Electrical Workshop Practice-II Prepared by Yirga Amaha

CHAPTER - I

DESIGN AND REWINDING OF LOW POWER SINGLE PHASE

TRANSFORMER

1.1. Introduction
 A transformer is a static electromagnetic device that changes AC electric power from one
voltage level to AC electric power at another voltage level through the action of a
magnetic field.
• Transformer consists of two or more coils of wire wrapped around a common
ferromagnetic core. These coils are (usually) not directly connected.
• The only connection between the coils is the common magnetic flux present
within the
 One of the transformer windings connected to the power source is called the primary
winding or input winding, and the winding connected to the loads is called the secondary
winding or output winding.

 The most important tasks performed by transformers are:

• Changing voltage and current levels in electrical power systems
• Matching source and load impedances for maximum power transfer in electronic
and control circuit and
• Electrical isolation (isolating one circuit from another )
 Therefore, Ac electric power can be generated at one central location, its voltage stepped
up for transmission over long distances at very low losses, and its voltage stepped down
again for final use.
1.2. Types of Transformer
 The transformer is extremely important as a component in many different types of
electric circuits, so we can classify transformers based on their construction, applications
and winding voltage and current ratings.
1.2.1. Based on Their Construction
 The two major types of construction of transformers (used in transmission and
distribution of electrical energy) are core type and shell type.
 Core Type Transformer

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 The magnetic core of the transformer is made up of laminations to form a rectangular

frame. The laminations are cut in the form of L-shape strips shown in the figure below.
For avoiding the high reluctance at the joints where laminations are butted against each
other, the alternate layer is stacked differently to eliminate continues joints.

 For simplicity, the primary and secondary winding is located on the separate limbs of the
core.

 The insulation layer is provided between the core and lower winding and between the
primary and the secondary winding. For reducing the insulation, the low winding is
always placed near to the core. The winding is cylindrical, and the lamination is inserted
later on it.
 Shall Type Transformer
 The laminations are cut in the form of a long strip of E’s, and I’s as shown in the figure
below. To reduce the high reluctance at the joints where the lamination are butted against
each other, the alternate layers are stacked differently to eliminate continuous joint.

 The shell type transformer has three limbs or legs. The central limb carries the whole of
the flux, and the side limb carries the half of the flux. Hence the width of the central limb
is about to double to that of the outer limbs.

 The primary and secondary both the windings are placed on the central limbs. The low
voltage winding is placed near the core, and the high voltage winding is placed outside
the low voltage winding to reducing the cost of insulation placed between the core and
the low voltage winding.
 The cross sectional area of the central limb is twice that of each side limbs.

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COMPARISON OF CORE & SHELL TYPE TRANSFORMERS

1.2.2. Based on Their Applications

 Transformers can be classified as distribution transformers and power transformers.
 Power Transformers
 Power transformers are used in transmission network of higher voltages for step-up and
step down application (400 kV, 200 kV, 110 kV, 66 kV, 33kV) and are generally rated
above 200MVA.
 Power transformer is used for the transmission purpose at heavy load, high voltage
greater than 33 KV & 100% efficiency. It also having a big in size as compare to
distribution transformer, it used in generating station and Transmission substation .high
insulation level.
 Distribution Transformers
 Distribution transformers: are used for lower voltage distribution networks as a means to
end user connectivity. (11kV, 6.6 kV, 3.3 kV, 440V, 230V) and are generally rated less
than 200 MVA.
 The distribution transformer is used for the distribution of electrical energy at low voltage
as less than 33KV in industrial purpose and 440v-220v in domestic purpose. It work at
low efficiency at 50-70%, small size, easy in installation, having low magnetic losses & it
is not always fully loaded.
 Instrumentation Transformer
 The electrical instruments are not directly connected to the meters or control apparatus of
high voltage for safety purpose. The instrument transformers like voltage transformer and
current transformer are used for connecting the electrical instruments to the measuring
instruments.
 These transformers reduce the voltage and current from high value to the low value which
can be measured by conventional instruments.
o Current Transformer (CT)
o Voltage Transformer (VT)
1.3. Core Characteristics
 A transformer core requires a low loss, high quality material for good performance. Items
affecting the core performance include: core loss, permeability, insulation coating,
thickness and physical characteristics.
 The composition of a transformer core depends on such factors as voltage, current, and
frequency.
 Commonly used core materials are air, soft iron, and steel. Each of these materials is
suitable for particular applications and unsuitable for others.
 Generally,

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o Air-core transformers are used when the voltage source has a high frequency
(above 20 kHz).
o Iron-core transformers are usually used when voltage the source frequency is low
(below 20 kHz).
o A soft-iron-core transformer is very useful where the transformer must be
physically small, yet efficient.
 Each transformer core material has its own cost/power consumption ratio = $/kW which
will influence the material selection.
 The lower this $/kW value is, the greater the material value will be in a transformer.
 The iron-core transformer provides better power transfer than does the air-core
transformer. A transformer whose core is constructed of laminated sheets of steel
dissipates heat readily; thus it provides for the efficient transfer of power.
 The majority of transformers contain laminated-steel cores. These steel laminations are
insulated with a non-conducting material, such as varnish, and then formed into a core.

 The purpose of the laminations is to reduce certain transformer losses.

1.4. Transformer Losses

Core Loss: when a magnetic flux flows in a transformers steel core, two types of losses occur
in the steel. One termed “eddy current losses” and the other termed “hysteresis losses”.
 Hysteresis Losses: are caused because of the friction of the molecules against the
flow of the magnetic lines of force required to magnetise the core, which are
constantly changing in value and direction first in one direction and then the other due
to the influence of the sinusoidal supply voltage.
 This molecular friction causes heat to be developed which represents an
energy loss to the transformer.
 Excessive heat loss can overtime shorten the life of the insulating materials
used in the manufacture of the windings and structures. Therefore, cooling of a
transformer is important.
 Transformers are designed to operate at a particular supply frequency.
Lowering the frequency of the supply will result in increased hysteresis and
higher temperature in the iron core.
 Eddy Current Losses: are caused by the flow of circulating currents induced into the
steel caused by the flow of the magnetic flux around the core.
 The eddy currents induced by a solid iron core is large.

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 Eddy currents do not contribute anything towards the usefulness of the

transformer but instead they oppose the flow of the induced current by acting
like a negative force generating resistive heating and power loss within the
core.

 Eddy current losses within a transformer core cannot be eliminated

completely, but they can be greatly reduced and controlled by reducing the
thickness of the steel core.
 Instead of having one big solid iron core as the magnetic core material of the
transformer or coil, the magnetic path is split up into many thin pressed steel
shapes called “laminations”.
 These laminations are insulated from each other by a coat of varnish or paper
to increase the effective resistivity of the core thereby increasing the overall
resistance to limit the flow of the eddy currents.
Copper Losses: are mainly due to the electrical resistance of the primary and secondary
windings.
 Most transformer coils are made from copper wire which has resistance in
Ohms, (Ω). This resistance opposes the magnetising currents flowing through
them.
 When a load is connected to the transformers secondary winding, large electrical
currents flow in both the primary and the secondary windings, electrical energy
and power (or the I2 R) losses occur as heat.
 Generally copper losses vary with the load current, being almost zero at no-load,
and at a maximum at full-load when current flow is at maximum.
1.5. Transformer Core Materials
 Amorphous Steel, Solid Iron Core, Amorphous Metals, Ferrite Ceramics
,Laminated Magnetic Cores, Carbonyl Iron Cores, Silicon Steel

1.6. TRANSFORMER DESIGN COMPUTATION

I. Output equation of single phase transformer
 The equation which relates the rated kVA output of a transformer to the area of core
and window is called output equation.
 In transformers the output kVA depends on flux density and ampere-turns.
 The flux density is related to core area and the ampere-turns is related to window area.
 The low voltage winding is placed nearer to the core in order to reduce the insulation
requirement.
 The space inside the core is called window and it is the space available for
accommodating the primary and secondary winding.
 The window area is shared between the winding and their insulations.

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 The induced Electromotive Force (EMF) in a transformer,

𝑬 = 𝟒. 𝟒𝟒𝒇ɸ𝒎 𝑵 𝒗𝒐𝒍𝒕𝒔
 Electromotive Force (EMF) per turn,
𝑬
𝑬𝒕 = = 𝟒. 𝟒𝟒𝒇ɸ𝒎 𝑽𝒐𝒍𝒕𝒔
𝑵
 The window in single phase transformer contains one primary and one secondary
winding.
 The window space factor Kw is the ratio of conductor area in window to total area of
window.
𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟 𝑎𝑟𝑒𝑎 𝑖𝑛 𝑤𝑖𝑛𝑑𝑜𝑤
𝑲𝑾 =
𝑇𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑤𝑖𝑛𝑑𝑜𝑤

𝐴𝐶
𝑲𝑾 =
𝐴𝑊
Where:
KW = Window Space Factor
AC = Conductor Area in Window
AW = Total Area of Window

 Conductor area in window,

𝑨𝑪 = 𝑲𝑾 𝑨𝑾
 The current density is same in both the windings. Therefore Current density,
𝑰𝑷 𝑰𝑺
𝜹= =
𝒂𝒑 𝒂𝒔
 Area of cross - section of primary conductor,
𝑰𝒑
𝒂𝒑 =
𝜹
 Area of cross - section of secondary conductor,
𝑰𝒔
𝒂𝒔 =
𝜹
 If we neglect magnetizing MMF then primary ampere turns is equal to secondary
ampere turns. Therefore ampere turns,
𝑨𝑻 = 𝑰𝒑 𝑵𝒑 = 𝑰𝒔 𝑵𝒔
 Total copper area in window,

AC = Copper area of primary winding + Copper area of secondary winding

= (Number of primary turns x area of cross-section of primary conductor) +
(Number of secondary turns x area of cross - section of secondary conductor)
𝑰𝒑 𝑰𝒔
𝑨𝑪 = 𝑵𝒑 𝒂𝒑 + 𝑵𝒔 𝒂𝒔 = 𝑵𝒑 𝜹
+ 𝑵𝒔 𝜹

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Therefore:
𝑰𝒑 𝑰𝒔
𝑎𝑝 = 𝒂𝒏𝒅 𝒂𝒔 =
𝜹 𝜹

𝟏
𝑨𝑪 = (𝑵𝒑 𝑰𝒑 + 𝑵𝒔 𝑰𝒔 )
𝜹

𝟏
= (𝑨𝑻 + 𝑨𝑻 )
𝜹

𝟐𝑨𝑻
𝐴𝑐 =
𝜹
 By equating the above equations, we get,
𝟐𝑨𝑻
𝑲𝑾 𝑨𝑾 =
𝜹
· Therefore Ampere turns,

𝟏
𝑨𝑻 = 𝑲𝑾 𝑨𝑾 𝜹
𝟐

 The KVA rating of single phase transformer is given by,

𝑺 = 𝑽𝒑 𝑰𝒑 𝒙𝟏𝟎−𝟑 = 𝑬𝒑 𝑰𝒑 𝒙𝟏𝟎−𝟑 By neglecting the voltage drop

𝑬𝒑
= 𝑵𝒑 𝑰𝒑 𝒙𝟏𝟎−𝟑
𝑵𝒑

𝑬𝒑
= 𝑬𝒕 𝑨𝑻 𝒙𝟏𝟎−𝟑 𝒘𝒉𝒆𝒓𝒆 𝑬𝒕 = 𝒂𝒏𝒅 𝑨𝑻 = 𝑵𝒑 𝑰𝒑
𝑵𝒑
 By substituting for Et and AT from equations we get,

𝑲𝑾 𝑨𝑾 𝜹 𝒙 𝟏𝟎−𝟑
𝑺 = 𝟒. 𝟒𝟒𝒇𝚽𝒎 ɸ𝒎
𝟐 𝑺𝒊𝒏𝒄𝒆 𝑩𝒎 =
𝑨𝒊
= 𝟐. 𝟐𝟐𝒇𝚽𝒎 𝑲𝑾 𝑨𝑾 𝜹 𝒙 𝟏𝟎−𝟑
Therefore:

𝑺 = 𝟐. 𝟐𝟐𝒇𝑩𝒎 𝑨𝒊 𝑲𝑾 𝑨𝑾 𝜹 𝒙 𝟏𝟎−𝟑

 The above equation is the output equation of single phase transformer.

II. VOLT PER TURN

 In the design of transformer for a given voltage it is necessary to calculate the number
of turns which can be calculated by knowing the voltage per turn ET as follows;
 Output rating S in kVA per phase is,
𝑆 = 𝐼𝑃 𝑥 𝑉𝑃 𝑥 10−3

𝑆 = 𝐸𝑇 𝑥 𝑁𝑃 𝑥 𝐼𝑃 𝑥 10−3

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Let’s substitute ET = 4.44 x f x ɸm in S,

 Therefore the equation is;

𝑆 = 4.44 𝑥 𝑓 𝑥 ɸ𝑚 𝑥 𝑁𝑃 𝑥 𝐼𝑃 𝑥 10−3
= 4.44 𝑥 𝑓 𝑥 ɸ𝑚 𝑥 𝐴𝑇 𝑥 10−3
 And by taking the magnetization characteristics of transformer core as liner, the flux
ɸm varies linearly as AT. ɸ𝑚
= 𝑟 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡
𝐴𝑇

ɸ𝑚
𝐴𝑇 =
𝑟

ɸ𝑚
𝑆 = 4.44 𝑥 𝑓 𝑥 ɸ𝑚 𝑥 𝑥 10−3
𝑟
𝑆𝑥𝑟
= ɸ2𝑚
(4.44 𝑥 𝑓 𝑥 10−3 )

(𝑆 𝑥 𝑟 𝑥 103 )
ɸ𝑚 = √
4.44 𝑥 𝑓

𝐸𝑡 = 4.44 𝑥 𝑓 𝑥 ɸ𝑚

𝑆 𝑥 𝑟 𝑥 103
𝐸𝑡 = 4.44 𝑥 𝑓 𝑥 √
4.44 𝑥 𝑓
𝐸𝑡 = √4.44 𝑥 𝑓 𝑥 𝑆 𝑥 𝑟 𝑥 103

𝐸𝑡 = √(4.44 𝑥 𝑓 𝑥 𝑟 𝑥 103 ) 𝑥 √𝑆

 By substituting constant k for √4.44 𝑥 𝑓 𝑥 𝑟 𝑥 103

𝐸𝑡 = 𝑘 √𝑆
 The value of constant k depends upon the type of transformer, its construction service
conditions. For some of the common used transformers it is given as follows;
Type K
Single Phase core type 0.75 to 0.85
Single Phase shell type 1.00 to 1.20
Three Phase core type 0.45

 Empirical formula used for window space factor (Kw) when the voltage is given in kV
8
Up to 50 kVA rating 𝐾𝑤 = 30+𝑘𝑉

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10
50 to 200 kVA rating 𝐾𝑤 = 30+𝑘𝑉
12
200 to 1000 kVA rating 𝐾𝑤 = 30+𝑘𝑉

Example 1: Design of Core type Transformer

Determine the dimension of core and yoke for a 1.1 kVA, 220/70 V, 50 Hz single phase core
type transformer. A square core is used with distance between adjacent limbs equal to 2.6
times the width of core laminations. Assume voltage per turn is 0.79 Vt, maximum flux
density is 0.9Wb/m2, current density δ = 3A/mm2 and stacking factor 0.8.
Computation:
So to calculate voltage per turn for the above example when k is 0.75.
1. Electromotive Force (EMF) per turn

𝐸𝑇 = 𝑘 √𝑆

𝐸𝑇 = 0.75 √1.1

= 0.79 𝑉𝑜𝑙𝑡𝑠
2. Size of the core

a) Core Area (Ai)

𝐸𝑡
𝐴𝑖 =
4.44 𝑥 𝑓 𝑥 𝐵𝑚
0.79
=
4.44 𝑥 50 𝑥 0.9

= 0.00395 𝑚2

= 39.5 𝑐𝑚2

b) Gross core area (AFe)

𝐴𝑖
𝐴𝐹𝑒 =
𝐾𝐹𝑒

0.00395 𝑚2
𝐴𝐹𝑒 = = 0.00494 𝑚2 = 49.4 𝑐𝑚2
c) Dimension of Center limb 0.8

As the core is square let us find the dimensions of the cross-section of the core
assuming that it will be inserted in to a circular coil.

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AFe is maximum when θ = 450

45𝑥0 𝐷𝑥 𝐷
𝐴𝐹𝑒 = 𝐷 cos 𝜃 𝜃 450
sinsin

𝐷2
=
2

𝐷 = √(2 𝑥 𝐴𝐹𝑒 )

= √(2 𝑥 49.4 𝑐𝑚2 )

= 9.94 𝑐𝑚
𝐷
𝐷 cos 450 = 𝑋 =
√2

𝑋 = 𝑦of=the
3. Window 7.03 𝑐𝑚 (𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑠𝑡𝑎𝑚𝑝𝑖𝑛𝑔)
Transformer

𝑆 = 2.22 𝑥 𝑓 𝑥 𝐵𝑚 𝑥 𝐴𝑖 𝑥 𝐾𝑊 𝑥 𝐴𝑊 𝑥 𝛿 𝑥 10−3

1.1 = 2.22 𝑥 50 𝑥 0.9 𝑥 3 𝑥 10 6 𝑥 0.265 𝑥 0.00395 𝑥 𝐴𝑊 𝑥 10−3

𝐴𝑊 = 0.0035 𝑚2

𝐴𝑊 = 35 𝑐𝑚2

𝐴𝑊 = 𝐻𝑊 𝑥 𝑊𝑊

Distance between core limbs = 2.6 x X

CORE LIMB

CORE LIMB

WW

𝐷 = 2.6 𝑥 𝑋 = 2.6 𝑥 7.03 = 18.28 𝑐𝑚

𝑊𝑊 = 𝐷 − 𝑋 = 18.28 − 7.03 = 11.25 𝑐𝑚

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𝐴𝑊 35
𝐴𝑊 = 𝐻𝑊 𝑥 𝑊𝑊 ; 𝐻𝑊 = = = 3.11 𝑐𝑚
𝑊𝑊 11.25
Depth of yoke Dy = Height of yoke Hy = X = 7.03 cm
3. Dimension of the Transformer
a) Overall height of the transformer

𝐻 = 2ℎ𝑦 + 𝐻𝑊 = 2 𝑥 7.03 + 3.11 = 17.17 𝑐𝑚

b) Overall width of the transformer

𝑊 = 2 𝑥 𝑋 + 𝑊𝑊

= 2 𝑥 7.03 + 11.25 = 25.31 𝑐𝑚

c) Mean length of L type stamping

𝑌𝑜𝑘𝑒 = 𝑋 + 𝑊𝑊 = 7.03 + 11.25 = 18.28 𝑐𝑚 = 182.8 𝑚𝑚

𝐶𝑜𝑟𝑒 = 𝑋 + 𝐻𝑊 = 7.03 + 3.11 = 10.14 𝑐𝑚 = 101.4 𝑚𝑚

4. Number of Stampings
Let us assume that the sheet metal we have is 0.5mm thick and we want to prepare
stampings from this metal for our transformer core. We want also to varnish the two
sides of the stamping before assembling and the thickness of the varnish as well
insulation is 0.1 mm. Totally the thickness of each stamping is 0.6mm. The total
number of the stampings is therefore calculated as.

𝑐𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑟𝑒

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑡𝑎𝑚𝑝𝑖𝑛𝑔𝑠 =
𝑐𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑖𝑛𝑔𝑙𝑒 𝑠𝑡𝑎𝑚𝑝𝑖𝑛𝑔

𝐴𝐹𝑒
𝑁𝑆𝑇 =
𝐴𝑆𝑇
70.3 𝑥 70.3
= = 117
0.6 𝑥 70.3

5. Computation of the copper wire in the window

a) Copper area in the window (ACU)

𝐴𝐶𝑈 = 𝐾𝑊 𝑥 𝐴𝑊

= 0.265 𝑥 0.0035 𝑚2

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= 0.0009275 𝑚2

b) Total copper area in the window

2 𝐴𝑇
𝐴𝐶𝑈 =
𝛿
2 𝐼𝑃 𝑥 𝑁𝑃
=
𝛿
𝛿
𝐴𝐶𝑈 𝑥 = 𝐼𝑃 𝑥 𝑁𝑃
2

3
927.5 𝑚𝑚2 𝑥 = 1391.25 𝐴𝑇 = 𝐼𝑃 𝑥 𝑁𝑃
2

𝑆 = 1100 𝑉𝐴 = 𝐼𝑃 𝑥 𝑉𝑃

1100 𝑉𝐴
𝐼𝑃 =
𝑉𝑃
1100 𝑉𝐴
= = 5𝐴
220 𝑉
6. Size of copper conductor in primary and secondary

a) Determine the number of turns in primary winding

1391.25 𝐴𝑇
𝑁𝑃 =
𝐼𝑃
1391.25 𝐴𝑇
𝑁𝑝 = = 279 𝑡𝑢𝑟𝑛𝑠
5𝐴

b) Size of copper in primary

𝐼𝑃
𝑎𝑃 =
𝛿

5
= 𝑚𝑚2 = 1.67 𝑚𝑚2
3

c) Determine the number of turns in secondary winding.

𝛿
𝐴𝐶𝑈 𝑥 = 𝐴𝑇 = 𝐼𝑆 𝑥 𝑁𝑆
2

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𝐴𝑇
𝑁𝑆 =
𝐼𝑆

1391.25 𝐴𝑇
=
𝐼𝑆
Now to calculate the secondary current IS, we will assume the secondary
voltage is 70 volts. Therefore we get the equation:

𝑆 = 𝐼𝑆 𝑥 𝑉𝑆 = 1100 𝑉𝐴

1100 𝑉𝐴
𝐼𝑆 =
𝑉𝑆
1100 𝑉𝐴
= = 15.714 𝐴
70 𝑉

So the number of turns in the secondary winding,

1391.25 𝐴𝑇
𝑁𝑆 =
𝐼𝑆
1391.25 𝐴𝑇
= = 89 𝑡𝑢𝑟𝑛𝑠
15.714 𝐴

d) Size of wire in the secondary

𝐼𝑆 15.714𝐴
𝑎𝑆 = = = 5.24 𝑚𝑚2
𝛿 𝛿

Example 2 – Design computation of Shell Type Transformer

Calculate the main dimension and winding details of a single phase transformer if the given
requirements are as follows; Power 11kVA, 220/50 volts, line frequency is 50 HZ, constant
for EMF per turn k is unity, flux density in core is 1.1 Wb/m2, window factor KW is 0.29 and
stacking factor kFe is 0.9.
Solution:
Given:
Power (S) = 11kVA
Frequency (f) = 50 HZ
EMF per turn = unity
Flux Density = 1.1 Wb/m2
Window factor (KW) = 0.29
Stacking factor (KFe) = 0.9

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Assume and 𝑐𝑜𝑟𝑒 𝑑𝑒𝑝𝑡ℎ

𝑤𝑖𝑛𝑑𝑜𝑤 ℎ𝑒𝑖𝑔ℎ𝑡
=3 = 2.5
𝑤𝑖𝑛𝑑𝑜𝑤 𝑤𝑖𝑑𝑡ℎ 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑐𝑒𝑛𝑡𝑟𝑎𝑙 𝑙𝑖𝑚𝑏
1. EMF per turn

𝐸𝑇 = 𝑘 √𝑆
= 1√11
= 3.32 𝑣𝑜𝑙𝑡𝑠

2. Core computation

a) Core area (Ai)

𝐸𝑇 3.32 𝑣𝑜𝑙𝑡𝑠
𝐴𝑖 = =
(4.44 𝑥 𝑓 𝑥 𝐵𝑚 ) 4.44 𝑥 50 𝐻𝑍 𝑥 1.1

= 0.0136 𝑚2 = 136 𝑐𝑚2

b) Gross iron core area of central limb.

𝐴𝑖
𝐴𝐹𝑒 =
𝐾𝐹𝑒

136 𝑐𝑚2
=
0.9
= 151.2 𝑐𝑚2

a HW WW a
2a

c) Core depth (b)/width of central limb (2a) = 2.5

𝑏
= 2.5
2𝑎
𝑏 = 2.5 𝑥 2𝑎 = 5𝑎

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d) Gross central limb cross-sectional area (AFe = b x 2a)

= 5a x 2a
= 10a2
Therefore;
AFe = 10a2

𝐴𝐹𝑒 𝐴𝐹𝑒 151.2

= 𝑎2 𝑎= √ = √
10 10 10

𝑎 = √15.12 = 3.89 𝑐𝑚

Width of central limb 2a = 2 x 3.89 = 7.78 cm

Core depth b = 2.5 x 2a = 2.5 x 7.78 = 19.45 cm

3. Yoke computation

The yoke carries half of the flux coming out of the central limb. Assume the same
flux density in yoke and core, the yoke area will be half that of core area. Therefore
the gross core area of the yoke.

151.2 𝑐𝑚2
𝐴𝑌 =
2
= 75.6 𝑐𝑚2
Depth of the yoke 𝐷𝑌 = 𝑏 = 19.45 𝑐𝑚
Height of the yoke 𝐴𝑌 75.6
𝐻𝑌 = = = 3.89 𝑐𝑚 = 𝑎
𝐷𝑌 19.45
4. Window computation
The side limbs carry half of the flux as in the central limb. Therefore the width of the
side limb will be half of the width of central limb as; a = 3.89 cm.
The output equation for a single phase transformer is,

𝑆 = 2.22 𝑥 𝑓 𝑥 𝐵𝑚 𝑥 𝐾𝑊 𝑥 𝛿 𝑥 𝐴𝑖 𝑥 𝐴𝑊 𝑥 10−3
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11 = 2.22 𝑥 50 𝑥 1.1 𝑥 0.265 𝑥 2 𝑥 106 𝑥 0.0136 𝑥 𝐴𝑊 𝑥 10−3

11
𝐴𝑊 =
2.22 𝑥 50 𝑥 1.1 𝑥 0.265 𝑥 2 𝑥 13.6

= 0.0125 𝑚2
= 125 𝑐𝑚2
Given:

𝑊𝑖𝑛𝑑𝑜𝑤 𝐻𝑒𝑖𝑔ℎ𝑡
=3
𝑊𝑖𝑛𝑑𝑜𝑤 𝑊𝑖𝑑𝑡ℎ

𝐻𝑊 = 3𝑊𝑊

𝐴𝑊 = 𝐻𝑊 𝑥 𝑊𝑊

= 3 𝑊𝑊 𝑥 𝑊𝑊
2
= 3 𝑊𝑊

𝐴𝑊
𝑊𝑊 = √( )
3

125
= √ = 6.46 𝑐𝑚
3

𝐻𝑊 = 3 𝑥 𝑊𝑊

= 3 𝑥 6.46

= 19.38 𝑐𝑚

5. Overall height of the transformer,

𝐻 = 𝐻𝑊 + 2𝑎
= 19.38 + 7.78 = 27.16 𝑐𝑚
𝑊 = 𝑎 + 𝑊𝑊 + 2𝑎 + 𝑊𝑊 + 𝑎

𝑊 = 4𝑎 + 2 𝑊𝑊

= 4 𝑥 3.89 + 2 𝑥 6.46

= 28.48 𝑐𝑚
6. Number of turns in Primary and secondary windings
Primary turns

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Electrical Workshop Practice-II Prepared by Yirga Amaha

𝐸𝑇 𝑥 𝑁𝑃 = 220 𝑣𝑜𝑙𝑡𝑠
220 𝑣𝑜𝑙𝑡𝑠
𝑁𝑃 =
3.32

= 67 𝑡𝑢𝑟𝑛𝑠
Secondary turns

𝐸𝑇 𝑥 𝑁𝑆 = 50 𝑣𝑜𝑙𝑡𝑠
50 𝑣𝑜𝑙𝑡𝑠
𝑁𝑆 =
𝐸𝑇
50 𝑣𝑜𝑙𝑡𝑠
=
3.32
= 16 𝑡𝑢𝑟𝑛𝑠

7. Size of wire in Primary winding

11000 𝑉𝐴
𝐼𝑃 = = 50 𝐴
220 𝑣𝑜𝑙𝑡𝑠

𝐼𝑝 50𝐴
𝑎𝑝 = = = 25 𝑚𝑚2
𝛿 2𝐴⁄
𝑚𝑚2

8. Size of wire in Secondary winding,

11000 𝑉𝐴
𝐼𝑆 = = 220 𝐴
50 𝑣𝑜𝑙𝑡𝑠
𝐼𝑆 220𝐴
𝑎𝑆 = =
𝛿 2𝐴⁄
𝑚𝑚2

𝑎𝑆 = 110𝑚𝑚2

9. Number of Stampings
Let us assume that the sheet metal we have is 0.5mm thick and we want to prepare
stampings from this metal for our transformer core. We want also to varnish the two
sides of the stamping before assembling and the thickness of the varnish as well
insulation is 0.1 mm. Totally the thickness of each stamping is 0.6mm. The total
number of the stampings is therefore calculated as.

𝑐𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑟𝑒

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑡𝑎𝑚𝑝𝑖𝑛𝑔𝑠 =
𝑐𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑖𝑛𝑔𝑙𝑒 𝑠𝑡𝑎𝑚𝑝𝑖𝑛𝑔

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𝐴𝐹𝑒 151.2 𝑐𝑚2

𝑁𝑆𝑇 = = = 324 𝑠𝑡𝑎𝑚𝑝𝑖𝑛𝑔𝑠
𝐴𝑆𝑇 7.78 𝑐𝑚∗ 0.06 𝑐𝑚

NOTE:
If the design is a welding transformer, limit the voltage per turn ET below 1 volt and
use capacitors as power correction. The rating would be multiples of 20uF per kVA.
The low voltage rating per turn is because the transformer is continues duty machine
with frequent short circuits and self-air cool.

1.7. REWINDING of TRANSFORMER

1.7.1.Rewinding of shell type transformer core dimension is given
In designing and computing for data required in transformer rewinding, one method that
can be used involves the following steps with given core material.
Given Data:
1. Primary Voltage (Vin) : 220 AC volt prepared
2. Secondary Voltage: 24 volt
3. Core Dimension
Width : 2 inches
Thickness : 2 inches
Design Computation
1) Find the Core Area in square inches:
𝐴𝑐 = 𝑤 𝑥 𝑡

𝐴𝐶 = 2 𝑖𝑛𝑐ℎ𝑒𝑠 𝑥 2 𝑖𝑛𝑐ℎ𝑒𝑠

𝐴𝐶 = 4 𝑖𝑛2

Where w: is the width of the central leg of the E-type core.

t: is the thickness of the central leg
Ac: is the area of the core in square inch.

2) Compute the number of Volt per Turns (𝐸𝑡 = 𝑉⁄𝑁)

𝐴𝑐
𝐸𝑡 = 𝑉⁄𝑇 =
𝐾

Note:
 Voltage per turn for both primary side and secondary side of the transformer is
the same.
𝐸1 𝐸
𝐸𝑡 = ⁄𝑁 = 2⁄𝑁 = 4.44 ∗ 𝑓 ∗ ∅𝑚
1 2

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 K is constant value, 7.5 if the line frequency is 60 HZ, 9 if the line frequency is
50 HZ and 12 if the line frequency is 25Hz.
𝐴𝑐
𝐸𝑡 = 𝑉⁄𝑇 =
𝐾
𝐴𝑐 4
𝐸𝑡 = 𝑉⁄𝑁 = = = 0.4444
𝐾 9

3) Find the total number of Primary Turns

𝑃𝑟𝑖𝑚𝑎𝑟𝑦 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 (𝐸𝑝) 220
𝑁𝑃 = =
𝐸𝑡 0.4444

𝑁𝑃 = 495 𝑇𝑢𝑟𝑛𝑠

4) Find the total number of Secondary Turns

𝑆𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 (𝐸𝑠) 24

𝑁𝑠 = =
𝐸𝑡 0.4444

𝑁𝑆 = 54 𝑡𝑢𝑟𝑛𝑠

5) Determine the type of winding to be employed, induction-type or auto type.

6) Determine the wattage of the core, if not given, by allowing 25 watts for every inch 2
of the core area. So power of The Transformer is

𝑊 = 25 𝑥 𝐴𝑐

𝑊 = 25 𝑥 4

𝑊 = 100 𝑤𝑎𝑡𝑡𝑠

Where W: is the total wattage of the transformer

25: the constant taken to output rating
Ac: is the core area of the central leg of the core.

7) Find the primary current

𝑊𝑎𝑡𝑡𝑠 (𝑊)
𝐼𝑃 =
𝑃𝑟𝑖𝑚𝑎𝑟𝑦 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 (𝐸𝑝)
100 𝑤𝑎𝑡𝑡𝑠
𝐼𝑃 =
220𝑉

𝐼𝑃 = 0.4546 𝐴

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8) Find the secondary Current

𝑊𝑎𝑡𝑡𝑠 (𝑊)
𝐼𝑆 =
𝑆𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 (𝐸𝑠)

100 𝑤𝑎𝑡𝑡𝑠
𝐼𝑃 =
24𝑉

𝐼𝑃 = 4.167 𝐴

9) Find the size of wire to be used in the transformer primary (cross sectional area in
circular mils of c.m.):

𝑃𝑟𝑖𝑚𝑎𝑟𝑦 𝑆𝑖𝑧𝑒 𝑜𝑓 𝑤𝑖𝑟𝑒 = 𝐼𝑃 𝑥 1000 𝑐. 𝑚.

𝑃𝑟𝑖𝑚𝑎𝑟𝑦 𝑆𝑖𝑧𝑒 𝑜𝑓 𝑤𝑖𝑟𝑒 = 0.4546 𝐴 𝑥 1000 𝑐. 𝑚.

𝑃𝑟𝑖𝑚𝑎𝑟𝑦 𝑆𝑖𝑧𝑒 𝑜𝑓 𝑤𝑖𝑟𝑒 = 454.6 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑟 𝑚𝑖𝑙𝑙𝑠

From table
The size of wire in AWG is approximately 24 and the size of wire in mm2 is 0.205.

10) Fine the size of wire to be used in the secondary (cross sectional area in circular mils
of c.m.):
𝑆𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝑆𝑖𝑧𝑒 𝑜𝑓 𝑤𝑖𝑟𝑒 = 𝐼𝑆 𝑥 1000 𝑐. 𝑚.

𝑆𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝑆𝑖𝑧𝑒 𝑜𝑓 𝑤𝑖𝑟𝑒 = 4.167 𝐴 𝑥 1000 𝑐. 𝑚.

𝑆𝑒𝑐𝑜𝑛𝑑𝑎𝑟𝑦 𝑆𝑖𝑧𝑒 𝑜𝑓 𝑤𝑖𝑟𝑒 = 4167 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑟 𝑚𝑖𝑙𝑙𝑠

From table
The size of wire in AWG is approximately 14 and the size of wire in mm2 is 2.08.

Where:
 1000 c.m. is constant for circular mil area of wire that will allow one ampere of flow.
Then see wire table to determine the size of wire in AWG.
 Is: is the current in the secondary
 Ip: is the current in primary

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Conversion table: AWG to mm2

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