Der-637 35watt High-Pf Isolated Flyback Switched Valley Fill PFC Lytswitch-6 Led Driver

Design Example Report
35 W High Power Factor Isolated Flyback

Title with Switched Valley Fill PFC Power Supply
Using LYTSwitchTM-6 LYT6068C
Specification 140 VAC – 320 VAC Input; 12 V, 2.92 A Output
Application Emergency Light with Battery Charging
Author Applications Engineering Department
Document
DER-637
Number
Date April 23, 2018
Revision 1.4
Summary and Features
 Accurate constant voltage regulation
 High power factor, >0.9 at 230 V and 277 V inputs
 Fast transient load response
 Highly energy efficient, >88 % at 230 V and 277 V inputs
 Integrated protection and reliability features
 Output short-circuit protection
 Line and output OVP
 Thermal foldback and over-temperature shutdown with hysteretic automatic power
recovery
 No damage during line brown-out or brown-in conditions
 Meets IEC 2.5 kV ring wave, 1 kV differential surge
 Meets EN55015 conducted EMI
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.
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DER-637 35 W High PF Isolated Flyback using LYTSwitch-6 23-Apr-18
Table of Contents
1 Introduction .........................................................................................................4
2 Power Supply Specification ...................................................................................6
3 Schematic ............................................................................................................7
4 Circuit Description ................................................................................................8
4.1 Input EMI Filter and Rectifier..........................................................................8
4.2 LYTSwitch-6 Primary Side Control ...................................................................8
4.3 LYTSwitch-6 Secondary-Side Control ...............................................................9
4.4 PFC Circuit Operation ................................................................................... 10
5 PCB Layout ........................................................................................................ 12
6 Bill of Materials .................................................................................................. 13
6.1 Main Bill of Material ..................................................................................... 13
6.2 Miscellaneous Parts ...................................................................................... 14
7 Flyback Transformer (T1) Specification ................................................................ 15
7.1 Electrical Diagram ........................................................................................ 15
7.2 Electrical Specifications ................................................................................ 15
7.3 Material List ................................................................................................ 15
7.4 Transformer Build Diagram .......................................................................... 16
7.5 Transformer Construction ............................................................................. 16
7.6 Transformer Winding Illustrations ................................................................. 17
8 PFC Inductor (T2) Specifications ......................................................................... 22
8.1 Electrical Diagram ........................................................................................ 22
8.2 Electrical Specifications ................................................................................ 22
8.3 Material List ................................................................................................ 22
8.4 Inductor Build Diagram ................................................................................ 23
8.5 Inductor Construction .................................................................................. 23
8.6 Inductor Winding Illustrations ...................................................................... 24
9 Design Spreadsheet............................................................................................ 26
10 Performance Data ........................................................................................... 30
10.1 Output Voltage Regulation ........................................................................... 30
10.2 System Efficiency......................................................................................... 31
10.3 Power Factor ............................................................................................... 32
10.4 %ATHD ...................................................................................................... 33
10.5 Individual Harmonics Content at Full Load ..................................................... 34
10.6 No-Load Input Power ................................................................................... 36
10.7 CV/CC Curve ............................................................................................... 37
11 Test Data ....................................................................................................... 38
11.1 Test Data at Full Load .................................................................................. 38
11.2 Test Data at No-Load ................................................................................... 38
11.3 Individual Harmonic Content at 230 VAC 50 Hz and Full Load ......................... 39
11.4 Individual Harmonic Content at 277 VAC 50 Hz and Full Load ......................... 40
12 Load Regulation Performance .......................................................................... 41
12.1 Output Voltage Load Regulation ................................................................... 41
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23-Apr-18 DER-637 35 W High PF Isolated Flyback using LYTSwitch-6
12.2 Efficiency vs. Load ....................................................................................... 42

12.3 Average Efficiency ....................................................................................... 42
12.3.1 Average Efficiency Measurement ............................................................ 42
12.4 Power Factor vs. Load .................................................................................. 43
12.5 %ATHD vs. Load ......................................................................................... 44
13 Thermal Performance ...................................................................................... 45
13.1 Thermal Measurements at Room Temp Ambient ............................................ 45
13.2 Thermal Performance at High Temp Ambient ................................................ 47
14 Waveforms ..................................................................................................... 49
14.1 Input Voltage and Input Current at Full Load................................................. 49
14.2 Start-up Profile at Full Load .......................................................................... 50
14.3 Output Voltage Fall ...................................................................................... 51
14.4 Power Cycling .............................................................................................. 52
14.5 Load Transient Response 3 Hz...................................................................... 53
14.6 Load Transient Response 100 Hz .................................................................. 55
14.7 LYTSwitch-6 Drain Voltage and Current Waveforms at Normal Operation ........ 57
14.8 LYTSwitch-6 Drain Voltage and Current at Full Load Start-up ......................... 60
14.9 LYTSwitch-6 Drain Voltage and Current during Output Short-Circuit ................ 62
14.10 PFC Diode Voltage and Current at Normal Operation .................................. 64
14.11 PFC Diode Voltage and Current at Start-up Full Load .................................. 65
14.12 SR FET Drain Voltage and Current at Normal Operation .............................. 66
14.13 SR FET Drain Voltage and Current at Full Load Start-up .............................. 68
14.14 Output Voltage Ripple............................................................................... 70
14.15 Output Current Ripple ............................................................................... 73
14.15.1 Equipment Used ................................................................................ 73
14.15.2 Ripple Ratio and Flicker % Measurement ............................................ 73
15 Conducted EMI ............................................................................................... 75
15.1 Test Set-up ................................................................................................. 75
15.1.1 Equipment and Load Used ..................................................................... 75
15.2 EMI Test Result ........................................................................................... 76
16 Line Surge ...................................................................................................... 78
16.1 Differential Surge Test Results ...................................................................... 79
16.2 Ring Wave Surge Test Results ...................................................................... 79
16.3 1 kV Differential Surge Test .......................................................................... 80
16.4 2.5 kV Ring Wave Surge Test ....................................................................... 81
17 Brown-in / Brown-out Test .............................................................................. 82
18 Revision History .............................................................................................. 83
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.
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1 Introduction
This engineering report describes a constant voltage (CV) output 35 W isolated flyback
power supply with a single-stage power factor correction circuit for LED lighting
application. The power supply is designed to provide a 12 V constant voltage across 0 A
to 2.92 A output current load. It’s also capable of providing 2.98 A constant current
output for LED lighting applications. The board is optimized to operate from an input
voltage range of 140 VAC to 320 VAC.
The LYTSwitch-6 IC combines primary, secondary and feedback circuits in a single

surface mounted off-line flyback switcher IC. It incorporates the primary FET, the
primary-side controller and a secondary-side synchronous rectification controller. The
device also includes an innovative new technology, FluxLink™, which safely bridges the
isolation barrier and eliminates the need for an optocoupler.
A switched valley-fill PFC circuit is added to meet the high PF requirement in lighting
applications. The energy stored across the PFC inductor is delivered to the load via direct
energy transfer reducing the power loss.
DER-637, using a LYTSwitch-6 IC, offers an accurate, fast transient response, constant
voltage supply with a high power factor throughout the input range. The key design
goals were high efficiency and high power factor throughout the input voltage range.
This document contains the power supply specification, schematic diagram, bill of
materials, transformer documentation, printed circuit board layout, and performance
data.
Figure 1 – Populated Circuit Board.

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Figure 2 – Populated Circuit Board, Top View.
Figure 3 – Populated Circuit Board, Bottom View.
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2 Power Supply Specification

The table below represents the minimum acceptable performance of the design. Actual
performance is listed in the results section.
Description Symbol Min Typ Max Units Comment
Input
Voltage VIN 140 230/277 320 Vac/Hz 2 Wire – no P.E.
Frequency fLINE 50
Output
Output Voltage VOUT 12 V CC Threshold: 2.98 A.
Output Current IOUT 0 2.92 A
Total Output Power
Continuous Output Power POUT 35 W
Efficiency
At 230 VAC / 50 Hz and 277 VAC /
50 Hz.
Full Load  88 % 25 ºC Ambient Temperature.
Average Efficiency
25%, 50%, 75%, and 100% 87 % Meets DOE Level VI.
Load
Environmental
Conducted EMI CISPR 15B / EN55015B
Safety Isolated
Ring Wave (100 kHz) 2.5 kV
Differential Mode (L1-L2) 1 kV

Measured at 230 VAC / 50 Hz
Power Factor 0.9 and 277 VAC / 50 Hz.
Ambient Temperature TAMB 60 ºC Free Air Convection, Sea Level.

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3 Schematic
Figure 4 – Schematic Diagram.
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4 Circuit Description
The LYTSwitch-6 device (LYT6068C) incorporates the primary MOSFET, the primary-side
controller and a secondary-side synchronous rectification controller in a single inSOP-24D
package. This IC also includes an innovative new technology, FluxLink™, which safely
bridges the isolation barrier and eliminates the need for an optocoupler. The LYTSwitch-6
IC is configured to drive a 35 W flyback power supply with a switched valley fill PFC
providing a high power factor 12 V constant voltage supply throughout the input range of
140 VAC to 320 VAC.
4.1 Input EMI Filter and Rectifier

The input fuse F1 provides safety protection from component failures. Varistor RV1 acts
as a voltage clamp that limits the voltage spike on the primary during line transient
voltage surge events. A 350 V rated part was selected, being slightly above the
maximum specified operating input voltage (320 V). The AC input voltage is full wave
rectified by BR1 to achieve good power factor and low THD.
The bulk capacitor (C4) provides input line ripple voltage filtering for a stable flyback DC
supply voltage and helps reduce EMI noise. It also stores excess energy generated by
the PFC during the power switch turn off time.
Capacitor C1, L1, C2, L2, and C3 forms a 2 stage LC EMI filter to suppress differential
mode noise caused by the PFC and flyback switching action. Common mode noise is
suppressed by Y capacitor C8.
Rectifier diode (D2) provides a bypass charging current to the bulk capacitor (C4) from
the input rectified voltage. Diode D2 also serves as a blocking diode during the power
MOSFET turn OFF to isolate the flyback DC supply from the PFC supply maintaining the
functionality of the added PFC circuit.
4.2 LYTSwitch-6 Primary Side Control

The isolated flyback power supply is controlled by the LYTSwitch-6 IC LYT6068C. One
side of the transformer (T1) primary is connected to the positive output terminal of the
bulk capacitor (C4) while the other side is connected to the drain of the integrated 650 V
power MOSFET inside the LYTSwitch-6 IC (U1). A low cost RCDZ snubber clamp formed
by D4, R2, R15, C7, R3, and VR1 limits the peak Drain voltage spike due to the effects of
transformer leakage inductance.
The VOLTAGE MONITOR (V) pin of the LYTSwitch-6 IC is connected to the positive of the
bulk capacitor (C4) to provide input voltage information. The voltage across the bulk
capacitor (C4) is sensed and converted into current through V pin resistors R4, R12, and
R5 to provide detection of overvoltage. The IOV- determines the input overvoltage
threshold.

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During the initial power-up, the internal high-voltage current source charges the BPP pin
capacitor (C6). Before switching, the primary will pause for around 80 ms to listen for
secondary request signals. When the primary starts switching after initial power-up, it will
initially assume control and require a handshake to pass the control to the secondary
side. The LYTSwitch-6 IC is at normal operation when switching with the secondary in
control. During normal operation the primary-side block is powered by the auxiliary
winding of the transformer. The output of this is configured as a flyback winding,
rectified and filtered (D3 and C5) and fed to the BPP pin via a current limiting resistor R1.
The value of the BPP pin capacitor C6 sets the current limit of the LYTSwitch-6 IC. The
0.47 F capacitance value for C6 corresponds to STANDARD current limit mode.
The thermal shutdown circuitry senses the primary MOSFET die temperature. The
threshold (TSD) is typically set to 142 °C with 70 °C hysteresis TSD(H). When the die
temperature rises above this threshold the power MOSFET is disabled and remains
disabled until the die temperature falls by TSD(H) at which point it is re-enabled. A large
hysteresis of 70 °C is provided to prevent over-heating of the PCB due to continuous
fault condition.
4.3 LYTSwitch-6 Secondary-Side Control

The secondary-side control of the LYTSwitch-6 IC provides output voltage and output
current sensing. The secondary of the transformer is rectified by a synchronous rectifier
MOSFET (Q1), driven by the Synchronous Rectifier Drive (SR) pin of LYTSwitch-6 IC. This
is then filtered by the output capacitors C10 and C16. Adding an RC snubber (R7 and C9)
across the SR FET reduces voltage stress across its drain-to-source. An LC filter (L3 and
C17) in series with the secondary winding of the transformer helps to further reduce the
voltage spike across the drain-to-source of the SR FET, if a simple RC snubber is not
enough, with little to no effect on system efficiency. Component L3 is a single-turn ferrite
bead that, in conjunction with a parallel ceramic capacitor C17, suppresses high
frequency spike present on the secondary of the transformer especially during start-up.
The secondary side of the IC is self-powered from either the secondary bias winding
forward voltage or the 12 V regulated output. During normal operation the regulated
output voltage powers the device, through the OUTPUT VOLTAGE (VOUT) pin. During
start-up operation, when the output voltage is still building-up, the device will power
itself from the secondary winding directly. During the ON-time of the primary-side
MOSFET the forward voltage that appears across the secondary winding is used to
charge the (BPS) capacitor C12 via the FORWARD (FWD) pin through resistor R6 and an
internal regulator.
During constant voltage mode operation, output voltage regulation is achieved through
sensing the output voltage via divider resistors R8 and R9. The voltage across R9 is fed
into the FB pin with an internal reference voltage threshold of 1.265 V. Filter capacitor
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C11 is added across R9 to eliminate unwanted noise that might trigger the OVP function
or increase the output ripple voltage. The feedforward network composed of C14 and
R14 across R8 helps reduce output voltage ripple and achieve better output voltage
regulation. Capacitor C13 filters out any unwanted noise that may enter the VOUT pin,
and also helps reduce output voltage ripple. During constant current operation, the
output current is set by the sense resistor (R18) across the IS pin and the GND pin. The
internal reference threshold for the IS pin is 35.8 mV. Diode D6 in parallel with the
current sense resistor serves as protection during output short-circuit conditions.
The thermal foldback is activated when the secondary controller die temperature reaches
124 °C, the output power is reduced by reducing the constant current reference
threshold.
4.4 PFC Circuit Operation

Without the added PFC circuit, the power factor of the flyback power supply is normally
around 0.5 to 0.6 at full load condition. The input of the flyback power supply circuit
usually consists of the full wave bridge rectifier (BR1) followed by a storage bulk
capacitor (C4) capable of maintaining a voltage approximately equal to the peak voltage
of the input sine wave until the next peak comes to recharge the capacitor. The input
charging pulse current must be high enough to sustain the load until the next peak. This
means that the charging pulse current is around 5-10 times higher than the average
current with a high phase angle difference from the voltage waveform; hence, the
expected PF from this standard configuration is low and THD is high.
The added PFC circuit is called “Switched Valley-Fill Single Stage PFC” (SVF S2PFC). It is
comprised of an inductor (T2) and diodes (D1 and D5) connected directly to the DRAIN
pin of the LYTSwitch-6 IC. The LYTSwitch-6 flyback switching action is able to draw a
high frequency pulse current from the full wave rectified input. This will reduce the rms
input current and the phase angle difference from the input line voltage will be lower;
hence, power factor will increase and will improve THD.
The PFC inductor T2 operates in DCM mode. During the LYTSwitch-6 turn ON time,
current drawn from the rectified input ramps through the PFC inductor (T2) storing
energy. The stored energy on T2 is then delivered to the load via direct energy transfer
between the primary and secondary winding of the flyback transformer T1. Any excess
energy from the PFC inductor that is not delivered to the load is being stored to the bulk
capacitor. During no-load and light load conditions (i.e, less than 250 mA output load
current), the secondary requires less energy from the primary; therefore, more excess
energy from the PFC inductor is stored on the bulk capacitor causing the voltage to rise
gradually. The expected voltage stress across the bulk capacitor C4 will be higher than
the peak input voltage. To limit the bulk voltage below the bulk capacitor rating,
especially at high input voltage, a Zener-resistor clamp circuit is used (VR2, VR3, and

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R19). The Zener voltage is set at 480 V; when the bulk voltage goes beyond this, the
Zener diodes conduct and bleed current from the bulk capacitor through resistor R19.
This prevents the bulk capacitor voltage to rise above 480 V. The power dissipation of
this Zener-resistor clamp should be considered at the worst-case creeping of the bulk
voltage – happens usually at light load condition. Diodes D1 and D5 are connected in
series to withstand voltage stress caused by the resonance ringing during the FET turn
off. The variability of the PFC inductor peak current will be compensated by LYTSwitch-6
primary and secondary side control maintaining the voltage regulation at all conditions.
A low cost RCD clamp circuit across the Drain-to-Source pins of the LYTSwitch-6 IC will
also limit the bulk voltage from rising at light load, but the additional dissipation will
cause a decrease in overall system efficiency and increase no-load input power
consumption.
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5 PCB Layout
Figure 5 – Top Side.
Figure 6 – Bottom Side.

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6 Bill of Materials
6.1 Main Bill of Material
Ref
Item Qty Description Mfg Part Number Mfg
Des
Bridge Rectifier, 1000 V, 4 A, 4-ESIP, D3K, -55°C ~ 150 °C
1 1 BR1 UD4KB100-BP Micro Commercial
(TJ), Vf=1 V @ 7.5 A
68 nF, ±10%, 330 VAC, 760 VDC, X1 Safety Rated,
2 1 C1 B32912A3683K000 Epcos
Metallized Polypropylene Film, RAD
68 nF, ±10%, 330 VAC, 760 VDC, X1 Safety Rated,
3 1 C2 B32912A3683K000 Epcos
Metallized Polypropylene Film, RAD
220 nF, ±5%,630 VDC, 250 VAC, Film, 12.5 mm L x 15.8
4 1 C3 MEXPF3220JJ Duratech
mm H x 9.0 mm T, 10 mm LS
5 1 C4 68 uF, 500 V, Electrolytic ,(18 x 41.5), LS 0.295" (7.50 mm) UCY2H680MHD Nichicon
6 1 C5 22 F, 35 V, Ceramic, X5R, 1206 C3216X5R1V226M160AC TDK
7 1 C6 470 nF, 50 V, Ceramic, X7R, 0805 GRM21BR71H474KA88L Murata
8 1 C7 3.3 nF, 200 V, Ceramic, X7R, 0805 08052C332KAT2A AVX
9 1 C8 CAP Ceramic 2.2nF 500 VAC VY1222M47Y5UQ63V0 Vishay
10 1 C9 470 pF, 200 V, Ceramic, X7R, 0805 C0805C471K2RACTU Kemet
11 1 C10 1000 F, 16 V, Electrolytic, Gen. Purpose, (10 x 17.5) 16ZLJ1000M10X16 Rubycon
12 1 C11 330 pF 50 V, Ceramic, X7R, 0603 CC0603KRX7R9BB331 Yageo
13 1 C12 2.2 F, 25 V, Ceramic, X7R, 1206 TMK316B7225KL-T Taiyo Yuden
10 F, ±10%, 16V, X7R, Ceramic Capacitor, -55°C ~
14 1 C13 CL21B106KOQNNNE Samsung
125°C, Surface Mount, MLCC 0805
15 1 C14 100 nF 50 V, Ceramic, X7R, 0603 C1608X7R1H104K TDK
16 1 C16 1000 F, 16 V, Electrolytic, Gen. Purpose, (10 x 17.5) 16ZLJ1000M10X16 Rubycon
17 1 C17 3.3 nF, 200 V, Ceramic, X7R, 0805 08052C332KAT2A AVX
18 1 D1 600 V, 2 A, Superfast, 35 ns, DO-214AC, SMA ES2J-LTP Micro Commercial
19 1 D2 600 V, 1 A, Standard Recovery, SMA S1J-13-F Diodes, Inc.
20 1 D3 Diode, Ultrafast, 200 V, 1 A, POWERDI123 DFLU1200-7 Diodes, Inc.
21 1 D4 1000 V, 1 A, DO-214AC GS1M-LTP Micro Commercial
22 1 D5 600 V, 2 A, Superfast, 35 ns, DO-214AC, SMA ES2J-LTP Micro Commercial
23 1 D6 Diode, SCHOTTKY, 40 V, 3 A, SMA, DO-214AA B340A-13-F Diodes, Inc.
24 1 F1 3.15 A, 250 V, Slow, 3.6 mm x 10 mm, Axial 08773.15MXEP Littlefuse
25 1 L1 8.8 mH, 0.7 mA, AC Filter T/H Common Mode Choke SU10VFC-R07088 Kemet
26 1 L2 1.5 mH, 0.8 A, 20% RL-5480-4-1500 Renco
3.5 mm x 4.45 mm, 56  at 100 MHz, 22 AWG hole, Ferrite
27 1 L3 2761001112 Fair-Rite
Bead
Alpha & Omega
28 1 Q1 MOSFET, N-CH, 150 V, 52 A, 8DFN AON6250
Semi
29 1 R1 RES, 10 k, 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF1002V Panasonic
30 1 R2 RES, 20 , 1%, 1/2 W, Thin Film, 1206 RNCP1206FTD20R0 Stackpole
31 1 R3 RES, 120 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ124V Panasonic
32 1 R4 RES, 1.60 M, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF1604V Panasonic
33 1 R5 RES, 1.30 M, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF1304V Panasonic
34 1 R6 RES, 47 , 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ470V Panasonic
35 1 R7 RES, 15 , ±1%, 0.75W, 3/4W, 1210, Thick Film CRCW121015R0FKEAHP Vishay Dale
36 1 R8 RES, 102 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF1023V Panasonic
37 1 R9 RES, 11.8 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF1182V Panasonic
38 1 R12 RES, 1.33 M, 1%, 1/4 W, Thick Film, 1206 RC1206FR-071M33L Yageo
39 1 R14 RES, 20 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF2002V Panasonic
40 1 R15 RES, 20 , 1%, 1/2 W, Thin Film, 1206 RNCP1206FTD20R0 Stackpole
0.012 , ±1%, ±100ppm/°C, 1 W, 1206 (3216 Metric),
43 1 R18 RUK3216FR012CS Samsung
Current Sense, Thick Film
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44 1 R19 RES, 1 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ102V Panasonic

Varistor, 350 VAC, 3.5K A, 10.5 mm, Bulk ZNR, ERZ-E,
45 1 RV1 ERZ-E08A561 Panasonic
Surge Absorber
46 1 T1 Bobbin, RM8, Vertical, 12 pins BRM08-1112CP-W-P5.0 MH&W
47 1 T2 Bobbin, EE13, Vertical, 10 pins P-1302-2 Pin Shine
DIODE, ZENER, 140 V, ±5%,1.5 W, DO204AL, DO-204AL
48 1 VR1 Z4KE140A-E3/54 Vishay
(DO-41)
240 V, 1.25 W, 600 W (Peak, non-repetitive),5%, DO214AC
49 1 VR2 BZG03C240TR Vishay
(SMA)
240 V, 1.25 W, 600 W (Peak, non-repetitive),5%, DO214AC
50 1 VR3 BZG03C240TR Vishay
(SMA)
Power
51 1 U1 LYTSwitch-6, InSOP24D LYT6068C
Integrations
6.2 Miscellaneous Parts

Ref Mfg Part
Item Qty Description Mfg
Des Number
1 1 +V Test Point, RED, Miniature THRU-HOLE MOUNT 5000 Keystone
2 1 RTN Test Point, BLK, Miniature THRU-HOLE MOUNT 5001 Keystone
3 1 L Test Point, WHT, Miniature THRU-HOLE MOUNT 5002 Keystone
4 1 N Test Point, BLK, THRU-HOLE MOUNT 5011 Keystone
5 1 FL1 Flying Lead, Hole size 50mils N/A N/A
6 1 FL2 Flying Lead, Hole size 50mils N/A N/A

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7 Flyback Transformer (T1) Specification

7.1 Electrical Diagram
Figure 7 – Transformer Electrical Diagram.
7.2 Electrical Specifications

Parameter Condition Spec.
Nominal Primary Measured at 1 VPK-PK, 100 kHz switching frequency, between pin 10
720 H
Inductance and pin 12 with all other windings open.
Tolerance Tolerance of Primary Inductance. ±5%
Leakage Inductance Measured across primary winding with all other windings shorted. <6 H
7.3 Material List

Item Description
[1] Core: RM8 PC95.
[2] Bobbin: Bobbin, RM8, Vertical, 12 pins; Part No. : 25-01084-00.
[3] Magnet Wire: #31 AWG.
[4] TIW: # 22 AWG.
[5] Polyester Tape: 9 mm.
[6] RM8 Core Clip with Terminal.
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7.4 Transformer Build Diagram
Figure 8 – Transformer Build Diagram.
7.5 Transformer Construction

Bobbin is oriented on winder jig such that terminal pin 10-12 is in the right side.
Winding Directions
The winding direction is clockwise.
Use bifilar magnetic wire, Item [3]. Start at pin 10 and wind 30 turns evenly in 2
Winding 1
layers. Finish the winding on pin 11.
Insulation Apply 1 layer of polyester tape, Item [5] for insulation
Use bifilar triple insulated wire, Item [4]. Start at the other side of the bobbin
(pin 4 – pin 9 side) and wind 9 turns evenly in 2 layers. Finished the winding on
Winding 2
the same side of the bobbin. Do not terminate the winding on any pin of the
bobbin; Just leave them as fly-leads.
Insulation Apply 1 layer of polyester tape, Item [5] for insulation.
Use bifilar magnetic wire, Item [3]. Start at pin 11 and wind 29 turns evenly in 2
Winding 3
layers. Finished the winding on pin 12.
Insulation Apply 1 layer of polyester tape, Item [5] for insulation.
Use magnetic wire, Item [3]. Start at pin 1 and wind 10 turns. Finish the winding
Winding 4
on pin 2.
Insulation Apply 2 layers of polyester tape, Item [5] for insulation.
Grind the center leg of the ferrite core to meet the nominal inductance
Core Grinding
specification of 720 H.
Use RM8 core clips with terminals, Item [6] to fix the 2 cores into the bobbin.
Assemble Core Cut the terminal of the clip on the left side of the bobbin, looking at the bottom
side facing the fly leads of the secondary winding.
Cut any excess pins of the bobbin (pins without wire terminations). Trim pin 11
Pins
as short as possible.
Finish Dip the transformer in a 2:1 varnish and thinner solution

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7.6 Transformer Winding Illustrations

Winding Directions
Pin 10
Bobbin is oriented on winder jig such that terminal
pin 10-12 is in the right side. The winding direction
is clockwise.
Pin 12
Winding 1
Use bifilar magnetic wire, Item [3]. Start at pin 10

and wind 30 turns evenly in 2 layers.
Pin 4
Pin 11
Pin 10
Finish the winding on pin 11.
Insulation
1 layer tape
Apply 1 layer of polyester tape, Item [5] for
insulation.
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Winding 2
Use bifilar triple insulated wire, Item [4]. Start at

the other side of the bobbin (pin 4 – pin 9 side) and
wind 9 turns evenly in 2 layers.
Pin 10
Finished the winding on the same side of the

bobbin. Do not terminate the winding on any pin of
the bobbin; Just leave them as fly-leads.
Insulation

insulation.

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Winding 3
Pin 11
Use bifilar magnetic wire, Item [3]. Start at pin 11
and wind 29 turns evenly in 2 layers.
Pin 12
Finished the winding on pin 12.
Insulation

Pin 12
insulation.
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Winding 4
Use magnetic wire, Item [3]. Start at pin 1 and wind

10 turns.
Pin 1
Finish the winding on pin 2. Pin 2
Insulation
Apply 2 layers of polyester tape, Item [5] for

insulation.

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Core Termination
Use two PC95 RM8 cores, Item [1] and assemble

them with the wounded bobbin.
Pin 11 RM8 Core

trimmed Clips
short
Core Clips
Use RM8 Core Clips with Terminals, Item [6] to fix

the 2 cores into the bobbin. Cut the terminal of the
clip on the left side of the bobbin, looking at the Terminal
bottom side facing the fly leads of the secondary Retained
winding. Terminal
Cut
Cut Excess
Pins
Pins
Cut any excess pins of the bobbin (pins without wire

terminations). Trim pin 11 as short as possible.
Fly Leads
Twist the fly leads for easier termination on the

PCB.
Varnishing
Dip the transformer in a 2:1 varnish and thinner

solution
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8 PFC Inductor (T2) Specifications

8.1 Electrical Diagram
Figure 9 – Inductor Electrical Diagram.
8.2 Electrical Specifications

Parameter Condition Spec.
Nominal Primary Measured at 1 VPK-PK, 100 kHz switching frequency,
760 H
Inductance between pin 1 and pin 10.
Tolerance Tolerance of Primary Inductance. ±5%
8.3 Material List

Item Description
[1] Core: EE13.
[2] Bobbin: Bobbin, EE13, Vertical, 10 pins; Part no. 25-01023-00.
[3] Magnet Wire: #31 AWG.
[4] Transformer tape: 7.7 mm.
[5] Transformer tape: 6 mm.

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8.4 Inductor Build Diagram
Figure 10 – Transformer Build Diagram.
8.5 Inductor Construction

Bobbin is oriented on winder jig such that terminal pin 1 – 5 is in the left side.
Winding Directions
The winding direction is clockwise.
Prepare the magnetic wire Item [3] for bifilar-wound type winding. Start at pin
Winding 1
1 and wind 119.5 turns bifilar in 9 layers. Finish the winding on pin 10.
Insulation Add 2 layers of tape, Item [4] for insulation.
Grind the center leg of the ferrite core evenly until it meets the nominal
Core Grinding
inductance of 760 H. Inductance is measured across pin 1 and pin 10.
Assemble Core Assemble the 2 cores on the bobbin.
Prepare a copper strip with a soldered magnetic wire, Item [3], at the middle
Core Termination as shown in the picture. Apply copper strip at the bottom part of the core and
terminate the magnetic wire on pin 6.
Add 2 layers of tape, Item [5], around the core to fix the 2 cores into the
Core Tape
bobbin.
Pins Pull out or cut terminal pin no. 2, 3, 4, 5, 7, 8, and pin 9.
Finish Dip the transformer assembly in 2:1 varnish and thinner solution.
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8.6 Inductor Winding Illustrations

Winding Directions 
Bobbin is oriented on winder jig such that terminal pin
1 – 5 is in the left side. The winding direction is Pin 1
clockwise.
Pin 5
Winding 1
Pin 1
Prepare the magnetic wire Item [3] for bifilar-wound
type winding. Start at pin 1 and wind 119.5 turns
bifilar in 9 layers.
Finish the winding on pin 10.
Insulation
Pin 1
Add 2 layers of tape, Item [4] for insulation
Pin 10

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Core Termination
Prepare a copper strip with a soldered magnetic wire,

Item [3], at the middle as shown in the picture. Apply
copper strip at the bottom part of the core and
terminate the magnetic wire on pin 6.
Pin 1
Copper Strip
Pin 10
Pin 6
Core Tape
Add 2 layers of tape Item [5] around the core to fix

the 2 cores into the bobbin.
PINS
Pull out or cut Terminal pin no. 2,3, 4, 5, 7, 8, and pin

9
Finish
Dip the transformer assembly in 2:1 varnish and

thinner solution.
2 layers of Tape
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9 Design Spreadsheet
ACDC_Flyback_PF_LYT
Switch-6_020318;
Switched Valley-Fill Single Stage
1 Rev.1.2; Copyright INPUT INFO OUTPUT UNITS
PFC (SVF S^2PFC)
Power Integrations
2018
2 Application Variables
3 VACMIN 140 140 V Minimum Input AC Voltage
Nominal AC Voltage (For universal
4 VACNOM 230 230 V designs low line nominal voltage is
displayed)
5 VACMAX 320 320 V Maximum Input AC Voltage
6 VACRANGE UNIVERSAL Input Voltage Range
7 FL 50 Hz Line Frequency
8 CIN 68.0000 68.0000 µF Minimum Input Capacitance
Input Capacitance Recommended
9 V_CIN 500 V
Voltage Rating
10 VO 12.00 12.00 V Output Voltage
11 IO 2.92 2.92 A Output Current
12 PO 35.04 W Total Output Power
13 N 88.00 Estimated Efficiency
14 Z 0.50 Loss Allocation Factor
15 Parametric Calculations Basis
ILIM Calculations Basis - NOM,MAX or
16 ILIMcalcBASIS Nom Nom
MIN only
Calculated Results Based on Selected
17 PARcalcBASIS Worst_Case Worst_Case VAC - VACNOM,VACMAX,VACMIN or
Worst Case only
18 Primary Controller Section
19 DEVICE_MODE Standard Standard Device Current Limit Mode
20 DEVNAME LYT6068C LYT6068C PI Device Name
21 RDSON 1.53 ohms Device RDSON at 100degC
22 ILIMITMIN 1.534 A Minimum Current Limit
23 ILIMITTYP 1.650 A Typical Current Limit
24 ILIMITMAX 1.766 A Maximum Current Limit
25 BVDSS 650 V Drain-Source Breakdown Voltage
26 VDS 2.00 V On state Drain to Source Voltage
Peak Drain to Source Voltage during
27 VDRAIN 600.55 V
Fet turn off
28 Worst Case Electrical Parameters
29 Boost Converter
30 IBOOSTRMS 296.90 mA Boost RMS current
31 IBOOSTMAX 788.21 mA Boost PEAK current
32 IBOOSTAVG 190.53 mA Boost AVG current
33 IINRMS 313.49 mA Input RMS current
34 PF_est 0.8258 Estimated Power Factor
35 Flyback Converter
Minimum Switching Frequency in a
36 FSMIN 47700 47700 Hz
Line Period
Maximum Switching Frequency in a
37 FSMAX 97880.19 Hz
Line Period
Minimum KP in a Line Period for VAC
38 KPmin 0.8528
specified by PARcalcBASIS
39 IFETRMS 498.46 mA Fet RMS current
40 IFETMAX 1647.13 mA Fet PEAK current
41 IPRIRMS 0.4040 A Primary Winding RMS current
42 IPRIMAX 1.4870 A Primary Winding PEAK current
43 IPRIAVG 0.0704 A Primary Winding AVG current
44 IPRIMIN 885.63 mA Primary Winding Minimum current
45 ISECRMS 4.19 A Secondary RMS current

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46 ISECMAX 10.11 A Secondary PEAK current

47 Boost Choke Construction Parameters
Boost Inductance and Flyback Primary
48 RATIO_LBST_LFB 1.0555 1.0555
Inductance Ratio
49 LBOOSTMIN 720.89 µH Minimum Boost Inductance
50 LBOOSTNOM 758.83 µH Nominal Boost Inductance
51 LBOOSTMAX 796.77 µH Maximum Boost Inductance
52 LBOOSTTOL 5.00 5.00 % Boost Inductance Tolerance
53 Boost Core and Bobbin Selection
54 CR_TYPE_BOOST EE13 EE13 Boost Core
55 CR_PN_BOOST PC40EE13-Z Boost Core Code
56 AE_BOOST 17.10 mm² Boost Core Cross Sectional Area
57 LE_BOOST 30.20 mm Boost Core Magnetic Path Length
Boost Core Ungapped Core Effective
58 AL_BOOST 1130.00 nH/turns²
Inductance
59 VE_BOOST 517.00 mm3 Boost Core Volume
60 BOBBINID_BOOST 548 Bobbin
61 AW_BOOST 22.20 mm² Window Area of Bobbin
62 BW_BOOST 7.40 mm Bobbin Width
63 MARGIN_BOOST 0.00 mm Safety Margin Width
64 BOBFILLFACTOR_Boost 40.32 % Boost Bobbin Fill Factor
65 Boost Winding Details
66 NBOOST 119.50 119.50 Boost Choke Turns
67 BP_BOOST 3057.81 Gauss Boost Peak Flux Density
Boost Core Ungapped Core Effective
68 ALG_BOOST 53.14 nH/turns²
Inductance
69 LG_BOOST 0.39 mm Boost Core Gap Length
70 L_BOOST 4.00 4.00 Number of Boost Layers
71 AWG_BOOST 31.00 Boost Winding Wire AWG
Boost Winding Wire Output Diameter
72 OD_BOOST_INSULATED 0.27 mm
with Insulation
Boost Winding Wire Output Diameter
73 OD_BOOST_BARE 0.23 mm
without Insulation
74 CMA_BOOST 269.68 Circular Mils/A Boost Winding Wire CMA
75 Flyback Transformer Construction Parameters
Secondary Voltage Reflected in the
76 VOR 78 78 V
Primary Winding
77 LP_MIN 682.98 µH Minimum Flyback Inductance
78 LP_NOM 718.93 µH Nominal Flyback Inductance
79 LP_MAX 754.88 µH Maximum Flyback Inductance
80 LP_TOL 5.00 5.00 % Flyback Inductance Tolerance
81 Flyback Core and Bobbin Selection
82 CR_TYPE RM8/I RM8/I Flyback Core
83 CR_PN RM8/I-3F3 Flyback Core Code
84 AE 63.00 mm² Flyback Core Cross Sectional Area
85 LE 38.40 mm Flyback Core Magnetic Path Length
Flyback Core Ungapped Core Effective
86 AL 3000.00 nH/turns²
Inductance
87 VE 2440.00 mm3 Flyback Core Volume
88 BOBBINID Ferroxcube Flyback Bobbin
Flyback Bobbin Orientation H -
89 BB_ORIENTATION H
Horizontal and V -Vertical
90 AW 30.90 mm² Flyback Window Area of Bobbin
91 BW 8.60 mm Flyback Bobbin Width
92 MARGIN 0.00 mm Safety Margin Width
93 Flyback Winding Details
94 NP 59.00 Primary Turns
95 BP 3670.89 Gauss Flyback Peak Flux Density
96 BM 3533.33 Gauss Flyback Maximum Flux Density
97 BAC 1487.83 Gauss Flyback AC Flux Density
98 ALG 206.53 nH/turns² Flyback Core Ungapped Core Effective
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Inductance
99 LG 0.36 mm Flyback Core Gap Length
100 L 2.00 Number of Flyback Layers
101 AWG 30.00 Primary Winding Wire AWG
Primary Winding Wire Output
102 OD 0.30 mm
Diameter with Insulation
Primary Winding Wire Output
103 DIA 0.26 mm
Diameter without Insulation
104 CMA 249.81 Circular Mils/A Primary Winding Wire CMA
105 NB 10.00 Bias Turns
Number of Flyback Bias Winding
106 L_BIAS 1.00
Layers
107 AWGpBias 36.00 Bias Wire AWG
108 NS 9 9 Secondary Turns
109 AWGS 20.00 Secondary Winding Wire AWG
Secondary Winding Wire Output
110 ODS 0.81 mm
Diameter with Insulation
Secondary Winding Wire Output
111 DIAS 1.12 mm
Diameter without Insulation
112 CMAS 244.62 Circular Mils/A Secondary Winding Wire CMA
113 Primary Components Selection
114 Line Undervoltage
Required AC RMS line voltage brown-
115 BROWN_IN_REQUIRED 85.00 85.00 V
in threshold
Two Resistors of this Value in Series
116 RLS 2.10 MOhm
to the V-pin
117 BROWN_IN_ACTUAL 84.15 V Actual AC RMS brown-in threshold
118 Line Overvoltage
Actual AC RMS line over-voltage
119 OVERVOLTAGE_LINE 350.90 V
threshold
120 Bias Voltage
121 VBIAS 13.0 13.0 V Rectified Bias Voltage
122 VF_BIASDIODE 0.70 V Bias Winding Diode Forward Drop
123 VRRM_BIASDIODE 89.70 V Bias diode reverse voltage
124 CBIAS 22.0 µF Bias winding rectification capacitor
125 CBPP 0.47 µF BPP pin capacitor
126 Bulk Capacitor Zener Clamp
Bulk Capacitor Clamp Needed? Yes,
127 Use_Clamp Yes
No or N/A
Zener 1 Voltage Rating (In Series with
128 VZ1_V 240.00 V
Zener 2)
129 PZ1_W 1.25 W Zener 1 Minimum Power Rating
130 VZ2_V 240.00 V Zener 2 Voltage Rating
131 PZ2_W 1.25 W Zener 2 Minimum Power Rating
Resistor in series with Zener 1 and
132 RZ 1000.00 ohms
Zener 2
133 Secondary Components Selection
134 Feedback Components
135 RFB_UPPER 102.00 kOhm Upper feedback 1% resistor
136 RFB_LOWER 12.10 kOhm Lower feedback 1% resistor
Lower feedback resistor decoupling at
137 CFB_LOWER 330.0 pF
least 5V-rating capacitor
138 CBPS 2.2 µF BPS pin capacitor
139 Secondary Auxiliary Section - For VO > 24V ONLY
140 Sec Aux Diode
141 VAUX 12.00 V Rectified auxiliary voltage
142 VF_AUX 0.70 V Auxiliary winding diode forward drop
143 VRRM_AUXDIODE 82.03 V Auxiliary diode reverse voltage
Auxiliary winding rectification
144 CAUX 22.00 µF
capacitor
145 NAUX_SEC 9.00 Secondary Aux Turns

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Number of Flyback Aux Winding

146 L_AUX 1.00
Layers
147 AWGSAUX 38 Secondary Aux Winding AWG
148 Output Parameters
149 VOUT_ACTUAL 12.00 V Actual Output Voltage
150 IOUT_ACTUAL 2.92 A Actual Output Current
151 ISECRMS 4.19 A Secondary RMS current for output
152 Output Components
153 VF 0.70 V Output diode forward drop
154 VRRM 81.03 V Output diode reverse voltage
155 COUT 2040.53 µF Output Capacitor - Capacitance
156 COUT_VOpercentRip 2.50 % Output Capacitor Ripple % of VOUT
Output Capacitor Estimated Ripple
157 ICOUTrms 3.00 A
Current
Output Capacitor Maximum
158 ESRmax 29.69 mohms
Recommended ESR
159 Errors, Warnings, Information
Although the design has passed the
VDRAIN,OVE
user should validate functionality on
160 Information RVOLTAGE_L
the bench. Please check the variables
INE
listed.
Design variables whose values exceed
161 Design Warnings
electrical/datasheet specifications.
The list of design variables which
162 Design Errors
result in an infeasible design.
Notes: Row 160 – Actual drain voltage stress does not exceed the absolute maximum V DS rating of
LYTSwitch-6 IC. Actual line overvoltage protection is below the absolute maximum V DS rating of LYTSwitch-
6 IC.
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10 Performance Data
All measurements were performed at room temperature.
10.1 Output Voltage Regulation

Set-up: Open frame unit
Load: 2.92 A CC load
Ambient Temperature: 25 ºC
Soak time: 180 seconds
16
15
14
Output Voltage (V)
13
12
11
10
8
140 160 180 200 220 240 260 280 300 320
Input Voltage (VAC)
Figure 11 – Output Voltage Regulation vs. Input Line Voltage.

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10.2 System Efficiency

91
90
89
Efficiency (%)
88
87
86
85
130 150 170 190 210 230 250 270 290 310 330
Input Voltage (VAC)
Figure 12 – Efficiency vs. Input Line Voltage.
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10.3 Power Factor

1.00
0.98
0.96
0.94
Power Factor
0.92
0.90
0.88
0.86
0.84
0.82
130 150 170 190 210 230 250 270 290 310 330
Input Voltage (VAC)
Figure 13 – Power Factor vs. Input Line Voltage.

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10.4 %ATHD
50
45
40
35
30
ATHD (%)
25
20
15
10
0
130 150 170 190 210 230 250 270 290 310 330
Input Voltage (VAC)
Figure 14 – %ATHD vs. Input Line Voltage.
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10.5 Individual Harmonics Content at Full Load

VIN: 230 V 50 Hz
30
Harmonic Content
Class C Limit
25
Harmonic Content
20
15
10
0
1 2 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47
Harmonic Order
Figure 15 – Full Load Input Current Harmonics at 230 VAC 50 Hz.

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Load: 2.92 A CC Load
VIN: 277 V 50 Hz
30
Harmonic Content
Class C Limit
25
Harmonic Content
20
15
10
0
1 2 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47
Harmonic Order
Figure 16 – Full Load Input Current Harmonics at 277 VAC 50 Hz.
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10.6 No-Load Input Power

Load: Open load
140
120
No-Load Input Power (mW)
100
80
60
40
20
0
130 150 170 190 210 230 250 270 290 310 330
Input Voltage (VAC)
Figure 17 – No-Load Input Power vs. Input Line Voltage.

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10.7 CV/CC Curve

Load: E-Load in CR mode
15
140 VAC, 50 Hz
230 VAC, 50 Hz
277 VAC, 50 Hz
300 VAC, 50 Hz
12
Output Voltage (V)
0
0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 3.25
Output Current (A)
Figure 18 – CV/CC Curve.
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11 Test Data
11.1 Test Data at Full Load
Input Input Measurement LED Load Measurement
Efficiency
VAC Freq VIN IIN PIN VOUT IOUT POUT
PF %ATHD (%)
(VRMS) (Hz) (VRMS) (mARMS) (W) (VDC) (mADC) (W)
140 50 139.96 330.37 40.31 0.872 48.04 12.05 2919.80 35.18 87.27
160 50 159.92 276.59 40.06 0.906 41.28 12.07 2919.80 35.23 87.95
180 50 179.97 236.51 39.88 0.937 33.09 12.07 2919.80 35.23 88.35
200 50 199.92 207.49 39.76 0.959 25.31 12.07 2919.80 35.24 88.63
220 50 219.96 186.47 39.69 0.968 20.08 12.07 2919.80 35.24 88.78
230 50 229.99 177.99 39.65 0.969 18.74 12.07 2919.70 35.23 88.86
240 50 240.01 170.58 39.63 0.968 18.05 12.07 2919.70 35.23 88.90
265 50 265.03 155.84 39.68 0.961 18.83 12.07 2919.70 35.24 88.80
277 50 277.02 149.89 39.72 0.957 19.35 12.07 2919.80 35.24 88.72
300 50 300.07 140.13 39.86 0.948 20.42 12.07 2919.70 35.23 88.39
310 50 309.84 136.14 39.92 0.947 20.79 12.08 2919.80 35.27 88.35
320 50 319.75 132.56 39.97 0.943 21.04 12.07 2919.70 35.24 88.17
11.2 Test Data at No-Load

Input Input Measurement Output Measurement
VAC Freq VIN IIN PIN VOUT
PF %ATHD
(VRMS) (Hz) (VRMS) (mARMS) (W) (VDC)
140 50 140.03 10.29 0.037 0.026 48.28 12.19
160 50 159.98 10.51 0.052 0.031 14.79 12.19
180 50 180.02 10.82 0.062 0.032 34.03 12.19
200 50 199.97 11.30 0.069 0.030 28.46 12.19
220 50 220.00 12.03 0.076 0.029 11.69 12.19
230 50 230.02 12.46 0.074 0.026 21.99 12.19
240 50 240.04 12.92 0.075 0.024 20.81 12.19
265 50 265.07 14.01 0.091 0.024 20.94 12.19
277 50 277.06 14.45 0.091 0.023 8.78 12.19
300 50 300.10 15.13 0.105 0.023 20.94 12.19
310 50 310.32 12.57 0.107 0.028 5.44 12.19
320 50 320.22 12.98 0.119 0.029 6.13 12.19

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11.3 Individual Harmonic Content at 230 VAC 50 Hz and Full Load

IIN
V Freq P PF %THD
(mARMS)
230 50.00 179.08 39.870 0.968 19.466
nth mA % mA Limit % Limit

Remarks
Order Content Content <25 W >25 W
1 175.32
2 0.09 0.05% 2.00% Pass
3 32.83 18.73% 135.56 29.04% Pass
5 3.91 2.23% 75.75 10.00% Pass
7 3.35 1.91% 39.87 7.00% Pass
9 3.33 1.90% 19.94 5.00% Pass
11 3.34 1.91% 13.95 3.00% Pass
13 2.52 1.44% 11.81 3.00% Pass
15 1.41 0.80% 10.23 3.00% Pass
17 1.81 1.03% 9.03 3.00% Pass
19 1.10 0.63% 8.08 3.00% Pass
21 1.11 0.63% 7.31 3.00% Pass
23 3.66 2.09% 6.67 3.00% Pass
25 3.86 2.20% 6.14 3.00% Pass
27 2.77 1.58% 5.69 3.00% Pass
29 1.05 0.60% 5.29 3.00% Pass
31 0.93 0.53% 4.95 3.00% Pass
33 0.81 0.46% 4.65 3.00% Pass
35 1.36 0.78% 4.39 3.00% Pass
37 0.93 0.53% 4.15 3.00% Pass
39 0.65 0.37% 3.94 3.00% Pass
41 1.47 0.84%
43 1.74 0.99%
45 2.56 1.46%
47 1.27 0.72%
49 1.15 0.66%
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11.4 Individual Harmonic Content at 277 VAC 50 Hz and Full Load

IIN
V Freq P PF %THD
(mARMS)
277 50.00 150.53 39.920 0.957 19.508
nth mA % mA Limit % Limit

Remarks
Order Content Content <25 W >25 W
1 146.61
2 0.15 0.10% 2.00% Pass
3 27.44 18.72% 135.66 28.72% Pass
5 2.37 1.62% 75.81 10.00% Pass
7 2.78 1.90% 39.90 7.00% Pass
9 1.74 1.19% 19.95 5.00% Pass
11 2.30 1.57% 13.97 3.00% Pass
13 1.65 1.13% 11.82 3.00% Pass
15 1.17 0.80% 10.24 3.00% Pass
17 2.26 1.54% 9.04 3.00% Pass
19 0.73 0.50% 8.09 3.00% Pass
21 1.13 0.77% 7.32 3.00% Pass
23 1.28 0.87% 6.68 3.00% Pass
25 1.39 0.95% 6.14 3.00% Pass
27 1.96 1.34% 5.69 3.00% Pass
29 1.41 0.96% 5.30 3.00% Pass
31 1.84 1.26% 4.96 3.00% Pass
33 1.23 0.84% 4.66 3.00% Pass
35 1.75 1.19% 4.39 3.00% Pass
37 1.96 1.34% 4.15 3.00% Pass
39 1.28 0.87% 3.94 3.00% Pass
41 1.27 0.87%
43 2.22 1.51%
45 2.60 1.77%
47 2.10 1.43%
49 1.94 1.32%

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12 Load Regulation Performance

Ambient Temperature: 25 ºC (Room Temp)
12.1 Output Voltage Load Regulation

12.5
140 VAC 50 Hz
230 VAC 50 Hz
277 VAC 50 Hz
12.4 320 VAC 50 Hz
Output Voltage (V, PCB Terminal)
12.3
12.2
12.1
12.0
11.9
11.8
10 20 30 40 50 60 70 80 90 100
Load (%)
Figure 19 – Output Voltage vs. Load.
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12.2 Efficiency vs. Load

90
89
88
87
86
85
Efficiency (%)
84
140 VAC 50 Hz
83 230 VAC 50 Hz
82 277 VAC 50 Hz
320 VAC 50 Hz
81
80
79
78
77
76
75
10 20 30 40 50 60 70 80 90 100
Load (%)
Figure 20 – Efficiency vs Load.
12.3 Average Efficiency
12.3.1 Average Efficiency Measurement

Efficiency (%)
%Load
230 V / 50 Hz 277 V / 50 Hz
100% 88.66 88.64
75% 89.24 88.64
50% 88.91 88.20
25% 87.53 86.41
Average Efficiency 88.59 87.97
DOE Level VI Limit 80.93

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12.4 Power Factor vs. Load

1.00
0.90
0.80
Power Factor
0.70
0.60
0.50
140 VAC 50 Hz
230 VAC 50 Hz
0.40 277 VAC 50 Hz
320 VAC 50 Hz
0.30
10 20 30 40 50 60 70 80 90 100
Load (%)
Figure 21 – Power Factor vs Load.
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12.5 %ATHD vs. Load

59
230 VAC 50 Hz
55 277 VAC 50 Hz
320 VAC 50 Hz
51 140 VAC 50 Hz
47
43
39
ATHD (%)
35
31
27
23
19
15
11
7
3
10 20 30 40 50 60 70 80 90 100
Load (%)
Figure 22 – %ATHD vs Load.

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13 Thermal Performance
13.1 Thermal Measurements at Room Temp Ambient
Figure 23 – Test Set-up Picture - Open Frame.
Unit in Open Frame was placed inside the acrylic enclosure to prevent airflow that might
affect the thermal measurements. Temperature was measured using T-type
thermocouple.
Equipment used:
1. KEYSIGHT 6812B AC Power Source/Analyzer
2. Chroma 6314A DC Electronic Load Mainframe and Chroma 63110A DC
Electronic Load
3. Yokogawa GP20 Data Logger
4. Yokogawa WT310E Digital Power Meter
5. CADWILL Step-up Transformer (for Inputs >300Vac)
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Ckt. Thermal Reading at Room Temperature

Description
Code 140 VAC 230 VAC 277 VAC 320 VAC
U1 LYTSwitch-6 IC 83.1 80 84.4 89.9
D4 Primary Snubber Diode 86.9 78.9 80.8 82.9
VR1 Primary Snubber Zener 78.1 69.6 70.8 72.5
Q1 SR FET 79.6 77.9 79.8 82.6
T2 PFC Inductor 63.1 63.4 65.9 67.6
T1 DCDC TRF Primary 82.1 81.3 84.3 86.5
L3 Bead on Secondary 78.5 76.1 78.2 81.4
D1 PFC Diode 54.2 50.5 50.2 49.5
D5 PFC Diode 60.4 56.3 56.8 56.8
BR1 Bridge Diode 52.4 43.9 42.5 41.8
R2 / R15 Primary Snubber Series Resistor 78.8 72 73.1 75
R7 Secondary Snubber Resistor 77.5 76.4 78.7 80.9
C4 Bulk Capacitor 48.2 43.8 44.2 44.2
C10 Output Capacitor 62.3 62.3 63.6 65.3
AMBIENT 27.2 28.6 28.7 28.4

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13.2 Thermal Performance at High Temp Ambient
Figure 24 – Test Set-up Picture Thermal at 60 ºC Ambient - Open Frame.
Open frame unit was placed inside the enclosure to prevent airflow that may affect the
thermal measurements. Ambient temperature inside enclosure is set at 60 ºC.
Temperature was measured using T-type thermocouple. Soak time at full load is more
than 1 hour.
Equipment used:
1. KEYSIGHT 6812B AC Power Source/Analyzer
2. Chroma 6314A DC Electronic Load Mainframe and Chroma 63110A DC
Electronic Load
3. Yokogawa GP20 Data Logger
4. Yokogawa WT310E Digital Power Meter
5. SPX Tenney TUJR Thermal Chamber
6. CADWILL Step-up Transformer (for Inputs >300Vac)
Power Integrations
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Ckt. Thermal Reading at High Temperature

Description
Code 140 VAC 230 VAC 277 VAC 320 VAC
U1 LYTSwitch-6 IC 116.6 112.2 116.9 123.4
D4 Primary Snubber Diode 117.1 110 111.5 114.5
VR1 Primary Snubber Zener 106.2 98.8 99.6 101.4
Q1 SR FET 112.3 110.4 112.6 114.6
T2 PFC Inductor 94.2 93.7 96.1 98.6
T1 DCDC TRF Primary 114.1 113.1 115.2 118.7
L3 Bead on Secondary 110.5 108.1 110.4 112.7
D1 PFC Diode 86.7 81.1 80.8 80.9
D5 PFC Diode 91.7 87.4 87.1 88.4
BR1 Bridge Diode 83.8 75.7 74.4 73.8
R2 / R15 Primary Snubber Series Resistor 108.7 102.2 103.5 105.5
R7 Secondary Snubber Resistor 110 108.5 110.5 113
C4 Bulk Capacitor 79.6 75.6 75.5 75.9
C10 Output Capacitor 95 93.7 95.2 96.7
AMBIENT 62.4 61.9 62.1 62.1

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14 Waveforms
Waveforms were taken at room temperature (25 ºC).
14.1 Input Voltage and Input Current at Full Load
Figure 25 – 140 VAC 50 Hz, Full Load. Figure 26 – 230 VAC 50 Hz, Full Load.
Upper: IIN, 200 mA / div. Upper: IIN, 100 mA / div.
Lower: VIN, 100 V / div., 10 ms / div. Lower: VIN, 100 V / div., 10 ms / div.
Upper: IIN, 100 mA / div. Upper: IIN, 100 mA / div.
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14.2 Start-up Profile at Full Load
Figure 29 – 140 VAC 50 Hz, Full Load Start-up. Figure 30 – 230 VAC 50 Hz, Full Load Start-up.
Upper: VOUT, 2 V / div. Upper: VOUT, 2 V / div.
Turn on Time: 102 ms. Turn on Time: 102 ms.
Turn on Time: 101.5 ms. Turn on Time: 101.5 ms.

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14.3 Output Voltage Fall
Figure 33 – 140 VAC 50 Hz, Full Load, Output Fall. Figure 34 – 230 VAC 50 Hz, Full Load, Output Fall.
Hold Up Time: 32 ms. Hold Up Time: 89 ms.
Figure 35 – 277 VAC 50 Hz, Full Load, Output Fall. Figure 36 – 320 VAC 50 Hz, Full Load, Output Fall.
Hold Up Time: 136.5 ms. Hold Up Time: 196.5 ms.
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14.4 Power Cycling
1 s Off, 1 s On. 1 s Off, 1 s On.
Lower: VIN, 100 V / div., 4 s / div. Lower: VIN, 100 V / div., 4 s / div.
0.3 s Off, 0.3 s On. 0.3 s Off, 0.3 s On.
Lower: VIN, 100 V / div., 1 s / div. Lower: VIN, 100 V / div., 1 s / div.

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14.5 Load Transient Response 3 Hz
Figure 41 – 230 VAC 50 Hz. Figure 42 – 230 VAC 50 Hz.

0% to 100% Load Change. 25% to 100% Load Change.
3 Hz, 50% Duty Cycle. 3 Hz, 50% Duty Cycle.
Slew Rate: 800 mA / s. Slew Rate: 800 mA / s.
Upper: VOUT, 2 V / div., 200 ms / div. Upper: VOUT, 2 V / div., 200 ms / div.
Lower: IOUT, 1 A / div. Lower: IOUT, 1 A / div.

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14.6 Load Transient Response 100 Hz

Upper: VOUT, 2 V / div., 5 ms / div. Upper: VOUT, 2V / div., 5 ms / div.
Lower: IOUT, 1 A / div. Lower: IOUT, 1A / div.

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14.7 LYTSwitch-6 Drain Voltage and Current Waveforms at Normal

Operation
Figure 57 – 140 VAC 50 Hz, Full Load Normal. Figure 58 – 140 VAC 50 Hz, Full Load Normal.
Upper: IDRAIN, 400 mA / div. Upper: IDRAIN, 400 mA / div.
Lower: VDRAIN, 100 V / div., 5 ms / div. Lower: VDRAIN, 100 V / div., 10 s / div.
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14.8 LYTSwitch-6 Drain Voltage and Current at Full Load Start-up
Figure 67 – 230 VAC, Full Load Start-up. Figure 68 – 230 VAC, Full Load Start-up.

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Figure 71 – 320 VAC, Full Load Start-up. Figure 72 – 320 VAC, Full Load Start-up.
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14.9 LYTSwitch-6 Drain Voltage and Current during Output Short-Circuit
Figure 73 – 140 VAC 50 Hz, Output Shorted. Figure 74 – 140 VAC 50 Hz, Output Shorted.
Lower: VDRAIN, 100 V / div., 1 s / div. Lower: VDRAIN, 100 V / div., 1 s / div.
PIN Average: 155.4 mW.
Figure 75 – 230 VAC, Output Shorted. Figure 76 – 230 VAC, Output Shorted.

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Figure 77 – 277 VAC 50 Hz, Output Shorted. Figure 78 – 277 VAC 50 Hz, Output Shorted.
Pin Average: 242.51 mW.
Figure 79 – 320 VAC, Output Shorted. Figure 80 – 320 VAC, Output Shorted.
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14.10 PFC Diode Voltage and Current at Normal Operation
Figure 81 – 140 VAC 50 Hz, 2.92 A CC Load. Figure 82 – 230 VAC 50 Hz, 2.92 A CC Load.
Upper: 200 mA / div. Upper: 200 mA / div.
Lower: 40 V / div. Lower: 50 V / div.
Horizontal: 5 ms / div. Horizontal: 5 ms / div.

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14.11 PFC Diode Voltage and Current at Start-up Full Load
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14.12 SR FET Drain Voltage and Current at Normal Operation
Upper: 4 A / div. Upper: 4 A / div.
Horizontal: 5 ms / div. Horizontal: 10 s / div.

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Upper: 4 A/ div. Upper: 4 A/ div.
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14.13 SR FET Drain Voltage and Current at Full Load Start-up

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14.14 Output Voltage Ripple
Figure 105 – Probe Set-up for Output Figure 106 – Unit Set-up for Output Voltage Ripple Test.
Voltage Ripple Test.
Ripple voltage was taken using a X1 probe with 47 F electrolytic capacitor and 0.1 F
ceramic capacitor connected in parallel across the probe.

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Figure 107 – 140 VAC 50 Hz, 2.92 A CC Load. Figure 108 – 140 VAC 50 Hz, 300 mA CC Load.
AC Coupling, 20 MHz Bandwidth AC Coupling, 20 MHz Bandwidth
VOUT, 50 mV / div., 100 ms / div. VOUT, 40 mV / div., 100 ms / div.
Ripple Voltage: 258.89 mVPK-PK. Ripple Voltage: 123.32 mVPK-PK.
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14.15 Output Current Ripple
14.15.1 Equipment Used

1. Rohde & Schwarz RTO1004 Oscilloscope
2. Rohde & Schwarz RT-ZC20 Current Probe
3. Keysight 6812B AC Power Source / Analyzer
4. 12 V LED Load
14.15.2 Ripple Ratio and Flicker % Measurement

VIN IOUT(MAX) IOUT(MIN) IMEAN Ripple Ratio % Flicker
(VAC) (mA) (mA) (mA) (IRP-P/IMEAN) 100 x (IRP-P / IO(MAX)+IO(MIN))
140 3030.8 2801.6 2923.9 0.08 3.93
230 3026.9 2793.7 2927 0.08 4.01
277 3030.8 2793.7 2928.8 0.08 4.07
320 3038.7 2789.7 2932.7 0.08 4.27
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Figure 115 – 140 VAC 50 Hz, 2.98 A LED Load. Figure 116 – 230 VAC 50 Hz, 2.98 A LED Load.
20 MHz Bandwidth 20 MHz Bandwidth
IOUT, 100 mA / div., 20 ms / div. IOUT, 100 mA / div., 20 ms / div.
Ripple Current: 229.25 mAPK-PK. Ripple Current: 233.2 mAPK-PK.
Figure 117 – 277 VAC 50 Hz, 2.98 A LED Load. Figure 118 – 320 VAC 50 Hz, 2.98 A LED Load.
20 MHz Bandwidth 20 MHz Bandwidth
IOUT, 100 mA / div., 20 ms / div. IOUT, 100 mA / div., 20 ms / div.
Ripple Current: 237.15 mAPK-PK. Ripple Voltage: 249.01 mAPK-PK.

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15 Conducted EMI
15.1 Test Set-up
15.1.1 Equipment and Load Used

1. Rohde and Schwarz ENV216 two line V-network
2. Rohde and Schwarz ESRP EMI test receiver
3. Hioki 3332 power hitester
4. Chroma Measurement Test Fixture model A662003
5. Resistive Load (set at Full Load)
6. HOSSONI TDGC2 VARIAC set at 230 VAC 60 Hz
Figure 119 – Conducted EMI Test Set-up.
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15.2 EMI Test Result
Figure 120 – Conducted EMI QP Scan at Full Load, 230 VAC 60 Hz and EN55015 B Limits.

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Figure 121 – Conducted EMI Data at 230 VAC 60 Hz, Full Load
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16 Line Surge
The unit was subjected to ±2500 V, 100 kHz ring wave and ±1000 V differential surge
using 10 strikes at each condition. A test failure was defined as a non-recoverable
interruption of output requiring repair or recycling of input voltage.
Figure 122 – Test Set-up for Line Surge Test.

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16.1 Differential Surge Test Results

Input
Surge Injection Injection Test Result
Voltage
Level (V) Location Phase (°) (Pass/Fail)
(VAC)
+1000 230 L to N 0 Pass
-1000 230 L to N 0 Pass
+1000 230 L to N 90 Pass
-1000 230 L to N 90 Pass
+1000 230 L to N 270 Pass
-1000 230 L to N 270 Pass
+1000 277 L to N 0 Pass
-1000 277 L to N 0 Pass
+1000 277 L to N 90 Pass
-1000 277 L to N 90 Pass
+1000 277 L to N 270 Pass
-1000 277 L to N 270 Pass
16.2 Ring Wave Surge Test Results

Input
Surge Injection Injection Test Result
Voltage
Level (V) Location Phase (°) (Pass/Fail)
(VAC)
+2500 230 L to N 0 Pass
-2500 230 L to N 0 Pass
+2500 230 L to N 90 Pass
-2500 230 L to N 90 Pass
+2500 230 L to N 270 Pass
-2500 230 L to N 270 Pass
+2500 277 L to N 0 Pass
-2500 277 L to N 0 Pass
+2500 277 L to N 90 Pass
-2500 277 L to N 90 Pass
+2500 277 L to N 270 Pass
-2500 277 L to N 270 Pass
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16.3 1 kV Differential Surge Test

The Drain voltage of U1-LYTSwitch-6 was measured during 1 kV differential surge test.
Figure 123 – (+)1 kV Differential Surge. Figure 124 – (-)1 kV Differential Surge.
90º Phase Angle, Input: 277 VAC. 90º Phase Angle, Input: 277 VAC.
VDRAIN, 200 V / div., 20 ms / div. VDRAIN, 200 V / div., 20 ms / div.
Peak VDRAIN: 595.833 V. Peak VDRAIN: 583.333 V.
Figure 125 – (+)1 kV Differential Surge. Figure 126 – (-)1 kV Differential Surge.

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16.4 2.5 kV Ring Wave Surge Test

The Drain voltage of U1-LYTSwitch-6 was measured during 2 kV ring wave surge test.
Figure 127 – (+) 2.5 kV Ring Wave Surge. Figure 128 – (-) 2.5 kV Ring Wave Surge.
Figure 129 – (+) 2.5 kV Ring Wave Surge. Figure 130 – (-) 2.5 kV Ring Wave Surge.
VDRAIN, 200 V / div., 20 ms / div. Lower: VDRAIN, 200 V / div., 20 ms / div.
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17 Brown-in / Brown-out Test

No abnormal overheating and nor voltage overshoot / undershoot was observed during
and after 0.5 V / s brown-in and brown-out test.
Figure 131 – Brown-in Test at 0.5 V / s.

Time Scale: 100 s / div.
Ch1: VOUT, 2 V / div.
Ch2: VIN, 100 V / div.
Figure 132 – Brown-in Test at 0.5 V / s.

Time Scale: 100 s / div.
Ch1: VOUT, 2 V / div.
Ch2: VIN, 100 V / div.

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18 Revision History
Date Author Revision Description and Changes Reviewed
23-Jan-18 EDdL 1.0 Initial Release. Apps & Mktg
16-Feb-18 EDdL 1.1 Minor Text Updates. PCB Images Updated.
21-Feb-18 EDdl 1.2 Added PIXls Spreadsheet.
26-Mar-18 EDdl 1.3 Updated Power Supply Specification, Section 2.0.
23-Apr-18 KCM 1.4 Updated Figure 4 Schematic.
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Der-637 35watt High-Pf Isolated Flyback Switched Valley Fill PFC Lytswitch-6 Led Driver

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Design Example Report

35 W High Power Factor Isolated Flyback

Specification 140 VAC – 320 VAC Input; 12 V, 2.92 A Output

Application Emergency Light with Battery Charging

Author Applications Engineering Department

Date April 23, 2018

Power Integrations, Inc.

12.2 Efficiency vs. Load ....................................................................................... 42

The LYTSwitch-6 IC combines primary, secondary and feedback circuits in a single

Figure 1 – Populated Circuit Board.

Power Integrations, Inc.

Figure 2 – Populated Circuit Board, Top View.

Figure 3 – Populated Circuit Board, Bottom View.

2 Power Supply Specification

Ring Wave (100 kHz) 2.5 kV

Differential Mode (L1-L2) 1 kV

Ambient Temperature TAMB 60 ºC Free Air Convection, Sea Level.

Power Integrations, Inc.

Figure 4 – Schematic Diagram.

4.1 Input EMI Filter and Rectifier

4.2 LYTSwitch-6 Primary Side Control

Power Integrations, Inc.

4.3 LYTSwitch-6 Secondary-Side Control

4.4 PFC Circuit Operation

Power Integrations, Inc.

Figure 5 – Top Side.

Figure 6 – Bottom Side.

Power Integrations, Inc.

44 1 R19 RES, 1 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ102V Panasonic

6.2 Miscellaneous Parts

Power Integrations, Inc.

7 Flyback Transformer (T1) Specification

Figure 7 – Transformer Electrical Diagram.

7.2 Electrical Specifications

7.3 Material List

7.4 Transformer Build Diagram

Figure 8 – Transformer Build Diagram.

7.5 Transformer Construction

Power Integrations, Inc.

7.6 Transformer Winding Illustrations

Use bifilar magnetic wire, Item [3]. Start at pin 10

Use bifilar triple insulated wire, Item [4]. Start at

Finished the winding on the same side of the

Apply 1 layer of polyester tape, Item [5] for

Power Integrations, Inc.

Apply 1 layer of polyester tape, Item [5] for

Use magnetic wire, Item [3]. Start at pin 1 and wind

Finish the winding on pin 2. Pin 2

Apply 2 layers of polyester tape, Item [5] for

Power Integrations, Inc.

Use two PC95 RM8 cores, Item [1] and assemble

Pin 11 RM8 Core

Use RM8 Core Clips with Terminals, Item [6] to fix

Cut any excess pins of the bobbin (pins without wire

Twist the fly leads for easier termination on the

Dip the transformer in a 2:1 varnish and thinner

8 PFC Inductor (T2) Specifications

Figure 9 – Inductor Electrical Diagram.

8.2 Electrical Specifications