A TOTAL LECTURE OF MAKING

TRANSFORMER (STEP UP, STEP DOWN, AUTO

TRANSFORMER)
STUDENT OF
UNIVERSITY OF INFORMATION TECHNOLOGY AND SCIENCES
Contact mail : asuvro@gmail.com
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Wire gauge in ampere

Primary/secondary Wire gauge in SWG Primary/secondary Wire gauge in SWG
current in amperes current in amperes
0.014 45 0.564-0.682 25
0.018 44 0.691-0.882 24
0.023 43 0.891-1.109 23
0.027 42 1.118-1.364 22
0.0318 41 1.5-1.8 21
0.0364 40 2.4 20
0.041-0.046 39 3 19
0.0545 38 3.6 18
0.064-0.073 37 4.6 17
0.082 36 5.8 16
0.091-0.109 35 7.2 15
0.118-0.127 34 9 14
0.136-0.164 33 11.2 13
0.173-0.182 32 14 12
0.191-0.227 31 17.6 11
0.236-0.273 30 22.4 10
0.282-0.327 29 27.8 9
0.345-0.373 28 34.8 8
0.382-0.473 27
0.482-0.544 26
 E & I core type single phase transformer
To make a transformer we need a calculation
Formula

(1) A= ( W) / 5.58
Here, A =cross section area
W= obtained secondary wattage in volt-ampere
(2) Find out number of turns per volt N
N = 108 / (4.4*F*H*A)
Here,
N= number of turns per volt
F= the frequency in Hz
A= cross section area of the core
H= maximum Number of lines of magnetic flux per square inch of the core
Note H=60000 lines per square inch which is commonly accepted value of its
In Bangladesh the above calculation is
N=7.5/A
For example
Make a transformer which primary voltage 200V, secondary voltage is
(1) 350V at 120mA
(2)6.3V at 3A
(3) 5V at 2.2A
Solution
Step 1
Find out the watts of the transformer
(a) 350V * 120mA = 42 watts
(b) 6.3V *3A= 18.9 watts
(c) 5V *2.2A =11 watts
Total = 71.9 watts
Step 2
Find out the cross section area of the core

A= =1.5 square inch

We give a safety margin 0.3 sq. in, so total A= 1.88sq.in
Step 3
Now find the input wattage thus assume the transformer to be 90% efficient.
So output is 72 watts
Input watts= 72* 100/90
= 80 watts
Step 4
Find out the primary current
At the working voltage of 200
(80/200)= 0.4A (27 SWG wire)
Step 5
Find the N (number of turn per volt)
N= 108/ (4.44*50*60,000*1.8) (in Bangladesh Hz= 50)
=4.2 turn per volt
Step 6
Primary 200V= 200*4.2= 840 turns
Secondary 350V= 350*4.2= 1050 turns
6.3V= 6.3*4.2= 26.5 turns
5V= 5*4.2= 21 turns
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