Republic of the Philippines

POLYTECHNIC UNIVERSITY OF THE PHILIPPINES

INSTITUTE OF TECHNOLOGY
Engineering Technology Department

Instructional Material
for

TRANSFORMER REWINDING AND

MOTOR CONTROL
(ELEN 30022)

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 TABLE OF CONTENTS

Overview ………………………………………………………………………………………1
Learning Objectives ………………………………………………………………………1
Course Materials …………………………………………………………………………..1
Outline ………………………………………………………………………………………….2
Lesson 1
Orientation/VGMO ………………………………………………………………………..3
Self-Assessment …………………………………………………………………………….4
Lesson 2
2.a. History of Transformer ………………………………………………………….5-7
2.b. Basic Transformer Principle ……………………………………………………..7
2.c. Types of Transformer ……………………………………………………………8-13
Lesson 3
3.a. Basic Transformer Equation ……………………………………………………..14
3.b. Exercises Problem ……………………………………………………………………15
3.c. Transformer Connections ……………………………………………………16-20
Lesson 4
4.a. Transformer Rewinding Materials ……………………………………….21-24
4.b. Procedure of Transformer Rewinding ………………………………….25-38
Lesson 5
5.a. Motor Control Definition ………………………………………………………….39
5.b. Functions of Motor Control ……………………………………………………...40
5.c. Basic Control Device …………………………………………………………….41-44
Lesson 6
6.a. AC Motor Control …………………………………………………………………45-59
6.b. AC Motors ……………………………………………………………………………60-65
Lesson 7
7.a. DC Motor Control …………………………………………………………………66-69
7.b. DC Motors ……………………………………………………………………………70-74

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 Lesson 8
Basic Troubleshooting …………………………………………………………….75-76
EAMINATIONS
Midterm Examination ……………………………………………………………..77-78
Finals Examination ………………………………………………………………….79-81

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The Overview:
A transformer is an electrical device which, by the principles of electromagnetic induction,
transfers electrical energy from one electric circuit to another, without changing the frequency. The
energy transfer usually takes place with a change of voltage and current. Transformers either increases
or decreases AC voltage.

Single-phase and three-phase AC squirrel cage induction motors need some type of circuit to
initiate a start or stop function. Usually single-phase motors and smaller horsepower three-phase
motors can be started with full voltage across the line. However, larger horsepower three-phase motors
require reduced voltage starting techniques.

The Learning Objectives:

After successful completion of this lesson, you should be able to:

 Define transformer
 Classify the different materials of transformer
 Apply theories and principles for proper installation.
 Define AC/DC Motors
 Classify the different electrical motor components and their functions.
 Obtain necessary information from reliable sources and be able to express it coherently.
 Use various educational tools, videos, etc. for updated learning.

Course Materials:
Watch:
 How Does a Transformer Work? ( https://www.youtube.com/watch?v=vh_aCAHThTQ)
 Step-up and Step-down Transformers (https://www.youtube.com/watch?v=LujTXYrFPRs)
 Electric Motors (https://www.youtube.com/watch?v=Q6ufVj0uhaE)
 How does an Electric Motor work? (DC Motor)
(https://www.youtube.com/watch?v=CWulQ1ZSE3c)
 How does an Induction Motor work? (https://www.youtube.com/watch?v=AQqyGNOP_3o)
 Start - Stop Motor Relay Circuit (https://www.youtube.com/watch?v=SfxW4o00bEk)
 Motor Forward Reverse Star-Delta - Control Circuit
(https://www.youtube.com/watch?v=5E17fK1Pp1o)

Read:
 https://edisontechcenter.org/Transformers.html
 (A Brief History of Transformers, Jan 06, 2016)
 https://edisontechcenter.org/GreatBarrington.html
 http://www.electrical4u.com

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 OUTLINE
WEEK TOPIC ACTIVITIES
1 Orientation/VMGO Meeting via Messenger / Zoom
 History of transformer Activity and Assessment
2-3  Basic Transformer Principle
 Types of Transformer
 Basic Transformer Equation Assessment and Quiz No. 1
4-5
 Exercise Problems
6  Transformer Connections and its Functions Activity and Assessment
 Motor Control Definition
7-8  Functions of Motor Control
 Basic Control Device
AC Motor Control
9-10
 AC Motors
DC Motor Control
11-12
 DC Motors
13 Basic Troubleshooting

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 Lesson 1: Orientation/VGMO

The Overview:

The Polytechnic University of the Philippines (PUP) is a government educational institution

governed by Republic Act Number 8292 known as the Higher Education Modernization Act of 1997,
and its Implementing Rules and Regulations contained in the Commission on Higher Education
Memorandum Circular No. 4, series 1997. PUP is one of the country's highly competent educational
institutions. The PUP Community is composed of the Board of Regents, University Officials,
Administrative and Academic Personnel, Students, various Organizations, and the Alumni.

Governance of PUP is vested upon the Board of Regents, which exercises policy-making
functions to carry out the mission and programs of the University by virtue of RA 8292 granted by the
Commission on Higher Education. The University is administered by an appointed President by virtue of
RA 8292 and is assisted by an Executive Vice President and the Vice Presidents for Academic Affairs,
Student Services, Administration, Research, Extension and Development, and Finance.

The Learning Objectives:

After successful completion of this topic, you should be able to:

 Recite the vision, mission, goals and objectives of the University.

 Identify the content of the syllabus, references, classroom rules and regulations, and
grading system.

Course Materials:

Orientation:

Please read page 1 to 3 of this course material.

VMGO

University Vision

Clearing the paths while laying new foundations to transform the Polytechnic University of the
Philippines into an epistemic community.

University Mission

Reflective of the great emphasis being given by the country's leadership aimed at providing
appropriate attention to the alleviation of the plight of the poor, the development of the citizens, and

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of the national economy to become globally competitive, the University shall commit its academic
resources and manpower to achieve its goals through:

1. Provision of undergraduate and graduate education which meet international standards of

quality and excellence;
2. Generation and transmission of knowledge in the broad range of disciplines relevant and
responsive to the dynamically changing domestic and international environment;
3. Provision of more equitable access to higher education opportunities to deserving and qualified
Filipinos; and
4. Optimization, through efficiency and effectiveness, of social, institutional, and individual returns
and benefits derived from the utilization of higher education resources.

Self- Assessment 1:

1. What is the vision of Polytechnic University of the Philippines?

__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________

2. During this Covid19 pandemic, the University implements online or modular learning
platforms. Which among the missions of the University is being achieved by this?
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
_________________________________________________________________

Self-Assessment Answer 2:

1. Clearing the paths while laying new foundations to transform the Polytechnic University of
the Philippines into an epistemic community.

2. Generation and transmission of knowledge in the broad range of disciplines relevant and
responsive to the dynamically changing domestic and international environment;

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 Lesson 2:

2.a. History of transformer

2.b. Basic Transformer Principle
2.c. Types of Transformer
The Overview:

This history of the transformer is discussed in this topic. Electrical transformers trace their
lineage to the English scientist and inventor Michael Faraday and his discovery of the law of electro-
magnetic induction. Also known as Faraday’s Law, the theory describes the phenomena of electrical
voltage generated when a coil of wire was wrapped around an iron core. That current would flow
through the iron to an opposite side (the iron was shaped not unlike a donut), and current with different
voltage could be created using wire that had more or fewer turns. Thus, the electricity was induced.
American scientist Joseph Henry is also credited with inventing the concept of electromagnetic
induction. (A Brief History of Transformers, Jan 06, 2016)

The Learning Objectives:

After successful completion of this lesson, you should be able to:

 Understand the history of electrical transformer.

 Explain the basic principle of transformer.
 Differentiate the different types of transformer.

Course Materials:
Supplemental Materials:
 https://acupwr.com/blogs/news/80121091-a-brief-history-of-
transformers#:~:text=Electrical%20transformers%20trace%20their%20lineage,wrapped%20arou
nd%20an%20iron%20core.
 https://edisontechcenter.org/Transformers.html

2.a. History of Transformer

Who invented the transformer? Ottó Bláthy, Miksa Déri, Károly Zipernowsky of the Austro-
Hungarian Empire First designed and used the transformer in both experimental, and commercial
systems. Later on Lucien Gaulard, Sebstian Ferranti, and William Stanley perfected the design. See the
next question for more details.

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 When was the transformer invented?: The property of induction was discovered in the 1830's
but it wasn't until 1886 that William Stanley, working for Westinghouse built the first reliable
commercial transformer. His work was built upon some rudimentary designs by the Ganz Company in
Hungary (ZBD Transformer 1878), and Lucien Gaulard and John Dixon Gibbs in England. Nikola Tesla did
not invent the transformer as some dubious sources have claimed. The Europeans mentioned above did
the first work in the field. George Westinghouse, Albert Schmid, Oliver Shallenberger and Stanley made
the transformer cheap to produce, and easy to adjust for final use.

Where were the first transformers used? The first AC power system that used the modern
transformer was in Great Barrington, Massachusetts in 1886. Earlier forms of the transformer were used
in Austro-Hungary 1878-1880s and 1882 onward in England. Lucien Gaulard (Frenchman) used his AC
system for the revolutionary Lanzo to Turin electrical exposition in 1884 (Northern Italy). In 1891
mastermind Mikhail Dobrovsky designed and demonstrated his 3 phase transformers in the Electro-
Technical Exposition at Frankfurt, Germany.

Click on the link below to learn about the Great Barrington Electrification:
https://edisontechcenter.org/GreatBarrington.html

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 The AC demonstration system built in Great Barrington in 1886 by William Stanley, financed by
Westinghouse was the greatest achievement in AC power until that point. This single event inspired
George Westinghouse to dive into AC current system development with significant resources. This of
course led to Westinghouse's great achievements a few years later, which in turn led to the formation of
General Electric as an opposition to Westinghouse's success.

This event caught the attention of the entire electrical industry as it used the first modern
transformers to make a complete distribution system. Stanley's big contributions were the design of an
E-shaped core in the transformer and designing the induction coils in parallel instead of in series. Stanley
also got valuable experience from this to help him advance the field of AC generators and full AC system
design. Many engineers after this studied the Great Barrington experiment and learned from it.

William Stanley had worked for Westinghouse in Pittsburgh and decided to set up this single
phase AC experiment in Great Barrington, Massachusetts. Like many small but wealthy towns of the
time one of Edison's companies had already installed a direct current power system. Stanley's system
quickly showed superior flexibility in its use as Stanley kept adding more stores and mansions to his
system. The DC power system had a limited in distance and did not compete. Stanley's system was
however an experimental system designed to be proof of concept. It was short lived as the weak points
in the system in the system eventually shut the system down (Westinghouse's steam engine was
unreliable and the Siemens generator was 'unsatisfactory'). Stanley's transformers however proved to
be a major step forward on the AC side of the 'war of currents'.

2.b. Basic Transformer Principle

DEFINITION OF TRANSFORMER:

A transformer is an electrical device that transfers energy between two or more circuits through
electromagnetic induction. (From Wikipedia)

A transformer is a static machine used for transforming power from one circuit to another
without changing frequency. (http://www.electrical4u.com)

A transformer is a static electrical device that transfers electrical power from one alternating
current (ac) circuit to another without change in frequency.

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 Transformer basically works on the principle of mutual induction of two coils. A changing
current in the first coil(the primary winding) creates a changing magnetic field. This changing magnetic
field induces a changing voltage in the secondary circuit(the secondary winding). This effect is called
mutual induction. If a load is connected to the secondary circuit, electric charge will flow in the
secondary winding of the transformer and transfer energy from the primary circuit to the load
connected to the secondary circuit.

2.c. Types of Transformer

General types of Transformer:

1. Step-up transformer
2. Step-down transformer

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TYPES ACCORDING TO CONSTRUCTION OF IRON CORE:

1. Core Type Transformer

2. Shell Type Transformer

TYPES ACCORDING TO CONSTRUCTION OF IRON CORE:

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SHELL TYPE, IRON CORE:

TYPES ACCORDING TO CONSTRUCTION OF WINDINGS:

Two Winding Transformer Autotransformer

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TYPES ACCORDING TO LOCATION OF INSTALLATION:

Indoor Transformer

Outdoor Transformer

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TYPES ACCORDING TO USE:

Power Transformer

Distribution Transformer

Instrument Transformer

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TYPES ACCORDING TO NUMBER OF PHASES:

Activities/Assessments:
1. What is Transformer? Define in your own words.
2. Who invented the transformer?
3. Where were the first transformers used?
4. Differentiate the transformer according to location of installation.
5. What are the different types of transformer according to use?

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 Lesson 3:

3.a. Basic Transformer Equation

3.b. Exercises
3.c. Transformer Connections

3.a. Basic Transformer Equation

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3.b. Exercises

Answer this exercise using the given equation and use space provided below to
solve the following questions.

1.) The 2,300/230-volt, 60-cycle transformer has 4800 turns in the primary.
Calculate:

a.) Mutual flux,

b.) ratio of transformation,
c.) Number of secondary coil turns

Answer:

a.) 179,867.67 maxwells

b.) 10
c.) 480 turns

2.) The secondary winding of a 4,600/230-volt transformer has 36 turns. How

many turns are there in the primary winding?

Answer: 720 turns

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3.) The secondary load current of a 2,300/115-volt transformer is 46 amperes.
Calculate the primary current.

Answer: 2.3 amperes

3.c. Transformer Connections

Transformer Star and Delta Configurations

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TRANSFORMER CONNECTIONS

Primary - Secondary

Y - Y

Δ - Δ

Y - Δ

Δ - Y

V - V (OPEN DELTA)

WYE-WYE CONNECTION

A Wye-wye connection is suitable for transformer applications that do not

need a neutral on the primary side. The three-wire configuration can be used on
three-phase and single-phase circuits. In the event one of the transformers fails
prematurely or gets damaged, the entire system could become compromised.

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 DELTA-DELTA CONNECTION

The delta-delta connection provides a closed path for circulation of third

harmonic component of current. The flux remains sinusoidal which results in
sinusoidal voltages. Suitable for Unbalanced Load: Even if the load is unbalanced
the three phase voltages remains constant. Thus it suitable for unbalanced
loading also.

WYE-DELTA CONNECTION

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 The delta connection assures balanced line-to-neutral voltages on the wye
side whether or not there is a neutral conductor on the wye side, and it provides a
path for the third harmonic components in the exciting current independent of
the neutral conductor.

DELTA-WYE CONNECTION

The delta–wye connection is the most commonly used three-phase

transformer connection. The wye-connected secondary allows single-phase load
to be distributed among the three phases to neutral instead of being placed all on
one winding as with a four-wire delta secondary.

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 OPEN DELTA CONNECTION

Open delta transformers are rare and are typically only used for small loads
where cost is important.

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 Lesson 4:

4.a. Transformer Rewinding Materials

4.b. Procedure of Transformer Rewinding

MATERIALS:

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 IRON CORE: BOBBIN

E-CORE
I-CORE

MAGNETIC WIRE

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 CLAMP
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INSULATING PAPER / FISH PAPER EYELETS

MASKING TAPE

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4.b. Procedure of Transformer Rewinding

Disassembling the E & I core Rewinding

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 Connection Terminal

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 Assembly

TESTING

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 Varnishing

DRYING

FINAL TESTING

Course Materials:
Read:
Practical Electronics (By: Pagarigan)

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Types of Current in which a Transformer can be used

There are only two types of currents in which a transformer can be used

1. Alternating current. This is a type of current which reverse direction a number of times per second. In
a 60-cycle current, the direction of current flow is reversed 120 times per second.

2. Pulsating current. This is a type of current which flows intermittently, that is at first instant the
current flows from zero to maximum and back to zero value. At the second instant no current flow (zero
value). At the third instant, there is current flow again with the same value of the first instant. This
process is repeated again and again

A transformer cannot be used in direct current because direct current flows continuously
through the coils producing a constant amount of field flux embraced by the circuit. So, there will be no
cutting of magnetic lines of force by the coils. On the other hand, the alternating current induces current
in the transformer coils every time there is reversal of current flow since the fluxes being collapses and
increases thereby the coils cut the magnetic lines of force. Hence, alternating current is used in the
transformer to produce electromagnetic induction,

The pulsating current has different characteristics from that of the alternating current so that
the time of intermission of the pulsating current flow follows the collapse and built up of magnetic flux
which produce cutting of magnetic lines of force by the coil, thereby inducing current to the transformer
coils.

If a direct current can be changed into an intermittent direct current to produce the collapse of
magnetic lines of force, then it can be used as an exciter for a transformer which is of the same principle
as in the use of pulsating current. This is done by means of a vibrator which cuts the direct current
source intermittently. This principle is used in battery-operated radios

To summarize, a transformer will function accordingly as long as there is relative motion

between the coils and the built-up magnetic flux.

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Transformer Rewinding

With transformer rewinding goes the designing and computation of the necessary data required
to complete the work. It is always practical to make the job plan in rewinding to facilitate the work and
avoid mistake.

In rewinding a burnt-out transformer coil, the following are followed: steps

1. Coil stripping and core cleaning. These are to remove the burnt-out coil and clean the core by
using cleaning materials like pieces of rugs and fine emery cloth.
2. Designing and computation. These are to assemble the cleaned iron core and secure the
measurement of the center leg thickness and width in inches. Determine the design of the
transformer. If it is induction type-step down/step-up or auto-type step-down/step-up trans-
former, then compute the data required based on the measurement of the center leg of the iron
core.
3. Preparation of wood form and bobbin (coil insulation). The wood form is made out of an
ordinary wood prepared and formed with the same size of the center leg of the transformer
core. The bobbin or coil insulator is made out of fish paper thick enough to withstand pressure
and to protect the coil from the core. The size of the bobbin is just enough for the wood form to
be inserted in it.
4. Beginning of coil. Check the position of the iron core to determine where to anchor the
beginning of the coil. This is necessary to avoid the extreme legs of the core in obstructing the
terminals. Linen tape or friction tape is used to begin the coil.
5. Tapping of coil. This is usually done at the secondary winding by making center tap mid-way the
total number of turns in the secondary or tapping at any portion of the secondary following the
design.
6. Ending the coil. This is done after completing the number of turns in the primary or secondary
by using linen tape or empire cloth similar to the beginning of the coil.
7. Connecting the terminal wires. After ending the coil of the secondary winding, wrap a one-and-
a-half turn of fish paper to the finished coil and place terminal wires (stranded hook-up wire)
gauge number 18 by inserting it in the fish paper 1 terminal wire of 8 inches long for every
terminal of the coils, primary and secondary then make the joints and solder each connected
terminal
8. Applying insulating varnish. Apply insulating varnish on the finished coil and bake it till it gets
dry.
9. Assembling the transformer. Insert the laminated iron core piece by piece on the coil until
completed. This should be done slowly and carefully to avoid injuring the coil insulator while
inserting the core.
10. Testing the rewinded transformer. Test the primary and secondary winding with a multimeter to
determine any possible open or grounded winding. If found with no defect, test the transformer
to the 220-v outlet and measure the voltage output (secondary voltage) if it gives the same
voltage as designed.

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Transformer Design Computation

In designing and computing for data required in trans former rewinding, one method that can
be used involves the following steps with a given core material

1. Find the core area in square inches:

Ac = w x t

Where: Ac is the area of the core in square inch. W is the width of the center leg of the E-type
core and t is the thickness of the center leg.

2. Compute the number of turns per volt

T / V = k / Ac

Where: T/V is assumed as the number of turns per volt.

K is constant equal to 7.5 for a 60 cycle current. 12 for 25-cycles and 9 for 50-cycles, and
AC is the area of core center leg in sq. inch.

3. Find the total number of turns in the primary:

TP = EP x T/V

4. Find the total number of turns in the secondary:

TS = ES x T/V

5. Determine the type of winding to be employed, induction-type or auto type.

6. Determine the wattage of the core, if not given, by allowing 25 watts for every inch2 of the
core area. Refer to table 2 for output rating of transformer with given core area.
W = 25 x Ac

7. Find the current primary:

IP = W/EP

Where: IP is the assumed current primary; W is the wattage of the transformer; and EP is the
voltage of the primary or input voltage.

8. Find the current secondary:

IS = W/ES

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 Where: IS is the assumed current in the secondary; W is the wattage of the transformer; and
ES is the voltage of the secondary or output voltage.

9. Find the size of the wire to be used in the primary (cross sectional area in circular mils of
c.m.):

c.m. pri = IP x 1,000

Where: c.m. pri. Is the assumed circular unit area of wire for the primary;
IP is the current in the primary; and 1,000 is the constant value for c.m. area per ampere to
flow. See Wire Table 1.4 to determine the size of the wire in A.W.G. or B & S gauge.

10. Find the size of the wire to be used in the secondary (cross sectional area in circular mils)
area of wire for the secondary.

c.m. sec. = IS x 1,000

Where: c.m. sec. is the assumed circular mil area of wire for the secondary; IS the current in
the secondary, and 1,000 constant for circular mil area of wire that will allow one ampere to
flow. See Wire Table 1.4 to determine the size of the wire in A.W.G. or B & S gauge.

Example Problem: Design and compute the data required of a given transformer with core
size of 2 in. width and thickness of 1 ¾ in.; step-down (220volts/110volts) induction-type,
60-cycle frequency.

Steps:

1. AC = W x t

=2x1¾

= 2 x 1.75

= 3.50 in.2

2. T/V = K / AC

= 7.5 / 3.5

= 2.14 turns

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 3. TP = EP x T/V

= 220 x 2.14

= 470.8 turns primary

4. Ts = Es x T/V

= 110 x 2.14

= 235.4 turns secondary

5. Type of winding – Induction type

6. W = 75 x AC
= 75 x 3.50
= 262.50 watts

7. IP = W / EP
= 262.50 / 220
= 1.193 amperes

8. IS = W/EX
= 262.50 / 110
= 2.386 amperes

9. c.m. primary = IP x 1,000

= 1.193 x 1,000
= 1,193 circular mils

Size of wire in A.W.G. = #19

10. c.m. secondary = IS x 1,000

= 2.386 x 1,000
= 2,386 circular mils

Size of wire in A.W.G. = #16

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Another method used in computing the data required of transformer rewinding when the wattage is
given is shown as follows:

Example: Given wattage of transformer is 600 watts.

1. Core area (Ac) = √ / 5.58

Where: Ac is the core area;

600 is the given wattage; and
5.58 is constant for 60-cycle frequency

2. Turns per volt (T/V) = K / Ac

Where: T/V is the turns per volt;

K is constant 7.5 for 60-cylce frequency;
And AC is the area of the core.

3. Turns primary (Tp) = Ep x T/V

Where: Tp is the assumed turns primary;

Ep is the voltage primary
T/V is the number of turns per volt.

4. Turns primary (Ts) = Es x T/V

Where: Ts is the assumed turns secondary;

Es is the voltage secondary
T/V is the number of turns per volt.

5. Wattage = 600 watts, given

6. Current primary (Ip) = W / Ep

7. Current secondary (Is) = W / Es

8. Circular mil area of wires for primary = Ip x 1,000. For the result of the product for c.m. area, see
transformer wire table 1.4 to get the size of the wire in A.W.G. or B & S gauge.

9. Circular mil area of wire for secondary = Is x 1,000. For the result of the product for c.m. area,
see transformer wire table 1.4 to get the size of the wire in A.W.G. or B & S gauge.

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Here is another example for the transformer design for 60 cycle current when the primary wattage of
the transformer is given. Primary wattage equals 100 watts.

1. For core type:

T/V = 41 / √
= 41 / 10
= 4.1 turns

2. For shell type:

T/V = 32 / √
= 32 / 10
= 3.2 turns

Note: For a different frequency of current like 25-cycle current, the constant number to use is 97’ and
the formula for core T/V = 97 / √ = 97 / 10 = 9.7 turns

For shell type, the formula is:

T/V = 77 / √ = 77 / 10 = 7.7 turns

Another formula, to determine the number of turns in the primary winding (Tp) transformer design is:

Tp= 108 x Ep /4.44 x f x Ac x BM

Where: Tp is the assumed primary turns;

108 is a constant value, lines of force cur per second;
Ep is the voltage primary;
4.44 is a constant value; f is the frequency of current;
Ac is the core area, center leg; and
BM is the flux density in lines per inch2 which is 60,000 lines.

Example: Given Ep = 100 volts

F = 60 cycle
Ac = 2.4 inch2

Find Tp

Tp = 100,000,000 x 110 / 4.44 x 60 x 2.4 x 60,000

= 11,000,000,000 / 38,361,600
=286.7 or 287 turns

The size of the primary wire can be determines by using the power law, as in previous examples.

Power = volt x ampere.

Ampere = volt-ampere/voltage primary

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To determine the secondary turns, the following formula is used:

No. of turns in primary voltage in primary

=
No. of turns in secondary voltage in secondary

Since the number of turns in the primary has been found equal to 287 turns; the primary voltage is 110;
and the secondary voltage is 220, the formula can be substituted thus:

287/Ts = 110/220

Ts = 287 x 220 / 110 = 574 secondary turns

To this add 6% for core losses. Thus, 6% of 574 is equal to 34 turns allowance for losses. Therefore, the
total number of turns in secondary is 574 plus 34 equals 608 turns.
For the size of secondary wire, the above formula can be used:

Power = volt x ampere

Ampere = volt-ampere / Es

Then find the circular mil area of wire by multiplying the current by 1,000. For the result of the
product, wee wire table 1.4 for A.W.G. gauge or B & S gauge.

1circular mil = 0.001 inch

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37 | ELEN 30022 (Transformer Rewinding and Motor Control)
38 | ELEN 30022 (Transformer Rewinding and Motor Control)
 Lesson 5:

5.a. Motor Control Definition

5.b. Functions of Motor control
5.c. Basic Control Devices

Motor control is a broad term that means anything from a simple toggle
switch to a complex system with components such as relays, timers, and switches.
The common function of all controls, however, is to control the operation of an
electric motor.

AC controllers convert an input AC frequency into a DC current that

simulates an AC frequency, which can then be set by the user, thus controlling the
speed of the motor. This is accomplished using three main components: a
rectifier, an inverter, and a DC circuit that connects the two.
(https://www.thomasnet.com/articles/instruments-controls/ac-motor-
controllers/#:~:text=As%20previously%20stated%2C%20AC%20controllers,circuit%20that%20connects%
20the%20two.)

DC motor controller is any device that can manipulate the position, speed,
or torque of a DC-powered motor. There are controllers for brushed DC motors,
brushless DC motors, as well as universal motors, and they all allow operators to
set desired motor behavior even though their mechanisms for doing so differ.
(https://www.thomasnet.com/articles/instruments-controls/dc-motor-
controllers/#:~:text=What%20are%20DC%20motor%20controllers,of%20a%20DC%2Dpowered%20moto
r.&text=Also%2C%20unlike%20some%20AC%20motors,runs%20in%20the%20opposite%20direction.)

39 | ELEN 30022 (Transformer Rewinding and Motor Control)

5.b. Functions of Motor control

1. Starting
- across-the-line, ramping
2. Stopping
3. Jogging(Inching)
-momentarily connecting the motor to full
line voltage(reduced voltage)
4. Speed Control
- rheostat, VFD/VSD
5. Motor and Circuit Protection
- fuse, circuit breaker, overload relay
6. Surge Protection
- Metal Oxide Varistor(MOV)
voltage spikes produced by collapsing magnetic fields when power is
turned off
7. Forward-Reverse Control

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5.c. Basic Control Devices

TOGGLE SWITCH PUSH BUTTON SWITCH

ROTARY SWITCH

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 MAGNETIC CONTACTOR

RELAY

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 TIMING RELAY

OVERLOAD RELAY

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 MAGNETIC CONTACTOR WITH OVERLOAD RELAY

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 Lesson 6:

6.a. AC Motor Control

6.b. AC Motors

AC MOTOR STARTING METHODS:

1. Direct On Line Starting

2. Autotransformer Starting

3. Part winding Starting

2-step

3-step

4. Primary Resistor Starting

5. Wye-Delta Starting

Use of Centrifugal switch (Single Phase)

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DIRECT ON LINE STARTING

JOGGING

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JOGGING

INCHING

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 AUTOTRANSFORMER STARTING METHOD

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 PART WINDING STARTING METHOD (2-step)

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 PART WINDING STARTING METHOD (2-step)

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 PART WINDING STARTING METHOD (3-step)

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 PRIMARY RESISTANCE STARTING METHOD

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 WYE-DELTA STARTING METHOD

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SPEED CONTROL OF AC MOTORS

1. By percentage tap in stator windings

2. By Two winding(separate)

3. By One winding (consequent pole)

4. By varying the frequency

5. By varying armature resistance (wound rotor induction motor)

SPEED CONTROL OF single phase AC MOTORS (% tap in main winding)

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TWO-SPEED, TWO-WINDING (SEPARATE)

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TWO-SPEED, ONE-WINDING (CONSEQUENT POLE)

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TWO-SPEED, ONE-WINDING (CONSEQUENT POLE)

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SPEED CONTROL OF AC MOTORS (VFD)

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WOUND ROTOR INDUCTION MOTOR

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6.b. AC Motors

An AC motors is a type of electric motor that is powered from alternating

current source.

BASIC TYPES OF AC MOTOR

SINGLE PHASE MOTOR

-INDUCTION TYPE

- SYNCHRONOUS TYPE

THREE PHASE MOTOR

- INDUCTION TYPE

- SYNCHRONOUS TYPE

UNIVERSAL MOTOR

60 | ELEN 30022 (Transformer Rewinding and Motor Control)

SQUIRREL CAGE INDUCTION MOTOR
When AC source is applied to the stator, the stator coils will produce
rotating /revolving magnetic field. These rotating magnetic field are cut by
squirrel cage bars imbedded in the rotor producing induced voltage. Since both
ends of squirrel cage bars are connected by end rings, there are closed loops
between adjacent bars where currents flow. These current flows will also produce
magnetic field that will interact with the revolving field of the stator producing
torque or rotation of rotor.

INDUCTION TYPE (SQUIRREL CAGE)

61 | ELEN 30022 (Transformer Rewinding and Motor Control)

 AC MOTORS
SINGLE PHASE

INDUCTION TYPE (SQUIRREL CAGE)

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AC MOTORS
- POLYPHASE

INDUCTION TYPE(WOUND-ROTOR)

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 SYNCHRONOUS TYPE

UNIVERSAL MOTOR

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 SPEED CONTROL OF single phase AC MOTORS(3-speed)

SPEED CONTROL OF single phase AC MOTORS (4-speed)

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 Lesson 7:

7.a. DC Motor Control

7.b. DC Motors

DC MOTOR STARTERS:

1. The 3 Point Starter

2. The 4 Point Starter

3. Automatic Starter

THE 3 POINT STARTER

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 THE 4 POINT STARTER

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 THE AUTOMATIC STARTER

SPEED CONTROL OF DC MOTORS

1. By inserting rheostat in series with the field winding

2. By inserting rheostat in series with the armature winding

3. By varying the supply voltage

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 RHEOSTAT

SPEED CONTROL OF DC MOTORS

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7.b. DC Motors

The DC motor is a type of electric motor that is powered from direct

current source.

PRINCIPLE OF OPERATION

A current-carrying conductor generates a magnetic field. When this is then

placed in an external magnetic field, it experiences a torque and has a tendency
to move. This is known as motor action.

Fleming’s left hand rule

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CLASSIFICATION OF DC MOTORS

BRUSHED, PERMANENT MAGNET

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BRUSHED

-SERIES WOUND -SHUNT WOUND

-COMPOUND WOUND

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-BRUSHLESS, PERMANENT MAGNET

BRUSHLESS, VARIABLE RELUCTANCE

A reluctance motor is a type of electric motor that induces non-permanent

magnetic poles on the ferromagnetic rotor. The rotor does not have any windings.
Torque is generated through the phenomenon of magnetic reluctance.

73 | ELEN 30022 (Transformer Rewinding and Motor Control)

BRUSHLESS, STEPPER MOTOR

A stepper motor (or step motor) is a brushless DC electric motor that

divides a full rotation into a number of equal steps. The motor's position can then
be commanded to move and hold at one of these steps without any feedback
sensor (an open-loop controller), as long as the motor is carefully sized to the
application.

SERVO MOTOR

A servomotor is a rotary actuator that allows for precise control of angular

position, velocity and acceleration. It consists of a suitable motor coupled to a
sensor for position feedback. It also requires a relatively sophisticated controller,
often a dedicated module designed specifically for use with servomotors.

74 | ELEN 30022 (Transformer Rewinding and Motor Control)

 Lesson 8:

BASIC TROUBLESHOOTING

TRANSFORMER

CONNECTIONS FROM THE POWER SOURCE

If no power:

1. Check for open fuse.

2. Check if the windings are defective (i.e. open or burned).

3. Check for open power cord.

If the fuse keeps blowing:

1. Check for shorted components in the load.

2. Check if the windings are shorted.

75 | ELEN 30022 (Transformer Rewinding and Motor Control)

AC MOTOR (ELECTRIC FAN)

WIRING CONNECTIONS

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Name:

Section: Date: Grade:

Midterm Transformer Rewinding

I. Identification (2 points each)
1. Who invented the transformer?
Answer:
2. When was the transformer invented?
Answer:
3. Where were the first transformers used?
Answer:
4. It is an electrical device that transfers energy between two or more circuits through
electromagnetic induction.
Answer:
5. 2 General types of Transformer
Answer:

II. Enumeration

TRANSFORMER CONNECTIONS
1.
2.
3.
4.
5.

TYPES ACCORDING TO USE

1.

2.

TYPES ACCORDING TO LOCATION OF INSTALLATION

1.

2.

3.

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 III. (2pts. Each)

(2.5pts. Each)

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Name:

Section: Date: Grade:

Finals Transformer Rewinding and Motor Control

I. Identification (2 points each)

1. It is a broad term that means anything from a simple toggle switch to a

complex system with components such as relays, timers, and switches. The
common function of all controls, however, is to control the operation of an
electric motor.
Answer:
2. It is a type of electric motor that is powered from alternating current source.
Answer:
3. It is a brushless DC electric motor that divides a full rotation into a number
of equal steps.
Answer:
4. It is a rotary actuator that allows for precise control of angular position,
velocity and acceleration.
Answer:
5. It is a type of electric motor that is powered from alternating current source.
Answer:
6. It is an electrical device that transfers energy between two or more circuits
through electromagnetic induction.
Answer:
7. Where were the first transformers used?
Answer:
8. 2 types of transformer according to number of phases.
Answer:
9. Who invented the transformer?
Answer:
10. 2 types of transformer according to installation of location.
Answer:

79 | ELEN 30022 (Transformer Rewinding and Motor Control)

 II. Enumeration

FUNCTIONS OF MOTOR CONTROL

1.
2.
3.
4.
5.
6.
7.

3 TRANSFORMER TYPES ACCORDING TO LOCATION OF INSTALLATION

1.

2.

3.

BASIC TYPES OF AC MOTOR

1.

2.

3.

GIVE ATLEAST 7 PARTS OF TRANSFORMER

1.

2.

3.

4.

5.

6.

7.

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 III. (2pts. Each)

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82 | ELEN 30022 (Transformer Rewinding and Motor Control)