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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.

TIDT249.PDF (1313 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

LMG3422R030600-V 30-mΩ GaN FET with integrated driver, protection and temperature reporting

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AND gates

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

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AND gates

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

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Analog switches & muxes

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

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Analog temperature sensors

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

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Buck converters (integrated switch)

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

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C2000 real-time microcontrollers

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

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Digital isolators

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

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Digital isolators

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

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Digital isolators

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

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General-purpose op amps

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

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General-purpose op amps

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

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High-speed op amps (GBW>=50MHz)

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

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Isolated CAN transceivers

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

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Isolated amplifiers

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

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Isolated amplifiers

AMC3330-Q1Automotive ±1-V input, precision reinforced isolated amplifier with integrated DC/DC converter

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Isolated gate drivers

UCC21222-Q1Automotive 4-A/6-A, 3.0-kVRMS 2-channel isolated gate driver with 8-V UVLO, programmable dead tim

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Linear & low-dropout (LDO) regulators

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

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Precision op amps (Vos<1mV)

OPA320-Q1Automotive Qualified, Precision, Zero-Crossover, 20MHz, 0.9pA Ib, RRIO, CMOS Operational Amplifier ;

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Series voltage references

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

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Supervisor & reset ICs

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

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Supervisor & reset ICs

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

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Transformer drivers

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

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Technical documentation

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Type Title Date
* Test report GaN-Based, 6.6-kW, Bidirectional, Onboard Charger Reference Design Sep. 08, 2021

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