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

Design and

Construction

of Constant Trans former

Voltage

Mendis N.N.R, Yatiyana E.M.M.B, Wijesinghe K.C, Lucas J.R and Perera R. Department of Electrical Engineering, Faculty of Engineering, University of Moratuwa Sri Lanka ,ha roidik.com, yatiyana c AK, Kasun ya oo.co, lVucas e ect.mrt"ac.k, *hyrp gelect.mrt.ac.lk

construction of Constant Voltage Transformer by means of conventional power transformer core structures. The Constant Voltage Transformer is suitable for use to mitigate the power quality problems associated with the Sri Lankan industrial sector. However, even in today's age of information, many Sri Lankan industrial facilities are not aware of one attractive Constant Voltage Transformer feature - "the ability to mitigate the effects of voltage sags". This method of maintaining the power quality has proven more effective and reliable in international arena

Abstract - This paper presents the design and

optimizing the design [ 1 ] of the constant voltage transforner. Based on this procedure, a proto type was built and tested .The test results indicated good argument between the predicted results through analysis and experimental measurements, thus validating the design procedure.
2.

THEORY OF OPERATION

1.

INRODUCTION

The operational theory of a constant voltage transforner is based on a well-known phenomenon known as "Ferroresonance" or Non-Linear Resonance. Some literature compares the circuit it to that of a Zener diode.
Ferroresonance is the property of a transformer design in which the transforner consists with two separate magnetic paths with limited coupling between them. The output contains a resonant circuit and it draws power from the primary to replace the power deliver to the load. The B-H characteristic of the transforner is given in (Fig- 1). It operates in the region where denoted as "saturated region". The following illustrate the way of achieving the constant voltage at a load end.

Sri Lanka is a country where variation in quality of power supply is too irregular. "Poor Power Quality" affects adversely to all over the sectors of the economy, resulting a huge loss of revenue to the county annually in tangible and intangible forms.

Although the most electrical equipments can operate without problems even if voltage varies by up to 6%, may out of tolerance voltages still occur the generally classified as sags, surges and brownouts. These problems disrupt the smooth functionality of the industrial processes.
Ferroresonant Voltage Transforner is popularly known, as CVT are robust and simple. It provides an A.C output voltage of nearly constant magnitude even when the input voltage changes over a specified range. It is also completely and continuously short circuited in use, without any adverse reaction. Ferro resonance regulators are the best and most reliable power conditioners for applications ranging from process control and automation to remote sites and third world applications. And many more other power quality features ensure the use of it as an excellent

Transforner output voltage is given by following equation.

E(av)output
Where
B
=

=4.44BNAJ

saturated flux density (T)

N = no of turns at out put

choice for mitigating power quality problems in Sri Lanka, where variations in the quality of the power supply are all too irregular, but where maintenance facilities are at a premium.
In this paper, a method of design involving the conventional power transforner cores is presented. Based on the analysis, step - by - step procedure is evolved for

f = operating frequency (Hz)


A = cross section area (m2) Let consider the working flux range (X-Y) of the transforner shown in (Fig -1).

1-4244-0322- 7/06/$20. 00 c2006 IEEE 40

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

AB= Bx

By

VL
L

But AB O

Therfore Bx

By

yin
*
....................... ....................................................

SR e> tvo
I
ioti

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

Fig 2 - Equivalent circuit of a ferro resonance regulator

A constant voltage is achieved during its operation.


Flux Density (B)

Where L-linear inductor

C-linear capacitor R-Load resistor The known parameters are


Vl- Input voltage (Voltage that take just before the regulation)

f - Source frequency
Magnetizing force (H)

W Output watts (VO2 /R) Parameters to be calculated


L
C

B-H LOOP FOR SR

Fig I - B-H curve Characteristic


3.

-Inductor value

DESIGNING THE PARAMETERS

-Capacitor value
-Input power factor -Voltage where SR designed to saturate

The design of constant voltage transformer is basically based on designing of its electrical parameters and mechanical parameters. The electrical parameters are associated with capacitance, inductance estimation, regulated voltage input range and short circuit current. etc. The mechanical parameters are dealt with calculation of
core dimensions.

Cos
VO

VL
Is

-Voltage across the inductor


-Short circuit current (when R=O)

Ii

-Input Current
-Determines the physical size of L and C.

3.1

ELECTRICAL PARAMETER CALCULATION

The equivalent circuit of a ferroresonance regulator is shown in (Fig -2). During the design process the values for linear inductor (L), Linear capacitor (C) and Short circuit current (Is) should be derived. During the above parameter estimation the saturating reactor (SR) is neglected due to its high impedance at low line condition compared to L, C and R. [1]

(Li2+Cv2)

The equivalent circuit (Fig -2) is used to derive the expressions for electric parameters. By applying the circuit laws, the expressions are derived to evaluate the values for
C, L, Cos (I) VO and Is.

1-4244-0322- 7/06/$20. 00 c2006 IEEE

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First International Conference

on

Industrial and Information Systems, ICIIS 2006, 8 - 11 August 2006, Sri Lanka

iW- i2 wVorK Cos/


w

(k

(1)

Where

K=Vo/V1,w =omega
2 -C Sin2$]

L=

kVl2
Ww

Cos$VI

(2)

CVo2 +Li2= _2 2
w L

Cos(t)
1

I1 -tan (t]

(3)

is
i

CosJI

QCOSj

_Sin2(j Q

(4)

Fig 3 - Power factor variation

Equation (3) gives the physical size of equipment and equation (4) gives the short circuit current. Both equation plots against k value for different input power factor values.

Considering all the practical issues and referring the phasor diagrams associate with the equivalent circuit in (Fig -2). The basic design equations can be summarised as in below. (1) (2)
Cos (I

According to the graph in (Fig-3) the best value k ( Vo/Vl) is 1.6. The value is chosen such that it gives a small short circuit current and smaller size at higher power factor of 0.97. The subsequent expressions for the equations (1), (2), (3) and (4) can be expressed as follows.

0.97

i1 W/(0.97 *V1)
L

1.48V12/ (W*w)
W/ (1.95*Vl2w)

(3)
(4)

1.48 *V12/(W*w) and VL

1.53 V1

Design saturating reactor to saturate at 1.6 VI

( CV2o + Li2 )

2.84WIw

Due the non-linearity of the saturating inductor (SR) the practical value of the capacitor is given by (4)

(5)
io i0

C =W/(1.77*Vl*w), CV2o
=

1.1

(6)

1.445 W / w

(7)
0

1.1

1-4244-0322- 7/06/$20. 00 c2006 IEEE 42

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

4.2

MECHANICAL PARAMETER CALCULATION

5. DESIGN OF FILTER CIRCUIT

The core is three-limed shell with a magnetic leakage path (Shunt), dividing the winding space. The secondary limb consists of two windings called capacitive winding and output winding (Secondary winding).

winding

Secondawy

The saturation of the core leads to there being harmonic fluxes present. These cause distortion of the output voltage waveform. Therefore to restore the quality of the voltage form the filter circuit is incorporated. Filtering is achieved by. And also a "compensating winding " can be introduced, in which it produces a small voltage that is used to buck the out put voltage.

Priame whnlng
Air gap
PRIMARY
ADD COMPENSATING WINDING

Capaidtive

wMndirig

ADD A CHOKE

230V
G

NEW

~~~~~~~~~~~~~~~~V0

Fig.4 -Basic core structure ofthe constant voltage transformer

The mechanical parameters (Core dimensions) are derived, referring the conventional power transformer core equations. Some of basic equations associate with core parameters estimation can be stated as follows. [5]

INCREASE TAPPING POINT ------l,TO OVERCOME VOLTAGE DROP IN COWPENSATING WDG.

V0

Fig 5 - Regulator with filter circuit

(1)A=

1.5*kVA

- Cross section area

calculation

The value for choke should be calculated such that,


L total = Leakage inductance + Choke inductance

(2) W*a=

17.26 * S * P
f*B

- Window size

5.

TEST RESULTS

(3) -=V 28.64*f*a*B


calculation Where
W
a

calculation 108 NT

The regulated input voltage range is in between 1 90V to 250 V.


- Per turn voltage

Output vs Input ourye for 25 (C Ia 51F}

..250
iso

f
B p

S N V

Window area in square inches Cross section area in square inches Frequency in hertz Flux density in gauss Power in watts Current density (CMIA) Number of turns Voltage in volts

I,I np.t

ic00

anoev

so

150 200 25

\AIQm

3U

Fig 6 - V out vs. V in

1-4244-0322- 7/06/$20. 00 c2006 IEEE 43

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

(Fig -6) shows, output voltage is nearly constant after saturation. The saturation voltage is 230 V. For 250 VA loads input voltage working range is 190-250V. For the above input range output is within 1%. The efficiency is in between 75-80%. According to the graph the efficiency of the regulator is almost 80% at the full load conditions. This is one of the drawbacks of the regulator. And also the transformer is less efficient at light load conditions. As a result, there is a fixed amount of power required to maintain the saturation. Losses are introduced due to the saturation of the core and the considerable current circulating in the secondary winding.
1E0-

The output waveform contains odd harmonics. The major harmonics are 3rd, 5th and 7th. Without having the arrangement as in Fig (5) the THD level is around 17% at 230 V. The secondary of the constant voltage transformer is driven in to the saturation mode of operation; hence it introduces a non-linear magnetic behaviour at the output. Therefore it contains considerable amount of harmonics. According the waveform observed it contains 3rd harmonics, 5th and 7th harmonics in large proportions. But it was reduced by 10%, introducing a filter circuit at output as in (Fig -5).

6.

TECHNICAL SPECIFICATIONS OF THE TRASFORMER

Rated Capacity
Input Voltage Range Frequency

250 VA

190 V - 250 V A.C, 1 CD 50 + 2.5 Hz


230 V A.C, 1 (D 1% @ rated load

Output Voltage
40 -

40

so

120

160

200

240

Fig 7- Efficiency curve for 25OwLoad (13.5gf)

Line Regulation Load Regulation THD Efficiency Capacitor Range Short Circuit Current

2%0 7O 80%0 12.5 iF -14 iF 1.6* rated current

Total Harmonic Distortion (THD) was recorded 700

CONCLUSION

I 10III e10 noh


60

The exhilarating work associated with construction had anticipated. The initial studies opened up Sri Lanka for new technology, methodologies and research avenues, which were unheard, therefore unexplored before. The main objective of introducing the constant voltage transformer technology to Sri Lanka was achieved. Analyzing constant voltage transformer technology, implementation of core by scarce resources and tuning the matching capacitor value proved to be difficult. Actual implementation was faced by many challenges such as lack of technological knowledge, machine limitation, and labour management. Group can state with pride that most of the issues hindering the project were dealt with and overcome successfully. The achievement is expected to bring more attention to constant voltage transformer concept, where it should undergo research to develop for a better version.

40
20

l[I1U 15 2 | 14
1

1 2

1r

IUHarn1. n be

Fig -8 Harmonics at output without filter

1-4244-0322- 7/06/$20. 00 c2006 IEEE


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

ACKNOWLEDGMENT

The Author thanks Mr. Kosal Gunawardne, Lanka Transformer (Pvt) Limited, Sri Lanka for the help rendered during the implementation of the project. And also the appreciation goes to Professor Rohan Lucas and Professor Ranith Prera for their great advices during the design and implementation of the project
REFERENCES:
[1] Harry P.Hart & Robert J.Kakalec, "The Derivation and Application of Design Equation for Ferroresonant Voltage regulators and Regulated Rectifiers" [2] B.Friedman, "The Analysis and Design of Constant Voltage Regulator", IEEE Trans.- Components parts, Mar. 1956, pp. 1 1-14

[3] H.P. Hart and R.J. Kaklec, "The Derivation and Application of design equations for Ferroresonant Voltage Regulators and Regulated Rectifiers" IEEE Trans. on Mngn., Mar. 1971, pp. 205-21 1. [4] IEEE Standard 44911984 for Ferroresonant Voltage Regulators

[5] Eric Lowdon,(1985) Practical Transformer Design Handbook, First Edition,51-82,BPB Publication, New Delhi.

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