TRANSFORMER

The transformer electrical component having the ability to change the voltage level and
current by two coils wound around a common core or center . The core consists of a large
number of plates or foils of an alloy of iron and silicon . This alloy reduces magnetic
hysteresis losses ( ability to maintain a magnetic signal after removal a magnetic field ) and
increases the resistivity of iron .
Operation of a transformer
The change in voltage or current that makes a transformer happens because the secondary
winding is induced by a magnetic field produced by the primary winding in conjunction with
the core. The change in voltage or current, delivered by the transformer is reversed, ie when
the transformer increases the voltage, low current; and when low voltage, current rises. This
leads to a law: the power transformer delivery, can not exceed the energy that goes into it.
Although the primary and the secondary winding are insulated by cardboard, waxed paper,
pressboard or plastic, the magnetic field is transmitted from the primary winding to the
secondary.
There is a relationship between the turns of the primary winding and the secondary winding.
This relationship determines the output voltage of the transformer are equal and the
relationship between the turns of the windings and the input and output voltages.
When the primary winding to the secondary winding is equal (1: 1), the voltage and input
current are equal to the output voltage and current. In this case the transformer only serves
to make galvanic isolation, meaning that we can touch the output current without being
electrocuted.
By changing the turns of the secondary winding wire, change the output voltage of the
transformer. Example: if every turn of the primary winding, give three laps in the secondary;
would, in the case of applying a voltage of 10 volts at the input, the output would be 30
volts. And as we wind wire around the side for every three turns of the primary; in the case
of applying a voltage to the input of 30 volts, we would have at the output 10 volts.
Then we will see a practical method to determine the characteristics of the transformer for
your amplifier or any other device. Actually there are many ways to assess and calculate a
transformer, which propose, leads easily and fairly accurately the transformer model we
need.
The starting point is to determine the power delivered each amplifier channel, if the
amplifier is stereo. Each channel will contribute half of the power amplifier. If it is a mono
amplifier, the total power will be delivered by the only exit.
An example: having a 100-watt stereo amplifier, means that each channel is 50 watts, which
means that the delivery channel power is 50 watts. In this case we use 8 ohm speakers,
namely the speaker impedance RL is 8 ohms, determined by the manufacturer of the
integrated output or circuit design itself.
This means that the actual voltage (RMS) of the transformer needed to power the amplifier
is equal to the continuous voltage that consumes the amplifier, divided by the square root of
2 (1.4141). Now, by that loss it is advisable to increase the value obtained in two or volts.
For instance; if your amplifier is powered with 34 volts DC, then the RMS voltage of the
transformer is calculated as follows:
RMS voltage = 34 / 2

34 / 1.4141 = 24 volts AC
The nickel is equal to 24 volts RMS voltage =

These 24 volts is advisable add about 2 volts, resulting in 26 volts AC

The transformer core defined dimension. Power is nothing but the product of multiplication
between the voltage and amperage of the transformer. Thus:
PT = V x I RMS RMS

For example in the previous case calculate a voltage of 24 volts (RMS) and a current of 5
amperes, then the power will be:
PT = 24V X = 120 watts 5Amp

TABLE AWG
The reason of increasing two volts in the secondary winding, to provide a margin loss caused
by the consumption of the rectifier diodes and the natural resistance of the transformer.
For your transformer respond properly and deliver the desired current, it must be built with
copper wire of sufficient gauge.
How to find the wire gauge of the secondary winding
To find the proper gauge wire of the secondary winding, must find the amp consumption of
the amplifier and then refer to Table AWG. In this case the amplifier consumes 5 amps we
got to divide the wattage of the amplifier between the output voltage (secondary winding). If
we look at the AWG table, we see that the 16-gauge wire, supports 5.2 amps, but in practice,
you can use a thinner gauge, for example 17, (not more than one point lower caliber
because it could overheat the transformer or not deliver the required power).
It is worth remembering that if we do not use amps, simply divide the power amplifier
between output volt transformer.
It is clear that if the amplifier's transistors, the secondary winding has been adding amps
consumed by transistors. For example, when an amplifier works with 4 transistors 2SC5200
and we know that each of these requires 1.3 amps, we have a total of 5.2 amps equivalent
to 16 gauge wire.
How to find the wire gauge of the primary winding
To find the gauge of the wire of the primary winding, first we have the amperage. This is
achieved by dividing the watt amplifier, the voltage between the outlet or public network in
your country.
In this case we have a supply of 120 volts in the public network.
RMS Amperes = Watts / Volts input
The nickel is equal to:
Amps = 120W / 120V = 1 Amp

120 watts divided 120 volts, equal to 1 ampere. If we look at our AWG table, the closest size
is 23.
As finding the area of the transformer core
Now the core section is related to the total power as follows:
Core section PT =
The core section is equal to the square root of the total power.
As we saw earlier, we obtained 120 watts of power to the transformer. Then the core section
should be:
core section = 120 = 10.95 square inches
This means that it will serve a core of 3.3 cm wide by 3.3 cm long, corresponding to a core
area of 10.89 square centimeters, although not necessarily have to be square. The sheets or
plates that come closest, with 3.2 inches long at its center, would place the number of
sheets to give us about 3.6 cm wide to achieve that goal. Commercial formwork for this case
is 3.2 cm by 4 cm which has a power output of 163 Watts. This power learned of squaring
the core area.
3.2 x 4 = 12.8 cms2
12.8 x 12.8 = 163.84W
It is best to always use a core size larger than we need to be more than enough potential
and not have problems to get the wire.
Measure to set the width of the core sheets or adding iron sheets
. PICTURE ANCO
In the figures, the transformer core seen above, the core section will be the product of the
length in centimeters per centimeter width shown. This should correspond to the value
calculated at least, as we said before, if higher the better, because it gives a margin of
power.
Calculating the number of turns of copper wire
There is a constant which is the number 42, we will not go into details about the origin of
this number, since the idea is not to delve into mathematics, if not get people with little
knowledge to achieve transfomradores.
To calculate the number of windings or turns of copper wire, in our example, 42 is divided
between 12.8 cms2, which are the core area of 3.2 x 4.
Number of turns = 42 / 12.8 Cm2
42 12.8 = 3.28 split turns or turns of wire per volt.

This means that for the primary winding, are 120-volt outlet, multiplied by 3.28, equals 393
turns or turns of copper wire. If in your country the public network voltage is 220V, multiply
220 by 3.28 volts = 721 turns on the primary winding.
To find the number of turns of the secondary winding, the transformer 26 volts are taken and
multiplied by 3.28 to obtain 85 coils or turns of wire.
Now that we know the wire sizes to use and the number of turns, we can make our
Transformer

Connecting two single transformers

In the case before us difficult to get a transformer with

TAP , an easy option is to connect two single
transformers ( No Central TAP) .
The figure shows how the correct connection is
simple to convert our two transformers in a
transformer with central TAP. Furthermore as the
amount of iron plates is doubled , it is increased
a little power , improving performance of the two
transformers .
At other times it becomes difficult to achieve high
transformers and can not get the materials to do so.
As a solution to this problem can be connected two transformers
so maintain double the amperage and voltage.

central

amperage
in parallel and

For example: We need a transformer 18 + 18 volts AC,

with a current of 12 amps to power amplifier 300W
with TDA7294.
We can connect in parallel two transformers of 18 +
18V AC, with a current of 6 amps and so we get the
transformer we require for this project.
If desired, you can use a program called transformer
calculation, which makes the calculation work for you.
For the calculations with the program out correctly, it
is necessary to add two millimeters on either side of
core Since the formwork where the wire is coiled wire
occupies space.
Another option is to use the official program from our
Web site, which was created by Jaider Martinez, one of
our loyal fans. Is a free software for calculating
dimensions and turns of wire gauge, by simply entering the voltage and amperage.

Examples of performing calculations for transformers

By Federico Michelutti of Argentina .
Before trying the examples we consider the following information:
Table core formwork
Measure the area of the core in centimeters. Compare the core area with the closest in the
table , use this or the next largest area you need and the number of turns per volt , calculate
the wire turns of the primary winding and secondary

NCLEO
1.6 x 1.9
2.2 x 2.8
2.5 x 1.8
2.5 x 2.8
2.8 x 1.5
2.8 x 2.5
2.8 x 3.5
2.8 x 5
3.2 x 3.5
3.2 x 4
3.2 x 5
3.8 x 4
3.8 x 5
3.8 x 6
3.8 x 7
3.8 x 8
3.8 x 9
3.8 x 10
3.8 x 11
3.8 x 12
4.4 x 9
4.4 x 10
4.4 x 11
4.4 x 12

POTENCIA
MXIMA
9W
37W
20W
49W
17W
49W
96W
196W
125W
163W
256W
231W
361W
519W
707W
924W
1170W
1444W
1747W
2079W
1568W
1940W
2342W
2787W

VUELTAS POR
VOLTIO
14
7
9.3
6
10
6
4.3
3
3.75
3.3
2.625
2.76
2.21
1.85
1.58
1.38
1.22
1.1
1.004
0.921
1.06
0.95
0.867
0.795

REA Cm
3.04
6.16
4.5
7
4.2
7
9.8
14
11.2
12.8
16
15.2
19
22.8
26.6
30.4
34.2
38
41.8
45.6
39.6
44
48.4
52.8

As the core :
Multiplying ( X) ( center width of the sheets )
by ( Y) (given by the number of caps
background ), we get the area in square
centimeters, the core of our transformer.
Means in millimeters available which have to
( X ) are : 16 , 20, 22 , 25 , 28, 32 , 38, 44 ,
50, 60 , 70, 80 , 100 .
( Y) is determined by the number of plates or
plates that will put one above the other.

Example No. 1:
Admission: ( primary winding ) 220 V
Output 1 : (winding side ) 60V to 4amp
The first thing to calculate is the power of our transformer:
In this case : x 4 Amp 60V . = 240 watts
Now , if we look at the table above we find the most approximate value is 256W (These are
maximum power and must be above to reduce losses )

NCLEO
3.2 x 5

POTENCIA MXIMA
256 W

VUELTAS POR VOLTIO

2.625

REA Cm
16

Thus far are the core that best suits our needs :
3.2 cm X = Y = 5 cm
However; by dividing the power of our amplifier , between the input voltage , we obtain the
amperage to the primary winding :
240w / 220v = 1.09 amp .
Now we look at the AWG table

Calibre
17
23

Mils Circulares
2.048
0.509

Dimetro mm
1.15
0.57

Amperaje
4.1
1.0

See, must use to the primary winding, magnet wire 23 gauge and 17 gauge wire for the
secondary winding since this requires 4 amps.
To calculate the number of turns of the primary winding, we must multiply the Turns per volt
(2.21 according to our core formwork table), by the amount of input volt transformer
(voltage public network):
220 x 2.625 = 578 turns for the primary winding.

For the secondary winding, the same but with the desired output voltage:
60V x 2,625 = 158 turns for the secondary winding.
Example No. 2:
Admission: (primary winding): 120V
Output 1: (secondary winding): 32 x 32V to 3Amp (TAP will use Central)
The first thing to calculate is the power of our transformer; In this case: 32 + 32V x 3 Amp.
= 192 Watts
Now, if we seek in our core formwork table, we find the value that comes closest is: 196W,
(as they are maximum powers).

NCLEO
2.8 x 5

POTENCIA MXIMA
196W

VUELTAS POR VOLTIO

3

REA Cm
14

Thus far found kernel we need, which is 2.8 cm X = Y = 5 cm

However; to divide our power amplifier between the input voltage , amperage get the value
for the primary winding :
192W / 120V = 1.6 amp .
Now we look at the AWG table

Calibre
21
18

Mils Circulares
810.1
1.624

Dimetro mm
0.72
1.02

Amperaje
1.6
3.2

You see, we use a 21 gauge for the primary winding, and a bore 18 for the secondary
winding, since this must submit 3 Amp.
To calculate the number of turns of the primary winding, we must multiply the Turns per volt
(Table 3 as core formwork), the amount of input volt (public network):
120V x 3 = 360 turns for the primary winding.
For the secondary winding, do the same but with the desired output voltage:
64V x 3 = 192 turns. In this case, to reach around 96, we welded wire TAP Central, or we can
wrap the wire twice and give only 96 laps, as seen in the video.
Example No. 3:
Input: 220V (primary winding)
Output 1: 24V 3 Amp (secondary winding)
Output 2: 9V 1.6 Amp (additional secondary winding)
The first is to calculate the power transformer to be delivered, in order to find the
appropriate size core.

For this case we take the power of the main secondary winding, which is 24V x 3 Amp) = 72
watts
Then look at the core of formwork table and find the approximate value more over, that is:
96W (Note be at least 20% up, thinking of the eddy current losses).

NCLEO
2.8 x 3.5

POTENCIA MXIMA
96W

VUELTAS POR VOLTIO

4.3

REA Cm
9.8

Thus far are the core we need:

X = Y = 2.8 cm by 3.5 cm .
However; to divide our power amplifier between the input voltage , amperage get the value
that must deliver the primary winding :
96W / 220V = 0.4 amp .
Now we look at the AWG table

Calibre
27
18
21

Mils Circulares
0.202
1.624
810.1

Dimetro mm
0.36
1.02
0.72

Amperaje
0.4
3.2
1.6

See, we use a 27 gauge for the primary winding 18 gauge to 21 gauge secondary winding
and to the additional winding.
To calculate the number of turns of the primary winding, we must multiply the Turns per volt
(4.3 per table formwork core) by the amount entered volts (voltage public network).
220 x 4.3 = 946 turns for the primary winding
For the secondary winding should do the same, but with the desired output voltage:
V 24 x 4.3 = 103 laps.
And for the additional winding, we have: 9V x 4.3 = 39 laps.
Example No. 4:
Input: 220V (primary winding)
Output 1: 33 + 33v to 3amp (secondary winding)
Output 2: 12v 0.8amp (additional secondary winding)
Let's start calculating is the power of our transformer:
In this case we take the power of main secondary winding, which is 33V + 33V Amp x 3 =
198 watts.
Now we seek in our core formwork table and find the approximate value more over, that is:
231W (Note be at least 20% up, thinking of the eddy current losses).

NCLEO

POTENCIA MXIMA

VUELTAS POR VOLTIO

REA Cm

3.8 x 4

231W

2.76

15.2

Thus we have found the most appropriate measure of core to our our core transformer:
X = Y = 3.8 cm by 4 cm .
However; to divide our power amplifier between the input voltage , amperage get the value
of the primary winding :
231W / 220V = 1.05 Amps.
Now we look at the AWG table

Calibre
22
18
24

Mils Circulares
642.4
1.624
0.404

Dimetro mm
0.65
1.02
0.51

Amperaje
1.2
3.2
0.8

You see, we used a .22 for the primary winding, though you can use 23 gauge, to be very
little difference.
We used for the secondary winding wire 18 gauge, as this winding takes 3 Amp and 3.2 Amp
delivery wire 18. And the additional winding use 24 gauge wire, requiring 0.8 Amps.
To calculate the number of turns of the primary winding, we must multiply the turns per volt
(2.76 according to our core formwork table), by the amount entered volts (voltage public
network):
220 x 2.76 = 607.2 turns for the primary winding.
For the secondary winding, the same is done, but with the desired output voltage:
33 + 33 V x 2.76 = 182 turns. In this case, to reach around 91, we welded wire TAP Central,
or we can wrap the wire twice and give only 91 laps, as seen in the video.
And we have the additional winding: 12Vx 2.76 = 33 laps.
Very special thanks Federico Michelutti of Argentina.