LNK3205

Confidentiality Level: Public
Non-Isolated AC/DC Power Supply Design and Implementation based

on Power Integrations LNK3205
Neil (Bing) Hao
15-Nov-2019
http://uniteng.com
Part I: Project Background
On 11-Oct-2017, my company planned to design a Plug-In Relay (On/Off) product
for our IEEE 802.15.4 based smart home application. The project was accomplished,
and the product got its FCC and UL certifications, recently. As a person who
involved in every detail of hardware design and manufacturing. I have to say based
on my personal working experience, if the RF related design is the first most
important thing for the product, the AC/DC should take the place just behand the
RF design. The communication range and quality are defined by the RF design which
may affect the user experience since the first time they are using the product.
However, to a certain extent, the product’s life span is defined by the AC/DC design
which may affect the manufacturer to define the warranty time. Especially, the
AC/DC circuit is the only module in our product which contains electrolytic
capacitors. For a well-designed product, electrolytic capacitor is the one of main
causes of product failure.
Let us focus on AC/DC design, the first thing needs to be cleared is why using Non-
Isolated AC/DC. I designed a satisfied 3.3VDC isolated AC/DC solution based on the
Power Integrations LNK363DN for our previous projects. Those projects already got
FCC and UL certifications. Therefore, in the very beginning, I preferred to reuse the
mature solution for this project, but after a little bit research I realized that the
isolated solution may rise the BOM cost significantly due to HLW8032 high-
precision energy metering IC. HLW8032 requires a 5VDC Non-Isolated AC/DC. So,
an additional small footprint 5VDC Non-Isolated AC/DC must be used even the
3.3VDC isolated AC/DC is already at there for powering up the SOC. Digital Isolators
also need to be added for the communication between the SOC and HLW8032.
According to the consideration of the product’s size, reliability and the BOM cost, I
Page 1 of 8
decided to design a new 5VDC Non-Isolated AC/DC based on Power Integrations

LNK3205 which has capability to power up the whole product.
Part II: Theoretical Analysis and Calculation
Front view of product Back view of product
5VDC Non-Isolated AC/DC Schematic

Design Requirements:
90VAC-264VAC Input, 5VDC 170mA Output. LNK3205’s operation frequency is
66kHz (fsw).
1. Inductor L2
Calculation of the Inductance Value
Page 2 of 8
According to the design requirements, 𝑉𝑉𝑉𝑉𝑉𝑉𝑚𝑚𝑚𝑚𝑚𝑚 = 90𝑉𝑉𝑉𝑉𝑉𝑉 multiply by 1.41

as the peak voltage and take a 20% margin. Thus,
𝑉𝑉𝑉𝑉𝑉𝑉𝑚𝑚𝑚𝑚𝑚𝑚 = 90𝑉𝑉𝑉𝑉𝑉𝑉 ∗ 1.41 ∗ 0.8 = 101𝑉𝑉
𝑉𝑉𝑜𝑜 5𝑉𝑉𝑉𝑉𝑉𝑉
𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷(𝑚𝑚𝑚𝑚𝑚𝑚) = = = 0.0495
𝑉𝑉𝑉𝑉𝑉𝑉𝑚𝑚𝑚𝑚𝑚𝑚 101𝑉𝑉
𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷(𝑚𝑚𝑚𝑚𝑚𝑚) 0.0495
𝑡𝑡𝑜𝑜𝑜𝑜 (𝑚𝑚𝑚𝑚𝑚𝑚) = = = 0.75𝑢𝑢𝑢𝑢
𝑓𝑓𝑓𝑓𝑓𝑓(𝑚𝑚𝑚𝑚𝑚𝑚) 66𝑘𝑘𝑘𝑘𝑘𝑘
𝐼𝐼𝐼𝐼(𝑚𝑚𝑚𝑚𝑚𝑚) takes a margin of about 20%, 𝐼𝐼𝐼𝐼(𝑚𝑚𝑚𝑚𝑚𝑚) = 170𝑚𝑚𝑚𝑚 ∗ 1.2 = 0.204𝐴𝐴
𝑉𝑉𝑉𝑉𝑉𝑉𝑚𝑚𝑚𝑚𝑚𝑚 −𝑉𝑉𝑜𝑜
𝐿𝐿 = 𝑡𝑡𝑜𝑜𝑜𝑜 (𝑚𝑚𝑚𝑚𝑚𝑚) ∗ (Where the critical point (peak) 𝐼𝐼𝑝𝑝 = 𝐼𝐼𝐼𝐼(𝑚𝑚𝑚𝑚𝑚𝑚) ∗ 2 = 0.408𝐴𝐴)
𝐼𝐼𝑝𝑝
101𝑉𝑉𝑉𝑉𝑉𝑉−5𝑉𝑉𝑉𝑉𝑉𝑉
= 0.75𝑢𝑢𝑢𝑢 ∗ = 176.47𝑢𝑢𝑢𝑢 => the inductor should be larger
0.408𝐴𝐴
than 177uH
So, I selected 680uH (required by datasheet and widely available in the
supply chain)
Calculation of the Inductor’s Current Rating

Assume that the minimum ON time at the maximum input voltage 264VAC
is
5𝑉𝑉𝑉𝑉𝑉𝑉
( )
𝑡𝑡𝑜𝑜𝑜𝑜 (𝑚𝑚𝑚𝑚𝑚𝑚) = 264𝑉𝑉𝑉𝑉𝑉𝑉 ∗ 1.41 = 0.2𝑢𝑢𝑢𝑢
66𝑘𝑘𝑘𝑘𝑘𝑘
𝑉𝑉𝑉𝑉𝑉𝑉 −𝑉𝑉 264𝑉𝑉𝑉𝑉𝑉𝑉∗1.41−5𝑉𝑉𝑉𝑉𝑉𝑉
Thus, 𝐼𝐼𝐼𝐼𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 = 𝑡𝑡𝑜𝑜𝑜𝑜 (𝑚𝑚𝑚𝑚𝑚𝑚) ∗ 𝑚𝑚𝑚𝑚𝑚𝑚 𝑜𝑜 = 0.2𝑢𝑢𝑢𝑢 ∗ = 0.108𝐴𝐴
𝐿𝐿 680𝑢𝑢𝑢𝑢
=> the inductor’s current rating should be larger than 0.2A.
2. Output Capacitor C3
Assume that the output ripple voltage (∆𝑉𝑉𝑉𝑉𝑉𝑉) is 100mV
∆𝑉𝑉𝑉𝑉𝑉𝑉 0.1𝑉𝑉
𝑍𝑍𝐶𝐶3 < = = 0.926 𝑂𝑂ℎ𝑚𝑚 @ 66𝑘𝑘𝑘𝑘𝑘𝑘 (𝑓𝑓𝑓𝑓𝑓𝑓(𝑚𝑚𝑚𝑚𝑚𝑚))
𝐼𝐼𝐼𝐼𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 0.108𝐴𝐴
Convert 𝑍𝑍𝐶𝐶3 from 66kHz to 100kHz
66
𝑍𝑍𝐶𝐶3 < 0.926 𝑂𝑂ℎ𝑚𝑚 ∗ = 0.611 𝑂𝑂ℎ𝑚𝑚 @ 100𝑘𝑘𝑘𝑘𝑘𝑘
100
The ripple current 𝐼𝐼𝑠𝑠 (𝑟𝑟𝑟𝑟𝑟𝑟):
1 1
𝐼𝐼𝑠𝑠 (𝑟𝑟𝑟𝑟𝑟𝑟) = 𝐼𝐼𝐼𝐼𝑠𝑠𝑠𝑠𝑠𝑠 ∗ � = 0.108𝐴𝐴 ∗ � = 0.06235𝐴𝐴
3 3
Page 3 of 8
Voltage Rating of Capacitor C3 is 𝑉𝑉𝑜𝑜 ∗ 2 = 5𝑉𝑉 ∗ 2 = 10𝑉𝑉
3. Output Diode D3
Since the output rectifier diode turns on and off at the switching frequency,
it uses a fast recovery diode that can switch at high speed (66kHz or above).
The reverse voltage applied to the output diode should be less than or
equal to the margin:
𝑉𝑉𝑉𝑉𝑉𝑉𝑚𝑚𝑚𝑚𝑚𝑚 264∗1.41 372
𝑉𝑉𝑑𝑑𝑑𝑑 = = = = 531𝑉𝑉 => select 600V products
0.7 0.7 0.7
Diode losses are approximate, but are:
𝑃𝑃𝑑𝑑 = 𝑉𝑉𝐹𝐹 ∗ 𝐼𝐼𝑜𝑜𝑜𝑜𝑜𝑜 = 1𝑉𝑉 ∗ 0.17𝐴𝐴 = 0.17𝑊𝑊
𝑉𝑉𝐹𝐹 means diode’s forward voltage.
4. 𝑅𝑅𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 (R4) and 𝑅𝑅𝐹𝐹𝐹𝐹 (R2)

The value of 𝑅𝑅𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 (R4) and 𝑅𝑅𝐹𝐹𝐹𝐹 (R2) are selected such that, at the regulated
output voltage, the voltage on the FEEDBACK pin(𝑉𝑉𝐹𝐹𝐹𝐹 ) is 2.0V. This voltage
is specified for a FEEDBACK pin current (𝐼𝐼𝐹𝐹𝐹𝐹 ) of 49uA.
Let the value of 𝑅𝑅𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 (R4) =2.49 kOhm; this bias the feedback network at
amount of ~0.8mA
Hence the value of 𝑅𝑅𝐹𝐹𝐹𝐹 (R2) is given by

𝑉𝑉𝑜𝑜 − 𝑉𝑉𝐹𝐹𝐹𝐹 (𝑉𝑉𝑜𝑜 − 𝑉𝑉𝐹𝐹𝐹𝐹 ) ∗ 𝑅𝑅𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵
𝑅𝑅𝐹𝐹𝐹𝐹 = =
𝑉𝑉𝐹𝐹𝐹𝐹 ( )
+ 𝐼𝐼𝐹𝐹𝐹𝐹 𝑉𝑉𝐹𝐹𝐹𝐹 + 𝐼𝐼𝐹𝐹𝐹𝐹 ∗ 𝑅𝑅𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵
𝑅𝑅𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵
(5𝑉𝑉𝑉𝑉𝑉𝑉 − 2𝑉𝑉𝑉𝑉𝑉𝑉 ) ∗ 2.49𝑘𝑘𝑘𝑘ℎ𝑚𝑚
=
2𝑉𝑉 + (49𝑢𝑢𝑢𝑢 ∗ 2.49𝑘𝑘𝑘𝑘ℎ𝑚𝑚)
= 3520.25 𝑂𝑂ℎ𝑚𝑚 =>3.48 kOhm
5. Verification
x = 4.9657 VDC
Part III: Circuit Implementation
Page 4 of 8
Internal Photo 1 Internal Photo 2
Internal Photo 3 FCC Test Setup

Components Theoretical Calculations Mfr. No
Inductor L2 680uH FH VLU0810-681KB
Current Rating > 0.2A
Capacitor C3 Less than 0.611 Ohm @ NIPPON CHEMI-CON
100kHz EKZE160ELL471MJC5S
Voltage Rating > 10V
Diode D3 Voltage Rating >= 600V VISHAY US1J-E3/61T
Fast Recovery Diode that can
switch at high speed (66kHz
or above)
𝑅𝑅𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 (R4) and 𝑅𝑅𝐹𝐹𝐹𝐹 (R2) 𝑅𝑅𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 (R4): 2.49 kOhm 1206, 1/4W, 1%, -
𝑅𝑅𝐹𝐹𝐹𝐹 (R2): 3.48 kOhm 55°C ~ 155°C
Page 5 of 8
C4, C5 and L1 are PI filter for EMI suppression. R34 and C36 in parallel to D3 are
used to reduce spikes occurring ON/OFF.
Some measurement results when the input was 220VAC, 50Hz:
Part IV: Mean Time To Failure (MTTF) and Thermal Analysis

Test Contents:
Page 6 of 8
Component Temperature Rise Curve
Page 7 of 8
Part V: Conclusion
The 5VDC Non-Isolated AC/DC based on Power Integrations LNK3205 was designed
to meet all project’s requirements successfully. It was integrated into the Plug-In
Relay (On/Off) product which already got its FCC and UL certifications. According
to the Mean Time To Failure Test above, the Plug-In Relay (On/Off) product’s high
temperature aging life was more than 11.4 years.
Part VI: References

[1] FCC Reports of Libre Home Inc Wireless Relay Control PRU. Retrieved Nov 15,
2019, from https://fccid.io/2AQXA-PRU
Page 8 of 8

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Confidentiality Level: Public

Non-Isolated AC/DC Power Supply Design and Implementation based

decided to design a new 5VDC Non-Isolated AC/DC based on Power Integrations

Part II: Theoretical Analysis and Calculation

Front view of product Back view of product

5VDC Non-Isolated AC/DC Schematic

According to the design requirements, 𝑉𝑉𝑉𝑉𝑉𝑉𝑚𝑚𝑚𝑚𝑚𝑚 = 90𝑉𝑉𝑉𝑉𝑉𝑉 multiply by 1.41

Calculation of the Inductor’s Current Rating

Voltage Rating of Capacitor C3 is 𝑉𝑉𝑜𝑜 ∗ 2 = 5𝑉𝑉 ∗ 2 = 10𝑉𝑉

4. 𝑅𝑅𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 (R4) and 𝑅𝑅𝐹𝐹𝐹𝐹 (R2)

Hence the value of 𝑅𝑅𝐹𝐹𝐹𝐹 (R2) is given by

Internal Photo 1 Internal Photo 2

Internal Photo 3 FCC Test Setup

Part IV: Mean Time To Failure (MTTF) and Thermal Analysis

Component Temperature Rise Curve

Part VI: References

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