A Proposed 37.

5KVA, 1, Distribution Transformer

Design a Transformer to meet the following Specification:
Type of Distribution : CORE
Output in KVA : 37.5kVA
Primary (HT) Volts : 2400 V
Secondary (LT) Volts : 240/120 V (multi-tap)
Frequency : 60 Cycle
Efficiency at Unity Power Factor
Full Load : 98.4 %
Load : 97.8 %
Temperature rise not to exceed to 55c


CALCULATIONS:

Guaranteed Losses:
Total Loss at Full Load

Total Loss at Full Load

Full Load Copper Loss

Core Loss

y Item 1. Voltage Per Turn use c = 62(core type distribution transformer)

= 3.1233 volts

y Item 2 to 4. Primary and Secondary Turns. It is desirable to use Two coils on the High
Tension Side and Four coils of the Low Tension Side.

Total Secondary Turns =

= 76 turns

Turns per Secondary coils =

= 19 turn/coil

Total Primary Turns = =760 turns

Turns per Primary coils =

= 384 turn/coil





y Item 5. Full Load Current

High Tension Low Tension

y Item 6 to 15. Before deciding upon the sizes of wire in the windings, it would be advisable to
the probable dimensions of the opening or window, which must accommodate both primary
and secondary windings. (assume Current Density = 1500 amp/sq. inch)
o Space factor =

o H x D=

inch
o D 4.5 inch
o inch

y the flux in the iron is

y From art 130. We select 70000 lines per sq. in as a trial density in the limbs under windings.
Hence the proportion S = 1.5L and stacking factor of 0.9

inch
inch inch

y Assuming M=L, the same cross section of iron and the same flux density in the end of the core
as in the limbs under windings M= 3.5 inch
y Weight of iron

Weight of iion
y Total core loss watts per pound of B= 70000 be 0.75 from fig. 154

Size of Wires And Winding Particulars

y Thickness CSA / Width

Length of winding space in the Layer = 11.25-0.5 = 10.75 (from fig.)
Width of one Conductor including insulation =

Cotton Coverings = 0.02 in (20 mils)
Width of Copper = 0.56579-0.02 = 0.54579 inch
Thickness =

= 0.285 inch
y For rectangular conductor

y For high tension side select the size of wire at the table on page 431 use size No.7 DCC wire

Length of winding Layer = 10.5 (from fig.)
Number of Wires per Layer = 10.5 x 6.36 = 66.78
where 6.35 is obtained from the wire table on page 431.
y Total Number of Layers of Wire

(for each 2 limbs)
y Volts (RMS)

y It is usual to limit the potential difference between layers which can generally be accomplish the
number of windings in the sufficient number of separate coils providing adequate insulation
between coils with core dimension. Thickness of copper and insulation is computed as follows.

y Item 16 to 23.
Materials Radial Thickness
Cotton tape binding assembled laminations
Varnished cambric
Pressboard
Clearance
0.018
0.010
0.030
0.067


t = 0.125
Inner L.T. coil (one layer) including cotton on wire
Parchment paper (0.010) between coils; allow
Outer L.T. coil (one layer)
0.305
0.015
0.305

s = 0.625
Pressboard around outer L.T. coil
Spacers of treated wood to form oil ducts
Pressboard
Two layers cotton tape
Parchment paper w/ crimped edges on w/c primary and
secondary coil will be wound
0.020
0.125
0.020
0.018

0.005


g = 0.188
6 layers of No. 7 dcc round wire
Two thickness of 0.005 papers between layers
Cotton tape, half lapped
Allowance for bulging (0.02 x 3.05)
0.936
0.080
0.018
0.090


p = 1.124
Total 2.062

Space available to accomodate this total thickness of copper and insulation =

=2.25 in.

CALCULATION OF COPPER LOSS

y The mean length per turn (MLT) of the windings

y Total Length of Wire
Primary Winding = 760 x 2.145 = 1630.2 ft
Secondary Winding = 76 x 1.69 = 128.44 ft
y Weight of Copper Loss
Primary Coils (No.7), 63 x 1.6302 = 102.70 lb
Secondary Coils = 0.32(.285 x 0.55 x 128.44 x 12) = 77.31lb
Since the resistance of No.7 DCC wire is 0.5790 ,

y Total Resistance
(Primary)
RT = 0.61 x 1.6302 = 0.99

IR = 15.625 x 0.99 = 15.497 volts

(Secondary)

RT=

IR = 156.25 x = 1.17 volts

Total Copper Loss = 242.23 + 183.11 = 425.34 watts

y Items 24 32.
Core and Copper Losses 158 + 425.34= 583.34 watts
Flux density in core under windings =

Cross section of iron core under winding =
Weight of two limbs =




y Items 33. Efficiency at unity power factor

@

Full Load :

@ Full load :

@ Half Full load :

@ Three quarter full load :

@ 25% over load :

Maximum Efficiency:

0.9864
y Items 34. Basis of 4 hour full load and 20 hour no load.

All Day Efficiency:






y Item 35. For the two limbs under the winding with mean length
B =
Mean Length = 2 x (3.5 + 5.25 + 4.5) = 26.5


For the two limbs outside the winding with mean length
x



Total (T x I) = + = 222.6 amp. turns

y Item 36 to 39. Regulation
Biop

% Regulation @ 0.80 power factor



y Item 40 to 42. The temperature rise of the windings as measured by the resistance method
must not exceed the specified 55.

For the dimension of tank total area





Dimension are 18.25 x 14.75 x 28.25 in high
Cooling Effective Surface

For temperature








Item No.

SUMMARY OF CALCULATIONS

1 Volts per turn : From formula = 3.1233 v
Windings High Tension Low Tension
2 Total numbers of turns 760 76
3 Numbers of coils 2 4
4 Turns per coil 384 19
5 Full Load Current (Amp) 15.625 156.25
6 Current Density(

) 955 997
7 Cross Section of Conductor 0.01635 0.15675
8 Dimension of Conductors No. 7 0.55 x 0.285
9 No. of Turns per Layer per Coil 69 19
10 No. of Layer per Coil 6 1
11 No. of Taps None 2
12 Volts per Coil 1200 60
13 Volts Between Layers 486.75
14 Length of Winding Layers 10.5
15 Length of Layer Including Insulation
16 Insulation Between Layers 0.02
17 Insulation on Wire dcc dcc
18 Length per Turn 2.145 1.69
19 Total Length, all Turn in series, ft 1630.2 128.44
20 Weight in Copper(lbs) 102.70 77.31
21 Resistance a 75 c All Coils 0.99 0.0075
22 IR Drop Volts 15.497 1.17
23 Full Load Copper Loss(Compare to Guaranteed)242.23 183.11



THE MAGNETIC CIRCUIT

24 Dimension of Windows 11.25 x 4.5
25 Total Flux, Maxwells 1185395.922
26 Flux Density in Core Under Windings 64500
27 Cross Section of Iron in Core Under Windings 18.375
28 Width of Stampings in Core Under Windings 3.5
29 Gross Thickness of Core 5.25
30 Total Weight of Iron in Core, lbs. 231.525
31 Watts Loss in Iron (compare to guaranteed) 158
32 Total Full Load Losses, watts 425.34



EFFICIENCY AND EXCITING CURRENT

33 Efficiency at Unity Power Factor
At Full Load 0.9847
At Load 0.9861
At Load 0.9806
At Load 0.9860
At 25% Over Load 0.9828
34 All Day Efficiency (4Hr Full Load) 0.9647
35 Primary Exciting Current, Amp. 0.2173

REGULATION

36 Total Equivalent IR Drop Percent 1.56
37 Total Reactive Drop Percent 3.56
38 Regulation on Unity Power Factor 1.56
39 Regulation on 0.80 Power Factor 3.384

DESIGN OF TANK TEMPERATURE RISE

40 Effective Cooling Surface of Tank, sq. inch. 2122.28
41 Watts per square inch of Tank 0.275
42 Approximate Temperature Rise, 67