Title Specification Application Author Document Number Date Revision

Title
Reference Design Report for a 5 W Charger

Using LNK616PG
Specification
85-265 VAC Input; 5 V, 1 A Output
Application
Low-cost Charger or Adapter
Author
Applications Engineering Department
Document
Number
RDR-158
Date
November 25, 2008
Revision
1.1
Summary and Features

Revolutionary control concept provides very low cost, low part-count solution
Primary-side control eliminates secondary-side control and optocoupler
Provides 5% constant voltage (CV) and 10% constant current (CC) accuracy
including output cable drop compensation for 26 AWG (0.49 ) or 24 AWG (0.3 )
cables
Over-temperature protection tight tolerance (5%) with hysteretic recovery for
safe PCB temperatures under all conditions
Auto-restart output short circuit and open-loop protection
Extended pin creepage distance for reliable operation in humid environments
>3.2 mm at package
EcoSmart Easily meets all current international energy efficiency standards China
(CECP) / CEC / ENERGY STAR 2 / EU CoC
No-load consumption <50 mW at 230 VAC
Ultra-low leakage current: <5 A at 265 VAC input (no Y capacitor required)
Design easily passes EN550022 and CISPR-22 Class B EMI testing with >10 dB
margin
Meets IEC 61000-4-5 Class 3 AC line surge
Meets IEC 61000-4-2 ESD withstand (contact and air discharge to 15 kV)
PATENT INFORMATION
The products and applications illustrated herein (including transformer construction and circuits external to the products) 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. Power Integrations grants its customers a license under
certain patent rights as set forth at <http://www.powerint.com/ip.htm>.
Power Integrations
5245 Hellyer Avenue, San Jose, CA 95138 USA.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
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RDR-158 5 V, 1 A, LNK616PG CV/CC Charger
25-Nov-08
Table of Contents
1
2
3
4
Introduction.................................................................................................................4
Power Supply Specification ........................................................................................6
Schematic...................................................................................................................7
Circuit Description ......................................................................................................8
4.1
Input Filter ...........................................................................................................8
4.2
LNK616PG Primary.............................................................................................8
4.3
Output Rectification and Filtering ........................................................................8
4.4
Output Regulation ...............................................................................................9
5 PCB Layout ..............................................................................................................10
6 Bill of Materials .........................................................................................................11
7 Transformer Specification.........................................................................................12
7.1
Electrical Diagram .............................................................................................12
7.2
Electrical Specifications.....................................................................................12
7.3
Materials............................................................................................................13
7.4
Transformer Build Diagram ...............................................................................13
7.5
Transformer Construction..................................................................................14
8 Design Spreadsheet .................................................................................................15
9 Performance Data ....................................................................................................18
9.1
Efficiency ...........................................................................................................18
9.2
Active Mode CEC Measurement Data...............................................................19
9.2.1
Energy Star v1.1 / CEC (2008)...................................................................19
9.2.2
Energy Star v2 (April 2008) ........................................................................20
9.3
No-Load Input Power ........................................................................................21
9.4
Regulation .........................................................................................................22
9.4.1
Load, Line and Temperature ......................................................................22
10
Thermal Performance ...........................................................................................26
10.1 Operating Temperature Survey .........................................................................26
11
Waveforms............................................................................................................27
11.1 Drain Voltage and Current, Normal Operation...................................................27
11.2 Output Voltage Start-up Profile..........................................................................27
11.2.1 No-Load Output Voltage Start-up Characteristic ........................................27
11.2.2 Output Voltage Start-up Characteristic - Resistive Load (5 ) ...................28
11.2.3 Output Voltage Start-up Characteristic - Battery-simulator Load................29
11.3 Drain Voltage and Current Start-up Profile ........................................................30
11.4 Load Transient Response (50% to 100% Load Step) .......................................31
11.5 Output Ripple Measurements............................................................................32
11.5.1 Ripple Measurement Technique ................................................................32
11.5.2 Ripple Measurement Results .....................................................................33
12
Line Surge.............................................................................................................35
13
Conducted EMI .....................................................................................................36
14
Revision History ....................................................................................................38
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Page 2 of 40
25-Nov-08
Important Note:
Although this board is designed to satisfy safety isolation requirements, the engineering
prototype has not been agency approved. Therefore, all testing should be performed
using an isolation transformer to provide the AC input to the prototype board.
Page 3 of 40
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25-Nov-08
1 Introduction
This engineering report describes a 5 W constant voltage/constant current (CV/CC)
universal-input power supply for cell phone or similar charger applications. This reference
design is based on the LinkSwitch-II family product LNK616PG.
Figure 1 RD-158 Board Photograph (top and bottom views).
The LNK616PG was developed to cost effectively replace all existing solutions in lowpower charger and adapter applications. Its core controller is optimized for CV/CC
charging applications with minimal external parts count and very tight control of both the
output voltage and current, without the use of an optocoupler. The LNK616PG has an
integrated 700 V switching MOSFET and ON/OFF control function which together deliver
high efficiency under all load conditions and low no-load energy consumption. Both the
operating efficiency and no-load performance exceed all current international energy
efficiency standards.
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25-Nov-08
The LNK616PG monolithically integrates the 700 V power MOSFET switch and
controller. A unique ON/OFF control scheme provides CV regulation. The IC also
incorporates both output cable voltage-drop compensation and tight regulation over a
wide temperature range for enhanced CV control. The switching frequency is modulated
to regulate the output current for a linear CC characteristic.
The LNK616PG controller consists of an oscillator, a feedback (sense and logic) circuit, a
5.8 V regulator, BYPASS pin programming functions, over-temperature protection,
frequency jittering, a current-limit circuit, leading-edge blanking, a frequency controller for
CC regulation, and an ON/OFF state machine for CV control.
The LNK616PG also provides a sophisticated range of protection features including autorestart for control loop component open/short circuit faults and output short circuit
conditions. Accurate hysteretic thermal shutdown ensures safe average PCB
temperatures under all conditions.
The IC package provides extended creepage distance between high and low voltage pins
(both at the package and PCB), which is required in highly humid environments to
prevent arcing and to further improve reliability.
The LNK616PG can be configured to either be self-biased from the high-voltage DRAIN
pin, or to receive an optional external bias supply. When configured to be self-biased, the
very low IC current consumption ensures a worst-case no-load power consumption of
less than 175 mW at 265 VAC, well within the 300 mW European Union CoC limit. When
fed from an optional bias supply (as in this design), the no-load power consumption
reduces to <50 mW.
The EE16 transformer bobbin in this design provides extended creepage to meet safety
spacing requirements.
This document contains the power supply specifications, schematic, bill of materials,
transformer specifications, and typical performance characteristics for this reference
design.
Page 5 of 40
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25-Nov-08
2 Power Supply Specification

Description
Input
Voltage
Frequency
No-load Input Power
Output
Output Voltage
Output Ripple Voltage
Output Current
Output Cable Resistance
Output Power
Name plate output rating
Name plate Voltage
Nameplate Current
Nameplate Power
Efficiency
Average Active Mode
Symbol
Min
Typ
Max
Units
Comment
VIN
fLINE
PNL
85
47
265
64
50
VAC
Hz
mW
2 Wire no P.E.
50/60
Measured at VIN = 230 VAC

All measured at end of cable
VOUT
VRIPPLE
IOUT
RCBL
POUT
4.75
900
5.00
150
1000
0.3
5
5.25
1100
V
mV
mA
VNP
INP
PNP
5
900
4.5
V
mA
W
74
Required average efficiency per

Energy Star EPS v1.1 / CEC
2008
ESV1.1
64
Required average efficiency per

Energy Star EPS v2 April, 2008
ESV2
67
5%
20 MHz bandwidth
10%
6 ft, 24 AWG
115 VAC / 230 VAC, 25 oC
Measured per Energy Star Test Method for Calculating the Energy
Efficiency of Single-Voltage External AC-DC and AC-AC Power
Supplies (August 11, 2004).
ESV1:(0.09 ln(PNP)+0.5
ESV2:(0.075 ln(PNP)+0.561
Environmental
Conducted EMI
Safety
Meets CISPR22B / EN55022B
>10 dB margin
Designed to meet IEC950, UL1950 Class II
Line Surge
Differential
Common Mode
1
2
ESD
Ambient Temperature
TAMB
kV
kV
-15
15
kV
40
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1.2/50 s surge, IEC 1000-4-5,

Series Impedance:
Differential Mode: 2
Common Mode: 12
Contact and air discharge to
IEC 61000-4-2
Case external, free convection,
sea level
Page 6 of 40
25-Nov-08
3 Schematic
Figure 2 RD158 Circuit Schematic.
Page 7 of 40
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25-Nov-08
4 Circuit Description
This circuit uses the LNK616PG in a primary-side regulated flyback power-supply
configuration.
4.1 Input Filter
The AC input power is rectified by diodes D1 through D4. The rectified DC is filtered by
the bulk storage capacitors C1 and C2. Inductors L1 and L2, with capacitors C1 and C2,
form pi () filters to attenuate conducted differential-mode EMI noise. This configuration,
along with Power Integrations transformer E-shield technology, allows this design to
meet EMI standard EN55022 class B with good margin and without a Y capacitor. The
transformer construction also gives very good EMI repeatability. Fusible resistor RF1
provides protection against catastrophic failure. It should be rated to withstand the
instantaneous dissipation when the supply is first connected to the AC input (while the
input capacitors charge) at VACMAX. This means choosing either an over-sized metal-film
or a wire-wound type. This design uses a wire-wound resistor for RF1.
4.2 LNK616PG Primary
The LNK616PG device (U1) incorporates the power switching device, oscillator, CV/CC
control engine, and startup and protection functions all on one IC. Its integrated 700 V
MOSFET allows sufficient voltage margins in universal input AC applications, including
extended line swells. The device is self-powered from the BYPASS pin via the decoupling
capacitor C4. The value of C4 also programs the cable-drop voltage compensation. In
this case, a 1 F capacitor gives the 350 mV (7% of VNO) compensation needed for the
nominal 24-AWG cable, with 0.3 impedance, used in this design. The optional bias
circuit consisting of D6, C5, and R7 increases efficiency and reduces no-load input
power.
The rectified and filtered input voltage is applied to one end of the transformer (T1)
primary winding. The other side of the transformers primary winding is driven by the
internal MOSFET of U1. An RCD-R clamp consisting of D5, R3, R4, and C3 limits drainvoltage spikes caused by leakage inductance. Resistor R4 has a relatively large value to
prevent any excessive ringing on the drain voltage waveform caused by the leakage
inductance. Excessive ringing can increase output ripple by introducing an error in the
sampled output voltage. IC U1 samples the feedback winding each cycle, 2.5 s after
turn-off of its internal MOSFET.
4.3 Output Rectification and Filtering
Transformer T1s secondary is rectified by D7, a Schottky barrier-type diode (chosen for
higher efficiency), and filtered by C7 and C8. In this application, C7 and C8 have
sufficiently low ESR characteristics to allow meeting the output voltage ripple requirement
without adding an LC post filter. Resistor R8 and capacitor C6 dampen high-frequency
ringing and reduce the voltage stress on D7.
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Page 8 of 40
25-Nov-08
In designs where lower average efficiency is acceptable (by 3% to 4%) D7 may be

replaced by a PN-junction to lower cost. In this case, ensure R5 and R6 are re-adjusted
as necessary to keep the output voltage centered.
4.4 Output Regulation
The LNK616PG regulates output using ON/OFF control for CV regulation, and frequency
control for CC regulation. The output voltage is sensed by a bias winding on the
transformer. The feedback resistors (R5 and R6) were selected using standard 1%
resistor values to center both the nominal output voltage and constant current regulation
thresholds. Resistor R9 provides a minimum load to maintain output regulation when the
output is unloaded.
Page 9 of 40
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25-Nov-08
5 PCB Layout
Notable layout design points are:
1
2
3
4
5
A spark gap and associated slot in the PCB between the primary and secondary
allows successful ESD testing up to 15 kV.
The preferential arcing point routes the energy from ESD discharges back
to the AC input, away from the transformer and primary circuitry.
The trace connected to the AC input side of the spark gap is spaced away
from the rest of the board and its components to prevent arc discharges to
other sections of the circuit.
The drain trace length has been minimized to reduce EMI.
Clamp and output diode loop areas are minimized to reduce EMI.
The AC input is located away from switching nodes to minimize noise coupling that
may bypass input filtering.
Place C4 (the bypass capacitor) as close as possible to the BYPASS pin on U1.
Figure 3 Printed Circuit Layout.
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Page 10 of 40
25-Nov-08
6 Bill of Materials
Item
1
Qty
1
Ref
Des
C1
C2
3
4
5
6
7
1
1
1
1
2
C3
C4
C5
C6
C7 C8
D1 D2
D3 D4
D5
9
10
1
1
D6
D7
11
12
13
14
15
16
17
18
19
20
21
22
23
2
1
2
2
1
1
1
1
1
1
1
1
1
J1 J2
J3
L1 L2
R1 R2
R3
R4
R5
R6
R7
R8
R9
RF1
T1
24
25
Description
4.7 F, 400 V, Electrolytic, (8 x 11.5)
Mfg
Taicon
Corporation
Mfg Part Number

TAQ2G4R7MK0811MLL3
10 F, 400 V, Electrolytic, Low ESR, 79 mA,

(10 x 12.5)
1 nF, 1000 V, Ceramic, X7R, 0805
1 F, 25 V, Ceramic, X7R, 0805
10 F, 16 V, Ceramic, X5R, 0805
2.2 nF, 50 V, Ceramic, X7R, 0805
470 F, 10 V, Electrolytic, Very Low ESR,
72 mOhm, (8 x 11.5)
1000 V, 1 A, Rectifier, DO-41
Ltec
TYD2GM100G13O
Kemet
Panasonic
Murata
Panasonic
Nippon ChemiCon
Vishay
C0805C102KDRACTU
ECJ-2FB1E105K
GRM21BR61C106KE15L
ECJ-2VB1H222K
EKZE100ELL471MHB5D
75 V, 0.15 A, Fast Switching, 4 ns, MELF

40 V, 4 A, Schottky, SMD, DO-214AB
Diode Inc.
Vishay
LL4148-13
SL44-E3/57T
Test Point, WHT,THRU-HOLE MOUNT

6 ft, 24 AWG, 2.1 mm connector (custom)
1.5 mH, 0.18 A, 5.5 x 10.5 mm
10 k, 5%, 1/4 W, Metal Film, 1206
470 k, 5%, 1/8 W, Metal Film, 0805
300 , 5%, 1/4 W, Metal Film, 1206
14.7 k, 1%, 1/16 W, Metal Film, 0603
9.76 k, 1%, 1/16 W, Metal Film, 0603
6.2 k, 5%, 1/10 W, Metal Film, 0603
100 , 5%, 1/8 W, Metal Film, 0805
1.2 k, 5%, 1/8 W, Metal Film, 0805
10 , 2 W, Fusible/Flame Proof Wire Wound
Custom Transformer, EE16, 10pins; per
Power Integrations' RD-158 Transformer
Specification
Keystone
CUI Inc
Tokin
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Vitrohm
Santronics
Ice Components
Precision, Inc
5012
CA-2184
SBC1-152-181
ERJ-8GEYJ103V
ERJ-6GEYJ474V
ERJ-8GEYJ301V
ERJ-3EKF1472V
ERJ-3EKF9761V
ERJ-3GEYJ622V
ERJ-6GEYJ101V
ERJ-6GEYJ122V
CRF253-4 10R
SNXR1346
TP07161
019-6120-00R
U1
LinkSwitch-II, LNK616PG, CV/CC, DIP-8C
Power
Integrations
LNK616PG
J3
Plastic housing for cable assembly
JST Sales
America Inc.
HER-2
Page 11 of 40
1N4007-E3/54
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7 Transformer Specification
7.1
Electrical Diagram
Figure 4 Transformer Electrical Diagram.
7.2
Electrical Specifications
Electrical Strength
60 seconds, 60 Hz, from Pins 1-5 to Pins 6-10
3000 VAC
Primary Inductance
Pins 1-4, all other windings open, measured at

100 kHz, 0.4 VRMS
1.074 mH, 10%
Resonant Frequency
Pins 1-4, all other windings open
Primary Leakage
Inductance
Pins 1-4, with Pins 8-10 shorted, measured at

100 kHz, 0.4 VRMS
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1000 kHz (min)

95 H (max)
Page 12 of 40
25-Nov-08
7.3
Materials
Item
Description
[1]
Core: EE16, NC-2H or equivalent, gapped for ALG of 88.55 nH/T

Bobbin: EE16, Horizontal, 10 pins, (5/5). See attached drawing
Magnet Wire: #35 AWG, for the Shield and the Primary Winding
Magnet Wire: #30 AWG, for the Bias Winding
Triple Insulated Wire: #22 AWG, for the Secondary Winding
Margin tape: 1.0 mm wide
[2]
[3]
[4]
[5]
[6]
[7]
Tape: 3M 1298 Polyester film, 2.0 mils thick, 8.0 mm wide

Tape: 3M Polyester film, 2.0 mils thick, 7.0 mm wide
Varnish
[8]
[9]
7.4
Transformer Build Diagram
8
10
WD5:
7T 22TIW
WD4:
6T 4x30AWG
WD3:
6T 4x30AWG
3
5
1
35T 35AWG
1mm tape margin

2 layers 7mm tape
WD2:
35T 35AWG
35T 35AWG
2 layers 8mm tape
2
WD1:
NC
15T 3x35AWG
Figure 5 Transformer Build Diagram.
The highlighted 1 mm tape margin (in yellow above) was added to improve consistency in
EMI performance in production. The spacing of the first two layers of the primary winding
improves the effect of the subsequent shield windings and makes the transformer design
less sensitive to winding variations. However, if the transformer can be manufactured
consistently to comply with EMI performance specifications without the extra margin tape,
omit the margin tape to reduce transformer cost and increase the wire gauge of the
primary winding so that each layer fills the bobbin window width in 35 turns.
Page 13 of 40
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7.5
25-Nov-08
Transformer Construction
Bobbin Preparation
Primary side of the bobbin is placed on the left hand side, and secondary side of
the bobbin is placed on the right hand side.
WD1
Shield
Temporarily hang the start end of the wires of item [3] on pin 7, wind 15 tri-filar
turns from right to left with tight tension and evenly. The maximum allowed gap
between the winding and the left and right lateral walls of the bobbin must be
less than 0.5 mm (20 mils). Cut the end of the wire and bring the start end of the
wire across the bobbin to the left to terminate at pin 2.
Insulation
WD2
Primary
Insulation
WD3
st
1 half Bias
Insulation
2
nd
WD4
half Bias
2 layers of tape item [7].

Apply 1 mm margin tape on both side of bobbin to match the height of one layer
of primary winding on the left side, and two layers of primary winding on the
right side. Start at pin 4, wind 35 turns of item [3] from left to right with tight
tension, and apply 2 layers tape item [8] and 1 mm margin tape to match
another two layers of primary on the left side. Continue winding 35 turns of item
[3] from right to left, repeat 2 layers tape item [8] and 1 mm margin tape on the
left side, continue wind another 35 turns of item [3] from left to right, at the last
turn bring the wire back to the left to terminate at pin 1.
Temporarily hang the start end of the wires on pin 6, wind 6 quad-filar turns of
item [4] from right to left uniformly, terminate the end of the wires at pin 3, bring
the start end of the wires across the bobbin to the left side to terminate at pin 5.
Temporarily hang the start end of the wires of item [4] on pin 6, wind 6 quad-filar
turns of item [4] from right to left uniformly, terminate the end of the wires at pin
2, bring the start end of the wires across the bobbin to the left side to terminate
at pin 3.
Insulation
WD5
Secondary
Start pin 10, wind 7 turns of item [5] from right to left uniformly, at the last turn
bring the wire across the bobbin to the right side to terminate at pin 8. Cut three
pins from the secondary side: 6, 7, and 9.
Insulation
Finish
Grind the core to get 1.074mH. Secure the core with tape. Dip vanish [9].
Note:
1. Tape between adjacent primary winding layers reduces primary capacitance and losses.
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25-Nov-08
8 Design Spreadsheet
RD-158 Power
Integrations
INPUT
INFO
OUTPUT
ENTER APPLICATION VARIABLES

VACMIN
85
VACMAX
265
fL
50
VO
5
IO
1
Power
n
5.00
0.70
0.50
tC
Add Bias Winding
YES
CIN
14.7
ENTER LinkSwitch-II VARIABLES

Chosen Device
LNK616
Package
PG
ILIMITMIN
ILIMITTYP
ILIMITMAX
FS
67.25
3.00
YES
UNIT
ACDC_LinkSwitch-II_040108_Rev1-0.xls;
LinkSwitch-II Discontinuous Flyback
Transformer Design Spreadsheet
V
V
Hz
V
A
Minimum AC Input Voltage

Maximum AC Input Voltage
AC Mains Frequency
Output Voltage (at continuous power)
Power Supply Output Current
(corresponding to peak power)
Continuous Output Power
Efficiency Estimate at output terminals.
Under 0.7 if no better data available
Z Factor. Ratio of secondary side losses to
the total losses in the power supply. Use 0.5
if no better data available
Bridge Rectifier Conduction Time Estimate
Choose Yes to add a Bias winding to power
the LinkSwitch-II.
Input Capacitance
ms
uF
LNK616
PG
0.39
0.41
0.45
67.25
A
A
A
kHz
VOR
82.50
VDS
10.00
VD
0.50
KP
2.31
FEEDBACK WINDING PARAMETERS

NFB
VFLY
VFOR
6.00
4.71
5.00
V
V
BIAS WINDING PARAMETERS

VB
9
9.00
NB
Page 15 of 40
6.00
Chosen LinkSwitch-II device

Select package (PG, GG or DG)
Minimum Current Limit
Typical Current Limit
Maximum Current Limit
Typical Device Switching Frequency at
maximum power
Reflected Output Voltage (VOR < 135 V
Recommended)
LinkSwitch-II on-state Drain to Source
Voltage
Output Winding Diode Forward Voltage
Drop
Ensure KDP > 1.3 for discontinuous mode
operation
Feedback winding turns

Flyback Voltage
Forward voltage
Bias Winding Voltage. Ensure that VB >

VFLY. Bias winding is assumed to be ACSTACKED on top of Feedback winding
Bias Winding number of turns
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DESIGN PARAMETERS
DCON
4.5
TON
4.50
4.31
us
us
RUPPER
RLOWER
12.88
9.16
k-ohm
k-ohm
25-Nov-08
Output diode conduction time

LinkSwitch-II On-time (calculated at
minimum inductance)
Upper resistor in Feedback resistor divider
Lower resistor in resistor divider
ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES

Core Type
Core
EE16
EE16
Enter Transformer Core. Based on the
output power the recommended core sizes
are EE19 or EE22
Bobbin
EE16_BOBBIN
Generic EE16_BOBBIN
AE
19.20
mm^2 Core Effective Cross Sectional Area
LE
35.00
mm^2 Core Effective Path Length
AL
1140.00 nH/turn Ungapped Core Effective Inductance
^2
BW
8.60
mm
Bobbin Physical Winding Width
M
0.00
mm
Safety Margin Width (Half the Primary to
Secondary Creepage Distance)
L
3.00
Number of Primary Layers
NS
7.00
Number of Secondary Turns. To adjust
Secondary number of turns change DCON
DC INPUT VOLTAGE PARAMETERS
VMIN
VMAX
87.45
374.77
V
V
Minimum DC bus voltage

Maximum DC bus voltage
CURRENT WAVEFORM SHAPE PARAMETERS

DMAX
0.29
IAVG
0.09
IP
0.39
IR
0.39
IRMS
0.14
A
A
A
A
Maximum duty cycle measured at VMIN

Input Average current
Peak primary current
primary ripple current
Primary RMS current
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Page 16 of 40
25-Nov-08
TRANSFORMER PRIMARY DESIGN PARAMETERS

LPMIN
966.73
uH
LPTYP
1074.14
uH
LP_TOLERANCE
10.00
NP
105.00
ALG
2200.00
2184.51
nH/turn
^2
Gauss
Gauss
BP
2643.26
Gauss
BAC
1092.26
Gauss
ur
LG
BWE
OD
165.37
0.25
25.80
0.25
mm
mm
mm
BM_TARGET
BM
87.68
2200
INS
0.05
DIA
AWG
0.20
33.00
CM
50.80
CMA
362.53
mm
TRANSFORMER SECONDARY DESIGN PARAMETERS

Lumped
parameters
ISP
5.84
A
ISRMS
2.16
A
IRIPPLE
1.92
A
CMS
432.77
AWGS
23.00
VOLTAGE STRESS PARAMETERS

VDRAIN
568.02
PIVS
29.98
Minimum Primary Inductance

Typical Primary inductance
Tolerance in primary inductance
Primary number of turns. To adjust Primary
number of turns change BM_TARGET
Gapped Core Effective Inductance
Target Flux Density
Maximum Operating Flux Density
(calculated at nominal inductance), BM <
2500 is recommended
Peak Operating Flux Density (calculated at
maximum inductance and max current limit),
BP < 3000 is recommended
AC Flux Density for Core Loss Curves (0.5
X Peak to Peak)
Relative Permeability of Ungapped Core
Gap Length (LG > 0.1 mm)
Effective Bobbin Width
Maximum Primary Wire Diameter including
insulation
Estimated Total Insulation Thickness (= 2 *
film thickness)
Bare conductor diameter
Primary Wire Gauge (Rounded to next
smaller standard AWG value)
Bare conductor effective area in circular
mils
Primary Winding Current Capacity (200 <
CMA < 500)
Peak Secondary Current

Secondary RMS Current
Output Capacitor RMS Ripple Current
Secondary Bare Conductor minimum
circular mils
Secondary Wire Gauge (Rounded up to
next larger standard AWG value)
Maximum Drain Voltage Estimate (Assumes

20% Zener clamp tolerance and an
additional 10% temperature tolerance)
Output Rectifier Maximum Peak Inverse
Voltage
Note: Different spreadsheet revisions may give slightly different spreadsheet values.
Page 17 of 40
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9 Performance Data
All measurements were taken at room temperature unless otherwise specified, with
60 Hz input frequency. Measurements were taken at the end of a 6 ft, 0.3 , 24 AWG
output cable.
9.1
Efficiency
85%
Vin=85 VAC
Vin=115 VAC
Vin=230 VAC
Vin=265 VAC
Energy Star v1.1 / CEC (2008)
Energy Star v2 (April 2008)
Efficiency
80%
75%
70%
Energy Star v2 Average Active Mode Efficiency (67%)
65%
Energy Star v1.1 / CEC (2008) Average Active Mode Efficiency (64%)
60%
0
Output Power (Watts)
Figure 6 Efficiency vs. Output Power.
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25-Nov-08
9.2 Active Mode CEC Measurement Data

The power supply passes both Energy Star v1.1 and v2 (April 2008) limits.
% of Full Load
Efficiency (%)
115 VAC
230 VAC
25
74.8
74.0
50
75.0
74.7
75
73.5
74.4
100
72.2
73.5
Average
73.9%
74.2%
Energy Star v1.1

Energy Star v2
64%
67%
64%
67%
Figure 7 Average Active Mode Efficiency.
9.2.1 Energy Star v1.1 / CEC (2008)

As part of the U. S. Energy Independence and Security Act of 2007 all single-output
adapters, including those provided with products for sale in the USA after July 1, 2008,
must meet the Energy Star v1.1 specification for minimum active-mode efficiency and noload input power. Note that battery chargers are exempt from these requirements except
in the state of California, where they must also be compliant.
Minimum active-mode efficiency is defined as the average efficiency at 25%, 50%, 75%,
and 100% of rated output power with the limit based on the nameplate output power:
Nameplate Output (PNP)
Minimum Efficiency in Active Mode of Operation
<1W
1 W to 49 W
> 49 W
0.5 PNP
0.09 ln (PNP) + 0.5 [ln = natural log]
0.84
Maximum No-load Input Power
All
0.5 W
For single-input voltage adapters the measurement is made at the rated (single) nominal
input voltage only (either 115 VAC or 230 VAC). For universal input adapters, the
measurement is made at both nominal input voltages (115 VAC and 230 VAC).
To meet the standard, the measured average efficiency (or efficiencies for universal input
supplies) must be greater than or equal to the efficiency specified by the CEC/Energy
Star v1.1 standard.
Page 19 of 40
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9.2.2 Energy Star v2 (April 2008)

The Energy Star v2 specification (planned to take effect Nov 1, 2008) increases the
previously stated requirements.
Standard Models

(Rounded to Hundreds)
1W
> 1 W to 49 W
0.48 PNP + 0.14

0.0626 ln (PNP) + 0.622
> 49 W
0.87
[ln = natural log]
0 to <50 W
50 to 250 W
0.3 W
0.5 W
Low-voltage Models
A low-voltage model is an external power supply (EPS) with a nameplate output voltage
of less than 6 V and a nameplate output current greater than or equal to 550 mA.

(Rounded to Hundreds)
1 W
>1 W to 49 W
>49 W
0.497 PNP + 0.067

0.075 ln (PNP) + 0.561
[ln = natural log]
0.86
0 to <50 W
50 to 250 W
0.3 W
0.5 W
For the latest up-to-date information, please visit the PI Green Room at
www.powerint.com.
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Page 20 of 40
25-Nov-08
9.3
No-Load Input Power

0.1
0.09
0.08
Input Power (W)
0.07
0.06
0.05
0.04
0.03
0.02
0.01
0
0
50
100
150
200
250
300
Input Voltage (Vac)

Figure 8 Zero Load Input Power vs. Input Line Voltage, Room Temperature, 60 Hz. (To achieve no-load
of less than 30 mW, remove the preload resistor (R9) and replace it with a 6.2 V clamp diode).
Page 21 of 40
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9.4
25-Nov-08
Regulation
9.4.1 Load, Line and Temperature

The output characteristic was tested at the end of a 6 output cable. The DC resistance
of the cable was approximately 0.3 .
The measurements were made with the supply inside a sealed plastic enclosure which
was then placed within a cardboard box. The cardboard box ensures air flow from the
thermal chamber does not affect the test. The ambient temperature inside the cardboard
box was monitored, and the temperature of the thermal chamber was adjusted to
maintain the desired temperature.
The unit was allowed to thermally stabilize for 30 minutes, unloaded, at each
measurement temperature prior to data being recorded.
6
Single Unit, Line and Temperature Variation
Output Voltage (VDC)
5
Minimum Limit
85 VAC, 40 Deg C
230 VAC, 40 Deg C
85 VAC, 25 Deg C
230 VAC, 25 Deg C
85 VAC, 0 Deg C
230 VAC, 0 Deg C
Maximum Limit
115 VAC, 40 Deg C
265 VAC, 40 Deg C
115 VAC, 25 Deg C
265 VAC, 25 Deg C
115 VAC, 0 Deg C
265 VAC, 0 Deg C
0
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
Output Current (mA)

Figure 9 Composite Output Regulation Across Load, Line, and Temperature.
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Page 22 of 40
25-Nov-08
6
0 C External Case Ambient
Minimum Limit
Maximum Limit
85 VAC
115 VAC
230 VAC
265 VAC
0
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
Output Current (mA)

Figure 10
Typical CV/CC Characteristic Over Line at 0 C.
5.5
5.4
5.3
Minimum Limit
Maximum Limit
85 VAC
115 VAC
230 VAC
265 VAC
5.2
5.1
5
4.9
4.8
4.7
4.6
4.5
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
Output Current (mA)

Figure 11
Typical CV/CC Characteristic Over Line at 0 C. Expanded View, Illustrating Effect of Cable
Drop Compensation.
Page 23 of 40
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6
Minimum Limit
Maximum Limit
85 VAC
115 VAC
230 VAC
265 VAC
0
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
Output Current (mA)

Figure 12 Typical CV/CC Characteristic Over Line at 25 C.
5.5
5.4
5.3
Minimum Limit
Maximum Limit
85 VAC
115 VAC
230 VAC
265 VAC
5.2
5.1
5
4.9
4.8
4.7
4.6
4.5
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
Output Current (mA)

Figure 13 Typical CV/CC Characteristic Over Line at 25 C. Expanded View Illustrating Effect of Cable
Drop Compensation.
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Page 24 of 40
25-Nov-08
6
85 VAC
115 VAC
230 VAC
265 VAC
Minimum Limit
Maximum Limit
0
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
Output Current (mA)

Figure 14 Typical CV/CC Characteristic Over Line at 40 C.
5.5
5.4
5.3
85 VAC
115 VAC
230 VAC
265 VAC
Minimum Limit
Maximum Limit
5.2
5.1
5
4.9
4.8
4.7
4.6
4.5
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
Output Current (mA)

Figure 15 Typical CV/CC Characteristic Over Line at 40 C. Expanded View Illustrating Effect of Cable
Drop Compensation.
Page 25 of 40
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10 Thermal Performance
10.1 Operating Temperature Survey
Thermal performance was measured inside an enclosure at full load with no airflow. A
thermocouple was attached to U1s source pin.
Item
85 VAC
Ambient
40 C
U1 Source Pin
97 C
115 VAC
40 C
90.7 C
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175 VAC
0
40 C
0
89.3 C
230 VAC
0
40 C
0
90.6 C
265 VAC
0
40 C
0
93.1 C
Page 26 of 40
25-Nov-08
11 Waveforms
11.1 Drain Voltage and Current, Normal Operation
Figure 16 85 VAC, Full Load.

Upper: VDRAIN, 100 V / div.
Lower: IDRAIN, 200 mA / div, 2 us / div.
Figure 17 265 VAC, Full Load.

Upper: VDRAIN, 200 V / div.
Lower: IDRAIN, 200 mA / div, 2 us / div.
11.2 Output Voltage Start-up Profile

11.2.1 No-Load Output Voltage Start-up Characteristic
Figure 18 Start-up Profile (No Load),

115 VAC, 1 V, 1 ms / div.
Page 27 of 40
Figure 19 Start-up Profile (No Load),

230 VAC, 1 V, 1 ms / div.
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11.2.2 Output Voltage Start-up Characteristic - Resistive Load (5 )

The voltage was measured at the load.
Figure 20 Start-up Profile,

115 VAC, 1 V, 2 ms / div.
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230 VAC, 1 V, 2 ms / div.
Page 28 of 40
25-Nov-08
11.2.3 Output Voltage Start-up Characteristic - Battery-simulator Load

Rcable
5 Ohm
Load
ESR
D1
1N4001
D2
1N4001
C1
10,000 uF
35 V
Figure 22 Battery Simulator Schematic.
The voltage was measured at the PCB.

115 VAC Vertical: 1 V / div.
Horizontal: 10 ms / div.
Page 29 of 40
Figure 24 Start-up Profile, 230 VAC

Vertical: 1 V / div.
Horizontal: 10 ms / div.
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11.3 Drain Voltage and Current Start-up Profile
Figure 25 85 VAC Input and Maximum Load

Upper VDRAIN, 100 V, 2 ms / div.
Lower: IDRAIN, 200 mA / div.
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Figure 26 265 VAC Input and Maximum Load

Upper: VDRAIN, 200 V, 2 ms / div.
Lower: IDRAIN, 200 mA / div.
Page 30 of 40
25-Nov-08
11.4 Load Transient Response (50% to 100% Load Step)
Figure 27 Transient Response, 115 VAC

100-50-100% Load Step
Output Voltage 100 mV, 5 ms / div.
Page 31 of 40
Figure 28 Transient Response, 230 VAC

100-50-100% Load Step
Output Voltage 100 mV, 5 ms / div.
Power Integrations
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11.5 Output Ripple Measurements

11.5.1 Ripple Measurement Technique
For DC output ripple measurements, use a modified oscilloscope test probe to reduce
spurious signals. Details of the probe modification are provided in figures below.
Tie two capacitors in parallel across the probe tip of the 4987BA probe adapter. Use a
0.1 F / 50 V ceramic capacitor and 1.0 F / 50 V aluminum electrolytic capacitor. The
aluminum-electrolytic capacitor is polarized, so always maintain proper polarity across
DC outputs.
Probe Ground
Probe Tip
Figure 29 Oscilloscope Probe Prepared for Ripple Measurement (End Cap and Ground Lead Removed).
Figure 30 Oscilloscope Probe with Probe Master 4987BA BNC Adapter (Modified with Wires for Probe
Ground for Ripple measurement and Two Parallel Decoupling Capacitors Added).
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25-Nov-08
11.5.2 Ripple Measurement Results
Figure 31 Ripple, 85 VAC, Full Load,

20 mV, 200 V / div.

20 mV, 20 s / div.
Figure 33 Ripple, 85 VAC, Worst-case Noise,

20 mV, 5 ms / div.
Figure 34 Ripple, 85 VAC, Worst-case Noise,

20 mV, 100 Cs / div.
Page 33 of 40
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20 mV, 200 s / div.

20 mV, 20 s / div.
Figure 37 Ripple, 265 VAC, Worst Case

Noise, 20 mV / div, 5 ms / div.
Figure 38 Ripple, 265 VAC, Worst Case

Noise, 20 mV / div, 100 s / div.
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Page 34 of 40
25-Nov-08
12 Line Surge
Differential input line 1.2 s / 50 s surge testing to IEC61000-4-5 standards was
completed on a single test unit. The input voltage was set at 230 VAC / 60 Hz. The output
current was 1 A and operation was verified following each surge event.
Surge
Level (V)
+500
-500
+750
-750
+1000
-1000
Page 35 of 40
Input
Voltage
(VAC)
230
230
230
230
230
230
Injection
Location
Injection
Phase ()
Test Result
(Pass/Fail)
L to N
L to N
L to N
L to N
L to N
L to N
90
90
90
90
90
90
Pass
Pass
Pass
Pass
Pass
Pass
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13 Conducted EMI
Figure 39 115 VAC Neutral, Output Earth

Grounded.
Figure 40 115 VAC Neutral, Table.
Figure 41 115 VAC Line, Output Earth

Grounded.
Figure 42 115 VAC Line, Table.
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Page 36 of 40
25-Nov-08
Power Integrations
29.Jan 08 11:11
RBW
MT
9 kHz
500 ms
Marker 1 [T1 ]
43.60 dBV
673.936068749 kHz
10 MHz
PASS
100 MHz
Att 10 dB AUTO
dBV
1 MHz
80
LIMIT CHECK
70
1 QP
CLRWR
EN55022Q
2 AV
CLRWR
EN55022A
SGL
60
TDF
50
1
40
30
6DB
20
10
-10
-20
150 kHz
MEI
100 MHz
LNK363; 30VAC with hand
Date: 29.JAN.2008
11:11:11
Figure 43 230 VAC Neutral, Output Earth

Grounded.
Figure 44 230 VAC Neutral, Table.
Figure 45 230 VAC Line, Output Earth

Grounded.
Figure 46 230 VAC Line, Table.
Page 37 of 40
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14 Revision History
Date
15-May-08
25-Nov-08
Author
JAC
SF
Revision
1.0
1.0
Description and changes

Initial Release
Updated no-load graph caption text in Figure 8
Power Integrations
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Reviewed
JD
Page 38 of 40
25-Nov-08

Notes
Page 39 of 40
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25-Nov-08
For the latest updates, visit our website: www.powerint.com

Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability.
Power Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER
INTEGRATIONS MAKES NO WARRANTY 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.
PATENT INFORMATION
The products and applications illustrated herein (including transformer construction and circuits external to the products)
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. Power
Integrations grants 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,
PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective
companies. Copyright 2008 Power Integrations, Inc.
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Title

Reference Design Report for a 5 W Charger

85-265 VAC Input; 5 V, 1 A Output

Low-cost Charger or Adapter

Applications Engineering Department

November 25, 2008

Summary and Features

RDR-158 5 V, 1 A, LNK616PG CV/CC Charger

RDR-158 5 V, 1 A, LNK616PG CV/CC Charger

RDR-158 5 V, 1 A, LNK616PG CV/CC Charger

Figure 1 RD-158 Board Photograph (top and bottom views).

RDR-158 5 V, 1 A, LNK616PG CV/CC Charger

RDR-158 5 V, 1 A, LNK616PG CV/CC Charger

2 Power Supply Specification

Measured at VIN = 230 VAC

Required average efficiency per

Required average efficiency per

115 VAC / 230 VAC, 25 oC

Meets CISPR22B / EN55022B

Designed to meet IEC950, UL1950 Class II

1.2/50 s surge, IEC 1000-4-5,

RDR-158 5 V, 1 A, LNK616PG CV/CC Charger

Figure 2 RD158 Circuit Schematic.

RDR-158 5 V, 1 A, LNK616PG CV/CC Charger

RDR-158 5 V, 1 A, LNK616PG CV/CC Charger

In designs where lower average efficiency is acceptable (by 3% to 4%) D7 may be

RDR-158 5 V, 1 A, LNK616PG CV/CC Charger

Figure 3 Printed Circuit Layout.

RDR-158 5 V, 1 A, LNK616PG CV/CC Charger

Mfg Part Number

10 F, 400 V, Electrolytic, Low ESR, 79 mA,

75 V, 0.15 A, Fast Switching, 4 ns, MELF

Test Point, WHT,THRU-HOLE MOUNT

LinkSwitch-II, LNK616PG, CV/CC, DIP-8C

Plastic housing for cable assembly

RDR-158 5 V, 1 A, LNK616PG CV/CC Charger

Figure 4 Transformer Electrical Diagram.

60 seconds, 60 Hz, from Pins 1-5 to Pins 6-10

Pins 1-4, all other windings open, measured at

1.074 mH, 10%

Pins 1-4, all other windings open

Pins 1-4, with Pins 8-10 shorted, measured at

1000 kHz (min)

RDR-158 5 V, 1 A, LNK616PG CV/CC Charger

Core: EE16, NC-2H or equivalent, gapped for ALG of 88.55 nH/T

Tape: 3M 1298 Polyester film, 2.0 mils thick, 8.0 mm wide

Transformer Build Diagram

1mm tape margin

2 layers 8mm tape

Figure 5 Transformer Build Diagram.

RDR-158 5 V, 1 A, LNK616PG CV/CC Charger

2 layers of tape item [7].

2 layers of tape item [7].

2 layers of tape item [7].

RDR-158 5 V, 1 A, LNK616PG CV/CC Charger

ENTER APPLICATION VARIABLES

ENTER LinkSwitch-II VARIABLES

Minimum AC Input Voltage

FEEDBACK WINDING PARAMETERS