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Home (/) /  Blog (/blog) /  Minimizing Transformer Inrush Current

Minimizing Transformer Inrush Current

Saturday, June 13, 2015

I have used three di erent Methods depending on the details of a speci c project plus I do not use the Method 4.

Method 1. Secondary pre-charge

This is normally the most economical Method. It uses a small pre-charge transformer to apply a voltage to the transformer's secondary
and I normally use 90% of the rated transformer's secondary voltage. The required current is approximately the transformer's
magnetizing current. A typical value is 0.5% of the rated winding current for a transformer with a single secondary. A resistor is normally
used between the pre-charge transformer and the main transformer to limit the initial current transient.

For this Method 1 to work a suitable AC voltage is required to feed the pre-charge transformer that is in phase with the operating voltage
of the main transformer's secondary winding. When the pre-charge current is applied the transformer's primary voltage will eventually
settle at to approximately 90% of the rated primary voltage. Most importantly the voltage across the transformer's primary breaker will
be very low so that it can be closed with virtually no inrush current.

I normally use a check-synch relay for the transformer's primary breaker as a safety check. Provided the transformer's primary voltage on
pre-charge is above 80% of rated the transformer's inrush current will be low. This gives the basis of the Method 1 and extra parts are
needed for protection switching, isolation and optimal operation.

Method 2. Primary pre-charge

This Method 2 can be used when a suitable AC power supply (http://www.gohz.com/) for Method 1 is not available, but needs an extra AC
supply energizing switch in addition to the transformer's primary breaker. The extra AC power supply energizing switch is connected via 3
pre-charge resistors to the transformer's primary connections.

When the extra AC power supply energizing switch is operated a lower inrush current can be achieved. After a short delay the
transformer's primary breaker is energized which shorts out the 3 pre-charge resistors, that can be short time rated. This gives the basis
of the Method 2 and extra parts are needed for protection switching, isolation and optimal operation.

Method 3. Transformer design

For Method 2 the cost of the extra parts can be signi cant. Method 3 is used when either Methods 1 & 2 are not viable or Method 3 is
acceptable versus the extra cost. Data from the internet gives the following data shown in ""
Laissez un message
"Transformers can be designed for reduced inrush current characteristics by tweaking some of the variables in the design process but
this requires certain compromises and inevitably a higher cost. Some factors that contribute to reducing the inrush current are:

1. Lower operating ux density reduces inrush. Typically larger core and/or more turns.
2. Leakage Impedance. Leakage of primary winding to core not just impedance de ned by the primary/secondary leakage.
3. Large primary winding area. Position in winding, layers and air ducts.
4. Relative number of conductor turns and relative core size
5. Core magnetic properties and its geometry."

I have used high impedance transformers, with impedances of 15%, to minimize inrush current.

Method 4. Di erential plus timed closing of transformer's primary breaker

I have not used this Method 4 for transformers due to the unknown residual ux level. When the transformer's primary breaker is
opened its currents will continue to a near zero value. However some breakers will arc chop at a low current level leaving residual ux in
the transformer's core.

Di erential plus timed closing of transformer's primary breaker works very well for avoiding over voltage transients in harmonic / power
factor correction (http://www.gohz.com/power-factor-correction) capacitor circuits.

For good results it is essential to discharge the capacitors before closing and a simple circuit is used to do this.

Tags: Transformer (/blog/tag/Transformer) , AC Power Source (/blog/tag/AC%20Power%20Source) , Basics (/blog/tag/Basics)

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Comments
Guest

Created on: 10/8/2016 6:26 AM

Is inrush current seen by the protective relay at the primary side or secondary side of transformer?

Guest

Created on: 10/8/2016 6:39 AM

Inrush current is dependent on where in the voltage cycle the transformer is switched on. In steady state operation the applied
voltage is opposed by the rate of change of ux, thus at peak voltage the rate of change of ux is at its peak and is passing through
zero. So in simplistic terms if switching on of a transformer is done at peak voltage when the ux is zero there will be no inrush
current, but if switching is done at zero voltage then there will be the largest inrush current as the transformer saturates in the next
half cycle of the applied voltage. This will continue for every other half cycle to a lesser extent each time until the ux attains the
steady state sinusoidal form. During inrush the ux will be a distorted sinusoid with a decaying dc component. Hence the inrush
current will be distorted. I have seen inrush currents of 10 times normal full load current, but it depends very much on the B-H curve
and how conservative the designer has been.

Guest

Created on: 2/4/2017 11:09 AM

relation between permeability of core and inrush current

Guest

Created on: 5/9/2018 11:11 AM

how to nd discharge resistors value? Any formula?

Guest

Created on: 5/27/2018 5:55 AM

"Transformers can be designed for reduced inrush current characteristics by tweaking some of the variables in the design process but
this requires certain compromises and inevitably a higher cost. Some factors that contribute to reducing the inrush current are:

Lower operating ux density reduces inrush. Typically larger core and/or more turns.
Leakage Impedance. Leakage of primary winding to core not just impedance de ned by the primary/secondary leakage.
Large primary winding area. Position in winding, layers and air ducts.
Relative number of conductor turns and relative core size
Core magnetic properties and its geometry."
I have used high impedance transformers, with impedances of 15%, to minimize inrush current

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