Lab Report: Detailed Repair and Working Analysis of a Variable
Transformer
Project Title:
Repair and Detailed Analysis of a 1kVA Variable Transformer
Objective:
1. To repair a 1kVA variable transformer with a shorted winding and a faulty voltmeter.
2. To understand and explain the working mechanism of a variable transformer.
3. To test the repaired transformer and ensure its proper functionality.
Apparatus and Tools Used:
1. Faulty Variable Transformer (1kVA): The subject of repair.
2. Multimeter: For diagnosing electrical continuity, resistance, and voltage.
3. Soldering Iron and Solder Wire: For repairing the winding and making electrical
connections.
4. Insulating Tape: For re-insulating the repaired winding.
5. Replacement Voltmeter: Procured from Karachi, identical to the original model for
compatibility.
6. Screwdrivers, Pliers, Wire Stripper, and Cutter: For mechanical disassembly and
wiring.
7. Insulating Varnish: For protecting the rewound winding from future damage.
8. AC Power Supply: To test the repaired transformer.
9. External Multimeter: For cross-checking voltage output.
Theory: Working of a Variable Transformer
A variable transformer (autotransformer) is a single-winding device capable of producing a
variable output voltage. Unlike standard transformers, which have separate primary and
secondary windings, a variable transformer uses one continuous winding with a sliding
contact (brush).
Core Components:
1. Winding: A single coil of copper wire, often with taps or a sliding brush to select
voltage output.
2. Brush/Sliding Contact: Adjusts the point of contact along the winding to control the
number of turns in the output circuit.
3. Core: Laminated iron core to reduce losses and enhance magnetic coupling.
4. Voltmeter: Displays the output voltage.
Number of Turns in a 1kVA Transformer:
The number of turns required for the winding depends on the voltage and frequency of
operation. For a typical 1kVA transformer operating at 50Hz, the formula for the number of
turns per volt is:
No. turns per volt=10000/4.44⋅B⋅A⋅f
Where:
B = Flux density (Tesla)
A = Cross-sectional area of the core (m²)
f= Frequency (Hz)
Principle of Operation:
When AC input is applied to the winding, the core magnetizes, inducing voltage along
the winding.
By moving the brush, the number of active turns in the output circuit changes, thereby
varying the output voltage.
The output voltage is proportional to the number of turns in the circuit, controlled by
the brush’s position.
Procedure:
Step 1: Initial Inspection
Visual Check: The transformer’s casing, winding, and connections were visually
inspected. The winding showed signs of insulation burn, indicating a short circuit.
Voltmeter Test: The built-in voltmeter showed no response when tested, confirming
it
was faulty.
Step 2: Diagnosis
1. The transformer was disconnected from any power source.
2. A multimeter was used to check continuity across the winding. A short circuit was
confirmed in the middle section of the winding.
3. The voltmeter was also tested for continuity and functionality, confirming it was
irreparable.
Step 3: Repair of Winding
1. Identifying the Fault: The shorted portion of the winding was located by carefully
tracing the burned section.
2. Removing Damaged Wires: The faulty turns were unwound, and new copper wire of
the same specifications was used to replace the damaged section.
3. Rewinding: The repaired section was carefully rewound onto the core, ensuring the
turns matched the original design.
4. Insulation: The repaired winding was coated with insulating varnish and covered
with insulating tape to prevent future shorts.
Step 4: Replacement of the Voltmeter
1. The faulty voltmeter was unscrewed and removed.
2. A compatible voltmeter, procured from Karachi, was installed in its place.
3. The wiring connections were redone according to the original configuration, ensuring
the new voltmeter accurately measured the output voltage.
Step 5: Testing
1. The repaired transformer was connected to an AC power supply.
2. The sliding brush was moved incrementally to observe changes in the output voltage.
3. The voltage output was cross-verified using an external multimeter to confirm
accuracy.
4. The new voltmeter functioned correctly, displaying the transformer’s output voltage.
Results:
1. The damaged winding was successfully repaired, restoring the transformer’s
functionality.
2. The voltmeter was replaced with a compatible unit, ensuring accurate output voltage
readings.
3. The transformer’s output voltage varied smoothly as the brush was moved,
confirming proper operation.
Conclusion:
The repair of the 1VA variable transformer was a success. The winding was restored to its
original functionality, and the faulty voltmeter was replaced, enabling smooth and accurate
operation. The transformer is now ready for use in applications requiring variable voltage
output.
