PMP41166

3.6kW 3-level flying cap totem-pole bridgeless PFC reference design

PMP41166

Design files

Overview

This reference design is a 3.6kW, single-phase, 3-level flying cap totem-pole bridgeless power factor correction (PFC) converter targeting modular hardware system common redundant power supply (M-CRPS) servers. The PFC operates at continuous conduction mode (CCM) with peak efficiency of 99%. The power stage is followed by a baby boost converter, which helps to greatly reduce the size of the bulk capacitor. This design also includes e-meter functionality with 0.5% accuracy using AMC1306 as a current sensing device, eliminating the need for external power metering ICs. An alternative low- cost current sensing option using TMCS1133 is also provided in this design. The LMG3522 top-side cooled GaN device with integrated driver and protection, enables higher efficiency and reduces power supply size and complexity. The TMDSCNCD28P55X C2000™ real-time microcontroller is used for all the advanced controls including PFC control and e-metering.

Features
  • High efficiency (99% peak efficiency) and high power density
  • New flying cap voltage method balancing method
  • Single current sensor for both PFC control and e-metering with < 0.5% accuracy
  • Includes baby boost to extend holdup time and reduce bulk capacitor
  • Re-rush current control when AC comes back from dropout
Output voltage options PMP41166.1
Vin (Min) (V) 90
Vin (Max) (V) 265
Vout (Nom) (V) 385
Iout (Max) (A) 9.35
Output Power (W) 3599.75
Isolated/Non-Isolated Non-Isolated
Input Type AC
Topology Boost- PFC
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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.

PDF | HTML
SLVT239.PDF (1065 KB)

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

SLVMEX1.ZIP (301 KB)

Detailed overview of design layout for component placement

SLVMEX3.ZIP (116 KB)

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

SLVMEX2.ZIP (8950 KB)

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

SLVC949.ZIP (2294 KB)

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

SLVMEX0.ZIP (2041 KB)

PCB layer plot file used for generating PCB design layout

SLVMEW9.ZIP (1712 KB)

Detailed schematic diagram for design layout and components

Products

Includes TI products in the design and potential alternatives.

Real-time motor control & automation MCUs

TMS320F28P550SGC2000™ 32-bit MCU with 150MHz 512KB flash C28x + CLA, five ADCs, CLB, AES and NPU

Data sheet: PDF | HTML
Automotive body & lighting MCUs

TMS320F28P559SG-Q1Automotive 32-bit C2000™ MCU with 150MHz 512 KB flash C28x + CLA, five ADCs, CLB, AES and NPU

Data sheet: PDF | HTML
Isolated ADCs

AMC1306M05±50-mV input, precision current sensing reinforced isolated modulator

Data sheet: PDF | HTML
Real-time digital power MCUs

TMS320F28P550SJC2000™ 32-bit MCU with 150MHz 1.1MB flash C28x + CLA, five ADCs, CLB, AES and NPU

Data sheet: PDF | HTML
Hall-effect current sensors

TMCS113380ARMS 1MHz Hall-effect current sensor with AFR and ALERT

Data sheet: PDF | HTML
Gallium nitride (GaN) power stages

LMG3522R030650-V 30-mΩ GaN FET with integrated driver, protection and temperature reporting

Data sheet: PDF | HTML

Technical documentation

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Top documentation Type Title Format options Date
* Test report 3.6kW 3-Level Flying Cap Totem-Pole Bridgeless PFC Reference Design PDF | HTML Mar 19, 2026

Related design resources

Reference designs

REFERENCE DESIGN
PMP23338 3.6kW single-phase totem-pole bridgeless PFC reference design with e-meter functionality PMP23537 3.6kW CCM-TCM multimode-controlled totem-pole bridgeless PFC reference design

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