Question about MOSFET switching loss with external Coss and custom commutation current in PLECS 4.7.4

The short answer is that you should not use an explicitly modeled Coss in conjunction with a PLECS thermal model as it invalidates the assumptions of the thermal model - namely an instantaneous transition from the off state to the on state.

You end up chasing various artifacts 1) the instantaneous current discharge of the Coss through the switch on-state resistance and 2) the parallel capacitance means the voltage across the switch voltage cannot change instantaneously at the switching moment. These distort the inputs into the look-up tables. You can use the workarounds you mention in your post like using the tank current, perhaps eliminating the artificial power losses from discharging Coss, but this isn’t a consistent engineering workflow one can make broad recommendations on.

The typical recommendations are twofold:

  • Clearly separate the thermal model used for loss analysis (requires some assupmtions, for example ZVS is always achieved or ZVS losses) from the model used to analyze ZVS/dead-time commutation. This is explained further in this post.
  • Use PLECS Spice which, with the appropriate model of the semiconductor device, can explicitly model the Coss, ZVS behavior, and power loss.