Research on Application of 36-Pulse Phase-Shifting Transformer to High-Voltage Frequency Converter

Jianchao Zhang, Wei Xu, Jun Wang

Research on Application of 36-Pulse Phase-Shifting Transformer to

High-Voltage Frequency Converter
1

1,

Jianchao Zhang, 2Wei Xu, 3Jun Wang

Engineering Training Center, Shijiazhuang Tiedao University, zhang.jianchao@yahoo.cn
*2,Corresponding Author
University of Macau, Jerryxw@live.com
3,
School of Mechanical Engineering, Shijiazhuang Tiedao University

Abstract
The power cell series multi-level high-voltage frequency converter is one of present electric power
electron area research hot spots. This paper selected the power unit tandem type structure to realize
the high-pressured frequency conversion, one of its biggest superiority was the input end uses the
phase-shifting transformer to realize inputs the multi-densification, thus served the input output
overtone small purpose. This paper also studies phase-shifting transformer's phase shifting principle
emphatically, and designs 36 pulse wave phase-shifting transformer's related parameter, will provide
the theory and the computation basis for the present phase-shifting transformer's design. Therefore,
this paper provided the important reference and the instruction for next high pressure frequency
changer's engineering design.

Keywords: Phase-Shifting Transformer, High-Voltage Frequency Converter, Power Unit, Harmonic

1. Introduction
AC variable frequency speed regulation technology is a main means of power saving and technical
process improvement so as to improve the quality of products nowadays. Variable frequency speed
regulation is generally recognized as the most promising speed regulation way due to its numerous
advantages such as good speed regulation and startup performances, high efficiency, high power factor
and power saving effect and wide scope of application.
Manjrekar et al.[1] investigate a hybrid multilevel power conversion system typically suitable for
high-performance high-power applications. In addition, performance of a multilevel current-regulated
delta modulator as applied to the single-phase full-bridge IGBT rectifier is discussed. A new topology
for a hybrid multilevel inverter is presented,[2] which significantly increases the level number of the
output waveform and thereby dramatically reduces the low-order harmonics and total harmonic
distortion. Rodriguez et al.[3]present a switching strategy for multilevel cascade inverters, based on the
space-vector theory. This new control method is an attractive alternative to the classic multilevel
pulsewidth modulation techniques. An improved carrier-based SVPWM scheme, which is fully
suitable for cascaded multilevel inverter topologies are introduced.[4] Zhong and Tolbert[5] present a
programmed PWM method to eliminate specific higher order harmonics of multilevel converters. Zhou
and Wang[7] analyze the relationship between space-vector modulation and three-phase carrier-based
pulse width modulation(PWM). Furthermore, the implementations of both space-vector modulation
and carrier-based PWM in a closed-loop feedback converter are discussed. Variable frequency speed
regulation technology has been widely used in low-voltage AC motor transmission field. Due to
various reasons, inverter hasn't been widely used in high-voltage motor. Using high-voltage inverter,
high-voltage motor can realize stepless speed regulation and meet the requirement of production
process for speed control of motor. The application of high-voltage inverter has important meanings for
improving the output and quality of products, saving energy drastically and reducing the production
cost.
As a resource-saving product, high-voltage inverter has integrated power technology, transmission
technology, mechatronics technology and communication internet technology. In particular, by
adopting multiplicity technology, high-voltage inverter has realized significant decrease of input and
output harmonic contents. It will certainly meet the requirement of human beings for product and
environmental protection in the 21st century. With the constant development of power electronic
technologies, constant improvement of products, deepening of the concept and expansion of the market,
it will show a great technical development prospect and market demand.

International Journal of Digital Content Technology and its Applications(JDCTA)

Volume7,Number5,March 2013
doi:10.4156/jdcta.vol7.issue5.144

1238

Research on Application of 36-Pulse Phase-Shifting Transformer to High-Voltage Frequency Converter

Jianchao Zhang, Wei Xu, Jun Wang

2. Application of phase-shifting transformer in high-voltage inverter

One of the major advantages of high-voltage inverter (Fig.1 shows its structure) adopting power unit
tandem-type multilevel technology is the use of phase-shifting transformer to realize the input of
multiplicity technology so as to decrease input harmonic. Phase-shifting transformer has the following
three functions:
1. Realize phase deviation of line voltages on the primary side and secondary side so as to eliminate
harmonic;
2. Obtain the required line voltage on the secondary side through transformation;
3. Realize electric isolation between rectifier and power grid.
What follows is the research on phase shift principles of phase-shifting transformer and the design
of 36-pulse phase-shifting transformer. The following assumptions are made for the purpose of clear
understanding:
1. The phase-shifting transformer is an ideal transformer without the influence of impedance and
leakage reactance etc.;
2. Power electronic devices such as diode are ideal devices without a switch time etc.;
3. DC side after rectification adopts LC filtering and the filter inductance L is large enough. The
direct current is a constant value.

Figure 1. Structure chart of high-voltage inverter

1239

Research on Application of 36-Pulse Phase-Shifting Transformer to High-Voltage Frequency Converter

Jianchao Zhang, Wei Xu, Jun Wang

3. Phase shift technology of extended delta of phase-shifting transformer

According to different connection modes of winding, phase-shifting transformer can be classified
into extended and non-extended transformers, i.e. the phase of winding line voltage on the secondary
side of transformer is one angle ahead or lagging than the winding line voltage on its primary side.

3.1. Extended phase-shifting transformer

Fig.2 shows the winding connection diagram and phasor diagram of extended phase-shifting
transformer respectively. The winding on its primary side is star connection, with the number of turns
of each winding as N1; each winding on the secondary side is composed of two coils, with the number
of turns respectively as N2 and N3. According to the analysis of phasor diagram, the phase-shifting
angle of extended phase-shifting transformer has the following relation:

V ab V AB

(1)

Where, VAB and Vab respectively refer to phasors of line voltages V AB and Vab on the primary
side and secondary side.
V CZ

N1 X
Y

x N2
vP
y

N3
vQ

V cz

V ax

a
VP

V AX

120

c V BY

V AB

V by

30

V ab

30
30

120 V Q

V AB

30

Figure 2. Extended Extended phase-shifting transformer

The side voltage on the primary side V AB is used as the reference voltage and the phase-shifting
angle by which V ab is ahead of V AB is positive. To calculate the turns ratio of the transformer,
the following can be obtained from the triangle composed of V Q, V
diagram:
VQ

sin 30

by

and V

ab

and in the phasor

Vby

sin 30

(2)

Where, 0 30; VQ is the effective voltage value of N3 coil; Vby is the effective voltage value
between b and y. For a three-phase symmetrical system, voltages Vby and Vax have the same value.
Equation (2) can be rewritten as:
VQ
Vax

sin 30

sin 30

(3)

The winding factor k on the secondary side can be obtained from the equation above:

1240

Research on Application of 36-Pulse Phase-Shifting Transformer to High-Voltage Frequency Converter

Jianchao Zhang, Wei Xu, Jun Wang

VQ sin 30
N3

N 2 N 3 Vax sin 30

(4)

Similarly, the following can be inferred from the phasor diagram

V by
Vab

sin 120
sin(30 )

That is Vax Vby

2
3

(5)

sin(30 )Vab , The turns ratio of transformer is

V
N1
AX
N2 N3
V ax

(6)

The following can be obtained by substituting equation (6) with equation Vax ,
n

V AB
N1
1

N 2 N 3 2 sin(30 ) Vab

(7)

Where, V AB 3V AX
Both extremes can be verified. Assuming that N2=0, the winding on the secondary side in Fig.2
turns into star connection. Thus voltages on the secondary side and primary side have the same phase,
i.e. =0; if N3=0, the winding on the secondary side turns into triangular connection. At this time,

=30. Therefore, the phase-shifting angle of extended phase-shifting transformer is within

0~30.

3.2. Non-extended phase-shifting transformer

Fig.3 shows the winding connection diagram and phasor diagram of non-extended phase-shifting
transformer respectively, where the winding on the primary side is star connection and the winding
connection order of triangle on the secondary side is opposite to that of extended phase-shifting
transformer. It can thus be seen that V ab lags behind V AB and is therefore negative.
Similar to the analysis of extended phase-shifting transformer, the winding factor k and turns ratio n
on the secondary side can be obtained as follows.
k

sin( 30 )
N3

N 2 N 3 sin( 30 )

V AB
N1
1

N 2 N 3 2 sin(30 ) Vab

(8)

(9)

Where, 0 30 .

1241

Research on Application of 36-Pulse Phase-Shifting Transformer to High-Voltage Frequency Converter

Jianchao Zhang, Wei Xu, Jun Wang

V cz
V CZ

N1 X

Y
Z

x N2
vP
y

N3
vQ

V AB

V AX
120

V AB

VP
V by
30 120

V BY

30

V ax

30

V ab

VQ

Figure 3. Non-extended phase-shifting transformer

Table 1. Turns ratio of extended and non-extended phase-shifting transformers
Phase-shifting angle
k
n
Application
Extended
Non-extended
0

1.0

1.0 VAB Vab

12, 18 and 24-pulse rectifiers

15

-15

0.366

0.707 VAB Vab

24-pulse rectifier

20

-20

0.227

0.653 VAB Vab

18-pulse rectifier

30

-30

0.577 VAB Vab

12 and 24-pulse rectifiers

Table 1 shows typical values of phase-shifting angle and turns ratio of multi-pulse rectifier
when using phase-shifting transformer with the two kinds of connection above. For 12, 18 and 24-pulse
rectifiers, the voltage ratio VAB Vab is generally 2, 3 and 4 respectively.
The principle of extended and non-extended phase-shifting transformers has been described above
and what follows is specific design calculation of 36-pulse phase-shifting transformer.

3.3. Structural design of 36-pulse phase-shifting transformer

It is known from design requirements that the network voltage is 6KV 10%, the frequency is
50HZ and the output power of inverter is 370KW. Then, the computational formula of transformer
capacity is:

S TN PCN / cos CN

(10)

Where: STN refers to the transformer capacity and PCN refers to the output power of transformer.

cos CN refers to the input power factor of inverter and refers to the efficiency of inverter.
Where, the power factor of inverter is between 0.8 and 0.85 with input AC reactor. Therefore,
cos CN =0.85, =0.9 and PCN =370KW. Then,

S TN PCN / cos CN 370 / 0.85 / 0.9 483.7 KVA

What's move, the reference value of transformer capacity recommended by the inverter
manufacturer is often 130% of the inverter capacity based on experience. That is, the capacity of
phase-shifting transformer is 630KVA.
The computational formula of phase-shifting angle of two adjacent windings is:

60 / N

(11)

Where, is the phase-shifting angle of two adjacent windings; N is the number of power
units in series

1242

Research on Application of 36-Pulse Phase-Shifting Transformer to High-Voltage Frequency Converter

Jianchao Zhang, Wei Xu, Jun Wang

This design adopts the program of 6 power units in series. Therefore, the phase-shifting angle of two
adjacent windings in phase-shifting transformer is:

60 / N 60 / 6 10

(12)

Therefore, the phase-shifting angle of input transformer is:+25+15+5-5-15-25.

The winding on the primary side is put on the inner side close to the iron core and that on the
secondary side is put on the most external side. Heat resisting and insulating cable is used between the
winding on the secondary side and phase-shifting winding to connect into an extended delta.
A rectangular winding structure is adopted on the primary side, in which an air passage for heat
dissipation is installed in the middle of multiple layers. It is winded with core limb by copper wire
wrapped by Nomex paper with turn insulation resisting 220C.
The winding on the secondary side is divided into 18 independent small windings. The capacity of
each small winding is 1/18 of the rated transformer capacity. Each phase winding is divided into three
major groups on average and each major group is designed into 6 small windings. The phase-shifting
angle of each winding is realized through different modes of external connection, i.e. extended delta, as
shown in Fig.2 and Fig.3.
The phase-shifting angle between adjacent windings is 10 and the sort order of phase-shifting
angles of small windings is:
The phase-shifting angle of No.1, No.7 and No.13 windings is -25;
The phase-shifting angle of No.2, No.8 and No.14 windings is -15;
The phase-shifting angle of No.3, No.9 and No.15 windings is -5;
The phase-shifting angle of No.4, No.10 and No.16 windings is +5;
The phase-shifting angle of No.5, No.11 and No.17 windings is +15;
The phase-shifting angle of No.6, No.12 and No.18 windings is +25;
No.1 to No.6 are in one group; No.7 to No.12 are in one group and No.13 to No.18 are in one group.
H class insulation structure is used among sections and groups for section fixation and insulation. The
lead of each section is drawn forth with copper bar and secondary winding is winded on primary
winding without any additional die, making primary and secondary windings an entirety.

4. Electromagnetic design of 36-pulse phase-shifting transformer

4.1. Selection of number of turns of winding
The relational expression of winding factor and turns ratio of 36-pulse phase-shifting transformer is
obtained from the analysis of equations (6), (7), (8) and (9). According to the design requirements, the
primary side of transformer is Y connection; the input line voltage is 6000V; 18 windings on the
secondary side is divided into 6 major groups and the phase difference of each group is 10. Table 2
shows relevant parameters.
1. Calculation of the number of turns on the primary side
The rated capacity of phase-shifting transformer P=630KVA; input rated voltage U1 =6000V;
voltage of each turn of phase-shifting transformer e t =10V. Therefore, the number of turns in star
connection on the primary side is:

W1 U1 et 600turns

2. Calculation of the number of turns on the secondary side

The number of turns of winding on the secondary side is analyzed as follows, taking extended
phase-shifting transformer for example.

Table 2. The relevant parameters of 6 groups of phase shift in phase-shifting transformer

Phase-shifting
Basic
Phase difference of
winding
Turns ratio
Winding
winding
primary and
Connection mode
factor
n
factor k
factor (1-k)
secondary voltages
Kn
n

1243

Research on Application of 36-Pulse Phase-Shifting Transformer to High-Voltage Frequency Converter

Jianchao Zhang, Wei Xu, Jun Wang

25

Extended

0.1698

0.1064

0.1420

0.0278

15

Extended

0.1296

0.3660

0.0822

0.0474

Extended

0.1052

0.7368

0.0277

0.0775

-5

Non-extended

0.1052

0.7368

0.0277

0.0775

-15

Non-extended

0.1296

0.3660

0.0822

0.0474

-25

Non-extended

0.1698

0.1064

0.1420

0.0278

12
0

Figure 4. Extended + phase-shifting connection diagram

In Fig.4, the number of turns of winding in the extended section of phase-shifting transformer:

Wextended=AZ=BX=CY
The number of turns of winding in the basic section of phase-shifting transformer:

Wbasic=ZX=XY=YZ
Moreover, AC=AB=BC=U2/ e t ; CZ=CY+YZ=AZ+ZX= Wextended + Wbasic. In ACZ, the following
can be obtained according to the sine rule:

AZ AC sin a sin120 Wextended (U 2 et )

CZ AC sin(60 a) sin120 (Wbasic Wextended ) (U 2 et )

The following can thus be obtained,

Wextended sin a sin120

U2
et

Wbasic [sin(60 a) sin a ] sin120

U2
et

(13)

Where, U2 refers to the line voltage on valve side and e t refers to the voltage of each turn of
phase-shifting transformer.
The number of turns in triangular connection on the secondary side can be obtained by substituting
equation (13) with the input rated voltage U2=550V and the voltage of each turn of phase-shifting
transformer e t =10V, as shown in table 3.

4.1. Determination of winding current

1Current on primary side
Rated capacity of phase-shifting transformer P=630KVA and input rated voltage U1 =6000V.
Therefore, the phase current in star connection on the primary side is:

1244

Research on Application of 36-Pulse Phase-Shifting Transformer to High-Voltage Frequency Converter

Jianchao Zhang, Wei Xu, Jun Wang

I 1 P / 3U 1 630 10 3 /( 3 6000 ) 61 A
Table 3. The number of turns in triangular connection on the secondary side of 36-pulse phase-shifting
transformer (unit: turn)

+25
+15
+5
-5
-15
-25

Wbasic

10

29

47

47

29

10

Wextended

27

16

16

27

2Current on secondary side

Each small winding on the secondary side is divided into basic winding and phase-shifting winding.
The capacity of a single small winding is 1/18 of the rated capacity of transformer. Therefore, the rated
current I 2 of phase-shifting winding is: I 2 P / 1 8 3U 2
Where, the rated capacity of phase-shifting transformer is P=630KVA and the rated output voltage
U 2 =550V.
I 2 P / 18 3U 2 630 10 3 / 18 3 550 36.7 A

The current relationship between basic winding and phase-shifting winding on the secondary side is
analyzed thereinafter. The following can be obtained at node Z according to the node current law:

I AZ I ZX I YZ

30

Figure 5. Current phasor diagram at node Z

The following can be obtained from analysis of Fig.5:

1
I AZ I ZX cos30
2
As I extended I AZ I BX I CY ; I basic I ZX I XY IYZ , therefore
I extended 3I basic

(14)

Magnetic potential balance equation: I extended Wextended I basicWbasic I1W1

Substitute it with equation (15):
The following can be obtained:

3I basicWextended I basicWbasic I1W1

I basic I1W1 ( 3Wextended Wbasic )

(15)

Where, I extended refers to the current in the extended section of winding on valve side; I basic refers to
the current in the basic section of winding on valve side; I1 refers to the phase current of winding on
grid side; W1 refers to the number of turns of winding on grid side. The current of basic winding and
phase-shifting winding can be obtained based on equations (14) and (15) and the number of turns of

1245

Research on Application of 36-Pulse Phase-Shifting Transformer to High-Voltage Frequency Converter

Jianchao Zhang, Wei Xu, Jun Wang

winding calculated above, as shown in table 4.

Table 4. Current value on secondary side of 36-pulse phase-shifting transformer (unit: A)

+25
+15
+5
-5
-15
-25
Ibasic
20.6
20.7
20.4
20.4
20.7
20.6
Iextended
35.6
35.8
35.4
35.4
35.8
35.6

5. Conclusion
This paper first analyzes the principle of extended and non-extended phase-shifting transformers
and designs 36-pulse phase-shifting transformer, mainly including the capacity of phase-shifting
transformer, the calculation of phase-shifting angle, the design of phase-shifting transformer and
insulation design, and the calculation of the number of turns of winding, winding current,
phase-shifting voltage and short-circuit impedance of phase-shifting transformer, which provide basis
for the design of phase-shifting transformer in the future.

6. Acknowledgment
This research is supported by the Natural Science Foundation of Hebei Province, China
(E2011210038) and the Research Foundation of Education Bureau of Hebei Province, China
(Q2012113).

7. References
[1] M.D.Manjrekar,P.K.Steimer,T.A.Lipo. Hybrid multilevel power conversion system: a competitive
solution for high-power applications[J]. IEEE Trans. on Industry Applications,
2000,36(3):834-841.
[2] Y.S.Lai,F.S.Shyu. Topology for hybrid multilevel inverter[J].IEEE Proceedings-Electric Power
Applications, 2002,149(6):449-458.
[3] Jose Rodriguez,L.Moran,P.Correa,C.Silva. A vector control technique for medium voltage
multilevel inverters[J].IEEE Transactions on Industrial Electronics, 2002 ,49(4):882-888.
[4] D.W.Kang,Y.H.Lee,B.S.Suh,C.H.Choi,D.S.Hyun. An improved carrier-based SVPWM method
using leg voltage redundancies in generalized cascaded multilevel inverter topology[J]. IEEE
Transactions on Power Electronics, 2003,18(1):180-187.
[5] D.Zhong, L.M.Tolbert,J.N.Chiasson. Harmonic elimination for multilevel converter with
programmed PWM method[J].IEEE Conference Proceedings of IAS'2004,2004,2210-2215.
[6] JIANG You-hua,CAOYi-long, GONG You-min, A Novel Topology of Hybrid Multilevel In verter
with Minimum Number of Separated DC Sources[J]. Journal of Shanghai University(English
Edition), NO2,2004:199-202.
[7] Zhou K, Wang D. Relationship Between Space-vector Modulation and Three-phase Carrier-based
PWM A Comprehensive Analysis[J]. IEEE Trans on Industry Electronics, 2002.49(1):186-196.
[8] Wang F. Sine-triangle Versus Space-vector Modulation for Three-level PWM Voltage-source
Inverters[J]. IEEE Trans on Industry Applications,2002,38(2): 500-506.

1246