ELECTRICAL ENGINEERING

WORKSHOP PRACTICE II
(ECEg 3133)

TRANSFORMER CONSTRUCTION
CHAPTER 1

Dr. Alejandro D. Pantallano

Assistant Professor
 OUTPUT EQUATION OF SINGLE PHASE TRANSFORMER
1. The equation which relates the rated kVA output of a transformer to the
area of core and window is called output equation.
2. In transformers the output kVA depends on flux density and ampere- turns.
3. The flux density is related to core area and the ampere-turns is related to
window area.
4. The low voltage winding is placed nearer to the core in order to reduce the
insulation requirement.
5. The space inside the core is called window and it is the space available for
accommodating the primary and secondary winding.
6. The window area is shared between the winding and their insulations.
7. The simplified cross-section of core type and shell type single phase
transformers are shown in Figures 1 and 2.
8. The induced Electromotive Force (emf) in a transformer,

E = 4.44𝑓𝛷𝑚 𝑇 volts

9. Electromotive Force (Emf) per turn,

𝑬
𝑬𝒕 = = 𝟒. 𝟒𝟒𝒇ɸ𝒎 𝑽𝒐𝒍𝒕𝒔
𝑻

10. The window in single phase transformer contains one primary and
one secondary winding.
11. The window space factor (Kw) is the ratio of conductor area in window
to total area of window.
𝐶𝑜𝑛𝑑𝑢𝑐𝑡𝑜𝑟 𝑎𝑟𝑒𝑎 𝑖𝑛 𝑤𝑖𝑛𝑑𝑜𝑤 𝐴𝐶
𝑲𝑾 = 𝑲𝑾 =
𝑇𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑤𝑖𝑛𝑑𝑜𝑤 𝐴𝑊
12. Conductor area in window,
𝑨𝑪 = 𝑲𝑾 𝑨𝑾

13. The current density is same in both the windings. Therefore Current density,

𝑰𝑷 𝑰𝑺
𝜹= =
𝒂𝒑 𝒂𝒔

14. Cross – section area of primary conductor,

𝑰𝒑
𝒂𝒑 =
𝜹
14. Cross - section area of secondary conductor,

𝑰𝒔
𝒂𝒔 =
𝜹

15. If we neglect magnetizing mmf then primary ampere turns is equal to

secondary ampere turns. Therefore turns,

𝑨𝑻 = 𝑰𝒑 𝑻𝒑 = 𝑰𝒔 𝑻𝒔
16. Total copper area in window,

Ac = Copper area of primary winding + Copper area of secondary

winding
= (Number of primary turns x area of cross-section of primary
conductor) + (Number of secondary turns x area of cross – section
of secondary conductor)

𝑰𝒑 𝑰𝒔 𝑰𝒑 𝑰𝒔
𝑨𝑪 = 𝑻𝒑 𝒂𝒑 + 𝑻𝒔 𝒂𝒔 = 𝑻𝒑 + 𝑻𝒔 𝑎𝑝 = and 𝒂𝒔 =
𝜹 𝜹
𝜹 𝜹

𝟏 𝟏
𝑨𝑪 = 𝑻𝒑 𝑰𝒑 + 𝑻𝒔 𝑰𝒔 = 𝑨𝑻 + 𝑨𝑻
𝜹 𝜹

𝟐𝑨𝑻
=
𝜹
17. On equating the above equations, we get,
𝟐𝑨𝑻 𝟏
𝑲𝑾 𝑨𝑾 = Therefore Ampere turns, 𝑨𝑻 = 𝑲 𝑨 𝜹
𝜹 𝟐 𝑾 𝑾

18. The kVA rating of single phase transformer is given by,

𝑺 = 𝑽𝒑 𝑰𝒑 𝒙𝟏𝟎−𝟑 𝑬𝒑 𝑰𝒑 𝒙𝟏𝟎−𝟑

𝑬𝒑 𝑬𝒑
= 𝑻𝒑 𝑰𝒑 𝒙𝟏𝟎−𝟑 𝑬𝒕 = and 𝑨𝑻 = 𝑻𝒑 𝑰𝒑
𝑻𝒑 𝑻𝒑

= 𝑬𝒕 𝑨𝑻 𝒙𝟏𝟎−𝟑
On substituting for E and AT from equations we get,

𝑲𝑾 𝑨𝑾 𝜹 𝒙 𝟏𝟎−𝟑
𝑺 = 𝟒. 𝟒𝟒𝒇𝚽𝒎
𝟐

= 𝟐. 𝟐𝟐𝒇𝚽𝒎 𝑲𝑾 𝑨𝑾 𝜹 𝒙 𝟏𝟎−𝟑

𝑺 = 𝟐. 𝟐𝟐 𝒙 𝒇 𝒙 𝑩𝒎 𝒙 𝑨𝒊 𝒙 𝑲𝑾 𝒙 𝑨𝑾 𝒙 𝜹 𝒙 𝟏𝟎−𝟑
 OUTPUT EQUATION OF THREE PHASE TRANSFORMER

SIMPLFIED CROSS-SECTION OF CORE TYPE THREE PHASE TRANSFORMER

(Figure 1)
1. The simplified cross-section of core type three phase transformer is
shown in Figure 1.
2. The cross-section has three limbs and two windows.
3. Each limb carries the low voltage and high voltage winding of a phase.

4. The induced Electromotive Force (EMF) per phase,

𝑬 = 𝟒. 𝟒𝟒𝒇ɸ𝒎 𝑻 𝒗𝒐𝒍𝒕𝒔

5. Electromotive Force (EMF) per turn,

𝑬
𝑬𝒕 = = 𝟒. 𝟒𝟒𝒇ɸ𝒎 𝑽𝒐𝒍𝒕𝒔
𝑻
In case of three phase transformer, each window has two primary and two secondary
windings.

The window space factor K is the ratio of conductor area in window to total
area of window,

𝑪𝒐𝒏𝒅𝒖𝒄𝒕𝒐𝒓 𝒂𝒓𝒆𝒂 𝒊𝒏 𝒘𝒊𝒏𝒅𝒐𝒘 𝑨𝑪

KW = =
𝑻𝒐𝒕𝒂𝒍 𝒂𝒓𝒆𝒂 𝒐𝒇 𝒘𝒊𝒏𝒅𝒐𝒘 𝑨𝑾

Therefore Conductor area in the window,

𝑨𝑪 = 𝑲𝑾 𝑨𝑾

6. The current density is same in both the windings. Therefore;

𝑰𝑷 𝑰𝑺
𝜹= =
𝒂𝒑 𝒂𝒔
where, I = Primary current per phase = Secondary current per phase
7. Area of cross - section of primary conductor,

𝑰𝒑
𝒂𝒑 =
𝜹

8. Area of cross - section of secondary conductor,

𝑰𝒔
𝒂𝒔 =
𝜹
9. If we neglect magnetizing magnetomotive force (mmf) then primary ampere
turns per phase is equal to secondary ampere turns per phase.

𝑨𝑻 = 𝑰𝒑 𝑻𝒑 = 𝑰𝒔 𝑻𝒔
9. Total copper area in window, Ac = (2 x Number of primary turns x area of cross-section of
primary conductor) + ( 2 x Number of secondary turns x area of cross - section of secondary
conductor)

𝑰𝒑 𝑰𝒔
𝑨𝑪 = 𝟐𝑻𝒑 𝒂𝒑 + 𝟐 𝑻𝒔 𝒂𝒔 = 𝑻𝒑 + 𝑻𝒔
𝜹 𝜹

𝑰𝒑 𝑰𝒔
𝑎𝑝 = and 𝒂𝒔 =
𝜹 𝜹
 𝟐
𝑨𝑪 = 𝑻𝒑 𝑰𝒑 + 𝑻𝒔 𝑰𝒔
𝜹

𝟐
= 𝑨𝑻 + 𝑨𝑻 𝑨𝑻 = 𝑰𝒑 𝑻𝒑 = 𝑰𝒔 𝑻𝒔
𝜹

𝟒𝑨𝑻
=
𝜹
On equating we get,

𝟒𝑨𝑻
𝑲𝑾 𝑨𝑾 =
𝜹
𝟏
𝑨𝑻 = 𝑲𝑾 𝑨𝑾 𝜹
𝟒
The kVA rating of three phase transformer is given by,
S = 3 x Volt-ampere per phase x 10-3

S= 𝟑𝑽𝒑 𝑰𝒑 𝒙𝟏𝟎−𝟑

𝑬𝒑 𝑬𝒑
= 𝟑 𝑻𝒑 𝑰𝒑 𝒙𝟏𝟎−𝟑 𝑬𝒕 = and 𝑨𝑻 = 𝑻𝒑 𝑰𝒑
𝑻𝒑
𝑻𝒑

= 𝟑𝑬𝒕 𝑨𝑻 𝒙𝟏𝟎−𝟑

On substituting for E and AT from equations we get,

𝑲𝑾 𝑨𝑾 𝜹 𝒙 𝟏𝟎−𝟑
𝑺 = 𝟑 𝒙𝟒. 𝟒𝟒𝒇𝚽𝒎
𝟒
ɸ𝒎
= 𝟑. 𝟑𝟑𝒇𝚽𝒎 𝑲𝑾 𝑨𝑾 𝜹 𝒙 𝟏𝟎−𝟑 𝑩𝒎 =
𝑨𝒊
On substituting for E and AT from equations we get,

𝑲𝑾 𝑨𝑾 𝜹 𝒙 𝟏𝟎−𝟑
𝑺 = 𝟑 𝒙𝟒. 𝟒𝟒𝒇𝚽𝒎
𝟒

𝑲𝑾 𝑨𝑾 𝜹 𝒙 𝟏𝟎−𝟑 ɸ𝒎
𝑺 = 𝟑 𝒙𝟒. 𝟒𝟒𝒇𝚽𝒎 𝑩𝒎 =
𝟒 𝑨𝒊

Therefore:

S = 𝟑. 𝟑𝟑𝒇𝑩𝒎 𝑨𝒊 𝑲𝑾 𝑨𝑾 𝜹 𝒙 𝟏𝟎−𝟑
Example 1: Design of Core type Transformer
Determine the dimension of core and yoke for a 1.1 kVA, 50 Hz single phase core type
transformer. A square core is used with distance between adjacent limbs equal to 2.6 times the
width of core laminations. Assume voltage per turn is 0.79 Vt, maximum flux density is
0.9Wb/m2, current density δ = 3A/mm2 and stacking factor 0.8.

Computation:

So to calculate voltage per turn for the above example when k is 0.75.

1. Electromotive Force (EMF) per turn

𝐸𝑇 = 𝑘 𝑆

𝐸𝑇 = 0.75 1.1

= 0.79 𝑉𝑜𝑙𝑡𝑠
2. Size of the core
a) Core Area (Ai)
𝐸𝑡
𝐴𝑖 =
4.44 𝑥 𝑓 𝑥 𝐵𝑚
0.79
=
4.44 𝑥 50 𝑥 0.9

= 0.00395 𝑚2 o𝑟 39.5 𝑐𝑚2

b) Gross core area (AFe)

𝐴𝑖
𝐴𝐹𝑒 =
𝐾𝐹𝑒

0.00395 𝑚2
= = 0.00494 𝑚2 𝑜𝑟 49.4 𝑐𝑚2
0.8
c) Dimension of Center limb

As the core is square let us find the

dimensions of the cross-section of the core
assuming that it will be inserted in to a
circular coil.
AFe is maximum when θ = 450

𝐴𝐹𝑒 = 𝐷 cos 𝜃 𝑥 𝐷 sin 𝜃 = 𝐷 cos 450 𝑥 𝐷 sin 450

𝐷2
=
2
𝐷= 2 𝑥 𝐴𝐹𝑒

= 2 𝑥 49.4 𝑐𝑚2

= 9.94 𝑐𝑚

𝐷
𝐷 cos 450 =𝑋= 𝑋 = 𝑦 = 7.03 𝑐𝑚 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑠𝑡𝑎𝑚𝑝𝑖𝑛𝑔
2
3. Window Area
𝑆 = 2.22 𝑥 𝑓 𝑥 𝐵𝑚 𝑥 𝐴𝑖 𝑥 𝐾𝑊 𝑥 𝐴𝑊 𝑥 𝛿 𝑥 10−3
1.1 = 2.22 𝑥 50 𝑥 0.9 𝑥 3 𝑥 10 6 𝑥 0.265 𝑥 0.00395 𝑥 𝐴𝑊 𝑥 10−3
𝐴𝑊 = 0.0035 𝑚2
𝐴𝑊 = 35 𝑐𝑚2
𝐴𝑊 = 𝐻𝑊 𝑥 𝑊𝑊

Distance between core limbs = 2.6 x X

𝐷 = 2.6 𝑥 𝑋 = 2.6 𝑥 7.03 = 18.28 𝑐𝑚

𝑊𝑊 = 𝐷 − 𝑋 = 18.28 − 7.03 = 11.25 𝑐𝑚

𝐴𝑊 35
𝐴𝑊 = 𝐻𝑊 𝑥 𝑊𝑊 ; 𝐻𝑊 = =
𝑊𝑊 11.25
= 3.11 𝑐𝑚

Depth of yoke dy = height of yoke hy = X = 7.03 cm

3. Dimension of the Transformer

a) Overall height of the transformer

𝐻 = 2ℎ𝑦 + 𝐻𝑊 = 2 𝑥 7.03 + 3.11 = 17.17 𝑐𝑚

b) Overall width of the transformer

𝑊 = 2 𝑥 𝑋 + 𝑊𝑊

= 2 𝑥 7.03 + 11.25 = 25.31 𝑐𝑚

c) Length of I type stamping

𝑌𝑜𝑘𝑒 = 𝑋 + 𝑊𝑊 = 7.03 + 11.25 = 18.28 𝑐𝑚 = 182.8 𝑚𝑚

𝐶𝑜𝑟𝑒 = 𝑋 + 𝐻𝑊 = 7.03 + 3.11 = 10.14 𝑐𝑚 = 101.4 𝑚𝑚

5. Number of Stampings

𝑐𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑟𝑒

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑡𝑎𝑚𝑝𝑖𝑛𝑔𝑠 =
𝑐𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑖𝑛𝑔𝑙𝑒 𝑠𝑡𝑎𝑚𝑝𝑖𝑛𝑔

𝐴𝐹𝑒
𝑁𝑆𝑇 =
𝐴𝑆𝑇

70.3 𝑥 70.3
= = 117
0.6 𝑥 70.3

Yoke stampings = 2 x 117 = 234

Core stamping = 2 x 117 = 234

6. Computation of the copper wire in the window

a) Copper area in the window (ACU)

𝐴𝐶𝑈 = 𝐾𝑊 𝑥 𝐴𝑊

= 0.265 𝑥 0.0035 𝑚2

= 0.0009275 𝑚2

b) Total copper area in the window

2 𝐴𝑇
𝐴𝐶𝑈 =
𝛿
2 𝐼𝑃 𝑥 𝑁𝑃
=
𝛿
𝛿
𝐴𝐶𝑈 𝑥 = 𝐼𝑃 𝑥 𝑁𝑃
2
3
927.5 𝑚𝑚2 𝑥 = 1391.25 𝐴𝑇 = 𝐼𝑃 𝑥 𝑁𝑃
2
7. Size of copper conductor in primary and secondary

a) Determine the number of turns in primary winding

1391.25 𝐴𝑇
𝑁𝑃 =
𝐼𝑃
1391.25 𝐴𝑇
=
5𝐴

= 279 𝑇𝑢𝑟𝑛𝑠

b) Size of copper in primary

𝐼𝑃
𝑎𝑃 =
𝛿

5
= 𝑚𝑚2 = 1.67 𝑚𝑚2
3
c) Determine the number of turns in secondary winding.
𝛿
𝐴𝐶𝑈 𝑥 = 𝐴𝑇 = 𝐼𝑆 𝑥 𝑁𝑆
2
𝐴𝑇
𝑁𝑆 =
𝐼𝑆
1391.25 𝐴𝑇
=
𝐼𝑆

Now to calculate the secondary current IS, we will assume the secondary
voltage is 70 volts. Therefore we get the equation:

𝑆 = 𝐼𝑆 𝑥 𝑉𝑆 = 1100 𝑉𝐴

1100 𝑉𝐴
𝐼𝑆 =
𝑉𝑆

1100 𝑉𝐴
= = 15.714 𝐴
70 𝑉
The number of turns in the secondary winding,

1391.25 𝐴𝑇
𝑁𝑆 =
𝐼𝑆

1391.25 𝐴𝑇
= = 89 𝑡𝑢𝑟𝑛𝑠
15.714 𝐴

d) Size of wire in the secondary

𝐼𝑆 15.714𝐴
𝑎𝑆 = = = 5.24 𝑚𝑚2
𝛿 𝛿
Example 2 – Design computation of Shell Type Transformer

Calculate the main dimension and winding details of a single phase transformer if the given
requirements are as follows; Power 11kVA, 2000/400 volts, line frequency is 50 HZ, constant
for EMF per turn k is unity, flux density in core is 1.1 Wb/m2, window factor KW is 0.29 and
stacking factor kFe is 0.9.

Assume:
𝑤𝑖𝑛𝑑𝑜𝑤 ℎ𝑒𝑖𝑔ℎ𝑡 𝑐𝑜𝑟𝑒 𝑑𝑒𝑝𝑡ℎ
=3 = 2.5
𝑤𝑖𝑛𝑑𝑜𝑤 𝑤𝑖𝑑𝑡ℎ 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑐𝑒𝑛𝑡𝑟𝑎𝑙 𝑙𝑖𝑚𝑏

1. EMF per turn

𝐸𝑇 = 𝑘 𝑆

= 1 11

= 3.32 𝑣𝑜𝑙𝑡𝑠
2. Core computation

a) Core area (Ai)

𝐸𝑇 3.32 𝑣𝑜𝑙𝑡𝑠
𝐴𝑖 = =
4.44 𝑥 𝑓 𝑥 𝐵𝑚 4.44 𝑥 50 𝐻𝑍 𝑥 1.1

= 0.0136 𝑚2

= 136 𝑐𝑚2

b) Gross iron core area of central limb.

𝐴𝑖
𝐴𝐹𝑒 =
𝐾𝐹𝑒

136 𝑐𝑚2 = 151.2 𝑐𝑚2

=
0.9
c) Core depth (b)/width of central limb (2a) = 2.5
𝑏
= 2.5 𝑏 = 2.5 𝑥 2𝑎 = 5𝑎
2𝑎

d) Gross central limb cross-sectional area (AFe = b x 2a

= 5a x 2a
= 10a2
Therefore; AFe = 10a2

𝐴𝐹𝑒 𝐴𝐹𝑒 151.2

= 𝑎2 𝑎= =
10 10 10

= 15.12 = 3.89 𝑐𝑚

Width of central limb 2a = 2 x 3.89 = 7.78 cm

Core depth b = 2.5 x 2a = 2.5 x 7.78 = 19.45 cm

 3. Yoke computation

The yoke carries half of the flux coming out of the central limb. Assume the same flux density
in yoke and core, the yoke area will be half that of core area. Therefore the gross core area of
the yoke.

151.2 𝑐𝑚2
𝐴𝑌 = = 75.6 𝑐𝑚2
2

Depth of the yoke 𝐷𝑌 = 𝑏 = 19.45 𝑐𝑚

𝐴𝑌 75.6
Height of the yoke: 𝐻𝑌 = = = 3.89 𝑐𝑚 = 𝑎
𝐷𝑌 19.45

4. Window computation
4. Window computation

The side limbs carry half of the flux as in the central limb. Therefore the width of the side limb will be
half of the width of central limb as; a = 3.89 cm.
The output equation for a single phase transformer is,

𝑆 = 2.22 𝑥 𝑓 𝑥 𝐵𝑚 𝑥 𝐾𝑊 𝑥 𝛿 𝑥 𝐴𝑖 𝑥 𝐴𝑊 𝑥 10−3

11 = 2.22 𝑥 50 𝑥 1.1 𝑥 0.265 𝑥 2 𝑥 106 𝑥 0.0136 𝑥 𝐴𝑊 𝑥 10−3

11
𝐴𝑊 =
2.22 𝑥 50 𝑥 1.1 𝑥 0.265 𝑥 2 𝑥 13.6

= 0.0125 𝑚2 = 125 𝑐𝑚2

𝑊𝑖𝑛𝑑𝑜𝑤 𝐻𝑒𝑖𝑔ℎ𝑡
=3
𝑊𝑖𝑛𝑑𝑜𝑤 𝑊𝑖𝑑𝑡ℎ
𝐻𝑊 = 3𝑊𝑊

𝐴𝑊 = 𝐻𝑊 𝑥 𝑊𝑊

= 3 𝑊𝑊 𝑥 𝑊𝑊

2
= 3 𝑊𝑊

𝐴𝑊 125
𝑊𝑊 = = = 6.46 𝑐𝑚
3 3

𝐻𝑊 = 3 𝑥 𝑊𝑊

= 3 𝑥 6.46

= 19.38 𝑐𝑚
5. Overall height of the transformer,

𝐻 = 𝐻𝑊 + 2𝑎

= 19.38 + 7.78 = 27.16 𝑐𝑚

𝑊 = 𝑎 + 𝑊𝑊 + 2𝑎 + 𝑊𝑊 + 𝑎

𝑊 = 4𝑎 + 2 𝑊𝑊

= 4 𝑥 3.89 + 2 𝑥 6.46
6. Number of turns in Primary and secondary windings

a) Primary turns

𝐸𝑇 𝑥 𝑁𝑃 = 220 𝑣𝑜𝑙𝑡𝑠

220 𝑣𝑜𝑙𝑡𝑠
𝑁𝑃 =
3.32

= 67 𝑡𝑢𝑟𝑛𝑠

b) Secondary turns

𝐸𝑇 𝑥 𝑁𝑆 = 50 𝑣𝑜𝑙𝑡𝑠

50 𝑣𝑜𝑙𝑡𝑠
𝑁𝑆 =
𝐸𝑇

50 𝑣𝑜𝑙𝑡𝑠
= = 16 𝑡𝑢𝑟𝑛𝑠
3.32
7. Size of wire in Primary winding 8. Size of wire in Secondary winding,

1100 𝑉𝐴 1100 𝑉𝐴
𝐼𝑃 = = 50𝐴 𝐼𝑆 = = 220𝐴
220 𝑣𝑜𝑙𝑡𝑠 50 𝑣𝑜𝑙𝑡𝑠

𝐼𝑃 𝐼𝑆
𝑎𝑝 = 𝑎𝑆 =
𝛿 𝛿

𝑎𝑝 220𝐴
50𝐴 𝑎𝑆 =
2𝐴ൗ
= 𝑚𝑚2
2𝐴ൗ
𝑚𝑚2

𝑎𝑝 = 25𝑚𝑚2 𝑎𝑆 = 110𝑚𝑚2