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Design and Construction of Constant Voltage Transformer

Conference Paper · September 2006

DOI: 10.1109/ICIIS.2006.365632 · Source: IEEE Xplore

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First International Conference on Industrial and Information Systems, ICIIS 2006, 8 - 11 August 2006, Sri Lanka
Design and Construction
Trans former
Mendis N.N.R, Yatiyana E.M.M.B, Wijesinghe K.C, Lucas J.R and Perera R.
Department of Electrical Engineering, Faculty of Engineering, University of Moratuwa Sri Lanka
,ha roidik.com, yatiyana c AK, Kasun ya oo.co, lVucas e ect.mrt"ac.k, *hyrp gelect.mrt.ac.lk
Abstract - This paper presents the design and
construction of Constant Voltage Transformer by means of
conventional power transformer core structures. The
Constant Voltage Transformer is suitable for use to mitigate
the power quality problems associated with the Sri Lankan
industrial sector. However, even in today's age of
information, many Sri Lankan industrial facilities are not
aware of one attractive Constant Voltage Transformer
feature - "the ability to mitigate the effects of voltage sags".
This method of maintaining the power quality has proven
more effective and reliable in international arena
1. INRODUCTION
Sri Lanka is a country where variation in quality of
power supply is too irregular. "Poor Power Quality" affects
adversely to all over the sectors of the economy, resulting a
huge loss of revenue to the county annually in tangible and
intangible forms.
Although the most electrical equipments can operate
without problems even if voltage varies by up to 6%, may
out of tolerance voltages still occur the generally classified
as sags, surges and brownouts. These problems disrupt the
smooth functionality of the industrial processes.
Ferroresonant Voltage Transforner is popularly known,
as CVT are robust and simple. It provides an A.C output
voltage of nearly constant magnitude even when the input
voltage changes over a specified range. It is also
completely and continuously short circuited in use, without
any adverse reaction. Ferro resonance regulators are the
best and most reliable power conditioners for applications
ranging from process control and automation to remote
sites and third world applications. And many more other
power quality features ensure the use of it as an excellent
choice for mitigating power quality problems in Sri Lanka,
where variations in the quality of the power supply are all
too irregular, but where maintenance facilities are at a
premium.
In this paper, a method of design involving the
conventional power transforner cores is presented. Based
on the analysis, step - by - step procedure is evolved for
1-4244-0322- 7/06/$20. 00 c2006 IEEE
of Constant Voltage
optimizing the design [ 1 ] of the constant voltage
transforner. Based on this procedure, a proto type was
built and tested .The test results indicated good argument
between the predicted results through analysis and
experimental measurements, thus validating the design
procedure.
2. THEORY OF OPERATION
The operational theory of a constant voltage transforner
is based on a well-known phenomenon known as
"Ferroresonance" or Non-Linear Resonance. Some
literature compares the circuit it to that of a Zener diode.
Ferroresonance is the property of a transformer design in
which the transforner consists with two separate magnetic
paths with limited coupling between them. The output
contains a resonant circuit and it draws power from the
primary to replace the power deliver to the load. The B-H
characteristic of the transforner is given in (Fig- 1). It
operates in the region where denoted as "saturated region".
The following illustrate the way of achieving the constant
voltage at a load end.
Transforner output voltage is given by following
equation.
E(av)output =4.44BNAJ
Where
B = saturated flux density (T)
N = no of turns at out put
f = operating frequency (Hz)
A = cross section area (m2)
Let consider the working flux range (X-Y) of the
transforner shown in (Fig -1).
40
First International Conference on Industrial and Information Systems, ICIIS 2006, 8 - 11 August 2006, Sri Lanka

VL
AB= Bx By

But AB O L

Therfore Bx By
yin SR e> tvo
*

(N, A and f are cons tan t for a given ....................... ....................................................

I ioti
transformer)
Fig 2 - Equivalent circuit of a ferro resonance regulator

A constant voltage is achieved during its operation. Where

Flux Density (B)

L-linear inductor
x y C-linear capacitor
R-Load resistor
The known parameters are
Vl- Input voltage (Voltage that take just before the
regulation)
f - Source frequency
Magnetizing force (H) W Output watts (VO2 /R)

B-H LOOP FOR SR

Parameters to be calculated
Fig I - B-H curve Characteristic L -Inductor value

3. DESIGNING THE PARAMETERS C -Capacitor value

The design of constant voltage transformer is basically Cos -Input power factor
based on designing of its electrical parameters and
mechanical parameters. The electrical parameters are VO -Voltage where SR designed to saturate
associated with capacitance, inductance estimation,
regulated voltage input range and short circuit current. etc. VL -Voltage across the inductor
The mechanical parameters are dealt with calculation of
core dimensions. Is -Short circuit current (when R=O)

Ii -Input Current
3.1 ELECTRICAL PARAMETER CALCULATION
(Li2+Cv2) -Determines the physical size of L and C.
The equivalent circuit of a ferroresonance regulator is
shown in (Fig -2). During the design process the values for The equivalent circuit (Fig -2) is used to derive the
linear inductor (L), Linear capacitor (C) and Short circuit expressions for electric parameters. By applying the circuit
current (Is) should be derived. During the above parameter laws, the expressions are derived to evaluate the values for
estimation the saturating reactor (SR) is neglected due to C, L, Cos (I) VO and Is.
its high impedance at low line condition compared to L, C
and R. [1]

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First International Conference on Industrial and Information Systems, ICIIS 2006, 8 - 11 August 2006, Sri Lanka

i2
C
w
iW-
wVorK Cos/
(k
(1)

Where K=Vo/V1,w =omega

kVl2 2
L= Cos$VI -C Sin2$] (2)
Ww
[

CVo2 +Li2= _22 I1 -tan (t] (3)

w L Cos(t)

is 1
(4)
i
CosJI QCOSj _Sin2(j
Q
Fig 3 - Power factor variation

Equation (3) gives the physical size of equipment and Considering all the practical issues and referring the
equation (4) gives the short circuit current. Both equation phasor diagrams associate with the equivalent circuit in
plots against k value for different input power factor (Fig -2). The basic design equations can be summarised as
values. in below.
According to the graph in (Fig-3) the best value k (
Vo/Vl) is 1.6. The value is chosen such that it gives a (1) Cos (I 0.97
small short circuit current and smaller size at higher power
factor of 0.97. The subsequent expressions for the
equations (1), (2), (3) and (4) can be expressed as follows. (2) i1 W/(0.97 *V1)

(3) L 1.48 *V12/(W*w) and VL = 1.53 V1

L 1.48V12/ (W*w)

(4) Design saturating reactor to saturate at 1.6 VI

C W/ (1.95*Vl2w)
Due the non-linearity of the saturating inductor (SR) the
practical value of the capacitor is given by (4)
( CV2o + Li2 ) 2.84WIw

(5) C =W/(1.77*Vl*w),
1.1
i0
io
(6) CV2o = 1.445 W / w

(7) 1.1
0

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First International Conference on Industrial and Information Systems, ICIIS 2006, 8 - 11 August 2006, Sri Lanka

4.2 MECHANICAL PARAMETER CALCULATION 5. DESIGN OF FILTER CIRCUIT

The core is three-limed shell with a magnetic leakage The saturation of the core leads to there being harmonic
path (Shunt), dividing the winding space. The secondary fluxes present. These cause distortion of the output voltage
limb consists of two windings called capacitive winding waveform. Therefore to restore the quality of the voltage
and output winding (Secondary winding). form the filter circuit is incorporated. Filtering is achieved
by. And also a "compensating winding " can be
introduced, in which it produces a small voltage that is
used to buck the out put voltage.
Secondawy
winding
Priame
whnlng
ADD COMPENSATING
Air WINDING
gap

PRIMARY

Capaidtive ADD A CHOKE

wMndirig
230V NEW
G
~~~~~~~~~~~~~~~~V0

Fig.4 -Basic core structure ofthe constant voltage transformer

INCREASE TAPPING POINT ------l,-
TO OVERCOME VOLTAGE C
DROP IN COWPENSATING WDG.
The mechanical parameters (Core dimensions) are V0
derived, referring the conventional power transformer core
equations. Some of basic equations associate with core
parameters estimation can be stated as follows. [5]
Fig 5 - Regulator with filter circuit

(1)A= 1.5*kVA - Cross section area

The value for choke should be calculated such that,
calculation
L total = Leakage inductance + Choke inductance

17.26 * S * P
(2) W*a= f*B - Window size 5. TEST RESULTS

calculation The regulated input voltage range is in between 1 90V to

250 V.
NT 108
(3) -=- - Per turn voltage Output vs Input ourye for 25 (C Ia 51F}
V 28.64*f*a*B
..250
calculation

Where
iso
W Window area in square inches I,I
np.t
anoev
a Cross section area in square inches ic00
f Frequency in hertz
B Flux density in gauss
p Power in watts
S Current density (CMIA)
U so 1 150 200 25 3U
\AIQm
N Number of turns
V Voltage in volts Fig 6 - V out vs. V in

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43
First International Conference on Industrial and Information Systems, ICIIS 2006, 8 - 11 August 2006, Sri Lanka

(Fig -6) shows, output voltage is nearly constant after
saturation. The saturation voltage is 230 V. For 250 VA
loads input voltage working range is 190-250V. For the
above input range output is within 1%.
The efficiency is in between 75-80%.
According to the graph the efficiency of the regulator is
almost 80% at the full load conditions. This is one of the
drawbacks of the regulator. And also the transformer is
less efficient at light load conditions. As a result, there is a
fixed amount of power required to maintain the saturation.
Losses are introduced due to the saturation of the core and
the considerable current circulating in the secondary
winding.
The output waveform contains odd harmonics. The major
harmonics are 3rd, 5th and 7th. Without having the
arrangement as in Fig (5) the THD level is around 17% at
230 V.
The secondary of the constant voltage transformer is
driven in to the saturation mode of operation; hence it
introduces a non-linear magnetic behaviour at the output.
Therefore it contains considerable amount of harmonics.
According the waveform observed it contains 3rd
harmonics, 5th and 7th harmonics in large proportions. But
it was reduced by 10%, introducing a filter circuit at output
as in (Fig -5).
6. TECHNICAL SPECIFICATIONS OF THE TRASFORMER

1E0-
Rated Capacity 250 VA
Input Voltage Range 190 V - 250 V A.C,
1 CD
Frequency 50 + 2.5 Hz
Output Voltage 230 V A.C, 1 (D
40 - Line Regulation 1% @ rated load
Load Regulation 2%0
THD 7°O
Q I
Efficiency 80%0
0 40 so 120 160 200 240
Capacitor Range 12.5 iF -14 iF
Short Circuit Current 1.6* rated current
Fig 7- Efficiency curve for 25OwLoad (13.5gf)

Total Harmonic Distortion (THD) was recorded 700 CONCLUSION

The exhilarating work associated with construction had

I 10III
e10 noh anticipated. The initial studies opened up Sri Lanka for
new technology, methodologies and research avenues,
which were unheard, therefore unexplored before.
60 The main objective of introducing the constant voltage
transformer technology to Sri Lanka was achieved.
40 Analyzing constant voltage transformer technology,
implementation of core by scarce resources and tuning the
20 matching capacitor value proved to be difficult. Actual
l[I1U
2 | 14 15 1 2 1r implementation was faced by many challenges such as lack
of technological knowledge, machine limitation, and
0 labour management. Group can state with pride that most
1 3 5 Harn1.
IU- n be of the issues hindering the project were dealt with and
overcome successfully. The achievement is expected to
Fig -8 Harmonics at output without filter bring more attention to constant voltage transformer
concept, where it should undergo research to develop for a
better version.

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First International Conference on Industrial and Information Systems, ICIIS 2006, 8 - 11 August 2006, Sri Lanka

ACKNOWLEDGMENT

The Author thanks Mr. Kosal Gunawardne, Lanka

Transformer (Pvt) Limited, Sri Lanka for the help rendered
during the implementation of the project. And also the
appreciation goes to Professor Rohan Lucas and Professor
Ranith Prera for their great advices during the design and
implementation of the project

REFERENCES:
[1] Harry P.Hart & Robert J.Kakalec, "The Derivation and Application
of Design Equation for Ferroresonant Voltage regulators and
Regulated Rectifiers"
[2] B.Friedman, "The Analysis and Design of Constant Voltage
Regulator", IEEE Trans.- Components parts, Mar. 1956, pp. 1 1-14
[3] H.P. Hart and R.J. Kaklec, "The Derivation and Application of
design equations for Ferroresonant Voltage Regulators and Regulated
Rectifiers" IEEE Trans. on Mngn., Mar. 1971, pp. 205-21 1.
[4] IEEE Standard 44911984 for Ferroresonant Voltage Regulators

[5] Eric Lowdon,(1985) Practical Transformer Design Handbook,

First Edition,51-82,BPB Publication, New Delhi.

1-4244-0322- 7/06/$20. 00 c 2006 IEEE

45

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