Professional Documents
Culture Documents
630.00
No.
1
2
3
4
5
6
7
8
10
D
C/l cm W/H cm Step No.
38.5 50 1 step
st
38.5 50 2nd step
38.5 50 3rd step
38.5 50 4th step
38.5 50 5th step
38.5 50 6th step
38.5 50 7th step
38.5 50 8th step
38.5 50 9th step
38.5 50 10th step
D
C/l cm W/H cm Step No.
38.5 50 1 step
st
WEIGHT OF CORE
Approxima 798.83
Calculated 771.23
27.59
Thermo flow :
Supporting strip 4 x 10 x 460
press board 0.5 x
Supporting strip 4 x 10 x 460
Axial length of HV coil 434
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm Step length (L)
200 20.0 70.0
190 19.0 69.0
180 18.0 68.0
165 16.5 66.5
150 15.0 65.0
135 13.5 63.5
120 12.0 62.0
100 10.0 60.0
90 9.0 59.0
75 7.5 57.5
Total
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm Step length (L)
200 20.0 97.0
190 19.0 96.0
180 18.0 95.0
165 16.5 93.5
150 15.0 92.0
135 13.5 90.5
120 12.0 89.0
100 10.0 87.0
90 9.0 86.0
75 7.5 84.5
276
360
999
46
480
246.43
258.75
Cd Et HV(KV)
3.00 11.04 33
Radial (mm)
1.8
0.08
1.88
0.03
1.909 Estimation of window height Values (mm)
Total axial length of the coil 434
(0.96mm,for first& 13th layerEnd packing insulation 23 x2 46
32.57 UpperWindow
and bottom yoke
Height mminsulations 20
LV Design Values
Current per phase(Is) 909.33
Current density(Cd) 3.00
Conductor area(Aw) 303.11
wire area with insulation 330.4
Strip wire size Required 336
2.80 10
3.1 10.3
strip size with insulation 383.16
21
Turns per phase
No. of coil per phase 1
Turns per coil 21
No. of layers 2
Turns per layer 21.0
No of pcieces
Weight in Kg
420 117.81
204 53.58
144 35.31
156 34.29
132 25.79
84 14.43
84 12.52
7.21
60
60 6.38
84 7.26
Total
314.59
B1 B2 Weight (Kg)
140.0 70.0 50.489
68.0 34.0 23.103
48.0 24.0 15.320
52.0 26.0 15.020
44.0 22.0 11.405
28.0 14.0 6.447
28.0 14.0 5.655
20.0 10.0 3.306
20.0 10.0 2.948
28.0 14.0 3.392
Total 137.085
Weight (Kg)
112.759
52.418
35.314
35.455
27.571
15.961
14.339
8.655
7.844
9.246
319.561
258.751
0.0210
23.696
2878.731
primary current(Ip) Area of primary wire Primary wire dia.
6.36 2.12 1.64
1.8/ 1.909
LV process
No. Description Length (mm)
1 Bare size of strip 10.00
2 Covered thickness towards TPC 0.20
3 Covered size of strip 10.20
4 Gap between two consecutive strips (assumed) 0.10
5 Insulated size of strip with working tolerance 10.30
6 Placement of strip (3W x 4D) 2.00
7 Effective dimension of each turn 20.60
8
9
10 Space required to accommodate 21 T + 1 22.0
11 Length of LV coil 453
12 Rounding off to with tolerance 460
13 End insulation (End packing) 10 mm on either side o 20
14 Length of LV coil 480.00
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
320 Secondary being star connected, the per phase seconda 230.94
310.4 Therefore per phase magnetizing current ( Im) 1.781
32053.71
32053.71
Efficiency:
Rated KVA 630
Core area
Stacks (K) in (mm) Gross core Area( sq mTotal Gross core area in (Sq mm)
57.13 11426.29 Radial bui
27.51 5226.71 Ra
12.49 1249.01
5.14 462.28
6.49 486.53
Bm
194.01 1.60
10
11
12
Area of secondary wire
303.11
4.00
212.00
4
216.00
23
239.00
23.00
262.00
KVA
315.00
D
C/l cm W/H cm Step No.
30.5 46 1 step
st
D
C/l cm W/H cm Step No.
30.5 46 1 step
st
WEIGHT OF CORE
Approxima 409.13
Calculated 408.89
0.24
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm Step length (L)
155 15.5 61.5
145 14.5 61.5
130 13.0 61.5
115 11.5 61.5
100 10.0 61.5
85 8.5 61.5
70 7.0 61.5
55 5.5 61.5
Total
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm Step length (L)
155 15.5 76.5
145 14.5 75.5
130 13.0 74.0
115 11.5 72.5
100 10.0 71.0
85 8.5 69.5
70 7.0 68.0
55 5.5 66.5
11
209.534
0.96,0.8 mm
222
287
800
40
440
122.28
128.40
Cd Et HV(KV)
2.80 7.05 15
Radial (mm)
1.8
0.08
1.88
0.03
1.909 Estimation of window height Values (mm)
Total axial length of the coil 400
(0.96mm,for first& 10th layerEnd packing insulation 20x2 40
24.47 Axial length of HV coil 440
+ 8 mm (Radial build of HV Upper and bottom yoke insulations 20
32.47 460
155.00
LV Design Values
Current per phase(Is) 454.70
Current density(Cd) A/sq.mm 2.80
Conductor area(Aw) 178.08
Strip wire size Required 203.55
2.65 11.2
2.95 11.5
Turns per phase 16.5
No. of coil per phase 1.0
Turns per coil 16.5
No. of layers 2.0
Turns per layer 16.5
No of pcieces
Weight in Kg
66.46 348
33.23 186
28.83 180
17.85 126
12.57 102
8.17 78
5.18 60
3.25 48
Total
175.55
B Weight (Kg) B2
174 29.044 116
93 14.657 62
90 12.893 60
63 8.092 42
51 5.773 34
39 3.802 26
30 2.440 20
24 1.554 16
Total
78.3
144.304
0.0210
13.215
1942.602
primary current(Ip) Area of primary wire Primary wire dia.
7.00 2.50 1.78
2.54 1.800
1.909
LV process
No. Description Length (mm)
1 Bare size of strip 11.20
2 Covered thickness towards TPC 0.20
3 Covered size of strip 11.40
4 Gap between two consecutive strips (assumed) 0.10
5 Insulated size of strip with working tolerance 11.50
6 Placement of strip (3W x 4D) 2.00
7 Effective dimension of each turn 23.00
8
9
10 Space required to accommodate 16T + 2 18.0
11 Length of LV coil 414
12 Rounding off to with tolerance 420
13 End insulation (End packing) 10 mm on either side o 20
14 Length of LV coil 440.00
15
Gap between upper & lower yoke and coil 20
16 Total window height 460
B1 Stack of B2 Stack of B1
58 31.32 15.66
31 16.74 8.37
30 16.2 8.10
21 11.34 5.67
17 9.18 4.59
13 7.02 3.51
10 5.4 2.70
8 4.32 2.16
1.70 Secondary being star connected, the per phase seconda 230.94
27-M4 Therefore per phase magnetizing current ( Im) 1.475
511.11 Therefore I (h+e) (No load loss )/(3 phase voltage) 1.212
Radial(mm) 19361.29
2.65 19361.29
0.2 19361.29
2.9 19361.29
0.1 19361.29
2.95 19361.29
3.00 19361.29
8.85 19361.29
0.24 mm(3 inter layer insulation ) 19361.29
9.09
8.85
17.94
18 mm ( Radial built of LV)
Weight of B2 Weight of B1
19.363 9.68
9.771 4.89
8.595 4.30
5.395 2.70
3.849 1.92
2.535 1.27
1.627 0.81
1.036 0.52
52.171 26.09
78.26
Efficiency:
Rated KVA 315
Core area
Stacks (K) in (mm) Required Stacks (K) i Gross core Area( sq mm)
47.11 46.98 7281.90
25.14 25.11 3640.95
24.42 24.30 3159.00
17.44 17.01 1956.15
13.35 13.77 1377.00
10.46 10.53 895.05
8.19 8.1 567.00
6.28 6.48 356.40
152.38 152.28 Total Gross core area in (Sq mm)
Bm 19233.45
1.70 127.84
4 5.000 6
209 209 209
825.000 1034.000 1243.000
%Error
-0.0222
-0.0130
-0.0033
-0.0171
-0.0316
Area of secondary wire
162.38
178.08
168.00
3 LV Coil inside diameter 85.00
4 Radial build of LV coil 18
218.00
7 HV coil inside diameter 111.00
32.00
224.00
8 Radial gap between HV limb and the phases 256.00
9 HV coil outside diameter 261.00
264.00
10 Gap between HV limb and Phase 290.00
11 Core limb center
12 Total Window Height
13 Window space factor
7.000 8 9.000
209 209 209
1452.000 1661.000 1870.000
X6 1870
X4 1924
X2 1978
X3 1978
X5 2031
X7 2084
X 2251
47.11 46.98 174.00
25.14 25.11 93.00
24.42 24.30 90.00
17.44 17.01 63.00
13.35 13.77 51.00
10.46 10.53 39.00
Diameter (mm) 8.19 8.10 30.00
162 6.28 6.48 24.00
4.00 152.38 152.28 564.00
166.00
4
170.00
18
188.00
18.00
206.00
8.00
214.00
8.00
222.00
32.00
254.00
32.00
287.00
13.00
305.00
460
3.22
10 11.000
172 209 2251.000
2042.000 2251.000
0
54
54
53
53
167
KVA
800.00
D
C/l cm W/H cm Step No.
45.8 51 1 step
st
D
C/l cm W/H cm Step No.
45.8 51 1 step
st
WEIGHT OF CORE
Approxima 912.63
Calculated 846.50
66.12
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm Step length (L)
200 20.0 71.0
190 19.0 70.0
180 18.0 69.0
165 16.5 67.5
150 15.0 66.0
135 13.5 64.5
120 12.0 63.0
100 10.0 61.0
90 9.0 60.0
75 7.5 58.5
Total
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm Step length (L)
200 20.0 111.6
190 19.0 110.6
180 18.0 109.6
165 16.5 108.1
150 15.0 106.6
135 13.5 105.1
120 12.0 103.6
100 10.0 101.6
90 9.0 100.6
75 7.5 99.1
24
111.111
0.96,0.8 mm
276
360
999
46
480
391.96
411.56
Cd Et HV(KV)
2.50 13.01 33
Radial (mm)
1.5
0.25
1.75
0.05
1.800 Estimation of window height Values (mm)
Total axial length of the coil 450
(0.96mm,for first& 23th layerEnd packing insulation 20 x2 40
59.26 Upper and bottom yoke insulations 20
+ 8 mm (Radial build of HV 510
67.26
70.00
70(Radial built of HV coil)
LV Design Values
Current per phase(Is) 909.33
Current density(Cd) 3.00
Conductor area(Aw) 303.11
wire area with insulation 330.4
Strip wire size Required 336
2.80 10
3.1 10.3
strip size with insulation 383.16
Turns per phase 21
No. of coil per phase 1
Turns per coil 21
No. of layers 2
Turns per layer 21.0
No of pcieces
Weight in Kg
420 119.49
204 54.36
144 35.83
156 34.81
132 26.18
84 14.65
84 12.72
60 7.33
60 6.49
84 7.38
Total
319.26
B1 B2 Weight (Kg)
140.0 70.0 51.331
68.0 34.0 23.491
48.0 24.0 15.579
52.0 26.0 15.278
44.0 22.0 11.603
28.0 14.0 6.560
28.0 14.0 5.756
20.0 10.0 3.366
20.0 10.0 3.002
28.0 14.0 3.455
Total 139.422
Weight (Kg)
137.330
63.756
42.896
42.984
33.362
19.278
17.287
10.410
9.423
11.089
387.817
37.689
7383.285
primary current(Ip) Area of primary wire Primary wire dia.
8.08 3.23 1.5 x 3.75
5.63 4.050
LV process
No. Description Length (mm)
1 Bare size of strip 11.80
2 Covered thickness towards TPC 0.20
3 Covered size of strip 12.00
4 Gap between two consecutive strips (assumed) 0.10
5 Insulated size of strip with working tolerance 12.10
6 Placement of strip (3W x 4D) 2.00
7 Effective dimension of each turn 24.20
8
9
10 Space required to accommodate 18 T + 1 19.0
11 Length of LV coil 460
12 Rounding off to with tolerance 466
13 End insulation (End packing) 10 mm on either side o 24
14 Length of LV coil 490.00
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
320 Secondary being star connected, the per phase seconda 230.94
310.4 Therefore per phase magnetizing current ( Im) 1.955
1.25 Therefore I (h+e) (No load loss )/(3 phase voltage) 2.165
Radial(mm) 35964.07
2.80 35964.00
0.2 35964.00
3.0 35964.00
0.1 35964.00
3.10 35964.00
6.00 35964.00
18.60 35964.00
35964.00
35964.00
35964.00
35964.00
20.00
20 mm ( Radial built of LV)
Percentage Reactance, Resistance and Impedance:-
Percentage Reactance x% 4.80
percentage Resistance (Calculated Load loss in KW)/(Rated KVA) 0.02
percentage Impedance Z(%)= 4.80
Efficiency:
Rated KVA 800
Core area
Stacks (K) in (mm) Gross core Area( sq mTotal Gross core area in (Sq mm)
51.15 10996.57 Radial bui
31.41 6439.51 Ra
269.00
12
281.00
12
293.00
70.00
363.00
70
433.00
20.00
458.00
2.15
KVA
100.00
D
Step No.
C/l cm W/H cm
23.8 38 1st step
23.8 38 2nd step
23.8 38 3rd step
D
C/l cm W/H cm Step No.
23.8 38 1st step
23.8 38 2nd step
23.8 38 3rd step
23.8 38 4th step
23.8 38 5th step
23.8 38 6th step
12 No.of layer 2
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm Step length (L) in cm
70 7.0 50.4
55 5.5 50.4
35 3.5 50.4
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm Step length (L) in cm
120 12.0 59.5
105 10.5 58.0
90 9.0 56.5
70 7.0 54.5
55 5.5 53.0
35 3.5 51.0
38
6 (4 full and 2 half papers)
175
222
64.71
60
364
57.02
63.2889902496
Cd Et HV(KV)
2.80 3.90 0.38
Radial (mm)
1.5
0.20
1.70
0.10
1.800 Estimation of window height Values (mm)
3 Total axial length of the coil 304
5.4 End packing insulation 30x2 60
0.4 (inter layer insulation) Axial length of HV coil 364
23.20 Upper and bottom yoke insulations 20
23(Radial built of HV coil) 384
23
504
504
504
504
504
504
LV Design Values
Current per phase(Is) 262.43
Current density(Cd) A/sq.mm 2.80
Conductor area(Aw) 96.00
Bare Strip size 2.65 x 9
Insulated Strip size 2.95 x9.3
Bare Strip Area 95.4
Turns per phase 16.5
No. of coil per phase 1.0
Turns per coil 16.5
No. of layers 2.0
Turns per layer 16.5
No.of pieces
300
228
132
96
90
54
59.868
0.0200
0.039
905.331
primary current(Ip) Area of primary wire Primary wire dia.
87.72 31.33 2.700
32.00 5.4
LV process
No. Description Length (mm)
1 Bare size of strip 9.00
2 Covered thickness towards TPC 0.20
3 Covered size of strip 9.20
4 Gap between two consecutive strips (assumed) 0.10
5 Insulated size of strip with working tolerance 9.30
6 Placement of strip (3W x 4D) 2.00
7 Effective dimension of each turn 18.60
8
9
10 Space required to accommodate 16T + 2 18.0
11 Length of LV coil 334.8
12 Rounding off to with tolerance 344
13 End insulation (End packing) 10 mm on either side of coil (2X10=20 mm)20
14 Length of LV coil 364
15
Gap between upper & lower yoke and coil 20
16 Total window height 384
1.6582.67)/(3230.94) = 1.35 A
value Im= 1.35 A+(2 x 1.35 A ) =4.05 A
1.55 Secondary being star connected, the per phase seconda 127.02
27-M4 Therefore per phase magnetizing current ( Im) 0.802
246.88 Therefore I (h+e) (No load loss )/(3 phase voltage) 0.945
12
24 mm ( Radial built of LV)
Stack of B1 Weight of B2
13.50 10.675
10.26 7.219
5.94 3.642
4.32 2.105
4.05 1.575
2.43 0.614
Total
25.83
38.7
Efficiency:
Rated KVA 100
Weight of B1
5.34
3.61
1.82 1 2
1.05 37 36
0.79 37 73
0.31 X6
Total X4
12.91 X2
X3
X5
X7
X8
No of Layer Seconadry turn(N2) Secondary current(Is)
2.77 32.57 262.432
3 33 262.430
Core area
Stacks (K) in (mm) Required Stacks (K) i Gross core Area( sq mm)
38.42 40.5 4860.00
31.23 30.78 3279.19
18.53 17.82 1667.93
16.58 12.96 1160.93
8.60 12.15 472.77
7.68 7.29 268.77
121.04 121.50 Total Gross core area in (Sq mm)
Bm 11709.59
1.55 -25.14
3
31
104
88
91 3
94 3
94
96 2
98 2
104 6
Area of secondary wire
93.73
96.00
132
3 LV Coil inside diameter 67
4 Radial build of LV coil 12
171
7 HV coil inside diameter 87
Radial build of HV coil 23
177
8 200
9 HV coil outside diameter 205
207.56
10 Gap between HV limb and Phase 225
11 Core limb center
12 Total Window Height
13 Window space factor
Calculated stack Required Stack B2
38.42 40.50 100.00
31.23 30.78 76.00
18.53 17.82 44.00
16.58 12.96 32.00
8.60 12.15 30.00
7.68 7.29 18.00
Diameter (mm) 121.04 121.50
126 0.27 1.50
4 0.27 1.50
130 0.27 1.50
4 0.27 1.50
134 0.27 1.50
12 0.27 1.50
146
12
159
8
167
8
175
23
198
23
222
11
238
384
3.44
Required No of plates B
150.00
114.00
66.00
48.00
45.00
27.00
wire size
10.2
10.78
Strip size
1.5 x3.75
2.36 x 11.
2.65x 9
3.35 x 7.5
2.65 x 11.
1.5 x 4.75
2.8 x10
2.8 x 11.8
1.1 x 520
1.1 x421
Core Dia.
184
184
184
184
184
184
184
184
Chaina
duby
5.625
26.432
214.65
25.125
178.08
7.125
28
33.04
572
463.1
Details of step (A):
C/l cm
36.5
36.5
36.5
36.5
36.5
36.5
36.5
36.5
DTAILS OF (B)
C/l cm
36.5
36.5
36.5
36.5
36.5
36.5
36.5
36.5
DTAILS OF (C)
C/l cm
36.5
36.5
36.5
36.5
36.5
36.5
36.5
36.5
Approxima
Calculated
No.
1
2
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18
19
20
21
22
23
secondary
215
215
primary
1.8
1.8
W/H cm
49.8
49.8
49.8
49.8
49.8
49.8
49.8
49.8
DTAILS OF (B)
W/H cm
49.8
49.8
49.8
49.8
49.8
49.8
49.8
49.8
DTAILS OF (C)
W/H cm
49.8
49.8
49.8
49.8
49.8
49.8
49.8
49.8
WEIGHT OF CORE
624.45
624.50
No.of layer
Turns per layer
Inter layer insulation
Tapping details
Inside diameter of coil
Outside diameter of coil
Winding length of coil in m
End packing details 19.3 x 10, 34.05
Over length of coil
Approximate bare weight of conducto
proximate Weight of covered conductor (considering coverage of 11%for LV strip & 5% for HV wire including leads) In Kg
Mean Diameter of LV and HV coils
Design of Thank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
No.
1
2
3
4
6
7
1st step
2nd step
3rd step
4th step
5th step
6th step
7th step
8th step
DTAILS OF (B)
Step No.
1st step
2nd step
3rd step
4th step
5th step
6th step
7th step
8th step
DTAILS OF (C)
Step No.
1st step
2nd step
3rd step
4th step
5th step
6th step
7th step
8th step
Wight difference
-0.05
s of LV and HV
LV
Cu,electrolytic grade
Left wound
Star
2.65 x 9
TPC-0.3 mm
2.95 x9.3
2 width x 3 depth(2W x 2D)
Yes
26
1.00
26.0
2
13.3
3 x 0.08 mm
None
192
228
17.2
20.0
470.0
98.3
109.1
260.3
Design of Thank
n parameters
o the inside of tank on length side
il to the inside of tank on width side
l to the inside of tank on width side
nd tank bottom
ratio switch base
de) : HV Coil OD + 2 x HV Gw
tank flange ) :
ation + W/H of core + 2 x width of 1st core step + 54 +H R/S + GR/ST
1120
Length
Brdeath
Height
730
Description
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
180
170
155
135
115
95
75
50
DTAILS OF (B)
Step width (W)in mm
180
170
155
135
115
95
75
50
DTAILS OF (C)
Step width (W)in mm
180
170
155
135
115
95
75
50
HV
Cu,electrolytic grade
Left wound
Delta
0.00
TPC-0.3 mm
0.00
2 width x 3 depth(2W x 3D)
No
3901.0
1.00
3901.0
15
268
6 (4 full and 2 half papers)
268
353
3805.97
40.0
470.0
182.9
203.0
ign of Thank
Values (mm)
65
115
65
50
54
94
50
nk dimensions as below:
1234
rounded off to
1210
533
545
Supporting strip
press board
Supporting strip
18.0
17.0
15.5
13.5
11.5
9.5
7.5
5.0
18.0
17.0
15.5
13.5
11.5
9.5
7.5
5.0
i.
ii.
iii
iv
v
vi
vii
viii
L
A
B
C
D
E
F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm
1.60
Length (mm)
1.5
0.100
1.60
0.01
1.606
4 x 10 x 435
0.5 x 435 x 200
4 x 10 x 435
430
85.8
84.8
83.3
81.3
79.3
77.3
75.3
72.8
67.8
67.8
67.8
67.8
67.8
67.8
67.8
67.8
26
17153.1
577.35
8.9
383
58.49
175.48
Parameters
Calculated Weight of copper per transform
Measured Weight of bith insulation & co
Weight of Insulations
498
353
374.11
180
50
Bottom core channel
Length of channel (L)
A (Spacing distance between core studs)
B(spacing distance of tie rods)
(C)Hole to fix bottom foot support
(D) Spacing between coil support pad
(E) width of coil support pad:
(F) Lenght of coil support pad:
(G) Distance of core stud hole:
Top HV core channel
Length of channel (L)
A (Spacing distance between core studs)
B(spacing distance of tie rods)
(C)Hole to fix bottom foot support
(D) Spacing between coil support pad
(E) width of coil support pad:
(F) Lenght of coil support pad: thickness 10 mm
(G) Distance of core stud hole:
Hole center for fixing ratio switch
Lifting plate height
Lifting plate width
thickness of lifting plate
Top LV core channel
Length of channel (L)
A (Spacing distance between core studs)
B(spacing distance of tie rods)
(C)Hole to fix bottom foot support
(D) Spacing between coil support pad
(E) width of coil support pad:
(F) Lenght of coil support pad: thickness 10 mm
(G) Distance of core stud hole:
Hole center for fixing ratio switch
Lifting plate height
Lifting plate width
thickness of lifting plate
Three Slots
Cd
2.80
Radial (mm)
1.5
0.100
1.60
0.01
1.606
858
848
833
813
793
773
753
728
678
678
678
678
678
678
678
678
678
678
HV copper
HV coil (mm)
268.00
353.11
310.556
975.6
3901
3805973.4
4.04
8.9
2.86
96.88
290.63
Kg Values
281.22
315
33.78
Winding resistance per phase at 75 c (R) in ohm
Core stack
Chaneel width ( clamp width)
spacer or core suporter
1162
984
374
698
958
72
88
50
1162
984
374
698
958
72
88
50
890
212.5
72
10 mm
1162
984
374
698
958
72
88
50
690
213
72
10 mm
Et
8.60
SQRT of d&w
38.16
70.40
99.15
125.02
143.63
157.58
168.02
177.08
L1 Of B2
95
90
82.5
72.5
62.5
52.5
42.5
30
180.00
100.00
40.00
Values (mm)
430
40
470
28
498
38.16
32.24
28.75
25.87
18.61
13.94
10.44
9.06
L2 Of B2
85
80
72.5
62.5
52.5
42.5
32.5
20
Weight (Kg)
71.807
58.583
45.029
31.856
17.216
11.547
9.250
4.708
Total
250.0
659.7
577.35
26
17153.1
8.9
215
32.77
98.31
108.14
0.021
0.0017
1678.149
3852.769
400
4252.769
4500
Vp-per phase(V)
33000
42.00
36.00
30.00
24.00
15.00
12.00
12.00
9.00
No.of pieces
311
267
222
178
111
89
89
67
calculation
and HV copper
HV coil (mm)
268
353
311
975.6
4.04
3901
3805973.4
8.9
1.80
60.97
182.92
192.061
0.021
44.403
2174.620
LL in KW
4.25
247.23
LV(V)
400
LV Design
Current per phase(Is)
Current density(Cd) A/sq.mm
Conductor area(Aw)
Bare Strip size
Insulated Strip size
Weight in Kg
76.07
61.58
46.79
32.60
17.36
11.47
9.06
4.53
Total
259.45
No of Plates in B
156
133
111
89
56
44
44
33
division of 2k by 2 and 4
42.00
18.00
15.00
12.00
7.50
6.00
6.00
4.50
111.00
1
2
3
4
5
6
7
8
9
10
11
12
13
HV length
LV length
A cu primary
A cu secondary
A cu
Aw
Vs-per phase(V)
230.94
Values
577.35
2.80
214.65
2.65 x 9
2.95 x9.3
95.4
13.3
1.0
13.3
2.0
13.3
No of pcieces
311
267
222
178
111
89
89
67
Weight (Kg)
32.986
26.930
20.720
14.678
7.943
5.334
4.278
2.181
Total
115.0
Core diameter
Core window height
Core limb center
Core gross area
Net core area
3806.0
17.2
15761.6161616162
15011.1
30772.7161616162
91632
primary current(Ip)
4.0404040
LV process
No.
1
2
3
4
5
6
7
8
9
10
11
12
14
15
16
42.00
18
15
12
7.5
6
6
4.5
No of Plates in B2
104
89
74
59
37
30
30
22
115.0
Tolerances
1
1
1
3
3
4
1
4
18
4.86
value
184
498
374
257.85
250.11
1.55
27-M4
1.1
25%
1.25
624.50
780.63
990
209.3750
Add 200% towards handling factor for stress developed during slitting, shearing, knotching and thickness variation.
Area of primary wire
1.44
1.77
LV process
Description
Bare size of strip
Covered thickness towards TPC
78.00
108.00
132.00
147.00
159.00
168.00
177.00
No of Plates in B1
52
44
37
30
19
15
15
11
approximate no of plates
143.6
119.5
108.4
95.6
66.0
48.4
41.7
29.9
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia.
1.355
1.5
Length (mm)
9.0
0.2
9.2
0.1
9.3
3.0
27.9
13.0
362.7
363
107
470
28
498
84
72
60
48
30
24
24
18
360
180
Stack of B2
28
24
20
16
10
8
8
6
230.94
1.396
4.188
990
230.94
1.429
1.998
0.35%
7
259.81
5.609
nd thickness variation.
16.826
1.9
25%
1483.188
1.903
16.933
2.93%
Primary turn(N1)
3715.2
Radial(mm)
2.65
0.2
2.85
0.1
2.95
3.00
8.85
0.4 mm(5 inter layer insulation )
18.10
18
18
18mm ( Radial built of LV)
42.00
18.00
15.00
12.00
7.50
6.00
6.00
4.50
Stack of B1
14.00
12.00
10.00
8.00
5.00
4.00
4.00
3.00
Efficiency:
Rated KVA
Load loss in KW
No-load loss in KW
24961
24961
24961
24961
24961
24961
24961
24961
24961
42.00
36.00
30.00
24.00
15.00
12.00
12.00
9.00
180
Weight of B2
21.991
17.953
13.814
9.785
5.295
3.556
2.852
1.454
Total
76.70
115.0
wisely ordered stackes
38.5
70.5
99.5
124.5
141.5
153.5
164.5
171.5
176.36
180.00
176.36
4.41
0.014
4.41
400
4.25
0.78
5.03
98.76
98.95
99.09
98.96
98.45
98.70
98.74
98.71
0.428
99.10
5% N1(Additional)
186
183.9
184
184
184
184
184
184
184
184
42
78
108
132
147
159
171
180
Weight of B1
11.00
8.98
6.91
4.89
2.65
1.78
1.43
0.73
Total
38.35
5th step
6th step
7th step
8th step
stacks
38.16
32.24
28.75
25.87
18.61
13.94
10.44
9.06
177.08
Axial length of coil
430
Step wdith
180
170
155
135
115
95
75
50
-1.240
0.810
-0.830
-0.640
0.830
0.640
0.9
0.660
1.130
1.13
Turn per layer
267.75
SQRTof D and
38.16
70.40
99.15
125.02
143.63
157.58
168.02
177.08
Total stack
38.880
32.400
29.160
25.920
17.820
12.960
11.340
8.100
176.58
No of Layer
14.57
15
25.87
18.61
13.94
10.44
9.06
177.08
-2.92
Seconadry turn(N2)
26.85
26
15
12
12
9
180.00
Bm
1.55
-0.05
Secondary current(Is)
577.35
577.35
Core area
Gross core Area( sq mm)
7560
6120
4650
3240
1725
1140
900
450
-824.00
33.3333333333
Area of secondary wire
206.20
214.65
247.00
5
6
8
9
10
11
12
13
Coil diameter and core limb center
Core diameter = 126mm (Previously calculated)
Radial build of secondary coil= 18 mm (Previously calculated)
Radial build of HV = 34 mm (Previously calculated)
Radial clearance between core to LV coil (assumed) = 4 mm
Radial clearance between LV & HV (assumed) = 8 mm
Radius(mm)
92.00
4.00
190.00
96
18
114
20
258
134
43
270
313
318
356
Diameter (mm)
184
4.00
188.00
4.00
192
18
210
18
228
20
248
20
268
43
311
43
353
21
374.112
498
2.62
Calculated stack
38.16
32.24
28.75
25.87
18.61
13.94
10.44
9.06
177.08
157.58
0.27
0.27
0.27
0.27
0.27
0.27
0.27
0.27
Acu primary
Acu secondary
A cu
Aw
Kw
365
Required Stack
42.00
36.00
30.00
24.00
15.00
12.00
12.00
9.00
180.00
180.00
1.50
1.50
1.50
1.50
1.50
1.50
1.50
1.50
6893.64
13787.27
94675.78
0.15
AW in sq. m
26.19
B2
28.00
24.00
20.00
16.00
10.00
8.00
8.00
6.00
120.00
B2
20
24
36.00
36.00
48
68.00
128.00
0.16
14.28
14.00
12.00
10.00
8.00
5.00
4.00
4.00
3.00
B
Required No of plates B
42.000
36.000
30.000
24.000
15.000
12.000
12.000
9.000
180.00
K
of plates B
1
255
255
33000
33000
33000
33000
33000
33000
33000
267.75
2
261
516
N
4
5
2
N
4
5
0.00
3
261
777
Ratio error at different tap position:
-2.5
-5.0
5.0
2.5
-2.5
-5.0
4
261
1038
Ratio error at different tap position:
BUT
Ratio error at different tap position:
Voltages of different tape
34650
33825
33000
32175
31350
5
261
1299
Ratio error at different tap position:
231
231
231
231
231
6
261
1560
ifferent tap position:
Voltage ratio
150.0389
146.4665
142.8942
139.3218
135.7495
7
261
1821
Total turns
3901.011431347
3808.1302067911
3715.2489822353
3622.3677576794
3529.4865331235
Total turns
4051
3956
3861
3765
3669
8
261
2082
Secondary turns
26.00
26.00
26.00
26.00
26.00
Secondary turns
27.00
27.00
27.00
27.00
27.00
9
261
2343
Turns Ratio
150.0389
146.4665
142.8942
139.3218
135.7495
Turns Ratio
150.0370
146.5185
143.0000
139.4444
135.8889
10
261
2604
Percentage Error
0.000000000000
0.000000000000
0.000000000000
0.000000000000
0.000000000000
Percentage Error
0.001
-0.035
-0.074
-0.088
-0.103
11
261
2865
12
261
3126
13
261
3387
14
256
3643
TAPES POSITION
X6
X4
X2
X3
X5
X7
X8
15
258
3901
TAPES POSITION
3403
3499
3595
3595
3690
3785
3901
96
96
95
95
116
498
Tap1
Tap2
Tap3
Tap4
Tap5
Tapes In percent
5
2.5
-2.5
-5.0
HV of each tape
34650
33825
33000
32175
31350
LV of each tape
400
400
400
400
400
In delta connection Vl=Vph
Rated KVA
400
400
400
400
400
lta connection Vl=Vph
I1 (Primary line current)
6.66
6.83
7.00
7.18
7.37
In Wye connection Il=Iph
I2(Secondary current)
577.35
577.35
577.35
577.35
577.35
nection Il=Iph
KVA
400.00
12 No.of layer 2
Design of Th
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between core yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as belo
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.43
Description
Bare conductor 1
Supporting strip 10
11
press board
Supporting strip 12
Axial length of HV coil 13
14
Details of step (A):
Step width (W)in mm Step width (W)in cm
178 17.8
170 17.0
155 15.5
140 14.0
125 12.5
110 11.0
95 9.5
75 7.5
45 4.5
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
178 17.8
170 17.0
155 15.5
140 14.0
125 12.5
110 11.0
95 9.5
75 7.5
45 4.5
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
178 17.8
170 17
155 16
140 14
125 13
110 11
95 10
75 8
45 4.5
14
132
6 (4 full and 2 half papers)
250
323
1657.02
46.0
470.0
179.2
199.0
ign of Thank
Values (mm)
40 W/H
50 HV OD
50 C/L
40 1st step width
20 Last step width
90
50 i.
nk dimensions as below: ii.
1094 iii
rounded off to iv
1140 v
423 vi
430 vii
viii
of 1st core step + 54 +H R/S + GR/ST
1051 L
1140 A
430 B
1050 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.65 2.8
84.6 846
83.8
838
82.3 823
80.8 808
79.3 793
77.8 778
76.3 763
74.3 743
71.3 713
668
668
Step length (L) in cm Step length (L) in mm
66.8 668
66.8 668
66.8 668
66.8 668
66.8 668
66.8 668
66.8 668
66.8 668
66.8 668
27 1841
17643.2 1657022.0
577.35 8.89
8.9 8.9
383 2.86
60.17 42.18
180.50 126.53
0.32 6.24
0.48
1.12
177.00
120.00
29.00
LV Design Values
Current per phase(Is) 577.35 No.
Current density(Cd) A/sq.mm 2.80 1
14
No of pcieces 15
Weight in Kg
68.82 289 16
45.50
200 39.00
46.10 222 13.5
29.15 156 15
22.31 133 10.5
13.09 89 9
11.30 89 6
6.69 67 6
4.02 67 4.5
Total
246.97
Weight (Kg)
No of Plates in B No of Plates in B2
144 29.826 96
100 19.857 67
111 20.375 74
78 13.046 52
67 10.110 44
44 6.004 30
44 5.249 30
33 3.158 22
33 1.940 22
Total
109.6
HV length 1657.0
A cu primary 16364.4444444444
A cu secondary 15588.45
A cu 31952.8944444444
Aw 89180
Add 200% towards handli
Area of primary wire
3.17
1.77
3.534
LV process
Description
Bare size of strip
Covered thickness towards TPC
14.40
No of Plates in B1
48
33
37
26
22
15
15
11
11
approximate no of plates
75
95
110
125
140
155
170
178
170
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Rated secondary phase voltage (V)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
2.01 1753.7
1.5
9.2 2.85
0.1 0.1
9.3 2.95
3.0 3.00
27.9 8.85
0.4 mm(5 inter layer insulation )
18.10
13.5
376.7
377 18
93 18
470 18mm ( Radial built of LV)
20 18.6
490 392.00
primary t 13.95
0
Stack of B2 Stack of B1
26 13
18 9
20 10
14 7
12 6
8 4
8 4
6 3
6 3
230.94 Efficiency:
1.349 Rated KVA
1.9
25%
1384.775
1.777
15.810
2.74%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
750 87.7 1841.4
1841
376.65
93.35
8
Weight of B2 Weight of B1
19.884 9.94
13.238 6.62
13.584 6.79
8.697 4.35
6.740 3.37
4.003 2.00
3.499
2.105
1.293
Total Total
66.15 33.07
99.2
3.57
0.010
3.57
400
4.16
0.73
4.89
98.79
98.99
99.12
99.02
98.49
98.74
98.79
98.78
0.418
99.14
Axial length of coil Turn per layer No of Layer Seconadry turn(N2)
424 132.00 13.95 26.85
14 27
Step wdith SQRTof D and Stacks (K) in (mm) Required Stacks (K) i
178 37.95 37.95 39
95 155.24 10.24 12
75 165.83 10.59 9
45 176.35 10.52 9
Core area
Core diameter = 126mm (Previously calculated)
Gross core Area( sq mm)
Radial build of secondary coil= 18 mm (Previously calcula
6942
Radial build of HV = 34 mm (Previously calculate
4590
4650 Radial clearance between core to LV coil (assumed) =
Radial clearance between LV & HV (assumed) = 8 mm
2940
2250 Core limb center calculations
1320 No.
1140 1
675 2
405
Total Gross core area in (Sq mm)
24912.00 3
-708.00 4
5
6
8
9
10
11
12
13
Core diameter = 126mm (Previously calculated)
Radial build of secondary coil= 18 mm (Previously calculated)
Radial build of HV = 34 mm (Previously calculated)
Radial clearance between core to LV coil (assumed) = 4 mm
Radial clearance between LV & HV (assumed) = 8 mm
188.00 4.00
LV Coil inside diameter 95 190
Radial build of LV coil 18 18
208
18
238
244 12
HV coil inside diameter 125 250
Radial build of HV coil 36 36
252 286
288 36
HV coil outside diameter 293 323
296.00
Gap between HV limb and Phase 326 21
Core limb center 344.00
Total Window Height 490
Window space factor 3.02
26.19
182 11 1.606
182 12 1.606
13 1.606
178 14 1.606
2
3 4 5 6
132 132 132 132
391 523 655 787
PRIMARY RADIAL BUILT CALCULATIONS
Thickness of layer insulaThermo flow Samation of wire depth an
1.12 2 5.452
0.96 2 5.132
0.96 0.320 2 5.772
0.96 2 5.132
0.96 2 5.132
0.96 0.640 2 6.412
0.96 2 5.132
0.96 13.0 2 31.132
0.96 0.320 2 5.772
0.96 2 5.132
0.96 2 5.132
0.96 2 5.132
Asending Order of HV di
Diameter required fAge paper Constant Length of Layer insulation
5.452 249.452 784 50 834
10.584 254.584 800 50 850
16.356 260.356 818 50 868
21.488 265.488 834 50 884
26.620 270.62 850 50 900
1085
85.332 329.332 1035 50
90.464 334.464 1051 50 1101
1123
97.516 341.516 1073 50
100.728 344.728 1083 50 1133
50.364 294.364 924.771779881
12 13 14
132 132 130
1579 1711 1841
TAPES POSITION
of Layer insulation X6 1588 Tap
X4 1632 44 87.69
X2 1676 44
X3 1676
X5 1720 44 176
X7 1764 44
X8 1841 77 253
KVA
400.00
D
Step No.
C/l cm W/H cm
35.6 46.0 1st step
35.6 46.0 2nd step
35.6 46.0 3rd step
D
C/l cm W/H cm Step No.
35.6 46.0 1st step
35.6 46.0 2nd step
35.6 46.0 3rd step
35.6 46.0 4th step
35.6 46.0 5th step
35.6 46.0 6th step
35.6 46.0 7th step
35.6 46.0 8th step
12 No.of layer 2
Design of Thank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.43
Description
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
Insulated size of conductors
with working tolerances
180 18.0
170 17.0
155 15.5
135 13.5
115 11.5
95 9.5
75 7.5
50 5.0
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
180 18.0
170 17.0
155 15.5
135 13.5
115 11.5
95 9.5
75 7.5
50 5.0
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
180 18.0
170 17.0
155 15.5
135 13.5
115 11.5
95 9.5
75 7.5
50 5.0
10
176
6 (4 full and 2 half papers)
248
336
1688.83
34.0
439.7
171.3
190.2
ign of Thank
Values (mm)
65 W/H
95 HV OD
65 C/L
50 1st step width
54 Last step width
94
50 i.
nk dimensions as below: ii.
1181 iii
rounded off to iv
1210 v
496 vi
510 vii
viii
of 1st core step + 54 +H R/S + GR/ST
1072.7 L
1210 A
510 B
1120 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.60 2.80
82.0 820
81.0 810
79.5 795
77.5 775
75.5 755
73.5 735
71.5 715
69.0 690
640
640
Step length (L) in cm Step length (L) in mm
64.0 640
64.0 640
64.0 640
64.0 640
64.0 640
64.0 640
64.0 640
64.0 640
27 1841
17812.8 1688832.2
577.35 8.89
8.9 8.9
383 2.86
60.74 42.99
182.23 128.96
178.00
100.00
40.00
LV Design Values
Current per phase(Is) 577.35 No.
Current density(Cd) A/sq.mm 2.80 1
14
No of pcieces 15
Weight in Kg
75.19 326 16
51.65 237 44.00
41.20 207 16
30.76 178 14
17.47 119 12
12.63 104 8
7.12 74 7
4.75 74 5
Total 5
240.76
Weight (Kg)
No of Plates in B No of Plates in B2
163 32.306 109
119 22.392 79
104 18.106 69
89 13.757 59
59 7.949 40
52 5.845 35
37 3.351 25
37 2.281 25
Total
106.0
HV length 1688.8
A cu primary 16364.4444444444
A cu secondary 15588.45
A cu 31952.8944444444
Aw 85044.5
Add 200% towards handli
Area of primary wire
3.17
1.77
LV process
Description
Bare size of strip
Covered thickness towards TPC
76.00
104.00
128.00
144.00
158.00
168.00
178.00
No of Plates in B1
54
40
35
30
20
17
12
12
approximate no of plates
143.6
119.5
108.4
95.6
66.0
48.4
41.7
29.9
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Rated secondary phase voltage (V)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
2.010 1753.7
1.5
9.2 2.85
0.1 0.1
9.3 2.95
3.0 3.00
27.9 8.85
0.4 mm(5 inter layer insulation )
18.10
13.0
362.7
368 18
72 18
440 18mm ( Radial built of LV)
20
460
88 44.00
64 16.00
56 14.00
48 12.00
32 8.00
28 7.00
20 5.00
20 5.00
356
178
Stack of B2 Stack of B1
29.3333333333 14.67
21.3333333333 10.67
18.6666666667 9.33
16 8.00
10.6666666667 5.33
9.3333333333 4.67
6.6666666667 3.33
6.6666666667 3.33
230.94 Efficiency:
1.332 Rated KVA
1.9
25%
1391.592
1.785
15.887
2.75%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
750 88 1841.4
1841
44.00 44
32.00 76
28.00 104
24.00 128
16.00 144
14.00 158
10.00 168
10.00 178
178
Weight of B2 Weight of B1
21.537 10.77
14.928 7.46
12.070 6.04
9.171 4.59
5.299 2.65
3.896 1.95
2.234
1.520
Total Total
66.90 33.45
100.4
wisely ordered stackes wisely ordered plates stacks
38.5 144 42.72
70.5 264 30.25
99.5 372 28.02
124.5 468 25.50
141.5 534 18.42
153.5 582 13.83
164.5 624 10.37
171.5 654 9.00
176.36 sum * by 0.27
178.00 176.58 178.12
176.36
3.79
0.013
3.79
400
4.13
0.73
4.86
98.80
98.99
99.13
99.02
98.50
98.74
98.80
98.78
0.421
99.14
Axial length of coil Turn per layer No of Layer Seconadry turn(N2)
406 175.93 10.46 26.85
11 27
Step wdith SQRTof D and Stacks (K) in (mm) Required Stacks (K) i
180 42.72 42.72 44
95 158.75 13.83 14
75 169.12 10.37 10
50 178.12 9.00 10
37.037037037
5
6
8
9
10
11
12
13
Coil diameter and core limb center
Core diameter = 126mm (Previously calculated)
Radial build of secondary coil= 18 mm (Previously calculated)
Radial build of HV = 34 mm (Previously calculated)
Radial clearance between core to LV coil (assumed) = 4 mm
Radial clearance between LV & HV (assumed) = 8 mm
D
Step No.
C/l cm W/H cm
37.5 50.0 1st step
37.5 50.0 2nd step
37.5 50.0 3rd step
D
C/l cm W/H cm Step No.
37.5 50.0 1st step
37.5 50.0 2nd step
37.5 50.0 3rd step
37.5 50.0 4th step
37.5 50.0 5th step
37.5 50.0 6th step
37.5 50.0 7th step
37.5 50.0 8th step
12 No.of layer 2
13 Turns per layer 13.3
14 Inter layer insulation 3 x 0.08 mm
Design of Thank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.43
Description
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
Insulated size of conductors
with working tolerances
180 18.0
170 17.0
155 15.5
135 13.5
115 11.5
95 9.5
75 7.5
50 5.0
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
180 18.0
170 17.0
155 15.5
135 13.5
115 11.5
95 9.5
75 7.5
50 5.0
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
180 18.0
170 17.0
155 15.5
135 13.5
115 11.5
95 9.5
75 7.5
50 5.0
13
189
6 (4 full and 2 half papers)
246
354
2313.78
38.0
473.6
256.7
284.9
ign of Thank
Values (mm)
65 W/H
95 HV OD
65 C/L
50 1st step width
54 Last step width
94
50 i.
nk dimensions as below: ii.
1237 iii
rounded off to iv
1210 v
514 vi
510 vii
viii
of 1st core step + 54 +H R/S + GR/ST
1112.6 L
1210 A
510 B
1120 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.60 2.50
86.0 860
85.0 850
83.5 835
81.5 815
79.5 795
77.5 775
75.5 755
73.0 730
680
680
Step length (L) in cm Step length (L) in mm
68.0 680
68.0 680
68.0 680
68.0 680
68.0 680
68.0 680
68.0 680
68.0 680
27 2455
17643.2 2313783.0
577.35 6.67
8.9 8.9
383 2.86
60.17 58.90
180.50 176.69
176.58
100.00
40.00
AWG 9.30
LV Design Values
Current per phase(Is) 577.35 No.
Current density(Cd) A/sq.mm 2.80 1
14
No of pcieces 15
Weight in Kg
70.59 288 16
55.55 240 38.88
45.59 216 16.2
35.29 192 14.58
20.67 132 12.96
12.42 96 8.91
8.58 84 6.48
4.08 60 5.67
Total 4.05
252.77
Weight (Kg)
No of Plates in B No of Plates in B2
144 30.619 96
120 24.303 80
108 20.194 72
96 15.894 64
66 9.460 44
48 5.775 32
42 4.052 28
30 1.967 20
Total
112.3 112.3
HV length 2313.8
LV length 17.6 220.3205
A cu primary 16366.6666666667
A cu secondary 15588.45
A cu 31955.1166666667
Aw 91926.4
Add 200% towards handli
Area of primary wire
2.67
2.78
3.720
LV process
Description
Bare size of strip
Covered thickness towards TPC
71.28
100.44
126.36
144.18
157.14
165.24
173.34
No of Plates in B1
48
40
36
32
22
16
14
10
approximate no of plates
143.6
119.5
108.4
95.6
66.0
48.4
41.7
29.9
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
1.843 2338.3
1.88
2.176
Gross core area (Ag)(sq
9.2 2.85
0.1 0.1
9.3 2.95
3.0 3.00
27.9 8.85
0.4 mm(5 inter layer insulation )
18.10
14.0
390.6
396 18
78 18
474 18mm ( Radial built of LV)
26
500
77.76 38.88
64.8 16.20
58.32 14.58
51.84 12.96
35.64 8.91
25.92 6.48
22.68 5.67
16.2 4.05
353.16
176.58
Stack of B2 Stack of B1
25.92 12.96
21.6 10.80
19.44 9.72
17.28 8.64
11.88 5.94
8.64 4.32
7.56 3.78
5.4 2.70
230.94 Efficiency:
1.416 Rated KVA
1.9
25%
1462.391
1.876
16.696
2.89%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
1000 117 2455.2
2455
38.88 39
32.40 71
29.16 100
25.92 126
17.82 144
12.96 157
11.34 168
8.10 177
177
Weight of B2 Weight of B1
20.413 10.21
16.202 8.10
13.463 6.73
10.596 5.30
6.307 3.15
3.850 1.92
2.702 1.35
1.312 0.66
Total Total
74.84 37.42
112.3
wisely ordered stackes wisely ordered plates stacks
38.5 144 38.16
70.5 264 32.24
99.5 372 28.75
124.5 468 25.87
141.5 534 18.61
153.5 582 13.94
164.5 624 10.44
171.5 654 9.06
176.36 sum * by 0.27
176.58 176.58 177.08
176.36
3.91
0.011
3.91
400
3.46
0.77
4.23
98.95
99.10
99.19
99.02
98.70
98.88
98.87
98.78
0.472
99.19
Axial length of coil Turn per layer No of Layer Seconadry turn(N2)
436 189.39 12.96 26.85
13 27
Step wdith SQRTof D and Stacks (K) in (mm) Required Stacks (K) i
180 38.16 38.16 38.88
30
5
6
8
9
10
11
12
13
Coil diameter and core limb center
Core diameter = 126mm (Previously calculated)
Radial build of secondary coil= 18 mm (Previously calculated)
Radial build of HV = 34 mm (Previously calculated)
Radial clearance between core to LV coil (assumed) = 4 mm
Radial clearance between LV & HV (assumed) = 8 mm
D
Step No.
C/l cm W/H cm
35.8 49.8 1st step
35.8 49.8 2nd step
35.8 49.8 3rd step
D
C/l cm W/H cm Step No.
35.8 49.8 1st step
35.8 49.8 2nd step
35.8 49.8 3rd step
35.8 49.8 4th step
35.8 49.8 5th step
35.8 49.8 6th step
35.8 49.8 7th step
35.8 49.8 8th step
5 Coverinig TPC-0.3 mm
12 No.of layer 2
13 Turns per layer 13.3
14 Inter layer insulation 3 x 0.08 mm
Design of Thank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.43
Description
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
Insulated size of conductors
with working tolerances
180 18.0
170 17.0
155 15.5
135 13.5
115 11.5
95 9.5
75 7.5
50 5.0
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
180 18.0
170 17.0
155 15.5
135 13.5
115 11.5
95 9.5
75 7.5
50 5.0
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
180 18.0
170 17.0
155 15.5
135 13.5
115 11.5
95 9.5
75 7.5
50 5.0
11
227
6 (4 full and 2 half papers)
246
336
2244.37
38.0
471.7
171.5
190.4
ign of Thank
Values (mm)
65 W/H
100 HV OD
65 C/L
50 1st step width
54 Last step width
94
50 i.
nk dimensions as below: ii.
1185 iii
rounded off to iv
1190 v
501 vi
504 vii
viii
of 1st core step + 54 +H R/S + GR/ST
1110.7 L
1190 A
504 B
1140 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Parameters
Calculated Weight of co
Measured Weight of bi
Weight of Insulations
Total wieight of insula
Bm Cd
1.60 2.50
85.8 858
84.8 848
83.3 833
81.3 813
79.3 793
77.3 773
75.3 753
72.8 728
678
678
Step length (L) in cm Step length (L) in mm
67.8 678
67.8 678
67.8 678
67.8 678
67.8 678
67.8 678
67.8 678
67.8 678
27 2455
17643.2 2244369.5
577.35 6.67
8.9 8.9
383 2.86
60.17 57.13
180.50 171.38
Parameters Kg Values
Calculated Weight of copper per transform 287.87
Measured Weight of bith insulation & co 300
Weight of Insulations 12.13
wire diameter
1.91
Estimation of window height Values (mm)
Total axial length of the coil 434
End packing insulation 30x2 38
Axial length of HV coil 472
Upper and bottom yoke insulations 26
498
176.58
100.00
40.00
LV Design Values
Current per phase(Is) 577.35 No.
Current density(Cd) A/sq.mm 2.80 1
14
No of pcieces 15
Weight in Kg
70.39 288 16
55.40 240 38.88
45.46 216 16.2
35.19 192 14.58
20.61 132 12.96
12.38 96 8.91
8.55 84 6.48
4.07 60 5.67
Total 4.05
252.06
Weight (Kg)
No of Plates in B No of Plates in B2
144 30.520 96
120 24.225 80
108 20.130 72
96 15.844 64
66 9.431 44
48 5.758 32
42 4.040 28
30 1.962 20
Total
111.9 111.9
HV length 2244.4
LV length 17.6 237.4528
A cu primary 16366.6666666667
A cu secondary 15588.45
A cu 31955.1166666667
Aw 91576.8
287.87 Add 200% towards handli
Area of primary wire
2.67
2.78
2.862
LV process
Description
Bare size of strip
Covered thickness towards TPC
71.28
100.44
126.36
144.18
157.14
165.24
173.34
No of Plates in B1
48
40
36
32
22
16
14
10
approximate no of plates
143.6
119.5
108.4
95.6
66.0
48.4
41.7
29.9
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
1.843 2338.3
1.88 2338.0
1.909
Gross core area (Ag)(sq
9.2 2.85
0.1 0.1
9.3 2.95
3.0 3.00
27.9 8.85
0.4 mm(5 inter layer insulation )
18.10
13.0
362.7
396 18
76 18
472 18mm ( Radial built of LV)
26
498
77.76 38.88
64.8 16.20
58.32 14.58
51.84 12.96
35.64 8.91
25.92 6.48
22.68 5.67
16.2 4.05
353.16
176.58
Stack of B2 Stack of B1
25.92 12.96
21.6 10.80
19.44 9.72
17.28 8.64
11.88 5.94
8.64 4.32
7.56 3.78
5.4 2.70
230.94 Efficiency:
1.385 Rated KVA
1.9
25%
1429.840
1.834
16.324
2.83%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
1000 116.9 2455.2
117 2455
32.40 #VALUE!
29.16 #VALUE!
25.92 #VALUE!
17.82 #VALUE!
12.96 #VALUE!
11.34 #VALUE!
8.10 #VALUE!
138
Weight of B2 Weight of B1
20.347 10.17
16.150 8.07
13.420 6.71
10.563 5.28
6.288 3.14
3.838 1.92
2.694 1.35
1.308 0.65
Total Total
74.61 37.30
111.9
wisely ordered stackes wisely ordered plates stacks
38.5 144 38.16
70.5 264 32.24
99.5 372 28.75
124.5 468 25.87
141.5 534 18.61
153.5 582 13.94
164.5 624 10.44
171.5 654 9.06
176.36 sum * by 0.27
176.58 176.58 177.08
176.36
3.52
0.013
3.52
400 Ratio
Primary rated voltage Tap Position
4.10
0.75 20000 1
4.85 20000 2
98.80 20000 N
98.99 20000 4
99.12 20000 5
99.00
98.51
98.74
98.79
98.76
0.429
99.13
Axial length of coil Turn per layer No of Layer Seconadry turn(N2)
434 227.19 10.81 26.85
11 27
Step wdith SQRTof D and Stacks (K) in (mm) Required Stacks (K) i
180 38.16 38.16 38.88
850.50 1
405.00 2
30
5
6
8
9
10
11
12
13
position:
Total turns Secondary turns
2455.1820197289 27.00
2396.7253049734 27.00
2338.268590218 27.00
2279.8118754625 27.00
2221.3551607071 27.00
Coil diameter and core limb center
Core diameter = 126mm (Previously calculated)
Radial build of secondary coil= 18 mm (Previously calculated)
Radial build of HV = 34 mm (Previously calculated)
Radial clearance between core to LV coil (assumed) = 4 mm
Radial clearance between LV & HV (assumed) = 8 mm
86.6025 0.000000000000
84.4375 0.000000000000
82.2724 0.000000000000
26.19
K
4 5 6 7
227 227 227 227
897 1124 1351 1578
8 9 10 11
227 227 196 227
1805 2032 2228 2455
TAPES POSITION
X6 2065
X4 2124 59
X2 2183 59 117
X3 2183
X5 2241 58
X7 2299 58
X8 2455 156 390
Tapes In percent
HV of each tape
LV of each tape Rated KVA
Tap1 5 21000 400 400
Tap2 2.5 20500 400 400
Tap3 20000 400 400
Tap4 -2.5 19500 400 400
Tap5 -5.0 19000 400 400
In Wye connection Il=Iph
I1 (Primary line current)
I2(Secondary current)
11.00 577.35
11.27 577.35
11.55 577.35
11.84 577.35
12.15 577.35
KVA
315
D
Step No.
C/l cm W/H cm
36.2 49.0 1st step
D
C/l cm W/H cm Step No.
36.2 49.0 1st step
36.2 49.0 2nd step
36.2 49.0 3rd step
36.2 49.0 4th step
36.2 49.0 5th step
36.2 49.0 6th step
36.2 49.0 7th step
36.2 49.0 8th step
12 No.of layer 2
Design of Tank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.42
Description
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
Insulated size of conductors
with working tolerances
165 16.5
150 15.0
135 13.5
120 12.0
105 10.5
90 9
70 7
40 4
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
165 16.5
150 15.0
135 13.5
120 12.0
105 10.5
90 9.0
70 7.0
40 4.0
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
165 16.5
150 15.0
135 13.5
120 12.0
105 10.5
90 9.0
70 7.0
40 4.0
18
259
6 (4 full and 2 half papers)
236
344
4237.35
44.0
460.0
229.7
254.9
ign of Tank
Values (mm)
65 W/H
115 HV OD
65 C/L
50 1st step width
54 Last step width
94
50 i.
nk dimensions as below: ii.
1201 iii
rounded off to iv
1200 v
524 vi
525 vii
viii
of 1st core step + 54 +H R/S + GR/ST
1073 L
1200 A
525 B
1120 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.60 3.00
82.0 820
80.5 805
79.0 790
77.5 775
76.0 760
74.5 745
72.5 725
69.5 695
655
655
Step length (L) in cm Step length (L) in mm
65.5 655
65.5 655
65.5 655
65.5 655
65.5 655
65.5 655
65.5 655
65.5 655
31 4651
19331.8 4237348.8
454.66 3.18
8.9 8.9
383 2.86
65.92 107.86
197.77 323.57
166.05
100.00
32.50
LV Design Values
Current per phase(Is) 454.66 No.
Current density(Cd) A/sq.mm 2.80 1
14
No of pcieces 15
Weight in Kg
71.46 330 16
56.69 288
29.76 168
18.90 120
13.23 96
10.39 88
6.61 72
3.57 68
Total
210.61
Weight (Kg)
No of Plates in B No of Plates in B2
165 31.228 110.00
144 25.100 96.00
84 13.348 56.00
60 8.583 40.00
48 6.084 32.00
44 4.840 29.33
36 3.130 24.00
34 1.730 22.67
615 Total 410
94.0
HV length 4237.3
A cu primary 14798.6363636364
A cu secondary 14094.46
A cu 28893.0963636364
Aw 83790
Add 200% towards handli
Area of primary wire
1.06
1.77
LV process
Description
Bare size of strip
Covered thickness towards TPC
Plates of A or C
330
288
168
120
96
88
72
68
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Rated secondary phase voltage (V)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
1.162 4429.7
1.5
Gross core ar
11.4 2.85
0.1 0.1
11.5 2.95
2.0 3.00
23.0 8.85
0.4 mm(5 inter layer insulation )
18.10
16.0
368.0
374 18
86 18
460 18mm ( Radial built of LV)
30
490
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Stack of B2 Stack of B1
29.70 14.85
25.92 12.96
15.12 7.56
10.80 5.40
8.64 4.32
7.92 3.96
6.48 3.24
6.12 3.06
110.7 55
166.05
230.94 Efficiency:
1.187 Rated KVA
1.9
25%
1222.960
1.569
13.962
3.07%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
1650 221 4651.2
4651
0.00 0
0.00 0
0.00 0
0.00 0
0.00 0
0.00 0
0.00 0
0.00 0
0
Weight of B2 Weight of B1 Final required stacks in B2
20.818 10.41 29.70
16.734 8.37 25.92
8.899 4.45 15.12
5.722 2.86 10.80
4.056 2.03 8.64
3.226 1.61 7.56
2.087 1.04 6.48
1.154 0.58 6.48
44.83
Total Total
62.70 31.35
94.0
wisely ordered plates Wisely ordered Stacks Normally required stacks
165 44.55 44.55
309 83.43 38.88
393 106.11 22.68
453 122.31 16.20
501 135.27 12.96
545 147.15 11.88
581 156.87 9.72
615 166.05 9.18
166.05
Standard value
Design value
3.87 4.50
0.009
3.87
315
2.88
0.64
3.52
98.89
99.05
99.14
98.96
98.62
98.82
98.80
98.71
0.473
99.14
Axial length of coil Turn per layer
416 259.03
Total stack
Final required stacks in B1 Final required no of plates in B2
14.85 110
12.96 96
7.56 56
5.40 40
4.32 32
3.78 28
3.24 24
3.24 24
332.1 166.05
166.05
No of Layer Seconadry turn(N2) Secondary current(Is)
17.96 30.98 454.66
18 31 454.66
Core area
Stacks (K) in (mm) Required Stacks (K) i Gross core Area( sq mm)
44.90 44.55 7350.75
37.20 38.88 5832.00
22.85 22.68 3061.80
16.87 16.20 1944.00
13.14 12.96 1360.80
10.43 11.88 1069.20
10.62 9.72 680.40
10.24 9.18 367.20
177.00
3 LV Coil inside diameter 90
4 Radial build of LV coil 18
232
7 HV coil inside diameter 117
Radial build of HV coil 54
238
8 292
9 HV coil outside diameter 297
300.00
10 Gap between HV limb and Phase 347
11 Core limb center
12 Total Window Height
13 Window space factor
Sectioning plates Sectioning stacks
165 165 44.55
72 309 83.43
42 393 106.11
30 453 122.31
24 501 135.27
21 543 146.61
18 579 156.33
18 615 166.05
26.19
Diameter (mm)
10.62 9.72 0.90
171
10.24 9.18 1.06
4.00
0.27 1.50 20
179 0.27 1.50 24
18 0.27 1.50 36.00
197 0.27 1.50 36.00
18 0.27 1.50 48
0.27 1.50 68.00
218
9 0.27 1.50 128.00
227 0.27 1.50
9
236
54
290 Acu primary 8219.00
54 Acu secondary
344 A cu 16437.99
Aw 93590.00
18 Kw 0.18 0.16
362 362 AW in sq. m 10.36
490
2.57
Required No of plates B
150.00 44.550 1 2
114.00 38.880 250 259
-1.33 22.680 250 509
-1.15 16.200 Odd
-0.97 12.960 1
-0.07 11.880 3.00
9.720 5
9.180 7.00
166.05 9
B K 11.00
13
15.00
17
3 4 5 6
259 259 259 259
768 1027 1286 1545
Depth of odd Even Depth of Even Sum of odd & even
2.560 2 2.240 4.800
2.240 4 2.240 4.480
8.560 6 2.240 10.800
2.240 8 2.240 4.480
2.240 10 2.240 4.480
2.240 12 2.240 4.480
16.560 14 2.240 18.800
2.240 16 2.240 4.480
2.560 18 2.709 5.269
7 8 9 10 11 12 13
259 259 259 259 259 259 259
1804 2063 2322 2581 2840 3099 3358
ID of LV plus tolera Circufrance Tolerance Total lengtEnd insulation
232 728 50 778 748 778
236 742 50 792 762 792
247 776 50 826 796 826
252 790 50 840 810 840
256 804 50 854 824 854
261 818 50 868 838 868
279 878 50 928 898 928
284 892 50 942 912 942
289 908 50 958 928 958
14 15 16 17 18
259 259 259 259 257
3617 3876 4135 4394 4651 Tapes In percent
TAPES POSITION Tap1 5
X6 4130 Tap2 2.5
X4 4241 111 Tap3
X2 4352 111 Tap4 -2.5
X3 4352 Tap5 -5.0
X5 4462 110 442
X7 4572 110
X8 4651 79 521
In delta connection Vl=Vph In Wye connection Il=Iph
HV of each tape LV of each tape Rated KVA
I1 (Primary line current)
I2(Secondary current)
34650 400 315 5.25 454.66
33825 400 315 5.38 454.66
33000 400 315 5.51 454.66
32175 400 315 5.65 454.66
31350 400 315 5.80 454.66
KVA
200.00
D
Step No.
C/l cm W/H cm
26.6 54.0 1st step
26.6 54.0 2nd step
26.6 54.0 3rd step
D
C/l cm W/H cm Step No.
26.6 54.0 1st step
26.6 54.0 2nd step
26.6 54.0 3rd step
26.6 54.0 4th step
26.6 54.0 5th step
26.6 54.0 6th step
26.6 54.0 7th step
5 Coverinig TPC-0.3 mm
12 No.of layer 7
13 Turns per layer 13.3
14 Inter layer insulation 3 x 0.08 mm
Design of Thank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.30
Description
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
Insulated size of conductors
with working tolerances
115 11.5
105 10.5
90 9.0
80 8.0
70 7.0
60 6.0
40 4.0
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
115 11.5
105 10.5
90 9.0
80 8.0
70 7.0
60 6.0
40 4.0
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
115 11.5
105 10.5
90 9.0
80 8.0
70 7.0
60 6.0
40 4.0
10
220
6 (4 full and 2 half papers)
194
251
1508.49
100.0
520.1
140.7
156.2
ign of Thank
Values (mm)
65 W/H
100 HV OD
65 C/L
50 1st step width
54 Last step width
94
50 i.
nk dimensions as below: ii.
916 iii
rounded off to iv
1190 v
416 vi
504 vii
viii
of 1st core step + 54 +H R/S + GR/ST
1023.1 L
1190 A
504 B
1140 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Parameters
Calculated Weight of co
Measured Weight of bi
Weight of Insulations
Total wieight of insula
Bm Cd
1.85 2.50
4 x 10 x 420 28.29
0.5 x 435 x 240 28.3
4 x 10 x 420 28.30
420 28.3 (Radial built of HV coil)
77.0 770
76.0 760
74.5 745
73.5 735
72.5 725
71.5 715
69.5 695
655
Step length (L) in cm Step length (L) in mm
65.5 655
65.5 655
65.5 655
65.5 655
65.5 655
65.5 655
65.5 655
94 2160
45773.0 1508492.3
166.70 7.70
8.9 8.9
383 2.86
156.09 38.40
468.27 115.19
Parameters Kg Values
Calculated Weight of copper per transform 241.27
Measured Weight of bith insulation & co 300
Weight of Insulations 58.73
wire diameter
1.91
Estimation of window height Values (mm)
Total axial length of the coil 420
End packing insulation 30x2 100
Axial length of HV coil 520
Upper and bottom yoke insulations 20
540
f HV coil)
114.00
100.00
7.50
LV Design Values
Current per phase(Is) 166.70 No.
Current density(Cd) A/sq.mm 2.80 1
14
No of pcieces
Weight in Kg
40.25 267
24.50 178
18.38 156
8.17 78
6.13 67
4.38 56
2.33 44
Total
104.13
Weight (Kg)
No of Plates in B No of Plates in B2
133 18.359 89
89 11.268 59
78 8.556 52
39 3.834 26
33 2.899 22
28 2.087 19
22 1.131 15
Total
48.14
HV length 1508.5
LV length 45.8 313.7936
A cu primary 16627.6877526612
A cu secondary 15669.8
A cu 32297.4877526612
Aw 64812
241.27 Add 200% towards handli
Area of primary wire
3.08
3.14
LV process
Description
Bare size of strip
Covered thickness towards TPC
approximate no of plates
143.6
119.5
108.4
95.6
66.0
48.4
48.4
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
1.980 2035.2
2 2057.0
9.2 2.85
0.1 0.1
9.3 2.95
1.0 3.00
9.3 8.85
0. 24mm(3 inter layer insulation )
27.03
47.0
437.1
442 27
78 27
520 27mm ( Radial built of LV)
20
540
Stack of B2 Stack of B1
24 12.00
16 8.00
14 7.00
7 3.50
6 3.00
5 2.50
4 2.00
calculated value
original value
400.00 Efficiency:
0.351 Rated KVA
1.9
25%
543.792
0.403
3.584
2.15%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
433 101.8 2138.2
103 2160
0.00
3.90
0.009
3.90
200 Ratio
Primary rated voltage Tap Position
2.79
0.29 8660 1
3.07 8660 2
98.49 8660 N
98.78 8660 4
99.03 8660 5
99.09
98.12
98.48
98.70
98.86
0.321
99.11
Axial length of coil Turn per layer No of Layer Seconadry turn(N2)
420 220.06 9.82 94.28
10 94
10.11
80.00
Step wdith SQRTof D and Stacks (K) in (mm) Required Stacks (K) i
115 34.28 34.28 36.00
1.210
1.21 170.37
Ratio error at different tap position:
Perceent in Tapping Voltages of diffeSecondary Phase volt Voltage ratio
5.0 9093.2667397 400 22.7332
2.5 8876.7603888 400 22.1919
240.00 1
Total Gross core area in (Sq mm) 2
10710.00
-60.00
3
#REF! 4
5
6
8
9
10
11
12
13
position:
Total turns Secondary turns
2136.9176838381 94.00
2086.0386913658 94.00
2035.1596988934 94.00
1984.2807064211 94.00
1933.4017139488 94.00
437.1
21.6506 0.000000000000
21.1094 0.000000000000
20.5681 0.000000000000
26.19
K
4 5 6 7
227 227 227 227
897 1124 1351 1578
8 9 10 11
227 227 196 227
1805 2032 2228 2455
TAPES POSITION
X6 2065
X4 2124 59
X2 2183 59 117
X3 2183
X5 2241 58
X7 2299 58
X8 2455 156 390
Tapes In percent
HV of each tape
LV of each tape Rated KVA
Tap1 5 9093 400 200
Tap2 2.5 8877 400 200
Tap3 8660 400 200
Tap4 -2.5 8444 400 200
Tap5 -5.0 8227 400 200
In Wye connection Il=Iph
I1 (Primary line current)
I2(Secondary current)
12.70 288.68
13.01 288.68
13.33 288.68
13.68 288.68
14.04 288.68
KVA
4000
12 No.of layer 9
Design of Tank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.45
Description
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
Insulated size of conductors
Placement of strips
325 32.5
305 30.5
285 28.5
260 26.0
235 23.5
210 21.0
185 18.5
165 16.5
145 14.5
125 12.5
95 9.5
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
325 32.5
305 30.5
285 28.5
260 26.0
235 23.5
210 21.0
185 18.5
165 16.5
145 14.5
125 12.5
95 9.5
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
325 32.5
305 30.5
285 28.5
260 26.0
235 23.5
210 21.0
185 18.5
165 16.5
145 14.5
125 12.5
95 9.5
Weight calculation of LV and HV copp
HV Particulars
Cu,electrolytic grade Inside diameter of coil
Left wound Outside diameter of coi
Delta Mean diameter of coil
16
77
6 (4 full and 2 half papers)
470
632
2112.30
35.0
813.0
803.7
892.1
ign of Tank
Values (mm)
110 W/H
160 HV OD
110 C/L
50 1st step width
60 Last step width
94
50 i.
nk dimensions as below: ii.
2160 iii
rounded off to iv
2164 v
902 vi
930 vii
viii
of 1st core step + 54 +H R/S + GR/ST
1763 L
2164 A
930 B
1770 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.60 3.00
1220.00
150.4 1504
146.4 1484
142.4 1464
137.4 1439
132.4 1414
127.4 1389
122.4 1364
118.4 1344
114.4 1324
110.4 1304
104.4 1274
Step length (L) in cm Step length (L) in mm
117.9 1179
115.9 1179
113.9 1179
111.4 1179
108.9 1179
106.4 1179
103.9 1179
101.9 1179
99.9 1179
97.9 1179
94.9 1179
1304
1304
1304
1304
1304
122 1220
152144.6 2112301.3
385.00 40.40
8.9 8.9
383 2.86
518.83 53.77
1556.50 161.30
f HV coil)
888
LV(V) Vs-per phase(V) primary current(Ip)
6000 3464.10 40.40
LV Design Values
Current per phase(Is) 385.00 No.
Current density(Cd) A/sq.mm 2.80 1
14
No of pcieces 15
Weight in Kg
443.56 578 16
314.77 444
173.43 267
154.75 267
113.94 222
79.59 178
51.35 133
29.94 89
19.35 67
16.35 67
12.04 67
Total
1409.07
Weight (Kg)
No of Plates in B No of Plates in B2
289 191.213 192.59
222 136.678 148.15
133 75.868 88.89
133 68.345 88.89
111 50.824 74.07
89 35.866 59.26
67 23.388 44.44
44 13.760 29.63
33 8.972 22.22
33 7.651 22.22
33 5.720 22.22
Total 618.284
No load loss calculations
No Particulars value
HV length 2112.3
A cu primary 49292.9292929293
A cu secondary 46970
A cu 96262.9292929293
Aw 285236
Add 200% towards handli
Area of primary wire
13.47
13.47
Secondary Turn per layer
LV process
Description
Bare size of strip
Covered thickness towards TPC
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Rated secondary phase voltage (V)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
4.141 1162.2
1.5
30.500 0.64
121.72 122.00
Length (mm) Radial(mm)
11.2 2.36
0.2 0.2
11.4 2.56
0.1 0.1
11.5 2.66
2 3
23.0 7.98
0.64 mm(8 inter layer insulation )
42.46
31.0 10 x2.0 x854(thermoflow)
713.0 10 x 3.0 x854 Thermo flow)
719 49
94 49
813
41
854 49 mm ( Radial built of LV)
Stack of B2 Stack of B1
52.00 26.00
40.00 20.00
24.00 12.00
24.00 12.00
20.00 10.00
16.00 8.00
12.00 6.00
8.00 4.00
6.00 3.00
6.00 3.00
6.00 3.00
Percentage Reactance, Resistance and Impedance:-
Percentage Reactance x%
percentage Resistance (Calculated Load loss in KW)/(
1.57 percentage Impedance Z(%)=
3479.60
3464.10 Efficiency:
0.527 Rated KVA
1.9
25%
8264.060
0.707
6.290
1.63%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
1650 58 1220.3
1220
4000
28.20
4.35
32.55
99.19
99.33
99.43
99.39
98.99
99.16
99.23
99.24
0.393
99.45
Axial length of coil Turn per layer
778 77.03
77
Core area
Stacks (K) in (mm) Required Stacks (K) i Gross core Area( sq mm)
77.01 78 25350
59.12 60 18300
38.03 36 10260
35.50 36 9360
27.68 30 7050
22.38 24 5040
18.36 18 3330
12.31 12 1980
10.49 9 1305
8.84 9 1125
10.48 9 855
320.20 321.00 Total Gross core area in (Sq mm)
-0.80 Bm 83955
1.57 -1351
89.49
Area of secondary wire
128.30
140.00
247.00
342.00
3 LV Coil inside diameter 173
4 Radial build of LV coil 49
464
7 HV coil inside diameter 233
Radial build of HV coil 81
472
8 553
9 HV coil outside diameter 558
561.12
10 Gap between HV limb and Phase 635
11 Core limb center
12 Total Window Height
13 Window space factor
Calculated stack Required Stack B2
77.01 78 -0.99
59.12 60 -0.88
38.03 36 2.03
35.50 36 -0.50
27.68 30 -2.32
22.38 24 -1.62
Diameter (mm)
18.36 18 0.36
334
12.31 12 0.31
6.00
10.49 9 -3.60
340.00
8.84 9 B2
6.00 10.48 9 20
346 1.50 24
49 1.50 36.00
395 1.50 36.00
49 1.50 48
1.50 68.00
448
11 0.27 1.50 128.00
459 0.27 1.50
11
470
81
551 Acu primary 16433.40
81 Acu secondary
632 A cu 32866.80
Aw 271845.28
20 Kw 0.12 0.16
652 652 AW in sq. m 49.31
854
2.68
Required No of plates B
150.00 0.000 1 2
114.00 0.000 250 259
-1.87 0.000 250 509
0.16 0.000 Odd
-2.16 0.000 1
-1.80 0.000 3.00
0.000 5
0.000 7.00
0.00 9
B K 11.00
13
15.00
17
246.00
11.00 235.00 325.00
225.00 310.00
215.00 295.00
200.00 275.00
180.00 255.00
160.00 240.00
135.00 220.00
115.00 200.00
85.00 175.00
60.00 155.00
125
3 4 5 6
259 259 259 259
768 1027 1286 1545
Depth of odd Even Depth of Even Sum of odd & even
2.660 2 2.340 5.000
2.340 4 2.340 4.680
8.560 6 2.340 10.900
2.340 8 2.340 4.680
2.340 10 2.340 4.680
2.340 12 2.340 4.680
16.560 14 2.340 18.900
2.340 16 2.340 4.680
2.660 18 2.709 5.369
7 8 9 10 11 12 13
259 259 259 259 259 259 259
1804 2063 2322 2581 2840 3099 3358
ID of LV plus tolera Circufrance Tolerance Total lengtEnd insulation
464 1457 50 1507 1477 1507
469 1472 50 1522 1492 1522
480 1506 50 1556 1526 1556
484 1521 50 1571 1541 1571
489 1536 50 1586 1556 1586
494 1551 50 1601 1571 1601
512 1610 50 1660 1630 1660
517 1625 50 1675 1645 1675
522 1641 50 1691 1661 1691
14 15 16 17 18
259 259 259 259 257
3617 3876 4135 4394 4651 Tapes In percent
TAPES POSITION Tap1 5
X6 4130 Tap2 2.5
X4 4241 111 Tap3
X2 4352 111 Tap4 -2.5
X3 4352 Tap5 -5.0
X5 4462 110 442
X7 4572 110
X8 4651 79 521
In delta connection Vl=Vph In Wye connection Il=Iph
HV of each tape LV of each tape Rated KVA
I1 (Primary line current)
I2(Secondary current)
34650 6000 4000 66.65 384.90
33825 6000 4000 68.27 384.90
33000 6000 4000 69.98 384.90
32175 6000 4000 71.78 384.90
31350 6000 4000 73.67 384.90
KVA
1250
12 No.of layer 1
Design of Tank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.410
15.93
51.96
Description 16.00
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
Insulated size of conductors
placement of strips(2 W x1 D)
230 23.0
220 22.0
205 20.5
185 18.5
165 16.5
145 14.5
125 12.5
100 10.0
60 6.0
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
230 23.0
220 22.0
205 20.5
185 18.5
165 16.5
145 14.5
125 12.5
100 10.0
60 6.0
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
230 23.0
220 22.0
205 20.5
185 18.5
165 16.5
145 14.5
125 12.5
100 10.0
60 6.0
Weight calculation of LV and HV copp
HV Particulars
Cu,electrolytic grade Inside diameter of coil
Left wound Outside diameter of coi
Delta Mean diameter of coil
17
65
6 (4 full and 2 half papers)
290
403
1187.28
34.0
560.0
462.2
513.0
ign of Tank
Values (mm)
65 W/H
115 HV OD
65 C/L
50 1st step width
54 Last step width
94
50 i.
nk dimensions as below: ii.
1381 iii
rounded off to iv
1390 v
583 vi
590 vii
viii
of 1st core step + 54 +H R/S + GR/ST
1293 L
1390 A
590 B
1295 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.65 3.16
1091.00
104.0 1040
102.0 1030
99.0 1015
95.0 995
91.0 975
87.0 955
83.0 935
78.0 910
70.0 870
Step length (L) in cm Step length (L) in mm
81.0 810
81.0 810
81.0 810
81.0 810
81.0 810
81.0 810
81.0 810
81.0 810
81.0 810
16 1091
12792.6 1187278.2
1804.20 27.78
8.9 8.9
383 2.86
43.62 30.22
130.87 90.66
f HV coil)
888
LV(V) Vs-per phase(V) primary current(Ip)
400 230.94 27.78
LV Design Values
Current per phase(Is) 1804.20 No.
Current density(Cd) A/sq.mm 2.80 1
14
No of pcieces 15
Weight in Kg
132.71 356 16
94.03 267
78.81 244
63.01 222
43.78 178
28.08 133
19.62 111
12.11 89
5.13 67
Total
477.30
Weight (Kg)
No of Plates in B No of Plates in B2
178 56.936 118.52
133 41.139 88.89
122 35.516 81.48
111 29.549 74.07
89 21.378 59.26
67 14.284 44.44
56 10.400 37.04
44 6.767 29.63
33 3.126 22.22
Total 219.095
HV length 1187.3
A cu primary 30305.5555555556
A cu secondary 28867.2
A cu 59172.7555555556
Aw 136300
Add 200% towards handli
Area of primary wire
8.79
Plates of A or C
330
288
168
120
96
88
72
68
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Rated secondary phase voltage (V)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
3.345 1039.2
1039.0
30.500
15.93 122.00
Length (mm) Radial(mm)
520.0 1.10
520.0 1.10
520.0 1.10
1.0 1.00
520.0 1.10
0.2 mm(1 inter layer insulation )
8.50
520.0 3 x 10 (thermo flow)
520.0 6.00
520 15
40
560 15mm ( Radial built of LV)
20
580
Stack of B2 Stack of B1
32.00 16.00
24.00 12.00
22.00 11.00
20.00 10.00
16.00 8.00
12.00 6.00
10.00 5.00
8.00 4.00
6.00 3.00
230.94 Efficiency:
2.711 Rated KVA
1.9
25%
2747.241
3.525
31.365
1.74%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
750 51.96 1091.0
52 1091
Total Total
146.06 73.03
219.10
219.1
wisely ordered plates Wisely ordered Stacks Normally required stacks
165 44.55 44.55
309 83.43 38.88
393 106.11 22.68
453 122.31 16.20
501 135.27 12.96
545 147.15 11.88
581 156.87 9.72
615 166.05 9.18
166.05
Standard value
Design value
4.39 6.50
0.031
4.39
1250
9.79
1.45
11.24
99.11
99.26
99.38
99.35
98.89
99.08
99.16
99.18
0.384
99.40
Axial length of coil Turn per layer
526 64.94
65
Core area
Stacks (K) in (mm) Required Stacks (K) i Gross core Area( sq mm)
48.22 48 11040
34.40 36 7920
32.28 33 6765
30.02 30 5550
22.42 24 3960
17.60 18 2610
14.07 15 1875
13.66 12 1200
14.55 9 540
227.21 225.00 Total Gross core area in (Sq mm)
2.21 Bm 41460
1.62 -663
20.84
Final required no of plates in B1 Plates of A or C
55 330 89.1
48 288 77.76
28 168 45.36
20 120 32.4
16 96 25.92
14 84 22.68
12 72 19.44
12 72 19.44
Area of secondary wire
570.96
572.00
241.00
3 LV Coil inside diameter 122
4 Radial build of LV coil 10
284
7 HV coil inside diameter 144
Radial build of HV coil 56
292
8 348
9 HV coil outside diameter 353
356.40
10 Gap between HV limb and Phase 406
11 Core limb center
12 Total Window Height
13 Window space factor
Diameter (mm)
14.07 30 10
235
13.66 18 6
4
14.55 18 6
239.00
227.21 B2
4 20
243 1.50 24
10 1.50 36.00
253 1.50 36.00
10 1.50 48
1.50 68.00
266
12 0.27 1.50 128.00
278 0.27 1.50
12
290
56
346 Acu primary 0.00
56 Acu secondary
403 A cu 0.00
Aw 108924.00
20 Kw 0.00 0.16
423 423 AW in sq. m #DIV/0!
580
3.09
B1 Required No of plates B
16 48 1 2
12 36 56 65
11 33 56 121
10 30 Odd
8 24 1
6 18 3.00
5 15 5
3 9.0 7.00
3 9 9
B 222 11.00
13
15.00
17
246.00
11.00 235.00 325.00
225.00 310.00
215.00 295.00
200.00 275.00
180.00 255.00
160.00 240.00
135.00 220.00
115.00 200.00
85.00 175.00
60.00 155.00
125
3 4 5 6
65 65 65 65
186 251 316 381
Depth of odd Even Depth of Even Sum of odd & even
2.660 2 2.340 5.000
2.340 4 2.340 4.680
8.560 6 2.340 10.900
2.340 8 2.340 4.680
2.340 10 2.340 4.680
2.340 12 2.340 4.680
16.560 14 2.340 18.900
2.340 16 2.340 4.680
2.660 18 2.709 5.369
7 8 9 10 11 12 13
65 65 65 65 65 65 65
446 511 576 641 706 771 836
ID of LV plus tolera Circufrance Tolerance Total lengtEnd insulation
283 889 50 939 909 939 927
288 904 50 954 924 954 953
299 938 50 988 958 988 13
303 953 50 1003 973 1003 26
308 967 50 1017 987 1017 13
313 982 50 1032 1002 1032 26
332 1042 50 1092 1062 1092 52
336 1056 50 1106 1076 1106 974
342 1073 50 1123 1093 1123
14 15 16 17
65 65 60 65
901 966 1026 1091 Tapes In percent
TAPES POSITION Tap1 5
X6 928 Tap2 2.5
X4 954 26 Tap3
X2 980 26 Tap4 -2.5
X3 980 Tap5 -5.0
X5 1006 26 104
X7 1032 26
X8 1091 59 163
In delta connection Vl=Vph In Wye connection Il=Iph
HV of each tape LV of each tape Rated KVA
I1 (Primary line current)
I2(Secondary current)
15750 400 1250 45.82 1804.22
15375 400 1250 46.94 1804.22
15000 400 1250 48.11 1804.22
14625 400 1250 49.35 1804.22
14250 400 1250 50.64 1804.22
KVA
200.00
D
Step No.
C/l cm W/H cm
28.0 45.3 1st step
28.0 45.3 2nd step
28.0 45.3 3rd step
D
C/l cm W/H cm Step No.
28.0 45.3 1st step
28.0 45.3 2nd step
28.0 45.3 3rd step
28.0 45.3 4th step
28.0 45.3 5th step
28.0 45.3 6th step
28.0 45.3 7th step
5 Coverinig TPC-0.3 mm
12 No.of layer 5
13 Turns per layer 13.3
14 Inter layer insulation 3 x 0.08 mm
Design of Thank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.3923
72.10
Description
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
Placment of wire 2 W x 1D
Insulated size of conductors
140 14.0
130 13.0
115 11.5
100 10.0
85 8.5
65 6.5
40 4.0
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
140 14.0
130 13.0
115 11.5
100 10.0
85 8.5
65 6.5
40 4.0
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
140 14.0
130 13.0
115 11.5
100 10.0
85 8.5
65 6.5
40 4.0
10
165
6 (4 full and 2 half papers)
214
260
1228.36
34.0
433.0
114.6
127.2
ign of Thank
Values (mm)
65 W/H
65 HV OD
65 C/L
50 1st step width
54 Last step width
94
50 i.
nk dimensions as below: ii.
953 iii
rounded off to iv
960 v
390 vi
394 vii
viii
of 1st core step + 54 +H R/S + GR/ST
986 L
960 A
394 B
990 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Parameters
Calculated Weight of co
Measured Weight of bi
Weight of Insulations
Total wieight of insula
Bm Cd
1.65 2.50
73.3 733
72.3 723
70.8 708
69.3 693
67.8 678
65.8 658
63.3 633
593
Step length (L) in cm Step length (L) in mm
59.3 593
59.3 593
59.3 593
59.3 593
59.3 593
59.3 593
59.3 593
72 1647
39222.2 1228355.8
166.70 7.70
8.9 8.9
383 2.86
133.75 31.27
401.26 93.80
Parameters Kg Values
Calculated Weight of copper per transform 189.49
Measured Weight of bith insulation & co 300
Weight of Insulations 110.51
f HV coil)
Core
Step stack (2K) in mm Weight (Kg) No.of pieces
78 39.706 289
54 25.785 200
48 20.583 178
36 13.624 133
27 8.813 100
24 6.106 89
12.0 1.923 44
Total
116.5
139.50
100.00
20.00
LV Design Values
Current per phase(Is) 166.70 No.
Current density(Cd) A/sq.mm 2.80 1
14
No of pcieces
Weight in Kg
48.05 289
30.89 200
24.29 178
15.84 133
10.10 100
6.86 89
2.11 44
Total
138.15
Weight (Kg)
No of Plates in B No of Plates in B2
144 21.190 96
100 13.752 67
89 10.967 59
67 7.253 44
50 4.688 33
44 3.244 30
22 1.020 15
Total
62.11
Core sectioning
Step widith
12.5 40 13.5
10 65 12.0
8 85 9.0
8 100 6.750
8 115 6.0
5 130 3.0
140 Tatal
comparison
HV length 1228.4
LV length 39.2 203.9944
A cu primary 12678.6119114042
A cu secondary 12002.4
A cu 24681.0119114042
Aw 65866.2
189.49 Add 200% towards handli
Area of primary wire
3.08
0.99
LV process
Description
Bare size of strip
Covered thickness towards TPC
Stack
39.0
66
90
108
121.5
133.5
139.5
139.50
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
1.980 1558.8
1.12 1559.0
9.2 2.85
0.1 0.1
9.3 2.95
1.0 3.00
9.3 8.85
0. 4mm(5 inter layer insulation )
18.10
36.0
334.8
338 18
95 18
433 27mm ( Radial built of LV)
20
453
Stack of B2 Stack of B1
26 13
18 9
16 8
12 6
9 5
8 4
4 2
400.00 Efficiency:
0.433 Rated KVA
1.9
25%
752.411
0.557
4.959
2.98%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
433 77.9 1646.8
88 1647
0.00
3.02
0.008
3.02
200 Ratio
Primary rated voltage Tap Position
2.47
0.40 8660 1
2.87 8660 2
98.59 8660 N
98.82 8660 4
99.00 8660 5
98.91
98.24
98.53
98.63
98.64
0.400
99.02
Axial length of coil Turn per layer No of Layer Seconadry turn(N2)
399 164.88 9.98 72.10
165 10 72
7.74
Step wdith SQRTof D and Stacks (K) in (mm) Required Stacks (K) i
140 39.26 39.26 39
85 117.97 12.42 14
65 130.06 12.10 12
40 139.79 9.73 6
5
6
8
9
10
11
12
13
position:
Total turns Secondary turns
1636.7880131526 72.00
1597.8168699823 72.00
1558.845726812 72.00
1519.8745836417 72.00
1480.9034404714 72.00
Coil diameter and core limb center
Core diameter = 126mm (Previously calculated)
Radial build of secondary coil= 18 mm (Previously calculated)
Radial build of HV = 34 mm (Previously calculated)
Radial clearance between core to LV coil (assumed) = 4 mm
Radial clearance between LV & HV (assumed) = 8 mm
21.6506 0.000000000000
21.1094 0.000000000000
20.5681 0.000000000000
26.19
K
4 5 6 7
165 165 165 165
660 825 990 1155
8 9 10 Break
165 165 162 (22*2)/(1+x))=1(break turns)
1320 1485 1647 1
TAPES POSITION
X4 1469 -5% 88
X2 1557 N sum
X1 1557 5% 88 178
X3 1645
X 1647 2
ak turns) Tapes In percent
HV of each tape
LV of each tape
Tap1 5 9093 400
Tap2 2.5 8877 400
Tap3 8660 400
Tap4 -2.5 8444 400
Tap5 -5.0 8227 400
In Wye connection Il=Iph
Rated KVA I1 (Primary line current)
I2(Secondary current)
200 12.70 288.68
200 13.01 288.68
200 13.33 288.68
200 13.68 288.68
200 14.04 288.68
KVA
4000
Details of step
Step No.
Core Dia. C/l cm W/H cm
328 65.5 82.9 1st step
328 65.5 82.9 2nd step
328 65.5 82.9 3rd step
328 65.5 82.9 4th step
328 65.5 82.9 5th step
328 65.5 82.9 6th step
328 65.5 82.9 7th step
328 65.5 82.9 8th step
328 65.5 82.9 9th step
328 65.5 82.9 10th step
328 65.5 82.9 11th step
328 65.5 82.9 12th step
328 65.5 82.9 13th step
328 65.5 82.9 14th step
328 65.5 82.9 15th step
Step No.
C/l cm W/H cm
65.5 82.9 1st step
12 No.of layer 9
13 Turns per layer 13.3
14 Inter layer insulation 3 x 0.08 mm
15 Tapping details None
Design of Tank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.45
Description
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
Insulated size of conductors
Placement of strips
320 32.0
305 30.5
290 29.0
270 27.0
250 25.0
230 23.0
210 21.0
185 18.5
165 16.5
145 14.5
125 12.5
110 11.0
90 9.0
70 7.0
45 4.5
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
320 32.0
305 30.5
290 29.0
270 27.0
250 25.0
230 23.0
210 21.0
185 18.5
165 16.5
145 14.5
125 12.5
110 11.0
90 9.0
70 7.0
45 4.5
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
320 32.0
305 30.5
290 29.0
270 27.0
250 25.0
230 23.0
210 21.0
185 18.5
165 16.5
145 14.5
125 12.5
110 11.0
90 9.0
70 7.0
45 4.5
13
97
6 (4 full and 2 half papers)
450
584
1980.15
56.0
809.0
1505.2
1670.8
ign of Tank
Values (mm)
110 W/H
160 HV OD
110 C/L
50 1st step width
60 Last step width
94
50 i.
nk dimensions as below: ii.
2024 iii
rounded off to iv
2140 v
854 vi
892 vii
viii
of 1st core step + 54 +H R/S + GR/ST
1728 L
2140 A
892 B
1630 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.66 3.00
1220.00
146.9 1469
143.9 1454
140.9 1439
136.9 1419
132.9 1399
128.9 1379
124.9 1359
119.9 1334
115.9 1314
111.9 1294
107.9 1274
104.9 1259
100.9 1239
96.9 1219
91.9 1194
114.9 1149
113.4 1149
111.9 1149
109.9 1149
107.9 1149
105.9 1149
103.9 1149
101.4 1149
99.4 1149
97.4 1149
95.4 1149
93.9 1149
91.9 1149
89.9 1149
87.4 1149
1310
1310
1310
1310
1310
122 1220
146725.1 1980148.4
385.00 40.40
8.9 8.9
383 2.86
500.35 50.40
1501.05 151.21
Weight of covered conductor (considering coverage
320.00
230.00
45.00
888
LV(V) Vs-per phase(V) primary current(Ip)
6000 3464.10 40.40
LV Design Values
Current per phase(Is) 385.00 No.
Current density(Cd) A/sq.mm 2.80 1
14
15
16
No of pcieces
Weight in Kg
392.89 533
246.39 356
173.38 267
145.32 244
96.08 178
75.91 156
58.29 133
41.76 111
36.51 111
25.15 89
21.24 89
9.20 44
7.36 44
2.80 22
1.75 22
Total
1312.91
Weight (Kg)
No of Plates in B No of Plates in B2
267 169.088 177.78
178 106.626 118.52
133 75.456 88.89
122 63.736 81.48
89 42.475 59.26
78 33.834 51.85
67 26.198 44.44
56 18.975 37.04
56 16.740 37.04
44 11.640 29.63
44 9.923 29.63
22 4.329 14.81
22 3.502 14.81
11 1.346 7.41
11 0.853 7.41
Total 584.723
HV length 1980.1
LV length 146.7 -4151.1942
A cu primary 49292.9292929293
A cu secondary 46970
A cu 96262.9292929293
Aw 271912
Add 200% towards handli
Area of primary wire
13.47
13.47
Secondary Turn per layer
LV process
Description
Bare size of strip
Covered thickness towards TPC
Ordering of steps
45
58
74
92
108
127
146
165
188
209
229
250
270
287
304
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Rated secondary phase voltage (V)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
4.141 1162.2
1.5
30.500 0.64
121.72 122.00
Length (mm) Radial(mm)
9.0 2.65
0.2 0.2
9.2 2.85
0.1 0.1
9.3 2.95
2 3
18.6 8.85
0.64 mm(8 inter layer insulation )
37.32
31.0 10 x2.0 x854(thermoflow)
580.00 10 x 3.0 x854 Thermo flow)
586.00 43
223 44
809 44 mm ( Radial built of LV)
20
829
Stack of B2 Stack of B1
48 24
32 16
24 12
22 11
16 8
14 7
12 6
10 5
10 5
8 4
8 4
4 2
4 2
2 1
2 1
ordering of stacks
72
120
156
189
213
234
252
267
282
294
306
312
318
321
324
3464.10 Efficiency:
0.527 Rated KVA
1.9
25%
7887.269
0.675
6.003
1.56%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
1650 58 1220.3
1220
4000
20.73
4.15
24.88
99.38
99.48
99.54
99.46
99.23
99.35
99.36
99.32
0.448
99.54
Axial length of coil Turn per layer
753 96.54
94
Core area
Stacks (K) in (mm) Required Stacks (K) i Gross core Area( sq mm)
72.00 72 23040
48.66 48 14640
32.58 36 10440
32.99 33 8910
26.09 24 6000
21.52 21 4830
18.11 18 3780
18.89 15 2775
12.63 15 2475
10.73 12 1740
9.04 12 1500
5.76 6 660
6.41 6 540
5.03 3 210
4.46 3 135
324.90 324.00 Total Gross core area in (Sq mm)
0.90 Bm 80130
1.65 -320
42.96
Area of secondary wire
128.30
140.00
247.00
336.00
3 LV Coil inside diameter 170
4 Radial build of LV coil 43
8
9 HV coil outside diameter
Diameter (mm)
18.11 18 12
328
18.89 15 10
6.00
12.63 15 10
334.00
10.73 12 8
6.00 9.04 12 8
340 5.76 6 4
43 6.41 6 4
383 5.03 3 2
43 4.46 3 2
426 324.90
12
438
12
450
67
517 Acu primary 16433.40
67 Acu secondary
584 A cu 32866.80
Aw 232650.56
25 Kw 0.14 0.16
609 655 AW in sq. m 42.72
829
2.95
B1 Required No of plates B
24 72 1 2
16 48 94 94
12 36 94 188
11 33 Odd
8 24 1
7 21 3.00
6 18 5
5 15 7.00
5 15 9
4 12 11.00
4 12 1.65 13
2 6 15.00
2 6 17
1 3
1 3
324
246.00
12 No.of layer 6
Design of Tank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.406
310.50
Description
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
Insulated size of conductors
300 30
290 29
280 28
270 27
260 26
250 25
240 24
220 22
200 20
180 18
160 16
140 14
120 12
80 8
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
300 30.0
290 29.0
280 28.0
270 27.0
260 26.0
250 25.0
240 24.0
220 22.0
200 20.0
180 18.0
160 16.0
140 14.0
120 12.0
80 8.0
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
300 30.0
290 29.0
280 28.0
270 27.0
260 26.0
250 25.0
240 24.0
220 22.0
200 20.0
180 18.0
160 16.0
150 15.0
150 15.0
150 15.0
13
105
6 (4 full and 2 half papers)
592
487
2254.20
56.0
835.0
1024.4
1137.1
ign of Tank
Values (mm)
110 W/H
160 HV OD
110 C/L
50 1st step width
60 Last step width
94
50 i.
nk dimensions as below: ii.
2035 iii
rounded off to iv
2140 v
861 vi
892 vii
viii
of 1st core step + 54 +H R/S + GR/ST
1734 L
2140 A
892 B
1630 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.666 3.00
1330.00
147.5 1475
145.5 1455
143.5 1435
141.5 1415
139.5 1395
137.5 1375
135.5 1355
131.5 1315
127.5 1275
123.5 1235
119.5 1195
115.5 1155
111.5 1115
103.5 1035
133 1330
164207.9 2254202.7
385.00 40.40
8.9 8.9
383 2.86
559.97 57.38
1679.91 172.14
6159.7 344.3
Weight of covered conductor (considering coverage
56
-3
300.00
230.00
35.00
888
LV(V) Vs-per phase(V) primary current(Ip)
6000 3464.10 40.40
LV Design Values
Current per phase(Is) 385.00 No.
Current density(Cd) A/sq.mm 2.80 1
Conductor area(Aw) 143.10 2
Bare Strip size 2.65 x 9 3
Insulated Strip size 2.95 x9.3 4
Bare Strip Area 95.4 5
Turns per phase 13.3 6
No. of coil per phase 1.0 7
Turns per coil 13.3 8
No. of layers 2.0 9
Turns per layer 13.3 10
11
12
14
15
16
Weight in Kg No of pcieces
418.52 593
150.42 222
115.19 178
87.17 141
70.07 119
58.44 104
51.63 96
78.65 163
60.63 141
45.09 119
31.95 96
23.20 81
19.49 81
12.47 81
1222.92 2215
HV length 2254.2
A cu secondary 51205
A cu 104942.373737374
Aw 271687.5
Add 200% towards handli
1129.4
Area of primary wire
13.47
14.20
Secondary Turn per layer
LV process
Description
Bare size of strip
Covered thickness towards TPC
Covered size of strip
Gap between two consecutive strips (assumed)
Insulated size of strip with working tolerance
Placement of strip (2W x 3D)
Effective dimension of each turn
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Rated secondary phase voltage (V)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
4.141 1267.0
1.5
30.500 0.64
134.94 122.00
Length (mm) Radial(mm)
9.0 2.65
0.2 0.2
9.2 2.85
0.1 0.1
9.3 2.95
2 3
18.6 8.85
0.64 mm(8 inter layer insulation )
79.0 55.60
31.0
580.00
586.00 56
170 56
756 55.6 mm ( Radial built of LV)
40 14.149
875
ordering of stacks
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
3464.10 Efficiency:
0.478 Rated KVA
1.9
25%
7199.416
0.616
5.480
1.42%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
1650 63 1330.3
1330
Gross core area (Ag)(sqr mm)core dia(sqr mm) Core step width
71556.54 310.5 No. of steps
71556.5 310.5 1st step
71556.5 310.5 2nd step
71556.5 310.5 3rd step
71556.5 310.5 4th step
71556.5 310.5 5th step
71556.5 310.5 6th step
71556.5 310.5 7th step
71556.5 310.5 8th step
71556.5 310.5 9th step
71556.5 310.5 10th step
71556.5 310.5 11th step
71556.5 310.5 12th step
71556.5 310.5 13th step
71556.5 310.5 14th step
4
5.00
Standard value 6.00
Design value
7.16 7.00
0.090 8.00
7.16
C1
4000 C2
C3
28.34
3.64 C4
31.97 99.20 C5
99.21
99.35
99.47
99.46
99.01
99.19
99.28
99.33
0.358
99.49
Axial length of coil Turn per layer
779 105.27
94
uc6 1.72
uc8 1.20
7535.08
12918.02
18218.31
No of Layer Seconadry turn(N2) Secondary current(Is)
14.15 134.94 384.90
13 133 385.00
Core area
Stacks (K) in (mm) Required Stacks (K) in (mm) Gross core Area( sq mm)
80.06 80 24000
30.89 30 8700
23.25 24 6720
19.13 19 5130
16.41 16 4160
14.41 14 3500
12.86 13 3120
22.11 22 4840
18.40 19 3800
15.49 16 2880
13.10 13 2080
20.27 11 1540
13.64 9 1080
10.48 13 1040
310.50 299.00 Total Gross core area in (Sq mm)
11.50 Bm 72590
1.64 -1033
-25.10
Unit cost of LV winding
Unit cost of HV winding
Unit cost of magnetic steel(core)
246.00
11.00
Acu primary 18886.00
Acu secondary
A cu 37772.00
Aw 262237.50
Kw 0.14 0.16
610 AW in sq. m 45.97
Required No of plates B B/2
72 72 1 2
48 24 94 94
33 16.5 94 188
33 16.5
24 12
21 10.5 1 2.3
18 9 2 2.3
18 9 3 2.3
15 7.5 4 2.3
12 6 5 2.3
12 6 6 2.3
6 3 7 2.3
6 3 8 2.3
3 1.5 9 2.3
3 1.5 10 2.3
324 11 2.3
12 2.3
13 2.3
235.00 325.00
225.00 310.00
215.00 295.00
200.00 275.00
180.00 255.00
160.00 240.00
135.00 220.00
115.00 200.00
85.00 175.00
60.00 155.00
125
3 4 5 6
94 94 94 94
282 376 470 564
Details of step
Step No.
Core Dia. C/l cm W/H cm
328 59.6 82.8 1st step
328 59.6 82.8 2nd step
328 59.6 82.8 3rd step
328 59.6 82.8 4th step
328 59.6 82.8 5th step
328 59.6 82.8 6th step
328 59.6 82.8 7th step
328 59.6 82.8 8th step
328 59.6 82.8 9th step
328 59.6 82.8 10th step
328 59.6 82.8 11th step
328 59.6 82.8 12th step
328 59.6 82.8 13th step
328 59.6 82.8 14th step
328 59.6 82.8 15th step
Step No.
C/l cm W/H cm
59.6 82.8 1st step
12 No.of layer 9
Design of Tank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.45
Description
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
Insulated size of conductors
Placement of strips
320 32.0
305 30.5
290 29.0
270 27.0
250 25.0
230 23.0
210 21.0
185 18.5
165 16.5
145 14.5
125 12.5
110 11.0
90 9.0
70 7.0
45 4.5
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
320 32.0
305 30.5
290 29.0
270 27.0
250 25.0
230 23.0
210 21.0
185 18.5
165 16.5
145 14.5
125 12.5
110 11.0
90 9.0
70 7.0
45 4.5
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
320 32.0
305 30.5
290 29.0
270 27.0
250 25.0
230 23.0
210 21.0
185 18.5
165 16.5
145 14.5
125 12.5
110 11.0
90 9.0
70 7.0
45 4.5
12
99
6 (4 full and 2 half papers)
458
570
1968.65
56.0
788.0
894.6
993.0
ign of Tank
Values (mm)
110 W/H
160 HV OD
110 C/L
50 1st step width
60 Last step width
94
50 i.
nk dimensions as below: ii.
1984 iii
rounded off to iv
2140 v
840 vi
892 vii
viii
of 1st core step + 54 +H R/S + GR/ST
1727 L
2140 A
892 B
1630 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.66 3.00
1220.00
0.200 0.200
7.30 2.20
0.10 0.10
7.40 2.30
1 1
7.400 2.300
0.8mm( 12 inter layer insulation)
98.92 41.42
+ 6.5 x 2 (Thermo flowl)
4 x 10 x 435 49.42
0.5 x 435 x 200 49.4
4 x 10 x 435 56.00
732 67 (Radial built of HV coil)
146.8 1468
143.8 1453
140.8 1438
136.8 1418
132.8 1398
128.8 1378
124.8 1358
119.8 1333
115.8 1313
111.8 1293
107.8 1273
104.8 1258
100.8 1238
96.8 1218
91.8 1193
114.8 1148
113.3 1148
111.8 1148
109.8 1148
107.8 1148
105.8 1148
103.8 1148
101.3 1148
99.3 1148
97.3 1148
95.3 1148
93.8 1148
91.8 1148
89.8 1148
87.3 1148
1192
1192
1192
1192
1192
122 1220
145192.0 1968650.1
385.00 40.40
8.9 8.9
383 2.86
495.12 50.11
1485.37 150.33
Weight of covered conductor (considering coverage
56
320.00
230.00
45.00
888
LV(V) Vs-per phase(V) primary current(Ip)
6000 3464.10 40.40
LV Design Values
Current per phase(Is) 385.00 No.
Current density(Cd) A/sq.mm 2.80 1
14
15
16
No of pcieces
Weight in Kg
392.54 533
246.17 356
158.79 244
145.19 244
95.99 178
75.84 156
58.23 133
50.06 133
36.47 111
25.13 89
21.22 89
9.19 44
7.36 44
2.80 22
1.75 22
Total
1305.63
Weight (Kg)
No of Plates in B No of Plates in B2
267 168.917 177.78
178 106.518 118.52
122 69.097 81.48
122 63.670 81.48
89 42.430 59.26
78 33.798 51.85
67 26.170 44.44
67 22.746 44.44
56 16.722 37.04
44 11.627 29.63
44 9.912 29.63
22 4.325 14.81
22 3.498 14.81
11 1.345 7.41
11 0.852 7.41
Total 581.626
HV length 1968.7
A cu secondary 46970
A cu 96262.9292929293
Aw 271584
Add 200% towards handli
Area of primary wire
13.47
14.20
Secondary Turn per layer
LV process
Description
Bare size of strip
Covered thickness towards TPC
Ordering of steps
45
58
74
92
108
127
146
165
188
209
229
250
270
287
304
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Rated secondary phase voltage (V)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
4.141 1162.2
1.5
30.500 0.64
121.72 122.00
Length (mm) Radial(mm)
9.0 2.65
0.2 0.2
9.2 2.85
0.1 0.1
9.3 2.95
2 3
18.6 8.85
0.64 mm(8 inter layer insulation )
37.32
31.0 10 x2.0 x854(thermoflow)
580.00 10 x 3.0 x854 Thermo flow)
586.00 43
202 44
788 44 mm ( Radial built of LV)
40 12.979
828
Stack of B2 Stack of B1
48 24
32 16
22 11
22 11
16 8
14 7
12 6
12 6
10 5
8 4
8 4
4 2
4 2
2 1
2 1
ordering of stacks
72
120
153
186
210
231
249
267
282
294
306
312
318
321
324
3464.10 Efficiency:
0.504 Rated KVA
1.9
25%
7512.323
0.643
5.718
1.49%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
1650 58 1220.3
1220
4000
25.37
3.95
29.32 99.27
99.27
99.40
99.49
99.45
99.09
99.25
99.30
99.31
0.395
99.50
Axial length of coil Turn per layer
732 98.92
94
Core area
Stacks (K) in (mm) Required Stacks (K) i Gross core Area( sq mm)
72.00 72 23040
48.66 48 14640
32.58 33 9570
32.99 33 8910
26.09 24 6000
21.52 21 4830
18.11 18 3780
18.89 18 3330
12.63 15 2475
10.73 12 1740
9.04 12 1500
5.76 6 660
6.41 6 540
5.03 3 210
4.46 3 135
324.90 324.00 Total Gross core area in (Sq mm)
0.90 Bm 79815
1.66 -5
46.06
Area of secondary wire
128.30
143.10
147.87
334.00
3 LV Coil inside diameter 168
4 Radial build of LV coil 43
8
9 HV coil outside diameter
Diameter (mm)
18.11 18 12
328
18.89 18 12
4.00
12.63 15 10
332.00
10.73 12 8
4.00 9.04 12 8
336 5.76 6 4
43 6.41 6 4
379 5.03 3 2
43 4.46 3 2
422 324.90
18
440
18
458
56
514 Acu primary 17324.00
56 Acu secondary
570 A cu 34648.00
Aw 221605.92
26 Kw 0.16 0.16
596 596 AW in sq. m 38.75
828
3.09
B1 Required No of plates B B/2
24 72 72 1
16 48 24 94
11 33 16.5 94
11 33 16.5
8 24 12
7 21 10.5 1
6 18 9 2
6 18 9 3
5 15 7.5 4
4 12 6 5
4 12 6 6
2 6 3 7
2 6 3 8
1 3 1.5 9
1 3 1.5 10
324 11
12
13
246.00
Step No.
C/l cm W/H cm
58.8 82.7 1st step
12 No.of layer 10
13 Turns per layer 13.3
14 Inter layer insulation 3 x 0.08 mm
15 Tapping details None
Design of Tank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.42
131.98
33.00
Description
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
Insulated size of conductors
310 31.0
290 29.0
270 27.0
250 25.0
230 23.0
210 21.0
190 19.0
170 17.0
150 15.0
130 13.0
110 11.0
90 9.0
70 7.0
45 4.5
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
310 31.0
290 29.0
270 27.0
250 25.0
230 23.0
210 21.0
190 19.0
170 17.0
150 15.0
130 13.0
110 11.0
90 9.0
70 7.0
45 4.5
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
310 31.0
290 29.0
270 27.0
250 25.0
230 23.0
210 21.0
190 19.0
170 17.0
150 15.0
130 13.0
110 11.0
90 9.0
70 7.0
45 4.5
13
101
6 (4 full and 2 half papers)
452
564
2106.63
42.0
787.2
957.3
1062.6
ign of Tank
Values (mm)
110 W/H
160 HV OD
110 C/L
50 1st step width
60 Last step width
94
50 i.
nk dimensions as below: ii.
1963 iii
rounded off to iv
2140 v
834 vi
892 vii
viii
of 1st core step + 54 +H R/S + GR/ST
1706.2 L
2140 A
892 B
1630 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.60 3.00
1320.00
320.00
0.200 0.200
7.30 2.20
0.10 0.10
7.40 2.30
1 1
7.400 2.300
0.8mm( 12 inter layer insulation)
100.70 41.42
+ 6.5 x 2 (Thermo flowl)
4 x 10 x 435 49.42
0.5 x 435 x 200 49.4
4 x 10 x 435 56.00
745 67 (Radial built of HV coil)
144.7 1447
140.7 1427
136.7 1407
132.7 1387
128.7 1367
124.7 1347
120.7 1327
116.7 1307
112.7 1287
108.7 1267
104.7 1247
100.7 1227
96.7 1207
91.7 1182
113.7 1137
111.7 1137
109.7 1137
107.7 1137
105.7 1137
103.7 1137
101.7 1137
99.7 1137
97.7 1137
95.7 1137
93.7 1137
91.7 1137
89.7 1137
87.2 1137
1176
1176
1176
1176
1176
132 1320
154264.8 2106626.4
385.00 40.40
8.9 8.9
383 2.86
526.06 53.62
1578.19 160.87
Weight of covered conductor (considering coverage
13.60
56
Total
468.00
24.0 29.412 89
18.0 19.291 67
18.0 16.470 67
12.0 9.064 44
12.0 7.112 44
6.0 2.311 22
Total
1177.4
310.00
230.00
40.00
888
LV(V) Vs-per phase(V) primary current(Ip)
6000 3464.10 40.40
LV Design Values
Current per phase(Is) 385.00 No.
Current density(Cd) A/sq.mm 2.80 1
14
15
16
No of pcieces
Weight in Kg
408.09 578
259.65 400
158.28 267
107.91 200
75.78 156
58.19 133
51.63 133
37.74 111
26.10 89
16.62 67
13.77 67
7.35 44
5.59 44
1.75 22
Total
1228.45
Weight (Kg)
No of Plates in B No of Plates in B2
289 176.234 192.59
200 112.975 133.33
133 69.401 88.89
100 47.694 66.67
78 33.769 51.85
67 26.148 44.44
67 23.404 44.44
56 17.261 37.04
44 12.051 29.63
33 7.746 22.22
33 6.481 22.22
22 3.495 14.81
22 2.687 14.81
11 0.851 7.41
Total 540.196
HV length 2106.6
LV length 154.3 1317.4283
A cu primary 53333.3333333333
A cu secondary 50820
A cu 104153.333333333
Aw 264704
Add 200% towards handli
Area of primary wire
13.47
14.20
Secondary Turn per layer
LV process
Description
Bare size of strip
Covered thickness towards TPC
Ordering of steps
45
70
90
110
130
150
170
190
210
230
250
270
290
310
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Rated secondary phase voltage (V)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
4.141 1257.5
1.5
33.000 0.64
131.98 122.00
Length (mm) Radial(mm)
9.0 2.65
0.2 0.2
9.2 2.85
0.1 0.1
9.3 2.95
2 3
18.6 8.85
0.64 mm(8 inter layer insulation )
37.32
33.0 10 x2.0 x854(thermoflow)
617.20 10 x 3.0 x854 Thermo flow)
617.20 43
170 44
787 44 mm ( Radial built of LV)
40 12.941
827
Stack of B2 Stack of B1
52 26
36 18
24 12
18 9
14 7
12 6
12 6
10 5
8 4
6 3
6 3
4 2
4 2
2 1
ordering of stacks
78
132
168
195
216
234
252
267
279
288
297
303
309
312
3464.10 Efficiency:
0.455 Rated KVA
1.9
25%
6996.886
0.598
5.325
1.38%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
1650 62.87 1320.3
1320
Total Total
360.13 180.07
540.20
Standard value
Design value
6.57
0.085
6.57
4000
26.80
3.68
30.48 99.24
99.24
99.38
99.48
99.47
99.06
99.22
99.30
99.33
0.371
99.51
Axial length of coil Turn per layer
745 100.70
102
Total stack
No of Layer Seconadry turn(N2) Secondary current(Is)
12.94 131.98 384.90
13 132 385.00
Core area
Stacks (K) in (mm) Required Stacks (K) in (mm) Gross core Area( sq mm)
79.37 78 24180
55.90 54 15660
36.48 36 9720
27.99 27 6750
22.74 21 4830
18.97 18 3780
16.03 18 3420
13.62 15 2550
11.56 12 1800
9.74 9 1170
8.10 9 990
6.58 6 540
5.17 6 420
4.57 3 135
78.40
Area of secondary wire
128.30
143.10
147.87
326.00
3 LV Coil inside diameter 164
4 Radial build of LV coil 44
8
9 HV coil outside diameter
Diameter (mm)
16.03 18 12
320
13.62 15 10
4.00
11.56 12 8
324.00
9.74 9 6
4.00 8.10 9 6
328 6.58 6 4
44 5.17 6 4
372 4.57 3 2
44
416 316.82
18
434
18
452
56
508 Acu primary 18744.00
56 Acu secondary
564 A cu 37488.00
Aw 221689.60
24 Kw 0.17 0.16
588 588 AW in sq. m 38.88
827
3.09
B1 Required No of plates B B/2
26 78 78 1
18 54 27 102
12 36 18 102
9 27 13.5
7 21 10.5
6 18 9 1
6 18 9 2
5 15 7.5 3
4 12 6 4
3 9 4.5 5
3 9 4.5 6
2.0 6 3 7
2 6 3 8
1 3 1.5 9
0 10
312 11
12
13
2 3 4 5
102 102 102 102
204 306 408 510
Step No.
C/l cm W/H cm
60.0 83.0 1st step
12 No.of layer 9
13 Turns per layer 13.3
14 Inter layer insulation 3 x 0.08 mm
15 Tapping details None
Design of Tank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.44
125.91
33.25
Description
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
Insulated size of conductors
320 32.0
300 30.0
280 28.0
260 26.0
240 24.0
220 22.0
200 20.0
180 18.0
160 16.0
140 14.0
120 12.0
100 10.0
80 8.0
50 5.0
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
320 32.0
300 30.0
280 28.0
260 26.0
240 24.0
220 22.0
200 20.0
180 18.0
160 16.0
140 14.0
120 12.0
100 10.0
80 8.0
50 5.0
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
320 32.0
300 30.0
280 28.0
260 26.0
240 24.0
220 22.0
200 20.0
180 18.0
160 16.0
140 14.0
120 12.0
100 10.0
80 8.0
50 5.0
13
101
6 (4 full and 2 half papers)
464
576
2136.79
42.0
790.0
971.0
1077.8
ign of Tank
Values (mm)
110 W/H
160 HV OD
110 C/L
50 1st step width
60 Last step width
94
50 i.
nk dimensions as below: ii.
1999 iii
rounded off to iv
2140 v
846 vi
892 vii
viii
of 1st core step + 54 +H R/S + GR/ST
1729 L
2140 A
892 B
1630 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.60 2.80
1308.00
327.62
0.200 0.200
7.30 2.20
0.10 0.10
7.40 2.30
1 1
7.400 2.300
0.8mm( 12 inter layer insulation)
101.08 41.42
+ 6.5 x 2 (Thermo flowl)
4 x 10 x 435 49.42
0.5 x 435 x 200 49.4
4 x 10 x 435 56.00
748 67 (Radial built of HV coil)
147.0 1470
143.0 1450
139.0 1430
135.0 1410
131.0 1390
127.0 1370
123.0 1350
119.0 1330
115.0 1310
111.0 1290
107.0 1270
103.0 1250
99.0 1230
93.0 1200
115.0 1150
113.0 1150
111.0 1150
109.0 1150
107.0 1150
105.0 1150
103.0 1150
101.0 1150
99.0 1150
97.0 1150
95.0 1150
93.0 1150
91.0 1150
88.0 1150
1200
1200
1200
1200
1200
126 1308
150419.5 2136785.7
385.00 40.40
8.9 8.9
383 2.86
512.95 54.39
1538.85 163.17
Weight of covered conductor (considering coverage
13.60
56
Total
648.00
24.0 31.914 89
18.0 21.131 67
18.0 18.272 67
12.0 10.240 44
12.0 8.263 44
12.0 5.231 44
Total
1286.4
320.00
230.00
45.00
888
LV(V) Vs-per phase(V) primary current(Ip)
6000 3464.10 40.40
LV Design Values
Current per phase(Is) 385.00 No.
Current density(Cd) A/sq.mm 2.80 1
14
15
16
No of pcieces
Weight in Kg
393.23 533
301.87 444
179.89 289
126.18 222
91.47 178
61.71 133
55.03 133
40.47 111
28.21 89
18.14 67
15.23 67
8.28 44
6.48 44
3.92 44
Total
1330.10
Weight (Kg)
No of Plates in B No of Plates in B2
267 169.259 177.78
222 130.898 148.15
144 78.601 96.30
111 55.565 74.07
89 40.605 59.26
67 27.622 44.44
67 24.844 44.44
56 18.433 37.04
44 12.965 29.63
33 8.415 22.22
33 7.133 22.22
22 3.918 14.81
22 3.099 14.81
22 1.903 14.81
Total 583.258
HV length 2136.8
LV length 150.4 1000.2513
A cu primary 52848.4848484849
A cu secondary 48510
A cu 101358.484848485
Aw 272240
Add 200% towards handli
Area of primary wire
14.43
14.20
Secondary Turn per layer
LV process
Description
Bare size of strip
Covered thickness towards TPC
Ordering of steps
50
80
100
120
140
160
180
200
220
240
260
280
300
320
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Rated secondary phase voltage (V)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
4.286 1200.3
31.500 0.64
125.91 122.00
Length (mm) Radial(mm)
9.0 2.65
0.2 0.2
9.2 2.85
0.1 0.1
9.3 2.95
2 3
18.6 8.85
0.64 mm(8 inter layer insulation )
37.32
32.0 10 x2.0 x854(thermoflow)
599.00 10 x 3.0 x854 Thermo flow)
599.00 43
191 44
790 44 mm ( Radial built of LV)
40 12.940
830
Stack of B2 Stack of B1
48 24
40 20
26 13
20 10
16 8
12 6
12 6
10 5
8 4
6 3
6 3
4 2
4 2
4 2
ordering of stacks
72
132
171
201
225
243
261
276
288
297
306
312
318
324
3464.10 Efficiency:
0.483 Rated KVA
1.9
25%
7599.523
0.650
5.784
1.50%
9%Vp (Addtional) 9% N1(Additional) Total primary turn(N1)
2970 108.03 1308.3
1308
Total Total
388.84 194.42
583.26
Standard value
Design value
6.34
0.085
6.34
4000
26.73
4.00
30.73 99.23
99.24
99.37
99.47
99.44
99.05
99.21
99.28
99.30
0.387
99.49
Axial length of coil Turn per layer
748 101.08
101
Total stack
No of Layer Seconadry turn(N2) Secondary current(Is)
12.94 125.91 384.90
13 126 385.00
108.03
Core area
Stacks (K) in (mm) Required Stacks (K) in (mm) Gross core Area( sq mm)
72.00 72 23040
60.60 60 18000
38.23 39 10920
29.13 30 7800
23.61 24 5760
19.71 18 3960
16.69 18 3600
14.23 15 2700
12.13 12 1920
10.29 9 1260
8.64 9 1080
7.12 6 600
5.71 6 480
6.07 6 300
87.17
Area of secondary wire LV Working current density HV Working current density
137.46 2.8 2.8
143.10
147.87
334.00
3 LV Coil inside diameter 168
4 Radial build of LV coil 44
8
9 HV coil outside diameter
Diameter (mm)
16.69 18 12
328
14.23 15 10
4.00
12.13 12 8
332.00
10.29 9 6
4.00 8.64 9 6
336 7.12 6 4
44 5.71 6 4
380 6.07 6 4
44
424 324.17
20
444
20
464
56
520 Acu primary 18573.60
56 Acu secondary
576 A cu 37147.20
Aw 225760.00
24 Kw 0.16 0.16
600 600 AW in sq. m 39.94
830
3.05
B1 Required No of plates B B/2
24 72 72 1
20 60 30 97
13 39 19.5 97
10 30 15
8 24 12
6 18 9 1
6 18 9 2
5 15 7.5 3
4 12 6 4
3 9 4.5 5
3 9 4.5 6
2 6 3 7
2 6 3 8
2 6 3 9
0 10
324 11
12
13
2 3 4 5
101 101 101 101
198 299 400 501
12 No.of layer 2
Design of Th
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between core yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as belo
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.43
Description
Bare conductor 1
Supporting strip 10
11
press board
Supporting strip 12
Axial length of HV coil 13
14
Details of step (A):
Step width (W)in mm Step width (W)in cm
175 17.5
160 16.0
140 14.0
120 12.0
100 10.0
80 8.0
60 6.0
40 4.0
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
175 17.5
160 16.0
140 14.0
120 12.0
100 10.0
80 8.0
60 6.0
40 4.0
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
175 17.5
160 16
140 14
120 12
100 10
80 8
60 6
40 4
14
132
6 (4 full and 2 half papers)
250
323
1657.02
46.0
470.2
179.2
199.0
ign of Thank
Values (mm)
40 W/H
50 HV OD
50 C/L
40 1st step width
20 Last step width
90
50 i.
nk dimensions as below: ii.
1094 iii
rounded off to iv
1140 v
423 vi
430 vii
viii
of 1st core step + 54 +H R/S + GR/ST
1045.15 L
1140 A
430 B
1050 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.65 2.80
84.0 840
82.5
825
80.5 805
78.5 785
76.5 765
74.5 745
72.5 725
70.5 705
665
665
Step length (L) in cm Step length (L) in mm
66.5 665
66.5 665
66.5 665
66.5 665
66.5 665
66.5 665
66.5 665
66.5 665
27 1841
17643.2 1657022.0
577.35 8.89
8.9 8.9
383 2.86
60.17 42.18
180.50 126.53
0.32 6.24
0.48
1.12
177.00
120.00
27.50
LV Design Values
Current per phase(Is) 577.35 No.
Current density(Cd) A/sq.mm 2.80 1
14
No of pcieces 15
Weight in Kg
88.10 378 16
56.86
267 51.00
41.46 222 18
24.88 156 15
14.81 111 10.5
9.48 89 7.5
3.55 44 6
2.37 44 3
Total 3
241.51
Weight (Kg)
No of Plates in B No of Plates in B2
189 38.257 126
133 25.011 89
111 18.549 74
78 11.316 52
56 6.847 37
44 4.453 30
22 1.697 15
22 1.149 15
Total
107.3
HV length 1657.0
A cu primary 16364.4444444444
A cu secondary 15588.45
A cu 31952.8944444444
Aw 89207.3
Add 200% towards handli
Area of primary wire
3.17
1.77
3.534
LV process
Description
Bare size of strip
Covered thickness towards TPC
14.40
87.00
117.00
138.00
153.00
165.00
171.00
177.00
No of Plates in B1
63
44
37
26
19
15
7
7
approximate no of plates
40
60
80
100
120
140
160
175
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Rated secondary phase voltage (V)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
2.010 1753.7
1.5
9.2 2.85
0.1 0.1
9.3 2.95
3.0 3.00
27.9 8.85
0.4 mm(5 inter layer insulation )
18.10
12.5
348.8
355 18
115 18
470 18mm ( Radial built of LV)
20 29.6
490 392.15
primary t 13.94
102 51.00
72 18.00
60 15.00
42 10.50
30 7.50
24 6.00
12 3.00
12 3.00
354
177
Stack of B2 Stack of B1
34 17
24 12
20 10
14 7
10 5
8 4
4 2
4 2
230.94 Efficiency:
1.347 Rated KVA
1.9
25%
1357.636
1.742
15.500
2.68%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
750 87.7 1841.4
1841
376.65
93.50
51.00 51
36.00 87
30.00 117
21.00 138
15.00 153
12.00 165
6.00 171
6.00 177
177
Weight of B2 Weight of B1
25.504 12.75
16.674 8.34
12.366 6.18
7.544 3.77
4.565 2.28
2.969 1.48
1.131
0.766
Total Total
69.62 34.81
104.4
3.43
0.013
3.43
400
4.16
0.71
4.88
98.80
98.99
99.13
99.03
98.50
98.74
98.81
98.80
0.414
99.15
Axial length of coil Turn per layer No of Layer Seconadry turn(N2)
424 132.05 13.94 26.85
14 27
Step wdith SQRTof D and Stacks (K) in (mm) Required Stacks (K) i
175 49.99 49.99 51
80 163.47 11.41 12
60 171.83 8.35 6
40 177.55 5.72 6
Core area
Core diameter = 126mm (Previously calculated)
Gross core Area( sq mm)
Radial build of secondary coil= 18 mm (Previously calcula
8925
Radial build of HV = 34 mm (Previously calculate
5760
4200 Radial clearance between core to LV coil (assumed) =
Radial clearance between LV & HV (assumed) = 8 mm
2520
1500 Core limb center calculations
960 No.
360 1
240 2
5
6
8
9
10
11
12
13
Core diameter = 126mm (Previously calculated)
Radial build of secondary coil= 18 mm (Previously calculated)
Radial build of HV = 34 mm (Previously calculated)
Radial clearance between core to LV coil (assumed) = 4 mm
Radial clearance between LV & HV (assumed) = 8 mm
188.00 4.00
LV Coil inside diameter 95 190
Radial build of LV coil 18 18
208
18
238
244 12
HV coil inside diameter 125 250
Radial build of HV coil 36 36
252 286
288 36
HV coil outside diameter 293 323
296.00
Gap between HV limb and Phase 326 21
Core limb center 344.00
Total Window Height 490
Window space factor 3.03
26.19
6 182 11 1.606
3 182 12 1.606
3 13 1.606
175 14 1.606
4
3 4 5 6
132 132 132 132
391 523 655 787
PRIMARY RADIAL BUILT CALCULATIONS
Thickness of layer insulaThermo flow Samation of wire depth an
0.56 2 4.332
0.48 2 4.172
0.48 0.320 2 4.812
0.48 2 4.172
0.48 2 4.172
0.48 0.640 2 5.452
0.48 2 4.172
0.48 6.5 2 17.172
0.48 0.320 2 4.812
0.48 2 4.172
0.48 2 4.172
0.48 2 4.172
Asending Order of HV di
Diameter required fAge paper Constant Length of Layer insulation
4.332 248.332 780 50 830
8.504 252.504 793 50 843
13.316 257.316 808 50 858
17.488 261.488 821 50 871
21.660 265.66 835 50 885
27.112 271.112 852 50 902
31.284 275.284 865 50 915
48.456 292.456 919 50 969
53.268 297.268 934 50 984
57.440 301.44 947 50 997
12 No.of layer 2
Design of Th
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between core yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as belo
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.43
Description
Bare conductor 1
Supporting strip 10
11
press board
Supporting strip 12
Axial length of HV coil 13
14
Details of step (A):
Step width (W)in mm Step width (W)in cm
178 17.8
170 17.0
155 15.5
140 14.0
125 12.5
110 11.0
95 9.5
75 7.5
45 4.5
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
178 17.8
170 17.0
155 15.5
140 14.0
125 12.5
110 11.0
95 9.5
75 7.5
45 4.5
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
178 17.8
170 17
155 16
140 14
125 13
110 11
95 10
75 8
45 4.5
18
104
6 (4 full and 2 half papers)
250
323
1657.02
46.0
378.9
179.2
199.0
ign of Thank
Values (mm)
40 W/H
50 HV OD
50 C/L
40 1st step width
20 Last step width
90
50 i.
nk dimensions as below: ii.
1094 iii
rounded off to iv
1140 v
423 vi
430 vii
viii
of 1st core step + 54 +H R/S + GR/ST
959.9 L
1140 A
430 B
1050 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.65 2.80
75.5 755
74.7
747
73.2 732
71.7 717
70.2 702
68.7 687
67.2 672
65.2 652
62.2 622
577
577
Step length (L) in cm Step length (L) in mm
57.7 577
57.7 577
57.7 577
57.7 577
57.7 577
57.7 577
57.7 577
57.7 577
57.7 577
27 1841
17643.2 1657022.0
577.35 8.89
8.9 8.9
383 2.86
60.17 42.18
180.50 126.53
0.32 6.24
0.48
1.12
177.00
120.00
29.00
LV Design Values
Current per phase(Is) 577.35 No.
Current density(Cd) A/sq.mm 2.80 1
14
No of pcieces 15
Weight in Kg
59.44 289 16
39.30
200 39.00
39.81 222 13.5
25.17 156 15
19.26 133 10.5
11.30 89 9
9.76 89 6
5.78 67 6
3.47 67 4.5
Total
213.29
Weight (Kg)
No of Plates in B No of Plates in B2
144 25.133 96
100 16.754 67
111 17.232 74
78 11.059 52
67 8.588 44
44 5.112 30
44 4.478 30
33 2.702 22
33 1.666 22
Total
92.7
HV length 1657.0
A cu primary 16364.4444444444
A cu secondary 15588.45
A cu 31952.8944444444
Aw 72599.8
Add 200% towards handli
Area of primary wire
3.17
1.77
3.534
LV process
Description
Bare size of strip
Covered thickness towards TPC
14.40
No of Plates in B1
48
33
37
26
22
15
15
11
11
approximate no of plates
75
95
110
125
140
155
170
178
170
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Rated secondary phase voltage (V)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
2.010 1753.7
1.5
10.2 3.00
0.1 0.1
10.3 3.10
2.0 4.00
20.6 12.40
0.4 mm(5 inter layer insulation )
25.20
12.5
257.5
264 25
115 18
379 18mm ( Radial built of LV)
20 29.6
399 300.90
primary t 17.76
0
Stack of B2 Stack of B1
26 13
18 9
20 10
14 7
12 6
8 4
8 4
6 3
6 3
230.94 Efficiency:
1.232 Rated KVA
1.9
25%
1264.785
1.623
14.440
2.50%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
750 87.7 1841.4
1841
278.10
100.80
8
Weight of B2 Weight of B1
16.755 8.38
11.169 5.58
11.488 5.74
7.372 3.69
5.726 2.86
3.408 1.70
2.986
1.801
1.111
Total Total
55.92 27.96
83.9
4.21
0.013
4.21
400
4.16
0.67
4.83
98.81
99.01
99.15
99.08
98.51
98.76
98.84
98.86
0.400
99.17
Axial length of coil Turn per layer No of Layer Seconadry turn(N2)
333 103.64 17.76 26.85
14 27
Step wdith SQRTof D and Stacks (K) in (mm) Required Stacks (K) i
178 37.95 37.95 39
95 155.24 10.24 12
75 165.83 10.59 9
45 176.35 10.52 9
Core area
Core diameter = 126mm (Previously calculated)
Gross core Area( sq mm)
Radial build of secondary coil= 18 mm (Previously calcula
6942
Radial build of HV = 34 mm (Previously calculate
4590
4650 Radial clearance between core to LV coil (assumed) =
Radial clearance between LV & HV (assumed) = 8 mm
2940
2250 Core limb center calculations
1320 No.
1140 1
675 2
405
Total Gross core area in (Sq mm)
24912.00 3
-708.00 4
5
6
8
9
10
11
12
13
Core diameter = 126mm (Previously calculated)
Radial build of secondary coil= 18 mm (Previously calculated)
Radial build of HV = 34 mm (Previously calculated)
Radial clearance between core to LV coil (assumed) = 4 mm
Radial clearance between LV & HV (assumed) = 8 mm
188.00 4.00
LV Coil inside diameter 95 190
Radial build of LV coil 18 18
208
18
238
244 12
HV coil inside diameter 125 250
Radial build of HV coil 36 36
252 286
288 36
HV coil outside diameter 293 323
296.00
Gap between HV limb and Phase 326 21
Core limb center 344.00
Total Window Height 399
Window space factor 2.46
26.19
182 11 1.606
182 12 1.606
13 1.606
178 14 1.606
2
3 4 5 6
132 132 132 132
391 523 655 787
PRIMARY RADIAL BUILT CALCULATIONS
Thickness of layer insulaThermo flow Samation of wire depth an
1.12 2 5.452
0.96 2 5.132
0.96 0.320 2 5.772
0.96 2 5.132
0.96 2 5.132
0.96 0.640 2 6.412
0.96 2 5.132
0.96 13.0 2 31.132
0.96 0.320 2 5.772
0.96 2 5.132
0.96 2 5.132
0.96 2 5.132
Asending Order of HV di
Diameter required fAge paper Constant Length of Layer insulation
5.452 249.452 784 50 834
10.584 254.584 800 50 850
16.356 260.356 818 50 868
21.488 265.488 834 50 884
26.620 270.62 850 50 900
1085
85.332 329.332 1035 50
90.464 334.464 1051 50 1101
1123
97.516 341.516 1073 50
100.728 344.728 1083 50 1133
50.364 294.364 924.771779881
12 13 14
132 132 130
1579 1711 1841
TAPES POSITION
of Layer insulation X6 1588 Tap
X4 1632 44 87.69
X2 1676 44
X3 1676
X5 1720 44 176
X7 1764 44
X8 1841 77 253
KVA
25.00
D
Step No.
C/l cm W/H cm
36.5 32.5 1st step
36.5 32.5 2nd step
36.5 32.5 3rd step
D
C/l cm W/H cm Step No.
36.5 32.5 1st step
36.5 32.5 2nd step
36.5 32.5 3rd step
36.5 32.5 4th step
36.5 32.5 5th step
36.5 32.5 6th step
36.5 32.5 7th step
36.5 32.5 8th step
12 No.of layer 8
13 Turns per layer 13.3
14 Inter layer insulation 3 x 0.08 mm
Design of Thank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.42
110
Description 16504
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
180 18.0
170 17.0
155 15.5
135 13.5
115 11.5
95 9.5
75 7.5
50 5.0
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
180 18.0
170 17.0
155 15.5
135 13.5
115 11.5
95 9.5
75 7.5
50 5.0
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
180 18.0
170 17.0
155 15.5
135 13.5
115 11.5
95 9.5
75 7.5
50 5.0
24
688
6 (4 full and 2 half papers)
169
216
9969.06
30.0
305.0
479.1
531.8
ign of Thank
Values (mm)
65 W/H
115 HV OD
65 C/L
50 1st step width
54 Last step width
94
50 i.
nk dimensions as below: ii.
820 iii
rounded off to iv
1210 v
396 vi
545 vii
viii
of 1st core step + 54 +H R/S + GR/ST
938 L
1210 A
545 B
1120 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.60 2.80
0.400 0.400
68.5 685
67.5 675
66.0 660
64.0 640
62.0 620
60.0 600
58.0 580
55.5 555
505
505
Step length (L) in cm Step length (L) in mm
50.5 505
50.5 505
50.5 505
50.5 505
50.5 505
50.5 505
50.5 505
50.5 505
110 16505
40432.3 9969063.0
577.35 0.25
8.9 8.9
383 2.86
137.88 253.75
413.64 761.26
Parameters Kg Values
Calculated Weight of copper per transform 710.84
Measured Weight of bith insulation & co 315
176.58
100.00
40.00
LV Design Values
Current per phase(Is) 577.35 No.
Current density(Cd) A/sq.mm 2.80 1
14
No of pcieces 15
Weight in Kg
52.45 288 16
41.28 240 38.88
33.87 216 16.2
26.23 192 14.58
15.36 132 12.96
9.23 96 8.91
6.37 84 6.48
3.04 60 5.67
Total 4.05
187.83
Weight (Kg)
No of Plates in B No of Plates in B2
144 21.552 96
120 17.166 80
108 14.338 72
96 11.360 64
66 6.805 44
48 4.180 32
42 2.950 28
30 1.443 20
Total
79.8 79.8
1 Core diameter 91
2 Core window height 325
3 Core limb center 236
4 Core gross area 250.61
5 Net core area 243.10
HV length 9969.1
LV length 40.4 351.3815
A cu primary 4167.9292929293
A cu secondary 63508.5
A cu 67676.4292929293
Aw 29575
Add 200% towards handli
Area of primary wire
0.09
1.77
LV process
Description
Bare size of strip
Covered thickness towards TPC
71.28
100.44
126.36
144.18
157.14
165.24
173.34
No of Plates in B1
48
40
36
32
22
16
14
10
approximate no of plates
143.6
119.5
108.4
95.6
66.0
48.4
41.7
29.9
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
0.339 15718.4
1.5
392.96
Gross core area (Ag)(sq
9.2 2.85
0.1 0.1
9.3 2.95
3.0 3.00
27.9 8.85
0.4 mm(5 inter layer insulation )
18.10
13.0
362.7
363 18
102 18
305 18mm ( Radial built of LV)
20
325
300.00
77.76 38.88
64.8 16.20
58.32 14.58
51.84 12.96
35.64 8.91
25.92 6.48
22.68 5.67
16.2 4.05
353.16
176.58
Stack of B2 Stack of B1
25.92 12.96
21.6 10.80
19.44 9.72
17.28 8.64
11.88 5.94
8.64 4.32
7.56 3.78
5.4 2.70
230.94 Efficiency:
0.287 Rated KVA
1.9
25%
1213.375
1.557
13.853
38.39%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
1650 786 16504.3
786 393 16505
394 16506
Gross core area (Ag)(sqr mm)core dia(sqr mm)
Core step width
6095 90.9 No. of steps
6095 91 1st step
6095 91 2nd step
6095 91 3rd step
6095 4th step
91
6095 91 5th step
6095 91 6th step
6095 91 7th step
6095 91 8th step
38.88 39
32.40 71
29.16 100
25.92 126
17.82 144
12.96 157
11.34 168
8.10 177
177
Weight of B2 Weight of B1
14.368 7.18
11.444 5.72
9.559 4.78
7.573 3.79
4.537 2.27
2.787 1.39
1.967 0.98
0.962 0.48
Total Total
53.20 26.60
79.8
wisely ordered stackes wisely ordered plates stacks
38.5 144 Err:502
70.5 264 Err:502
99.5 372 Err:502
124.5 468 Err:502
141.5 534 Err:502
153.5 582 Err:502
164.5 624 Err:502
171.5 654 24.50
176.36 sum * by 0.27
176.58 176.58 Err:502
176.36
55.00
0.014
55.00
25
4.38
0.64
5.02
83.29
85.81
87.82
87.26
79.95
82.87
84.08
84.57
0.382
88.20
Axial length of coil Turn per layer No of Layer Seconadry turn(N2)
275 687.50 24.01 109.97
688 15 110
Step wdith SQRTof D and Stacks (K) in (mm) Required Stacks (K) i
180 Err:502 Err:502 38.88
0.39
-0.49
-1.240 38.880
0.810 32.400
-0.830 29.160
-0.640 25.920
0.830 17.820
0.640 12.960
0.9 11.340
0.660 8.100
1.130
1.13 176.58
Secondary current(Is) Area of secondary wire
36.08 12.89
577.35 214.65
247.00
-18966.39 4
30
5
6
8
9
10
11
12
13
Coil diameter and core limb center
Core diameter = 126mm (Previously calculated)
Radial build of secondary coil= 18 mm (Previously calculated)
Radial build of HV = 34 mm (Previously calculated)
Radial clearance between core to LV coil (assumed) = 4 mm
Radial clearance between LV & HV (assumed) = 8 mm
0.00
4 5 6 7
688 688 688 688
2752 3440 4128 4816
Ratio error at different tap position:
BUT
Ratio error at different tap position:
Voltages of different tapeSecondary Phase voltag Voltage ratio Total turns
NO. HV ID WI D LI (Full) LI (Half) Termo flo Total D sum Length in each layer
455
465
475
505
515
525
535
545
575
585
595
605
615
6250
Step No.
C/l cm W/H cm
65.2 81.6 1st step
12 No.of layer 1
13 Turns per layer 13.3
14 Inter layer insulation 3 x 0.08 mm
15 Tapping details None
Design of Tank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.42
6.96
34.10
Description
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
Insulated size of conductors
345 34.5
335 33.5
320 32.0
305 30.5
290 29.0
275 27.5
260 26.0
245 24.5
230 23.0
215 21.5
200 20.0
185 18.5
170 17.0
145 14.5
100 10.0
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
345 34.5
335 33.5
320 32.0
305 30.5
290 29.0
275 27.5
260 26.0
245 24.5
230 23.0
215 21.5
200 20.0
185 18.5
170 17.0
145 14.5
100 10.0
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
345 34.5
335 33.5
320 32.0
305 30.5
290 29.0
275 27.5
260 26.0
245 24.5
230 23.0
215 21.5
200 20.0
185 18.5
170 17.0
170 17.0
170 17.0
5
90
6 (4 full and 2 half papers)
525
629
886.41
42.0
796.0
1189.3
1320.1
ign of Tank
Values (mm)
110 W/H
160 HV OD
110 C/L
50 1st step width
60 Last step width
94
50 i.
nk dimensions as below: ii.
2152 iii
rounded off to iv
2140 v
899 vi
892 vii
viii
of 1st core step + 54 +H R/S + GR/ST
1765 L
2140 A
892 B
1630 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.69 2.80
489.00
350.61 49.60
0.200 0.200
7.70 3.55
0.10 0.10
7.80 3.65
1 2
7.800 7.3
90.26 43.80
2+2 =4 (Thermo flow)
51.80
51.8
704.00 52
754 45(Radial built of HV coil)
150.6 1506
148.6 1486
145.6 1456
142.6 1426
139.6 1396
136.6 1366
133.6 1336
130.6 1306
127.6 1276
124.6 1246
121.6 1216
118.6 1186
115.6 1156
110.6 1106
101.6 1016
116.1 1161
115.1 1151
113.6 1136
112.1 1121
110.6 1106
109.1 1091
107.6 1076
106.1 1061
104.6 1046
103.1 1031
101.6 1016
100.1 1001
98.6 986
96.1 961
91.6 916
1304
1304
1304
1304
1304
7 489
9434.2 886409.8
9021.10 138.89
8.9 8.9
383 2.86
32.17 22.56
96.52 67.69
Weight of covered conductor (considering coverage
50.25
13.60
56
24.0 48.703 89
24.0 45.814 89
18.0 32.163 67
18.0 29.936 67
18.0 27.680 67
18.0 27.680 67
345.00
230.00
57.50
888
LV(V) Vs-per phase(V) primary current(Ip)
400 230.94 138.89
LV Design Values
Current per phase(Is) 9021.10 No.
Current density(Cd) A/sq.mm 2.80 1
14
15
16
No of pcieces
Weight in Kg
392.34 489
240.34 311
194.22 267
152.23 222
114.24 178
106.86 178
74.73 133
69.44 133
42.85 89
39.48 89
27.14 67
24.73 67
22.39 67
18.61 67
24.47 133
Total
1544.08
Weight (Kg)
No of Plates in B No of Plates in B2
244 167.022 162.96
156 102.684 103.70
133 83.433 88.89
111 65.759 74.07
89 49.632 59.26
89 46.698 59.26
67 32.853 44.44
67 30.712 44.44
44 19.067 29.63
44 17.680 29.63
33 12.235 22.22
33 11.225 22.22
33 10.229 22.22
33 8.604 22.22
67 11.567 44.44
Total 669.399
HV length 886.4
LV length 9.4 693.3801
A cu primary 67916.6666666667
A cu secondary 63147.7
A cu 131064.366666667
Aw 286416
Add 200% towards handli
Area of primary wire
49.60
14.20
Secondary Turn per layer
LV process
Description
Bare size of strip
Covered thickness towards TPC
Ordering of steps
170
170
185
200
215
230
245
260
275
290
305
320
335
345
335
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Rated secondary phase voltage (V)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
7.947 454.7
31.500 0.64
6.96 122.00
Length (mm) Radial(mm)
11.2 2.65
0.2 0.2
11.4 2.85
0.1 0.1
11.5 2.95
8 14
92.0 41.30
41.30
8 Thermo flow (2 x 7 x 2)
740 28
740 69
56 70
796 70mm ( Radial built of LV)
20
816
Stack of B2 Stack of B1
44 22
28 14
24 12
20 10
16 8
16 8
12 6
12 6
8 4
8 4
6 3
6 3
6 3
6 3
12 6
ordering of stacks
66
108
144
174
198
222
240
258
270
282
291
300
309
318
336
230.94 Efficiency:
9.143 Rated KVA
1.9
25%
9132.578
11.717
104.264
1.16%
9%Vp (Addtional) 9% N1(Additional) Total primary turn(N1)
1125 34.10 488.8
489
6250
42.24
4.81
47.04 99.25
99.25
99.39
99.51
99.53
99.07
99.24
99.34
99.41
0.337
99.55
Axial length of coil Turn per layer
754 90.26
126
78.54
Area of secondary wire LV Working current density HV Working current density
3221.82 2.8 9.8
143.10
147.87
357.00
3 LV Coil inside diameter 180
4 Radial build of LV coil 70
8
9 HV coil outside diameter
Diameter (mm)
17.68 18 12
351
15.55 18 12
4.00
13.79 12 8
355.00
12.30 12 8
4.00 11.00 9 6
359 9.84 9 6
70 8.80 9 6
429 12.57 9 6
70 16.80 18 12
499 336.45 336.00
13
512
13
525
52
577 Acu primary 6943.80
52 Acu secondary
629 A cu 13887.60
Aw 243984.00
21 Kw 0.06 0.16
650 652 AW in sq. m 148.89
816
2.73
B1 Required No of plates B B/2
22.0 66 66 1
14.0 42 21 97
12.0 36 18 97
10.0 30 15
8.0 24 12
8.0 24 12 1
6.0 18 9 2
6.0 18 9 3
4.0 12 6 4
4.0 12 6 5
3.0 9 4.5 6
3.0 9 4.5 7
3.0 9 4.5 8
3.0 9 4.5 9
6.0 18 9 10
336 11
12
13
2 3 4 5
101 101 101 101
198 299 400 501
D
Step No.
C/l cm W/H cm
28.0 45.3 1st step
28.0 45.3 2nd step
28.0 45.3 3rd step
D
C/l cm W/H cm Step No.
28.0 45.3 1st step
28.0 45.3 2nd step
28.0 45.3 3rd step
28.0 45.3 4th step
28.0 45.3 5th step
28.0 45.3 6th step
28.0 45.3 7th step
5 Coverinig TPC-0.3 mm
12 No.of layer 5
13 Turns per layer 13.3
14 Inter layer insulation 3 x 0.08 mm
Design of Thank
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as below:
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.3923
72.10
Description
Bare conductor
Oxide Covered thickness( Varnish)
Covered conductor
Gap between two consecutive conductors
Placment of wire 2 W x 1D
Insulated size of conductors
140 14.0
130 13.0
115 11.5
100 10.0
85 8.5
65 6.5
40 4.0
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
140 14.0
130 13.0
115 11.5
100 10.0
85 8.5
65 6.5
40 4.0
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
140 14.0
130 13.0
115 11.5
100 10.0
85 8.5
65 6.5
40 4.0
10
165
6 (4 full and 2 half papers)
214
260
1228.36
34.0
433.0
114.6
127.2
ign of Thank
Values (mm)
65 W/H
65 HV OD
65 C/L
50 1st step width
54 Last step width
94
50 i.
nk dimensions as below: ii.
953 iii
rounded off to iv
960 v
390 vi
394 vii
viii
of 1st core step + 54 +H R/S + GR/ST
986 L
960 A
394 B
990 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Parameters
Calculated Weight of co
Measured Weight of bi
Weight of Insulations
Total wieight of insula
Bm Cd
1.65 2.50
73.3 733
72.3 723
70.8 708
69.3 693
67.8 678
65.8 658
63.3 633
593
Step length (L) in cm Step length (L) in mm
59.3 593
59.3 593
59.3 593
59.3 593
59.3 593
59.3 593
59.3 593
72 1647
39222.2 1228355.8
166.70 3.50
8.9 8.9
383 2.86
133.75 31.27
401.26 93.80
Parameters Kg Values
Calculated Weight of copper per transform 189.49
Measured Weight of bith insulation & co 300
Weight of Insulations 110.51
f HV coil)
Core
Step stack (2K) in mm Weight (Kg) No.of pieces
78 39.706 289
54 25.785 200
48 20.583 178
36 13.624 133
27 8.813 100
24 6.106 89
12.0 1.923 44
Total
116.5
139.50
100.00
20.00
LV Design Values
Current per phase(Is) 166.70 No.
Current density(Cd) A/sq.mm 2.80 1
14
No of pcieces
Weight in Kg
48.05 289
30.89 200
24.29 178
15.84 133
10.10 100
6.86 89
2.11 44
Total
138.15
Weight (Kg)
No of Plates in B No of Plates in B2
144 21.190 96
100 13.752 67
89 10.967 59
67 7.253 44
50 4.688 33
44 3.244 30
22 1.020 15
Total
62.11
Core sectioning
Step widith
12.5 40 13.5
10 65 12.0
8 85 9.0
8 100 6.750
8 115 6.0
5 130 3.0
140 Tatal
comparison
HV length 1228.4
LV length 39.2 203.9944
A cu primary 5763.0054142746
A cu secondary 12002.4
A cu 17765.4054142746
Aw 65866.2
189.49 Add 200% towards handli
Area of primary wire
1.40
0.99
LV process
Description
Bare size of strip
Covered thickness towards TPC
Stack
39.0
66
90
108
121.5
133.5
139.5
139.50
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
1.335 3429.5
1.12 1559.0
9.2 2.85
0.1 0.1
9.3 2.95
1.0 3.00
9.3 8.85
0. 4mm(5 inter layer insulation )
18.10
36.0
334.8
338 18
95 18
433 27mm ( Radial built of LV)
20
453
Stack of B2 Stack of B1
26 13
18 9
16 8
12 6
9 5
8 4
4 2
400.00 Efficiency:
0.433 Rated KVA
1.9
25%
752.411
0.557
4.959
2.98%
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
953 171.5 3517.5
88 1647
0.00
3.02
0.005
3.02
200 Ratio
Primary rated voltage Tap Position
1.43
0.40 19053 1
1.83 19053 2
99.09 19053 N
99.21 19053 4
99.25 19053 5
99.04
98.87
99.01
98.95
98.80
0.526
99.25
Axial length of coil Turn per layer No of Layer Seconadry turn(N2)
399 164.88 9.98 72.10
165 10 72
7.74
Step wdith SQRTof D and Stacks (K) in (mm) Required Stacks (K) i
140 39.26 39.26 39
85 117.97 12.42 14
65 130.06 12.10 12
40 139.79 9.73 6
5
6
8
9
10
11
12
13
position:
Total turns Secondary turns
3600.9336289357 72.00
3515.197113961 72.00
3429.4605989864 72.00
3343.7240840117 72.00
3257.9875690371 72.00
Coil diameter and core limb center
Core diameter = 126mm (Previously calculated)
Radial build of secondary coil= 18 mm (Previously calculated)
Radial build of HV = 34 mm (Previously calculated)
Radial clearance between core to LV coil (assumed) = 4 mm
Radial clearance between LV & HV (assumed) = 8 mm
47.6314 0.000000000000
46.4406 0.000000000000
45.2498 0.000000000000
26.19
K
4 5 6 7
165 165 165 165
660 825 990 1155
8 9 10 Break
165 165 162 (22*2)/(1+x))=1(break turns)
1320 1485 1647 1
TAPES POSITION
X4 1469 -5% 88
X2 1557 N sum
X1 1557 5% 88 178
X3 1645
X 1647 2
ak turns) Tapes In percent
HV of each tape
LV of each tape
Tap1 5 20005 400
Tap2 2.5 19529 400
Tap3 19053 400
Tap4 -2.5 18576 400
Tap5 -5.0 18100 400
In Wye connection Il=Iph
Rated KVA I1 (Primary line current)
I2(Secondary current)
200 5.77 288.68
200 5.91 288.68
200 6.06 288.68
200 6.22 288.68
200 6.38 288.68
KVA
50.00
12 No.of layer 6
Design of Th
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between core yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as belo
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.42
78.00
Description
Bare conductor 1
Supporting strip 10
11
press board
Supporting strip 12
Axial length of HV coil 13
14
Details of step (A):
Step width (W)in mm Step width (W)in cm
100 10.0
90 9.0
80 8.0
70 7.0
60 6.0
0 0.0
0 0.0
0 0.0
0 0.0
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
100 10.0
90 9.0
80 8.0
70 7.0
60 6.0
0 0.0
0 0.0
0 0.0
0 0.0
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
100 10.0
90 9
80 8
70 7
60 6
0 0
0 0
0 0
0 0.0
14
381
6 (4 full and 2 half papers)
148
194
2857.97
50.0
330.0
309.2
343.2
ign of Thank
Values (mm)
40 W/H
50 HV OD
50 C/L
40 1st step width
20 Last step width
90
50 i.
nk dimensions as below: ii.
707 iii
rounded off to iv
1140 v
294 vi
430 vii
viii
of 1st core step + 54 +H R/S + GR/ST
745 L
1140 A
430 B
1050 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.60 2.8
54.0 540
53.0
530
52.0 520
51.0 510
50.0 500
44.0 440
44.0 440
44.0 440
44.0 440
440
440
Step length (L) in cm Step length (L) in mm
44.0 440
44.0 440
44.0 440
44.0 440
44.0 440
44.0 440
44.0 440
44.0 440
44.0 440
78 5320
29405.3 2857969.7
72.17 1.11
8.9 8.9
383 2.86
100.28 72.75
300.83 218.24
0.32 6.24
0.48
1.12
93.00
120.00
-10.00
LV Design Values
Current per phase(Is) 72.17 No.
Current density(Cd) A/sq.mm 2.80 1
14
No of pcieces 15
Weight in Kg
29.39 333 16
10.58
133 45.00
6.27 89 9
4.11 67 6
3.53 67 4.5
0.00 0 4.5
#REF! #REF! 0
#REF! #REF! #REF!
#REF! #REF! #REF!
Total
#REF!
Weight (Kg)
No of Plates in B No of Plates in B2
167 13.023 111
67 4.748 44
44 2.849 30
33 1.893 22
33 1.643 22
0 0.000 0
#REF! #REF! #REF!
#REF! #REF! #REF!
#REF! #REF! #REF!
Total
#REF!
HV length 2858.0
A cu primary 5911.1111111111
A cu secondary 5629.26
A cu 11540.3711111111
Aw 34000
Add 200% towards handli
Area of primary wire
0.40
1.77
3.534
LV process
Description
Bare size of strip
Covered thickness towards TPC
14.40
26.50
15.00
No of Plates in B1
56
22
15
11
11
0
#REF!
#REF!
#REF!
approximate no of plates
0
0
0
60
70
80
90
100
90
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Rated secondary phase voltage (V)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
0.71 5066.2
1.5
11.4 2.56
0.1 0.1
11.5 2.66
1.0 1.00
11.5 2.66
0. mm(3 inter layer insulation )
11.36
20.0
230.0
230 11
100 12
330 12 mm ( Radial built of LV)
10 22.1
340 252.00
0.00
Stack of B2 Stack of B1
30 15
12 6
8 4
6 3
6 3
0 0
#REF! #REF!
#REF! #REF!
#REF! #REF!
230.94 Efficiency:
#REF! Rated KVA
1.9
25%
#REF!
#REF!
#REF!
#REF!
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
750 253.3 5319.6
5320
155.25
174.75
8
Weight of B2 Weight of B1
8.682 4.34
3.166 1.58
1.900 0.95
1.262 0.63
1.095 0.55
0.000 0.00
#REF!
#REF!
#REF!
Total Total
16.10 8.05
24.2
2.05
0.001
2.05
50
0.50
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
Axial length of coil Turn per layer No of Layer Seconadry turn(N2)
280 380.95 13.97 78.00
381 13 78
409.23
Step wdith SQRTof D and Stacks (K) in (mm) Required Stacks (K) i
100 45.83 45.83 45
90 63.25 17.42 18
80 75.50 12.25 12
70 84.85 9.35 9
60 92.20 7.34 9
Core area
Core diameter = 126mm (Previously calculated)
Gross core Area( sq mm)
Radial build of secondary coil= 18 mm (Previously calcula
4500
Radial build of HV = 34 mm (Previously calculate
1620
960 Radial clearance between core to LV coil (assumed) =
Radial clearance between LV & HV (assumed) = 8 mm
630
540 Core limb center calculations
No.
Total Gross core area in (Sq mm) 1
8250.00 2
575.00
3
4
5
6
8
9
10
11
12
13
Core diameter = 126mm (Previously calculated)
Radial build of secondary coil= 18 mm (Previously calculated)
Radial build of HV = 34 mm (Previously calculated)
Radial clearance between core to LV coil (assumed) = 4 mm
Radial clearance between LV & HV (assumed) = 8 mm
106 4
LV Coil inside diameter 54 108
Radial build of LV coil 12 12
120
12
140
144 8
HV coil inside diameter 74 148
Radial build of HV coil 23 23
150 171
173 23
HV coil outside diameter 178 194
181.00
Gap between HV limb and Phase 197 21
Core limb center 215
Total Window Height 340
Window space factor 3.0
26.19
27.00
Err:502 11 0.735
Err:502 12 0.735
13 0.735
103 14 0.735
4
3 4 5 6
381 381 381 381
1143 1524 1905 2286
PRIMARY RADIAL BUILT CALCULATIONS
Thickness of layer insulaThermo flow Samation of wire depth an
1.12 2 3.710
0.96 2 3.390
0.96 0.320 2 4.030
0.96 2 3.390
0.96 2 3.390
0.96 0.640 2 4.670
0.96 2 3.390
0.96 13.0 2 29.390
0.96 0.320 2 4.030
0.96 2 3.390
0.96 2 3.390
0.96 2 3.390
Asending Order of HV di
Diameter required fAge paper Constant Length of Layer insulation
3.710 247.71 778 50 828
7.100 251.1 789 50 839
11.130 255.13 802 50 852
14.520 258.52 812 50 862
17.910 261.91 823 50 873
1024
66.170 310.17 974 50
69.560 313.56 985 50 1035
1052
74.870 318.87 1002 50
76.340 320.34 1006 50 1056
38.17 282.17 886.463199063
5320
12 13 14
381 371 377
4572 4943 5320
TAPES POSITION
of Layer insulation X6 4762 Tap
X4 4889 127 253.31
X2 5016 127 126.6562153035
X3 5016 506.6248612139
X5 5143 127 508
X7 5270 127
X8 5320 50 558
Tapes T1 T2 TR Tap position
X6 4764 78 61.0769 5
X4 4890 78 62.6923 4
X2 5016 78 64.3077 3
X3 5016 78 64.3077 2
X5 5143 78 65.9359 1
X7 5270 78 67.5641
X8 5320 78 68.2051
Average of terminals Average of terminals Ratio range
6&4 61.88 61.38 to 61.99
4&2 63.50 62.99to 63.63
2&3 65.12 64.61 to 65.26
12 No.of layer 4
Design of Th
Given parameters
(i) Gap between HV coil to the inside of tank on length side
( ii ) Gap between HV coil to the inside of tank on width side
( iii ) Gap between LV coil to the inside of tank on width side
( iv ) Gap between core yoke and tank bottom
( v ) Gap between yoke to ratio switch base
( vi ) Height of ratio switch
( vii) Gap between ratio switch top to inside of tank cover
Based on the above internal clearances, let me form the tank dimensions as belo
(a) Length of tank(inside) :2 x C/L of core + HV Coil OD + 2 x 60mm
730
k-factor
0.41
Secondary turns 56
Description
Bare conductor 1
Supporting strip 10
11
press board
Supporting strip 12
Axial length of HV coil 13
14
Details of step (A):
Step width (W)in mm Step width (W)in cm
100 10.0
90 9.0
80 8.0
70 7.0
60 6.0
0 0.0
0 0.0
0 0.0
0 0.0
DTAILS OF (B)
Step width (W)in mm Step width (W)in cm
100 10.0
90 9.0
80 8.0
70 7.0
60 6.0
0 0.0
0 0.0
0 0.0
0 0.0
DTAILS OF (C)
Step width (W)in mm Step width (W)in cm
100 10.0
90 9
80 8
70 7
60 6
0 0
0 0
0 0
0 0.0
13
296
6 (4 full and 2 half papers)
177
221
2387.55
42.0
400.4
258.3
286.7
ign of Thank
Values (mm)
40 W/H
50 HV OD
50 C/L
40 1st step width
20 Last step width
90
50 i.
nk dimensions as below: ii.
784 iii
rounded off to iv
1140 v
321 vi
430 vii
viii
of 1st core step + 54 +H R/S + GR/ST
815.4 L
1140 A
430 B
1050 C
D
290.00 E
306.00 F
G
H
I
I
K
L
A
B
C
D
E
F
G
H
I
I
K
M
Bm Cd
1.60 3.0
61.0 610
60.0
600
59.0 590
58.0 580
57.0 570
51.0 510
51.0 510
51.0 510
51.0 510
510
510
Step length (L) in cm Step length (L) in mm
51.0 510
51.0 510
51.0 510
51.0 510
51.0 510
51.0 510
51.0 510
51.0 510
51.0 510
56 3819
25861.6 2387550.7
72.17 2.22
8.9 8.9
383 2.86
88.19 60.77
264.57 182.32
0.32 6.24
0.48
1.12
0.56
93.00
120.00
-10.00
LV Design Values
Current per phase(Is) 72.17 No.
Current density(Cd) A/sq.mm 2.80 1
14
No of pcieces 15
Weight in Kg
34.09 333 16
12.27
133 45.00
7.27 89 9
4.77 67 6
4.09 67 4.5
0.00 0 4.5
#REF! #REF! 0
#REF! #REF! #REF!
#REF! #REF! #REF!
Total
#REF!
Weight (Kg)
No of Plates in B No of Plates in B2
167 15.374 111
67 5.595 44
44 3.351 30
33 2.222 22
33 1.925 22
0 0.000 0
#REF! #REF! #REF!
#REF! #REF! #REF!
#REF! #REF! #REF!
Total
#REF!
HV length 2387.6
A cu primary 8486.6666666667
A cu secondary 4041.52
A cu 12528.1866666667
Aw 52120.8
Add 200% towards handli
Area of primary wire
0.74
1.77
3.534
LV process
Description
Bare size of strip
Covered thickness towards TPC
14.40
26.50
15.00
No of Plates in B1
56
22
15
11
11
0
#REF!
#REF!
#REF!
approximate no of plates
0
0
0
60
70
80
90
100
90
1.6582.67)/(3230.94) = 1.35 A
Im= 1.35 A+(2 x 1.35 A ) =4.05 A
Add 200% towards handling factor shearing, knotching and thickness variation Therefore ( I m)
(ii) Hysteresis and eddy current (I h+e):-
Guaranteed no-load loss in (W)
Rated secondary phase voltage (V)
Therefore( I h+e)
Therefore No-load current I0
No-load current at 112.5% voltage as a percentage of the full load current
Primary wire dia. Primary turn(N1)
0.97 3637.3
1.5
52.86
Gross core are
9.2 2.85
0.1 0.1
9.3 2.95
1.0 2.00
9.3 5.90
0. mm(3 inter layer insulation )
12.04
28.0
260.4
260 12
140 12
400 12 mm ( Radial built of LV)
10 42.1
410 322.40
0.00
Stack of B2 Stack of B1
30 15
12 6
8 4
6 3
6 3
0 0
#REF! #REF!
#REF! #REF!
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230.94 Efficiency:
#REF! Rated KVA
1.9
25%
#REF!
#REF!
#REF!
#REF!
5%Vp (Addtional) 5% N1(Additional) Total primary turn(N1)
750 181.9 3819.2
5% tape 182 3819
2.5 % tape 91
Gross core area (Ag)(sqr mm)core dia(sqr mm)
Core step width
11900 127.6 No. of steps
8825 110 1st step
8825 110 2nd step
8825 110 3rd step
8825 110 4th step
8825 110 5th step
3820.00
3142.00
125.55
274.85
8
Weight of B2 Weight of B1
10.249 5.12
3.730 1.86
2.234 1.12
1.482 0.74
1.283 0.64
0.000 0.00
#REF!
#REF!
#REF!
Total Total
18.98 9.49
28.5
1.07
0.002
1.07
100
0.76
#REF!
#REF!
#REF!
#REF!
#REF!
#REF!
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#REF!
#REF!
#REF!
#REF!
#REF!
Axial length of coil Turn per layer No of Layer Seconadry turn(N2)
358 296.20 12.89 56.33
296 13 56
293.77
Step wdith SQRTof D and Stacks (K) in (mm) Required Stacks (K) i
100 45.83 45.83 45
90 63.25 17.42 18
80 75.50 12.25 12
70 84.85 9.35 9
60 92.20 7.34 9
Core area
Core diameter = 126mm (Previously calculated)
Gross core Area( sq mm)
Radial build of secondary coil= 18 mm (Previously calcula
4500
Radial build of HV = 34 mm (Previously calculate
1620
960 Radial clearance between core to LV coil (assumed) =
Radial clearance between LV & HV (assumed) = 8 mm
630
540 Core limb center calculations
No.
Total Gross core area in (Sq mm) 1
8250.00 2
575.00
3
417.8318229274 4
5
6
8
9
10
11
12
13
Core diameter = 126mm (Previously calculated)
Radial build of secondary coil= 18 mm (Previously calculated)
Radial build of HV = 34 mm (Previously calculated)
Radial clearance between core to LV coil (assumed) = 4 mm
Radial clearance between LV & HV (assumed) = 8 mm
133 4
LV Coil inside diameter 68 135
Radial build of LV coil 12 12
147
12
168
173 9
HV coil inside diameter 89 177
Radial build of HV coil 22 22
179 199
201 22
HV coil outside diameter 206 221
209.00
Gap between HV limb and Phase 224 19
Core limb center 240
Total Window Height 410
Window space factor 3.6
26.19
127.32
694.29
27.00
Err:502 11 1.210
Err:502 12 1.210
13 1.210
103
4
3 4 5
296 296 296
878 1174 1470
PRIMARY RADIAL BUILT CALCULATIONS
Thickness of layer insulaGBLV and HV Thermo flow LV OD
0.45 18 160
0.38 18
0.38 18 0.320
0.38 18
0.38 18
0.38 18 0.640
0.38 18
0.38 18 13.0
0.38 18 0.320
0.38 18
0.38 18
0.38 18
18 0.80
6 7 8 9 10
296 296 296 296 296
1766 2062 2358 2654 2950
30 550
30 590
30 620
30 690
30 720
30 750
30 770
Tap
181.87
90.9326673974
363.7306695895
364
414
Tap position Average of terminals Average of terminals
5 6&4 61.88
4 4&2 63.50
3 2&3 65.12
2 3&5 65.94
1 5&7 67.07
1 133 1.21
2 1.21
3 1.21
4 1.21
Ratio range 5 1.21
61.38 to 61.99 6 1.21
62.99to 63.63 7 1.21
64.61 to 65.26 8 1.21
11 1.21
12 1.21
13 1.21
0.45 0.225 0.675 2.42 1.35 3.77 136.77
0.375 0.225 0.6 2.42 1.2 3.62 140.39
0.375 0.225 0.6 2.42 1.2 3.62 144.01
0.375 0.225 0.6 2.42 1.2 3.62 147.63
0.375 0.225 0.6 2.42 1.2 3.62 151.25
0.375 0.225 0.6 2.42 1.2 3.62 154.87
0.375 0.225 0.6 2.42 1.2 16.62 171.49
0.375 0.225 0.6 2.42 1.2 3.62 175.11