Power Supply Design - Power Loss Calculation

             
Input data Vinn= 230.0 Vrms Nom AC Input Voltage    
  Iinn= 12.24 Arms Nom rms Input Current    
  Irpkn= 17.32 Apk Nom line peak rectified current    
  Iravgn= 11.02 Aavg Nom avg rectified current    
  Ibpkn= 20.13 Apk Boost Ind, Switch and Diode nom avg pk current    
  Ibacn= 2.00 Arms Boost Ind ripple nom rms current    
  PF= 0.9993   Estimated Input Power Factor @ Full Load    
  Voutn= 27.22 Vdc Nominal DC Output Voltage    
  Ioutn= 90.00 Adc Nominal Output Current    
  Pomax= 2,450 W Maximum Output Power, DC/DC Stage    
  Iaux= 56 mA Auxiliary Power Supply current    
  Tamb= 50.0 °C Maximum Ambient Temperature    
             
Output data Pin= 2,814 W Input Active Power    
  Ppfc= 2,689 W Maximum Output Power, PFC Stage    
  Pinl= 35.5 W Total Input Stage power loss    
  Ppfcl= 89.5 W Total PFC Stage power loss    
  Pdcl= 60.7 W Total DC/DC Stage power loss    
  Poutl= 156.1 W Total Output Stage power loss    
  Paul= 22.8 W Auxiliary circuits power loss    
  Pm= 39.9 W Total Magnetics loss    
  Ps= 243.6 W Total Semiconductors Loss    
  Ptl= 364.6 W Total Power Loss    
  Effpfc= 95.56 % PFC (+ Input Stage, + Aux) Efficiency Measured: XX.X %  
  Effdc= 91.87 % DC/DC (+ Output Stage) Efficiency Measured: YY.Y %  
  Eff= 87.04 % Total Efficiency Measured: ZZ.Z %  
             
             
  Input Stage Loss Evaluation    
             
Input data Rif= 2.00 mOhm DC Resistance, Input Fuses 20A/250V/S/HC(*2)  
  Ricm1= 7.57 mOhm DC Resistance, Input CM Inductor 1 1mH (*2)  
  Ricm2= 7.57 mOhm DC Resistance, Input CM Inductor 2 1mH (*2)  
  Ridm= 17.17 mOhm DC Resistance, Input DM Inductor(s) 30uH (*2)  
  Rbinlf= 19.10 mOhm PCB AC Input path, low frequency    
  Vidb= 0.89 V Voltage drop, one diode Input Bridge @ Iinnpk 1/4*D25XB60, typ  
  Visb= 0.89 V Voltage drop, one SCR Input Bridge @ Iinnpk 1/4*D25XB60, typ  
  Rdthjc= 2.00 °C/W Input diodes junction to case thermal resistance 1/2*D25XB60  
  Rdthcs= 0.22 °C/W Input diodes case to heat sink thermal resistance 1/2*D25XB60  
  Rsthjc= 2.00 °C/W Input SCRs junction to case thermal resistance 1/2*D25XB60  
  Rsthcs= 0.22 °C/W Input SCRs case to heat sink thermal resistance 1/2*D25XB60  
  Tidjx= 125 °C Input diodes maximum junction temperature D25XB60  
  Tidj= 125 °C Input diodes actual junction temperature Estimated  
  Tisjx= 125 °C Input SCRs maximum junction temperature D25XB60  
  Tisj= 125 °C Input SCRs actual junction temperature Estimated  
             
Output data Pif= 0.6 W Power loss, input fuses 2*MDA-V-20  
  Picm1= 2.3 W Power Loss, Input CM Inductor 1    
  Picm2= 2.3 W Power Loss, Input CM Inductor 2    
  Pidm= 5.1 W Power Loss, Input DM Inductor(s)    
  Pbinlf= 5.7 W Power loss, PCB, input stage 2 x 1/2  
  Pidb= 9.8 W Power Loss, Input Diode Bridge 1/2*D25XB60  
  Pisb= 9.8 W Power Loss, Input SCR Bridge 1/2*D25XB60  
  Pinu= 35.5 W Total Input Stage power loss    
  Tdc= 105 °C Case temperature, diodes    
  Tsc= 105 °C Case temperature, SCRs    
  Tdh= 103 °C Diodes heat sink temperature    
  Tsh= 103 °C SCRs heat sink temperature    
  Ridthsx= 5.46 °C/W Max. Diodes Heat sink Thermal Resistance    
  Ridths= 2.25 °C/W Chosen Diodes Heat sink Thermal Resistance    
  Risthsx= 5.46 °C/W Max. SCRs Heat sink Thermal Resistance    
  Risths= 2.25 °C/W Chosen SCRs Heat sink Thermal Resistance    
             
             
  PFC Stage Loss Evaluation      
             
Input data Vba= 407.0 Vdc Average Boost Voltage    
  fpfc= 140 kHz PFC Switching Frequency    
  Iba= 6.61 A Average PFC output current    
  Iba= 6.81 A Average PFC output current Copy from above cell  
  Ibswn= 6.9 Arms Switch rms current at nom line    
  Ibpkon= 7.9 Apk SW turn ON, Diode turn OFF pk current, max avg    
  Ibpkoff= 16.5 Apk SW turn OFF, Diode turn ON pk current, max avg    
  kf= 1   1 for Hard SW, 2 for Soft SW Hard switching  
  dIf/dt= 1,042 A/us Turn-ON current slope, max, should be chosen < 1259  
  Lsnb= 0.00 uH Boost snubber inductor NOT required  
  dVd/dton= -23.0 kV/us SS turn ON dV/dt for MOSFET drain voltage < NOT required  
  nd= 1   Number of boost diodes APT30DS60B  
  Vbd= 2.83 V Diode forward voltage @ peak line current APT30DS60B  
  Vbdfr= 21.00 V Diode forward recovery voltage APT30DS60B  
  tfrx= 50.0 ns Diode forward recovery time APT30DS60B  
  Irrpk= 21.8 A Boost diode pk reverse recovering current APT30DS60B  
  trrx= 30.0 ns Boost diode reverse recovering time APT30DS60B  
  ta= 20.9 ns   APT30DS60B  
  tb= 9.1 ns   APT30DS60B  
  Rthjc= 0.66 °C/W Boost diode(s) junction-case thermal resistance APT30DS60B  
  Rthcs= 0.71 °C/W Boost diode(s) case-heatsink thermal resistance APT30DS60B  
  Tjbdx= 130 °C Boost diode(s) maximum junction temperature    
  Tjbd= 135 °C Boost diode(s) junction temperature same htsk with BT  
  Tjbd= 135 °C Boost diode(s) junction temperature Copy from above cell  
  nt= 2   Number of transistors    
  Rdso= 0.070 Ohm MOSFET Rdson, max @25°C SPW47N60S5  
  Rds= 0.072 Ohm Actual MOSFET(s) Rds ON SPW47N60S5  
  Vgsth= 6.50 V Gate Threshold Voltage SPW47N60S5  
  Vx= 25.0 V Vds voltage @ t3 SPW47N60S5  
  gfs= 30.0 S Forward Transconductance SPW47N60S5  
  Q3= 6.4 nC Gate charge t2 -> t3 SPW47N60S5  
  Cisu= 8,360 pF Ciss @ Vds=Vba & Vgsth<Vgs<Vgsp SPW47N60S5  
  Coer= 233 pF MOSFET output capacitance @ Vba SPW47N60S5  
  rg= 8.70 Ohm Transistor intrinsic gate resistance SPW47N60S5  
  Ls= 9.0 nH Source inductance SPW47N60S5  
  Vgson= 14.0 V Effective gate ON voltage    
  Vgsoff= -5.0 V Effective gate OFF voltage    
  Vgst2->3= 6.81 V Vgs from t2b to t3    
  Vgst2->3= 6.81 V Vgs from t2b to t3 Copy from above cell  
  Vgst2a= 6.63 V Vgs when Id=Idiode    
  Vlsta= 4.69 V Voltage across Ls during turn-on, t1->t2    
  t:1->2a= 7.6 ns time from Id starting to rise to Id reaching the Idiode    
  t:2->3= 16.6 ns time from Vds starting to drop to Vds=Vx Hard switching  
  dVd/dton= -23.0 kV/us Turn ON dV/dt for MOSFET drain voltage    
  Vsaton= 0.6 V Vdrain after turn-on    
  Icossf= -5.3 A Coss current during voltage falling SPW47N60S5  
  Rswonc= 10.2 Ohm Gate turn ON resistor Determined by dI/dt  
  Rswon= 10.0 Ohm Gate turn ON resistor, chosen =Rswonc  
  Rswoff= 0.5 Ohm Gate turn OFF resistor, chosen    
  Csf= 0 pF Optimum Boost snubber capacitor NOT required  
  Csf= 0 pF Boost snubber capacitor NOT required  
  Vsatoff= 1.2 V Vdrain before turn-off    
  Vgst3r= 6.78 V Vgs @ t3r, before Vds begins to rise Hard switching  
  t:3r->2r= 10.8 ns time from Vds=Vx to  Vds=Vb Hard switching  
  dVd/dtoff= 35.5 kV/us Turn OFF dV/dt for MOSFET drain voltage    
  Icossr= 8.27 A Coss current during voltage rising    
  Icsf= 0.00 A Csf current during voltage rising not present  
  Icht3r->2r= 0.00 A Internal channel current    
  Vgst2r= 6.50 V Vgs @ t2r, after Vds reach Vb Hard switching  
  dId/dt= -2,013 A/us Turn-OFF current slope (internal channel !)    
  t:2r->1r= 8.2 ns time from Ichannel going from Id to zero    
  Vlsoff= -9.06 V Voltage across Ls during turn-off    
  Rthjc= 0.30 °C/W MOSFET(s) junction to case thermal resistance SPW47N60S5  
  Rthcs= 0.71 °C/W MOSFET(s) case to heat sink thermal resistance SPW47N60S5  
  Tjbtx= 125 °C MOSFET(s) Maximum junction temperature    
  Tjbt= 110 °C MOSFET(s) actual junction temperature    
  Resrlf= 63 mOhm ESR@100Hz, Boost Capacitors 3*470uF  
  Resrhf= 36 mOhm ESR@100kHz, Boost Capacitors 3*470uF  
  Rspfc= 15.0 mOhm PFC shunt resistor    
  Rbpfchf= 6.4 mOhm PCB PFC path high frequency    
  Pbitl= 12.4 W Boost Inductor total loss    
             
Output data Pt5= 3.5 W Conduction Loss in MOSFET(s)    
  Pt1->2= 5.5 W Turn ON Switching Loss in MOSFET(s) Hard switching  
  Pt2a->2b= 22.4 W MOSFET turn ON Switching Loss due to the diode    
  Pt2->2b= 5.7 W Turn ON Switching Loss due to the diode MOSFET(s) + Diode(s)  
  Pt4= 3.9 W Turn OFF Switching Loss in MOSFET(s)    
  Pt5= 5.4 W Transistor Capacitance discharge Loss    
  Ptr= 43.5 W Total Losses Main Switch(s)    
  Pdc= 19.3 W Conduction losses in the Boost Diode(s)    
  Pdoff= 1.2   Switch turn OFF losses in the Boost Diode(s) Forward recovery  
  Pd= 23.3 W Total Losses Main Diode    
  Pdsn= 2.3 W Snubber diodes losses    
  Pbs= 69.1 W Total PFC Stage Semiconductors Loss    
  Tcbtx= 118 °C MOSFET(s) max allowable case temperature    
  Thpfcx= 103 °C MOSFET(s) heat sink max allowable temperature    
  Tcbd= 120 °C Boost diode case temperature same htsk with BT  
  Rths 0.77 °C/W PFC heat sink Thermal Resistance    
  Pish= 1.9 W Power loss, PFC Shunt    
  Pbpfclf= 0.8 W Power loss, PCB PFC path high frequency    
  Pbo= 2.0 W Total PFC Stage Other Losses    
  Pesrlf= 1.4 W Boost Capacitors low frequency Loss    
  Pesrhf= 2.0 W Boost Capacitors high frequency Loss    
  Pbt= 89.5 W Total PFC Stage Loss    
             
             
  DC/DC Stage Loss Evaluation    
             
Input data Rdso= 0.200 Ohm MOSFET Rds, max @25°C APT5020BVFR  
  Rdsd= 0.379 Ohm MOSFET(s) Rds ON Resistance @125°C APT5020BVFR  
  Rthjc= 0.11 °C/W MOSFET(s) junction to case thermal resistance 4*APT5020BVFR  
  Rthcs= 0.18 °C/W MOSFET(s) case to heat sink thermal resistance 4*APT5020BVFR  
  Tj= 125 °C MOSFET(s) Maximum junction temperature APT5020BVFR  
  Tja= 110 °C MOSFET(s) actual junction temperature APT5020BVFR  
  Coer= 253 pF MOSFET output capacitance @ Vba 2*APT5020BVFR  
  Ibchfx= 2.69 Arms DC input Capacitor, max HF ripple current    
  Ibchfx= 2.69 Arms DC input Capacitor, max HF ripple current Copy from above cell  
  Resrin= 36 mOhm ESR@100kHz, Boost Capacitors 3*470uF  
  Rdcm= 10.00 mOhm DC Resistance, DC/DC CM Inductor    
  Rbdcp= 38.19 mOhm PCB DC/DC path primary    
  Pttl= 14.9 W Power transformer total loss    
             
Output data Pdc= 43.4 W Conduction Loss in Phase Shift Bridge transistors    
  Psw= 2.2 W Switching Loss in Phase Shift Bridge transistors    
  Ptr= 45.5 W Total Losses Bridge Switches    
  Tc= 120 °C Case temperature    
  Th= 112 °C Heat sink temperature    
  Rths 1.37 °C/W PS Bridge Heat sink Thermal Resistance    
  Pcin= 0.3 W Power Loss, Input Capacitor    
  Pcin= 0.0 W Power Loss, DC/DC CM Inductor    
  Pbdcp= 2.2 W Power loss, PCB DC/DC path primary    
  Pdctot= 60.7 W Total DC/DC Stage power loss    
             
             
  Output Stage Loss Evaluation    
             
Input data Rbdcslf= 0.4 mOhm PCB DC/DC path secondary, low frequency    
  Rbdcshf= 2.5 mOhm PCB DC/DC path secondary, high frequency    
  Rocm= 0.20 mOhm DC Resistance, Output CM Inductor    
  Rodm= 0.10 mOhm DC Resistance, Output DM Inductor    
  Rosh= 0.49 mOhm DC Resistance, Output Shunt    
  Rbdco= 0.57 mOhm PCB DC/DC path output    
  Roc= 1.00 mOhm DC Resistance, Output Connector    
  Poitl 3.0 W Output Inductor(s) total loss    
  nrd= 2   Number of rectifier diodes 1/2*63CPQ100  
  Ddcn= 86.84 % Nominal DC/DC Stage Duty Cycle    
  Ddcn= 86.84 % Nominal DC/DC Stage Duty Cycle Copy from above cell  
  Vfr= 0.70 V Diode forward voltage @ Tja 1/2*63CPQ100  
  Rthjc= 0.20 °C/W Output Diode(s) junction-case thermal resistance nrd*63CPQ100  
  Rthcs= 0.12 °C/W Output Diode case-heatsink thermal resistance nrd*63CPQ100  
  Tj= 145 °C Output Diode Maximum junction temperature 63CPQ100  
  Tja= 135 °C Output Diode actual junction temperature 63CPQ100  
  Tc= 81 °C Output diode case temperature    
  nod= 4   Number of OR-ing diodes 1/2*STPS6045CW  
  Vfo= 0.59 V OR-ing diode forward voltage @ Tja 1/2*STPS6045CW  
  Rthjc= 0.24 °C/W OR-ing Diode junction to case thermal resistance nod*1/2*STPS6045CW  
  Rthcs= 0.12 °C/W OR-ing Diode case-heatsink thermal resistance nod*1/2*STPS6045CW  
  Tj= 145 °C OR-ing Diode Maximum junction temperature STPS6045CW  
  Tja= 140 °C OR-ing Diode actual junction temperature STPS6045CW  
  Resro= 9 mOhm ESR Output Capacitor 2 x 1800uF/35V  
  PLmin= 2.0 W Power loss R Load min    
  Psnb= 1.0 W Power loss Clamping    
             
Output data Pbdcs= 5.9 W Power loss DC/DC path secondary    
  Psatind= 4.0 W Power loss saturable inductors    
  Pocm= 3.2 W Power Loss, Output CM Inductor    
  Podm= 0.8 W Power Loss, Output DM Inductor    
  Posh= 4.0 W Power Loss, Output Shunt    
  Rbdco= 4.