Auto Transformer Standard Design

14-Aug-19 Operating Tesla Loss/Kg Peak F. Strn. Cu. dia CULL dia Ohms/Mtr Cu. size Copper weight in Kg/1000Mtr
Ref: - 0.30 0.038 - 0 0 50µm/10mm 0.72
0.31 0.041 - 0 0 0 0 0 0.056 0.0236 36µm/8mm 0.40
Given Data : Auto Transformer (Type B), Voltage 0V, 120V/4.8A, 140V/5.6A, 170V/6.9A, 200V/8A, 230V/50Hz 0.32 0.044 - 1 0.056 0.074 6.94 1 0.071 0.0378 50µm/8mm 0.41
Vp1 (volts) 120 0.33 0.046 - 2 0.071 0.091 4.318 2 0.08 0.0478 25µm/6mm 0.41
Vp2 (volts) 140 0.34 0.049 - 3 0.08 0.101 3.401 3 0.085 0.0533 25µm/10mm 0.33
Vp3 (volts) 170 0.35 0.052 - 4 0.085 0.107 3.012 4 0.09 0.0604 36µm/6mm 0.32
Vp4 (volts) 200 0.36 0.055 - 5 0.09 0.113 2.687 5 0.1 0.0743 36µm/10mm 0.52
Vp5 (volts) 230 0.37 0.058 10.0 6 0.1 0.125 2.176 6 0.112 0.0928 36µm/13mm 0.71
Frequency (Hz) 50 0.38 0.061 10.2 7 0.112 0.139 1.735 7 0.118 0.1027 50µm/13mm 0.93
Version Open 0.39 0.065 10.5 8 0.118 0.145 1.563 8 0.125 0.115 100µm/10mm 1.51
Yoganand:
Secondary voltage (volts) Sec current (Amps) Power (VA) Trafo size (VA) Total Loss (W) Enter the total loss value 0.40 0.067 10.7 9 0.125 0.154 1.393 9 0.132 0.129 100µm/13mm 1.90
120 4.8 576 275.478 27.500 from design detail file for 0.41 0.070 11.0 10 0.132 0.162 1.249 10 0.14 0.145 50µm/6mm 0.48
140 5.6 784 306.783 Max trafo sixe rating 0.42 0.073 11.2 11 0.14 0.171 1.11 11 0.15 0.166 100µm/60mm 9.06
170 6.9 1173 306.000 0.43 0.077 11.4 12 0.15 0.182 0.9673 12 0.16 0.188 50µm/19mm 1.49
200 8 1600 208.696 0.44 0.080 11.6 13 0.16 0.194 0.8502 13 0.17 0.212 100µm/19mm 2.77
0 0 0 0.000 0.45 0.084 11.8 14 0.17 0.205 0.7531 14 0.18 0.237
0 0 0 0.000 0.46 0.086 12.0 15 0.18 0.217 0.6718 15 0.19 0.264 0 Coating
4133 306.783 0.47 0.090 12.2 16 0.19 0.228 0.6029 16 0.2 0.292 1 50µm/10mm 0.72
0.48 0.095 12.4 17 0.2 0.239 0.5441 17 0.212 0.327 2 36µm/8mm 0.40
0.49 0.098 12.6 18 0.212 0.254 0.4843 18 0.224 0.365 3 50µm/8mm 0.41
0.50 0.102 12.8 19 0.224 0.266 0.4338 19 0.236 0.405 4 25µm/6mm 0.41
Calculating Up current & Down current 0.51 0.106 12.9 20 0.236 0.283 0.3908 20 0.25 0.454 5 25µm/10mm 0.33
Segment Current Iup (A) Segment Current Idown (A) 0.52 0.109 13.1 21 0.25 0.297 0.3482 21 0.265 0.51 6 36µm/6mm 0.32
(0-120V) 2.30 (230V-120V) 2.62 0.53 0.113 13.2 22 0.265 0.314 0.3099 22 0.28 0.568 7 36µm/10mm 0.52
(0-140V) 2.19 (230V-140V) 3.53 0.54 0.117 13.3 23 0.28 0.329 0.2776 23 0.3 0.651 8 36µm/13mm 0.71
(0-170V) 1.80 (230V-170V) 5.22 0.55 0.120 13.5 24 0.3 0.352 0.2418 24 0.315 0.717 9 50µm/13mm 0.93
(0-200V) 1.04 (230V-200V) 7.08 0.56 0.126 13.7 25 0.315 0.367 0.2193 25 0.335 0.811 10 100µm/10mm 1.51
0.57 0.129 13.9 26 0.335 0.391 0.1939 26 0.355 0.909 11 100µm/13mm 1.90
0.58 0.133 14.0 27 0.355 0.411 0.1727 27 0.375 1.01 12 50µm/6mm 0.48
0.59 0.137 14.2 28 0.375 0.434 0.1548 28 0.4 1.15 13 100µm/60mm 9.06
0.60 0.142 14.4 29 0.4 0.459 0.136 29 0.425 1.3 14 50µm/19mm 1.49
Input Voltage Max current (A) Total VA (VA) 0.61 0.146 14.6 30 0.425 0.488 0.1205 30 0.45 1.46 15 100µm/19mm 2.77
(0-120V) 2.30 275.5 0.62 0.149 14.8 31 0.45 0.513 0.1075 31 0.475 1.62
(120V-140V) 2.62 52.5 0.63 0.155 14.9 32 0.475 0.541 0.09646 32 0.5 1.79
(140V-170V) 3.53 105.8 0.64 0.160 15.0 33 0.5 0.566 0.08706 33 0.53 2.02
(170V-200V) 5.22 156.6 0.65 0.164 15.2 34 0.53 0.6 0.07748 34 0.56 2.25
(200V-230V) 7.08 212.3 0.66 0.169 15.4 35 0.56 0.63 0.0694 35 0.6 2.58
802.7 0.67 0.175 15.6 36 0.6 0.674 0.06046 36 0.63 2.84
0.68 0.180 15.8 37 0.63 0.704 0.05484 37 0.67 3.21
DESIGN I/P : 0.69 0.186 15.9 38 0.67 0.749 0.04848 38 0.71 3.6
0.70 0.189 16.0 39 0.71 0.789 0.04318 39 0.75 4.02
VA : 401.34 0.71 0.195 16.2 40 0.75 0.834 0.03869 40 0.8 4.57
Steel Grade/Thickness CRGO/27M0H 0.72 0.200 16.4 41 0.8 0.884 0.03401 41 0.85 5.15
Core OD (mm) : 110 0.73 0.204 16.5 42 0.85 0.939 0.03012 42 0.9 5.78
Core ID (mm) : 60 0.74 0.210 16.6 43 0.9 0.989 0.02687 43 0.95 6.43
Core HT (mm) : 26 0.75 0.215 16.8 44 0.95 1.044 0.02412 44 1 7.12
CSA (mm2) : 650 0.76 0.220 17.0 45 1 1.094 0.02176 45 1.06 8
Frequency : 50 0.77 0.226 17.1 46 1.06 1.157 0.01937 46 1.12 8.93
Prim.Current Density (A/mm2) : 3.8 0.78 0.231 17.3 47 1.12 1.217 0.01735 47 1.18 9.9
Sec.Current Density (A/mm2) : 3.8 0.79 0.237 17.4 48 1.18 1.279 0.01563 48 1.25 11.1
B (Tesla) : 1.68 Insulation Layer Thickness Over Lapping 0.80 0.242 17.6 49 1.25 1.349 0.01393 49 1.32 12.4
Regulation (%) : 12 Core 2 50µm/10mm 50% 0.81 0.248 17.8 50 1.32 1.422 0.01249 50 1.4 13.9
A.V.A : 449.4973913043 Pri to Sec 1 50µm/10mm 50% 0.82 0.255 17.9 51 1.4 1.502 0.0111 51 1.5 16
Loss / Kg (W/Kg) = 1.035 Final insl 2 50µm/10mm 50% 0.83 0.261 18.0 52 1.5 1.606 0.009673 52 1.6 18.2
Stacking factor = 0.98 Cu screen 0 - - 0.84 0.268 18.2 53 1.6 1.706 0.008502 53 1.7 20.5
Prim. M. Factor for DCR : 1.15 Insulation 0 - - 0.85 0.273 18.4 54 1.7 1.809 0.007531 54 1.8 23
Sec. M. Factor for DCR : 1.12 0.86 0.279 18.6 55 1.8 1.909 0.006718 55 1.9 25.6
Core Density : 7.65 0.87 0.286 18.8 56 1.9 2.012 0.006029 56 2 28.3
0.88 0.292 18.9 57 2 2.112 0.005441 57 2.12 31.8
0.89 0.299 19.0 58 2.12 2.235 0.004843 58 2.24 35.5
0.90 0.304 19.1 59 2.24 2.355 0.004338 59 2.36 39.4
DESIGN O/P : 0.91 0.312 19.2 60 2.36 2.478 0.003908 60 2.5 44.2
Winding 0.92 0.317 19.4 61 2.5 2.618 0.003482 61 2.65 49.6
Segment Input Voltage Winding sequnces No of conductor Prim Turns (Np) Input Current Ip Øp Actual CULL dia Ohms/Mtrs KG/1000 Mtr NO Øp Selected V/T 0.93 0.324 19.6 62 2.65 2.772 0.003099 62 2.8 55.4
(0-120V) 120 W2 1 495 2.2957 0.877 0.989 0.02687 5.78 43 0.90 0.242424 0.94 0.332 19.7 63 2.8 2.922 0.002776 63 3 63.5
(120V-140V) 20 W3 1 83 2.6239 0.938 1.044 0.02412 6.43 44 0.95 0.95 0.337 19.8 64 3 3.126 0.002418 64 3.15 70
(140V-170V) 30 W4 1 124 3.5283 1.087 1.217 0.01735 8.93 47 1.12 0.96 0.346 19.9 65 3.15 3.276 0.002193 65 3.35 79.2
(170V-200V) 30 W5 1 124 5.2196 1.322 1.422 0.01249 12.4 50 1.32 0.97 0.353 20.0 66 3.35 3.479 0.001939 66 3.55 88.9
(200V-230V) 30 W1 1 124 7.0761 1.540 1.706 0.008502 18.2 53 1.60 0.98 0.363 20.1 67 3.55 3.679 0.001727 67 3.75 99.2
0.99 0.368 20.2 68 3.75 3.883 0.001548 68 4 113
1.00 0.375 20.4 69 4 4.133 0.00136 69
1.01 0.383 20.6
Build-up Calculation 1.02 0.390 20.8
1.03 0.397 21.0
OD ID HT MTL 1.04 0.404 21.1
110 60 26 1.05 0.411 21.2
Core insulation 111 59 27 106 PRIMARY 1.06 0.419 21.3
3.5 6.9 6.9 118.1 No. OD No Of Turns ID No Of Turns Turns/Layer OD Turns/Layer ID Turns/Layer OD Turns/Layer ID 1.07 0.426 21.4
Wdg1 114.5 52.1 33.9 130.2 1 208 106 1 1.17 1 2 1.08 0.434 21.5
Insul 0.5 0.5 0.5 2 349 152 1.42 3.8 2 4 1.09 0.441 21.7
115 51.6 34.4 132.2 3 266 92 1 2.69 1 3 1.10 0.446 21.8
CU Screen 0 0 0 4 0 0 0.00 0.00 0 0 1.11 0.455 21.9
+ 115 51.6 34.4 132.2 5 0 0 0 0 0 0 1.12 0.463 22.0
Insulation 0 0 0 1.13 0.470 22.2
115 51.6 34.4 132.2 1.14 0.477 22.4
4.2 8.4 8.4 146.9 1.15 0.485 22.5
Windg 2&3 119.2 43.2 42.8 161.6 1.16 0.492 22.6
2.9 8.6 8.6 175.95 1.17 0.501 22.7
Windg 4&5 122.1 34.6 51.4 190.3 1.18 0.510 22.8
0 0 0 190.3 1.19 0.517 22.9
Windg 6 122.1 34.6 51.4 190.3 1.20 0.527 23.0
0 0 0 190.3 1.21 0.534 23.1
Windg 7 122.1 34.6 51.4 190.3 1.22 0.543 23.2
Final insl 1 1 1 1.23 0.549 23.3
FINAL TRAFO 123.1 33.6 52.4 194.3 1.24 0.557 23.4
1.25 0.565 23.5
1.26 0.576 23.6
Wdg Resistance 1.27 0.583 23.7
Wdg1 (ohms) 0.1429 1.28 0.595 23.8
Wdg2 (ohms) 2.1883 1.29 0.606 24.0
Wdg3 (ohms) 0.3274 1.30 0.616 24.2
Wdg4 (ohms) 0.4231 1.31 0.623 24.4
Wdg5 (ohms) 0.3294 1.32 0.634 24.6
Wdg6 (ohms) 0 1.33 0.643 24.8
1.34 0.654 25.0
Core Weight (kg) 1.3012767 1.35 0.661 25.2
Core Loss (W) 1.3468214 1.36 0.674 25.4
Copper loss (W) 35.1835967 1.37 0.683 25.6
1.38 0.692 25.8
1.39 0.701 26.0
1.4 0.71 24.5
1.41 0.72 25
Primary 1.42 0.73 25.2
Wire diameter (mm) Turns 1.43 0.74 25.5
124 1.60 1.44 0.75 25.7
495 0.90 1.45 0.76 25.9
83 0.95 1.46 0.77 26
124 1.12 1.47 0.78 26.1
124 1.32 1.48 0.79 26.6
1.49 0.8 26.9
1.5 0.81 27.3
Total Loss (W) 36.5304181 1.51 0.83 27.9
Surface Area (cm2) 368.1080296 1.52 0.84 28.2
Temp rise (°C) 68.66 1.53 0.845 28.9
Efficiency (%) 91.66% 1.54 0.86 29.4
1.55 0.87 30
1.56 0.88 30.4
Core Io 1.57 0.89 31.2
Input Output 1.58 0.9 32
Core OD :- 110 Core CSA :-(mm2) 650 1.59 0.91 32.9
Core ID :- 60 Input Voltage for 'N' Turns(+ % 1.6 0.925 33.5
of Rise) (volts) 1.455
Core HT :- 26 1.61 0.94 34.2
B (Tesla) :- 1.68 Magnetic length (cm) 26.704 1.62 0.95 35
Peak Field Strength :- 44.5 Magnetising Current (A) 1.980 1.63 0.96 36
Loss/Kg (W/Kg) :- 1.035 Loss Current (A) 0.926 1.64 0.975 37.8
Frequency (Hz) :- 50 No-load Current (A) 2.186 1.65 0.99 39
Number of Turns :- 6 Volt/Turn (Volts) 0.242 1.66 1 41
% in RISE 0 1.67 1.02 42.5
1.68 1.035 44.5
1.69 1.05 47
Trafo Io Output 1.7 1.07 49
Input B (Tesla) :- 1.68 1.71 1.09 52
Core OD :- 110 Peak Field Strength :- 44.5 1.72 1.11 56
Core ID :- 60 Loss/Kg (W/Kg) :- 1.035 1.73 1.12 59
Core HT :- 26 Core CSA (mm2) 650 1.74 1.15 65
Frequency :- 50 Magnetic length (cm) 26.704 1.75 1.18 69
Prim. Turns :- 949 Magnetising Current (A) 0.013 1.76 1.21 75
Input Voltage :- 230 Loss Current (A) 0.0059 1.77 1.23 82
No-load Current (A) 0.014 1.78 1.26 91
1.79 1.3 100
1.8 1.33 116
costing 1.81 1.36 130
35JN300 88.00 INR 1.82 1.39 150
1 USD 1 Euro 1Str 30M1H 2.134 Str 1.83 1.42 170
45.7 62.80 74.15 LME Copper 10.2 USD 1.84 1.47 200
1.85 1.5 230
1.86 1.56 260
Parameter / Element / Factor CRGO design
1.87 1.6 290
Core: 110X60X26 1.88 1.64 340
Wire diameter (mm) Turns 1.89 1.7 390
124 1.60 1.9 1.77 450
495 0.90
83 0.95
124 1.12
124 1.32
core wt in KG with rejection 1.39
wdg1 Cu wt in KG 0.2926
wdg2 Cu wt in KG 0.4413
wdg3 Cu wt in KG 0.0818
wdg4 Cu wt in KG 0.2139
wdg5 Cu wt in KG 0.2970
Core price in Euro: 3.5130
Cu Price wdg1 in Euro: 2.4560
Cu Price wdg2 in Euro: 3.7184
Cu Price wdg3 in Euro: 0.6894
Cu Price wdg4 in Euro: 1.7953
Cu Price wdg5 in Euro: 2.4930
Cost (Cu & steel) 14.6651
 DESIGN DETAILS

Print Trafo :

VA Core Size (Print) Core size (Open) Tesla %Uo

1.6 31x16x10 33x18x10 1.7000 28.6
3.2 35x16x10 37x18x10 1.6998 40.7
5 40x16x10 42x18x10 1.7534 44.5
7 40x17x13 41x19x15 1.6994 33.9
10 46x17x15 48x19x15 1.7000 20.0
15 50x18x15 52x20x15 1.6995 23.0
25 50x23x25 53x26x25 1.6979 18.9
35 58x32x20 58x32x20 1.6999 15.0
50 65x38x23 65x38x23 1.6995 15.0

Open Trafo :

VA Core size (Open) Tesla %Uo Current Desity A/mm2

5 40x20x20 1.70 9.50 3.9
10 50x30x13 1.70 9.50 3.9
15 50x30x20 1.70 9.50 3.8
20 50x30x25 1.70 8.70 3.8
25 60x40x17 1.70 8.70 3.8
30 60x40x20 1.70 9.50 3.8
40 60x40x25 1.70 8.70 3.8
45 70x40x17 1.70 8.70 3.8
50 60x40x30 1.70 8.00 3.8
50 70x40x20 1.70 8.00 3.8
65 70x40x25 1.70 7.20 3.8
70 80x50x17 1.70 8.70 3.8
80 70x40x30 1.70 6.50 3.8
80 80x50x20 1.70 8.00 3.8
80 85x50x17 1.70 8.00 3.8
100 80x50x25 1.70 7.20 3.8
100 85x50x20 1.70 7.40 3.8
120 80x50x30 1.70 6.50 3.8
120 85x50x25 1.70 6.60 3.8
135 100x60x17 1.70 7.50 3.8
145 85x50x30 1.70 6.10 3.8
160 80x50x40 1.69 5.70 3.8
160 100x60x20 1.70 7.00 3.8
170 100x50x17 1.70 6.70 3.8
200 85x50x40 1.69 5.20 3.8
200 100x50x20 1.70 6.20 3.8
 200 100x60x25 1.70 6.20 3.8
200 120x70x17 1.70 6.70 3.8
225 100x60x30 1.70 6.00 3.8
250 80x50x50 1.69 4.90 3.8
250 85x50x50 1.69 4.50 3.8
250 100x50x25 1.70 5.60 3.8
250 120x70x20 1.70 6.20 3.8
300 100x50x30 1.69 4.90 3.8
300 100x60x40 1.68 4.70 3.8
300 120x70x25 1.69 5.60 3.8
375 100x60x50 1.68 4.10 3.8
375 120x70x30 1.68 4.90 3.8
400 100x50x40 1.68 4.10 3.8
400 145x80x20 1.68 5.50 3.8
500 100x50x50 1.67 3.50 3.8
500 120x70x40 1.67 4.10 3.8
600 145x80x25 1.67 4.70 3.8
625 120x70x50 1.66 3.70 3.8
625 145x80x30 1.66 4.20 3.8
800 145x80x40 1.65 3.50 3.8
1000 120x70x80 1.63 2.30 3.8
1000 145x80x50 1.63 2.80 3.8
1000 180x100x30 1.65 3.50 3.8
1300 145x80x60 1.60 2.40 3.8
1300 180x100x40 1.61 2.80 3.8
1600 180x100x50 1.59 2.30 3.8
1900 180x100x60 1.56 2.00 3.6
2200 180x100x70 1.54 1.80 3.2
2500 180x100x80 1.52 1.80 2.7
2500 220x120x60 1.52 1.80 2.7
2800 180x100x100 1.50 1.70 2.3
2800 220x120x60 1.50 1.80 2.3
3200 220x120x70 1.47 1.70 2.0
3700 220x120x80 1.47 1.70 2.0
4400 250x140x60 1.47 1.70 2.0
5000 250x140x80 1.47 1.70 2.0
6000 250x140x90 1.47 1.70 2.0
7500 300x140x60 1.47 1.70 2.0
Current Desity A/mm2 Case Dimension(mm)
3.74, 3.87 39.6x39.6x18.5
5.1, 5.86 44.7x44.7x19.5
6.43, 6.62 49.7x49.7x19.5
5.3, 6.68 49.7x49.7x23.1
4.93, 5.35 55.0x55.0x26.0
5.98, 5.68 60.0x60.0x26.3
5.11, 5.87 60.0x60.0x37.5
4.1, 3.74 72.0x72.0x37.5
3.51, 3.92 82.4x82.4x37.5

Core Weight Kg Copper Loss Watts Core Loss in Watts

0.141 1.00 0.16
0.123 2.10 0.14
0.188 3.30 0.21
0.236 4.30 0.26
0.200 5.40 0.22
0.236 6.40 0.26
0.295 7.40 0.33
0.330 7.90 0.37
0.353 8.30 0.39
0.389 8.30 0.43
0.486 10.70 0.54
0.391 11.60 0.43
0.583 13.20 0.65
0.459 13.20 0.51
0.473 13.20 0.53
0.574 14.80 0.64
0.557 14.80 0.62
0.689 16.40 0.76
0.696 16.40 0.77
0.641 19.00 0.71
0.835 20.70 0.93
0.919 23.30 1.00
0.754 23.30 0.84
0.751 23.40 0.83
1.113 23.70 1.20
0.884 23.70 0.98
 0.942 23.70 1.00
0.951 23.70 1.10
1.131 24.00 1.30
1.149 26.00 1.30
1.392 25.00 1.50
1.104 25.00 1.20
1.119 25.00 1.20
1.325 26.00 1.50
1.508 26.00 1.70
1.399 26.00 1.60
1.885 32.00 2.10
1.679 32.00 1.90
1.767 34.00 2.00
1.723 34.00 1.90
2.209 35.00 2.50
2.238 35.00 2.50
2.154 35.00 2.40
2.798 43.00 3.10
2.584 43.00 2.90
3.446 46.00 3.80
4.477 47.00 5.00
4.307 47.00 4.80
3.958 47.00 4.40
5.169 65.00 5.70
5.278 66.00 5.90
6.597 67.00 7.30
7.917 69.00 8.80
9.236 79.00 10.30
10.556 85.00 11.70
12.017 85.00 13.30
13.195 96.00 14.60
12.017 96.00 13.30
14.019 97.00 15.60
16.022 102.00 17.80
15.162 116.00 16.80
20.216 120.00 22.40
22.743 135.00 25.20
24.881 153.00 27.60