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Abstract
The aim of this report is to test and design a transformer of 230/16 volt 70VA step down transformer. The
transformer was tested through numbers of tests to confirm that it’s not corrupted. Research was done
to investigate the transformer design and how it built. After that, the research was compared with the
testing result.

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Table of Contents
Abstract...........................................................................................................................................................2
Objectives .......................................................................................................................................................4
Introduction: ...................................................................................................................................................4
Technical section: ...........................................................................................................................................5
Transform design (230/16 V, 70VA)............................................................................................................5
Step down transformer:..........................................................................................................................5
Rule of thumb .........................................................................................................................................5
Core cross sectional area CSA .................................................................................................................6
Number of turns .....................................................................................................................................6
Winding CSA............................................................................................................................................6
Transformer testing: ...................................................................................................................................7
Open circuit test: ....................................................................................................................................7
Short circuit test:.....................................................................................................................................8
Polarity test: ............................................................................................................................................9
Load test: ..............................................................................................................................................10
Insulation test: ......................................................................................................................................11
Discussion section .........................................................................................................................................12
Conclusion:....................................................................................................................................................12
References: ...................................................................................................................................................13

Table of Tables
Table 1 open circuit result ..............................................................................................................................7
Table 2 short circuit result ..............................................................................................................................8
Table 3 polarity test result ..............................................................................................................................9
Table 4 load test result .................................................................................................................................10
Table 5 insulation test result ........................................................................................................................11

Table of Figures
Figure 1 open circuit test diagram ..................................................................................................................7
Figure 2 open circuit test ................................................................................................................................7
Figure 3 short circuit test diagram ..................................................................................................................8
Figure 4 short circuit test ................................................................................................................................8
Figure 5 polarity test diagram .........................................................................................................................9
Figure 6 polarity test .......................................................................................................................................9
Figure 7 load test diagram ............................................................................................................................10
Figure 8 load test ..........................................................................................................................................10
Figure 9 insulating test diagram ...................................................................................................................11
Figure 10 insulating test................................................................................................................................11

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Objectives
☺ Research about the theory of transformer and its performance.
☺ Research on how to build and design a 230/16 volt, 70VA transformer.
☺ Make calculations to find the primary and secondary CSA and number of turns.
☺ Find the design and construct of transformer.
☺ Show fully understand of circuit design.
☺ To show effective use of the components.
☺ Show the results and compare it with the theory.

Introduction:
Transformer is a device that transform electrical energy from a circuit to other. It can increase or
decrease voltage where the primary has more winding than the secondary (step down transform), and
the secondary have more winding when decreasing the voltage (step up transform). Transformer was
tested through five different methods using a 230/16-volt 70 VA transformer to make sure that are safe
to use.
The transformer test methods:
1. Open circuit test.
2. Short circuit test.
3. Polarity circuit test.
4. Load test.
5. Insulation test.

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Technical section:
Transform design (230/16 V, 70VA)
Transformer is wire wounded around a steel coil causes magnetic field or magnetic flux that have
flow of electrical current. In addition, more current flow will cause stronger magnetic field. However,
the current flow in a transformer is alternative current, so alternative current in one winding
(primary) cause moving magnetic field that induce voltage in the second winding (secondary). In
addition, the magnetic field will lose it strength quickly in air. However, the current in the second
winding was induced by the first winding which it called (electromagnetic induction).

There are two types of transformer; shell type and closed core type. The shell core type is a
transformer where the winding pass into the magnetic core which cause a shell around the winding.
While the closed core type is a transformer where the winding wounds outside the core.

Step down transformer:

If the secondary voltage is less than the primary where the first coil has more turn than the other, it
will be called a step-down transformer.

The frequency rating = 50Hz, so copper is a good core type to be used.

The flux density range of steel (B) = 1.3 wb/m2.

Flux carrying capacity will be reduced if the staking factor (S) < 1.

Rule of thumb
δlam = lamonitaion thickness = 0.1

0.0425⋅δlam+0.6032⋅arctan (108.16⋅δlam) → 0.0425*0.1+0.6032*tan¬-1 (108.16*0.1) = 0.896

Current for primary and secondary

*note: most transformer efficiency = 0.9.

𝑉𝐴 70
𝐼𝑝 = 𝑉𝑝
→ 230∗0.9 = 0.34𝐴

𝑉𝐴 70
𝐼𝑠 = 𝑉𝑝
→ 16∗0.9 = 4.86𝐴

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Core cross sectional area CSA
𝑐𝑜𝑟𝑒 𝐶𝑆𝐴 = 1.152 ∗ √𝑣𝑜𝑙𝑡𝑎𝑔𝑒 𝑜𝑢𝑡𝑝𝑢𝑡 ∗ 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝑜𝑢𝑡𝑝𝑢𝑡 → 1.152 ∗ √16 ∗ 4.86 = 10.15 cm2

Number of turns
Primary:
𝑉𝑝 230
𝑁𝑃 = → = 884.28 turns
4.4∗10−4 ∗𝐵∗𝐶𝑆𝐴∗𝑓∗𝑆 4.4∗10−4 ∗1.3∗10.15∗50∗0.896

Secondary
𝑉𝑠 16
𝑁𝑠 = 4.4∗10−4 ∗𝐵∗𝐶𝑆𝐴∗𝑓∗𝑆 → 4.4∗10−4 ∗1.3∗10.15∗50∗0.896 = 61.51 turns

To find the ratio:

𝑉𝑠 𝑁𝑠 𝐼𝑝
𝑉𝑝
= 𝑁𝑝
= 𝐼𝑠

𝑉𝑠
Ratio = 𝑉𝑝 → 16/230=0.07

Winding CSA
Turns per sq.cm for current → (primary = 415)/(Secondary = 35.2).

𝑁𝑝 884.28
CSA (P) = 𝑡𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑠𝑞.𝑚 → 415
= 2.13cm.

𝑁𝑠 61.51
CSA (S) = 𝑡𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑠𝑞.𝑚 → 35.2
= 1.75cm.

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Transformer testing:
Open circuit test:

Figure 1 open circuit test diagram

Figure 2 open circuit test

The open circuit test is to determine the core losses amount when no load is connected, and the
load of parameter branch. A single phase was applied to the transformer, and the voltage was
adjusted with variac. In addition, the secondary winding was open.

Table 1 open circuit result

Voltage (V) 230.2
Current (A) 0.086
Power (w) 2.7
Apparent power (VA) 19.7
Reactive power (VAR) 19.5
Power factor 0.14

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 Short circuit test:

Figure 3 short circuit test diagram

Figure 4 short circuit test

Short circuit test was done to find the copper loss and the equivalent circuit parameter. The secondary
winding was shorted with a wire, so large current will pass through it because of the small resistance. and
the primary winding was connected to AC supply with variac, ammeter, wattmeter and voltammeter.
Because high current reduces heating and it could burn the transformer, so 5% to 10% of the normal
voltage was applied to the primary side 230*10/100=23v.

Table 2 short circuit result

Voltage (V) 22.9

Current (A) 0.094
Power (w) 2.1
Apparent power (VA) 2.2
Reactive power (VAR) 0.7
Power factor -

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 Polarity test:

Figure 5 polarity test diagram

Figure 6 polarity test

The test was done to know the voltage direction in secondary and primary winding. Three DMM was
connected in parallel; the first one on the secondary, second on the primary and the third was to
find the difference. First and second one was used in the addictive polarity and the third one in the
subtractive polarity.

The correct polarity on DMM shows the difference.

The reverse polarity on the DMM shows summation of voltage.

Table 3 polarity test result

Digital Multimeter 1 230

Digital Multimeter 2 13.5
Digital Multimeter 3 215.7

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 Load test:

Figure 7 load test diagram

Figure 8 load test

The load test was done to find the total load when there is a connected load to the secondary
winding to identify the output and efficiency of the transformer.

Due to the resistive and the reactive component there will be some voltage drop on the primary and
secondary side. Therefore, the primary voltage will be lower than the supply, and the secondary less
than the primary and the supply.

Table 4 load test result

Primary windings Secondary windings

Load(Ω) Voltage Current Power Voltage Current Power
(V) (A) (W) (V) (A) (W)
Full load 230 0.212 44.4 10.8 3.11 33.4
3.3Ω
Half load 230.8 0.170 34 11.00 2.31 25.5
4.7Ω
Quarter load 231.4 0.119 19.5 12.6 1.243 15.6
10Ω
No load 230.4 0.086 2.6 13.6 *** ***

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 Insulation test:

Figure 9 insulating test diagram

00…

Figure 10 insulating test

The performance of the insulator must be checked to check that there is no damage; because any
temperature extreme or any chemical pollution can quick the deteriorate. As a reason it can affect
the personal safety or a dangerous situation.

In this test, the insulator was turned on to 500 volts, then two terminals each time were connected
to check that the resistance. If the resistance is less than 550 means that the insulator is damaged or
there’s short in the two wires.

Table 5 insulation test result

Primary- core 550 MΩ
Secondary- core 550 MΩ
Primary- secondary 550 MΩ

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Discussion section
To check the safety of the transformer, five different tests was done (short circuit, open circuit,
voltage regulation, insulation and polarity test). The tests were done to investigate certain
parameter in the transformer.

Open circuit: determine the core losses amount when no load is connected. There will not be
current flow while the secondary side is open. the test result founded that there was 85mA primary
current while there wasn’t any current flow in the secondary winding.

Short circuit: the short circuit was completed to find the parameter of the circuit when the
secondary winding is shorted using a wire. However, a large current will flow due to the small
resistance. As a result, the current for only 10% of the primary voltage was 0.104A.

Polarity test: the polarity test was done to check the direction of the primary and secondary
windings. When the primary voltage was 231.1v, and the secondary 13.6v; the volt between the
primary and secondary winding founded was 217.3, so they are in opposite direction.

Load test: The load test was to find the total load when there is a connected load to the secondary
winding to find the difference between secondary voltage and different loads.

Insulation test: the insulation test is to check the wire insulating.

A research was done for a transformer design of 230/16 V, 70VA with a copper coil. Then using
different formulas, the cross-sectional area core and the number of turns were founded.

Conclusion:
To conclude, the first part of the report was done by designing a 230/16v 70VA step down
transformer, by finding the coil type, CSA and number of turns. In addition, the second part was
done by examining five different transformer tests (short circuit, open circuit, voltage regulation,
insulation and polarity test). due to the results, the purpose was well realized.

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References:
− Exhod Follow. (2014, June 14). Transformer design by s u khaparkar. Retrieved from
https://www.slideshare.net/exhod/x-mer-design-by-s-u-khaparkar
− Vrutik. (2017, December 24). Open Circuit and Short Circuit Test on Transformer. Retrieved
from https://www.electronicshub.org/open-circuit-and-short-circuit-test-on-transformer/
− Christensen, E. (2018, May 04). Build Your Own Transformer. Retrieved December 24, 2018,
from https://www.electronicdesign.com/power/build-your-own-transformer
− Transformer Basics and Transformer Principles of Operation. (2018, August 16). Retrieved
from https://www.electronics-tutorials.ws/transformer/transformer-basics.html
− Ullah, A. (2017, October 12). Calculations for Design Parameters of Transformer. Retrieved
from http://engineerexperiences.com/design-calculations.html

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