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


Design files


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.

  • 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
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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 (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


Includes TI products in the design and potential alternatives.

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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 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

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