NXP TEA2093DB2202 Synchronous Rectifier Evaluation Board User Manual

NXP TEA2093DB2202 Synchronous Rectifier Evaluation Board

Product Information

synchronous rectifier (SR) driver, TSOP-6, high efficiency, power
supply, evaluation board
Abstract| Downloaded from Arrow.com. NXP Semiconductors

Product Usage Instructions

1. Important Notice: This product is intended for engineering development or evaluation purposes only.

2. Safety Warning: The board application is AC-mains voltage powered. Avoid touching the board while it is connected to the mains voltage and when it is in operation. An isolated housing is obligatory when used in uncontrolled, non-laboratory environments. Galvanic isolation from the mains phase using a fixed or variable transformer is always recommended.

3. Introduction: The TEA2093DB2202 evaluation board and user manual are intended for engineers involved in the evaluation and design of switch-mode power supplies (SMPS). This document contains all the information required to replace the secondary-side rectification of an existing SMPS with an asymmetrical half-bridge topology using the TEA2093DB2202 evaluation board.

4. Finding Kit Resources and Information on the NXP
   Website: NXP Semiconductors provides online resources for this user manual and its supported devices at https://www.nxp.com. This design example user manual can be found at: https://www.nxp.com/TEA22093DB2202.

5. Collaborate in the NXP Community: In the NXP community, you can share ideas and tips, ask and answer technical questions, and receive input on just about any embedded design topic. The NXP community can be found at https://community.nxp.com.

Document information

synchronous rectifier (SR) driver, TSOP-6, high efficiency, power supply, evaluation board
Abstract| This user manual describes the TEA2093DB2202 evaluation board. A functional description is provided, including instructions about how to connect the board, for the best results and performance. The TEA2093DB2202 evaluation board contains the secondary part of a single output asymmetrical half-bridge converter, excluding the output capacitors and the feedback control hardware. To use the TEA2093DB2202 evaluation board correctly, an asymmetrical half-bridge converter board in which the evaluation board can replace the secondary rectifier part is required.

Revision history

Important notice

IMPORTANT NOTICE
For engineering development or evaluation purposes only:
NXP provides the product under the following conditions: This evaluation kit is for use of ENGINEERING DEVELOPMENT OR EVALUATION PURPOSES ONLY. It is provided as a sample IC presolderedto a printed-circuit board to make it easier to access inputs, outputs and supply terminals. This evaluation board may be used with any development system or other source of I/O signals by connecting it to the host MCU computer board via off-the-shelf cables. This evaluation board is not a Reference Design and is not intended to represent a final design recommendation for any particular application. Final device in an applicationheavily depends on proper printed-circuit board layout and heat sinkingdesign as well as attention to supply filtering, transient suppression, and I/Osignal quality.The product provided may not be complete in terms of required design,marketing, and or manufacturing related protective considerations, including product safety measures typically found in the end device incorporating theproduct. Due to the open construction of the product, it is the responsibility of the user to take all appropriate precautions for electric discharge. In order to minimize risks associated with the customers’ applications, adequate design and operating safeguards must be provided by the customer to minimize inherent or procedural hazards. For any safety concerns, contact NXP sales and technical support services.

Safety warning

The board application is AC-mains voltage powered. Avoid touching the board while it is connected to the mains voltage and when it is in operation. An isolated housing is obligatory when used in uncontrolled, non-laboratory environments. Galvanic isolation from the mains phase using a fixed or variable transformer is always recommended.
Figure 1 shows the symbols on how to recognize these devices.

Introduction

WARNING- Lethal voltage and fire ignition hazard
The non-insulated high voltages that are present when operating this product, constitute a risk of electric shock, personal injury, death and/ or ignition of fire. This product is intended for evaluation purposes only. It shall be operated in a designated test area by personnel qualified according to local requirements and labor laws to work with noninsulated mains voltages and high- voltage circuits. This product shall never be operated unattended.
The TEA2093DB2202 evaluation board and user manual are intended for engineers involved in the evaluation and the design of switch-mode power supplies (SMPS). This document contains all the information required to replace the secondary-side rectification of an existing SMPS with an asymmetrical half- bridge topology with the TEA2093DB2202 evaluation board.

Finding kit resources and information on the NXP website

NXP Semiconductors provides online resources for this user manual and its supported devices at https://www.nxp.com.
This design example user manual can be found at: https://www.nxp.com/TEA22093DB2202.

1. Collaborate in the NXP community
   In the NXP community you can share ideas and tips, ask and answer technical questions, and receive input on just about any embedded design topic. The NXP community can be found at https://community.nxp.com.

Getting ready

• Box contents
  The box contains the TEA2093DB2202 evaluation board, which incorporates the TEA2093TS in a TSOP-6 package and a MOSFET in a TDSON-FL package with a typical RDSon of 2.3 mΩ. Figure 2 shows the front side and the back side of the TEA2093DB2202 evaluation board. The TEA2093DB2202 evaluation board is a singlelayer board, which includes plated-through vias for external connections and a TO-220 MOSFET as a replacement for the mounted MOSFET Q4.

• Additional hardware
  The TEA2093DB2202 evaluation board must be placed on an existing SMPS. Details can be found in Section 6.3 and Section 7.

Getting to know the hardware

Overview
The TEA2093DB2202 evaluation board contains a TEA2093TS SR controller in a TSOP-6 package and a 100 V MOSFET in a TDSON-FL package. It replaces the secondary-side rectification part of an SMPS with an asymmetrical half-bridge topology. Additionally, the TEA2093DB2202 evaluation board contains an option to replace the mounted MOSFET by a MOSFET in a TO-220 package. The TEA2093TS is a dedicated controller IC for synchronous rectification (SR) on the secondary side of asymmetrical half-bridge converters. It incorporates the sensing stage and the driver stage for driving the SR MOSFET, which rectifies the output of the secondary transformer winding. The TEA2093TS can generate its own supply voltage or operate with an external applied voltage. The self- supply function is intended for: .

• Battery-charging applications with a 2 V (USB BC) output voltage
• Applications with high-side rectification without an auxiliary winding
• Multiple output voltage applications with or without auxiliary winding

Features

• Easy replacement of secondary-side rectifier
• A 100 V/2.7 mΩ MOSFET is incorporated
• Self-supplying for low-side rectification with low output voltage (CC mode)
• Self-supplying for high-side rectification without the use of an auxiliary winding
• Operates with standard-level and logic-level SR MOSFETs

Block diagram

Board description
The board incorporates the TEA2093TS SR controller and a power MOSFET. The TEA2093TS acts as a controlled amplifier. The input is the voltage difference between the DRAIN and the SOURCE pins. The corresponding gate driver signal is the output. The amplifier regulates the source-to-drain voltage difference to 37 mV in the rectification phase. To facilitate easy layout design for a single-sided board, resistors R1 and R2 are added. They must be between 0 Ω and 10 Ω. For the fastest turn-off time, use the lowest value. By default, the TDSON-FL MOSFET Q4 is mounted with a 0 Ω gate resistor (R1). It is also possible to mount a TO220 MOSFET Q5 with gate resistor R2. Capacitors C1 and C2 are decoupling capacitors for the VCC of the TEA2093TS. To ensure sufficient charge power during the secondary stroke to drive the external MOSFET, a value of 100 nF is used for capacitor C2. To prevent unwanted oscillation of the VCC supply, capacitor C1 is added. A provision is made for snubber R3/C3. The components are not mounted. However, if high-voltage spikes occur on the drain-source connections of the MOSFETs, they can be added. To facilitate optimal configurations for either the low-side or the high-side connection, jumpers JP1 and JP2 are added (see the diagrams in Section 7).

Configuring the hardware

• Connected at low-side SR
  The TEA2093DB2202 evaluation board must be incorporated in an existing asymmetrical half-bridge SMPS. Figure 4 shows the connection of the TEA2093DB2202 evaluation board to the secondary side of an asymmetrical half- bridge SMPS as low-side SR.

Figure 4(a) shows the configuration for SR low-side applications, which include CC mode (for example, USB BC specification for an operation between 2 V and 5 V). When Vout ≥ 4.7 V, the TEA2093TS uses the voltage on the XV pin as supply. The resulting voltage on the CAP pin is typically 0.7 V below the voltage on the XV pin. It is used as supply voltage for the gate drive output to the external MOSFET. When Vout < 4.7 V (CC mode), the TEA2093TS uses the pulsed voltage on the drain input to generate the voltage for the CAP pin. When 0 V < Vout < 4.7 V, the regulated voltage on the CAP pin is 4.0 V (typical). Figure 4(b) shows the configuration for SR low-side application for CV mode only. Vout must be ≥ 4 V. In this case, the CAP pin can be connected directly to the XV pin. The result of connecting the CAP pin directly to the XV pin is 0.7 V additional gate drivevoltage compared to the configuration in Figure 4(a). To achieve the best efficiency, the additional gate drive voltage drives the external MOSFET to a lower RDSon. The maximum gate drive voltage is 12 V.
Maximum voltage ratings for TEA2093TS pins:

• Pins XV and CAP: 38 V
• Pin DRAIN: 120 V

Connected at high-side SR
Figure 5 shows the connection of the TEA2093DB2202 evaluation board to the secondary side of an asymmetrical half-bridge SMPS as high-side SR.

Figure 5(a) shows the configuration for SR high-side applications with self- supply. In this case, the TEA2093TS retrieves its supply from the pulsed voltage on the DRAIN input. The regulator inside the TEA2093TS converts these pulses to regulated DC voltage of approximately 9 V. If the XV pin is connected to the IC ground, the TEA2093TS generates 9 V. This voltage is present on the CAP pin. It is the reference voltage for the gate drive of the external MOSFET. Figure 5(b) shows the configuration for SR high-side application which is supplied by an additional auxiliary winding. This configuration can deliver the best possible efficiency for high-side application. If the auxiliary voltage drops to below 4 V for the lower output voltages in a multipleoutputs application, the TEA2093TS generates its own supply voltage. It maintains a minimum supply of 4 V on the CAP pin. The auxiliary voltage can then be optimized for the higher output voltages. In this way, maximum efficiency at maximum power is achieved.
Maximum voltage ratings for TEA2093TS pins:

• Pins XV and CAP: 38 V
• Pin DRAIN: 120 V

Schematic, board layout and bill of materials

Schematic

Bill of materials (BOM)

Table 1.

Reference| Description and values| Part number| Manufacturer
---|---|---|---
C1| capacitor; 100 pF; 50 V; 0805| 08055A101KAT2A| AVX
C2| capacitor; 0.1 μF; 50 V; 0805| X7R0805HTTD104K| Koa Speer
C3| capacitor; not mounted; 10 nF; 250 V; 0805| CGA4J3X7R2E103K125AA| TDK
D1| diode; not mounted; SOD323| BAS316| Nexperia
JP1; JP2| header; straight; 1 × 2-way| SL 11 124 2 G| Fischer
MCL1; MCL2| jumper; with handle; P = 2.54 mm| CAB 9 GS| Fischer
R1| resistor; 0 Ω; 1206| CRCW12060000Z0EA| Vishay
R2| resistor; not mounted; 0 Ω; 1206| CRCW12060000Z0EA| Vishay
R3| resistor; not mounted; 10 Ω; 0805| CR0805-JW-100ELF| Bourns
Q4| MOSFET; TDSON-FL| ISC027N10NM6ATMA1| Infineon
Q5| MOSFET; not mounted; TO220AB| PSMN4R3-100PS| Nexperia
U1| SR controller; TSOP6| TEA2093TS| NXP Semiconductors

Layout
Below are several important guidelines for a good layout:

• Keep the trace from the DRAIN pin to the MOSFET drain as short as possible.
• Keep the trace from the SOURCE pin to the MOSFET source as short as possible.
• Keep the area of the loop from the DRAIN pin to the MOSFET drain, to the MOSFET source, and to the SOURCE pin as small as possible. Ensure that the overlap of this loop over the power drain track or the power source track is as small as possible. The two loops must not cross each other.
• Keep the track from the GATE pin to the gate of the MOSFET as short as possible.
• Use separate clean tracks for the XV and the GND pins. If possible, use a small ground plane underneath the IC, which improves the heat dispersion.
• Place capacitors C1 and C2 close to the IC.

Abbreviations

Table 2. Abbreviations

References

1. TEA2093TS data sheet — GreenChip synchronous rectifier controller; 2022, NXP Semiconductors.

Legal information

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