CHAPTER FIVE

TRANSFORMER AND Charging Section

5.1 What is a transformer?

A transformer can be defined as a static device which helps in the

transformation of electric power in one circuit to electric power of the same frequency
in another circuit. The voltage can be raised or lowered in a circuit, but with a
proportional increase or decrease in the current ratings. In this article we will be
learning about Transformer basics and working principle

5.2 Transformer – Working Principle

The main principle of operation of a transformer is mutual inductance
between two circuits which is linked by a common magnetic flux. A basic transformer
consists of two coils that are electrically separate and inductive, but are magnetically
linked through a path of reluctance. The working principle of the transformer can be
understood from the figure below.

Figure 5.1: The Working Principle of The Transformer

  As shown above the electrical transformer has primary and secondary

windings. The core laminations are joined in the form of strips in between the strips
you can see that there are some narrow gaps right through the cross-section of the
core. These staggered joints are said to be ‘imbricated’. Both the coils have high
mutual inductance. A mutual electro-motive force is induced in the transformer from
the alternating flux that is set up in the laminated core, due to the coil that is
connected to a source of alternating voltage. Most of the alternating flux developed by
this coil is linked with the other coil and thus produces the mutual induced electro-
motive force. The so produced electro-motive force can be explained with the help of
Faraday’s laws of Electromagnetic Induction as

e=M*dI/dt

If the second coil circuit is closed, a current flows in it and thus electrical
energy is transferred magnetically from the first to the second coil.

The alternating current supply is given to the first coil and hence it can be
called as the primary winding. The energy is drawn out from the second coil and thus
can be called as the secondary winding.

In short, a transformer carries the operations shown below:

1. Transfer of electric power from one circuit to another.

2.  Transfer of electric power without any change in frequency.

3. Transfer with the principle of electromagnetic induction.

4. The two electrical circuits are linked by mutual induction.

5.3 Transformer Construction

For the simple construction of a transformer, you must need two coils having
mutual inductance and a laminated steel core. The two coils are insulated from each
other and from the steel core. The device will also need some suitable container for
the assembled core and windings, a medium with which the core and its windings
from its container can be insulated.

In order to insulate and to bring out the terminals of the winding from the
tank, apt bushings that are made from either porcelain or capacitor type must be used.
In all transformers that are used commercially, the core is made out of
transformer sheet steel laminations assembled to provide a continuous magnetic path
with minimum of air-gap included. The steel should have high permeability and low
hysteresis loss. For this to happen, the steel should be made of high silicon content
and must also be heat treated. By effectively laminating the core, the eddy-current
losses can be reduced. The lamination can be done with the help of a light coat of core
plate varnish or lay an oxide layer on the surface. For a frequency of 50 Hertz, the
thickness of the lamination varies from 0.35mm to 0.5mm for a frequency of 25
Hertz.

5.4 Center-tap transformer

The transformer used for this project has a center-tapping which divides the
primary into two equal sections. This center-tapping is connected to the positive
terminal of the battery. Two ends of the primary are connected to the negative
terminal of the battery through switches S1 and S2. These switches S1 and S2 are
turned ON/OFF alternatively to generate current in the primary coil. When the switch
S1 is closed and S2 is opened, the current flows in the first part of the primary
winding and the EMF is induced in the secondary winding. When the switch S2 is
closed and S1 is opened, the current flows in the second part of the primary winding
and the EMF of opposite polarity is induced in the secondary winding. Thus, if the
switches S1 and S2 are alternatively opened and closed at constant rate, then the
output from the secondary winding is a square wave of the frequency at which the
switches S1 and S2 are opened and closed.

Figure 5.2: The Center-Tap Transformer

5.5 Design Parameters of Transformer:-

For designing a transformer, we need:

1. Power rating
2. Voltage levels (primary and secondary)
3. Currents on both sides
4. Primary and secondary coils wire diameter/size
5. Iron Core area
6. Numbers of turns (primary and secondary)

The power Rating for the Inverter transformer (KVA) =3.0KVA , E2=12V.
Assuming the efficiency of transformer =80%
Then Input rating =output /Efficiency=3000VA/0.80= 3750VA
We are going to design a 3750VA step up transformer of 12-0-12V to 230V.
Necessary calculations along with formulae are given below in details:
5.6 Calculations for Transformer Design:

5.6.1 Core Calculations:

Calculate area of core (central limb) by using following formula:

E∗108
Ai=
4.44∗f ∗Bm∗Te

Where,
Ai= Area of Core
f = Operating Frequency
Bm= magnetic flux density
Te = turns per volts
Ai for transformer in this inverter=3cm*6cm=18 cm2=2.79 inch2 .

E∗10 8
Te=
4.44∗F∗Ai∗Bm
 1∗100000000
Te=
4 .44∗50∗Ai∗60000

7.5
Te=
Ai

Hence Ai=2.79 inch2

7.5
Te= =2.68 turn per volts
2 .79

5.6.2 Primary Winding Calculations:-

For Transformer Design Calculation we first calculate parameters for Primary

side then secondary side.

5.6.2.1 Primary Current Calculation:-

Voltage Primary = Vp = 230 V

Primary current (Ip):

VA 3750
Ip= = =16 .30 A
Vp 230

Therefore, Primary Current = 16.30Amp

5.6.2.2 Number of Turns:-

Primary side number of turns can be calculated as:

Total number of turns (N1) = turns per volts x primary side voltage
N1 = 2.68 x 230 = 616.4 turns
N1=2.68×230 N1≈617turns
 5.6.3 Secondary Winding Calculations:-

5.6.3.1 Secondary Current Calculation:-

Secondary Voltage = Vs=12V

VA
Secondary Current¿
Vs
3750
Is= =312.5 A
12
5.6.3.2 Secondary Number of Turns:-

Secondary side number of turns can be calculated as:

Total number of turns (N2) = turns per volts x Secondary side voltage
N2 = 2.68 x 12 = 32.16 turns
N2≈32 turns

5.7 Charging Section:-

In inverter designing, one of the most required tasks is a good charging
system. A good inverter charger will increase battery life span and will also increase
the run time of the inverter.

Many inverter chargers exist but one that will keep the battery always fully
charges is the best. These type of chargers are known as float chargers.

A float charger is a charger that keeps the battery always under its float
voltage level or fully charged level without over charging it.

Many poor or basic chargers consists of relays that disconnects the power
supply line when the battery reaches its full state. This is not best because the relay
contacts may stack and the battery will be overcharged and even swell up.

It’s a good idea to start by understanding few basic things about a Lead acid
battery so that leads to build charger more efficiently. Most of the lead acid batteries
in the market are 12V batteries. The Ah (Ampere hours) of each battery may vary
based on the required capacity, a 7 Ah battery for example will be able to provide 1
Amps for a duration of 7 hours (1 Amps *7 hours = 7 Ah). Now after complete
discharge the battery percentage should be around 10.5, this is the time for us to our
batteries. The charging current of a battery is recommended to be 1/10th of the Ah
rating of the battery. So for a 7 Ah battery the charging current should be around 0.7
Amps. Current greater than this may harm the battery resulting in reduced battery life.

Here is the circuit diagram of a simple and straight forward 12 V battery

charger circuit with diagram. This circuit can be used to charge all type of 12V
rechargeable batteries including car batteries.

5.7.1 Charger Circuit Diagram

Figure 5.3: The Battery Charger And Monitor

5.7.2 Components required:-

• Transistor– BD139 – Tow pieces

• Transistor – BC548C – Tow pieces
• Zener diode – 13.7v – One piece
• Zener diode – 10.2v – One piece
• Resistor – 1k – Tow pieces
• Resistor– 100 – Tow pieces
• Capacitor – 100uf/25v – One piece
• LED – green 5mm – One piece
• LED – red 5mm – One piece
• LED – yellow 5mm – One piece
• Transformer – 220V-12V,8A.
• Bridge rectifier– One piece
• Relay – 12v – One piece

5.7.3 Calibration of the circuit:-

The best way to calibrate the circuit is to use a variable voltage, regulated
power supply. This is connected to the circuit in the place of the battery. Set the
regulated power supply to 14.5 volts or fully charged battery.

5.7.4 Description:-

To begin with, an AC220V will flow to a transformer to transform to 12volts. 

Then, flow to bridge diode to rectifier AC to DC pulse 12V. Then the positive
terminal of the charger will connect to the relay terminal (NC) where the
corresponding relay terminal is connected to the positive terminal of the battery.

This is the circuit diagram of a 3 LED battery monitor circuit that is ideal for
monitoring the voltage level of an inverter battery. When battery voltage is 11.5V or
less the LED D2 (Red led) will be glowing. When battery voltage is between 11.5
and 14.2V, the LED D3 (Yellow LED) will be glowing and the transistor Q10 will be
On (Q10 works on relay bias to turn on charger) and the transistor Q8 will be On (Q8
turns off the red LED ) . When battery voltage is above 14.3V the LED D7 will be
glowing and the transistor Q9 will be On (Q9 turns off the red LED) and the transistor
Q7 will be On (Q7 turns off the Yellow and works to disconnect the charger ) .