1.

42 WELDING TRANSFORMERS
Figure 1.59 shows a schematic diagram of a welding transformer having thin primary windings with a large number of turns.
On the other hand, the secondary has more area of cross-section and less number of turns ensuring less voltage and very
high current in the secondary. One end of the secondary is connected to the welding electrode, whereas the other end is
connected to the pieces to be welded. If any high current flows, heat is produced due to the contact resistance between the
electrode and the pieces to be welded. The generated heat melts a tip of the electrode and the gap between the two pieces
is filled.

Figure 1.59 Welding Transformer

Figure 1.60 Volt-ampere Characteristic of a Welding Transformer

The winding used for the welding transformer is highly reactive. Otherwise, a separate reactor may be added in series with
the secondary winding.
Figure 1.60 shows the volt-ampere characteristic of a welding transformer.

1.42.1 Reactors Used with Welding Transformers

To control the arc, various reactors are used with welding transformers. Some methods to control the arc are given below:

i. Tapped reactor: With the help of taps on the reactor, the output current is regulated. This has limite number of
current settings shown in Figure 1.61.
ii. Moving coil reactor: Figure 1.62 shows a moving coil reactor in which the reactive distance between primary and
secondary is adjusted. The current becomes less if the distance between the coils is large.

Figure 1.61 Tapped Reactor

 Figure 1.62 Moving Coil Reactor

iii. Moving shunt reactor: Figure 1.63 shows a moving shunt reactor in which the position of the central magnetic
shunt can be adjusted. Change of the output current is obtained due to the adjustment of the shunted flux.
iv. Continuously variable reactor: Figure 1.64 shows a continuously variable reactor in which the height of the reactor
is continuously varied. Greater reactance is obtained due to greater core insertion and hence the output current
is less.
v. Saturable reactor: Figure 1.65 shows a saturable reactor. To adjust the reactance of the reactor, the required DC
excitation is obtained from a DC controlled transducer. Reactor approaches saturation if the DC excitation
current is more. Therefore, changes of current are obtained due to the change of reactance.

Figure 1.63 Moving Shunt Reactor

Figure 1.64 Continuously Variable Reactor

Figure 1.65 Saturable Reactor
Designing Your Own Transformer
written by: Swagatam • edited by: Lamar Stonecypher • updated: 11/1/2011

Designing a transformer is not easy simply because the criteria involved with these
devices are critical and elaborate. However some meticulously arranged data regarding
the various calculations can make the procedure easier. Learn how to make a transformer
through using simple formulas.

Introduction

We have already studied a lot about transformers in Bright Hub and we know that it’s
simply a device used for either stepping-up or stepping down an applied input AC through
magnetic induction in between its two windings.

Basically a transformer will have the following main components:

 Iron core stampings (configured either as U/T or E/I, generally the later is used more
extensively)
 Central plastic or ceramic bobbin surrounded by the above iron core stampings
 Two windings (electrically isolated and magnetically coupled) using super enameled
copper wire made over the bobbin
 Normally the winding which is designated to receive the input supply is termed as the
“Primary” and the winding which in response to this input produces the required induced
voltage as the output is termed as the “secondary” winding.

Designing your own transformer as per a specific application can be interesting, but not
feasible without calculating the various parameters typically involved with them. The
following discussion will take you through a few important steps and formulas and explain
how to make a transformer.

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Calculating the Core Area (CA) of the Transformer

The Core Area is calculated through the formula given below:

CA = 1.152 ×√ (Output Voltage × Output Current)

Calculating Turns per Volt (TPV)

It is done with the following formula:

TPV = 1 / (4.44 × 10-4 × CA × Flux Density × AC frequency)

where the frequency will depend on the particular country’s specifications (either 60 or 50
Hz), the standard value for the flux density of normal steel stampings may be taken as 1
Weber/sq.m, for ordinary steel material the value is 1.3 Weber/sq.m

Primary Winding Calculations

Basically three important parameters needs to be figured out while calculating the primary
winding of a transformer, they are as follows:

 Current through the primary winding

 Number of turns of the primary winding
 Area of the primary winding

Let’s trace out each of the above expressions:

Primary Winding Current = (Secondary Volts × Secondary Current) ÷ (Primary Volts ×
Efficiency), the average value for the efficiency of any transformer nay be presumed to be
0.9 as a standard figure.

Number of Turns = TPV × Primary Volts

Primary Winding Area = Number of Turns / Turns per Sq. cm (from the table A)

Reading Table A is easy – just find out the relevant figures (wire SWG and Turns per
sq.cm.) by tallying them with the closest matching value of your selected primary current.

Secondary Winding Calculations

As explained above, with the help of Table A you should be able to find the SWG of the
wire to be used for the secondary winding and the TPV simply by matching them with the
selected secondary current.

The Number of turns for the secondary winding is also calculated as explained for the
primary winding, however considering high loading conditions of this winding, 4 % extra
turns is preferably added to the over all number of turns. Therefore the formula becomes:

Secondary Number of Turns = 1.04 × (TPV × secondary voltage),

Also secondary winding area = Secondary Turns / Turns per sq. cm. (from table A).

Calculating the Core Size of the Steel Laminations or the Stampings

The core size of the steel stampings to be used may be easily found from Table B by
suitably matching the relevant information with Total Winding Area of the transformer. The
Total Winding Area thus needs to be calculated first, it’s as follows:

Total Winding Area = (Primary Winding Area + Total Secondary Winding Area) × Space for
External Insulation.

The third parameter i.e. the space for the insulation/former etc. may be taken
approximately 25 to 35 % of the sum of the first two parameters.

Therefore, the above formula becomes:

Total Winding Area = (Primary Winding Area + Total Secondary Winding Area) × 1.3

Normally, a core having a square central pillar is preferred and

used - other factors involved are also appropriately illustrated in the adjoining figure and
calculated as follows:

Gross Core Area = Core Area from Table B / 0.9 (sq.cm.)

Tongue Width = √Gross Core Area (cm)

After calculating the Tongue Width, it may be used as a reference value and matched
appropriately in Table B to acquire the actual CORE TYPE.

Your quest regarding how to make a transformer gets over when you finally finish
calculating the stack height, using the formula:

Stack Height = Gross Core Area / Tongue Width.

Table A

The table below helps you to select the gauge and turns per sq. cm of copper wire by
matching them with the selected current rating of the winding appropriately.

SWG------- (AMP)------- Turns per Sq.cm.

10----------- 16.6---------- 8.7

11----------- 13.638------- 10.4

12----------- 10.961------- 12.8

13----------- 8.579--------- 16.1

14----------- 6.487--------- 21.5

15----------- 5.254--------- 26.8

16----------- 4.151--------- 35.2

17----------- 3.178--------- 45.4

18----------- 2.335--------- 60.8

19----------- 1.622--------- 87.4

20----------- 1.313--------- 106

21----------- 1.0377-------- 137

22----------- 0.7945-------- 176

23----------- 0.5838--------- 42

24----------- 0.4906--------- 286

25----------- 0.4054--------- 341

26----------- 0.3284--------- 415

27----------- 0.2726--------- 504

28----------- 0.2219--------- 609

29----------- 0.1874--------- 711

30----------- 0.1558--------- 881

31----------- 0.1364--------- 997

32----------- 0.1182--------- 1137

33----------- 0.1013--------- 1308

34----------- 0.0858--------- 1608

35----------- 0.0715--------- 1902

36----------- 0.0586---------- 2286

37----------- 0.0469---------- 2800

38----------- 0.0365---------- 3507

39----------- 0.0274---------- 4838

40----------- 0.0233---------- 5595

41----------- 0.0197---------- 6543

42----------- 0.0162---------- 7755

43----------- 0.0131---------- 9337

44----------- 0.0104--------- 11457

45----------- 0.0079--------- 14392

46----------- 0.0059--------- 20223

47----------- 0.0041--------- 27546

48----------- 0.0026--------- 39706

49----------- 0.0015--------- 62134

50----------- 0.0010--------- 81242

Table B

This Table B enables you to make your own transformer design by comparing the
calculated Winding Area with the relevant required Tongue Width and Lamination Type
number.

Type-------------------Tongue----------Winding

No.---------------------Width-------------Area

17(E/I)--------------------1.270------------1.213
12A(E/12I)---------------1.588-----------1.897

74(E/I)--------------------1.748-----------2.284

23(E/I)--------------------1.905-----------2.723

30(E/I)--------------------2.000-----------3.000

21(E/I)--------------------1.588-----------3.329

31(E/I)--------------------2.223-----------3.703

10(E/I)--------------------1.588-----------4.439

15(E/I)-------------------2.540-----------4.839

33(E/I)--------------------2.800----------5.880

1(E/I)----------------------2.461----------6.555

14(E/I)--------------------2.540----------6.555

11(E/I)---------------------1.905---------7.259

34(U/T)--------------------1/588---------7.259

3(E/I)-----------------------3.175---------7.562

9(U/T)----------------------2.223----------7.865

9A(U/T)----------------------2.223----------7.865

11A(E/I)-----------------------1.905-----------9.072

4A(E/I)-----------------------3.335-----------10.284

2(E/I)-----------------------1.905-----------10.891

16(E/I)---------------------3.810-----------10.891

5(E/I)----------------------3.810-----------12.704
4AX(U/T) ----------------2.383-----------13.039

13(E/I)--------------------3.175-----------14.117

75(U/T)-------------------2.540-----------15.324

4(E/I)----------------------2.540----------15.865

7(E/I)----------------------5.080-----------18.969

6(E/I)----------------------3.810----------19.356

35A(U/T)-----------------3.810----------39.316

8(E/I)---------------------5.080----------49.803
Kapp regulation diagram
From Encyclopedia Magnetica

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S. Zurek, Kapp regulation diagram, Encyclopedia Magnetica, {accessed 6 Apr 2013}

edited 1 Jan 2012 — 1 Feb 2013 reviewed by J. Leicht on 1 Feb 2013

Kapp regulation diagram[1]

fot. S. Zurek, Encyclopedia Magnetica, license: CC-BY-3.0

Kapp regulation diagram - a graphical method of determining the voltage regulation in a

transformer caused by changes in load and power factor. [1]

The output voltage of a mains power transformer when loaded reduces for inductive load (power
factor lagging) and increases for capacitive load (power factor is leading).

The Kapp diagram is helpful in finding the voltage drop or increase (voltage regulation). The main
disadvantage is that the voltage regulation phasors are much smaller than the radii of the main
circles, so the diagram has to be drawn on a very large scale to get sufficiently accurate results.[1]
Drawing algorithm
In order to create the diagram it is necessary to know the equivalent reactance X02 and resistance R02
of the transformer as referred to the secondary side. The following algorithm should be used:

1. Draw phasor OL representing secondary terminal voltage V2 on load

2. Draw OX representing the phase of the secondary current at an angle Φ2 to OL such that
cosΦ2 is the power factor of the load
3. Draw phasor LM (I2 R02 - voltage drop on resistance referred to the secondary side) parallel
to OX, and then MN (I2 X02 - voltage drop on reactance referred to the secondary side).
The resulting NL is the total voltage drop.
4. Transfer the impedance triangle NLM to OO'P which gives O'L = ON = 0V2. Therefore, for
given secondary current the locus of N is a circle with centre O and radius 0V2, while the
locus of L has the same radius but with the centre O'
5. To find the voltage drop on full load at any power factor the radius OQS should be drawn
at at angle Φ to OX. If the impedance triangle is drawn in position UQT then OU = OS. The
length of QS represents the voltage drop.

References
Making a welder out of an old transformer.

Seeing the post a while back about the burnt out 3 phase
transformer has got
me thinking again.

After getting my old Forney welder, I have been playing around

with seeing
how hard it really is to design your own welder to operate the
way you want
it too. That has led me to experiments with a couple old 480V
to 120/240
volt transformers I have.

I have decided to post a little article on possible methods to

convert an
old transformer into a welder. Opinions on my ideas is welcome.

This post will be very long.

The type of transformer you are looking for is one with a large
open core. A
single phase with two coils on a single donut core (two leg). Or
a three
phase one with three windings and three legs that are bridged at
the top and
bottom (three leg).

Those types have a large core that will have a lot of flux
leakage when
driven by only one leg.

Transformers that have the E-I core with the return path going
around both
sides of a single winding have very little flux leakage and you
will have a
problem designing a reasonable current limited transformer out
of it.

You get the current limiting action by arranging the windings on

the core so
that there is a large leakage path between them. The farther
apart you have
the primary and secondary, the more flux leakage. The closer you
have them
located, the leakage and you will get less of a current limiting
action.

The primary produces flux when it energized. That flux tries to

take the
easiest path to form a loop. Be it steel, air, or water. The
easiest path
for it to take is steel, when the coil is wound around a steel
donut, then
the magnetic flux generally prefers to go through that steel
donut to form a
loop. Path of least resistance. But if you put a shorted coil on
the other
side of the loop, then it stops the flux from passing through
the complete
donut. The flux will jump across the middle of the donut between
the primary
and secondary to complete the flux loop. Longer, and narrower
the gap that
the flux has to jump across, the more counter EMF the secondary
has to
generate to force the primary EMF to jump that gap.

A tall but narrow donut with the primary on the right and
secondary on the
left leg. With the primary and secondary side by side. It will
take more amp
turns in the secondary to get the primary flux to bypass the
secondary.

If you have a wide but short donut with the primary and
secondary on the
right and left leg, the gap between the primary and secondary is
large. Then
the gap between the top and bottom part of the donut where the
flux has to
jump is short and wide. It takes a lot less current in the
secondary to
force the primary flux to jump the gap between the primary and
secondary.
And example of a simple transformer for making a welder.
A 240/480 to 120/240 single or three phase transformer.

Single phase has....

One 240V primary and a 120V secondary on each leg. The primaries
are stung
in series for 480V or in parallel for 240V. The secondary
windings are in
series for 120/240 center tapped. Or can be put in parallel for
120V. Often
the secondary windings are split between the legs to even out
loading, and
reduce leakage. That means that there is two 60V secondary
windings on each
side that is in series with the opposed one on the other side.

Three phase with three legs that are bridged at the top and
bottom. Each leg
has one primary and one secondary. wye or delta on primary and
secondary

If you are lucky, there is enough room between the existing

coils to wind
your custom windings.

If it is tightly packed, then you may have to remove all, or

part of, the
windings on one side to make room for your custom windings..

Pick a coil/side/leg for your primary. If you have a transformer

that has a
mixture of damaged windings and good ones, then pick a good one.
It should
have a 208,240 277, or 480V primary and one or more secondary
windings on
that leg of the transformer.

Remove the damaged windings. Then start experimenting.

Example. (from the experiments I did with one of my

transformers. 15KVA
240/480 to 120/240 single phase) Your transformer has a 240V
primary on each
leg. Hook 120V to one primary. Run a single turn or a couple
turns around
the core and measure the voltage across it. If you have three
turns and you
get 3.6V AC then your transformer is running at 1.2V per turn.
Since
designed operating voltage for the transformer is twice what you
have the
primary hooked too, then designed operating level will be 2.4V
per turn.

When testing, you want to leave the transformer hooked to the

lowest
exciting voltage you have, that will make the testing safer, and
the
currents developed for that core the lowest possible.

Lets say that you have the above stated situation. 120V hooked
to a 240V
winding which yields you a 1.2V per turn. On a single phase
transformer.

That tells you that the primary on each leg has 100 turns.
Some will have a secondary by it's self on each leg that has 50
turns.
Some single phase transformers will have each secondary split
between both
legs, so you have two 25 turn secondary windings on each leg.

When you have the one primary excited with 120V you will have
120V on the
other primary and 60V or two 30V on the secondary windings on
each leg.

Now to find out the current characteristics of your transformer.

There is two factors that limit current in the setup. The

conductor
resistance. And the flux leakage. Conductor resistance makes the
windings
hot, so we want the windings big enough that that isn't a
factor.
Lets say that your transformer has an available current of
2040Amp turns
into a shorted leg when the other leg is excited by 120V.

If you had a single turn large enough to handle that current on

that leg
then you would have close to 2040A on that turn when it's
shorted, or 1.2V
when it's open.

(If you made that single turn with a 4 foot piece of 10g wire,
the current
would be limited by the wires resistance. 1.2V across 4 feet of
wire is
close to 300 amps. The wire will get hot very quickly. The wire
will be
giving in, not the flux in the transformer. The voltage across
the leg doesn't
drop, the wire is just forced to drop the voltage across it's
length.)

Lets continue with that train of though.

If you had two turns of wire adequate for the current, you would
get 2.4V
when open, and 1020A when closed. That would be in about the
right range for
spot welding, but not for arc welding. So lets continue on.

10 turns would yield 12V at 204A

20 turns would yield 24V at 102A close but not quite.

30 turns would yield 36V at 68A getting real close to the right
voltage.

40 turns yield 48V which does quite well at 51A with the 1/16
6013 rod.

50 turns yields 60V that also does quite well at around 41A

Considering that the two low voltage windings I have are 25

turns each. I
can have one winding plus 15 more turns of wire with it to get
40 turns, or
use both in series to get 50 turns.

So, my transformer without major modification can serve as a 40

or 50a
welder with the addition one 15 turns of wire on one side. You
could use the
other unused 100 turn primary on that side for a 120V OC 20A
welder. Now if
I could only find 1/32 welding rod! :-)

For the secondary windings left over on the side that you are
driving as the
primary. since they are in the same coil as the driven primary,
there will
be no real current limiting. So you could use them as a CV
output to drive a
mig gun, If you hook them in parallel for 30V. Considering that
my
transformer is rated at 15KW you should have 120A continuous
duty on hand to
drive that mig gun.

That is what you could do with a very simple winding

arrangement.

Now, lets get to the complex winding arrangements for an arc

welder.

Lets go for a base 50V OC on all outputs.

Lets hook up the two secondary windings on the output (current

limited) side
in parallel so that we have 30V OC with a short circuit output
of 81A that
will allow us to make use of what is already there.

Take that as are base winding. The winding can handle up to 120A
continuously (two 60A windings in parallel)

For are 50A tap, run are base winding in series with 16
additional turn new
winding. That yields 49V at close to 50A

For the 40A tap, we can't just use a 25 turn tap in series with
the base
winding because that will yield 60V OC. Remember we want a
nominal 50V OC.
Here is where we get into the complex windings.

To do that, we have to have the additional 25 turn winding in

series with a
buck winding on the primary driven side. A buck winding on the
primary side
is close coupled with the driven winding so it will reduce the
output
voltage but it won't reduce the current available at the output
since there
won't be any current limiting action.

So, you will have a winding with 25 turns on the current limited
side plus 8
reverse turns on the driven side. That will yield you 40A at 50V
OC. (you
get the output current from 50 turns on the current limited
side, and you
use 8 buck turns to get the voltage down to spec) Now, it won't
be exactly
that because with the buck winding, you are not directly
shorting the
current limited side. So you may have to take a winding may have
to take a
turn off of each side until current comes up to spec for that
tap.

Now lets go for the 60A tap.

Lets take the base winding and add a 9 turn new winding to the
current
limited side.(9 turns of the new 15 turn winding for the 50A
tap) And run
that to a 7 turn boost winding on the primary driven side. That
will get you
60A at 50V. (34 turns on the current limited side plus 7 boost
turns)
The highest we could wind this transformer for is 70A and still
maintain
100% duty cycle, which would be 29 current limited turns plus 12
boost
turns. (base winding plus 4 with 12 boost turns)

Now if we went with interment ant duty we could easily go 80A

which is the
base winding plus 12 boost windings. In actuality, that setup
would be
closer to 100A or higher because the current limited winding
will be driven
beyond shorted. It will actually be driven reverse polarity. (0V
- boost
voltage)

So, just experiment and move the winding around till you find
the current
you want.

You can tailor it to get about any OCV you want. If you want a
digging arc
or a rubbery arc, you can tailor it to fit your desires.

To get 100A out, at 50 OCV you will want to run it on a 50A 120V
breaker.

If you drive the primary at full rated 240V you will have to
arrange the
secondary and buck boost windings to compensate for a higher
amp turns that
is available on the current limited side, plus the additional
volt turns.

"Now wait a second" you say "how does all that help me find out
how much
current my transformer will put out?????????"

Well. Put some test windings on your transformer and Either run
you selected
transformer primary off of 120V or even 60Vor 30V from another
transformer.
Have a current meter on the test windings and short them out for
a second to
see what you get. Rearrange the test windings and try again.

When you get the current down to a relatively low level at 30 or

60 V then
you can step up to the next drive voltage level and check what
affect that
has. Rearrange the windings, and step up another voltage level.

I would not suggest that you power the selected primary to full
rated
voltage and then short a test winding on it with no prior
knowledge of the
transformer in question. You may be in for a little bit more
current than
you bargained on. Plus a lot of melted wires to boot.

One way of bringing up the power level more gradually is use a

large variac
to slowly bring up the voltage level on a shorted test winding
and see where
the current levels off. You will be able to see if the current
is climbing
way faster than you anticipated with the voltage, and if you
will need to
change your winding layout before bringing it to full voltage.

If you have a transformer that you have taken one of the coils
off one of
the legs, then you will have a lot more freedom to arrange the
windings.

If you have a three phase transformer with two bare legs then
that opens up
a world of possibilities. When you short a winding out on one
leg, then the
flux will shift to the other leg. You could use one winding on
one leg as an
output winding and have a winding on the other that is connected
to SCR's to
vary the current. When the SCR's are full on, then it forces all
the current
to the output winding, and when they are full off, then none of
the current
is forced to the output. (it bypasses the output winding through
the open
SCR winding)
Don't forget the secondary windings on the drive leg. They can
be run in
series with the primary to reduce the volts turn drive level at
a specified
supply voltage!!!

Now it is getting late, and I am getting tired, so I am going to

wrap this
up and post it to see what you people think.
CURSO DE SOLDADURA SMAW (11)

20:15 No comments

Capitulo 11: MAQUINAS DE SOLDAR (transformador).

Aparato eléctrico que transforma la corriente eléctrica

bajando la tensión de la red de alimentación a una
tensión e intensidad adecuada para soldar. Dicha CA
de baja tensión (65 a 75 voltios en vacío) y de
intensidad regular. Permite obtener la fuente de calor
necesaria para la soldadura.

El transformador consta de un núcleo que está

compuesto por láminas de acero al silicio y de dos
bobinas de alambre; el de alta tensión, llamado
PRIMARIO y el de baja tensión llamado
SECUNDARIO.
La corriente que proviene de la línea circula por
el primario.
Los transformadores se construyen para
diferentes tensiones, a fin de facilitar su conexión, en
todas las redes de alimentación.
La transformación eléctrica se explica de la forma
siguiente: "La corriente eléctrica que circula por el
primario genera un campo de lineas de fuerza
magnética en el núcleo, dicho campo actuando sobre
la bobina secundaria, produce en este, una corriente
de baja tensión y alta intensidad, la cuál se aprovecha
para soldar.
 CARACTERÍSTICAS
La regulación de la intensidad se hace
comúnmente por dos sistemas:
1- Regulación por bobina desplazante: Consiste
en alejar el primario y el secundario
entre sí.

Observación: Esta sistema es recomendable por

su regulación gradual.
2- Regulación por clavija: Funciona aumentando
o disminuyendo el número de espiras.
 Los transformadores se conocen también como
MAQUINAS ESTATICAS por no tener piezas móviles.
VENTAJAS
El uso del transformador se ha generalizado por:
-4- Bajo costo de adquisición
-5- Mayor duración y menor gasto de
mantenimiento
-6- Mayor rendimiento y menor consumo en
vacío
-7- Menor influencia del soplo magnético
DESVENTAJAS
Entre sus desventajas se pueden mencionar:
-8- Limitación en el uso de algunos tipos de
electrodos
-9- Dificultad para establecer y mantener el
arco
 MANTENIMIENTO
Debe mantenerse el equipo libre de polvo y
humedad
PRECAUCIÓN
Toda acción de limpieza debe efectuarse con la
máquina desconectada
Al instalarla debe elegirse un lugar seco fijando
en la máquina, una conexión a tierra.
ACTIVIDAD
27- Nombre las dos formas para regular el
amperaje en las máquinas estáticas
28- ¿Cuáles son los principales componentes de
una máquina estática y a que se debe su nombre.
 TRANSFORMER DESIGN, CONSTRUCTION & THEORY

Presented here is an overview of transformers for hobbyists that want to expand

their knowledge of this essential electrical component.

Of the 3 basic passive electrical components, R, L, C, the transformer is simply a

special case of the inductor with either taps or multiple windings that are coupled.
It will operate over the full range of frequencies and may be either iron or air
cored; most of the following discussions will concentrate on low frequency, iron
cored transformers.

The basic transformer to be discussed is the voltage (or power transformer), which
operates at mains frequency and is step up or down. There are also special cases,
such as current transformers, pulse transformers and audio (output and driver)
types that cater for a wider band of frequency.
3 phase transformers are simply a special case of the single-phase transformer
with the core arranged to give a balanced magnetic circuit.

Transformers consist of a core and windings; the core is usually an iron alloy to
suit the application and the windings consist of coils of insulated copper or
aluminium wire.

There is no absolutely correct design for any given transformer; as in all matters of
good engineering there are many design and cost compromises to be made.
Having selected a core and decided on a flux density, the T/V figure is calculated
and then it is a matter of seeing if the turns will fit on the bobbin available for the
selected core.

THE CORE

All transformers follow the basic transformer equation and work by reason of the
fact that the magnetic flux, produced by the primary applied voltage is constantly
changing. This is basic magnetic theory. It appears confusing as it is taught in
many systems of units. I will concentrate on the MKS system where the units are
Metres. DO NOT USE mm!!!
This is a practical system where the unit of flux density is the TESLA. Normal
transformers operate at levels around 1T depending on the materials used.

Transformer equation:

N = E / 4.44 B F Ae Where:

N = turns
 E = applied voltage in volts
4.44 is a constant for sine waves
B = desired flux density in Tesla
F = frequency in Hz
Ae = transformer centre limb area in M²
Stalloy or silicon iron, which is widely used as a core material is normally operated
at a flux density of 1T. Unisil, a grain orientated material, which is a little more
expensive can be run at 1.5 T. Special alloys for Mil and aerospace applications can
be run up to 2T where a compact design is a requirement.
Running at a higher flux density allows the turns/ volt to be reduced and the cost
of copper and copper losses; however this increases the losses in the iron and
increases the magnetising (idling) current. Design curves are available showing
watts loss per Kg at various flux densities.
Traditional design theory would make copper and iron losses equal at normal load
levels (say 80% of full load)

An important fact of life with iron cores is Saturation. When we increase the
voltage across an iron cored coil the current will initially increase in a linear
manner. When we reach a certain level the current will start to increase much
more rapidly than the voltage. This is the “Knee point” where a lot of transformers
are designed to operate.
Note that Stalloy has a fairly rapid turn into saturation, Unisil much less so. Hence
lower distortion when used in the output transformer of a Hi-Fi amplifier.

To determine the operating level of an unknown core it is simply a matter if

winding a know number of turns onto the core, and then plotting a V/A curve. At
the point at where it starts to turn into saturation will be the operating level, and it
is then easy to read off the Turns/Volt from the plot.

Other core losses are determined by the circulation of eddy currents in the
laminations. Thinner lams and lower frequencies give lower losses, but increase
the cost of the lams. A solid core would have very high losses, hence the lams are
lightly oxidised to give insulation between them. These losses are frequency
dependant.
Most laminations available these days are “lossless” types.
This means that they are “E” & “I” shapes stamped out of sheet so as to leave no
waste. Many other forms will be encountered in vintage equipment.
Transformers should normally be laminated to leave as small a gap between lams
as possible, interleaving and tapping them together during assembly. The
exception to this is transformers carrying DC, as in Class A valve output stages,
where the standing DC current could cause saturation and a small air gap, usually
made from thin paper is inserted between the “E” & “I” lams that are not now
interleaved.
Clamping bolts, when inserted through the lams should have an insulation washer
between the lam face and the nuts. If this is not done there can be high currents
circulating through the bolt.

Toroidal transformer cores can be run at higher flux densities and have the
advantage of a much lower stray field, useful in audio applications

THE WINDINGS

These are usually of enamelled copper wire but various other insulations are
available. The insulation should be as thin as possible consistent with a suitable
electrical withstand level. Windings often had a thin layer of paper between layers
of winding. With present wire insulation this is not necessary every layer, and is
often replaced with Type 56 Polyester tape every few layers, again depending on
application.
The normal wire current density is typically 3A per mm² and this figure is often
shown in wire tables.
Note that wire sizes, in SWG, AWG or mm are based on bare wire, not coated
diameter.
The current density figure is based on a max internal temperature for the
transformer of 120°C; the limit for normal materials, other design factors may
dictate different values.
Wire tables will also give the resistance/ Mtr of wire. This is used to calculate the
winding resistance from the mean length of turn. Note that copper resistivity
increases by 0.3% per °C rise.

The transformer equation gives the primary turns; secondaries can then be
calculated by the turns ratio. If very exact ratios are required it may be necessary
to increase the primary turns so as to get an integral number of turns on the
secondary of importance.
If an exact voltage is required it is often necessary to add compensating turns to a
secondary to allow for the volt drops (calculated from mean length of turn and
resistance per mtr) in both primary and secondary.
It can also be necessary to allow for the increase of resistance due to temperature
rise as well.
Further compensation is sometimes necessary to allow for the imperfect coupling
between primary and secondary which appears as a parasitic loss.

Primaries and secondaries are normally wound on top of each other for good
coupling; where additional safety separation is required, they may be wound side
by side with a centre insulated barrier (some transformer kits with pre-wound
 primaries are like this).
This gives inferior coupling and additional compensating turns will be needed to
compensate for this.
For very close coupling the primary and secondary will be wound together with Bi-
filar wire. Where insulation levels make this impossible, the primary and secondary
are wound in several sections, one on top of the other. For balance this would
usually be one more primary section than secondary section.

Wire is commonly insulated with synthetic enamels in either 1 or 2 coats. Most

modern enamels can be vaporised with solder and are known as solderable types.
Where high levels of insulation are required in a small space (such as a switch
mode transformer), then triple insulated wire can be used. This is certified for
supply to low voltage windings without additional insulation.

An earthed copper screen is often placed between the primary and secondary; this
is for both safety and as an interference screen against noise impulses.

Windings are not normally carried to the outside of the bobbin on multi-layer
windings due to the danger of a turn slipping down the side of the bobbin and
“seeing” a higher voltage, possibly causing breakdown. Paper margin tapes, a few
mm wide are often used here.
With EHT transformers this margin is often tapered inwards (wider) as the outer
layers are added and the winding voltage to earth increases.

Copper is the important part of the winding so thin insulation is used, as there is
only a relatively low voltage between turns and layers. This is usually capable of
withstanding a minimum of 120ºC.

The windings are often vacuum impregnated to seal against moisture and prevent
chafing movement under operating or fault conditions. It is possible to spray
varnish them while building, or they can be paraffin wax impregnated in a
container of molten wax.
For voltages above 6KV it is usual to seal the transformer in a can of specially
refined mineral oil.

Tapping points on windings can be “brought out” of the body of the winding by
looping the wire out and back again. Lead-out wires are often soldered on to the
winding at an appropriate point. These must be well insulated.

The forgoing should allow a reasonably competent person to design and build their
own transformers when size and cost are not the driving factors as in commercial
applications. It should always be remembered that these devices are connected to
the mains and can easily kill or start serious fires; all possible safety precautions
should be taken when using them.
© Ed Dinning 2009
Please help,I want to design a welding machine of 50A,100A and
150A output.?
my input supply is of 220v 30A
now give the idea about wire size of primary and secondary and core size.

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by Steve C
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Mejor respuesta - elegida por los votantes

Welding transformers are somewhat different to normal "voltage" transformers... They are
Leakage transformers, so the design specs are likely quite different. Believe this is what provides
the current limiting, and stop the welder blowing a fuse while the arc starts/if it shorted out, and
helps stop all kind of other nasty stuff happening

You'll have to do a LOT more research on the matter, and on your own head be it. here a few
pointers

believe arc welding machines normally output about 55V.

The design of arc welder is to dump the power into an arc. Once struck the resistance of the arc is
likely to be far higher than that of an "decently" sized coils. As such much more the heating power
will end in the arc. remember P=R*I^2 . If the arc has 100* the resistance of the coils, the coils will
only produce 1/101 the heat.

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67% 2 votos
 4 times as many turns in the primary as the secondary will give you 57 volts with no
secondary current. The primary current will be 40 amps when the secondary current
is 160 amps. Most 30 amp circuit breakers trip in about one second supplying 40
amps = your welder will be marginal at 150 amps. You are likely ok anywhere from
3 to 5 turns ratio. Pick the wire size that let's you fill about half of the square
centimeters available in the transformer core for the primary and half for the
secondary. Unless your transformer weighs 5 or 10 kilograms, the core will saturate
at about 40 amps input, so that prevents the output from going much over 160 amps,
even briefly. I don't know how commercial welders limit the current to 100 amps or
50 amps. Variable flux gap, perhaps? Likely some of the newer ones use switching
type power supply technology which uses only tiny transformers and inductors. If
you are going to build the welder, a used transformer with the old secondary
removed will be easiest, except you have to guess how many turns the primary has.
Possibly you can wind 11 turns of any size enameled wire, then energize the
transformer. If you measure 11 volts you have one volt per turn and need 55 turns to
get 55 volts. I think less than one volt per turn per volt is typical. Neil
Equations
There are two approaches used in designing transformers. One uses the long formulas, and the other
uses the Wa product. The Wa product is simply the cores window area multiplied by the cores area.
Some say it simplifies the design, especially in C-core (cut core) construction. Most manufacturers
of C-cores have the Wa product added into the tables used in their selection. The designer takes the
area used by a coil and finds a C-core with a similar window area. The Wa product is then divided
by the window area to find the area of the core. Either way will bring the same result.

For a transformer designed for use with a sine wave, the universal voltage formula is:Ref:[4][5][6][7][8]

thus,

where,

 E is the sinusoidal rms or root mean square voltage of the winding,

 f is the frequency in hertz,
 N is the number of turns of wire on the winding,
 a is the cross-sectional area of the core in square centimeters or inches,
 B is the peak magnetic flux density in Teslas or Webers per square meter (MKS meas. sys.),
gausses per square centimeter, or lines (maxwells) per square inch (cgs meas. sys.).
 P is the power in volt amperes or watts,
 W is the window area in square centimeters or inches and,
 J is the current density.
 Note: 10 kilogauss = 1 Tesla.

This gives way to the following other transformer equations for cores in square centimeters (cgs
meas. sys.):
The derivation of the above formula is actually quite simple. The maximum induced voltage, , is
the result of N times the time-varying flux:

If using RMS voltage values and E equal the rms value of voltage then:

and

Since the flux is created by a sinusoidal voltage, it too varies sinusoidally:

where = area of the core

Taking the derivative we have:

Substituting into the above equation and using and the fact that we are only concerned
with the maximum value yields

[edit] Imperial measurement system

The formulas for the imperial (inch) system are still being used in the United States by many
transformer manufacturers. Most steel EI laminations used in the US are measured in inches. The
flux is still measured in gauss or Teslas, but the core area is measured in square inches. 28.638 is
the conversion factor from 6.45 x 4.44 (see note 1) the 6.45 factor is simply the square of 2.54 cm in
1 Inch. The formulas for sine wave operation are below. For square wave operation, see Note (3):
To determine the power (P) capability of the core, the core stack in inches (D), and the window-
area (Wa) product, the formulas are:

where,

 P is the power in volt amperes or watts,

 T is the volts per turn,
 E is the RMS voltage,
 S is the current density in circular mils per ampere (Generally 750 to 1500 cir mils),
 W is the window area in square inches,
 C is the core width in square inches,
 D is the depth of the stack in inches and,
 Wa is the product of the window area in square inches multiplied by the core area in
square inches. This is especially useful for determining C-cores, but can also be used with
EI types. The window area is simply the windows height multiplied by its width.

[edit] Simpler formulae

A shorter formula for the core area (a) and the turns per volt (T) can be derived from the long
voltage formula by multiplying, rearranging, and dividing out. This is used if one wants to design a
transformer using a sine wave, at a fixed flux density, and frequency. Below is the short formulas
for core areas in square inches having a flux density of 12 kilogauss at 60 Hz (see note 2):

And for 12 kilogauss at 50 Hz:

[edit] Equation notes

 Note 1: The factor of 4.44 is derived from the first part of the voltage formula. It is from 4
multiplied by the form factor (F) which is 1.11, thus 4 multiplied by 1.11 = 4.44. The
number 1.11 is derived from dividing the rms value of a sine wave by its average value,
where F = rms / average = 1.11.

 Note 2: A value of 12 kilogauss per square inch (77,400 lines per sq. in.) is used for the
short formulas above as it will work with most steel types used (M-2 to M-27), including
unknown steel from scrap transformer laminations in TV sets, radios, and power supplies.
The very lowest classes of steel (M-50) would probably not work as it should be run at or
around 10 kilogauss or under.

 Note 3: All formulas shown are for sine wave operation only. Square wave operation does
not use the form factor (F) of 1.11. For using square waves, substitute 4 for 4.44, and 25.8
for 28.638.

 Note 4: None of the above equations show the stacking factor (Sf). Each core or lamination
will have its own stacking factor. It is selected by the size of the core or lamination, and
the material it is made from. At design time, this is simply added to the string to be
multiplied. Example; E = 4.44 f N a B Sf