DI-18 Design Idea

®
LinkSwitch

Low Cost 2.75 W CV/CC Charger or Adapter

Application Device Power Output Input Voltage Output Voltage Topology

Charger/Adapter LNK501PN 2.75 W 85 – 265 VAC 5.5 V Flyback

Design Highlights
• Replaces a linear transformer based supply at the same or
lower cost but with much higher performance
• <0.3 W consumption at zero load meets worldwide guidelines
(EC’s 0.3 W, USA’s 1 W for example)
• Extremely simple circuit – only 17 components (14 with
integrated bridge) for production-worthy design
• Primary based CV/CC output – no secondary sense compo-
nents required
• ±10% output voltage and ±20% output current tolerances at
peak power point
• Fully protected for thermal, short circuit and open loop faults
• >70% efficiency
• Meets CISPR22B/EN55022B and FCC B EMI limits
• Meets 2.5 kV EN61000-4-5 differential surge
• Ultra-low leakage current design <5 μA
• EE13 core for low cost and small size
Operation
The AC input is rectified and filtered by D1-D4, C1 and C2.
Conducted EMI filtering is provided both by a π filter (C1, L1 and
C2) and a differential filter (RF1 and C1). Together with a shield in
the transformer (formed from part of the primary) the design meets
conducted EMI limits with no Y-capacitor between primary and
secondary. Resistor RF1 also functions as a fuse.
LinkSwitch derives all feedback information from the primary.
During output diode conduction, the output voltage transformed
through the turns ratio is sampled and held by C4. The feedback
voltage across C4 (VOR) is converted into feedback current by R1
and fed into the CONTROL pin. This feedback current regulates
the output by PWM control during CV operation, and by reducing
the internal current limit during CC operation. Below an output
voltage of ~2 V LinkSwitch enters auto-restart, limiting average
output current to <50 mA. The nominal transition from CV to CC
occurs at 5.5 V, 0.5 A. The output envelope characteristic and
specification limits are shown in Figure 2.
Together with D5, C4 and R1 are also part of the primary clamp,
limiting the peak drain to source voltage due to leakage induc-
tance. Resistor R2 filters the leading edge leakage inductance
spike, reducing the error in the feedback voltage. The CONTROL
pin capacitor C3 provides energy storage for supply startup and
sets auto-restart timing during fault conditions.

LinkSwitch
U1
D1, D2, D3, D4 L1 LNK501PN
1N4005 X 4 1 mH T1 5.5 V, 0.5 A
D S
1 5
C C3 104 T 15 T
0.22 MF 30 AWG C5
34 AWG 470 MF
50 V T.I.W.
4 10 V
6
RF1 12 T
10 71 W R1 C4 RTN
20.5 k7 0.1 MF 2 x 30 AWG D6
Fusible 11DQ06
1% 100 V
3 1A, 60 V
C1 C2
85 - 265 4.7 MF 4.7 MF EE13
VAC 400 V 400 V LP = 2.55 mH
D5
1N4937

R2
100 7

PI-3364-092908

Figure 1. LinkSwitch 2.75 W Charger Power Supply.

www.powerint.com October 2008

Key Design Points 0.3

PI-3362-091602
No-Load Power Consumption (W)
• Select transformer turns ratio to give a VOR of 40-60 V. Lower
values reduce power capability, higher values increase no-load 0.25
consumption.
• R1 provides 2.3 mA into the CONTROL pin at the peak power
0.2
point at 85 VAC. The value can be adjusted to center the
output voltage.
• To maintain the ±20% CC tolerance the primary inductance 0.15
tolerance should be tighter than ±10%.
• Minimize zero load consumption by reducing drain node capaci- 0.1 85 VAC: 174 mW
tance: Use double coated/grade 2 wire for primary and do not 115 VAC: 179 mW
vacuum impregnate. Avoid using an RC snubber across the 185 VAC: 211 mW
0.05 230 VAC: 229 mW
output diode. 265 VAC: 250 mW
• For resistive loads increase C3 to 1 μF (electrolytic) to allow
0
adequate time for start-up at full load.
50 100 150 200 250 300
• For battery loads an output π filter is typically not required but
can be added for resistive loads to reduce switching ripple. Input Voltage (VAC)
• L1 can be replaced with a 22 Ω to 100 Ω fusible resistor for Figure 3. No-load Input Power Consumption.
lower cost but lower efficiency (~10% reduction).
• Adding a 1 mA to 2 mA pre-load reduces zero load voltage by
~1V but increases power consumption by ~10 mW.
• Diode D6 can be replaced with a PN diode for lower cost but Transformer Parameters
reduced efficiency. Core Material TDK PC40 EE13, ALG = 190 nH/t²
• See AN-35 and EPR-16 for more information.
Bobbin EE13 Horizontal 8 pin
Primary: 104T, 34 AWG
10 Shield: 12T, 2 × 30 AWG
PI-3363-091402

Winding Details
VIN=85 V VIN=115 V Secondary: 15T, 30 AWG T.I.W.
VIN=185 V VIN=265 V Flux Band: 1T, 6 mm Cu foil
8
Secondary (5–6), tape, Shield (3–4), tape,
Output Voltage (V)

Winding Order
(pin numbers) Parimary (4–1), tape, Flux band (3–NC)
6 Primary: 2.55 mH, ±10%
Inductance
Leakage: 50 μH (maximum)

4 Primary Resonant 300 kHz (minimum)

Frequency
Table 1. Transformer Parameters. (AWG = American Wire Gauge,
2 T.I.W. = Triple Insulated Wire, NC = No Connection)

0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
Output Current (A)
Figure 2. Load Regulation - CV/CC Characteristics with Limits.

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-18
DI-19 Design Idea
®
LinkSwitch

Low Cost 1.5 W CV/CC Charger or Adapter

Application Device Power Output Input Voltage Output Voltage Topology

Charger/Adapter LNK501PN 1.5 W 85 – 265 VAC 5.5 V Flyback

Design Highlights
• Replaces a linear transformer based supply at the same or
lower cost but with much higher performance
• <0.3 W consumption at zero load meets worldwide guidelines
(EC’s 0.3 W, USA’s 1 W for example)
• Extremely simple circuit – only 15 components for production-
worthy design
• Primary based CV/CC output – no secondary sense compo-
nents required
• ±10% output voltage and ±22% output current tolerances at
peak power point
• Fully protected for thermal, short circuit and open loop faults
• >62% efficiency (>70% with R1 replaced by an inductor)
• Meets CISPR22B/EN55022B EMI limits with low cost resistive
input filter
• Ultra-low leakage current design <5 μA
• EE13 core for low cost and small size
Operation
The AC input is rectified and filtered by D1, D2, C1 and C2.
Conducted EMI filtering is provided both by a π filter (C1, R1 and
C2) and a differential filter (RF1 and C1). Together with a shield in
the transformer (formed from part of the primary) the design meets
conducted EMI limits with no Y-capacitor between primary and
secondary. Resistor RF1 also functions as a fuse.
LinkSwitch derives all feedback information from the primary.
During output diode conduction, the output voltage transformed
through the turns ratio is sampled and held by C4. The feedback
voltage across C4 (VOR) is converted into feedback current by R2
and fed into the CONTROL pin. This feedback current regulates
the output by PWM control during CV operation, and by reducing
the internal current limit during CC operation. Below an output
voltage of ~2 V, LinkSwitch enters auto-restart, limiting average
output current to <50 mA. The nominal transition from CV to CC
occurs at 5.5 V, 0.27 A. The output envelope characteristic and
specification limits are shown in Figure 2.
Together with D3, C4 and R2 are also part of the primary clamp,
limiting the peak drain to source voltage due to leakage induc-
tance. Resistor R3 filters the leading edge leakage inductance
spike, reducing the error in the feedback voltage. The CONTROL
pin capacitor C3 provides energy storage for supply start-up and
sets auto-restart timing during fault conditions.

LinkSwitch
R1 U1
68 7 LNK501PN
Flameproof T1 5.5 V, 0.27 A
D S
1
C 104T 5
C3
0.22 MF 34 AWG
D1 15 T C5
1N4007 4 30 AWG 220MF
RF1 C4 12T T.I.W.
2 x 30 AWG 16V
10 7 R2 0.1 MF 6
Fusible 21 k7 100 V
FILM 3 RTN
85 - 265 C1, C2
VAC 2.2 MF EE13 D4
400 V D3 LP = 1.36 mH UF4002
1N4937 1A 100V

D2 R3
1N4007 100 7

PI-3367-092908

Figure 1. LinkSwitch 1.5 W Charger Power Supply.

www.powerint.com October 2008

Key Design Points 0.3

PI-3373-091402
No-Load Power Consumption (W)
• Select transformer turns ratio to give a VOR of 40 V
to 60 V. Lower values reduce power capability; higher values 0.25
increase no-load consumption.
• R2 provides 2.3 mA into the CONTROL pin at the peak power
0.2
point at 85 VAC. The value can be adjusted to center the
output voltage.
• To maintain the ±22% CC tolerance the primary inductance 0.15
tolerance should be tighter than ±10%.
• Minimize zero load consumption by reducing drain node capaci- 0.1
tance: Use double coated/grade 2 wire for primary and do not 85 VAC: 180 mW
vacuum impregnate. Avoid using an RC snubber across the 0.05 110 VAC: 190 mW
output diode. 230 VAC: 264 mW
265 VAC: 270 mW
• For resistive loads, increase C3 to 1 μF (electrolytic) to allow
0
adequate time for start-up at full load.
50 100 150 200 250 300
• For battery loads, an output π filter is typically not required but
can be added for resistive loads to reduce switching ripple. Input Voltage (VAC)
• R1 can be replaced with an inductor for higher efficiency (~10% Figure 3. No-load Input Power Consumption.
increase).
• Adding a 1 mA to 2 mA pre-load reduces zero load voltage by
~1 V but increases power consumption by ~10 mW.
• Diode D4 can be replaced with a Schottky for higher efficiency. Transformer Parameters
• See AN-35 for more information.
Core Material TDK PC40 EE13, ALG = 101 nH/t²
Bobbin EE13 Horizontal 8 pin
10 Primary: 104T, 34 AWG
PI-3372-091502

VIN = 85 VAC Shield: 12T, 2 × 30 AWG

VIN = 265 VAC Winding Details
Secondary: 15T, 30 AWG T.I.W.
8 Flux Band: 1T, 6 mm Cu foil
Output Voltage (V)

Winding Order Secondary (5–6), tape, Shield (3–4), tape,

6 (pin numbers) Parimary (4–1), tape, Flux band (3–NC)
Primary: 1.36 mH, ±10%
Inductance
Leakage: 50 μH (maximum)
4 Primary Resonant 300 kHz (minimum)
Frequency
Table 1. Transformer Parameters. (AWG = American Wire Gauge,
2 T.I.W. = Triple Insulated Wire, NC = No Connection)

0
0 0.09 0.18 0.27 0.36
Output Current (A)
Figure 2. Load Regulation – CV/CC Characteristics
with Limits.

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-19