PMP22650

GaN-based, 6.6-kW, bidirectional, onboard charger reference design

PMP22650

Design files

Overview

The PMP22650 reference design is a 6.6-kW, bidirectional, onboard charger. The design employs a two-phase totem pole PFC and a full-bridge CLLLC converter with synchronous rectification. The CLLLC utilizes both frequency and phase modulation to regulate the output across the required regulation range. The design uses a single processing core inside a TMS320F28388D microcontroller to control both the PFC and CLLLC. Synchronous rectification is implemented via the same microcontroller with Rogowski coil current sensors. High density is achieved through the use of high-speed GaN switches (LMG3522). The PFC is operating at 120 kHz and the CLLLC runs with a variable frequency from 200 kHz to 800 kHz. A peak system efficiency of 96.5% was  achieved with an open-frame power density of 3.8 kW/L. While the design calcualtions were done for a 6.6-kW output power, the design represents a suitable starting point for a 7.x-kW (e.g. 7.2-kW to 7.4-kW) rated OBC operating from a 240-V input with a 32-A breaker.

Features
  • 96.5% system efficiency
  • 3.8-kW/L power density
  • GaN enabled high-operating frequency (500 kHz to 800 kHz)
  • GaN optimized with driver integration
  • Single TMS controller for both PFC and CLLLC
Output voltage options PMP22650.1
Vin (Min) (V) 90
Vin (Max) (V) 264
Vout (Nom) (V) 350
Iout (Max) (A) 19
Output Power (W) 6650
Isolated/Non-Isolated Isolated
Input Type AC
Topology Boost- PFC^Full Bridge- LLC

A fully assembled board has been developed for testing and performance validation only, and is not available for sale.

Design files & products

Design files

Download ready-to-use system files to speed your design process.

PDF | HTML
TIDT249.PDF (1341 K)

Test results for the reference design, including efficiency graphs, test prerequisites and more

TIDM921.ZIP (1530 K)

Detailed schematic diagram for design layout and components

TIDM922.ZIP (230 K)

Complete listing of design components, reference designators, and manufacturers/part numbers

TIDM923.ZIP (711 K)

Detailed overview of design layout for component placement

TIDM925.ZIP (15249 K)

Files used for 3D models or 2D drawings of IC components

TIDCG21.ZIP (1519 K)

Design file that contains information on physical board layer of design PCB

TIDM924.ZIP (8811 K)

PCB layer plot file used for generating PCB design layout

Products

Includes TI products in the design and potential alternatives.

Gallium nitride (GaN) ICs

LMG3522R030-Q1Automotive 650-V 30-mΩ GaN FET with integrated driver, protection and temperature reporting

Data sheet: PDF | HTML
AND gates

SN74AHCT08Q-Q1Automotive, 4-channel, 2-input 4.5-V to 5.5-V AND gates with TTL-compatible CMOS inputs

Data sheet: PDF
AND gates

SN74HC21-Q1Automotive 2-ch, 4-input, 2-V to 6-V AND gates

Data sheet: PDF
Analog switches & muxes

TMUX1208-Q1Automotive 5-V, 8:1, 1-channel multiplexer with 1.8-V logic

Data sheet: PDF
Analog temperature sensors

TMP235-Q1Automotive, 1.5C analog temperature sensor, 10 mV/C

Data sheet: PDF | HTML
Buck converters (integrated switch)

TPS62170-Q13-17V 0.5A Automotive Step-Down Converter in 2x2 QFN package

Data sheet: PDF
C2000 real-time microcontrollers

TMS320F28388DC2000™ 32-bit MCU w/ connectivity manager, 2x C28x+CLA CPU, 1.5-MB flash, FPU64, CLB, ENET, EtherCAT

Data sheet: PDF | HTML
Digital isolators

ISO7730Robust EMC, triple-channel, 3/0, reinforced digital isolator

Data sheet: PDF | HTML
Digital isolators

ISO7741-Q1Automotive, robust EMC, quad-channel, 3/1, reinforced digital isolator

Data sheet: PDF
Digital isolators

ISO7761Robust EMC, six-channel, 5/1, reinforced digital isolator

Data sheet: PDF | HTML
General-purpose op amps

LMV796-Q1Automotive-grade, single, 5-V, 17-MHz, low noise (5.8-nV/√Hz) operational amplifier

Data sheet: PDF
General-purpose op amps

TLV314-Q1Automotive-grade, single, 5.5-V, 3-MHz, low quiescent current (65-μA), RRIO operational amplifier

Data sheet: PDF | HTML
High-speed op amps (GBW ≥ 50 MHz)

OPA365-Q1Automotive 2.2V, 50MHz, Low-Noise, Single-Supply Rail-to-Rail Operational Amplifier

Data sheet: PDF | HTML
Isolated CAN transceivers

ISO1042-Q1Automotive, isolated CAN transceiver with 70-V bus fault protection & flexible data rate

Data sheet: PDF
Isolated amplifiers

AMC3302±50-mV input, precision current sensing reinforced isolated amplifier with integrated DC/DC

Data sheet: PDF | HTML
Isolated amplifiers

AMC3330-Q1Automotive, ±1-V input, precision voltage sensing reinforced isolated amplifier with int. DC/DC

Data sheet: PDF | HTML
Isolated gate drivers

UCC21222-Q1Automotive 3.0kVrms, 4A/6A 2-channel isolated gate driver w/ disable, programmable deadtime, 8V UVLO

Data sheet: PDF | HTML
Linear & low-dropout (LDO) regulators

TPS745-Q1Automotive 500-mA, low-IQ, high-PSRR, low-dropout (LDO) voltage regulator with power good

Data sheet: PDF | HTML
Precision op amps (Vos<1mV)

OPA320-Q1Automotive qualified, precision, zero-crossover, 20-MHz, 0.9-pA Ib, RRIO, CMOS operational amplifier

Data sheet: PDF | HTML
Series voltage references

REF4132-Q1Automotive 12-ppm/°C low-noise low-power precision voltage reference

Data sheet: PDF | HTML
Supervisor & reset ICs

TPS3703-Q1Automotive high-accuracy window supervisor with reset time delay

Data sheet: PDF | HTML
Supervisor & reset ICs

TPS3850-Q1Automotive, window supervisor for OV & UV monitoring with window watchdog timer & programmable delay

Data sheet: PDF | HTML
Transformer drivers

SN6501-Q1Automotive low-noise, 350-mA, 410-kHz transformer driver for isolated power supplies

Data sheet: PDF | HTML

Technical documentation

star
= Top documentation selected by TI
No results found. Please clear your search and try again.
View all 3
Type Title Date
* Test report GaN-Based, 6.6-kW, Bidirectional, Onboard Charger Reference Design PDF | HTML Sep. 08, 2021
More literature Optimizing GaN-Based High-Voltage, High-Power Designs PDF | HTML Dec. 07, 2021
More literature Optimizing GaN-based high-voltage, high-power designs PPT Dec. 02, 2021

Support & training

TI E2E™ forums with technical support from TI engineers

View all forum topics

Content is provided "as is" by TI and community contributors and does not constitute TI specifications. See terms of use.

If you have questions about quality, packaging or ordering TI products, see TI support. ​​​​​​​​

Videos