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The Voltech Handbook of Transformer Testing

Description
This article covers a wide range of transformer theory and Voltech's testing capability.
The Voltech Handbook of Transformer Testing
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Expand 1 Transformer Basics1 Transformer Basics
Collapse 2 Available Tests2 Available Tests
2.1 CTY - Continuity
2.2 R - Winding Resistance
2.3 RLS or RLP - Equivalent Series or Parallel R
2.4 LS_LP - Primary Inductance
2.5 LSB_LPB - Inductance With Bias Current
2.6 QL - Q factor
2.7 D - Dissipation Factor
2.8 LL - Leakage Inductance
2.9 C - Inter-winding Capacitance
2.10 TR - Turns Ratio and Phasing
2.11 TRL - Turns Ratio by Inductance
2.12 Z_ZB - Impedance_Impedance with Bias
2.13 R2 - DC Resistance Match
2.14 L2 - Inductance Match
2.15 C2 - Capacitance Match
2.16 GBAL - General Longitudinal Balance
2.17 LBAL - Longitudinal Balance
2.18 ILOS - Insertion Loss
2.19 RESP - Frequency Response
2.20 RLOS - Return Loss
2.21 ANGL - Impedance Phase Angle
2.22 PHAS - Inter-winding Phase Test
2.23 TRIM - Trimming Adjustment
2.24 OUT - Output To User Port
2.25 IR - Insulation Resistance
2.26 HPDC - DC HI-POT
2.27 HPAC - AC HI-POT
2.28 SURG - Surge Stress Test
2.29 STRW - Stress Watts
2.30 MAGI - Magnetizing Current
2.31 VOC - Open Circuit Voltage
2.32 WATX - Wattage (External Source)
2.33 STRX - Stress Watts (External Source)
2.34 MAGX - Magnetizing Current (Ext. Source)
2.35 VOCX - O.C. Voltage (External Source)
2.36 LVOC - Low Voltage Open Circuit
2.37 ILK - Leakage Current
2.38 LSBX - Inductance with External Bias (Series)
2.39 LPBX - Inductance with External Bias (Parallel)
2.40 ZBX - Impedance with External Bias
2.41 ACRT - AC HI-POT Ramp
2.42 DCAT - DC HI-POT Ramp
2.43 ACVB - AC Voltage Break Down
2.44 DCVB - DC Voltage Break Down
2.45 WATT - Wattage
2.0 Available Tests On The AT Series
Expand 3 Examples of Different Transformer Types3 Examples of Different Transformer Types

2.34 MAGX - Magnetizing Current (External Source)

Where Used

The AT offers two basic alternative ways to confirm that the transformer has been assembled properly, with the appropriate number of primary and secondary turns, the right grade of magnetic material for the core, and the correct air gap if required.

Magnetising current and open circuit voltage are the preferred tests for line frequency transformers, designed to operate over the full extent of the B-H curve, including the non-linear regions. (For other transformers, such as pulse transformers and those used in switched mode power supplies, inductance and turns ratio are the preferred tests.)

This version of the MAGI test uses an external source to provide the test signal, which must be coupled to the tester via a Voltech AC Source Interface (contact your supplier for details).

See the AC Source Interface user manual or the Editor help system for details of how to configure external ac sources for use with an AT.

Measurement Conditions

When measuring magnetising current, you should normally program the test to apply the highest working voltage at the lowest working frequency to the primary winding.

In the case of a transformer with a split primary, the test can be conducted equally well by energising just one of the primary windings, as opposed to the two in series. The expected current will be greater for the single winding, rising in proportion to the turns ratio: -

IA = IAB x (NAB / NA)

Where
IA = The current to be specified when testing with winding A
IAB = The current for windings A and B in series
NA = The number of turns on winding A
NAB = The number of turns on A and B in series

(As an alternative, the formula above can be written using the voltage ratio between the two windings, rather than the turns ratio.)

In principle, you may measure the magnetising current using any winding, or any series combination of windings, with the current limit adjusted according to the formula above, because the Ampere-turns required to magnetise a transformer to a given flux level is independent of which winding is used.

In practice, the magnetising current waveform may have a transient component following the switch-on of the test voltage.

To give repeatable accurate results, the measurement does not start until any transient has settled.

The test signal can have a frequency in the range 20Hz to 5KHz, and an amplitude from 5V to 600V depending on the type of external source used.

The current rating of a single AC Source Interface is 10A rms.

See also the MAGI test which uses the ATs internal generator, which can provide up to 270V ac at 25W.

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