Need help with LNK623 design
We have an industrial controller used in Solar application. It has two inputs for power supply:
1) R Phase of Grid (R-N nominal 240VAC, 50Hz): Wide variation in input, upto +/-30% change, with 45-55Hz
2) 48VDC (Variation from 40-60VDC)
We want to generate 2 output voltages from the SMSP power supply: An isolated 5V for isolated RS485 communication (max 200mA load) and a 5V supply for driving relays with total load of 800mA. We are using LNK623 for this application.
We also want the power supply to be protected upto 10kV (1.2/50us / 8/20us combinational waveform) surge on either AC or DC input. Ambient temperature is from -20C to 85C.
Attached is the schematic of an old power supply circuit we have used in another controller. We have lost the calculation for this circuit. Please show us the calculation and let us know the changes if any in the circuit.
Transformer details are as following:
Core Type: EE13 (ferrite), gapped
AL Value: 155 nH/turn²
Primary Inductance: 1.548 mH
Windings Table
Winding Turns Wire Gauge Winding Direction Pins
Primary 100T 40 SWG Clockwise 1,2
Sec 1 18T 34 SWG CW 9,10
Sec 2 12T 32 SWG CW 6,7
Sec 3 13T × 4 42 SWG multifilar CW 4,5
This project is bit urgent so any quick help will be much appreciated.

Hello Sakjain,
For design calculations, you can use our PI XLS tool to generate a transformer design and some other component recommendations to use in your application. I have generated an initial PI XLS design to get you started. I will link it below.
PI XLS Design: https://piexpertonline.power.com/fileManager/index?shared=8afb410649592dd0ad341a057678f30f8e99f4a827bba3e4d8d904ecf4449a46
For the rest of the design parameters, please refer to the device's datasheet and App Note.
Datasheet: LinkSwitch-CV Data Sheet | Power Integrations
App note: AN-45 - LinkSwitch-CV Design Guide | Power Integrations
Make any changes you think will be needed in the spreadsheet in regards to your requirements and if there are no warnings, the design should work as long as all the other guidelines in the datasheet and app note are followed.
Please note though that when I generated the initial PI XLS design, I needed to increase the device size to LNK624 and increase the minimum operating voltage to 70V in order to remove the warnings so I cannot recommend using LinkSwitch-CV at an input voltage below 70V.