NXP Semiconductors GreenChip TEA2209DB1584 User manual

UM11493
TEA2209DB1584 active bridge rectifier controller demo board
Rev. 1.1 — 6 April 2021 User manual
Document information
Information Content
Keywords TEA2209T, TEA2209DB1584, active bridge rectifier controller, X-capacitor
discharge, self-supplying, high efficiency, traditional diode bridge, power
supply, demo board
Abstract The TEA2209T is an active bridge rectifier controller replacing the traditional
diode bridge. Using the TEA2209T with low-ohmic high-voltage external
MOSFETs significantly improves the efficiency of the power converter as the
typical rectifier diode-forward conduction losses are eliminated. In addition,
the TEA2209T includes an X-capacitor discharge function. To reduce power
consumption at a standby condition, an external signal via the COMP pin can
disable the TEA2209T. This user manual describes how the TEA2209DB1584
demo board can be used to replace the traditional diode bridge. This demo
board contains a TEA2209T and four low-ohmic high-voltage MOSFETs.

NXP Semiconductors UM11493
TEA2209DB1584 active bridge rectifier controller demo board
Rev Date Description
v.1.1 20210406 Updated version
Modifications: •Figure 6 in Section 5 has been updated.
•Figure 9 in Section 6.3 has been updated.
v.1 20210129 Initial version
Revision history
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TEA2209DB1584 active bridge rectifier controller demo board
1 Introduction
Note: This product has not undergone formal EU EMC assessment. As a component
used in a research environment, it is the responsibility of the user to ensure that the
finished assembly does not cause undue interference when used. It cannot be CE
marked unless assessed.
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 non-
insulated mains voltages and high-voltage circuits. This product shall
never be operated unattended.
This user manual describes the TEA2209DB1584 demo board. It provides a functional
description, supported with instructions on how to connect the board to obtain the best
results and performance.
The TEA2209T is a product of a new generation of active bridge rectifier controllers
replacing the traditional diode bridge.
Using the TEA2209T with low-ohmic high-voltage external MOSFETs significantly
improves the efficiency of the power converter as the typical rectifier diode-forward
conduction losses are eliminated. Efficiency can improve up to about 1.4 % at 90 V (AC)
mains voltage.
The TEA2209T is intended for power supplies with a boost-type power-factor controller
as a first stage. The second stage can be a resonant controller, a flyback controller, or
any other controller topology. It can be used in all power supplies requiring high efficiency
such as adapters, server and telecom power supplies, desktop PCs, all-in-all PC power
supplies, and television power supplies.
aaa-038079
IC
L VR
VCCHL HVS
GATEHL GATEHR
HVS VCCHR
GATELL R
VCC HVS
GND GATELR
COMP_POL COMP
1
2
3
4
5
6
7
8
10
9
12
11
14
13
16
15
Figure 1. Pin configuration diagram (SO16)
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NXP Semiconductors UM11493
TEA2209DB1584 active bridge rectifier controller demo board
1.1 Features
•Elimination of forward conduction losses of the diode rectifier bridge
•Very low IC power consumption (2 mW)
•Integrated high-voltage level shifters
•Directly drives four rectifier MOSFETs
•Very low external part count
•Integrated X-capacitor discharge (2 mA)
•Self-supplying
•Full-wave drive improving total harmonic distortion (THD)
•Undervoltage lockout (UVLO) for high-side and low-side drivers
•Drain-source overvoltage protection for all external power MOSFETs
•Gate pull-down currents at start-up for all external power MOSFETs
•Disable function for all external power FETs
2 Safety warning
This demo board is connected to the mains voltage. 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.
019aab173
019aab174
a. Isolated b. Not isolated
Figure 2. Isolation symbols
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TEA2209DB1584 active bridge rectifier controller demo board
3 Board photographs
The TEA2209DB1584 demo board consists of the TEA2209T in an SO16 package with
four MOSFETs (600 V; 28 mΩ). Figure 3 shows the front side of demo board.
Figure 3. TEA2209DB1584 demo board photograph
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TEA2209DB1584 active bridge rectifier controller demo board
4 TEA2209DB1584 demo board setup
The TEA2209DB1584 demo board contains four 600 V/28 mΩ MOSFETs. It makes the
board suitable for universal AC input and output power applications of several hundreds
of Watts. The TEA2209DB1584 demo board contains four leads that can easily replace
a traditional diode bridge. The outer two leads are connected to positive and negative
rectified voltages. The inner two leads are connected to AC mains lines. These four leads
are pin-to-pin with typical bridge rectifier diodes pins. Figure 4 describes the difference
between bridge diodes and active bridge configurations.
aaa-036471
aaa-039044
TEA2209T
a. Diode bridge b. Active bridge
Figure 4. Diode bridge configuration versus TEA2209DB1584 demo board typical
configuration
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NXP Semiconductors UM11493
TEA2209DB1584 active bridge rectifier controller demo board
Figure 5 shows an example of the TEA2209DB1584 demo board mounted on an NXP
Semiconductors TEA2016DB1519 demo board.
Figure 5. TEA2209DB1584 demo board added to 240 W resonant adapter board
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NXP Semiconductors UM11493
TEA2209DB1584 active bridge rectifier controller demo board
5 Operation
The TEA2209T is a controller IC for an active bridge rectifier. It can directly drive the four
MOSFETs in an active bridge. Figure 6 shows a typical configuration. As the output is a
rectified sine wave, a boost-type power-factor circuit must follow the application.
aaa-038080
CONTROL
VCC
1.3 V SUPPLY
+
XCAP DISCH
GATELR
GNDCOMP_POL
R
GATEHR
VCCHR
COMP
enable
GATELL
L
GATEHL
200 nF 200 nF
2.2 µF
VCCHL VCCVCC
VR
VR
LEVEL
SHIFT
LEVEL
SHIFT
Figure 6. Typical configuration
The control circuit of the TEA2209T senses the polarity of the mains voltage between
pins L and R. Depending on the polarity, either GATELL or GATELR is switched on. The
comparator in the control circuit, which compares the L and R voltages, has thresholds of
250 mV and −250 mV depending on the slope polarity. If the difference voltage between
L and R is less than 250 mV both GATELL and GATELR are low.
The gate drivers are high-current rail-to-rail MOS output drivers. An on-chip supply circuit
which draws current from either L or R generates the gate driver voltage. After a zero-
crossing of the mains voltage, the supply capacitor CVCC is charged to the regulation
level Vreg. Then the discharge state is entered. The resulting power dissipation from
the mains voltage is about 1 mW excluding gate charge losses of the external power
MOSFETs. These gate charge losses typically add 1 mW of dissipation.
At start-up, the supply capacitor is first charged to the Vstart voltage and enters the start-
up state. After a next zero-crossing of the mains voltage, the supply capacitor is charged
to Vreg in the charging state. When the voltage at the supply capacitor exceeds Vdis, the
gate driver outputs are enabled. When all drivers are active, the MOSFETs take over the
role of the diodes which, compared to a passive diode rectifier bridge, results in lower
power loss.
When the mains voltage is disconnected, the internal bias current in the discharge state
discharges the supply capacitor. When the voltage at pin VCC drops to below Vdis, the X-
capacitor discharge state is entered, which draws 2 mA of current from VR to discharge
the X-capacitor. The waiting time td until X-capacitor discharge starts is:
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NXP Semiconductors UM11493
TEA2209DB1584 active bridge rectifier controller demo board
(1)
Using a typical value of 2.2 μF for CVCC yields about 0.24 s. While VR discharges the
X-capacitor, the mains can be reconnected. In that case, the charge mode is entered
again. Figure 7 describes the start-up, the normal operation, and the power-off of the
TEA2209T.
aaa-038081
td
L-R
VR
Vreg
Vdis
Vstartup
VCC
GATELL
startup charge
charge charge charge charge charge
discharge
X-capacitor discharge
discharge discharge discharge discharge discharge
GATEHR
GATELR
GATEHL
mains
discount
Figure 7. TEA2209T signals (start-up, normal operation and power-off)
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TEA2209DB1584 active bridge rectifier controller demo board
6 Performance
6.1 Test facilities
•Oscilloscope: Agilent Technologies DSOX3034T
•AC power source: Chroma 61504
•Electronic load: Chroma 63600-2
•Digital power meter: WT210
•Power board: TEA2016DB1519
6.2 Test setup
To measure the system performance the TEA2209DB1584 is mounted on
the TEA2016DB1519. The diode bridge rectifier, BD101, is removed from the
TEA2016DB1519 and replaced by the TEA2209DB1584. Figure 8 shows details of the
test setup.
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