UNIVERSITY OF TECHNOLOGY JAMAICA

FACULTY OF EDUCATION & LIBERAL STUDIES

SCHOOL OF TECHICAL & VOCATIONAL EDUCATION
BACHELOR OF EDUCATION IN INDUSTRIAL TECHNOLOGY
ELECTRICAL MAJOR
NETWORK ANALYSIS 2:
LECTURER: MR. E. LEWIS
STUDENT: RYAN BONNER, 1203323

ACKNOWLEDGEMENT
Thanks to the following people in my life for the support and the strength; My mother,
Father, family, friends and classmates.

Figures used

Tables used

Abstract

The aim here is to build a Single-Phase Power Transformer. The transformer here must
step down an Alternating source of 110V to 26V and accommodate 555mA. Due to assumptions
the Transformer could only be stepped down to 30V. I was assisted by my colleagues as well as
Mr. Lewis and Mr. Samuels, and due to the different stages in the design process of the
transformer I put together some video documentation on a DVD that reads as a USB drive. I used
a machine to wind the primary and secondary wires around the transformer core. I used some
formulae to convert the reading of 60Hz to 50Hz to get a percentage of 80%. The other formulae
I used to get the amount of turns for primary and secondary winding had them be 664 and 160
respectively.

Objective: To design a 110V 50 cycle power transformer for a full wave rectifier and choke-input
filter, where, the d-c output voltage and current from the filter are to be 30 volts and 2 A
respectively.

Apparatus/Material: Watt metre, Ammeter, ohmmeter, 19 and 21 single enamel wire,

Compressed cardboard for bobbin, Hampden model H-MWS-1 motor winding station, Masking
tape, 2 x 4 lumber( for inside of bobbin), 4 nut and bolt, metal frame, metal stand, NI multisim
13.0

Introduction
I obtained the material needed to build the transformer from a friend that had an extra
with more laminas than I knew what to do with. The transformer had E and I Laminas that
were the essential part of the transformer. These parts were needed for the specific calculations
for the transformer so that it will be able to step down 110V to 30V and accommodate 2A. This
was a step by step process that included creating the bobbing, winding the transformer and
placing the Es and the Is on the transformer. There is evidence to show the steps were
documented on a DVD I put together..
The transformer is a static electromagnetic device, which transfers electrical energy from
one electrical circuit to another electrical circuit through the medium of magnetic field (magnetic
coupling) and without a change in the frequency. The two circuits are not connected electrically,
but coupled magnetically and electromagnetic energy conversion takes place. Since a
transformer has no moving part, it has maximum efficiency of all machines. Important
applications of a transformer are:

1. For changing voltage and current levels from one circuit to another.
2. For impedance matching of a source and its load for maximum power transfer in electronic
and control circuits.
3. For isolating DC while permitting flow of AC between two circuits or for isolation.. They are
used to step-up generator voltage to an appropriate voltage level for power transfer. Stepping
down the transmission voltage at various levels for distribution and power utilization.

In the case of this report, A shell type Single phase transformer was built. The coils are
form-wound (Interleaved). The different layers are insulated from each other by tape. The
complete winding consists of stacked layers with insulation space between the coilsthe spaces
forming horizontal cooling and insulating ducts. A shell-type transformer may have a simple
rectangular form

Transformer Theory
A basic transformer is an electrical device constructed of two coils of wire (windings)
magnetically coupled to each other so that there is a mutual inductance for the transfer of power
from one winding to the other (Floyd, 2007)

Basic Components of Transformers

The transformer is based on two principles: firstly, that an electric current can produce a
magnetic field (electromagnetism) and secondly that a changing magnetic field within a coil of
wire induces a voltage across the ends of the coil (electromagnetic induction). Changing the
current in the primary coil changes the magnitude of the applied magnetic field. The changing
magnetic flux extends to the secondary coil where a voltage is induced across its ends.
A transformer consists of two coils electrically separate but linked by a common magnetic
circuit of low reluctance formed by a laminated soft iron core. If one coil (the primary coil) is
connected to an AC supply, an alternating magnetic flux is set up in the iron core. This
alternating magnetic flux passes through the secondary coil and induces and alternating voltage
in the secondary coil. The magnitude of the secondary voltage is directly proportional to the ratio
of the number of turns in the secondary and primary windings and to the primary voltage.

Classification of transformers
1. According to construction
I. Core type transformers
II. Cell (Shell) type transformers

2. According to number of phases

i. Single-phase transformers
ii. Three Phase transformers (Polyphase transformers)

3. According to application
i. Power Transformer
ii. Instrument Transformer

Core Type & Cell Transformers

Transformers are manufactured in many types the most widely used in power systems are
classified with their core types as seen below. Core type where each of the windings are wound
on one leg of the core, while the shell core type, in which both windings are wound on the same

leg. Each type has its own advantages and disadvantages. Core type is very reliable and easy to
maintain, but take larger space, however, shell type is smaller but not reliable.

z
Fig. Core type transformer

Fig. Cell type transformer

The Ideal Transformer - The transformer works by electromagnetic induction. If a

sinusoidal ac voltage of is applied to a coil, then it will produce a magnetic field where the flux
will alternate at the same frequency as the voltage. Conversely if a coil is placed in an alternating
magnetic field then a voltage will be induced in the coil that will alternate at the same frequency
as the magnetic field. This is Faradays law of electromagnetic induction.

e = voltage induced in the coil

N = number of turns in the coil

= flux within the coil in Webbers (Wb)

= flux linkage = N(Wb)
t = time in seconds
If we now consider two coils that are closely coupled and we apply a
sinusoidal voltage to one of the coils where the voltage is defined as:
v = Vmax cos (t)Vv)
(Where: v = the instantaneous value of the voltage; Vmax = the peak value of
the voltage; = 2f)

The magnetic field produced by the first coil will induce a voltage in the
second coil. This is transformer action. To ensure that the coils are closely
coupled the coils should be wound on an iron core, which will provide a path
for the mutual flux linking the coils. To further improve the coupling the
second coil should be wound on top of the first coil. For now the coupling
between the coils will be assumed to be ideal.

L = the self inductance of the coil = N2/(reluctance)

i = current producing the mutual flux
C = a constant of integration that will be zero in this case
The current that produces the mutual flux will be a sine wave that lags
the voltage by 900, the flux will be in phase with the current. In the case of
the ideal transformer the reluctance of the core will be zero (r = ) and the
current required to produce the mutual flux will be zero.

The Real Transformer - In practice the transformer windings will have resistance they will
not be perfectly coupled, the transformer core will not have zero reluctance and the alternating
flux in the core will result in core losses. In a real transformer, these all need to be included in
the analysis. To take these factors into account the equivalent circuit of the transformer will be of
the form below:

This considers differences between the ideal and the real transformer as follows:

Winding Resistance ( R1 and R2) Both the primary and the secondary winding will have
resistance. These are represented by R1 and R2 in the equivalent circuit. There will be
a voltage drop and a power loss associated with these resistances. The
power loss is often referred to as the copper loss of the transformer.

Leakage Inductance (l1 and l2) As the windings are not perfectly coupled
some of the flux in the primary will not link the secondary and some of the
flux in the secondary will not link the primary. This can be taken into account
by introducing the primary and secondary leakage inductances l1 and l2.
These represent a voltage loss (loss of flux) but not a power loss.

Magnetising Inductance ( Lm) As the transformer core will have a finite value of reactance
(r ) then the self inductance of the windings will be finite. This will result
in a magnetising current flowing in Lm to produce the mutual flux.

Magnetising Resistance (Rm) The process of producing an alternating flux in

the transformer core produces loses in the core. These losses are a result of
the hysteresis of the core material and the production of eddy currents in the
core. The combined loss is called the iron loss of the transformer (Q: What
form will the iron loss take?). This is represented in the equivalent circuit by
a resistance Rm.

Laminated Steel Cores

The reason we laminate the iron cores in transformers is because we want to limit what are
called eddy currents. Transformers are basically two coils of wire wrapped around a core of iron.
They work by induction. Induction occurs when current flows in one conductor (or one set of
windings in the transformer) and the magnetic field that forms around that conductor (that set of
windings) sweeps the other conductor (the other set of windings) and induces a voltage. In order
to increase the effectiveness of the transformer, we need to improve the way the magnetic fields
are coupled from one set of windings to the other set.

Iron conducts magnetic lines of force well, so we use that to help conduct the magnetic lines
of force from coil A to coil B. Problem is, iron is also a conductor, and it's being swept by the
magnetic field as well. If we didn't use laminations, the iron core would provide a place for the
magnetic lines to produce (induce) current, and that current flowing in the core would heat the
core up fast and waste energy. By laminating the cores, we break up the current paths within that
core and limit eddy currents.

Fig. Laminated Steel Core

Transformation Ratio (Turn Ratio)

This is the ratio of input voltage (VP) to output voltage (VS). It can also be expressed as the
number of turns on the input or primary winding (NP) side of the transformer to the number of
turns on output or secondary winding (NS) side of transformer. Also another way of expressing
the transformation ratio is output current (IS) to input current (IP) .The transformation ratio a
transformer is given the symbol ''.

Losses
The losses that occur in transformers must be accounted for in any accurate model of transformer
behavior.

1. Copper (I2R) losses. Copper losses are the resistive heating losses in the primary and
secondary windings of the transformer. They are proportional to the square of the current in the
windings. Total Cu loss=I12R1+I22R2= I12R01=I22R02. The value of copper loss is found from the
short circuit test

Core loss
Eddy current losses. Eddy current losses are resistive heating losses in the core of the
transformer. They are proportional to the square of the voltage applied to the transformer.
Hysteresis losses. Hysteresis losses are associated with the rearrangement of the magnetic
domains in the core during each half-cycle. They are a complex, nonlinear function of the
voltage applied to the transformer.

Leakage flux. The fluxes which escape the core and pass through only one of the transformer
windings are leakage fluxes. These escaped fluxes produce a self-inductance in the primary and
secondary coils, and the effects of this inductance must be accounted for.

Single Phase Transformer

This can be used to transform an AC voltage or current in a circuit from one
level to another and it can provide electrical isolation between circuits. By
using transformers, we can efficiently transmit electricity over a great
distance at a high voltage and then reduce the voltage to safe level at the
point of use. The voltage can then be further reduced and used to obtain the
low voltage dc power supplies used in various electrical appliances.

Types of Single Phase Transformers:

Audio, balun, buck-boost, constant voltage (CVT), constant current, distribution, fly back
(FBT), generator step-up (GSU), harmonic mitigating, high frequency, high voltage, impedance
matching, and industrial control transformers. Categories of single phase transformers also

include interface, inverter, isolation, leakage, lighting, medical, multi-ratio, neutral grounding,
power, rectifier, resonant, solar power, and substation transformers. Autotransformers and variac
or variable autotransformers are also available from single phase transformer suppliers.
Product Specifications
This is a Dry-type laminated Shell type transformer.

Three Phase Transformer

Three phase transformers are used throughout industry to change values of three phase
voltage and current. Since three phase power is the most common way in which power is
produced, transmitted, and used, an understanding of how three phase transformer connections
are made is essential.
Since three-phase is used so often for power distribution systems, it makes sense that we
would need three-phase transformers to be able to step voltages up or down. This is only partially
true, as regular single-phase transformers can be ganged together to transform power between
two three-phase systems in a variety of configurations, eliminating the requirement for a special
three-phase transformer. However, special three-phase transformers are built for those tasks, and
are able to perform with less material requirement, less size, and less weight than their modular
counterparts.

Delta connection

Star connection

The various possible three phase connections are:

(a) Star Star

(b) Star Delta

(c) Delta Delta

(d) Delta Star

Nb: Star is also known as Wye.

Observations for verification of voltage relations.

S, No,

Type of
Input
Connections Voltage

1
2
3
4

-
-

Output
Voltage

Transformation Ratio
From Exp. From
Calcu.
1:1
23: 1
1:1
1: 23

Procedure:
1- The primary and secondary rms currents, as well as, the average of the primary and
secondary volt-ampere rating were determined.
2- Figure 14.19 was used to determine the primary and secondary wire sizes. (assuming to
be around 0.5 for a 40 [degree] Celsius+
3- The tentative thickess of the lamination stalk was determined (should be approximately 1
sq. in.
4- The core flux density was determined.
5- The tentative number of primary turns to operate the core at a maximum flux density of
77,000 lines/sq. in was determined.
6- The tentative number of primary and secondary turns and how they fit in the window fill
was established.
7- The resistance of the primary and secondary windings were determined.
8- The calculated values of the resistance were used to determine the corrected number of
primary and secondary turns.
9- The corrected depth of the lamination stack was determined based on the number of
primary turns in step 8 and flux density of 77,000 lines/sq. in
10- The core losses were determined.
11- The copper losses were determined
12- The efficiency of the transformer was determined.
Polarity Test
To determine the polarity test with AC source:
1. Connect the high voltage winding to the low voltage AC source.
2. Connect the jumper to any adjacent high voltage and low voltage terminal.

3. Connect a voltmeter between the other two adjacent high voltage and low voltage
terminal.
4. Connect another voltmeter across High side of transformer.

Transformer Calculations:
Given: Input voltage (VP = 110Vrms), Output voltage (Vs = 24V, 26V or 30V), Max. load current
(IL(max) = 2A = Is)
Formulae:
Determine the primary and secondary r.m.s currents and the average of the primary and
secondary volt-ampere ratings.
Secondary rms current = 0.707 x dc load current
= 0.707 x 2A
= 1.414A
Secondary VA rating: = V s out [rms] Iout [rms] = Pout
= 30 V 2 = 60 VA

Primary VA rating=

Output Power
60 W
60 W
250
=
=
=
=83.333 VA
3
( Efficiency x Power factor ) 100 ( 80 x 0.9 ) 100 ( 72 ) 100

Primary (rms) Current =

primary VA
83.333VA
=
=0.75 A
Primary Voltage
110 V

The efficiency of the transformer was found using Fig. 14.20, where you use the output VA to
find the efficiency of the transformer. Where the graph was plotted an efficiency of 85 was
assumed. Since this table is based on a 60Hz cycle, a formula was used to convert it to 50Hz.
Efficiency =

JA Hz
85
x
USA Hz 100

50 96
4800
4
x
x 100=
x 100= x 100=80
60 100
6000
5

80% assumed efficiency

Average Primary and secondary VA =

Secondary VA + Primary VA
2

60+ 83.3
2

71.65VA
Determining primary and Secondary Wire sizes
Based on figure 14.19, the ratio of wire circular mills to the rms current in milliamperes
should be 0.77

Pri. Circ. mills =

RMS current x Pri RMS full load current}

. mills
= 0.77 x 661.68 mA = 509.4936

circ. Mills
Sec. Circ. mills =

. mills
=0.77 x 2000 mA =1540. mills
RMS current x Secondary VA

figure 14.3 the single enamel wire from the table used are:
Primary Wire gauge = 0.77A = 21
Secondary Wire gauge = 2.0A = 19

Determine the tentative thickness of the lamination stack using fig 14.24. the effective
area of the core material.

An assumption was made that the primary and secondary volt of 71.66VA approximately 1.5

Ae
Stack Depth = Width of the lmination

Ae is determined using table 14.24 (Averaging the primary and secondary Voltampere ratings)
Ae
1.4
Stack Depth = Width of the lmination = 1.313 =1.066

core flux density for the lamination, the existing current starts to become very large at core flux
densities of approximately 80,000 lines per sq in. lamination is a maximum flux density of
77,000 lines per sq in.

max

Ep x 108
4.44 x f x Np x Ae

Np=

110 x 10 8
4.44 x 50 x 1 x 77000 =

Ns=

30 x 108
30 x 108
=
=159.5456 turns=160 turns
4.44 50 1.1 77000 18803400

Coil length
2.00
Margins = 0.056 2 = 0.112
Winding Length

110 x 108
=643.5006
17094000

turns = 644 turns

= coil length margin

= 2.00 0.112= 1.888
1.9
Number of turns per layer
Primary winding
=

Winding Length
Wire Diameter

1.888
= 0.03045
= 62
Secondary winding
Winding Length
= Wire Diameter
=

1.888
0.0438

= 43.1
Number of Layer
Primary
Number of turns
= Number of turn per layer
=

644
62

= 10.38 Layers = 10 layers

Secondary

Number of turns
= Number of turn per layer
=

160
43.1

=3.71 Layers

The wire diameter was found using a diameter circle the primary was 21 and the secondary was
19( size 18 ran out so 19 had to be used)

Wire Insulation thickness

This is the thickness of the masking tape used to insulate the wires. The thickness was
assumed to be 0.004 inch.
Build-up of wire
Primary
= number of layers diameter
10.64 0.0312 = 0.3319
Secondary
= number of layers diameter
= 4.24 0.050 = 0.213

Build-up of insulation = insulation thickness x number of layers

Primary
= 10.64 0.004
= 0.0425

Secondary
= 4.24 0.004
= 0.017

Total build up = build-up of insulation +build-up of wire

Primary
= 0.0425 + 0.3319
=0.3744
Secondary
= 0.017 + 0.213
= 0.23
Winding form: Margin = 0.056
Winding fill

= winding form + Primary + Secondary = 0.056 + 0.3744 + 0.23 = 0.6604

% Window fill =
=

Winding Fill
100
Window Form
0.6604
100
0.75

= 0.88 100
=88%
Design summary:
Testing:
Three tests were done on the transformer: The short circuit test, the open circuit test and the
polarity test.

Short circuit test: Connection

Open circuit test: connection

Polarity test: Connection

ME working on the transformer:

I have attached a dvd with the work done on the transformer, this includes images as well
as video.
Discussion:`
The transformer core was made from a compressed cardboard bobbin. The stack depth,
the winding length plus the margin x 2, and the width.1 mm gaps were measured between the
sides to allow for proper forming of corners. The copper wire was wrapped around the winding
length of the bobbin (primary then secondary). Each layer was insulated with masking tape. The
last layer was wrapped with two layers of insulation. The high voltage side was established
before (for H1) and during (for H2) the winding of the transformer at the motor winding station;
The low voltage side was established during (After winding Primary winding but before
secondary winding(X1) ) and after (X2) completely winding the transformer. The wires for H1
and two and X 1 and 2 had the ends scrapped off of their insulation for testing and connection
purposes.
Transformer Losses reduce the efficiency of the transformer. This is represented as waste
power (Such as heat and sound) and is normally kept to a minimum.

Copper Loss and Leakage this is basically the fundamental factor that follows the law of
conservation of energy. This loss is due to the winding of the copper around the transformer, as
current flows heat is emitted and this is the loss of energy heat is what is referred to as copper
loss.
Hysteresis Loss - is caused by a lagging effect, as when the change in magnetism of a
body lags behind changes in the magnetic field.
Eddy Current Loss removes energy from the transformer winding and it is represented as
waste power.
Saturation Loss Is when there is additional primary current after the transformer is said to
be saturated.
Conclusion: The transformer was designed as a 110V 50 cycle power device for a full
wave rectifier and choke-input filter, where, the d-c output voltage and current from the filter
were to be 35 volts and 2 A respectively

References
Bhadu, K. (2011, December 04). Transformer. Retrieved December 12, 2016, from
https://www.scribd.com/doc/74698923/Electrical-Machine-2011
http://cronus.uwindsor.ca/users/n/nkar/main.nsf/4a55f8116fa1f0608525698a00593653/a1
15aa4131c79b6f85256dc10053ec41/$FILE/Lecture_Transformers.ppt.
http://www.elec-toolbox.com/usefulinfo/xfmr-3\h.htm
http://www.slideshare.net/annuarunpatel/transforme-rs
http://www.scribd.com
http://www.alltestpro.com
Floyd, T. (2007). Principles of Electric circuits, 8th edition. Retrieved: December 16 ,
2016. pp.