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Toroidal Transformers design steps
Toroidal Transformers design steps
Where VA is volt-ampere
VFL is full-load AC secondary voltage in volts
IFL is full-load AC secondary current in amperes
A smaller transformer can be used if the load is intermittent. Because the output
power in this case significantly exceeds the nominal power, the secondary voltage
drops below the voltages given. The voltage drop increases proportionately with
the current being drawn.
The majority of toroidal power transformers are designed to operate in 50/60 Hz,
60 Hz, or 400 Hz applications. As the frequency increases, the transformer size
decreases accordingly. A 60 Hz toroidal transformer will be ~20% smaller than a
50 Hz toroidal transformer.
Step 5: Turns Ratio
Step 6: Regulation
The secondary voltages and currents are valid for normal output power. At partial
load, the output voltage, as a function of transformer size, will be accordingly
higher. The below figure shows the voltage increase for Talema standard toroidal
transformers for partial loads.
As can be seen from the graphs below, Talema standard toroidal transformers are
designed for a temperature rise of 60 °C to 70 °C at nominal load. When choosing a
transformer size, the ambient temperature and heat sink coefficient of the
mounting place must be taken into consideration. Figures show the typical
temperature change which occurs as a function of output power or overload.
Step 9: Multiple Windings or Single Winding (Autotransformer)
Talema has family approval for autotransformers to 25 KVA for UL5085 (general
purpose transformers) and 40 KVA for UL60601-1 (transformers for medical and
dental equipment) standards.
The below figures give formulae for the calculation of approximate values of the
transformers and are primarily dependent on the size of the loading capacitor to
be used. The applied form factor “F” is rated between 1.1 for smaller capacitors
and 2.5 for relatively large capacitors.
The absence of a gap in the toroidal core means that the maximum possible
remanence (residual magnetization of the core in a particular direction and
magnitude can be substantially more pronounced in a toroid when compared to an
E-I laminate). This residual magnetism is the mechanism by which old computer
core memories functioned. The core “stores” the static magnetic bias when the
power is switched off. If the removal of power occurs at an unfavorable time, the
strongest magnetic remanence will be stored in the core. When power is again
applied to the primary, the peak inrush current may be as great as
where Vp-pk is the peak primary voltage, and Rp is the DC resistance of the primary
winding, depending on the power capability of the transformer, and on how
strongly the core was magnetized. This inrush current peak occurs for a short time
during the first or second half period of the power sine wave.
1. Adding an NTC thermistor in series with the primary winding of the transformer
2. Using slow-blow fuses for utilizing delayed actions
3. Reduce the residual flux which will increase the magnetization current in the
core. Methods used to reduce residual flux include introducing a gap or utilizing
alternate materials or annealing methods.
The purpose of these devices is to cut off the transformer in the event of
overheating. The one-shot fuse is used primarily for protection from internal
transformer faults, tripping at a preset temperature. The auto-resettable thermal
switch provides intermittent protection from internal transformer faults and
external overloads. This device opens at a preset high temperature and closes at a
preset lower temperature. These devices are mounted internally to the
transformer and wired in series with the primary or secondary winding.
Thermal Switch