STATEMENT OF THE PROBLEM

A distributor company asked the students of Electrical Engineering of UE-Manila to design a

current transformer for a Watt-hour meter of its customers. Each student was given different

types of specification to be considered. For this design, the ratio of the current transformer must

be 1000:5. The voltage of the primary circuit which the source would come from is 6900 volts

for having its frequency of 60 Hz with an external burden of 12.5 VA and 0.9 power factor. The

permissible limits of error over the range from 10 to 100 percent of rated current.

Current transformers are one of the types of instrument transformers. According to

Wikipedia, instrument transformers are “high accuracy class electrical devices used to isolate or

transform voltage or current levels.” It applies to the operate instruments or metering instruments

from high voltage or high current circuits. It has to types to be known for, these are current

transformer and potential transformer.

Current transformer is a type of transformer that used to measure alternating current

(Wikipedia, 2019). These transformers are usually small of size. The function of this transformer

is to provide a current for measuring instruments which shall be as nearly as possible

proportional to the line current from the primary winding. Usually, it has 5 ampere rated

secondary current to provide a supply source to the measuring instrument.

Figure no. 1 Current Transformer

 In the figure above, it shows the flow of current in the hot wire with a current transformer

connected to a ammeter, reading the high current flows on the wire.

Potential transformer is a voltage step-down transformer which reduces the voltage of a

high voltage circuit to a lower level for the purpose of measurement. It has been connected in

parallel to the line in which it has been monitored.

Figure no. 2 Potential Transformer

In the figure above, shows the connection of the potential transformer in a high voltage
line. The potential transformer is in parallel with the line while on its secondary side, a voltmeter
was placed to measure the voltage flow on the circuit.

According to Siskind in his book of Elements of Electrical Machine Design, a current

transformer does not differ fundamentally from a potential transformer, but since the primary
windings are in series with the primary circuit, the voltage across both primary and secondary
terminals will not be approximately constant, as in potential transformer, but will follow the
changes in the primary current.
 SPECIFICATION AND DESIGN SHEETS

Table 1 Single Phase Distribution Transformer Specification

Ratio 1000 : 5
Voltage of Primary Circuit 6 900 Volts
Frequency 60 Hz
External Burden
Volt Ampere 12.5
Power Factor 0.9

DESIGN SHEET FOR TRANSFORMER

Permissible limits of error over range from 10 to 100 percent of rated current
Phase Angle 20 min
Ratio 0.5 per cent
Item Primary Secondary
Windings
No. Initial Final Initial Final
1 Secondary amp-turns ……... …….. 1000 2000
2 Full load current, amp 1000 1000 5 5
3 Total number of turns 1.5 2 300 400
4 Number of coils 1 1 1 1
5 Turns per coil 1.5 2 300 400
6 Current density, amp per sq. in 2295.7 2295.7 1075 1075
7 Cross section of conductor, sq. in. 0.667 0.667 0.0047 0.0047
No. 13 No. 13
8 Dimensions of conductor 0.96x0.7 0.96x0.7
Square Square
9 Number of turns per layer of winding 10 10 30 40
10 Number of layers per coil 1 1 10 10
11 Insulation between layers, in. None None 0.005 0.005
12 Mean length per turn, ft. 1.37 1.37 1.58 1.58
13 Total length of wire, ft. 13.7 13.7 474 474
14 Weight of copper, lb. 2.58 2.58 7.43 7.43
Resistance of the secondary @75°C,
15 ……….. ……….. 0.521 0.521
ohms
16 IR drop in secondary, volts ……….. ……….. 2.605 2.605
17 Total secondary burden, volt-amp ……….. ……….. 14.15 14.15
18 Power-factor of total burden (cosɸ) ……….. ……….. 0.971 0.971
The Magnetic Circuit
Initial Final
19 Dimensions of window, in 4 ½ x 1.945 4 ½ x 1.945
Total flux (Maxwells) at 100 per cent
20 5730.73 4298.05
rating
Flux density in iron of core, lines per sq.
21 2865.37 2865.37
in.
22 Cross section of iron in core, sq. in. 2 2
23 Width of stampings in core, in. 1½ 1½
24 Gross thickness of core, in. 1½ 1½
25 Mean length of flux path, in. 20 39/100 20 39/100
26 Weight of iron in core, lb. 11.42 11.42
Sketch showing cross section through
27 Fig. no. 1 Fig. no. 1
window
Full Burden 1/10th Burden
Calculated Performance
Initial Final Initial Final
28 Amp-turns per in. (from Fig. 178) 0.4 0.4 0.08 0.08
29 Watts per lb. (from Fig. 179) 0.0025 0.0025 0.00006 0.00006
30 Component Io of exciting current 2.90 2.90 0.29 0.29
31 Component Iw of exciting current 1.25 1.25 0.3132 0.3132
32 Phase angle by formula (151) +7 +7 +1 +1
33 Per cent ratio error, by formula (152) 0.0533 0.0533 0.273 0.273
 COMPUTATIONS

Items 1 to 5. Within certain limits, a large number of turns in the windings will tend to
reduce the errors because the exciting current component in the primary will be a small
percentage of the total current. We shall assume the total secondary ampere-turns to be
2000. Since Ip = 1000 and Is = 5, the number of turns are Tp = 2 and Ts = 400, but a very slight
change in the secondary turns may be made later to compensate for ratio error.
Assuming a core – type transformer as shown in section (Fig. 180), there is no serious
objection to winding both primary and secondary on both limbs as in a distributing or
power transformer. We shall, however, assume the winding to consist of a single coil
containing both primary and secondary turns.

Items 6 to 8. A high current density in the secondary should be avoided as it tends to

increase the IR drop in the winding. This is apart from heating effects, which are not likely to
give trouble on normal loads but may be very serious on momentary overloads such as
occur in the case of short circuits on the primary system.
Assuming current densities of 1200 and 1500 amp per sq. in. in secondary and primary,
respectively, we have 5/1200 = 0.00417 as the cross section of the secondary wire. From
the wire table on page 432, we select no. 13 square wire with a cross section of 0.00465 sq.
in. The current density in the secondary is, therefore, ∆ = 5/0.00465= 1075 amp per sq. in.
Before deciding upon the actual dimensions of the primary winding, which will probably
consist of a fairly heavy conductor of rectangular section, it will be advisable to settle upon
the approximate dimensions for the window or opening to accommodate the windings.

Items 19 to 24. By formula (134) we have sf = 10(30+6.9)=0.271 but this should be reduced
to at least 10 percent because of the small size of the transformer. We shall try sf = 0.24;
whence, for an average current density of about 1200, we have for the area of the opening
in the core, H x D = (2x1500)/(1200x0.24) = 10.42 sq. in. If the length H of the window is
made equal to about 2.5 the width D , we may try the dimensions H = 4 ½ in. and D = 2 ¼
in. The width D may be altered later if necessary to accommodate the coils.
A rough estimate must now be made of the core cross section in order that the lengths of
wire in the windings may be calculated. The total flux in the core will depend upon the total
voltage to be generated in the secondary and not only on the amount of the external
burden. We shall assume the total burden (including secondary winding and connecting
 leads) to be 15 volt-amp which, with the secondary current of 5 amp, means that the flux in
the core must develop 3 volts in the 400 turns of secondary winding.
Thus,
4 × 108
𝜃= = 3753.75 𝑚𝑎𝑥𝑤𝑒𝑙𝑙𝑠
4.44 × 60 × 400
Very low flux densities must be used in order to avoid exceeding the limits of error as
specified. If we use a good quality of silicon – steel, which is a cheaper material than nickel –
steel, we may select a flux density as low as B’’ = 2000 lines per sq. in. This leads to a core
section about 1 ½ in. by 1 ½ in. which, with a stacking factor of 0.89, makes the cross
section of iron equal to 1.5 x 1.5 x 0.89 = 2.00 sq. in.

Items 8 to 14. For the primary winding we need a copper cross section of about 1000/1500
= 0.667 sq. in. and, since we have to insulate for 6900 volts, we shall assume a winding layer
4 ¼ in. long, leaving ½ in. at each end between high – tension winding and core. Two strips
in parallel, each 0.96 by 0.35 in., wound one on top of the other to make one layer of ten
turns will probably be satisfactory. The current density in primary is therefore 1000/[2(0.66
x 0.33)] = 2295.68 amp per sq. in. For the secondary, the length of layer may be 4 ¾ in.
There will be ten layers of No. 13 square dcc wire with 0.005-in. paper between layers.
As a check on width of window opening, and in order to calculate length of wire, we have
the total thickness of coil built up as follows:

` t = 0.125
Secondary coil consisting of 10 layers of wire with 0.005-in. paper s = 1.07
between layers, and a small allowance for “bulging”
Insulation between primary and secondary, built up of press – board, g = 0.15
varnished cambric, or flexible mica, and cotton tape (no oil ducts)
Primary coil, two layers of dcc copper strip 0.16 in. thick, with allowance p = 0.45
for bulging
Insulation, primary to core (same as g) 0.15
Total Σ = 1.945 in

With a window opening D = 1.945 in., there should be plenty of room to accommodate the
windings. The reason why this dimensions is appreciably less than the estimated 2 in. is that
the windings are all in one limb instead of on both limbs as in power transformers, and also
that solid insulation has been used there are no ducts for oil circulation. The mean length
per turn of primary is 1.37 ft., and of the secondary, 1.577 ft. The weight of primary is 2.58
lb., and of secondary, 7.43 lb.
Items 15 to 18. From the wire table on page 431, the resistance per 1000 ft. of square No.
13 wire is found to be 2.3280 ohms at 600C. Whence the secondary resistance at 750C is
2.3280 X 0.213 X [(235+75)/(235+60)] = 0.521 ohm, and the IR drop is 0.521 X 5 = 2.605
volts. Including connections between transformer and instrument, this drop might be 0.5
volts. In order to calculate the total burden (internal plus external), we have for the
instrument burden, IZ = 12.5/5 = 2.5 volt; IR = 2.5 x 0.9 = 2.25 volt, and IX = 2.5 x 0.436 =
1.09 volt. If we assume the reactance of the secondary winding and leads to be negligible,
the total IR is 2.75 and the total IX is 1.09. Tan Ө = 1090/4450 = 0.245; whence (from
trigonometric tables) cos Ө = 0.971 and sin Ө = 0.238. The total emf to be developed in the
secondary winding is 2.75/0.971 = 2.83 volts, and the total secondary burden is 2.83 x 5 =
14.15 volt – amp.

Items 19 to 27. The corrected window dimensions are 5 ¼ by 1 189/200 in. The total flux is
φ = 4.58x108/(4.44 x 60 x 400) = 4298.05 Maxwell; whence B’’ = 4298.05/2 = 2149.03 lines
per sq. in. when the secondary current has its full rated value of 5 amp.
The mean length of flux path in the core is 2(5 ¼ + 1 189/200 + 3) = 20 39/100 in.
The weight of iron is 20.39 x 2 x 0.28 = 11.42 lb.

Items 28 to 31. From Fig. 1 we read the ampere – turns per inch for the iron (silicon – steel),
about 0.4 for B’’ = 2865.37, and 0.08 for B’’ = 286.537. From Fig. 179 we read watts per
pound = 0.0025 for B’’ = 2865.37. It is practically impossible to read the losses at one-tenth
rated burden from this curve, but by assuming the iron loss to vary as B1.6, we have for B’’ =
286.54, watts per pound = 0.0025 x (1/10)1.6 = 0.000062797.

In calculating the magnetizing current component we shall make no allowance for joints in
the magnetic circuit because the reluctance of the joints is negligible at very low flux
densities. Then, by formula at full load,
𝑎𝑚𝑝𝑒𝑟𝑒 − 𝑡𝑢𝑟𝑛𝑠 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑐𝑜𝑟𝑒
𝐼𝑂 =
√2 𝑇𝑝

20.50 𝑥 0.4
𝐼𝑂 = = 2.90 𝑎𝑚𝑝
√2 𝑥 2

and at one-tenth load, Io = 0.29 amp.

By formula at full load,

 𝑇𝑜𝑡𝑎𝑙 𝑃𝑜𝑤𝑒𝑟 𝐿𝑜𝑠𝑠 𝑖𝑛 𝑐𝑜𝑟𝑒 𝑖𝑛 𝑊𝑎𝑡𝑡𝑠 𝑇𝑝
𝐼𝑤 = ( )
𝐸𝑠 𝑇𝑠
400 11.42 𝑥 0.0025
𝐼𝑤 = ( ) = 1.25 𝑎𝑚𝑝
2 4.58
and at one tenth load,

400 11.42 𝑥 0.000062797

𝐼𝑤 = ( ) = 0.3132 𝑎𝑚𝑝
2 0.458

Items 32. By formula (151), the tangent of the phase angle with 100 percent rated current is
2.90 cos 25.84 − 1.25 sin 25.84
tan 𝛼 = = 0.0021
400
× 5
2
whence α = +7’.
Similarly, with one – tenth rated current, we have tan α = 0.0004 and α = +1’.

These results are well within the specified limit of 20 min.

Item 33. If we leave the secondary winding unchanged with 400 turns, the ratio with full –
rated current, by formula;
𝐼𝑝 𝐼𝑤 cos ∅ + 𝐼𝑜 sin ∅ 𝑇𝑝
= +( )
𝐼𝑠 𝐼𝑠 𝑇𝑠
𝐼𝑝 1.25 cos 25.54 + 2.90 sin 25.84 400
= +( )
𝐼𝑠 5 2
𝐼𝑝
= 200 + 0.478
𝐼𝑠

and with one – tenth rated current,

𝐼𝑝 0.3132 cos 25.54 + 0.58 sin 25.84 400
= +( )
𝐼𝑠 5 2
𝐼𝑝
= 200 + 0.1069
𝐼𝑠

the maximum percentage ratio error being 100 x (0.1069/200) = 0.0535 which is well within
the specified limit of 0.5 percent. If desired, this error can be reduced by altering the
number of secondary turns. Thus, if we remove one turn of the secondary, the
compensation for ratio error is 399/2 -200 = -0.5, which makes the actual ratio at full load
equal to 40.378 and at one – tenth load, 40.007, the percentage errors being 0.0533 and
0.273 respectively.
Since the calculated performance of this transformer is somewhat better than that called
for in the specification, it is possible that some saving of material might be effected (1) by
reducing the number of primary turns from 7 to 6, without decreasing the core section, or
(2) by leaving the number of turns unchanged and slightly decreasing the core section. The
greatest saving in weight would be obtained by using nickel – steel instead of silicon – steel
for the transformer core.

Effect of overload on temperature of windings. A short circuit may cause the current
through the primary windings of current transformers to be from fifty to one hundred times
the rated full – load value, and, unless the circuit breakers interrupt this current in a very
short interval of time, the instrument transformer may burn up. This is apart from possible
mechanical injury which will be considered in the following chapter.

In order to calculate with maximum length of time during which such a condition may exist
without damage from overheating, it is usual to neglect the very small amount of heat
which will be dissipated by surface radiation and consider merely the thermal capacity of
the coils.

Assuming that a temperature above 180°C would be injurious to the insulation, and that the
copper temperature is 75°C under normal operating conditions with 1000 amp in primary,
the permissible rise of temperature is 180 – 75 = 105°C.

The primary copper loss when the current is 200 amps at a density of 2295.68 amp per sq.
in. may be calculated by formula in Art. 130. Thus, at 75°C, the loss in the primary coils is
2.57∆2
𝑊𝑎𝑡𝑡𝑠 𝑙𝑜𝑠𝑡 𝑝𝑒𝑟 𝑝𝑜𝑢𝑛𝑑 𝑜𝑓 𝑐𝑜𝑝𝑝𝑒𝑟 =
106
2.57(2295.68)2
𝑊𝑎𝑡𝑡𝑠 𝑙𝑜𝑠𝑡 𝑝𝑒𝑟 𝑝𝑜𝑢𝑛𝑑 𝑜𝑓 𝑐𝑜𝑝𝑝𝑒𝑟 = × 0.043 = 0.58 𝑤𝑎𝑡𝑡𝑠
106

The permissible watt – seconds per pound of copper are calculated as explained in Art. 64,
and, since 177 watts will raise the temperature of 1 lb of copper 1°C in 1 sec, the
permissible amount of heat which can be stored in the primary coil before the temperature
becomes excessive is 177 x 0.0043 x 105 = 799.16 watt – sec. Suppose that, under short –
circuit conditions, the current through transformer primary may be fifty times normal, or
1000 x 50 = 50 000 amp. The rate at which energy in the form of heat is being stored in the
copper will be 0.58 x (50)2 = 1450 watts, and since 799.16/1450 = 0.55 sec, this is the
maximum time during which the short – circuit current may pass through the coil without
damage to the transformer.

FIGURES

Fig. no. 1 Cross section through current transformer of illustrative examples of Art. 151 in
the book of Elements of Electrical Machine Design by Still and Siskind
 TABLES AND GRAPHS

Figure no. 2 Table of Wire Table, Square Double-Cotton-Covered Copper Wires

Figure no. 3 Magnetization curves for low values of flux density for current transformer

Figure no. 4 Watts loss per lb. at 60 cycle

 REFERENCES

Still & Siskind. Elements of Electrical Machine Design. Current Transformer. Pp 396-
403. March 11, 2019.

Wikipedia.com. Instrument Transformers.

https://en.wikipedia.org/wiki/Instrument_transformer. March 19, 2019

Wikipedia.com. Current Transformers.

https://en.wikipedia.org/wiki/Current_transformer. March 19, 2019

Electronics Hub. Potential Transformer

https://www.electronicshub.org/potential-transformers/. March 19, 2019