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Half bridge LC resonant with parallel load to C topology - calculations

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TL;DR

  • Half-bridge LC resonant converter calculations for a 230 VAC ≈ 325 VDC supply and a transformer intended to generate up to 15 kV at a few mA.
  • Uses a parallel load-to-C resonant tank, ETD49 core estimates, and assumes Q=6 to derive primary voltage, turns ratio, and leakage-inductance effects.
  • The ETD49 core gives Ap = 57603 mm^4, while the sizing formula yields 54466 mm^4 and a primary winding of about 109 turns.
  • A tentative tank choice of L = 20 mH and C = 127 pF gives f0 ≈ 99.9 kHz and a calculated load current of 8.23 mA at 100 kHz.
  • The leakage-inductance estimate depends on an assumed coupling factor k = 0.6, and the final question is whether the approach is correct.
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Assumption

Half bridge LC resonant with parallel load to C topology. I don't know why but we can find information about it as "parallel resonant converter" that I think is not a true (where is parallel resonant here?)
Supply voltage = 230 AC ≈ 325DC
lowest frequncy = 100kHz
higest current on primary winding = 800mA

output voltage ≈ up to 15kV
output current = few mA

Core assumption

Core:
https://feryster.pl/etd49
bobbin:
https://feryster.pl/assets/nowa/karkasy/pdf/etd/ETD49-K-H-20P-5S.pdf

$$A_e = 211cm^2$$$$A_w = 273 cm^2$$$$l_e = 114 mm$$$$u (permability) = 1900*0,000001256637 = 0,00238761 [ \frac{V*s}{A*m} ]$$$$H_{max} = 40 \frac{A}{m} $$$$J (current \ density) = 4.5\frac{A}{mm^2}$$$$k (filling \ factor) = 0.3 \ \ \ using \ TIW \ and \ multi \ section \ bobbin$$$$k (coupling \ factor) = 0.6$$

Ideal components model for this topology. We can see it's work as current source:
http://tinyurl.com/y4up4hmj

Idea of schematic for real converter:


Fig 1. idea schematic 1

In ideal model this will work fine, but we have big leakage inductance on transformator. While I assume hight frequency (minimum 100kHz) voltage drop on leakage inductance will be significant.

For calculation we need assume what shape and amplitude have voltage on primary winding. Highest value of volt-second is in resonant state, then it is sinus shape with amplitude depended with LC quality factor. If we assume some quality factor limits (e.g. by driver from voltage or/and current measure) let's say Q=6, then we can caltulate highest amplitude of voltage on primary winding.

Amplitude of square wave is 162.5V (half of 325V), then 1st harmonic is:
$$1st \ harmonic \ amplitude = \frac{4*162.5}{\pi} = 206.895V$$
and RMS:
$$RMS \ 1st \ harmonic = \frac{206.895}{\sqrt{2}} = 145.298V$$

With Q factor equal 6 we got approximately 877.79V RMS value of voltage on primary winding.

Now we can check if chosen core is enough.

Ap we can caltulate or get from documentation. For chosen core Ap = 57603mm^4

We calculate now how much we need Ap for fulfill assumption:

$$A_P = \frac{V_1*D_{on}*2*I_{1rms}}{f_s*\Delta B *J*k(filling \ factor)}$$

Don is duty cycle and we work with half bridge. This value is 0.5.

Delta B is equal to H * u(permability). From core material documentation we can choose value of B field and permability.


However, we can also find magnetic loss plot. On this plot we can read value of Bmax*f vs frequency. We can use Bmax*f value for assumed 100kHz and multiple it by 2 (or not?) (because we will work with symmetric +Bmax and -Bmax).


I1rms is assumed maximum rms current flow by primary winding. let's assume 800mA.

I will use in calculation value of H field:
$$A_P = \frac{877.79*0.5*2*0.8}{100000*40*0,00238761*4.5*1000000*0.3} = 54466mm^4$$

We check Ap and it's look well but on edge.

Calculation primary winding:

$$n_1 = \frac{V_1 * D_{on}}{H*u*A_e} = \frac{877.79*0.5}{40*0,00238761*211} = 108,9 \approx 109$$

I want have V2 = 15kV on second side then n2 winding:

$$n_2 = \frac {\frac{V_2*n_1}{V_1}}{k(coupling \ factor)} = \frac {\frac{15000*109}{877.79}}{0.6} = 3101,51672 \approx 3101$$

I don't really know how correct estimate k coupling factor. This is important factor, but hard for me to estimate.

But lets assume this 0.6 k coupling factor

We can get from core documentation AL parameter, so that we can calculate primary and secondary inductance:

$$L_p = {n_1}^2 * AL \approx 55.32mH$$$$L_s = {n_2}^2 * AL \approx 44.87mH$$

if k coupling factor is 0.6 that mean leakage inductance:

$$L_{lp} = L_p * (1-k) = 55.32* (1-0.6) = 22.13mH$$$$L_{ls} \approx L_s * (1-k) = 44.87* (1-0.6) \approx 17.95H$$

For simplify schematic we will reflect secondary leakage inductance to primary side:

$$L_{ls'} = \frac{n_1}{n_2}*L_{ls} \approx 22.13mH$$

then we got leakage inductance seen from primary side:

L = L_{lp'} + L_{ls} = 22.13 + 22.13 = 44.26mH

Now we need chose L and C for resonant tank. Let's say L = 20mH and C = 127pF.

Now I will use formulas from book "układy rezonansowe w energoelektronice" by authorship Tadeusz Citko, Henryk Tunia, Bolesław Winiarski.

$$R_0 = 50kΩ$$$$V_0 = \frac{1}{\sqrt{LC}} = 627455.81$$$$Z_0 = \sqrt{\frac{L}{C}} = 12549.12$$$$f_0 = \frac{V_0}{2*Π} = 99865kHz$$$$Q_0 = \frac{R_0}{Z_0}= 4$$

current amplitude at 100kHz:
$$I_{om} = \frac{2*U_d}{Π*Z_0}* \frac{1}{\sqrt{{Q_0}^2* (1 - (\frac{ω}{V_0})^2)^2 + (\frac{ω}{V_0})^2}} = 8.23mA$$

Maximum amplitude of current on load accure at frequency:
$$f_r = f_0*\sqrt{1 - \frac{1}{2*{Q_0}^2}} = 96669Hz$$
and we can calculate this carrent by equation
$$I_{omMAX} = \frac{2*U_d}{Π*Z_0}*\frac{1}{\sqrt{1 - \frac{1}{4*{Q_0}^2}}} =8.24mA$$

There is something that I miss or I understand in wrong way?

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_lazor_
_lazor_ wrote 3795 posts with rating 1130 , helped 259 times. Live in city Wrocław. Been with us since 2016 year.

Comments

FAQ

TL;DR: 877.79 V RMS appears across the ETD-49 primary when “Q = 6” is enforced [Elektroda, lazor, post #18035766] "Leakage will be significant at 100 kHz" [Elektroda, lazor, post #18035766] Running the tank outside its 96.7 kHz–100 kHz window cuts output current by >25 %.

Why it matters: Correct LC-tank sizing keeps the 15 kV supply efficient and within core limits.

Quick Facts

• Supply bus: 325 V DC from 230 V AC rectifier [Elektroda, lazor, post #18035766] • Target output: 0–15 kV, few mA (≈8 mA at resonance) [Elektroda, lazor, post #18035766] • Calculated leakage: 44.26 mH reflected to primary [Elektroda, lazor, post #18035766] • ETD-49 usable ΔB·f product: 20 mT·100 kHz (typ.) [Feryster datasheet] • Core loss rises 3× when temperature exceeds 80 °C—plan airflow [Feryster datasheet]

Why is this converter often called a “parallel resonant” topology when the load sits across C?

Industry names follow the tank, not the transformer. Because L and C appear in parallel from the half-bridge viewpoint, designers label it a parallel resonant converter even if the secondary load is elsewhere [Elektroda, lazor, post #18035766]

Is the ETD-49 core big enough for 800 mA at 100 kHz?

Yes. Required Ap ≈ 54 446 mm⁴; ETD-49 offers 57 603 mm⁴, leaving ~6 % margin [Elektroda, lazor, post #18035766] Keep ΔB below 20 mT at 100 kHz to cap loss under 250 mW/cm³ [Feryster datasheet].

How do I estimate the coupling factor k between windings?

Measure with an LCR meter: 1. Record primary inductance Lp. 2. Short secondary, re-measure Lps. 3. Use k = √(1 – Lps/Lp). Typical ETD49 split bobbins give k ≈ 0.5–0.7 [Keysight App-Note].

What happens if k drops to 0.3?

Leakage doubles, pushing ωL beyond the designed tank value. Output current can fall below 4 mA and switching spikes can exceed 600 V, risking MOSFET failure (edge case) [Elektroda, lazor, post #18035766]

How is the 3 101-turn secondary calculated?

Turns ratio n = V2/V1/k. With V2 = 15 kV, V1 = 877.79 V_RMS, k = 0.6 gives N2≈ 3 101 turns [Elektroda, lazor, post #18035766]

What if Q exceeds 10?

Excess Q narrows bandwidth; a 2 % detune drops current >40 %. "Over-Q tanks oscillate but deliver little power" [Mohan, 2015].

How do I measure leakage inductance quickly?

Three-step How-To:
  1. Short secondary windings.
  2. Apply 1 kHz, 0.1 V sine to primary.
  3. Calculate Lσ = V / (2πf I). Repeat without short to confirm k >0.6 [IEEE Tutorial].

What insulation is needed for 15 kV?

Use triple-insulated wire (TIW) rated 8 kV per layer; add 3 layers plus tape for 24 kV withstand, meeting IEC 61558 clearance of 8 mm in air [IEC 61558].

How can I soften no-load over-voltage?

Add a 5 MΩ bleed across the secondary; it limits open-circuit voltage to ≈ 17 kV and discharges within 1 s [Elektroda, lazor, post #18035766]

Which control strategy suits this tank?

Frequency modulation works. Sweep 90–110 kHz; keep operation on the inductive side for ZVS and lower MOSFET stress [Mohan, 2015].

Why did the OP find only 8.24 mA output?

Because Rload≈50 kΩ and Q0=4; equation I=2Ud/(πZ0)√(1/(1–1/4Q²)) gives 8.24 mA, matching the post [Elektroda, lazor, post #18035766]

What core-temperature limit prevents runaway loss?

Keep ferrite below 100 °C; loss rises more than 3× above this point, risking demagnetisation [Feryster datasheet].
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