CCR Efficiency Calculator | Precision AGL Academy

CCR Performance / Efficiency Calculator

Turn FAT and SAT meter readings into input and output kVA, power factor, efficiency, losses and a pass or fail summary.

About this calculator

A constant current regulator is judged on what it takes in, what it delivers and how steady the output current stays. Enter the readings from the power analyser and the output test, set the limits from your specification, and this tool works out the rest, including heat released into the CCR room and the current deviation at each load point and brightness step.

CCR & Input Readings

Rated size

Nameplate rating, kW treated as kVA.

Input supply

Input voltage (V)

Line-to-line for a three-phase supply.

Input current (A)

Input real power (kW)

From the power analyser or wattmeter.

Output Readings

Output voltage (V)

Across the load or the series circuit.

Output current (A)

Load power factor

1.00 for a resistive load bank. For a real circuit, use the measured value.

Rated output current (A)

Reference for the regulation checks.

Acceptance Limits from your specification

Minimum efficiency (%)

Placeholder. Use the specification or data sheet figure.

Minimum input power factor

Placeholder. Use the specification or data sheet figure.

Output current tolerance (± A)

Placeholder, in amperes. FAA AC 150/5345-10 (edition F onward) allows ±0.1 A on a 6.6 A CCR and ±0.3 A on a 20 A CCR; confirm in the edition named in your specification. Applies to the load points and the steps below.

Load Regulation optional

Measured output current at different loads on the CCR. Clear a row to leave it out.

Load (% of rated)	Output current (A)	Deviation	Result
		—	—
		—	—
		—	—
		—	—

Brightness-Step Currents optional

CCR class and steps

Choosing a set loads its nominal currents, the rated output current and the usual tolerance (±0.1 A for 6.6 A, ±0.3 A for 20 A). Edit them afterwards if your specification differs.

Step	Nominal	Deviation	Result
B1	2.8 A	—	—
B2	3.4 A	—	—
B3	4.1 A	—	—
B4	5.2 A	—	—
B5	6.6 A	—	—

Report Details

Project / Test Site (for report)

CCR Tag / Serial (for report)

Acceptance Summary

Check	Measured	Limit	Result

Calculator #51 | Rev. 1.1 | 23 Oct 2026

Engineering reference tool. Acceptance shall be judged against the project specification and the CCR manufacturer's test procedure.

Method & Reference

How the test readings are worked up

Every step is shown so the result can be checked by hand.

1. Input side

Apparent power comes from voltage and current, with a √3 factor on a three-phase supply. The power factor is real power over apparent power.

S_in = V × I (×√3) ÷ 1000 PF_in = P_in ÷ S_in

2. Output side

S_out = V_out × I_out ÷ 1000 P_out = S_out × PF_load

3. Efficiency and loss

η = P_out ÷ P_in Loss = P_in − P_out

The loss all becomes heat in the CCR room. One kilowatt is about 3,412 BTU per hour, which is useful when sizing cooling.

4. Regulation and steps

Each measured current is compared with its nominal value. Pass or fail uses the tolerance in amperes, since the limit is an absolute current rather than a percentage. The spread is the gap between the highest and lowest load-point current, as a percentage of the rated current.

Deviation = (I_meas − I_nom) ÷ I_nom × 100

Worked example

Item	Value
230 V × 45 A, single-phase	10.35 kVA
Input power 9.85 kW	PF 0.952
1,400 V × 6.6 A, PF 1.00	9.24 kW
Efficiency 9.24 ÷ 9.85	93.8 %
Loss	0.61 kW
Heat at 3,412 BTU per kW	2,081 BTU/h
Loading on 10 kW CCR	92.4 %
Currents 6.59 to 6.62 A	0.45 % spread

What this tool does not do

It does not measure harmonics, ripple or waveform shape, and it assumes the readings are true RMS. The limits are placeholders until you enter your specification values, and a CCR's rated size, step currents and test conditions come from its data sheet and the applicable standard.

CCR Performance / Efficiency Calculator: Frequently Asked Questions

Quick answers on how the calculator works up CCR test readings for FAT and SAT.

What does the CCR Performance / Efficiency Calculator do?

It works up test readings from a constant current regulator for factory and site acceptance testing. From the input and output readings it calculates input and output kVA, power factor, efficiency, total loss, loading and load impedance. It also checks load regulation and brightness-step currents against limits you enter, and it produces a PDF test report.

How are CCR efficiency and loss calculated?

Output real power is output kVA times the load power factor, and efficiency is output real power divided by input real power. Loss is input real power minus output real power. The result depends on meter accuracy, waveform distortion and the load type, so record the instrument class with the test.

How is input power factor worked out?

Input apparent power is voltage times current divided by 1,000, multiplied by the square root of 3 on a three-phase supply. Power factor is the input real power from your power analyser or wattmeter divided by that apparent power. For a three-phase supply, enter the line-to-line voltage.

How does the load regulation and step current check work?

Each measured current is compared with its nominal value, and the result passes or fails against a tolerance in amperes, because the limit is an absolute current and not a percentage. FAA AC 150/5345-10 (edition F onward) allows plus or minus 0.1 A on a 6.6 A CCR and plus or minus 0.3 A on a 20 A CCR. Confirm this in the edition named in your specification. The regulation spread is the gap between the highest and lowest load-point current as a percentage of rated current.

Are the acceptance limits built in?

No. Minimum efficiency, minimum input power factor and output current tolerance are placeholders until you enter the figures from your specification or the CCR data sheet. Selecting a CCR class and step set loads the nominal step currents and the usual tolerance, which you can edit if your specification differs.

Can you give a worked example?

A 10 kW CCR fed at 230 V and 45 A single-phase draws 10.35 kVA and 9.85 kW, a power factor of 0.952. With 1,400 V at 6.6 A and a power factor of 1.00, the output is 9.24 kW. That gives an efficiency of 93.8 percent, a loss of 0.61 kW, which is about 2,081 BTU per hour of heat into the room at 3,412 BTU per kW, and a loading of 92.4 percent.

What does the calculator not cover?

It does not measure harmonics, ripple or waveform shape, and it assumes the readings are true RMS. A CCR's rated size, step currents and test conditions come from its data sheet and the applicable standard. The nameplate rating in kW is treated as kVA.

Can I use the result as the final acceptance decision?

No. It is an engineering reference tool. Acceptance shall be judged against the project specification and the CCR manufacturer's test procedure. The acceptance summary and PDF report record the checks and the limits you entered, so those limits must come from your own documents.

Important Notice, Disclaimer & Limitation of Liability

Please read before relying on any content on this page or on any result or record produced by it.

Specific to this page: Applies to the CCR Performance / Efficiency Calculator (calculator), including its PDF reports.

Calculated results. Results, tables, charts, status indicators (such as “OK”, “within limit” or “pass”/“fail”), recommended or selected values and the example presets on this page are first-pass planning and training estimates calculated in your browser from the values you enter, using simplified formulas, generic tables and typical values. They do not take account of every factor of a real installation, may contain errors or rounding differences, and are not a design, specification, selection, sizing, procurement or acceptance decision. A competent person must check them against the approved design, the manufacturer’s data and the applicable standard before any use. “Recommended” means an indicative estimate, not an endorsement of any rating, product or supplier.

Electrical values. Voltage, current, resistance, impedance, power, power factor, voltage drop, loss, load, capacity and efficiency figures depend on cable data, temperature, connector and transformer losses, CCR type, tolerances and other site conditions that a simplified calculation cannot fully capture. Default and example values are typical only. Do not rely on a result to load, energise, re-rate, tap or modify any circuit, CCR, cable or transformer.

Reports, downloads and printouts. PDF reports, CSV files and printed pages produced by this tool are uncontrolled working records generated in your browser. They are not approved designs, drawings, controlled documents, certificates, permits or regulatory records. Calculator numbers, revision labels, dates, project names, signature or approval fields on them are layout only and carry no authority unless made under your own approved document-control system. You must not present an output as an approved, verified or certified document. If you enter personal or confidential information, you are responsible for handling any exported file lawfully, including under the Digital Personal Data Protection Act, 2023.

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