113

Determination of Leakage Inductances of Three-

Winding Transformer for HF-PSA Resonant Circuit

Jevgeni klovski, Kuno Janson, Helar Niilo
Tallinn University of Technology
jevgeni@staff.ttu.ee, kuno.janson@ttu.ee, helar.niilo@ttu.ee


Abstract- This paper presents a practical way to determine
leakage inductances of the windings in inverter transformer of
the HFPSA (High Frequency Parallel/Series Resonance
Alternating) converter individually for each winding based on
the results of specially developed test and tuning procedure.
I. INTRODUCTION
Growing number of resonant-type power sources for
DC/DC applications has put some specific requirements on
inverter transformers used to match the mains voltage to load
level and provide galvanic isolation for safety reasons.
Often these transformers are not only to provide needed
voltage matching, but to build up a part of resonant circuit
with their leakage inductances [8]. Thus, it is desirable to
estimate transformer leakage inductance level yet on early
design stages [2], and, if possible, to design a transformer
having leakage inductances to replace completely or partially
inductors of resonant circuits.
This can decrease not only the number of elements in unit,
but also could reduce its size and weight. There are two main
methods to estimate leakage inductance of the transformer:
the analytical calculations, that is relatively simple and
approximate method, and computer simulation (usually by
FEM software), that could be relatively accurate, but time
consuming way. Missing the value of the leakage inductance
could not only change the resonant tank behavior, but impose
some stresses on power semiconductors. Generally, it will be
a good practice to test new transformer for its parameters
estimated before, while leakage inductance has to be defined
for each winding separately. There are some practical
approaches, based on measurement and calculation, to
determine individual leakages for two-winding transformers
[9] and some in case of multi-winding transformer [11].
This paper describes the method developed for testing
inverter transformer used to supply PSA resonant circuit and
tuning this circuit at the same time.

II. TRANSFORMER IN THE PSA CONVERTER
The main property of PSA resonant converters the
presence of one or more inductive and capacitive branches
(Fig.1), which can form parallel or series resonant circuits
depending on load condition and due to the natural
commutation of diodes V1 V6 in the output rectifier. More
information about given circuit specialties in case of mains
power supply can be found in [12, 13] and for the inverter-
type power supply in [14].
W1
W2 W3
m
I
C
U
d
U
v
I
L2
I
L1
L1 L2
a
b
c
C
V1 V4
V6
V2
V3
V5
T

Fig. 1. A simple PSA resonant circuit with three-winding transformer.
As it seen in Fig.1 the transformer of simple PSA converter
is a three-winding one having two secondary windings
connected in series. Depending on load, there are up to six
different circuit topologies available in resonant tank with one
or two secondary windings involved. So, it is highly desirable
to know the value of individual leakage inductance for each
winding.
For relatively high-frequencies (40-100 kHz) and high-
current (100-200 A) power conversions the PSA converter is
to be equipped with resonant inductors (L1 L3) up to some
H and consequently, leakage inductance of the transformer
must be considered as exactly as possible.
In general, the properly calculated resonant circuit in PSA
converter prevents overload of inverter switches and
transformer at any conditions from no-load to short-circuit.


Fig. 2. Power circuit of inverter-type PSA converter.


114

III. TESTING AND TUNING PROCEDURE
A. Transformer Analysis Ways
Multi-winding transformers are widely used in power
electronics and the leakage inductance becomes more and
more crucial issue in view of increasing operation
frequencies. Mostly, there is a trend of decreasing leakage
inductance to reduce stresses on switches. However, there is a
class of so called load-resonant converters, which can utilize
leakage for resonant mode operation. So, it is desirable to
know these leakages, at least approximately, before prototype
is built and develop corresponding model of transformer.
There are different approaches for analytical study of the
leakage inductances in transformer.
The leakage depends mostly on geometry and placement of
the windings. When the windings are distributed non-
uniformly with large insulation spacing or with significantly
different winding heights the conventional formulas for the
leakage inductance do not provide accurate results because of
the highly non-uniform flux distribution [5].
The analytical approach is based on study of field
distribution near winding and equivalent circuit drawing
representing the real transformers to more or less extent.
As one method the ladder model with energy (axial and
radial components) storage calculation method are suggested
in [5].
Another method is a full-order model (extended cantilever
form) that could provide even more accurate result [4, 6].
Additionally, in the case of changing circuit topology of
transformer windings the mutual leakage inductances can
vary that should be also considered [7].
Testing the transformer for its equivalent parameters
identification is also a common practice, where along with
well-known No-Load and Short-Circuit Tests [10] the Series-
Coupling Tests have been adopted [1, 3].
However, these methods are mostly to define total leakages
reflected in the primary winding, while in many designs the
value of individual leakage inductance for each winding is
necessary. So, modeling of transformer with FEM software
could be a good alternative here.
B. Transformer Test and Circuit Turning
One of the goals during development of converter circuit
was to achieve a minimal possible increase of load current in
case of transition from rated load to short-circuit condition. It
was found that willing to reduce short-circuit current it is
necessary to have close to zero current in secondary winding
W2. Such a condition is possible if voltage drop on inductor
L2 is equal to voltage across winding W2 (Fig.2.). In this case
voltage between terminals A and B is about zero and there is
almost no current appear in winding W2.
As the circuit contains real capacitor, inductors and
transformer that are non-ideal so to achieve a zero current in
W2 it is needed to correct parameters of the circuit or tune
circuit. In the given case changing the inductance value of L2
is used. It was easily made by changing height of the winding,
The circuit shown in Fig.3 describes the tuning setup. The
primary winding of transformer has a 40 kHz power supply
realized by sinusoidal voltage generator. Input terminals in
rectifier bridge A, B, C are short-circuited and one of the
switches (S1 or S2) is opened.
First step is tuning, while S2 was closed and S1 opened the
voltmeter V7 shows voltage between A and B. By changing
the inductance of L2 the indication of V7 was observed to
have it as small as possible. In that way the resonant circuit
was tuned up to desirable condition.

Fig. 3. Test and tuning circuit of converter.
Second test is to control circuit parameters for rated
conditions when S2 was opened and S1 closed with keeping
output short-circuited. The measurement of all voltages and
currents was accomplished in this case to determine values of
inductances and capacitance in circuit.
C. Test Results
The results of measurement are given in Table I. It also
contains calculated values of inductance and capacitance for
reactive elements. Table II shows the values of calculated
leakage inductances.
The phasor diagram below (Fig. 4.) shows voltages on
elements and windings at first and second steps that gives a
good overview of circuit properties. So, for the first step it is
seen that difference between U
2
and U
4
must be as small as
possible that yields in smaller U
7
, which in its turn hints to
smaller short-circuit current.


(a) (b)
Fig. 4. Phasors of resonant circuit at tuning and control, a) switch S1 is OFF
and S2 is ON, b) switch S1 is ON and S2 is OFF.
Measurements in both steps are to provide us with data
needed for determination of elements values in resonant
circuit. Knowing the voltage and current in element its
impedance could be found easily with Ohms law. As the test
was conducted with relatively low supply voltage and current
and windings have relatively large effective cross-section area
(11 mm2 for W1 and 48 mm2 for W2 and W3) the own
resistance of windings and inductors was neglected in the
calculations.
U6
U
4
U7
U2
U3
U5
U6
U2
U3
U5
115

For a tuning test inductance value of inductor L2 was
changed by stretching it to achieve minimal possible U
7

value.
Calculation of leakage inductance is a bit different. Based
on the transformer design symmetry, there is an assumption
that leakage inductances of secondary windings are equal. In
the first test with disconnected W2 we can see the voltage on
this winding that is equal to induced EMF (E). Knowing the
turns ratio 11:1:1 of transformer, the EMF of primary
winding W1 and other secondary W3 can be also derived:

2
1
2
1
E
E
N
N
=

,
(1)
2 2
2
1
1
11 E E
N
N
E = =
,
(2)

2 3
E E = .
(3)
Having the E value for each winding one can compare it
with value of measured voltage. The voltage difference
indicated here in Table II as U
XS
in our suggestion is the
voltage drop on leakage inductance of the corresponding
winding:

E U U
xs
= .
(4)
This way the leakage inductances for each winding were
determined in both tests and shown in Table below.


D. Test Setup Description
The transformer has a shell-type core made of two
0P49928EC E100 ferrites. The windings are made two
concentric layers placed on center leg. The first layer is a 11-
turn primary winding and second layer is a two 1-turn
windings connected in series. Windings are made of Litz-
wire.
W1 - primary 11 turns
W2 - 1 turn
W3 - 1 turn

Fig. 5. Tested transformer core and windings.
The measurement devices were used: Digital Scope
Tektronix DPS200 and AC/DC current clamps Tektronix
i30s, Hameg HZ56-2. The PeakTech DDS Function
Generator 4040 as a signal source with signal amplifier build
on TDA7294V was adopted here as a high-frequency power
source.

TABLE I
MEASUREMENT RESULTS AND CALCULATED VALUES OF ELEMENTS
Test U1,V I1,A U2,V U3,V U4,V (L2) U5,V (L3) U6,V (C) U7,V I2,A U8,V
I
n
i
t
i
a
l
Measured 4,94 0,48 0,4 0,91 0,97 0,48 2,56 0,69 5,57 1,47
Calculated, Ohm - - - - 0,17 0,086 0,46 - - -
Calculated, H / F - - - - 0,69 0,34 8,70 - - -
T
u
n
e
d

Measured 6,55 0,39 0,53 0,97 0,52 0,37 2,1 0,07 4,5 -
Calculated, Ohm - - - - 0,12 0,082 0,47 - -
Calculated, H / F - - - - 0,46 0,33 8,50 - -
S
e
r
i
e
s

c
i
r
c
u
i
t

(
S
1
-
o
n
,

S
2
-
o
f
f
)

Measured 2,9 0,5 0,47 0,47 - 0,28 1,3 - 2,77 -
Calculated, Ohm - - - - - 0,10 0,47 - - -
Calculated, H / F - - - - - 0,40 8,50 - - -
TABLE II
DETERMINATION OF INDIVIDUAL LEAKAGE INDUCTANCES FROM TEST RESULTS
Test w1 w2 w3
O
n
l
y

W
3

U E UXS U E UXS U E UXS
Voltage and EMF (V) 6,55 5.83 0.72 0,53 0,53 - 0,97 0,53 0,44
Current (A) 0,39 - 4,5
Lea-
kage
reactance () 1,85 - 0,097
inductance (H) 7,3 - 0,39
W
2

&

W
3


(
S
1
-
o
n
,

S
2
-
o
f
f
)

Voltage and EMF (V) 2,9 1,98 0,92 0,47 0,18 0,29 0,47 0,18 0,29
Current (A) 0,5 2,77 2,77
Lea-
kage
reactance () 1,85 0,10 0,10
inductance (H) 7,3 0,41 0,41
.
116

IV. ANALYSIS
The currents and voltages measured during test on
transformer windings and reactive elements make possible to
calculate and verify values of corresponding elements. For
example it could be seen that value of capacitance C lays in
the range of specified parameters, as calculated capacitance
yields in 8.5 8.7 F, while installed capacitors has 9 F
10%. In the case of tuned resonant circuit it was determined
that L2=460 nH and L3=330 nH.
The leakage inductance of secondary windings is
determined by voltage measured on transformer terminals,
defined EMF and current measured in windings. Based on
this data, the calculated value of one-turn secondary winding
yields to about 400 nH in both test

V. CONCLUSIONS
In this paper, the simple method for tuning resonant circuit
and determining individual leakage inductances is presented.
Complicated calculations are avoided and only a simple
measurement procedure is needed that has a twofold effect:
firstly, the PSA resonant circuit could be tuned for optimal
operation and, secondly, the individual leakage inductances
can be defined for steady state operation. This could be
helpful in further tests and analysis of resonant circuit.

ACKNOWLEDGMENTS
This paper was supported by European Social Funds
Doctoral Studies and Internationalisation Programme DoRa.
Authors thank Estonian Archimedes Foundation (Inter-
disciplinary project Optimal energy conversion and control
in Smart and Microgrids within the framework of Doctoral
School of Energy and Geotechnology-II) for support of this
study.















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