 3W 85 – 265 VAC 5 V, 600 mA Flyback

Design Highlights The circuit meets CISPR-22 Class B conducted EMI limits without
• Less than 200 mW no-load power consumption (for a Y capacitor, and therefore has very low AC leakage current. This
115 or 230 VAC input) EMI performance is achieved via the TinySwitch-II internal jitter,
• Meets CISPR-22 Class B without Y capacitor use of a shield winding, an output RC snubber, and the primary
• Low cost, low component count solution RCD clamp.

Operation Key Design Points

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.
• 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 con-
sumption.
• Resistor R7 limits the peak current into the optocoupler LED to
prevent damage during unusual transients.

C5 R3
470 pF 33 7

D7
11DQ06 5 V, 0.6 A
1 8
L1 C6 L3
1.0 mH C3 8T 470 MF
R1 390 pF Ferrite
100 k7 24 AWG 10 V R7 R4
1 kV Bead
7 4.7 7 1.5 k7
D1 D2 102T 3
RF1 1N4005 1N4005
8.2 7 33 AWG
D5 15T C7
L 1.0 W 1N4007G 2 2 x 32 AWG 100 MF
Q1 10 V
R2 4 2N3906
330 7 T1 EE13
C1 C2 1/2 W LP = 1.9 mH
85 - 265
VAC 4.7 MF 4.7 MF
400 V 400 V
TinySwitch-II VR3
R5 BZX79B5V1
N U1 820 7
D TNY264PN
EN

BP
U2
D3 D4
1N4005 1N4005 L2 S C4 R6
Bead 0.1 MF U2 2.4 7
2.2 MH 50 V PC817A 2W RTN

Figure 1. TinySwitch-II 3 W Cell Phone Charger. PI-3681-102108

www.powerint.com October 2008

 80 6

PI-3688-082803

PI-3684-082603
70
(QP) 5
60

Output Voltage (VDC)

Amplitude (dBμV)

(AV)
50
4
40 115 VAC
230 VAC
30 3

20
2
10 Limits for
Quasi-Peak Scan Output Voltage
0 1
and Current
Average Scan
-10
0
-20
0 100 200 300 400 500 600 700
0.15 1 10 50
Output Current (mA)
Frequency (MHz)
Figure 4. 5.0 VDC, 600 mA CV/CC Curve.
Figure 2. Conducted EMI, Full Load, 230 VAC, Grounded to
"Artificial Hand" of LISN.

200 Transformer Parameters

PI-3685-082703

EE13 TDK PC40 or equivalent, gapped for

No-load Consumption (mW)

Core Material
ALG of 128 nH/t²
150
Bobbin EE13, 8 pin

Winding Order Primary (1–2), tape, Bias (3–4), tape,

(pin numbers) Secondary (7–8), 5 V, tape
100
Primary Inductance 1.9 mH, ±10%
Primary Resonant 500 kHz (minimum)
Frequency
50
Leakage
Inductance 50 μH (maximum)

0 Table 1. Transformer Parameters.

80 120 160 200 240 280
Input Voltage (VAC)
Figure 3. No-load Input Power vs. Line Voltage.

Power Integrations Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power
5245 Hellyer Avenue Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS
San Jose, CA 95138, USA. MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED
Main: +1 408-414-9200 WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS.
Customer Service The products and applications illustrated herein (transformer construction and circuits external to the products) may be covered by
Phone: +1-408-414-9665 one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations.
Fax: +1-408-414-9765 A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants
Email: usasales@powerint.com its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm.
The PI logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET,
On the Web PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies.
www.powerint.com ©2004, Power Integrations, Inc.

C
10/08 DI-174