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IJISET - International Journal of Innovative Science, Engineering & Technology, Vol.

4 Issue 1, January 2017


ISSN (Online) 2348 – 7968 | Impact Factor (2015) - 4.332
www.ijiset.com

Design Analysis and Parametric Modeling of Harmonics Effects


on a 1.5kva Single Phase Wooden Cross Cutting Machine Step
Down Transformer
France O. Akpojedje1, Yussuf O. Abu2 and Clement Agbeboaye3
P P P P P P P P

1,3
P Department of Electrical/Electronic Engineering Technology, National Institute of Construction Technology,
P

Uromi, Nigeria.
2
PDepartment of Science Laboratory Technology, University of Benin, Benin City, Nigeria.
P

Abstract for the design, construction and operation of many


This paper aims at x-raying the design analysis and electrical and electronics devices [4]. The principle
parametric modeling of harmonics effects on a of operation is based on the basic principle of
1.5KVA single phase wooden cross cutting electromagnetic induction which was discovered by
machine step down electric service transformer. Michael Faraday in 1813 [4].
The literature survey was considered and the Transformers are basically passive devices for
research work was realised through analytical transforming voltage and current [5]. One of the
designs and parametric modeling of harmonics windings, generally termed as secondary winding,
effects on a single phase, core type electric service transforms energy through the principle of mutual
transformer which steps down the 240volts mains induction and delivers power to the load [5]. The
voltage to the appropriate voltage level of 120volts. voltage levels at the primary and secondary
The electric service transformer has efficiency of windings are usually different and any increase or
96.02% with maximum load efficiency of 42.69%, decrease of the secondary voltage is accompanied
and 5.07% of total losses in the system. This by corresponding decrease or increase in current
research work will be relevant to transformer [5]. Transformers are among the most efficient
designers and students, as it exposes the full design machines; 95% efficiency being common in lower
analysis and calculations of transformers; and its capacity ranges, while an efficiency of the order of
basic parametric models. 99% is achievable in high capacity range [5].
Keywords: Design and analysis, losses, model, According to Evbogbai and Obiazi [6],
magnetic flux density, parametric, transformer transformers can be manufactured from locally
calculations materials as reported in their work titled "Design
1.0 INTRODUCTION and construction of small power transformers using
Transformers are veritable tools in electrical power locally available materials". The study showed that
system and their functions are significant especially electrical machines could be constructed locally
in stepping up and stepping down (transformation) since Nigeria is blessed with iron, steel, and the
of voltages/currents for appropriate usage. The availability of copper and aluminum conductors for
advent of transformer has given leverage to long the windings [4].
transmission of electricity from the point of In this research work we trying to get clear cut for
production to the point of consumption. Electricity design analysis and parametric modeling of
is a particularly attractive form of energy that can harmonics effect of a 1.5KVA single phase wooden
be easily produced, transmitted and transformed cross cutting machine step down transformer in
into other form of energy [1]. The transformation carpentry workshop of the School of Engineering
of voltage and current in electricity supply is Technology, National Institute of Construction
carried out by an apparatus called the transformer. Technology, Uromi, Nigeria.
"Transformers are very useful in many electrical 1.2 TYPES OF TRANSFORMERS IN
circuits. Consequently, the transformer is a device TERMS OF CONSTRUCTION
which plays a vital and essential role in many Transformers are classified according to their
facets of electrical engineering" [2]. Therefore, construction into two main types namely: Core and
"Transformer is a static (stationary) piece of Shell types [7]:
apparatus by means of which electric power in one a. Core Type Transformer
circuit is transformed into electric power of the Every transformer consists of a magnetic
same frequency in another circuit" [3]. It can raise circuit of laminated iron core with which
or lower the voltage in a circuit but with the electric circuits, primary and
corresponding decrease or increase in current secondary are linked. The coils in this
[3].The importance of transformer in voltage type are cylindrical in form and placed
transformation in our everyday life cannot be one inside the other with proper
overemphasized [4]. Transformer forms the basis insulation between them. The portion of

97
IJISET - International Journal of Innovative Science, Engineering & Technology, Vol. 4 Issue 1, January 2017
ISSN (Online) 2348 – 7968 | Impact Factor (2015) - 4.332
www.ijiset.com
the core over which comes the windings Window space factor K w = R R 10 = 0.33
is called limb or leg whereas the core 30 + kv
which connects the two limbs are called
the yoke. The cross - sectional area of the Type of construction : core type
yoke is normally greater than that of the Cooling medium : Air Natural Air Natural
limb but it may be equal also. (ANAN)
b. Shell Type Transformer
In the shell type of transformer, both the 1.4.2 DESIGN ANALYSIS AND
windings, low voltage (L.V) and high CALCULATIONS
voltage (H.V) are put around the central Core - Design
limb. The winding is called the Sandwich The voltage per turn, Et = K S (1)
winding where flat rectangular or circular
coils, alternately L.V and H.V., are E t = 0.98V
R R

arranged one above the other with the


necessary insulation between them. The
cross - sectional area of the central limb
is twice that of the side limbs as it carries Calculating the core area, A i R

double the flux than the side limbs. Et


Consequently, the width of the central Ai =
limb is twice that of the side limbs 4.44 FBm (2)
keeping the same core depth throughout.

1.3 MATERIALS AND METHODS


A 1.5KVA, 240volts, single phase transformer A i = 35cm2
R R P

transform the mains voltage to 120volts; 12.5amps


to power a single phase wooden cross cutting Calculating the magnetic flux, φm
machine in the Civil Engineering Department of
the School of Engineering Technology in the φ m = Ai B m (3)
National Institute of Construction Technology,
Uromi, Edo State, Nigeria. The transformer was φm = 4.38 mWb
designed using indigenous knowledge in view of Calculating the diameter of circumscribing
local materials available for its realization. The circle around core, d
harmonics effect was analyzed to mitigate any Since the transformer is core type and square
possible losses that may be caused by it. The section that is to be used.
wooden cross cutting machine, its function is to A gross = 0.5d2
R R (4) P P

provide cross cutting wooden materials for a


specified purpose(s). The wooden cross cutting
machine provides human-machine interface with its A i = k s A gi
R R R R R R (5)
function of optimizing cutting in wooden materials. Assuming stacking factor k s = 0.9 R R

Ai
1.4 DESIGN SPECIFICATIONS AND ⇒d = (6)
ANALYSIS .0.9 x 0.5
1.4.1 DESIGN SPECIFICATIONS d = 8.82cm
The machine design procedure for core and shell
types of power and distribution transformers have Calculating the width of lamination
been reported by [ 5 & 7]. The design differences Since, the core is to be square section,
lies on the specifications of the machine to be Width of lamination is (a) = 0.71d (7)
designed and plan. = 6.26cm
The following are the specifications of the single Calculating the net window area (A w ) R R

phase wooden cross cutting machine step down


The expression for the output power of a
electric service transformer that the design strives
to achieve. single phase transformer is:
KVA 1-ph = S = 2.22f B m A i A w K w δx10-3 (8)
R R R R R R R R R R P P

Power rating, S = 1.5KVA


Input voltage, V 1 = 240V
R R

A w = S x103∕ 2.22f B m A i K w δ
R R P P R R R R R R

Output voltage, V 2 = 120V


R R

Frequency, F = 50Hz
Maximum flux density, B m = 1.25wbm-2 A w = 32.18 cm2
R R R R P

However, A w = H w xW w (9)
R R P

Current density, δ = 2.5A/mm2 = 2.5x106 Amp/m2


P P P P P
R R R R R R

Constant K = 0.8 Window Design

98
IJISET - International Journal of Innovative Science, Engineering & Technology, Vol. 4 Issue 1, January 2017
ISSN (Online) 2348 – 7968 | Impact Factor (2015) - 4.332
www.ijiset.com

Calculating the core dimensions T 1 = 245 turns


R R

The centre - to - centre distance of the core is Calculating the secondary turn, T 2 R

twice the core width, i.e (stack) T2 = V2/ Et


R R R R (19) R R

This will be equal to 2x0.71d = 1.42d (10) T 2 = 122 turns


R R

= 12.52cm Calculating the conductor size for the


Centre - to - centre distance between limbs primary and secondary windings
Limbs = W w x d R R The cross sectional of the conductor is:
(11) A = I/δ (20)
W w x d = 12.52
R R
Calculating the primary conductor size, A 1 R

W w = 12.52 - d From equation 20, A 1 = I 1 /δ R R R R

A 1 = 2.5mm2
R R

W w = 3.7cm
R R P

R R

Calculating the secondary conductor size, A 2 R

From equation 20, A 2 = I 2 /δ


Therefore, H w = 8.70cm
R R R R

R R

A 2 = 5mm2
Calculating overall core height, H
R R P

Calculating the diameter of the conductor


The overall core height, H
Area, A = πd 2 4
H = H w + 2(0.71d) R (12)
R
(21)
H = 21.22cm 4a
Calculating the overall with of core, W
∴d =
π (22)
The overall width of core, W
W = W w + d + 0.71d R (13)R
Where d = diameter of the conductor
W = 18.78cm Calculating the diameter of the primary
Yoke Design conductor, d 1 R

Calculating the stack height, S h R

4x 2.5
Stack height, S h d1 = = 1.7mm
π
R R
R R

Ai
Sh = Calculating the diameter of the secondary
0.9 x 0.71d
(14) conductor, d 2 R

35
= = 6.21cm 4x5
0.9 x 0.71 x 8.82 d2 = = 2.52mm
π
R R

Calculating the number of lamination, n L R

d 1 corresponds to standard wire gauge of 15


R R

nL = R R stack height d 2 corresponds to standard wire gauge of 12


R R

thickness of laminar (15) Calculating the window space factor, k w R

Kw = R 10 = 0.33
R

n L = 207
R R (23)
30 + kv
Calculating the current for both primary and
secondary circuits Calculating the mean length per turn (L mt ) R R

Given the output power, S = 1.5KVA


for both primary and secondary coils
The primary voltage (Input voltage) V 1 = 240V
L mt = (L mt1 + L mt2 )/2 = πD m = π[d + W w /2] (24)
R R

Input current at the primary winding of the


R R R R R R R R R R

transformer is: L mt = 0.3352m


R R

I 1 = S/ V 1
R R (16)
R R
Calculating the length of primary turns, L 1 R

I 1 = 6.25A
R R
Length of primary coils, L 1 = L mt x T 1 R R R R R R (25)
I 2 = S/ V 2
R R (17)
R R

L 1 = 82.12m ≈ 82m
I 2 = 12.5A
R R

Calculating the length of secondary turns, L 2


R R

Given the voltage per turn, E t = 0.98V


R

Length of secondary coils, L 2 = L mt x T 2 (26)


R R

Calculating the primary turn, T 1 R


R R R R R R

T1 = V1/ Et
R R R R (18) R R
L 2 = 40.89m ≈ 41m
R R

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IJISET - International Journal of Innovative Science, Engineering & Technology, Vol. 4 Issue 1, January 2017
ISSN (Online) 2348 – 7968 | Impact Factor (2015) - 4.332
www.ijiset.com

Calculating the resistance of the primary Calculating resistance drop per unit in the coils
winding, R 1 R
or winding for both primary and secondary
R 1 = ρL 1 / A 1
R R R R R R (27) Calculating the resistance drop per unit winding
R 1 = 0.5584Ω
R R
for primary
Calculating the resistance of the secondary P.U. resistance drop, ε r1 = I 1 R 1 /V 1 R R R R R R R R (41)
winding, R 2 R ε r1 = 0.0145pu
R R

R 2 = ρL 2 / A 2 R R R R R R (28) Calculating resistance drop per unit winding for


R 2 = 0.1390 Ω
R R

secondary
Calculating the yoke dimensions P.U. resistance drop, ε r2 = I 2 R 2 /V 2 R R R R R R R R (42)
Calculating the depth of the yoke, D y R
ε r2 = 0.01458pu
R R

D y = a = 2 x 0.71d
R R (29) Calculating the inductance of coils or turns for
D y = 12.52cmR R both primary and secondary windings
Calculating the area of the yoke, A y R
Calculating the inductance of primary turns,
A y = 1.2A y = 1.2 x 0.5d2 = 0.6 d2
R R R R

PR
P P P P (30) L L1 R

A y = 46.68cm2
R R P
L L1 = T 1 Φ/I 1
R R R R R R (43)
Calculating the height of the yoke, h y R
L L1 = 171.70 H
R R

h y = A y /D y
R R (31) R R R R
Calculating the inductance of secondary turns,
h y = 3.73cm
R R
L L2 R

Calculating the weight of the iron core, W ic R


L L2 = T 2 Φ/I 2
R R R R R R (44)
Weight of iron core = L L2 = 42.75 H R R

(iron volume) x (iron density) (32) Calculating the weight of iron in core and yoke
Volume of iron core = total length of mean assembly
flux path (L m ) x iron area (A i ) R R R R (33) Weight of two limbs in a core = 2h w A i D L R R R R R R (45)
L m = 2[W w + d] + 2[H w + a]
R R R R R R (34) = 4.628kg
L m = 54.96cm
R R
Weight of one yoke = WA y D L R R R R (46)
Volume of iron core = Lm x A i R R (35) = 6.663kg
= 1923.6cm 3
P
Calculating the core losses in limb and yoke
Weight of iron core (W ic ) = Lm x A i x D R R R R (36) Core loss in limb = 2 x weight of limb (47)
= 1923.6 x 7.870 x10 -3 = 15.138kg P P
= 9.256Watts
Calculating the weight of both primary and Core loss in yoke = 1.4 x weight of yoke (48)
secondary coils or windings, W c R R
= 9.328Watts
The weight of primary coils or winding, W c1 R R
Total core loss (Iron loss) (P i ) = R R

W c1 = DA 1 LmtT 1 R R R R R R
core loss in yoke + core loss in limb (49)
(37) P i = 18.584Watts
R R

W c1 = 1.83kg R R
Total losses in the transformer (P T ) = copper losses R R

The weight of secondary coils or winding, W c2 R R


(P c ) + iron losses (P i )
R R R R

W c2 = DA 2 LmtT 2 R R R R R R (38) PT = Pc + Pi
R R R R R R (50)
-
W c2 = 1.82kg R R
P T = 62 x 10 3 kW
R R P P

Total weight of copper in transformer, W T R


Calculating the load for maximum efficiency
W T = W c1 + W c2 R R R R R R (39) For maximum efficiency to occur:
= 3.65kg X2P c = P i P P R R R R (51)
Calculating the total copper loss, P c Pi
⇒X = (52)
R

2 2
Pc = I1 R1 + I2 R2
R R R RP P R R R RP P R R Pc
(40) X = 0.4269
P c = 43.53 watts
R R

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IJISET - International Journal of Innovative Science, Engineering & Technology, Vol. 4 Issue 1, January 2017
ISSN (Online) 2348 – 7968 | Impact Factor (2015) - 4.332
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Meaning that the maximum efficiency occurs at are as follows: transformers, converters, generators,
0.4269 times of full load. Recall that the maximum motors, fluorescent lighting, electric ballast, arc
efficiency of a distribution (service) transformer welding machine etc.
occurs at or near 1/2 full load. The interest of harmonics effect is placed on the
Calculating the efficiency of the service subject because of the harmfulness they have on
transformer power system and its equipment. The harmonics
Efficiency at full load and unity P.F (ᶯ T ) = R R effect are enormous and they include: overheating,
[Output power/Output power + losses] x 100 vibration, reduction of system efficiency, aging of
ᶯR
T R = [Output power/Input power] X 100 (53) system installation, poor system power factor,


inaccurate operation of system protection
T = 96.02%
equipment, humming of system machines, increase
R R

1.5 PARAMETRIC MODELING AND in system I2R losses etc. P P

ANALYSIS OF HARMONICS EFFECTS ON 1.5.2 PARAMETRIC MODELING OF


ELECTRIC SERVICE TRANSFORMER HARMONICS EFFECTS ON ELECTRIC
The impact of harmonics currents on transformers SERVICE TRANSFORMER
is more serious on convectional conductors because "The effect of harmonics in electric service
the resistive skin effect is enhanced within closely - transformer increase the eddy current and
spaced transformer windings [8]. Harmonics are hysteresis losses in the system. But transformers
one of the major power quality problems that are designed to deliver the required power to the
exists. Harmonics are complex waveforms load with minimum losses at the fundamental
produced due to the superposition of sinusoidal frequency"; though the multiple integer of the
waves of different frequencies [3]. The flux fundamental frequency increases losses in the
density in transformer is usually maintained at a system. Hence, the harmonics of the devices in the
fairly high value in order to keep the required system are modeled through the copper losses since
volume of iron to the minimum; but due to the non- the copper loss is the summation of eddy current
linearity of magnetisation curve, some third loss (P e ) and hysteresis (P h ) losses in the system
R R R R

harmonic distortions are always produced [3]. respectively. If the output voltage is small, then the
Most electric service transformers are highly output current increases which causes great heat
vulnerable to overheating, leading to insulation and losses in the system. The total losses of a
damage which causes the premature failure of the transformer are obtained by calculating the sum of
transformer. As reported by [8], "The failure rate of these losses (P c ). R R

transformer caused by harmonics effect is very P c = P e + P h = K h fBx pk +K e (fB pk )2


R R R R R R R R P PR R R R R R P P (54)
high in India; around 25% per annum, which is Modeling copper losses under linear load condition
favourably comparable to international norms of 1 - due to resistance is given as:
2%". Therefore, an attempt was made in this P c = I2 L (R 1 + R 2 )/A 2
R R P PR R R R R R P P (55)
research work to analyse and carry out the Modeling nonlinear currents of different harmonic
parametric modeling of harmonics effect on the frequency:
1.5KVA service transformer. ∞

1.5.1 CAUSES OF HARMONICS AND


I L (t ) = I 2 Sin (wt + θ 2 ) + ∑ I 2h Sin (hwt + θ h ) (56)
h =1
EFFECTS ON ELECTRIC SERVICE When harmonic currents flow in the windings of
TRANSFORMER the electric service transformer, then they
The main sources or causes of harmonics in produces a voltage drop across the device
electrical power system are non-linear loads that which lead to copper losses under harmonics
produce harmonic voltage and current in the which is modeled as (P ch ): R R

system. The nonlinear load that causes harmonics

101
IJISET - International Journal of Innovative Science, Engineering & Technology, Vol. 4 Issue 1, January 2017
ISSN (Online) 2348 – 7968 | Impact Factor (2015) - 4.332
www.ijiset.com
∞ ∞ 2
Pch = ∑ Rh1 I h21 +  Ih 
∑R 2
I
h2 h2 (57)
I THD = ∑
n
  (64)
h =1 h =1 I 
R R

Where P ch is the copper losses under harmonic


h=2  (1 ) 
Consequently, the total harmonic distortion is
R R

environment, R h1 and R h2 are the primary and


the ratio between residue and effective value
R R R R

secondary winding resistance in the h - order


harmonic respectively, while I h1 and I h2 are the R R R R
of fundamental wave function:
primary and secondary currents. n

1.5.2.1 MODELING OF HARMONIC ∑V


h =1
h
2

VOLTAGE AND CURRENT DISTORTIONS δv = x 100% (65)


The power quality of a system can be impressed by V1
improving or better still minimising the harmonic 1.5.2.4 MODELING OF HARMONIC LEVEL
voltage and current distortions in power utility IN ELECTRIC SERVICE TRANSFORMER
devices. The most prominent thing is voltage and The harmonic level of the electric service
current which are non - sinusoidal quantities. transformer can be determined by the ratio between
Harmonic voltage function is modeled as: the effective value of the considered harmonic and
n
Vh (t ) = ∑ Vh 2 Sin(hwt + Yh )
effective value of the fundamental as shown in the
(58) parametric model below:
h =1
Vh
Similarly, the harmonic current function is Y Level = x 100% (66)
modeled as: V1
n Where Y level is the harmonic level of the
I h (t ) = ∑ I h 2 Sin(hwt + Y − φ h ) (59)
R R

transformer, V 1 is the fundamental voltage


R R

h =1
and V h is the harmonic voltage considered.
Where V h and I h are the RMS of each h - harmonic
R R

1.6 MITIGATION OF HARMONIC


R R R R

of voltage and current respectively while ω, ɸ h and


EFFECT ON ELECTRIC SERVICE
R R

Y h are the angular frequency, Phase angle


R R

difference and phase angle respectively as well. TRANSFORMER


1.5.2.2 MODELING OF HARMONIC Harmonics affect transformers primarily in
POWER DISTORTIONS two major ways: voltage harmonics and
The harmonic active power is modeled as follows:
current harmonics. "The voltage harmonics
n
Ph = ∑ V h I h Cosφ h (60) produces additional losses in the transformer
h =1 core as the higher frequency harmonic
The harmonic reactive power is modeled as: voltages set up hysteresis loops, which
n superimpose on the fundamental loop" [9].
Q h = ∑ V h I h S in φ h (61) "The second and a more serious effect of
h =1
harmonics is due to harmonic frequency
While the harmonic apparent power is
currents in the transformer windings" [9]. The
modeled as:
harmonic currents increase the net RMS
current flowing in the transformer windings
n n
Sh = ∑Vh2
h =1
∑I h =1
2
h (62)
which results in additional I2R losses [9]. P P

Winding eddy currents are circulating


1.5.2.3 MODELING OF TOTAL HARMONIC currents induced in the conductors by the
DISTORTION (THD) leakage magnetic flux [9]. And this winding
The total harmonic distortion is expressed through eddy current increases the losses in the system
the voltage and current distortion. by causing temperature rise in the windings.
Hence, total voltage harmonic distortion V THD is
In order to handle this losses and temperature
R R

modeled as:
2 effect the K - factor method is employed for
n  Vh  transformers that supply nonlinear load.
V THD
R R = ∑ 
V 
 (63)
The K - factor transformer is designed to
h=2  (1 ) 
accommodates the temperature rise caused by
Similarly, the total current harmonic distortion
current harmonic in the transformer windings.
I THD is modeled as:
In addition to the fundamental frequency
R R

losses. K - factor is a constant that specifies the

102
IJISET - International Journal of Innovative Science, Engineering & Technology, Vol. 4 Issue 1, January 2017
ISSN (Online) 2348 – 7968 | Impact Factor (2015) - 4.332
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ability of the transformer to handle harmonic F = Frequency (Hertz)


heating, as a multiple of the normal eddy K = Constant
δ = Current density (A/M2)
current losses which are developed by a
P P

Kw = Window space factor


sinusoidal current in the transformer
R R

Bm = Magnetic flux density (Telsa)


windings.
R R

T1 = R R Primary turns
A good engineering practice calls for the T2 = R R Secondary turns
derating of transformer that serves nonlinear Aw = R R Window area m2 P

loads to an equivalent 80% of the nameplate Ay = R R Area of yoke m2 P

A1 = Net core section m2


KVA [8].
R R P

A1 = Primary conductor section m2


The parametric modeling of the K - factor is
R R P

A2 = R R Secondary conductor section m2 P

given as: d1 = Primary conductor diameter, mm


k = ∑ I h2 h 2 (h = 1, 2, 3,  n )
R R

(67) d2 = R R Secondary conductor diameter, mm


a = Thickness of lamination
Et = R R E.M.F. per turn
IL =
R R Load current
1.7 CONCLUSION θ = Phase angle
Transformers are the major and most Lh = R R Harmonic inductance
important equipment in electrical power Rh = R R Harmonic resistance
ηT = Efficiency
system. Their role in changing voltage and
R R

Ih = Harmonic current
current levels cannot be overemphasized in
R R

Vh = Harmonic voltage
electrical power system. Hence, the full design
R R

δh = R R Total harmonic distortion


analysis and parametric modeling of YL = R R Harmonic level
harmonics effect of a 1.5KVA single phase V THD = R R Total harmonic distortion voltage
wooden cross cutting machine step down I THD =
R R Total harmonic distortion current
K = derating factor
electric service transformer has been
L mt = Mean length of turn
successfully presented in this research work.
R R

ω = Angular frequency
The transformer designs have been obtained PT = R R Total power loss
with step by step analysis and calculations in P ch = R R Harmonic copper losses in power
details. The methodology has been applied to LL = R R Inductance of winding R

1.5KVA single phase electric service Lm = Total length of mean flux path
transformer with a rated frequency of 50Hz. εr R R = Resistance drop per unit of coils
The importance of this research work lies on Wc = R R Weight of coils
the fact that a step by step design analysis and W ic = Weight of iron core R R

calculations of a single phase electric service REFERENCES


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R R

V 2 = Output voltage
Published by S.K. Kataria & Sons, 6, Guru
R R

AC = Alternating current
I1 =
R RInput current Nanak Market, Nai Sarak, Delhi. Part III, Pg. 1
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ISSN (Online) 2348 – 7968 | Impact Factor (2015) - 4.332
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Electrical and Power Engineering", 1(5), 2007. Pg.
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