
AN-30
5
B
12/02
The efficiency of the power system is an important consideration
in every design.  The designer should have a goal for the
efficiency of the system at the start of the design, based on
reasonable allowances for power lost in the specific areas of the
power supply.
The efficiency goal should take into account losses in the
transformer, inductors, output rectifiers, and clamp circuits.
Most high power designs have some form of power factor
correction (PFC).  The type of PFC will affect the efficiency.
For example, the voltage drop on a passive PFC (a large
inductor in series with the AC line input) will reduce the
minimum input voltage at the converter, and will also reduce
system efficiency.
Total system efficiency should consider losses in the AC input
circuit, including the EMI filter, that are not part of this design
methodology.  Only a bench evaluation can determine the
actual efficiency of the power supply.  If the efficiency is not
satisfactory, the designer must revise the values of component
parameters or change the output topology for a repeat design.
If the requirements call for a holdup time, the designer must
determine the amount of bulk input capacitance that is required
to achieve the specified holdup time from the designated input
voltage.  It is often necessary to adjust parameters by iteration
to meet the objectives of the design.
PI Expert
 performs the calculations to allow the designer to see
the interactions of the variables immediately.
After the values of the major power components are determined,
the designer needs to check voltage and current stress to select
components with the proper ratings.  Then the designer can
choose values for small signal components that set voltage
detection thresholds and other control parameters.
The final step is an evaluation of a prototype on the bench.  This
is the only way to confirm that the design is satisfactory, and to
get necessary information to adjust the parameters if a redesign
is necessary.
Definition of Variables
Table 1 gives a set of system parameters that should be known
at the start of the design.  The list is general, so all the parameters
will not necessarily be relevant to all applications.  Some values
will be given by the system specification, while others are the
designer’s choice.
The notation in this document uses descriptive subscripts to
keep track of variables.  Quantities that refer to the main output
are designated with the subscript 
.  Variables associated
with an auxiliary output are identified by the subscript 
, and
those related to an independent output have the subscript 
IND
.
These conventions are used to identify voltages, currents, and
components.
When there is more than one output in a category, the individual
members are distinguished by numbers appended to the subscript,
as in 
, 
 and 
 for three independent outputs.  Quantities
related to the magnetic amplifier have 
 appended to the
subscript, as in 
 referring to the magnetic amplifier on the
secondary winding for the main output.  This notation has the
generality necessary to expand the allowable output options.
Turns ratios on magnetic components are designated by lower
case n with appropriate subscripts, while actual numbers of
turns are distinguished by upper case N with identifying
subscripts.
There are a few other variables and notations that need definition.
Figure 4 shows a section of output circuitry that identifies some
important electrical quantities.  Each output of a forward
converter has two diodes.  One is designated the forward diode
and the other is the catch diode.  Associated quantities have
F
 or 
C
 appended to their respective subscripts.
Name
Description
η
f
L
f
S
I
AUX
I
IND
I
MAIN
I
MAINMA
t
H
V
ACMAX
V
ACMIN
V
ACNOM
V
ACUV
V
AUX
V
AUXREF
V
DROPOUT
V
DSOP
V
HOLDUP
V
IND
V
MAIN
V
MAINMA
Total system efficiency
AC mains frequency
TOPSwitch-GXswitching frequency
Current from auxiliary output
Current from independent output
Current from main output
Current from magnetic amplifier
Holdup time
Maximum AC input voltage
Minimum AC input voltage
Nominal AC input voltage
AC under-voltage threshold
Auxiliary output voltage
Auxiliary output reference voltage
Lowest DC bus voltage for regulation
Maximum drain-to-source voltage
DC bus voltage at start of t
H
Independent output voltage
Main output voltage
Magnetic amplifier output voltage
Table 1.  System Parameters Needed to Start a Design.