Many times I've had to go through old documentation to figure out how to wind a transformer. I decided to put the calculations in a web-based calculator. It is a simple calculator - it just calculates the number of turns. You have to figure out how big the wire needs to be and if it will fit on the bobbin.

The two things you need to know about the transformer are the Bmax, which you can generally guess at without too much trouble, and the cross-sectional area in cm2. Bmax is the maximum flux density you want in the core. 1500G with a 3622-77 pot core at 25kHz will produce 0.68W in core losses. Lower the Bmax as the frequency increases. Don't use type 77 over 100kHz. For type 77 it looks like you can't saturate the core if you keep Bmax below 3000, but then those core losses will get you. One-half to one-third of that is more appropriate. Your turns count will increase as you decrease the Bmax. So will your winding losses. Ae is the cross-sectional area, and that is always in the datasheet. If it is given in mm2 divide by 100 to get cm2.


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Pay attention to the switching frequency. If you are using something like an LM3524D, the frequency it runs is twice the actual transformer frequency. If it has a clock frequency of 50kHz, the transformer is only running at 25kHz. If you don't take that into account you will design a transformer that is very much too small for the frequency.

I am designing a spot welder using a transformer from an old microwave and need to calculate the welding current that will be generated. I'm fairly certain that knowing the input voltage and power rating as well as the number of turns on the coils will allow me to do this, although I'm not entirely certain what's going on with my primary coil. It seems as though it has 16 'layers' and 8 turns on each layer. I'm not sure how this would effect my calculations, am I supposed to take the number of coils on my primary as 128?

It looks like you already wound the secondary. I think you probably know how many turns you have on the secondary or can count them pretty easily since there are just a few. So just measure the primary and secondary voltages while the secondary is open-circuited. Then you can calculate the primary turns using the basic voltage equation for transformers.

Have you ever wondered how the electric current from the high voltage power lines turns into a familiar 110 V\small 110\ \mathrm{V}110 V (or 220 V\small 220\ \mathrm{V}220 V) in the outlet socket? That's what electric transformers do via voltage regulation (we talk about this in our voltage regulation calculator).

Coming back to the transformer, essentially, the magnetic field transfers the energy from one circuit to the other. If you're surprised that a magnetic field can transfer energy, you might check the energy density equation calculator.

Current transformers are used to provide a precise measurement of the current. In current transformers, there are more secondary windings than primary windings. Therefore, the secondary current is smaller than the primary current. This way, we can monitor or measure large currents using standard, small current measuring devices. We usually connect the current transformer in series.

Voltage transformers are parallel connected, and their usual role is to decrease the voltage. The reduced voltage is useful for running household electrical items. Also, like in the case of current transformers, it allows for standard measuring devices to monitor high-voltage lines. In voltage transformers, there are more primary than secondary windings.

The Construction Monkey Transformer Calculator lets you figure out electrical characteristics of your system given a specific transformer size. By inputting the primary and secondary electrical system characteristics and the transformer properties Construction Monkey will calculate the disconnect size and feeder size for both the primary and secondary.

Wye-connected transformers have one lead from each of three windings connected to a common point. The other leads from each of the windings connect to the line conductors. A wye-configured secondary is often represented with a Y-shaped arrangement of the windings (Fig. 2)

A quarter wave transformer is used to match two transmission lines with different impedances. As the name suggests, the length of this transmission line if fixed at a quarter of the wavelength (/4). The wavelength can be calculated based on frequency here.

While formulas for determining transformer properties such as full load amps or infinite bus through-fault current are relatively simple, running the calculations takes time away from other activities. Sometimes being able to plug in the numbers and get the information you need is a valuable way to save you time while designing the electrical system around a transformer. This calculator will let you plug some numbers in and get a quick result that you can use to properly size the system.

Transformer Calculations

By knowing the capacity of the transformer as well as the primary and secondary voltages, you will be able to calculate the full load capacity (in Amps) of the transformer for both the primary and secondary sides. These values can then help you determine the appropriate primary and secondary overcurrent protection necessary to meet NEC requirements, a key component to designing the electrical system around a transformer.

Infinite Bus Calculations

When a fault occurs on the secondary of a transformer, its impedance limits the amount of fault current capable of being supplied through the transformer windings. By utilizing the transformer impedance, and assuming an infinite power source on the primary, you can determine the absolute maximum amount of through-fault current capable of being supplied across the transformer. This current alongside other fault contributors on the secondary side of the transformer (generators, large induction motors, etc.) can help you identify the maximum available fault current on the secondary of the transformer and determine the minimum allowable short circuit and interrupting capacity ratings you should be specifying for downstream equipment.

Through Fault Calculations

When the limitations of maximum available fault current are known on the primary of the transformer you are also able to determine the actual maximum available fault current on secondary of the transformer. This information may be useful but use of the infinite bus method explained above is recommended for determining short circuit and allowable interrupting ratings as the primary system may change and the maximum available fault current at the primary of the transformer may vary over time.

Transformer Voltage Drop

In many cases, the voltage drop across a transformer is not considered when assessing the voltage at a given load. By knowing the transformer X/R ratio and the power factor of the downstream load on a transformer, you can use this calculator and determine the voltage drop that can be experienced across a given transformer and determine if it's significant enough to consider in your system design. In many cases, this voltage drop can be accounted for by adjusting the voltage tap on the transformer to compensate for the difference in voltage.

The HPS Buck-Boost Selector will allow you to select the most economical way to both raise supply voltage caused by line drop or equipment demand on the distribution system, or lower voltage caused by increased system voltage due to supply line adjustments. 


Simply enter your parameters below and the Selector tool will determine the best suitable buck-boost transformer for your application.

The HPS Buck-Boost Selector is for information purposes only. Hammond Power Solutions Inc. ("HPS") makes no guarantee, representation or warranty in connection with the accuracy or the use of the selector. 


HPS assumes no responsibility for the results generated by the selector or for any errors or omissions in connection with the use of (or the results generated by) the selector and under no circumstances shall HPS be held liable for any damages in connection with the use of (or the results generated by) the selector.


The information used by the selector may be modified, deleted or replaced from time to time and at any time in the absolute discretion of HPS.


Please visit a local HPS representative or contact HPS directly for more information prior to purchasing a transformer.

You can easily calculate the right amount of inhibitor or passivator to add to your transformer with our Inhibitor and Passivator Content Calculator. This application generates a recommended amount of Nynas Nyhib 10 or Nypass based on your inputted data.

HPS is the largest manufacturer of dry-type transformers in North America. We engineer and manufacture a wide range of standard and custom transformers that are exported globally in electrical equipment and systems.

As a professional landscape lighting designer looking to install and operate a new low voltage lighting system, you need to consider what transformer will be required to convert your standard line voltage outlets using 110-120V into your outdoor low voltage 12V-15V lighting design. This consideration as an outdoor lighting installer allows your landscape lights to function properly for many years ahead and will reduce issues with lights failing or ending up with weak outputs further down the line of wire connections around the property landscapes, keeping your clients happy and referring customers for many years ahead.

Now, to figure out how many 12V lights you can power outside with a single low voltage transformer, look to the wattage and VA ratings for the fixtures being installed. Once that has been considered and calculated with the number of lights on the systems run, you can look for a low voltage transformer that has a higher minimum wattage rating. 006ab0faaa

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