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Study Unit
38700801
Study Unit
Transformers for
Electronic and Other
Applications
By
Robert L. Cecci
All terms mentioned in this text that are known to be trademarks or service
marks have been appropriately capitalized. Use of a term in this text should
not be regarded as affecting the validity of any trademark or service mark.
Pr eview
common uses of transformers are in the transmission of
electric power, in control and signal circuits, and in
electronic and radio equipment.
This study unit will introduce you to the fundamental
concepts of transformers.
iii
OPERATION OF TRANSFORMERS 1
Contents
What Is a Transformer? 1
Mutual Inductance 2
Step-Down and Step-Up Transformers 3
Turns Ratio 4
Voltage Ratio and Secondary Voltage 5
Conditions in Open and Closed Secondary Circuits 6
Power in Primary and Secondary Windings 7
Load Current in Primary and Secondary Windings 9
Transformer Losses 11
Reducing Losses 11
Transformer Regulation 12
TYPES OF TRANSFORMERS 14
Transformer Construction 14
Core-Form and Shell-Form Transformers 14
Power Transformers 16
Distribution Transformers 17
Instrument Transformers 18
Transformers with Two Secondaries 18
Autotransformers 19
Transformers for Radio and Electronics 21
Specialty Transformers 21
Inductors 22
Saturable Reactors 23
Magnetic Amplifiers 23
Shielded Transformers 25
Constant-Voltage Transformers 25
Transformer Insulation 29
Transformer Ratings 30
Causes of Transformer Problems 30
SELF-CHECK ANSWERS 33
EXAMINATION 35
v
Transformers for Electronic and
Other Applications
OPERATION OF TRANSFORMERS
What Is a Transformer?
A transformer changes, or transforms, an alternating voltage
to a higher or lower alternating voltage. A transformer acts
very much like a pump in a water system that changes the
water pressure in the system.
If you take a basic transformer apart, you’ll find two separate
coils wound around an iron core (Figure 1). These are the
main parts of the transformer. The alternating voltage from a
voltage source (an alternator or a distribution power line) is
FIGURE 1—The primary winding in this transformer has 16 turns and the secondary has eight turns. The second-
ary voltage will therefore have one-half the value of the primary voltage. (The lower transformer symbol shown is
now the most commonly used transformer symbol.)
1
applied to one coil, which is called the primary winding, or
simply, the primary. The other coil is called the secondary
winding, or the secondary. The secondary isn’t connected in
any way to the primary or to any other voltage source. The
secondary is used to connect to the control circuit or elec-
tronic circuit.
Both coils are insulated from the core. The transformer sec-
ondary is normally connected to an electrical load, such as a
lamp or a motor. The primary is in a closed circuit with an
AC (alternating current) voltage source, the secondary is in a
closed circuit that includes the electrical load. The two cir-
cuits are magnetically coupled, but electrically isolated, from
each other. Normally the primary side of the transformer will
contain a fuse in its circuit. The secondary circuit also may
contain a fuse in its circuit.
When a voltage is applied to the primary, a voltage is induced
(or produced) in the secondary winding, and an alternating
current flows through the load. The applied voltage is also
called the primary voltage, and the induced voltage is the
secondary voltage. The induced voltage is due to mutual
inductance, which is an effect of electromagnetic induction.
Mutual Inductance
The relative movement between magnetic lines of force and a
conductor can generate, or produce, a voltage. In a generator,
a group of conductors is moving in a magnetic field, and a
voltage is induced in them. In a transformer, the conductors
don’t move, but the magnetic lines of force change because
the applied voltage changes.
The magnetic lines of force (or flux) created by the applied
voltage are shown by broken lines through the iron core
(Figure 1). The magnetic field indicated by these lines
changes with any variation in the applied voltage. The lines of
force change in number and in direction as they pass over
the turns of the secondary. The change of the magnetic field
has the same effect as movement, and the result is mutual
inductance—or a voltage induced in the secondary winding.
Turns Ratio
The change, or transformation, of voltage depends on the
ratio of number of turns in the primary to number of turns in
the secondary. The turns ratio is therefore a very important
factor in transformer structure. If the number of turns in the
primary is indicated by the symbol Np and the number of
turns in the secondary by the symbol Ns, the turns ratio can
be written as follows:
Np
ᎏᎏ or Np : Ns
Ns
1200
Es = ᎏᎏ ⫻ 50 Substitute the vaules of Ns, Np,
100
and Ep. Divide 1200 by 100.
Es = 12 ⫻ 50 Multiply 12 ⫻ 50.
Without using the formula, you can find the secondary volt-
age by reasoning as follows: The turns ratio is 100 : 1200 =
1 : 12. That means that the secondary has 12 times more
turns than the primary. It must, therefore, have a voltage 12
times higher, or 12 ⫻ 50 = 600 V.
Or, if a primary voltage of 24 V is applied to a step-down
transformer with 200 primary turns and 50 secondary turns,
the secondary voltage will be
Ns 50
Es = ᎏᎏ ⫻ Ep = ᎏᎏ ⫻ 24 = 6 V
Np 200
200
Ip = ᎏᎏ ⫻ 2 = 4 A
100
Reducing Losses
In a high-quality transformer, the losses are very small. For
example, the coils are wound with a wire large enough to keep
the I2R losses low, and the reluctance of the iron core is low,
keeping magnetic leakage very low. The use of certain alloys
Transformer Regulation
The resistance and other losses in a transformer reduce the
secondary voltage, making the value of the secondary voltage
under load different from the no-load value. When no load is
connected to the secondary, the ratio of primary to secondary
voltage is practically equal to the turns ratio. However, when
a load is connected to the secondary and current flows in the
transformer windings, there will usually be a decrease in the
secondary voltage. The change in secondary voltage resulting
from applying a load to a transformer divided by the full-load
secondary voltage is called the regulation of the transformer.
Transformer regulation, which is expressed as a percent is
given by the following formula:
Vs No Load – Vs Full Load
% Regulation = ⫻ 100
Vs Full Load
In a perfect transformer, which has no losses, the no-load
secondary voltage will be the same as the full-load voltage
and the transformer will have 0% regulation. Special trans-
formers known as constant-voltage transformers will be
discussed later in this study unit. Now, review what you’ve
learned by completing Self-Check 1.
1. The device that can change an AC voltage from one value to another is called a(n)
_______.
2. A change of voltage in one coil that leads to a voltage in another nearby coil is a result
of (self-, mutual) inductance.
3. If the secondary winding has five times as many turns as the primary winding, the
secondary voltage is _______ the primary voltage.
a. one-fifth c. five times
b. the same as d. twenty-five times
4. If the primary winding of a transformer has more turns than the secondary winding, it’s
called a step-_______ transformer. If the secondary has more turns, it’s called a step-
_______ transformer.
5. In the transformer shown below, find the secondary voltage if the primary voltage is
12 V.
6. The current that flows in the transformer primary with no load connected to the
secondary is called the _______ current.
7. What is the primary current in the transformer of question 5 when the secondary load
current is 4 A?
__________________________________________________________________________
Transformer Construction
A transformer, no matter what its type or form, is relatively
simple. It consists of an iron core, primary and secondary
windings, insulation, mechanical bracing (or other means of
holding the parts together as a unit), cooling means, case,
and bushings.
An iron core is needed in a transformer to provide an intense
magnetic field. An intense magnetic field produces the rated
voltage in the windings with a minimum of exciting current.
The iron core permits more lines of force to concentrate
within its own volume than within the same volume of air or
some other nonmagnetic material.
Cores are always laminated, that is, they’re made of thin steel
sheets called laminations. The laminations make transformers
cost more. They also reduce the eddy currents (currents
induced in the iron parts of the transformer). Laminations
are usually rectangle-shaped. However, on small transform-
ers, L-shaped and E-shaped laminations are sometimes used.
FIGURE 6—Each of the three-phase transformers here has three sets of primary windings and three sets of
secondary windings.
FIGURE 7—Transformers of
this size are seldom
installed inside a building.
Much of the equipment on
this transformer is required
for cooling the coils.
FIGURE 10—The potential transformer and two current transformers shown here are examples of instrument
transformers. The number on a current transformer is the value of full-load primary current required for a 5A sec-
ondary current.
Autotransformers
The usual transformer has two windings that aren’t wired
directly to each other. In an autotransformer, one of the
windings is connected in series with the other, as shown in
Figure 12A. (This is a step-up autotransformer.)
Specialty Transformers
Specialty transformers make up a large class of transformers
used for changing line voltage to some particular value best
suited to the load. The primary voltage is generally 600 V, or
less. A sign-lighting transformer is one example of a specialty
transformer in which the 120 V is stepped down to 25 V for
low-voltage tungsten sign lamps. Other examples include
arc-lamp autotransformers, where 240 V is stepped down to
the voltage required for best operation of the arc, and trans-
formers that are used to change 240 V power to 120 V for
operating portable tools, fans, welders, and other devices.
Also included in this specialty class are neon-sign transform-
ers that step the 120 V up to between 2000 and 15,000 V for
the operation of neon signs. Many special step-down trans-
formers are used for small work, such as ringing bells,
running electrical toys, operating battery-charging rectifiers,
and lighting individual low-voltage lamps.
FIGURE 14—Pulsating DC is
the voltage output of the
rectifier. It always has the
same polarity because it
varies between zero and a
positive maximum value. It
isn’t constant in value, hav-
ing pulses like the tips of an
AC wave.
Shielded Transformers
In a typical transformer, the primary and secondary windings
are somewhat linked together by the capacitance between the
windings. This capacitance will allow electrical noise or a
voltage to pass directly from the primary to the secondary
windings without being magnetically coupled through the
transformer core. A special transformer, known as a shielded
transformer, has been designed to eliminate the passage of
this noise.
In a shielded transformer, a metallic shield is placed between
the primary and secondary windings. This shield is then
grounded. The grounding prevents the capacitive coupling
from being present, and all but eliminates the transfer of
electrical noise between the primary and secondary windings
by means of the capacitance between these windings.
Constant-Voltage Transformers
Most modern electronic equipment is very sensitive to voltage
fluctuations. For example, electronic motor controllers con-
tain circuitry that monitors the incoming voltage and will
shut down the controller if the AC voltage becomes too high
or too low. A constant-voltage transformer supplies a constant
AC secondary voltage even if the primary winding voltage
varies over a wide range.
The constant-voltage transformer consists of a transformer
core, a primary winding, a secondary winding, a resonating
winding, and two magnetic shunts. Figure 17A shows a side
view of the transformer core before the windings and
(A)
SIDE VIEW OF CONSTANT–VOLTAGE
TRANSFORMER CORE
(B)
SIDE VIEW OF
CONSTANT–VOLTAGE TRANSFORMER
Transformer Insulation
The transformers used in industrial plants
include the dry, the askarel-insulated, and
the oil-insulated types. Figure 19 shows a
dry-type transformer. Dry-type transformers
don’t use any liquid to cool the windings.
They can be installed without fireproof
vaults in all areas except some hazardous
ones. Transformers rated at less than
112 1/2 kVA or 35,000 V can be installed
within a plant without the use of a trans-
former room or vault. However, they must FIGURE 19—Dry-type transformers like this one are
frequently used in industrial plants to step 480 V
be kept isolated from combustible materials. down (to 120 V or 240 V) to supply electric lights.
Askarel-insulated transformers contain
special nonflammable liquids within their
cases. These liquids help to insulate the windings and cool
the transformer. Transformers rated in excess of 25 kVA are
provided with pressure-relief valves and require special venti-
lation if they’re installed in poorly ventilated areas. They’re
installed in vaults if the rated voltage exceeds 35,000 V.
Oil-insulated transformers are filled with oil to provide insula-
tion for the windings and to cool the transformer. Generally,
oil-insulated transformers of any voltage are placed in vaults
when used within a building. Oil-insulated transformers are
either self-cooled by radiators exposed to the atmosphere, as
shown in Figure 20, or cooled by fans that circulate the air.
Transformer Ratings
Small transformers are usually rated in terms of secondary
volts and amperes. Larger transformers are rated in
kilovolt-amperes, or kVA. Transformers that supply lighting
loads shouldn’t have a capacity less than the total connected
load. For incandescent-lamp circuits, the kilovolt-ampere
rating of the transformer should equal the total wattage of
the lamps. For example, a 10 kW (kilowatt) incandescent
lamp load could be supplied by a transformer furnishing
240 V at 41.7 A (240 ⫻ 41.7 = 10,008 VA) = 10 kVA.
Power and motor loads should be computed as being equal to
the connected load. In practical applications, 1 kVA of trans-
former rating is to be supplied for each horsepower. For
example, a 5 hp (horsepower) motor will be supplied by a
5 kVA transformer.
4. Fill in each of the spaces with one of the four words from the list below.
b. Transformers which are used to change a primary voltage to another value for operat-
ing bells, signs, and battery-charging rectifiers are known as _______ transformers.
5. Which current(s) is/are applied to the control winding of a magnetic amplifer?
a. Output current c. AC signal current only
b. DC control current only d. DC supply and AC control currents
32
Transformers for Electronic and Other Applications
Self-Check 1
1. transformer
Answers
2. mutual
3. c
4. down, up
5. 36 V
Ns
Es = ᎏᎏ ⫻ Ep
Np
600
= ᎏᎏ ⫻ 12
200
= 3 ⫻ 12
= 36 V
6. exciting
7. 12 A
Self-Check 2
1. core, shell
2. b
3.
4. a. electronic
b. specialty
5. d
33
NOTES
34 Self-Check Answers
Examination
925 Oak Street
Scranton, Pennsylvania 18515-0001
EXAMINATION NUMBER:
38700801
Whichever method you use in submitting your exam
answers to the school, you must use the number above.
When you feel confident that you have mastered the material in
this study unit, complete the following examination. Then submit
only your answers to the school for grading, using one of the
examination answer options described in your “Test Materials”
envelope. Send your answers for this examination as soon as you
complete it. Do not wait until another examination is ready.
35
3. In a magnetic amplifier, a large AC voltage is controlled by a
A. varistor and resistor combination.
B. set of three batteries.
C. small AC voltage.
D. rectifier.
4. An inductor for which reactance can be varied by supplying current through a separate DC
winding is called a(n)
A. reactance tube. C. autotransformer.
B. current transformer. D. saturable reactor.
5. If the turns ratio of a transformer is 4 : 1 and the incoming voltage is 120 VAC, what is the
secondary voltage?
A. 30 VAC C. 240 VAC
B. 120 VAC D. 480 VAC
6. If the primary in a transformer has more turns than the secondary, the secondary has
A. lower current. C. higher power.
B. lower voltage. D. lower ampere-turns.
7. What type of transformer is used to prevent electrical noise from passing from the primary
winding to the secondary winding?
A. Dry-type transformer C. Shielded transformer
B. Oil-filled transformer D. Delta transformer
8. You’ll work at times with a transformer that has one winding connected in series with the
other to form the equivalent of a single winding. This is called a(n)
A. distribution transformer. C. specialty transformer.
B. electronic transformer. D. autotransformer.
9. If the power in the primary circuit of a 4 : 1 transformer is 12 watts, what will be the power
in the secondary of this transformer?
A. 3 watts C. 12 watts
B. 4 watts D. 48 watts
10. What would be the power in the secondary of a transformer that has a voltage of 48 VAC
and a current of 2.2 A?
A. 52.8 watts C. 121.8 watts
B. 105.6 watts D. 212.6 watts
36 Examination
11. What is the kVA rating of a transformer in which the secondary winding is delivering 10
amps at 480 VAC?
A. 4.8 kVA C. 480 kVA
B. 48 kVA D. 4800 kVA
12. A basic transformer consists of two separate conductive coils wrapped around a(n) _____
core.
A. copper C. iron
B. oiled paper D. plastic
13. Inductors are used in AC circuits to oppose changes in current value. What are two com-
mon names for inductors?
A. Choke and rectifier C. Choke and reactor
B. Rectifier and reactor D. Coil and rectifier
14. The primary current drawn by the transformer shown below will be
A. 2 A. C. 10 A.
B. 5 A. D. 50 A.
15. What special installation or maintenance requirements are needed for askarel-insulated
transformers?
A. Cooling water must be supplied to the transformer core.
B. The transformer must be installed in a vault if the voltage exceeds 35,000 VAC.
C. The oil must be changed at least once a year.
D. The radiator must be installed where air can circulate and the fins must remain clean.
16. The property that allows the change of voltage in one coil to lead to a change of voltage in
another coil is called mutual
A. reactance. C. reduction.
B. inductance D. impedance.
Examination 37
18. If 120 VAC is applied to a transformer with a turns ratio of 6 : 1, what type of transformer is
present and what is the output voltage of the secondary?
A. Step-up, 720 VAC C. Step-down, 20 VAC
B. Step-up, 600 VAC D. Step-down, 60 VAC
19. When a load is suddenly connected to a transformer, the secondary voltage will be
reduced. This drop in voltage is called transformer
A. seduction. C. excitation.
B. regulation. D. conductance.
20. Most small electronic devices, such as portable radios, contain an internal 120 VAC trans-
former. Usually, what type of transformer is this?
A. Step-down C. Oil-filled
B. Step-up D. Air-gap
38 Examination