Veda Circuit Solution

A
Practical Training Report

On

Transformer
In partial fulfillment
for the award of the degree of
Bachelor of Technology
In Department of Electrical Engineering

Submitted to ;. Submitted by;

Dr.Dwarka Prasad. Subhash Kumar
Vice principal 20ELDEE013
Department of Electrical Engineering
Laxmi Devi Institute of Engineering and Technology chikani ,alwar

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 ACKNOWLEDGEMENT

A research report cannot be completed without the help guidance of

various & individual Institutions. I expressed my sincere thanks and
gratitude to my family & all those who made it possible for me to
complete this report.
With great pleasure and sincerely I wish to express my deepest sense of
gratitude to my guide for their valuable guidance and practice
suggestions and for patiently my numerous queries.
I would like to special thanks to my guide Dr.Dwarka Prasad ( vice
principal) who extended their full co-operation during my training
period and encouraging me to clear my doubts and enlightened me on
the various aspects of an industry, and helps me on successful
completion of my training.
I wish to thank to Veda Circuit Solution. For providing meanopportunity
to work with them on the project . Me stay in the organization has
been a great learning experience. This exposure has greatly enrich me
with knowledge.

Subhash

20ELD

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 EE008

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 TABLE OF CONTENTS

ACKNOWLEDGEMENT. 2
CERTIFICATE. 3
TABLE OF CONTENTS. 3
CHAPTER 1. 4-5
1.1 INTRODUCTION. 4
CHAPTER 2. 5-8
WORKING OF TRANSFORMER. 5
VOLTAGE AND TURN RATIO. 6
TRANSFORMER RATINGS. 7
TYPES OF TRANSFORMER. 8
CHAPTER 3. 9-12
3.1. CONNECTING TRANSFORMER WINDING. 9
THREE PHASE TRANSFORMER. 11
WINDINGS TAP. 12
OVERCURRENT PROTECTION. 12
CHAPTER 4. 13-18
RESISTIVE LOSS. 13
EDDY CURRENT LOSS. 15
HISTARISIS LOSS. 15
FLUX LOSS. 16

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TRANSFORMER CONFIGURATION. 18
CHAPTER 5. 18-23
AUTO TRANSFORMER. 19
ISOLATION TRANSFORMER. 20
5.3. SUMMARY. 23

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1.1 INTRODUCTION
After studying this unit, the student will be able to
• state the purpose of a transformer.
• explain the principle of mutual induction.
• determine the output voltage of a transformer if the input voltage
and turns ratio are Known.
• determine the full-load current of a transformer given the kVA and
voltages of the Primary and secondary windings.
• identify the common types of transformers from their schematic
diagrams.
• read transformer winding diagrams and connect a transformer for the
desired primary And secondary voltage.
• choose the proper transformer taps to obtain the desired output
voltage.
• connect buck and boost transformers to obtain desired voltage for a
single-phase applications.
• choose the correct transformer kVA for the application, given the
voltage, current, and Phase requirement of a load.
• size over current protection for dry-type transformers operating
at600 V or less.
• size the feeder conductor for the transformer and wires from the
transformer to loads.
• properly ground a transformer, and the secondary electrical system
produced by the Transformer.

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The purpose of a transformer is to change electrical Voltage to a
different value. For example, a farmer has a Large, 480-V, 3-phase
motor powering a well. The motor Is in a building, and the farmer
wants one 120-V circuit For a few lights and a receptacle outlet. A
transformer isA small transformer inside the equipment lowers the line
voltage to 24 V for the control circuit. Transformers are frequently
used inside electronic equip- A small transformer inside the equipment
lowers the line voltage to 24 V for the control circuit. Transformers are
frequently used inside electronic equip-ment.
WORKING OF TRANSFORMER
A clear understanding of how transformers work is Necessary in order
to wire them properly in an electrical System. Understanding input and
output current and Grounding are particularly troublesome. A dual-
voltage Transformer can be ruined when power is applied, if the
Connections are made improperly. An important property of electricity
is that a magnetic field is produced around a wire in which electrical
Current is flowing, Figure 14-3. The more current that Flows, the
stronger is the magnetic field. An even Stronger magnetic field can be
produced by winding the Wire into a coil. Now the magnetic fields of
adjacent Wires add together to form one strong magnetic field. The
electrical current flowing in a transformer is al-Treating current. The
current flows first in one direction, stops, then reverses and flows in
the other direc 274 Unit 74 Transformers Tion. The magnetic field
around the winding is constantly In motion. Figure 14-4 shows the
magnetic field during One cycle. Notice that the north and south poles
of the Magnetic field reverse when the flow of current reverses.
Another property of electricity is important to the Operation of a
transformer. When a magnetic field move Across a wire, a voltage is
induced into the wire, Figure 14-5. If the wire forms a complete circuit,

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current will Flow in the wire. If a second coil of wire is placed in a
Moving magnetic field, then a voltage will be induced in This second
coil, Figure 14-6. This phenomenon is called Mutual induction.
Alternating current in one winding Produces a moving magnetic field
that induces a voltag~ In a second winding. Electrical energy is
converted into’ Magnetic field and then converted back into electrical
Energy in a second winding. The trick is to do this wit Little or no loss
of energy. The magnetic field loses strength quickly in air Therefore; a
special steel core is used. The core is com Posed of thin sheets of a
silicon-steel alloy. The magnetic field is concentrated in the core, and
energy losses Are reduced to a minimum. Figure 14-6 shows the tw<
Windings separated. Most transformers have one winding placed
directly over the other to further reduce th( Loss of energy,
VOLTAGE AND TURNS RATIO
The input winding to a transformer is called the pri-Mary winding. The
output winding is called the second-Ary winding. If there are more
turns of wire on the pri-Mary than on the secondary, the output voltage
will be Lower than the input voltage. This is illustrated in Figure 14-8 for
a step-down and a step-up transformer. Notice That the winding with
the greater number of turns has the
Higher voltage. In Figure 14-8, one winding has twice as Many turns as
the other. In one case the voltage is Stepped down to half, while in the
other the voltage is. Stepped up to double. It is important to know the
ratio of the number of Turns of wire on the primary winding as
compared to the Secondary winding. This is called the turns ratio of the
Transformer, Equation 14.1. The actual number of turns Is not
important, just the turns ratio. Turns ratio Eq. 14.1 Number of turns on
the pwumy Number of turns on the secondary

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Turn ratio = number of turns in primary
Number of turns in secondary

Primary voltage = Secondary voltage x turns ratio

TRANSFORMER RATINGS

Transformers are rated in volt-amperes (VA) or kilo-Volt-amperes (kVA).

This means that the primary and the Secondary winding are designed to
withstand the VA or kVA rating stamped on the transformer nameplate.
The primary and secondary full-load currents usually are not given. The
installer must be able to calculate the primary and secondary currents
from the nameplate information. When the volt-ampere (or kilovolt-
ampere) rating is Given, along with the primary voltage, then the
primary Full-load current can be determined, using Equation 14.4 (for a
single-phase transformer) or Equation 14.5 (for a 3-phase transformer).
Full-load current = VA ratings
Voltage
For three phase
Full load current = VA ratings
1.73×voltage
TYPES OF TRANSFORMERS
Transformers are of the dry type or oil filled. From 2% to 5% of the
electrical energy is lost in a transformer, Mostly due to the resistance of
the windings. Large trans-Formers circulate oil through the windings to
remove the Heat. Dry transformers use air for cooling. Heat is moved

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From the windings to the case by conduction in smaller Sizes of the dry
type. Large dry-type transformers actu-Ally allow air to circulate
through the windings. Oil-filled transformers are used by the electric
utility, and for industrial or large commercial applications.
Transformersinstalled for applications on a farm electrical system are
almost alwaysdry-type transformers. Only dry-type transformers
operating at less than 600 V Are discussed in this unit. Common two-
winding transformers are often called Insulating transformers. The
primary winding and the Secondary winding are separate and not
connected.
An Autotransformer has its windings interconnected so that The
primary and the secondary share the same windings. Autotransformers,
therefore, have an electrically connected primary and secondary. These
two basic types of Transformers are shown in Figure 14-10. A 3.1 3.1
3.1 CONNECTING TRANSFORMER WINDINGS
Transformer wiring diagrams are printed on the transformer nameplate
which may be affixed to the out-side of the transformer or printed
inside the cover to the wiring compartments. The lead wires or
terminals are marked with the letters Hand X. Those lettered Hare the
Noise Voltage spikes and noise distort the normal alternating-voltage
sine wave. primary (high-voltage) leads, and those lettered X are the
secondary (low-voltage) leads. Some transformers have two primary
and two secondary windings (as shown in Figure 14- I 3) so they can be
used for several applications. These are called dual-voltage
transformers. Connections must be made correctly with dual-voltage
transformers. If connected improperly, it is possible to create a dead
short that will usually ruin the transformer when it is energized.
consider a dual-voltage transformer rated at 240/ 480 V on the primary,
and 120/240 V on the secondary. Each of the two primary windings is,
rated at 240 V. Each secondary winding is rated at 120 V. The
transformer must be connected so that each primary winding receives
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the proper voltage. In Figure 14-13, the transformer is shown with the
primary windings con- in series, with HI and H4 connected to a 480-V
supply. The voltage across HI and H2 is 240 V and the voltage across H3
and H4 is 240 V. Each winding is receiving the proper voltage. With
each primary winding receiving the proper 240 V, each secondary
winding will have an output of 120 V. Connecting the secondary
windings in series produces 240 V across XI and X4. Now consider a
case where the primary voltage available is 480 V, but the desired
output is 120 V. In this case, the primary windings are connected in
series, gas in Figure 14-13. The secondary windings are, how-ever,
connected in parallel, Figure 14-14. This is accom- by connecting Xl to
X3, and X2 to X4. If this is not done properly, a 240-V dead short will
occur. A voltmeter can be used to make sure the connection is correct.
Connect X 1 to X3, and then connect a voltmeter
between X2 and X4. Energize the primary and read the major
advantageof autotransformers over the insulating types is their Lighter
weight and compact size. Autotransformers are Used for electric-
discharge lighting ballasts.
A special type of autotransformer, called a grounding autotransformer
or zigzag transformer, is occasion-Ally used to create a neutral wire or a
ground for an Ungrounded 480-V, 3-phase system. These transformers
Are found occasionally in industrial wiring. Standard insulating
transformers can be used to make a zigzag trans-Former. The wiring of
these transformers is covered in NEC Section 450-5. Control
transformers are special insulating trans-Formers commonly used to
supply power for control of Appliances, equipment, and motor starters.
A control transformer is required when the control circuit Voltage is
different from the line voltage supplied. Com-Mon control circuit
voltages are 24 V and 120 V. A 120-V control circuit to a start -stop

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push-button station May be desirable foa 125-hp, 480-V, 3-phase
motor Powering an irrigation pump. The control transformer Would
step down the 480 V to 120 V for the control Circuit. Control
transformers are designed to withstand short-Duration overloads with
minimal output voltage drop. Motor starter solenoid coils draw six to
eight times as Much current when they are closing as is required to
hold Them closed. Constant output voltage transformers or voltage
regulating transformers produce a nearly constant output Voltage, even
though the input voltage may not be constant. The voltage supplied by
the utility typically will Fluctuate up and down a few percent during the
day. This Voltage fluctuation is of little concern except for certain
Equipment, such as electronic computers. Installing a Constant output
voltage transformer to supply sensitive Equipment will eliminate
undesirable voltage fluctuations. Special filters can also be added to
these transformers to eliminate voltage spikes and electrical noise
Caused by other equipment operating on the electrical System.
If the connection is correct, the voltmeter will Read zero. If the
voltmeter reads something other than Zero, check all primary and
secondary connections to Make sure they are connected exactly as
indicated by the Manufacturer. The primary on the example
transformer has two Windings; therefore, it can also be connected for a
240-V Supply. The primary windings must be placed in parallel By
connecting HI to H3 and H2 to H4. If this is not done As indicated on the
transformer nameplate, the magnetic Fields created by each winding
will oppose each other. The magnetic fields work together when the
windings Are properly placed in parallel.
THREE-PHASE TRANSFORMERS

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Changing the voltage of a 3-phase system can be Done with a 3-phase
transformer or with single-phase Transformers. Three-phase
transformers are generally Designed and constructed for specific
voltages. For example, a transformer may have a 480-V delta primary
And a 120/208-V wye secondary. A typical nameplate for This type of
transformer is shown in Figure 14-15. The 3-phase transformer has one
core with three sets Of windings. A primary and a secondary winding
are 280 Unit 14 Transformers CORPORATION Nameplate of a 3-phase
transformer Placed one on top of the other on each of the three legs of
The core, Figure 14-16. The secondary windings are connected in either
wye or delta, as required by the load to Be supplied. The primary is
connected in wye or delta, Depending upon the type of electrical
systemavailable. Common 3-phase transformer connections, listing pri-
Mary windings first, are: delta-delta, wye-delta, and Delta-wye. A wye-
wye connection is usually not recommended. In a wye-wye connection,
a third harmonic current may occur, causing possible current
overloadingand Damage to the primary neutral wire. A delta-wye
transFormer can usually be substituted. Always be sure to Consult the
transfo-rmer manufacturer before installing a Wye-wye connection.
WINDING TAPS

Transformers, except for small sizes, are often supplied with winding
taps to compensate for abnormally Low or high primary voltage.
Assume, for example, that A transformer is rated 480 V primary and
240 V secondary. This means that 240 V will be the output if the input
Is 480 V. But, what if the input is only 444 V? The turns Ratio for this
transformer is 2 to 1; therefore, using Equation 14.3, the output will be
222 V.
Secondary voltage = 444÷2=222v

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 OVERCURRENT PROTECTION
Wiring a transformer circuit is one of the most difficult of wiring tasks,
unless the installer understands Transformer fundamentals. This unit
deals with dry-type Transformers operating at 600 V and less. Rules for
size over current protection for this type of transformer are Coveredin
NEC Section 450-J(b). It must be noted that These rules apply only tothe
transformer itself, and not Necessarily to the input and output circuit
wires. Sizing And protecting transformer input and output wires is
covered in the next section. Three methods of providing over current
protection For transformers is covered by the National Electrical Code.
Both the primary and the secondary windings Must be protected. The
procedure begins by calculating The primary and the secondary full-
load current, using Equation 14.4 for single-phase transformers, and
Equation 14.5 for 3-phase transformers. A transformer can be
protected by one over current Device on the primary side rated at not
more than 1.25 (125%) times the primary full-load current, Figure 14-
24. This over current device can be a set of fuses in a Panel board, a
fusible switch, or a circuit breaker. Consider that a 25-kVA, single-phase
transformer Has a 480-V primary and a 120/240-V, 3-wire secondary.
The primary full-load current is 52 A.

Primary full load current =

25kva×1000
450

Maximum size overcurrent device = 52A×1.25=65A

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 Resistive Loss
Resistive loss, or I2R loss, or copper loss, is the power loss in a
transformer caused by the resistance of the copper wire used to make
the windings. Since higher frequencies cause the electrons to travel
more toward the outer circumference of the conductor (skin effect),
electrical disturbances called harmonics have the effect of reducing the
wire size and increasing resistive loss. These losses are the same as the
power losses in any conductor and are calculated as follows:

P=I2R
Where
P = power (in W)
I = current (in A)
R = resistance (in Ω)

For example, if a transformer primary is wound with 100′ of #12 copper

wire that carries 15 A, what is the resistive loss in that coil?
The resistance of #12 copper wire is 1.588 Ω/1000′ at room
temperature. Therefore, the resistance of 100′ of the wire is 0.1588 Ω.

P=I2R=152×0.1588=35.7W

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 The transformer primary wiring consumes 35.7 W of power that is
wasted as heat. If the transformer is not cooled properly, this heat
increases the temperature of the transformer and the wires. This
increased temperature causes an increase in the wire resistance, and
the voltage dropped across the conductor. This loss varies with the
current and is always present in the primary when it is energized. The
secondary sees very little loss of this type when unloaded.
Note
Changes that an electric utility makes to power delivery can affect the
operation of in-plant transformers. A new area substation can boost
the delivered voltage. New factories or commercial buildings may
increase the local load and decrease the voltage available. The taps on
in-plant transformers may need to be adjust.

EDDY Current Loss

Eddy current loss is power loss in a transformer or motor due to
currents induced in the metal parts of the system from the changing
magnetic field. Any conductor that is in a moving magnetic field has a
voltage and current induced in it. The iron core offers a low reluctance
to the magnetic flux for mutual induction. The magnetic flux induces
current at right angles to the flux. This means that current is induced
across the core. This current causes heating in the core. The heat
produced by eddy currents increases as the square of the frequency.
For example, the third harmonic (180 Hz) has nine (32) times the
heating effect of the fundamental (60 Hz) frequency.
Constructing the core from thin sheets of iron laminated together can
minimize this loss. The thin sheet-iron layers shorten the current path

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and minimize the eddy currents (see Figure 1). Each sheet is coated
with an insulating varnish that forces these currents to only flow within
individual laminations. This reduces the overall eddy currents in the
entire core. These thin sheets are manufactured from silicon-iron or
nickel-iron alloys that can be magnetized more readily than pure iron.
The use of alloy cores also improves the age resistance of the core. The
sheets are often made from 29-gauge alloy, which is only 0.014′′ thick.
Hysteresis Loss
Hysteresis loss is loss caused by the magnetism that remains (lags) in a
material after the magnetizing force has been removed. Magnetic
domains are small sections of a magnetic material that act together
when subject to an applied magnetic field. Magnetic domains have
magnetic properties and move in iron when subjected to a magnetic
field. When the iron is subjected to a magnetic field in one polarity, the
magnetic domains will be forced into alignment with the field. When
the polarity changes twice each cycle, power is consumed by this
realignment, and this reduces the efficiency of the transformer. This
movement of the molecules produces friction in the iron, and thus heat
is a result. Harmonics can cause the current to reverse direction more
frequently, leading to more hysteresis loss. Hysteresis is reduced
through the use of highly permeable magnetic core material.
Flux Loss
Flux loss occurs in a transformer when some of the flux lines from the
primary do not pass through the core to the secondary, resulting in a
power loss. There are two main reasons for flux lines to travel through
the air instead of through the core. First, the iron core can become
saturated so that the core cannot accept any more flux lines. The lines
of flux then travel through the air and are not cut by the secondary.
Second, the ratio of the reluctance of the air and the core in the

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unsaturated region is typically about 10,000:1. This means that for
every 10,000 lines of flux through the core, there is 1 line of flux
through the air. Flux loss is generally small in a well-designed
transformer.
Transformer Efficiency
The ratio of a transformer’s output power to its input power is known
as transformer efficiency. The effect of transformer losses is measured
by transformer efficiency, which is typically expressed as a percentage.
The following formula is used to measure transformer efficiency:

n= P OUT/P IN
Where

n = transformer efficiency (in %)

POUT = transformer output power (in W)

PIN = transformer input power (in W)

Example: What is the efficiency of a transformer that has an output

power of 1500 W and input power of 1525 W?

Efficiency=OUT/IN=1500W/1525W=98.36

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The efficiencies of power transformers normally vary from 97 to 99
percent. The power supplied to the load plus resistive, eddy current,
hysteresis, and flux losses must equal the input power. The input power
is always greater than the output power
Transformer Configurations
There are different configurations for both single-phase and three-
phase systems.
Single-phase Power – Single-phase transformers are often used to
supply power for residential lighting, receptacle, air-conditioning, and
heating needs. Single phase transformers can be made even more
versatile by having both the primary winding and secondary winding
made in two equal parts. The two parts of either winding can then be
reconnected in series or parallel configurations.
Three-phase Power – Power may be supplied through a three-phase
circuit containing transformers in which a set of three single-phase
transformers is used, or on three-phase transformer is used. When a
considerable amount of power is involved in the transformation of
three-phase power, it is more economical to use a three-phase
transformer. The unique arrangement of the windings and core saves a
lot of iron.
Delta and Wye Defined – There are two connection configurations for
three-phase power: Delta and Wye. Delta and Wye are Greek letters
that represent the way the conductors on the transformers are
configured. In a delta connection, the three conductors are connected
end to end in a triangle or delta shape. For a wye, all the conductors
radiate from the center, meaning they are connected at one common
point.

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Three-phase Transformers – Three-phase transformers have six
windings; three primary and three secondary. The six windings are
connected by the manufacturer as either delta or wye. As previously
stated, the primary windings and secondary windings may each be
connected in a delta or wye configuration. They do not have to be
connected in the same configuration in the same transformer. The
actual connection configurations used depend upon the application.

Autotransformer
The autotransformer is a special type of power transformer. It
consists of a single, continuous winding that is tapped on one side
to provide either a step-up or a step-down function. This is
different from a conventional two-winding transformer, which has
the primary and secondary completely isolated from each other,
but magnetically linked by a common core. The autotransformer's
windings are both electrically and magnetically interconnected.
An autotransformer is initially cheaper than a similarly-rated two-
winding transformer. It also has better regulation (smaller voltage
drops), and greater efficiency. Furthermore, it can be used to
obtain the neutral wire of a three-wire 240/120-volt service, just
like the secondary of a two0winding transformer. The
autotransformer is considered unsafe for use on ordinary
distribution circuits. This is because the high-voltage primary
circuits are connected directly to the low-voltage secondary
circuit.

Isolation Transformer
An isolation transformer is a very unique transformer. It has a 1:1 turn’s
ratio. Therefore, it does not step voltage up or down. Instead, it serves
as a safety device. It is used to isolate the grounded conductor of a

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power line from the chassis or any portion of a circuit load. Using an
isolation transformer does not reduce the danger or shock if contact is
made across the transformer’s secondary winding.
Technically, any true transformer, whether used to transfer signals or
power, is isolating, as the primary and secondary are not connected by
conductors but only by induction. However, only transformers whose
primary purpose is to isolate circuits (opposed to the more common
transformer function of voltage conversion), are routinely described as
isolation transformers.
SUMMARY
A transformer is an electrical device which, by the principles of
electromagnetic induction, transfers electrical energy from one electric
circuit to another, without changing the frequency. The energy transfer
usually takes place with a change of voltage and current. Transformers
either increases or decreases AC voltage.
Transformers are used to meet a wide variety of needs. Some
transformers can be several stories high, like the type found at a
generating station or small enough to hold in your hand, which might
be used with the charging cradle for a video camera. No matter what
the shape or size, a transformers purpose remains the same:
transforming electrical power from one type to another.
There are many different types of transformers in use today. This
resource will take a closer look at Power Transformers, Auto
Transformers, Distribution Transformers, Instrument Transformers,
Isolation Transformers, Potential Transformers and Current
Transformer by the current flowing through the windings, which
are also known as coils.
There are four primary parts to the basic transformer. The parts

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include the Input Connection, the Output Connection, the
Windings or Coils and the Core.

 Input Connections - The input side of a transformer is

called the primary side because the main electrical power to
be changed is connected at this point.
 Output Connections - The output side or secondary side of
the transformer is where the electrical power is sent to the
load. Depending on the requirement of the load, the
incoming electric power is either increased or decreased.
 Winding - Transformers have two windings, being the
primary winding and the secondary winding. The primary
winding is the coil that draws power from the source. The
secondary winding is the coil that delivers the energy at the
transformed or changed voltage to the load. Usually, these
two coils are subdivided into several coils in order to reduce
the creation of flux.
 Core - The transformer core is used to provide a controlled
path for the magnetic flux generated in the transformer. The
core is generally not a solid bar of steel, rather a
construction of many thin laminated steel sheets or layers.
This construction is used to help eliminate and reduce
heating.
Transformers generally have one of two types of cores: Core
Type and Shell Type. These two types are distinguished
from each other by the manner in which the primary and
secondary coils are place around the steel core.
o Core type - With this type, the windings surround the
laminated core.
o Shell type - With this type, the windings are surrounded
by the laminated core.

When an input voltage is applied to the primary winding,

alternating current starts to flow in the primary winding. As the
current flows, a changing magnetic field is set up in the

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transformer core. As this magnetic field cuts across the secondary
winding, alternating voltage is produced in the secondary winding.
The ratio between the number of actual turns of wire in each coil
is the key in determining the type of transformer and what the
output voltage will be. The ratio between output voltage and input
voltage is the same as the ratio of the number of turns between
the two windings.
A transformers output voltage is greater than the input voltage if
the secondary winding has more turns of wire than the primary
winding. The output voltage is stepped up, and considered to be a
"step-up transformer". If the secondary winding has fewer turns
than the primary winding, the output voltage is lower. This is a
"step-down transformer".

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