EVBUM2651/D
15W Auxiliary Power for
White Goods and Industrial
Equipment with FSL538APG
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EVAL BOARD USER’S MANUAL
Table 1. GENERAL SPECIFICATIONS
Devices
Applications
Input Voltage
Output Power
Topology
Board Size
FSL538APG
White Goods and
Industrial Power
Supplies
90–265 Vac
15 W
Isolated Flyback
88 × 38 × 22 mm
2.89 W/inch3
Output Spec.
Turn on time
Efficiency
Operating
Temperature
Cooling
Standby Power
15 V/0.15 A
&
12 V/1 A
< 200 ms
Above 85%
@ Full Load
Convection Open
Frame
< 50 mW
@ 230 Vac
0–50°C
Key Features
Description
This user manual provides elementary information about
a Non−isolated dual output flyback with FSL538APG, it performs
high efficiency and smaller than 50 mW no−load power consumption.
FSL538APG is an integrated pulse width modulation (PWM) and
800 V power switch with SENSEFET®, it can help to save external
MOSFET and sense resistor, increase power density and reliability.
This application is targeting auxiliary power supply for white goods
and industrial equipment, such as refrigerator, E−metering or similar
types of equipment.
The PWM controller includes an integrated variable frequency
oscillator, Under−Voltage Lockout (UVLO), Leading Edge Blanking
(LEB), optimized gate driver, internal soft−start, and built−in error
amplifier for feedback connection directly and self−protection
circuitry. This design focuses mainly on the FSL538APG
current−mode PWM controller. Please refer to FSL538APG’s
materials to get more information about this device.
The FSL538APG is a current−mode PWM controller, it can have
better response to handle dynamic operation. Controller combines line
detection and burst−mode adjustment in one pin. It’s easy to achieve
these functionalities just need voltage divider and one Zener diode.
Line detection includes brown−in, brown−out and line OVP,
burst−mode adjustment is for fine tune audible noise and light load
efficiency. Of course, it also provides frequency reduction with
loading decreasing for gaining more design margin to improve light
load efficiency.
© Semiconductor Components Industries, LLC, 2019
July, 2019 − Rev. 1
1
• Integrated Rugged 800 V Super Junction
•
•
•
•
•
•
•
•
•
•
MOSFET with SENSEFET Technology
Built−in HV Current Source for Start−up
Peak−Current−Mode Control with Slope
Compensation
Line Compensation for Maximum
Over−Power Limiting
Advanced Soft−start for Low Electrical
Stress
Peak−Current−Mode Control with Built−in
Slope Compensation
Pulse−by−pulse Current Limit
Line Brown−in, Brown−out,
and Over−Voltage Protection (LOVP)
Adjustable Burst−mode Operation
Frequency Hopping for Better EMI
Various Protections:
♦ Auto Restart Mode: Brown−out, OLP,
OVP, AOCP and TSD
♦ Recovery Immediately by Triggering
Level: LOVP
Publication Order Number:
EVBUM2651/D
EVBUM2651/D
DETAIL DEMO−BOARD SCHEMATIC DESCRIPTION
Figure 1. FSL538AFLYGEVB Demo−Board – Main Board Schematic
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2
EVBUM2651/D
The input EMI filter is formed by components L1 and
C1. Bleeder for X−cap, R27 and R28, are left not connected.
The primary side of flyback converter is composed of
these devices; power transformer TX1, dc−link capacitor,
TVS snubber, the integrated switcher U1(FSL538APG) and
related components. Meanwhile, the integrated switcher has
a peak current mode PWM controller and 800 V super
junction MOSFET. D1, R3 and D8 form TVS snubber to
protect instant voltage spike produced by leakage
inductance. The FB pin of U1 needs to connect to reference
ground due to isolated flyabck already exists regulator as
KA431LZ so that don’t need to employ internal error
amplifier. U2 couples the reactive current of U3 to primary
side and connect to COMP pin, the coupled current and
internal sourcing current is converted to control voltage of
PWM for output voltage regulation, R23 and C10 can be
used for adjusting response of feedback signal. LINE pin of
U1 connects voltage divider from bulk capacitor to detect
input voltage for some protections of brown−in, brown−out
and LOVP. Besides, there is parallel−connected D2 on LINE
pin to adjust burst threshold to fine tune audible noise and
light load efficiency. C17 is used to avoid larger switching
noise interference, which is usually recommended around
1 nF~3.3 nF. Auxiliary winding shares same ground
reference with U1. That is, reference ground is negative
terminal of output of bridge rectifier BD1. Transformer
winding is also used for providing VCC voltage in normal
operation. R9 and D3 provide path to delivery energy when
PWM is turned off. C16 can keep enough voltage if PWM
is turned off for a while, and C15 is for better stability.
The secondary−side output is composed of two outputs.
One is 15 V output terminal in which there are D5, C6 and
C6A. The other is 12 V output terminal that composed of
D7, C18 and C18A. When the MOSFET integrated in the
switcher turns off, energy stored in the coupled inductor is
transferred to the secondary side. At the time, there is
switching noise on the output voltage, which can be,
however, reduced by a LC filter on each output terminal
formed by L2 and C7 (L3 and C19). U3 is a shunt regulator,
and output is taken into account for generating feedback
signal with network formed by R19 and R14. R18, C13, and
R11 are used to adjust feedback response and bias U3. R17
provides additional biasing current for U3 to keep its
required operating current. Cathode current of U3 is coupled
to primary side by an opto−coupler, U2. R10 is used as
dummy load for better line and load regulation at no−load
condition.
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EVBUM2651/D
CIRCUIT LAYOUT
The PCB consists of a double layer FR4 board with 2 oz. copper cladding.
Figure 2. Main Board Top Layer
Figure 3. Main Board Bottom Layer
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EVBUM2651/D
CIRCUIT LAYOUT (Continued)
Figure 4. Main Board Top Side Components
Figure 5. Main Board Bottom Side Components
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5
EVBUM2651/D
BOARD PICTURES
Figure 6. Main Board Photo − Top Side
Figure 7. Main Board Photo − Bottom Side
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EVBUM2651/D
TRANSFORMER DATA
Table 2.
Primary−Side Inductance
Pin
Specification
Remark
Drain − B+
850 mH (Typ.)
100 kHz, 1 V
Table 3.
TERMINAL
Isolation Layer
Start Pin
End Pin
WIRE
Turns
Turns
Primary Winding (Np1)
3
2
2UEW 0.3
32
1
Secondary (Ns1)
10
6, 7
0.25 * 4
2
1
Secondary (Ns2)
6
8
0.27 * 2
10
1
Secondary (Ns3)
7
9
0.27 * 2
10
1
Primary Winding (Np2)
2
1
2UEW 0.3
30
1
AUX Winding
5
4
2UEW 0.3 * 1
11
3
Layer
• Cut off Pin2.
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EVBUM2651/D
TEST DATA
Figure 8. Operation, Full Load, 115 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo)
Figure 9. Operation, Full Load, 230 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo)
Figure 10. Zoom in Operation, Full Load, 115 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo)
Figure 11. Zoom in Operation, Full Load, 230 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo)
Figure 12. Operation, No Load, 115 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo)
Figure 13. Operation, No Load, 230 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo)
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EVBUM2651/D
TEST DATA (Continued)
Figure 14. Ton On time, 115 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Vac, Ch4: Vo)
Figure 15. Ton on time, 230 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Vac, Ch4: Vo)
Figure 16. Output Ripple, Full Load, 115 Vac
(Ch1: VO−12V (AC), Ch2: VO−15V (AC))
Figure 17. Output Ripple, Full Load, 230 Vac
(Ch1: VO−12V (AC), Ch2: VO−15V (AC))
Figure 18. Dynamic operation (20%~80% of the
Full Load for 15 V Output, 5 ms Duty Cycle,
2.5 A/ms Rise/Fall Time), 115 Vac
(Ch1: Vo(AC), Ch3: Io)
Figure 19. Dynamic Operation (20%~80% of the
Full Load for 15 V Output, 5 ms Duty Cycle,
2.5 A/ms Rise/Fall Time), 230 Vac
(Ch1: Vo(AC), Ch3: Io)
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EVBUM2651/D
TEST DATA (Continued)
Figure 20. Output Short Triggers OLP,
Full Load, 115 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo)
Figure 21. Output Short Triggers OLP,
Full Load, 230 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo)
Figure 22. Short R14 to Trigger VCC OVP,
No Load, 115 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo)
Figure 23. Short R14 to Trigger VCC OVP,
No Load, 230 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo
Figure 24. Short Output Schottky Diode to
Trigger AOCP, Full Load, 115 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo)
Figure 25. Short Output Schottky Diode to
Trigger AOCP, Full Load, 230 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo)
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EVBUM2651/D
TEST DATA (Continued)
Figure 27. Heating on IC’s Case to Trigger TSD,
Full Load, 230 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo)
Figure 26. Heating on IC’s Case to Trigger TSD,
Full Load, 115 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo)
Figure 28. Remove Heating from IC’s Case to
Recover TSD Protection, Full Load, 115 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo)
Figure 29. Remove Heating from IC’s Case to
Recover TSD Protection, Full Load, 230 Vac
(Ch1: VCC, Ch2: COMP, Ch3: Drain, Ch4: Vo)
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EVBUM2651/D
Table 4. BROWN IN/OUT
NOTE:
Behavior
Vin (Vrms)
Brown In
78
Brown Out
65
Test condition is full load.
Gradually increase/decrease input AC by 1 V/step.
Table 5. NO−LOAD INPUT POWER CONSUMPTION
NOTE:
Input Voltage [Vac]
Power Consumption [mW]
115 Vac
33.8
230 Vac
40.1
Test condition: Outputs are connected to electronic load, but loading is not applied. Input power is integrated over three minutes.
Table 6. EFFICIENCY
Input Voltage [Vac]
25% Load
50% Load
75% Load
100% Load
Avg.
115 Vac
88.29%
88.69%
88.72%
88.23%
88.48%
230 Vac
85.29%
86.85%
88.40%
88.82%
87.34%
Figure 30. Board Efficiency
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EVBUM2651/D
Table 7. LINE/LOAD REGULATION
Input Voltage
[Vac]
Load
85 Vac
115 Vac
230 Vac
265 Vac
Line Regulation
(+)
VO1 (V)
VO2(V)
VO1 (V)
VO2(V)
VO1 (V)
VO 2(V)
VO1 (V)
VO2(V)
VO1 (V)
VO2(V)
0W
12.501
14.916
12.499
14.916
12.512
14.914
12.515
14.915
0.001
0.007%
0.1 W
12.3525
14.915
12.346
14.915
12.346
14.912
12.339
14.914
0.001
0.010%
0.25 W
12.3235
14.913
12.307
14.914
12.313
14.911
12.297
14.912
0.001
0.010%
0.5 W
12.307
14.912
12.285
14.913
12.302
14.906
12.286
14.908
0.001
0.023%
25%
12.213
14.908
12.193
14.908
12.168
14.894
12.140
14.896
0.003
0.047%
50%
12.163
14.905
12.146
14.905
12.132
14.888
12.106
14.888
0.002
0.057%
75%
12.106
14.905
12.105
14.903
12.100
14.888
12.073
14.885
0.001
0.067%
100%
12.072
14.905
12.070
14.902
12.065
14.887
12.051
14.882
0.001
0.077%
Load
Regulation (±)
1.746%
0.035%
1.744%
0.047%
1.821%
0.091%
1.887%
0.109%
NOTE:
Equation of line/load regulation is ±(max − min) / (max + min).
Measured within load range shown in specification.
Figure 31. Temperature Checking on Bottom
Side, Full Load, 115 Vac
Figure 32. Temperature Checking on Bottom
Side, Full Load, 230 Vac
Figure 33. Temperature Checking on Top Side,
Full Load, 115 Vac
Figure 34. Temperature Checking on Top Side,
Full Load, 230 Vac
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EVBUM2651/D
RBW
Att
dBμV
1
100
10
dB
9
kHz
MT
10
PREAMP
OFF
Att
MHz
LIMIT
RBW
ms
10
CHECK
dBμV
MHz
2
LIMIT
1
kHz
10
PREAMP
OFF
ms
10
CHECK
MHz
PASS
PK
CLRWR
80
AV
CLRWR
9
MT
90
PK
CLRWR
dB
MHz
PASS
90
1
1
100
10
2
TDF
70
80
AV
CLRWR
EN55022Q
TDF
70
EN55022Q
60
60
PRN
EN55022A
PRN
EN55022A
50
50
6DB
6DB
40
40
30
30
20
20
10
10
0
0
150
Date:
kHz
11.DEC.2018
30
MHz
150
14:46:24
Date:
11.DEC.2018
Figure 35. Conducted EMI, 115 Vac, LINE
RBW
Att
dBμV
1
100
10
dB
9
100
PREAMP
OFF
LIMIT
RBW
ms
Att
10
CHECK
dBμV
MHz
2
dB
9
10
PREAMP
OFF
MHz
LIMIT
kHz
MT
ms
10
CHECK
MHz
PASS
90
1
PK
CLRWR
80
AV
CLRWR
1
100
10
PASS
PK
CLRWR
MHz
14:48:19
kHz
MT
MHz
30
Figure 36. Conducted EMI, 230 Vac, LINE
90
1
kHz
2
TDF
70
80
AV
CLRWR
EN55022Q
TDF
70
EN55022Q
60
60
PRN
EN55022A
PRN
EN55022A
50
50
6DB
6DB
40
40
30
30
20
20
10
10
0
150
Date:
0
kHz
11.DEC.2018
30
MHz
150
14:43:59
Date:
Figure 37. Conducted EMI, 115 Vac, Neutral
kHz
11.DEC.2018
30
14:50:14
Figure 38. Conducted EMI, 230 Vac, Neutral
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14
MHz
EVBUM2651/D
BILL OF MATERIALS
Table 8. BILL OF MATERIALS
Parts
Qty
Description
Value
Tolerance
Footprint
Manufacturer
Manufacturer
Part Number
Substitution
Allowed
Pb−Free
C1
1
X2 Capacitor
0.33 mF/275 V
±10%
17 × 7.5 ×
15.5 mm
Pitch =
15 mm
CARLI
PX334K3ID1
Yes
Yes
C2
1
MLCC X7R
Capacitor
102 pF/1 kV
±10%
1206
KEMET
C1206C102KDRACTU
Yes
Yes
C4
1
Electrolytic
Capacitor
47 mF/400 V
±20%
12.5 × 20 mm
Rubycon
QXW
Yes
Yes
C5
1
MLCC X7R
Capacitor
221 pF/100 V
±10%
1206
Taiwan−Resister
CP221K100XRC
Yes
Yes
C6, C6A
2
Electrolytic
Capacitor
220 mF/35 V
±20%
8 × 11 mm
JACKCON
LHK
Yes
Yes
C7, C16
2
Electrolytic
Capacitor
22 mF/50 V
±20%
5 × 11 mm
JACKCON
LHK
Yes
Yes
C10, C17
2
MLCC X7R
Capacitor
102 pF/50 V
±10%
0805
Taiwan−Resister
CP102K050XRB
Yes
Yes
C13, C15
2
MLCC X7R
Capacitor
104 pF/50 V
±10%
0805
Taiwan−Resister
CP104K050XRB
Yes
Yes
C14
1
Y1 Capacitor
222 pF/250 V
±20%
UNIVERSE
CD12−E2GA222MYASA
Yes
Yes
C18, C18A
2
Electrolytic
Capacitor
470 mF/25 V
±10%
10 × 20 mm
Chemi−con
KME
Yes
Yes
C19
1
Electrolytic
Capacitor
68 mF/25 V
±20%
5 × 11 mm
Rubycon
ZLH
Yes
Yes
R3, R21
2
Resistor SMD
0W
±5%
1206
Taiwan−Resister
RP12000JR
Yes
Yes
R4, R5
2
Resistor SMD
240 W
±5%
1206
Taiwan−Resister
RP12240RJR
Yes
Yes
R1, R2, R8
3
Resistor SMD
200 kW
±5%
1206
Taiwan−Resister
RP12200KJR
Yes
Yes
R9
1
Resistor SMD
1W
±5%
1206
Taiwan−Resister
RP1201ROJR
Yes
Yes
R10
1
Resistor SMD
24 kW
±5%
0805
Taiwan−Resister
RP0824KOJR
Yes
Yes
R11, R17
2
Resistor SMD
5.1 kW
±5%
0805
Taiwan−Resister
RP0805K1JR
Yes
Yes
R14
1
Resistor SMD
30 kW
±5%
1206
Taiwan−Resister
RP1230KOJR
Yes
Yes
R18
1
Resistor SMD
2 MW
±5%
1206
Taiwan−Resister
RP1202MJR
Yes
Yes
R19
1
Resistor SMD
150 kW
±5%
1206
Taiwan−Resister
RP12150KJR
Yes
Yes
R22
1
Resistor SMD
22 MW
±5%
1206
Taiwan−Resister
RP1222MOJR
Yes
Yes
R23
1
Resistor SMD
100 kW
±5%
1206
Taiwan−Resister
RP12100KJR
Yes
Yes
D1
1
Fast Rectifier
600 V, 1 A
DO−214AC
ON Semiconductor
ES1J
Yes
Yes
D2
1
Zener Diode
7.5 V, 0.2 W
SOD−523F
ON Semiconductor
MM5Z7V5
Yes
Yes
D3
1
Fast Rectifier
200 V, 1 A
DO−214AC
ON Semiconductor
RS1D
Yes
Yes
D4
1
Jumper Wire
Short
Yes
Yes
D5
1
Schottky
Rectifier
150 V, 10 A
TO−277
ON Semiconductor
FSV10150V
Yes
Yes
D7
1
Schottky
Rectifier
120 V, 10 A
TO−277
ON Semiconductor
FSV10120V
Yes
Yes
15 V,12 V,
GND, L, N
5
TEST PIN
Pin Y2.2 ×
18.2 mm
OEM−10
2.2 × 18.2 m
m
KANG YANG
SG004−05 Pin
Yes
Yes
F1
1
Fuse
FUSE
CERAMIC
1 A/ 250 V
SLOW
3.6 × 10 mm
37SG
Yes
Yes
MOV
1
MOV
470 V
THINKING
MOV−471KD10SBNL
Yes
Yes
BD1
1
Bridge
Rectifier
600 V, 2 A
SDIP−4
ON Semiconductor
DF06S
Yes
Yes
L1
1
Common−
mode Choke
10 mH
UU9.8
SEN HUEI
TRN0356
Yes
Yes
L2, L3
2
Inductor,
Ferrite Core
1 mH
DR 6 × 8
WURTH
744772010
Yes
Yes
±10%
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EVBUM2651/D
Table 8. BILL OF MATERIALS (continued)
Parts
Qty
Description
Value
Tolerance
Footprint
TX1
1
Transformer
850 mH
±10%
EE−25−10 pin
U1
1
PWM with
Power
SENSEFET
U2
1
Opto Coupler
CTR =
80−160%
U3
1
Shunt
Regulator
Adjustable,
2.5 V
1
PCB
2
Teflon Tube
D4, F1
1%
Manufacturer
Manufacturer
Part Number
Substitution
Allowed
Pb−Free
No
Yes
7DIP
ON Semiconductor
FSL538APG
No
Yes
DIP 4−pin
ON Semiconductor
FOD817A
Yes
Yes
TO−92
ON Semiconductor
NCP431AVLPRAG
Yes
Yes
PLM0434V0
No
Yes
Yes
Yes
17L × 305 m
SENSEFET is a registered trademark of Semiconductor Components Industries, LLC (SCILLC) or its subsidiaries in the United States and/or other
countries.
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requalification, delay, loss of profits or goodwill, arising out of or in connection with the board, even if ON Semiconductor is advised of the possibility of such damages. In no event shall
ON Semiconductor’s aggregate liability from any obligation arising out of or in connection with the board, under any theory of liability, exceed the purchase price paid for the board, if any.
For more information and documentation, please visit www.onsemi.com.
PUBLICATION ORDERING INFORMATION
LITERATURE FULFILLMENT:
Email Requests to: orderlit@onsemi.com
ON Semiconductor Website: www.onsemi.com
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