DESIGN OF THE LOW POWER MAINS TRANSFORMER

AI.1. Miscellaneous
· The single-phase low power mains transformer is a component part present in almost all types
of supply schemes of stationary electronic devices. It is destined to achieve following functions:
- Changes the values of voltages and currents, from the level where they are taken over by the
primary circuit, from the network, to the values demanded in the circuit or circuits of the
secondary;
- Assures the galvanic insulation to the network of the mounting board of the electronic device,
where it is mounted, thus assuring the electrical security of people that manipulates it.
· A mains transformer has following component parts (fig. AI.1):
- electric insulated coil formers;
- windings: primary and secondary;
- magnetic core;
- screw system of the core and fixing system of the transformer.

Fig. AI.1. Mounted mains transformer: 1 – coil former, 2 – windings, 3 – magnetic core, 4 – casing for
screwing the core, 5 – ears foreseen with fixing hole.

The primary and secondary windings are manufactured of copper or aluminium wires, insulated
with enamel and placed on a housing of electric insulated material (pressboard, textile laminate, glass
textile laminate, plastic material, etc.).
Inside the coil former is the magnetic core, formed of ferromagnetic laminations, screwed with
a casing. The laminations are obtained by press forming and afterwards they are submitted to an
annealing treatment for stress relieving and recovering of the magnetic properties affected by the
mechanic processing. The casing is achieved, also by pressing the iron sheet thick of 1-1,5 mm that is
afterwards galvanically covered (usually – passivated zinc coated). The entire transformer is usually
impregnated, through inertia in melted paraffin or in varnish that are polymerized through heating in
the furnace, at 80-100ºC.
For a better understanding of the design method of a distribution transformer, there are given at
the beginning some notions that interfere in calculus.

1
 Type of lamination. Usually there are used STAS-laminations, of type (E+I) – fig. AI.2. The
lamination sizes are mentioned by letter E, followed by the basic size of the lamination, a, expressed in
[mm].
Thus, there exist following types of laminations: E5, E6,4; E8; E10; E12,5; E14; E16; E18;
E20; E25, E32.
The main geometric parameters of a lamination (E+I) STAS are presented in figure AI.2. The
thickness of the laminations is g1 = 0,35 mm or g2 = 0,5 mm.
AF
a

a
a

2a

Fig. AI.2. Economical STAS-lamination: AF – area of the lamination window.

The area of the lamination window, AF [cm2] represents the surface destined to the
introduction of the windings and is presented shaded in figure AI.2.
Its value is given by the relation:

AF [cm2] = 0,03 · a2 [mm].

The iron section, SFe [cm 2] represents the area of the magnetic core section, situated inside the
winded housing (fig. AI.3).

SFe

Fig. AI.3. Cross section through the distribution transformer: SFe – iron section.

2
 The filling factor of the window, g, represents the ratio between the total area Atot [cm 2]
occupied by the windings in the lamination window and the area of the lamination window, AF [cm2]:

g =
[ ]
Atot cm 2
=
[ ]
Atot cm 2
[ ]
AF cm 2 0,03 × a 2 [mm]

For the transformer to be achieved easily in the series production, the value of g is usually (0,65
– 0,75).

AI.2. Initial design data

Usually, from the design of an electric scheme for an electronic device equipped with the
supply part formed of a distribution transformer, there result true root mean square values of the
voltages and currents needed in the secondary, U2k, respectively I2k, as well as the number of windings
in the secondary, K (fig. AI.4). There are also known, the true root mean square voltage in the primary,
U1 = 220 V, that is the voltage of the single-phase network of alternative current, as well as the
frequency of the network, that is of 50 Hz.
I21
n21
U21
d21
I22
n22
U22 d22
I1
U1

n1 I2k
n2k
d1 U2k d2k

Fig. AI.4. Distribution transformer – electric scheme: n1 – number of windings of the primary winding,
n2k – the number of windings in the secondary k; d1 – the diameter of the winding wire in the primary;
d2k – the diameter of the winding wire in the secondary k.

By the designing of the transformer, it is followed to find through calculus the data needed for
its practical achievement, that is:
n1 – the number of windings in the primary;
n2k – the number of windings in the secondary k;
d1 – the diameter of the winding wire in the primary;
d2k – the diameter of the winding wire in the secondary k;
a – the STAS-lamination type;
N – the number of needed laminations.

3
AI.3. Design method of the distribution transformer
· It is calculated the total power absorption in the secondary, P 2[W], as follows:

P2 [W ] = å P2k = åU 2k I 2 k
k k

· Further on, is calculated the power absorption in the primary, P1[W], considering the rating of
the transformer, h @ 0,85;
P [W ] P2 [W ]
P1 [W ] = 2 = = 1,176 × P2 [W ]
h 0.85
· It is sized the iron section, SFe[cm2] of the magnetic core, from the relation:

[ ]
S Fe cm 2 = (0,8...1,6 ) × P1 (W )

Usually, to the beginning, it is chosen:

[ ]
S Fe cm 2 = 1,2 P1 [W ]

· There is calculated the needed number of windings per Volt, n0, with relation:
40
n0 [sp / V ] =
[ ]
S Fe cm 2

deducted from the electromagnetic induction law, for f = 50 Hz and for the maximal admitted induction
in the laminations:
Bmax = 1,2 T.

The justification of this relation is following:

The voltage induced in a winding by n windings, is:
dF
U=
dt
where F is the magnetic flux through the transformer core. But F = BSFe, where B is the core
induction. Considering that previous relations are written with true root mean square values (the
voltage is usually expressed in root mean square values), there results that the first relation might be re-
written in sine-wave regime, as follows:
dBef
U ef = S Fe
dt
or, transforming into amplitude peak values for the induction:
dBv
U ef 2 = S Fe
dt
where: Bv is the amplitude of the induction in sine-wave regime.
Due to the fact that in sine-wave regime, the time derivative of a measure is equivalent with the
multiplication with w = 2pf, with f the frequency, the previously written relation becomes:
U ef 2 = S Fe 2pfBv

4
 As the core induction, for hot-rolled silicon laminations, can take over only at most the value
Bmax = 1,2 T, there results that the winding number on Volt (needed for obtaining the true root mean
square value of the induced voltage of 1 V), is:
n 2
n0 = =
U ef 2pfS Fe B max

For f = 50 Hz and SFe expressed in [cm2] it results:

2 × 10 4 38
n0 = =
[ ]
100 × S Fe cm × 1,2 S Fe cm 2
2
[ ]
It is chosen, as a cover value:
40 ¸ 48
n0 =
[ ]
S Fe cm 2

due to the fact that thus is avoided the strong saturation of the core at an increase of the network
voltage over the normal value of 220 Vef.

· It is calculated the number of windings needed in the primary, n1, with relation:
n1 = n0U 1

· It is calculated the number of windings in the secondary k, n2k, with relation:

n2 k = 1,1 × U 2 k × n0

· It is estimated the current in the primary, I1:

P1 [W ]
I 1 [ A] =
U 1 [V ]

· It is sized the diameter d1[mm] of the winding wire in the primary and d2k [mm] in the
secondary K, with relation:
d1; 2k [mm] = 0,65 I 1; 2k [A]

· For a maximal current density admitted in copper:

I é A ù
I max = = 3ê 2ú
pd 2
ë mm û
4
The value resulted by the calculus for the diameter d [mm] is rounded at the standardized value
immediately higher from table AI.1.

5
 TABLE AI.1.
The STAS diameters of the winding wires and the filling coefficients
The STAS diameter of the wire C1 [sp/ cm2] (with insulation C2 [sp/ cm2] (without insulation
[mm] between layers) between layers)
0,05 13250 16150
0,07 8330 9700
0,1 4460 6100
0,12 3190 4120
0,15 2260 2880
0,18 1730 2050
0,2 1465 1715
0,22 1210 1460
0,25 978 1140
0,28 813 925
0,3 722 807
0,35 530 594
0,4 350 470
0,45 277 371
0,5 224 300
0,55 190 252
0,6 162 209
0,65 142 180
0,7 125 153
0,8 95,5 127
0,9 78 93
1 65 75
1,2 40,5 52
1,3 26,5 33,5
2 15,5 19

· It is calculated the area occupied by the windings in the lamination window for the primary A1
[cm2] and for the secondary A2 [cm2], using the calculus coefficients, C1 for the case that the
winding shall be made with insulation between layers or C2 for the case that the winding is
made without insulation between layers. These coefficients are according to the diameter
chosen for the winding wires and are given in table AI.1.
[ ] n
[ ] n
A1 cm 2 = 1 ; A2 cm 2 = 2 k
C1; 2 C1; 2

· It is calculated the total area occupied by windings, Atot [cm2]:

[ ] [ ] [ ]
Atot cm 2 = A1 cm 2 + A2 cm 2

· The needed lamination, respectively parameter a [mm] for an optimal filling factor (g = 0,7)
are sized with relation:

a[mm] =
[ ]
Atot cm 2
[ ]
= 6,9 Atot cm 2
0,03 × 0,7

6
If, for parameter a [mm] it is obtained no standardized value, then the standardized value is the
immediate superior or inferior standardized value and it is checked if, with the chosen value, it is
obtained:

g STAS =
[ ]
Atot cm 2
= 0,65 ¸ 0,75
0,03 × a STAS
2
[mm]
· It is calculated the thickness of the lamination package, b [mm], using the STAS-lamination:

b[mm ] =
[ ]
S Fe cm 2
0,02 × a STAS [mm]
· It is calculated the needed lamination number for the manufacturing of the magnetic core,
according to their thicknesses, g (0,35 mm or 0,5 mm):
b[mm]
N=
g [mm]
The design method of a distribution transformer might be easily remembered, by using table
AI.2.
TABLE AI.2
Method for the design of the distribution transformer
Initial design data Data that must result from Used calculus relations
calculation

U2k [V]; I2k [A] P2 [W] P2 = åU

k
2k I 2k

h = 0,85 P1 [W] P1 = 1,176 P2

SFe [cm2] S Fe = 1, 2 P1
Bmax [T] n0 [sp/ V]
n0 =
(40 ¸ 48)
f [Hz] [ ]
S Fe cm 2
U1 [V] n1 windings n1 = n0U 1
k; U2k [V] n2k windings n2 k = 1,1n0U 2 k
U1 [V] I1 [A] P1
I1 =
U1
I2k; Imax = 3 [A/mm2] d1 [mm]; d2k [mm] d1; 2 k = 0,65 I 1; 2k
2 2
C1 –with insulation between A1 [cm ]; A2 [cm ] n1 n
layers Atot [cm2] A1 = ; A2 = 2 k
C1; 2 C1; 2
C2 without insulation between
layers Atot = A1 ¸ A2
goptim = 0,7 a [mm] = type of the STAS- a = 6,9 × Atot
lamination
aSTAS [mm] b [mm] = thickness of the S Fe
lamination package b=
0,02 × a STAS
g = - 0,35 mm N (laminations) = needed b
= - 0,5 mm number of laminations N=
g

7
AI.4. Design Example
There must be designed a distribution transformer that has the initial data:
U1 = 220 V; f = 50 Hz;
U21 = U22 = 24 V; I21 = I22 = 1,5 A
U23 = 6,3 V, I23 = 0,3 A
· It is estimated the total power in the secondary:
P2 = 2 × 24 × 1,5 + 6,3 × 0,3 = 73,89 W .
· The power absorption in the primary, for h = 0,85 shall be:
P1 = 1,176 × 73,89 = 86,89 W .
· The needed core section SFe, is:
S Fe = 1,2 86,89 = 11,18 cm 2 .
· The winding/ Volt number that must be winded shall be:
40
n0 = = 3,6 sp / V .
11,18
· It is calculated the number of windings in the primary:
n1 = 3,6 × 220 = 792 windings
· It is calculated the number of windings in the secondary:
n21 = n 22 = 1,1 × 3,6 × 24 = 71 windings ;
n23 = 1,1 × 3,6 × 6,3 = 24,8 windings .
The value n23 is rounded to:
n23 = 25 windings
· It is calculated the current absorption from the primary:
86,89
I1 = = 0,39 A.
220
· There are estimated the wire diameters in the primary and secondary:
d1 = 0,65 0,39 = 0, 4 mm;
d 21 = d 22 = 0,65 1,5 = 0,79 mm;
d 23 = 0,65 0,3 = 0,35 mm.
There are chosen the standardized diameters:
d1 = 0,4 mm; d21 = d22 = 0,8 mm; d23 = 0,35 mm
· It is calculated the area occupied by windings under the hypothesis that the winding is done
without insulation between layers, by using the calculus coefficients C2 from table AI.1 (in this
case, there exists only insulation between the primary and secondary, as well as to the outside of
the windings):
792
A1 = = 1,7 cm 2 ;
470
æ 71 ö 25
A2 = 2 × ç ÷+ = 1,17 cm 2 .
è 127 ø 594
· It is calculated the total area occupied by windings:
Atot = 1,7 + 1,17 = 2,87 cm 2 .

8
 · It is sized the needed lamination for goptim = 0,7, as follows:
a[mm] = 6,9 2,87 = 11,6 mm.
Remark: It is chosen the STAS-lamination E 12,5 and there must be checked g with the chosen
lamination:
2,87
g STAS = = 0,612 < 0,7;
0,03 × 12,5 2
and thus, the STAS-lamination is well chosen.
· It is calculated the thickness of the lamination package, b, with relation:
11,18
b= = 46,5 mm.
0,02 × 12
· The needed number of laminations with the thickness g = 0,35 mm, shall be:
46,5
N= = 133 laminations
0,35