Customer Part number : EI54/18.

8
Primary voltage : 230VAC,50-60Hz
Sec voltage : : 230V/50Hz
Voltage Regulation : 12.45
Mechanical dimensions : --
Temperature class : ta 40°C
No load voltage :257±1V

Design
Materials Selection
Materials Description Manufacturer/Supplier
Bobbin EI54x20D/S -
Lamination (0.50mm thick) Std EI54 pattern,CRNO 0.50 Steel -

Prim1 voltage (V) 230

Sec1 voltage (V) 230
Power (VA) 20
Frequency (Hz) 50
Stack width (mm) 18.8
Lamination thickness (mm) 0.5
Regulation (%) 12.45
Flux density (Tesla) 1.45
Prim Current density (A/mm2) 5
Sec Current density (A/mm2) 5
Core Loss (W/Kg)for 1.70T 1.3

Core selected is std EI41A with 17mm stack

CSA (mm²) 368.48

Prim turns 1939
V/T 0.11861
Sec turns 2180

Turns/Wire size
Wdg Calculated Cu wire size in mm Selected Cu wire size in mm
Prim 0.158 0.15
Sec 0.149 0.15

Primary wdg build up

Bobbin width (mm) 11.25

20.5

20.8

Turns 62
Turns/Layer 31
 Build up (mm) 5.642
Before wdg build up (mm) 82.60
After wdg build up (mm) 105.17
MTL primary (mm) 93.88

DCR Prim including 15% warm

202.509
(ohms)
DCR Sec including 12% warm
225.220
(ohms)
Core weight (Kg) 0.31453434

Iteration

VA : 20.00000
Core Loss : 0.40889 22.11188
Sec. cu. loss : 1.70299
Prim. Cu. Loss : 1.93617
A.V.A : 22.49000 24.04805
I/P Voltage : 230.00000 230.00000
I/P Current : 0.09778 0.10456

Primary voltage drop(%) 9.34

Secondary voltage drop(%) 8.51
Regulation (%) 18.64

Temperature Rise

Core loss (W) 0.4089

Primary Cu loss (W) 2.2771
Sec Cu loss (W) 1.7030
Total transformer loss (mW) 4388.9853
Surface area of transformer (cm3) 85.8240
Temp.Rise (°C) 26.51
 Remarks
-
-

2L (mm) ohms/mtr W/Kg Current (A)

0.182 0.9673 0.166 0.0978
0.182 0.9673 0.166 0.0870

Secondary wdg build up

Bobbin width (mm) 11.25

20.5

20.8

Turns 62
Turns/Layer 35
 Build up (mm) 6.370
Before wdg build up (mm) 82.60
After wdg build up (mm) 108.08
MTL secondary (mm) 95.34

EI66 core weight calculation

Total volume (cm3) 1.215

Free space (cm3) 0.1215
EI 1.0935
Lamination weight (gms) 8.365275
No.of laminations Total weight (gms) 314.53434
38

Primary copper weight (Kg) 0.0317308649

Secondary copper weight (Kg) 0.0382293234

22.11188 22.11188 22.11188 22.11188

2.21399 2.26510 2.27496 2.27668

24.32587 24.37698 24.38684 24.38856
230.00000 230.00000 230.00000 230.00000
0.10576 0.10599 0.10603 0.10604

Sec 1 New Turns 2301

V0 (V) 272.87
Cu. dia CUL dia CULL dia Ohms/Mtr
0 0 0 0
0.056 0.067 0.074 6.94
0.063 0.076 0.083 5.484
0.071 0.084 0.091 4.318
0.08 0.094 0.101 3.401
0.085 0.1 0.107 3.012
0.09 0.105 0.113 2.687
0.1 0.117 0.125 2.176
0.118 0.136 0.145 1.563
0.125 0.144 0.154 1.393
0.132 0.152 0.162 1.249
0.14 0.16 0.171 1.11
0.15 0.171 0.182 0.9673
0.16 0.182 0.194 0.8502
0.17 0.194 0.205 0.7531
0.18 0.204 0.217 0.6718
0.19 0.215 0.228 0.6029
0.2 0.226 0.239 0.5441
0.212 0.24 0.254 0.4843
0.224 0.252 0.266 0.4338
0.236 0.267 0.283 0.3908
0.25 0.281 0.297 0.3482
0.265 0.297 0.314 0.3099
0.28 0.312 0.329 0.2776
0.3 0.334 0.352 0.2418
0.315 0.349 0.367 0.2193
0.335 0.372 0.391 0.1939
0.355 0.392 0.411 0.1727
0.375 0.414 0.434 0.1548
0.45 0.499 0.513 0.1075
0.475 0.519 0.541 0.09646
0.5 0.544 0.566 0.08706
0.53 0.576 0.6 0.07748
0.56 0.606 0.63 0.0694
0.6 0.649 0.674 0.06046
0.63 0.679 0.704 0.05484
0.67 0.722 0.749 0.04848
0.71 0.762 0.789 0.04318
0.75 0.805 0.834 0.03869
0.8 0.855 0.884 0.03401
0.85 0.909 0.939 0.03012
2 2.074 2.112 0.005441
2.12 2.196 2.235 0.004843
 2.24 2.316 2.355 0.004338
2.36 2.438 2.478 0.003908
2.5 2.578 2.618 0.003482
2.65 2.73 2.772 0.003099
2.8 2.88 2.922 0.002776
3 3.083 3.126 0.002418
3.15 3.233 3.276 0.002193
3.35 3.435 3.479 0.001939
3.55 3.635 3.679 0.001727
3.75 3.838 3.883 0.001548
4 4.088 4.133 0.00136

28.3080906 33 4.6919094

43.515237133 58 14.4847629

22.11188

2.27710
24.38899
230.00000
0.10604
Copper weight in
Kg/1000Mtr
0
0.0236
0.0297
0.0378
0.0478
0.0533
0.0604
0.0743
0.1027
0.115
0.129
0.145
0.166
0.188
0.212
0.237
0.264
0.292
0.327
0.365
0.405
0.454
0.51
0.568
0.651
0.717
0.811
0.909
1.01
1.46
1.62
1.79
2.02
2.25
2.58
2.84
3.21
3.6
4.02
4.57
5.15
28.3
31.8
35.5
39.4
44.2
49.6
55.4
63.5
70
79.2
88.9
99.2
113
No Load Current Calculation

Input Voltage(V) 230

Primary turns 1939
Core weight (KG) 0.31453434
Core weight (lb) 0.1429701545
Specific core loss @ 1.7T (W/lb) 0.59
Specific exciting power @ 1.7T (VA/lb) 22.272727273
Flux density (Gauss) 17000
Gap distance in stacked laminations (inches) 0.003
Stacking factor 0.98

Magnetizing current = (Wt x VA/lb / Vin) + ((1.43 x B x g x s) / N)

Loss current = ((Wt x W/lb) / Vin)

No load current = sqrt(Mag.ct^2+Loss ct^2)

Magnetizing current (A) 0.050704

Loss Current (A) 0.002569
No load Current (A) 0.050769 50.769 mA