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.
| 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.
Download ready-to-use system files to speed your design process.
Test results for the reference design, including efficiency graphs, test prerequisites and more
Detailed schematic diagram for design layout and components
Complete listing of design components, reference designators, and manufacturers/part numbers
Detailed overview of design layout for component placement
Files used for 3D models or 2D drawings of IC components
Design file that contains information on physical board layer of design PCB
PCB layer plot file used for generating PCB design layout
Includes TI products in the design and potential alternatives.
| 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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