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Transfopower Industries (Private) Limited was established in 1993 to manufacture distribution transformers (Pole Mounted
& Kiosks), power transformers and special purpose transformers to meet the requirement for the local market i.e: WAPDA,
KESC, AJK and Private Sector as well as export markets.
Presently, we are manufacturing transformers from 5KVA to 5000KVA for WAPDA, KESC, AJK and the Private Sector. Also
Furnace Transformers have been manufactured for Steel Mills in Pakistan and Africa. We also manufacture special purpose
transformers designed for specific application.
Our transformers are designed by a team of qualified engineers. The manufacturing process is supervised by experienced
engineers and a strict quality control is assured at all stages. Tests according to relevant standards are carried out before
despatch.

"- / 0 -/!0!- ! 
Design, Manufacture & Sale of Distribution, Power, Furnace and Special Transformers

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‡ Distribution Transformers ‡ Power Transformers ‡ Furnace Transformers ‡ Special Transformers

Specific requirement of the customers

‡ Dry Type Transformers ‡ Non flammable Transformers

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The manufacturing of transformers is according to customer¶s requirements corresponding to the following standards:
8 !/- c
± International Electro Technical Commission (1974 Edition, Test on Hollow Insulator for use in Electrical Equipment)
8 !/-(,
±International Electro Technical Commission (1976 Edition & Use for Transformers)
8 !/-(c&,
±International Electro Technical Commission (1982 Edition & Use for Oil)
8 9 1 () 
() ±Water & Power Development Authority
(2003 Edition & Use for Transformers)
A  7 is an electrical device that transfers energy from one circuit to another purely by magnetic coupling. Relative
motion of the parts of the transformer is not required for transfer of energy. Transformers are often used to convert between
high and low voltages, to change impedance, and to provide electrical isolation between circuits.

777
An ideal transformer would have no losses, and would therefore be 100% efficient. In practice energy is dissipated due both
to the resistance of the windings (known as È

 ), and to magnetic effects primarily attributable to the core (known as
   ). Transformers are in general highly efficient, and large power transformers (around 100 MVA and larger) may
attain an efficiency as high as 99.75%. Small transformers such as a plug-in "power brick" used to power small consumer
electronics may be less than 85% efficient.

The losses arise from:

 9
  77 5

Current flowing through the windings causes resistive heating of the conductors.

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: 5 7

Induced currents circulate in the core and cause its resistive heating.

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Not all the magnetic field produced by the primary is intercepted by the secondary. A portion of the leakage flux may induce
eddy currents within nearby conductive objects such as the transformer's support structure, and be converted to heat. The
familiar hum or buzzing noise heard near transformers is a result of stray fields causing components of the tank to vibrate,
and is also from magnetostriction vibration of the core.

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Each time the magnetic field is reversed, a small amount of energy is lost to hysteresis in the magnetic core. The level of
hysteresis is affected by the core material.

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The alternating magnetic field causes fluctuating electromagnetic forces between the coils of wire, the core and any nearby
metalwork, causing vibrations and noise which consume power.

  75

The flux in the core causes it to physically expand and contract slightly with the alternating magnetic field, an effect known
as magnetostriction. This in turn causes losses due to frictional heating in susceptible ferromagnetic cores.

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Large power transformers may be equipped with cooling fans, oil pumps or water-cooled heat exchangers designed to
remove the heat caused by copper and iron losses. The power used to operate the cooling system is typically considered
part of the losses of the transformer.
Transformers for use at power or audio frequencies have cores made of many thin laminations of silicon steel. By
concentrating the magnetic flux, more of it is usefully linked by both primary and secondary windings. Since the steel core is
conductive, it, too, has currents induced in it by the changing magnetic flux. Each layer is insulated from the adjacent layer
to reduce the energy lost to eddy current heating of the core. A typical laminated core is made from E-shaped and I-shaped
pieces, leading to the name "EI transformer".

Certain types of transformer may have gaps inserted in the magnetic path to prevent magnetic saturation. These gaps may
be used to limit the current on a short-circuit, such as for neon sign transformers.

A steel core's magnetic hysteresis means that it retains a static magnetic field when power is removed. When power is then
reapplied, the residual field will cause a high inrush current until the effect of the remanent magnetism is reduced, usually
after a few cycles of the applied alternating current. Overcurrent protection devices such as fuses must be selected to allow
this harmless inrush to pass. On transformers connected to long overhead power transmission lines, induced currents due
to geomagnetic disturbances during solar storms can cause saturation of the core, and false operation of transformer
protection devices.

Distribution transformers can achieve low off-load losses by using cores made with amorphous (non-crystalline) steel, so-
called "metal glasses" - the high cost of the core material is offset by the lower losses incurred at light load, over the life of
the transformer.

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In circuits that operate above mains frequencies, up to a few tens of kilohertz, such as switch-mode power supplies,
powdered iron cores are used. These materials combine a high magnetic permeability with a high bulk material resistivity. At
even higher frequencies, typically radio frequencies, other types of core made of non-conductive magnetic materials, such
as various ceramic materials called a , are common. Some transformers in radio-frequency circuits have adjustable
cores which allow tuning of the coupling circuit.

ë 

High-frequency transformers may also use air cores. These eliminate the loss due to hysteresis in the core material. Such
transformers maintain high coupling efficiency (low stray field loss) by overlapping the primary and secondary windings.

 

 

Toroidal transformers are built around a ring-shaped core, which is made from a long strip of silicon steel or permalloy
wound into a coil, or from ferrite, depending on frequency. The strip construction ensures that all the grain boundaries are
pointing in the optimum direction, making the transformer more efficient by reducing the core's reluctance. The ring shape
eliminates the air gaps inherent in the construction of an EI core. The cross-section of the ring is usually square or
rectangular, but more expensive cores with circular cross-sections are also available. The primary and secondary coils are
wound concentrically to cover the entire surface of the core. This minimises the length of wire needed, and also provides
screening to prevent the core's magnetic field from generating electromagnetic interference.

Ferrite cores are used at frequencies up to a few tens of kilohertz to reduce losses, particularly in switch-mode power
supplies.

Toroidal transformers are more efficient (around 95%) than the cheaper laminated EI types. Other advantages, compared to
EI types, include smaller size (about half), lower weight (about half), less mechanical hum (making them superior in audio
amplifiers), lower exterior magnetic field (about one tenth), low off-load losses (making them more efficient in standby
circuits), single-bolt mounting, and more choice of shapes. This last point means that, for a given power output, either a
wide, flat toroid or a tall, narrow one with the same electrical properties can be chosen, depending on the space available.
The main disadvantage is higher cost.
A drawback of toroidal transformer construction is the higher cost of windings. As a consequence, toroidal transformers are
uncommon above ratings of a few kVA. Small distribution transformers may achieve some of the benefits of a toroidal core
by splitting it and forcing it open, then inserting a bobbin containg primary and secondary windings.

When fitting a toroidal transformer, it is important to avoid making an unintentional short-circuit through the core. This can
happen if the steel mounting bolt in the middle of the core is allowed to touch metalwork at both ends, which could result in
a dangerously large current flowing in the bolt.

9
 7

In most practical transformers, the primary and secondary conductors are coils of conducting wire because each turn of the
coil contributes to the magnetic field, creating a higher magnetic flux density than would a single conductor.

The winding material depends on the application. Small power and signal transformers are wound with insulated solid
copper wire, often enameled. Larger power transformers may be wound with wire, copper or aluminum rectangular
conductors, or strip conductors for very heavy currents. High frequency transformers operating in the tens to hundreds of
kilohertz will have windings made of Litz wire, to minimize the skin effect losses in the conductors. Large power
transformers use multiply-stranded conductors as well, since even at low power frequencies non-uniform distribution of
current would otherwise exist in large windings. Each strand is insulated from the others, and the strands are arranged so
that either at certain points in the winding or throughout the winding, each portion occupies different relative positions in the
complete conductor. This "transposition" equalises the current flowing in each strand of the conductor, and reduces eddy
current losses in the winding itself. The stranded conductor is also more flexible than a solid conductor of similar size. ( see
reference (1) below)

Windings on both primary and secondary of a power transformer may have external connections (called taps) to
intermediate points on the winding to allow adjustment of the voltage ratio; taps may be connected to automatic on-load tap
changer switchgear for voltage regulation of distribution circuits. Audio-frequency transformers used for distribution of audio
to public address loudspeakers have taps to allow adjustment of power supplied to each speaker. A center-tapped
transformer is often used in the output stage of an audio power amplifier in a push-pull circuit. Tapped transformers are also
used as components of amplifiers, oscillators, and for feedback linearization of amplifier circuits.

! 7

The conductor material must have insulation to ensure the current travels around the core, and not through a turn-to-turn
short-circuit.

In power transformers, the voltage difference between parts of the primary and secondary windings can be quite large.
Insulation is inserted between layers of windings to prevent arcing, and the transformer may also be immersed in
transformer oil that provides further insulation. To ensure that the insulating capability of the transformer oil does not
deteriorate, the transformer casing is completely sealed against moisture ingress. The oil serves as both cooling medium to
remove heat from the core and coil and as part of the insulation system.

"
 

Although an ideal transformer is purely magnetic in operation, the proximity of the primary and secondary windings can
create a mutual capacitance between the windings. Where transformers are intended for high electrical isolation between
primary and secondary circuits, an electrostatic shield can be placed between windings to minimize this effect.

Transformers may also be enclosed by magnetic shields, electrostatic shields, or both to prevent outside interference from
affecting the operation of the transformer, or to prevent the transformer from affecting the operation of other devices (such
as CRTs in proximity to the transformer).
- 

All transformers must have some circulation of coolant to remove the waste heat produced by losses. Small transformers up
to a few kilowatts in size usually are adequately cooled by air circulation. Larger "dry" type transformers may have cooling
fans. Some dry transformers are enclosed in pressurized tanks and are cooled by nitrogen or sulfur hexafluoride gas.

The windings of high-power or high-voltage transformers are immersed in transformer oil - a highly-refined mineral oil that is
stable at high temperatures. Large transformers to be used indoors must use a non-flammable liquid. Formerly,
polychlorinated biphenyl (PCB) was used as it was not a fire hazard in indoor power transformers and it is highly stable. Due
to the stability of PCB and its environmental accumulation, it is no longer permitted in new equipment. Today, nontoxic,
stable silicone-based oils or fluorinated hydrocarbons may be used, where the expense of a fire-resistant liquid offsets
additional building cost for a transformer vault. Other less-flammable fluids such as canola oil may be used but all fire
resistant fluids have some drawbacks in performance, cost, or toxicity compared with mineral oil.

The oil cools the transformer, and provides part of the electrical insulation between internal live parts. It has to be stable at
high temperatures so that a small short or arc will not cause a breakdown or fire. The oil-filled tank may have radiators
through which the oil circulates by natural convection. Very large or high-power transformers (with capacities of millions of
watts) may have cooling fans, oil pumps and even oil to water heat exchangers. Oil-filled transformers undergo prolonged
drying processes, using vapor-phase heat transfer, electrical self-heating, the application of a vacuum, or combinations of
these, to ensure that the transformer is completely free of water vapor before the cooling oil is introduced. This helps
prevent electrical breakdown under load.

Oil-filled power transformers may be equipped with Buchholz relays - safety devices sensing gas buildup inside the
transformer (a side effect of an electric arc inside the windings) and switching off the transformer.

Experimental power transformers in the 2 MVA range have been built with superconducting windings which eliminates the
copper losses, but not the core steel loss. These are cooled by liquid nitrogen or helium.

 7

Very small transformers will have wire leads connected directly to the ends of the coils, and brought out to the base of the
unit for circuit connections. Larger transformers may have heavy bolted terminals, bus bars or high-voltage insulated
bushings made of polymers or porcelain. A large bushing can be a complex structure since it must both provide electrical
insulation, and contain oil within the transformer tank.

/ 57

Small transformers often have no enclosure. Transformers may have a shield enclosure, as described above. Larger units
may be enclosed to prevent contact with live parts, and to contain the cooling medium (oil or pressurized gas).

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7 7

 77

An autotransformer has only a single winding, which is tapped at some point along the winding. AC or pulsed voltage is
applied across a portion of the winding, and a higher (or lower) voltage is produced across another portion of the same
winding. For voltage ratios not exceeding about 3:1, an autotransformer is less costly, lighter, smaller and more efficient
than a two-winding transformer of a similar rating.

By exposing part of the winding coils and making the secondary connection through a sliding brush, an autotransformer with
a near-continuously variable turns ratio can be obtained, allowing for very small increments of voltage.
:47  77

Wye and delta winding connections

For three-phase power, three separate single-phase transformers can be used, or all three phases can be connected to a
single polyphase transformer. The three primary windings are connected together and the three secondary windings are
connected together. The most common connections are Y-ǻ, ǻ-Y, ǻ-ǻ and Y-Y. A vector group indicates the configuration
of the windings and the phase angle difference between them. If a winding is connected to earth (grounded), the earth
connection point is usually the center point of a Y winding. There are many possible configurations that may involve more or
fewer than six windings and various tap connections.

7    77

A resonant transformer is one that operates at the resonant frequency of one or more of its coils. The resonant coil, usually
the secondary, acts as an inductor, and is connected in series with a capacitor. If the primary coil is driven by a periodic
source of alternating current, such as a square or sawtooth wave, each pulse of current helps to build up an oscillation in
the secondary coil. Due to resonance, a very high voltage can develop across the secondary, until it is limited by some
process such as electrical breakdown. These devices are therefore used to generate high alternating voltages. The current
available from this type of coil can be much larger than that from electrostatic machines such as the Van de Graaff
generator and Wimshurst machine. They also run at a higher operating temperature than standard units.

A voltage regulating transformer uses a resonant winding and allows part of the core to go into saturation on each cycle of
the alternating current. This effect stabilizes the output of the regulating transformer, which can be used for equipment that
is sensitive to variations of the supply voltage. Saturating transformers provide a simple rugged method to stabilize an ac
power supply. However, due to the hysteresis losses accompanying this type of operation, efficiency is low.

! 7   77

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Current transformers used as part of metering equipment for three-phase 400 ampere electricity supply

A 5   7 is designed to provide a current in its secondary which is accurately proportional to the current
flowing in its primary.

Current transformers are commonly used in electricity meters to facilitate the measurement of large currents which would be
difficult to measure more directly.

Care must be taken that the secondary of a current transformer is not disconnected from its load while current is flowing in
the primary as in this circumstance a very high voltage would be produced across the secondary.

Current transformers are often constructed with a single primary turn either as an insulated cable passing through a toroidal
core, or else as a bar to which circuit conductors are connected.
Ò


 

Voltage transformers (also known as potential transformers) are used in the electricity supply industry to measure
accurately the voltage being supplied. They are designed to present negligible load to the voltage being measured.

7  77

A 47  7 is a transformer that is optimised for transmitting rectangular electrical pulses (that is, pulses with fast
rise and fall times and a constant amplitude). Small versions called 
 types are used in digital logic and
telecommunications circuits, often for matching logic drivers to transmission lines. Medium-sized
 versions are used in
power-control circuits such as camera flash controllers. Larger
 versions are used in the electrical power distribution
industry to interface low-voltage control circuitry to the high-voltage gates of power semiconductors such as TRIACs, IGBTs,
thyristors and MOSFETs. Special high voltage pulse transformers are also used to generate high power pulses for radar,
particle accelerators, or other pulsed power applications.

To minimise distortion of the pulse shape, a pulse transformer needs to have low values of leakage inductance and
distributed capacitance, and a high open-circuit inductance. In power-type pulse transformers, a low coupling capacitance
(between the primary and secondary) is important to protect the circuitry on the primary side from high-powered transients
created by the load. For the same reason, high insulation resistance and high breakdown voltage are required. A good
transient response is necessary to maintain the rectangular pulse shape at the secondary, because a pulse with slow edges
would create switching losses in the power semiconductors.

The product of the peak pulse voltage and the duration of the pulse (or more accurately, the voltage-time integral) is often
used to characterise pulse transformers. Generally speaking, the larger this product, the larger and more expensive the
transformer.

0  77

For radio frequency use, transformers are sometimes made from configurations of transmission line, sometimes bifilar or
coaxial cable, wound around ferrite cores. This style of transformer gives an extremely wide bandwidth, however only a
limited number of ratios (such as 1:9, 1:4 or 1:2) can be achieved with this technique. The ferrite increases the inductance
dramatically while also lowering its Q factor. The cores of such transformers help performance at the lower frequency end of
the band. This style of transformer is frequently used as an impedance matching balun to convert from 300 ohm balanced to
75 ohm unbalanced in FM receivers.


  77

Traditionally, in the valve amplifier, the function of the output transformer was to convert the low alternating current music
signal (that had been imposed on top of the high-voltage direct current from the plate electrode of the final output tube) into
a useable high-current/low-voltage level for conversion by the loudspeakers.

In early transistor amplifiers, such transformers were also used.

277   77

 Electric power transmission over long distances.

 High-voltage direct-current HVDC power transmission systems
 Large, specially constructed power transformers are used for electric arc furnaces used in steelmaking.
 Rotating transformers are designed so that one winding turns while the other remains stationary. A common use
was the video head system as used in VHS and Beta video tape players. These can pass power or radio signals from a
stationary mounting to a rotating mechanism, or radar antenna.
 Sliding transformers can pass power or signals from a stationary mounting to a moving part such as a machine
tool head. An example is the linear variable differential transformer,
 Some rotary transformers are precisely constructed in order to measure distances or angles. Usually they have a
single primary and two or more secondaries, and electronic circuits measure the different amplitudes of the currents in the
secondaries, such as in synchros and resolvers.
 Small transformers are often used to isolate and link different parts of radio receivers and audio amplifiers,
converting high current low voltage circuits to low current high voltage, or vice versa.
 Balanced-to-unbalanced conversion. A special type of transformer called a balun is used in radio and audio
circuits to convert between balanced circuits and unbalanced transmission lines such as antenna downleads. A balanced
line is one in which the two conductors (signal and return) have the same impedance to ground: twisted pair and "balanced
twin" are examples. Unbalanced lines include coaxial cables and strip-line traces on printed circuit boards. A similar use is
for connecting the "single ended" input stages of an amplifier to the high-powered "push-pull" output stage.

With thousands of types of transformers in use today, the distinction between power transformers and distribution
transformers may be arbitrary, depending on your trade. Not many distinct differences will apply.

75  7

Tiny power transformers work in electronic devices.

A basic transformer has two coils, a primary and secondary. Electricity applied to the primary coil induces power into the
secondary, either to increase or decrease it, or isolate it for numerous reasons and applications.

 7 

1. The number of coils in the primary of a transformer compared to those of the secondary determines the turns ratio
and also the output. A ratio of 1:2 with 100 volts applied would put out 200 volts, and vice-versa.

;  7

2. A power transformer like the one on the pole outside a house changes 480 volts to 240. But a power transformer
in a radio transmitter may connect and boost the signal from the power amplifier to the antenna lead.

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3. A distribution transformer in a neighborhood power grid may distribute electricity to several homes. A distribution
transformer in a TV set may produce several different voltages to power different circuits.

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7

4. A power transformer usually has one primary and one secondary, and one input and output. A distribution
transformer may have one primary and one divided or "tapped" secondary, or two or more secondaries.

;*17<  77

5. Depending on the trade, the terminology can change. For example, a TV set that has one transformer to change
the input to several other voltages could be called either a power or a distribution transformer.