TRANSFORMER

Group Members

Usman Aslam (170932)

Ehtisham Ul Haq (171007)

BACHELOR OF ELECTRICAL ENGINEERING

(2017-2021)

Project Supervisor
Engr Mughees Ahmed
Lab Engineeer

DEPARTMENT OF ELECTRICAL ENGINEERING

FACULTY OF ENGINEERING
AIR UNIVERSITY, ISLAMABAD
Air University

Abstract
The following report is written about the construction of a transformer. The
transformer we are making is a single phase transformer with one primary
winding and two secondary windings. This transformer is commonly used in
labs for practical works and various tests. Construction of a transformer
requires calculation for selection of framework, wire gauges, and no of turns
for each winding. We also calculated the quantity of wire required for each
winding. First winding that is wounded on the framework is primary winding,
after each winding a cover of masking tape and wax paper is applied to
prevent the physical connection between different windings. When all the
windings are completed, we started to insert silicon iron sheets of shape E and
I which are normally referred as core of transformer. After insertion of core,
last step is to test your working. We tested the primary and secondary voltages
using a voltmeter. The results proved that our transformer is in working
condition.

II
Air University

Table of Contents

TRANSFORMER .............................................................................................. I
Abstract ......................................................................................................... II
List of Tables .................................................................................................... V
Introduction .................................................................................................... 1
Design Calculation ......................................................................................... 1
Design Procedure ........................................................................................... 4
Results and Discussion .................................................................................. 5
Open Circuit Test ....................................................................................... 6
Short Circuit Test ....................................................................................... 8
Efficiency ................................................................................................. 10
Voltage Regulation .................................................................................. 10
Conclusion ................................................................................................... 14
References .................................................................................................... 15
Appendix A .................................................................................................. 16
Appendix B .................................................................................................. 17

III
Air University

List of Figures
Figure 1: Open Circuit Test ............................................................................... 6
Figure 2: Open Circuit Test Readings ............................................................... 7
Figure 3: Short Circuit Test ............................................................................... 8
Figure 4: Short Circuit Test Reading ................................................................. 9
Figure 5: Unity Power Factor Reading Table .................................................. 10
Figure 6: Unity Power Factor Graph ............................................................... 11
Figure 7: Leading Power Factor Reading Table .............................................. 11
Figure 8: Leading Power Factor Graph ........................................................... 12
Figure 9: Lagging Power Factor Reading Table .............................................. 12
Figure 10: Lagging Power Factor Graph ......................................................... 13

IV
Air University

List of Tables
Table 1: Transformer Windings Requirements.................................................. 1
Table 2: No of turns for windings ...................................................................... 2
Table 3: AWG SWG Table ................................................................................ 3
Table 4: Measured Values ................................................................................. 5
Table 5: AWG SWG table ............................................................................... 16
Table 6:Cost Prices .......................................................................................... 17

V
Air University

Introduction
Transformer is a static electrical device used for transmission of electrical
energy between two or more circuits. Transformer works on the principle of
mutual induction. A varying current in one coil of the transformer produces a
varying magnetic flux, which, in turn, induces a varying electromotive
force across a second coil wound around the same core. Electrical energy can
be transferred between two coils without a metallic connection between two
circuits. In this project we constructed a transformer to better understand the
phenomenon of working of transformer and a general knowhow of its
construction. The transformer we built is a single phase transformer with one
primary and two secondary windings. Our requirement is listed in table 1

Table 1: Transformer Windings Requirements

Name Tapping-1 Tapping-2 Tapping-3 Total Current

Voltage

Primary NIL NIL NIL 220V 0.25A

Secondary 190V 139V 51V 380V 0.15A

Secondary 110V 110V NIL 220V 0.25A

The design procedure is described as follows

Design Calculation
First of all we need to select a framework for transformer on which all the
primary and secondary windings will be wounded. To select the area
framework we have an equation

1
Air University

𝐴 = √𝑆 𝑐𝑚2

Where A is area of framework and S is the reactive power of transformer

In our case, S=55VA

𝐴 = √55 𝑐𝑚2

𝐴 = 7.416 𝑐𝑚2

To reduce the no of turns we multiply the area by a factor of 2 which results in

𝐴 = 14.83 𝑐𝑚2

For convenience, A = 16 𝑐𝑚2 we select the 4cm x 4cm framework.

Next, we need to select the no of turns per volt by following formula

42
𝛼=
𝐴

42
𝛼=
16

𝛼 = 2.625 𝑡𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑣𝑜𝑙𝑡.

𝑇𝑜𝑡𝑎𝑙 𝑇𝑢𝑟𝑛𝑠 = 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 × 𝛼

Table 2 shows the no of turns for each voltage.

Table 2: No of turns for windings

Name Tap-1 Turns Tap-2 Turns Tap-3 Turns Total Total

Voltage Turns
Pri NIL NIL NIL NIL NIL NIL 220V 577.5

Sec-1 190V 498.75 139V 364.875 51V 133.875 380V 997.5

Sec-2 110V 288.75 110V 288.75 NIL NIL 220V 577.5

2
Air University

Now we need to select the wire gauges for different values of currents with the
help of AWG or SWG table

Table 3 shows the required gauge for given value of current

Table 3: AWG SWG Table

Currents AWG SWG Diameter

0.15A 30 33 0.25mm
0.25A 29 31 0.28mm

To select the length of wire required for each winding we need to calculate the
circumference of framework

𝐶 = 2〈𝑊 + 𝐿〉

𝐶 = 2〈4 + 4〉

𝐶 = 16 𝑐𝑚

The circumference of framework increases gradually after each cover of wire

′ ′
on the framework. For this we introduce a factor 𝑙𝑝′ , 𝑙𝑠1 and 𝑙𝑠2 which are
equal to 10% of the calculated length for each winding.

Length of primary (𝐿𝑝 ):

𝐿𝑝 = (16 × 577.5) + 𝑙𝑝′

𝐿𝑝 = 9240 + 924

𝐿𝑝 = 10164𝑐𝑚

𝐿𝑝 = 101.64𝑚

Length of Secondary-1 (𝐿𝑠1 ):

′
𝐿𝑠1 = (16 × 997.5) + 𝑙𝑠1

𝐿𝑠1 = 15960 + 1596

3
Air University

𝐿𝑠1 = 17556𝑐𝑚

𝐿𝑠1 = 175.56𝑚

Length of Secondary-2 (𝐿𝑠2 ):

′
𝐿𝑠2 = (16 × 577.5) + 𝑙𝑠2

𝐿𝑠2 = 9240 + 924

𝐿𝑠2 = 10164𝑐𝑚

𝐿𝑠2 = 101.64𝑚

Design Procedure
As discussed in the design calculations, we need to select a 4cm x 4cm
framework. Start with the primary winding of gauge 31 and start winding.
Carefully count the no of turns as increasing or decreasing no of turns will
cause change in required voltage. For convenience after each 100 turn place a
mark using masking tape. When primary winding is completed, wrap a full
cover of masking tape and then one layer of wax paper on top for insulation so
that both windings do not touch each other. If the primary winding is
clockwise then both secondary windings must be wounded clockwise. If not,
we may experience between primary and secondary voltages. Now start with
the secondary winding using 33 gauge wire, in this case we have tapping, for
first tapping after 190V or 500 turns pull out a loop and continue to wind.
Similarly for second tap pull out another loop after 365 turns and complete the
secondary winding after another 135 turns. Again cover the winding with a
layer of masking tape and wax paper. Now start with the second secondary
winding, this time using 31 gauge wire, after 290 turns pull out a loop and
then after another 290 turns, complete the secondary winding. Make sure that
all the windings are coming out from different regions of framework. Apply
another layer of masking tape and wax paper. Cover the wax paper with
binding tape so it does not detach.

4
Air University

Now start inserting E type core alternatively from each side. When there is no
space to insert more, start inserting I in between E’s on both side. Use hammer
where necessary. After inserting the core, tighten it using nut and bolts.

Remove the enamel coating from each end of wire and loops coming from the
transformer using sand paper to give external connection. Make sure that the
loop does not break. Solder the wires coming out of transformer and external
wires, also apply thermal insulation for safety. Attach a connecting strip to the
transformer and connect both all secondary wires inside it because it makes it
easier to measure the voltage.

For testing, we connected the primary with 220V and measured the secondary
voltages.

Results and Discussion

Table 4 shows the measured input and output voltages

Table 4: Measured Values

Name Measured Value

Primary (220V) 217.5V

Secondary-I Tapping-1 (190V) 193V

Secondary-I Tapping-2 (139V) 141V

Secondary-I Tapping-3 (51V) 51V

Secondary-I Total (380V) 385V

Secondary-II Tapping-1 (110V) 112V

Secondary-II Tapping-2 (110V) 112V

Secondary-II Total (220V) 224V

We noticed that the measured values are different from required voltages. The
reason for this is variation in no of turns and less than required primary
voltage.

5
Air University

Open Circuit Test

Open circuit test is used to determine the components of excitation branch of a
transformer. It is also known as no load test. The secondary of the transformer
is left open-circuited. A wattmeter is connected to the primary. An ammeter is
connected in series with the primary winding. Since magnetization branch is
parallel with the applied voltage. Same potential difference is created across
magnetization branch and hence core losses are maximum. Since the
impedance of the series winding of the transformer is very small compared to
that of the excitation branch, all of the input voltage is dropped across the
excitation branch. Thus the wattmeter measures only the iron loss. This test
only measures the combined iron losses consisting of the hysteresis loss and
the eddy current loss. Although the hysteresis loss is less than the eddy current
loss, it is not negligible. Since the secondary of the transformer is open, the
primary draws only no-load current, which will have some copper loss. This
no-load current is very small and because the copper loss in the primary is
proportional to the square of this current, it is negligible. There is no copper
loss in the secondary because there is no secondary current. Following figure
shows the equivalent circuit of short circuit test

Figure 1: Open Circuit Test

Following table shows the result of short circuit test performed

6
Air University

Figure 2: Open Circuit Test Readings

𝐼𝑜𝑐 = 0.557 𝐴

𝑉𝑜𝑐 = 214 𝑉

𝑃𝑜𝑐 = 28.15 𝑊

𝑃𝑜𝑐 = 𝑉𝑜𝑐 𝐼𝑜𝑐 𝑐𝑜𝑠𝜃𝑜𝑐

28.15
𝑐𝑜𝑠𝜃𝑜𝑐 =
214 × 0.557
𝑐𝑜𝑠𝜃𝑜𝑐 = 0.236

𝜃𝑜𝑐 = 76.35

𝐼𝑜𝑐
𝑌𝑎𝑏𝑠 = = 0.00260 𝑆
𝑉𝑜𝑐

𝑌 = 𝑌𝑎𝑏𝑠 𝜃𝑜𝑐

𝑌 = 0.00260 cos −76.36 + 0.00260 sin −76.36

𝑌 = 6.131 × 10−6 − 𝑗2.52 × 10−3

Comparing with

1 𝑗
𝑌= −
𝑅𝑐 𝑋𝑚

𝑅𝑐 = 163𝑘𝑜ℎ𝑚

𝑋𝑚 = 396 𝑜ℎ𝑚

7
Air University

Short Circuit Test

The purpose of a short-circuit test is to determine the series branch parameters
of the equivalent circuit of a real transformer. The test is conducted on the
high-voltage (HV) side of the transformer where the low-voltage (LV) side or
the secondary is short circuited. A wattmeter is connected to the primary. An
ammeter is connected in series with the primary winding. A voltmeter is
optional since the applied voltage is the same as the voltmeter reading. The
LV side of the transformer is short circuited. Now with the help of varying
applied voltage is slowly increased until the ammeter gives reading equal to
the rated current of the HV side. After reaching at rated current of HV side, all
three instruments reading (Voltmeter, Ammeter and Watt-meter readings) are
recorded. The ammeter reading gives the primary equivalent of full load
current IL. As the voltage applied for full load current in short circuit test on
transformer is quite small compared to the rated primary voltage of the
transformer, the iron losses in transformer can be taken as negligible here.
Following figure shows the equivalent circuit of short circuit test.

Figure 3: Short Circuit Test

Following table shows the result of short circuit test performed

8
Air University

Figure 4: Short Circuit Test Reading

𝐼𝑠𝑐 = 0.248 𝐴

𝑉𝑠𝑐 = 26.54 𝑉

𝑃𝑠𝑐 = 3.887 𝑊

𝑃𝑠𝑐 = 𝑉𝑠𝑐 𝐼𝑠𝑐 𝑐𝑜𝑠𝜃𝑠𝑐

3.887
𝑐𝑜𝑠𝜃𝑠𝑐 =
26.54 × 0.248
𝑐𝑜𝑠𝜃𝑠𝑐 = 0.591

𝜃𝑠𝑐 = 53.803

𝑉𝑠𝑐 26.54
𝑍𝑎𝑏𝑠 = = = 107.016 𝑆
𝐼𝑠𝑐 0.248

𝑍 = 𝑍𝑎𝑏𝑠 𝜃𝑠𝑐

𝑍 = 107.016 cos 54.803 + 0.00260 sin 54.803

𝑍 = 61.68 + 𝑗87.45

Comparing with

𝑍 = 𝑅𝑠 + 𝑗𝑋𝑠

𝑅𝑠 = 61.68 𝑜ℎ𝑚

9
Air University

𝑋𝑠 = 87.45 𝑜ℎ𝑚

Efficiency
Efficiency of a transformer can be defined as the output power divided by the
input power. That is efficiency = output / input.

Transformers are the most highly efficient electrical devices. Most of the
transformers have full load efficiency between 95% and 98.5%. As a
transformer being highly efficient, output and input are having nearly same
value, and hence it is impractical to measure the efficiency of transformer by
using output / input. A better method to find efficiency of a transformer is
using, efficiency = (input - losses) / input = 1 - (losses / input).

Voltage Regulation
The measure of how well a power transformer maintains constant secondary
voltage over a range of load currents is called the transformer’s voltage
regulation. It can be calculated from the following formula:

𝑉𝑛𝑜 𝑙𝑜𝑎𝑑 − 𝑉𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑

𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑅𝑒𝑔𝑢𝑙𝑎𝑡𝑖𝑜𝑛 % = × 100
𝑉𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑

Unity Power Factor (Resistive Load)

Figure 5: Unity Power Factor Reading Table

Above figure displays the table for resistive load

10
Air University

Below figure shows the graph for resistive load

Figure 6: Unity Power Factor Graph

Leading Power Factor (Capacitive Load)

Figure 7: Leading Power Factor Reading Table

Above figure displays the table for capacitive load

Below figure shows the graph for capacitive load

11
Air University

Figure 8: Leading Power Factor Graph

Lagging Power Factor (Inductive Load)

Figure 9: Lagging Power Factor Reading Table

Above figure displays the table for inductive load

12
Air University

Below figure shows the graph for inductive load

Figure 10: Lagging Power Factor Graph

13
Air University

Conclusion
We constructed a single phase transformer following the basic design
procedure. This transformer is commonly used in labs for practical works and
performing open circuit test, short circuit test and to calculate voltage
regulation. Basically it is a step up transformer of ratio 11:19 and 1:1 if we
consider primary and secondary-II winding. In a way we can also refer it as a
step down transformer because of the tapping. We realize that the primary
voltage is less as compared to secondary but primary current is high as
compared to secondary. If we calculate the reactive power of both windings it
comes out to be 55VA which means reactive power throughout the
transformer remains same. We also used laminated silicon iron sheets to
reduce the eddy current losses. To reduce hysteresis loss we used soft
ferromagnetic material which is iron. Open circuit test and short circuit test
were performed on the transformer to measure the values of components that
deal with the losses of transformer. We also measured efficiency and voltage
regulation of transformer at unity, leading and lagging power factor.

14
Air University

References
http://www.construyasuvideorockola.com/transformador.php

https://www.youtube.com/watch?v=s6NyTprQCBI

https://en.wikipedia.org/wiki/Transformer

15
Air University

Appendix A

Table 5: AWG SWG table

16
Air University

Appendix B
Table 6:Cost Prices

Items Price in Rs

Framework 80

Core 680

Wax Paper 35

Masking Tape 60

Wire 450

Thermal Insulation, 200

Miscellaneous
Items

Total 1505

17