How To Build Step Down Transformers With Calculations1

04/03/2022 12:16 How to Build Step Down Transformers with Calculations
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BY SWAGATAM (HTTPS://WWW.HOMEMADE-
CIRCUITS.COM/AUTHOR/SWAG/)
A step down transformer is a device which reduces a higher AC potential to a lower AC potential
as per its winding ratio and specifications.
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In this article we are going to discuss how to design and construct a basic step down transformer
which are typically applied in mains-operated power supplies.
Introduction
This will likely help electronic hobbyists to develop and build their very own transformers based on
their particular demands. Within the next pages, a simplified layout method is presented in order to
achieve satisfactorily developed transformers. On the other hand, the design process may be a
subject of some experimentation.
The tables presented in this article trim computations short which help the designer to find the
appropriate size of wire or even core lamination. Exclusively pertinent data and calculations are
https://www.homemade-circuits.com/how-to-make-transformers/ 1/38
supplied here to ensure that the designer is absolutely not baffled by unwanted details.
Here we will specifically discuss about transformers (https://www.homemade-circuits.com/how-

transformers-work/) which possesses 2 or more winding of insulated copper wire around an iron
core. These are: one primary winding and one or maybe more secondary winding.
Each winding is electrically isolated from the other however are magnetically connected by using a
laminated iron core. Small transformers possess a shell style structure, i.e. the winding are
encircled by the core as demonstrated in Fig. 1. The power supplied by the secondary is in fact
transmitted from the primary, although at a voltage level dependent on the winding ratio of the a
pair of winding.
Video Interpretation
How to Design and Make Transformers (Iron Core)
Basic Transformer Design

As the initial phase towards the design of a transformer, the primary and secondary voltage
evaluations and the secondary ampere rating has to be distinctly expressed.
After that determine the core content to be employed: ordinary steel stamping or cold rolled grain
oriented (CRGO) stamping. CRGO features a greater allowable flux density and reduced losses.
The best possible cross-sectional part of the core is roughly assigned by:
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Core Area: 1.152 x √(output voltage x output current) sq cm.
With regard to transformers having several secondaries, the sum of the the output volt-amp
product of each winding needs to be considered.
The quantity of turns on the primary and secondary winding is determined using the formula for
turns per volt ratio as:
Turns per volt = 1/ (4.44 x 10-4 frequency x core area x flux density)
Here, the frequency is usually 50Hz for Indian household mains source. The flux density could be
considered as approximately 1.0 Weber/ sq. m. intended for ordinary steel stamping and
approximately 1.3 Weber/ sq. m. for CRGO stamping.
Calculating Primary Winding

The current in the primary'winding is presented by the formula:
Primary Current = Sum of o/p Volt and o/p Amp divided by Primary Volts x efficiency
The efficiency of small transformers can deviate between 0.8 to 0.§6. A value of 0.87 works
extremely well for regular transformers.
The appropriate wire size needs to be determined for the winding. The wire diameter is dependent
upon the current rated for the winding and also the permitted current density of the wire.
The current density could be as tall as 233 amps/ sq. cm. in small transformers and as minimal as
155 amps/ sq. cm. in big ones.

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Winding Data
Typically, a value of 200 amps/ sq. cm. may be considered, according to which Table#1 is created.
The amount of turns in the primary winding is presented by the formula:
Primary Turns = Turns per Volt x Primary Volts
The room consumed by the winding is determined by the insulation density, technique of winding
and the wire diameter.
Table#1 provides the estimated values of the turns per square cm. through which we are able to
calculate the window area consumed by the primary winding.
Primary winding Area = Primary turns / Turns per sq. cm from Table#1
Calculating Secondary Winding

Considering that we have the assumed secondary current rating, we are able to determine the
wire size for the secondary winding simply by going through Table#1 directly.
The quantity of turns on the secondary is calculated in the identical method when it comes to
primary, but around 3% excess turns should be included to reimburse for the internal drop of
secondary winding voltage of the transformer, upon loading. Hence,
Secondary turns = 1.03 (turns per volt x secondary volts)
The window area necessary for secondary winding is identified from Table#2 as
Secondary window area = Secondary turns / Turns per sq. cm. (from Table#2 below)

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Calculating Core size

The principal qualifying measure in picking the core could be the total window area of winding
space accessible.
Total window area = Primary window area + sum of secondary window areas + space for
former & insulation.
A little extra space is necessary to support the former and insulation in between winding. The
specific quantity of extra area may differ, even though 30% could be considered to begin with
although this may need to be customized later on.
Table Dimension of Transformer Stamping
The perfect core sizes possessing a more substantial window space are generally determined
from Table#2 taking into consideration the gap between lamination while stacking them (the core
stacking element may be taken as 0.9), we now have
Gross core area = Core Area / 0.9 sq cm. In general, a square central limb is preferred.
For this, the width of the tongue of lamination is
Tongue width = √Gross core area (sq.cm)
Now refer to Table#2 once again and as a final point find the appropriate core size, having
adequate window area and a nearby value of the tongue width as calculated. Modify thel stack
height as needed to acquire the intended core section.
Stack Height = Gross Core Area / Actual Tongue Width
The stack must not be a lot under the tongue width rather should be more. However, it must not be
greater than 11/2 times the tongue width.

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Core Assembly Diagram
How to Assemble the Transformer

The winding are done over an insulating former or bobbin that fits on the middle pillar of the core
lamination. The primary is generally wound first, and next it is the secondary, keeping an insulation
between the two layers of the winding.
One last insulating layer is applied on top of the winding to safeguard all of them from mechanical
and vibration deterioration. Whenever thin wires are employed, their particular ends needs to be
soldered to heavier wires in order to bring the terminals outside the former.
The lamination are usually put together on the former by alternate lamination reversed in set up.
The lamination has to be tightly bound together through an appropriate clamping framework or by
using nuts and bolts (in case through holes are supplied within the lamination assembly).
How to Apply Shielding

This can be a wise idea to utilize an electrostatic shielding between the primary and secondary
winding to circumvent electrical interference from moving across to the secondary from the
primary.
The shield for step down transformers can be constructed from a copper foil which can be wound
between the two winding for somewhat more than a tum. Insulation has to be presented across the
entire foil and proper care taken in order that the two ends of the foil never come in contact with
each other. Additionally a wire could be soldered with this shielding field and connected with the
ground line of the circuit or with the lamination of the transformer which may be clamped with the
ground line of the circuit.
For Torroidal Transformer designing, you can refer to the following pdf
document:
https://www.homemade-circuits.com/wp-content/uploads/2021/04/torroidal-
transformer compressed pdf (https://www homemade circuits com/wp
transformer_compressed.pdf (https://www.homemade-circuits.com/wp-
content/uploads/2021/04/torroidal-transformer_compressed.pdf)

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About Swagatam
I am an electronic engineer (dipIETE ), hobbyist, inventor, schematic/PCB designer,

manufacturer. I am also the founder of the website: https://www.homemade-circuits.com/,
where I love sharing my innovative circuit ideas and tutorials.
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If you have any circuit related query, you may interact through comments, I'll be most
happy to help!
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Comments
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Faith says
February 10, 2018 at 5:58 pm (https://www.homemade-circuits.com/how-to-make-
transformers/#comment-58344)
This is a very interesting topic especially for me thank you for that
But what in a case i have a transformer salvage from ups and i want to redesign it how do i go
about the calculationt
Thanks and best regards
And as for the sinewave inverter using spwm i’m still on it when I’m done i will share the good
news
thank you once more for help God bless you real good
REPLY
Swag says
Thank you Faith, for modifying a readymade transformer you may have to go in the reverse
manner and first identify the core size and the other parameters then compare them with the
values given in the respective tables and subsequently evaluate the wire sizes and the number
of turns
REPLY
cristian says
February 14, 2018 at 10:52 am (https://www.homemade-circuits.com/how-to-make-
hello friend long time
i looking circuit for water level for up tank and down tank
down tank is whit water and up is low level turn pump on and so
d h hi k i i l 30 3h 220 ?
and what y think i use a automotive rele 30amp to turn a 3hp 220 water pump ?
REPLY
Swag says
hello cristian, you can use any set-reset circuit using IC or transistor, and use the “set” points
at the bottom of the ground tank and use the “reset” points at the brim of the overhead tank,
and wire the relay accordingly.
yes 220V/30 amp relay will work
REPLY
cristian says
i show this but not look ic model
https://http2.mlstatic.com/tablero-con-automatico-para-tanque-cisterna-listo-para-usar-
D_NQ_NP_675905-MLA25094466995_102016-F.jpg (https://http2.mlstatic.com/tablero-con-
automatico-para-tanque-cisterna-listo-para-usar-D_NQ_NP_675905-
MLA25094466995_102016-F.jpg)
REPLY
Swag says
the design is correct, may be the ICs are IC 555
REPLY
charan says

This was useful.Hope you can make a similar post on ferrite core transformers and its switching
supply circuits.
pp y
REPLY
Swag says
I am glad you liked it, if I happen to find the ferrite core formulas, will surely update it here…
REPLY
Sherwin Baptista says

March 1, 2018 at 1:17 pm (https://www.homemade-circuits.com/how-to-make-
Dear,
Now I’ve started to build my own transformers (i’m describing an IRON CORE trafo). First i
considered this difficult and never knew how to do so. Previously i had to compensate someone in
the field to build as per my specs.
Now I’ve cracked the way how to build my own only after seeing this page in your blog.
I’ve got the stamping and frame ordered from Lamington road, purchased varnish and other basic
materials required to build the transformer.
Till date I’ve made just one successfully.
I calculated all the electrical parameters involved in its construction and now its been constructed
and working properly.
REPLY
Swag says
That’s great Sherwin, I am glad you could do it so easily…keep up the good work
REPLY
paaker says
September 3, 2018 at 9:42 pm (https://www.homemade-circuits.com/how-to-make-

Hi Swag,
I got some microwave oven transformers. to rewind for battery charging / inverter purpose. I try to
rewind this transformers secondary line 12-0- 12 my coil gauge was SWG 10 and I have
rewinding it bifilar type finally I got
8v-08v coz no more space to wind.and its working perfect. on this way I have rewind several
transformers with different gauge wires.
now my question is I know how much the voltage output from this transformer. but how to check
how much ampere its giving. it is possible to check a transformers output current without
connecting a load?
regards.
REPLY
Swag says
September 4, 2018 at 8:58 am (https://www.homemade-circuits.com/how-to-make-
Hi Paaker, probably the only way to know is by connecting a correctly rated ammeter directly
across the output wires of the transformer and check the measurement. Do it only for a couple
of seconds, otherwise the transformer or the meter or both could start fuming.
REPLY
paaker says
fine.
its possible to make a Battery charger with this transformer( 8v-0v-8v) to charge 12V 150A
battery? I thing my transformer is around 40-45A. coz the wire I use to wind it was SWG 10.
REPLY
Swag says
yes its possible. use the outer wire to get 16V, and then add a voltage regulator to stabilize
at 14.2V
REPLY
Paaker says
Fine,
can you please suggest me a perfect circuit for this purpose.
Regards.
REPLY
Swag says
September 7, 2018 at 2:11 pm (https://www.homemade-circuits.com/how-to-
make-transformers/#comment-62869)
Here’s a simplest design:
https://www.homemade-circuits.com/wp-content/uploads/2018/08/DC-motor-mosfet-
speed-manage.jpg (https://www.homemade-circuits.com/wp-
content/uploads/2018/08/DC-motor-mosfet-speed-manage.jpg)
Replace the motor with a 1K resistor, adjust the pot to get exactly 14.2V across the 1K
That’s all…now you can connect your battery and let it charge until its terminals reach
14.2V.
For better protection connect a 0.3 ohm 25 watt resistor in series with the positive line,
put this resistor over a large heatsink, and do the same to the mosfet also
REPLY
Osei Kwame says

May 30, 2019 at 11:23 pm (https://www.homemade-circuits.com/how-to-make-
teacher Swagatam I was reading your article on transformer calculations
now how do I know out put current when calculating core area per your calculations. 2 is this
formula applicable to E and I transformers that handle 5Kw of power thanks teacher
REPLY
Swagatam says

Hello Osei, The formulas are applicable for 5 kW but the tables are not, they are limited to 10
amps max.
REPLY
Osei Kwame says

June 1, 2019 at 3:29 am (https://www.homemade-circuits.com/how-to-make-
Thanks teacher Swagatam
REPLY
DEV DATT says

June 4, 2019 at 1:22 pm (https://www.homemade-circuits.com/how-to-make-
Sir thanks for such a good circuit diagrams & details the one thing which is very important
designing the transformer for SMPS Power supplies so sir is it possible to have some help from
your side related to this topic as this is a very critical.
Hope to receive the reply.
Thanks & Regards
REPLY
Swagatam says
Thank you Dev, you can read the following post:
https://www.homemade-circuits.com/how-to-design-and-calculate-ferrite-core-transformers-for-
inverters/ (https://www.homemade-circuits.com/how-to-design-and-calculate-ferrite-core-
transformers-for-inverters/)
REPLY
Victory says
Good day sir, is it possible to wind like 10pcs of wire at same time for primary coil to make it faster
and fewer number of turns and join end to start
REPLY
Swagatam says
Victory, the number of turns should be as per the calculations, adding more number of wires
will increase the current handling capacity of the winding.
REPLY
Christo says
Hi Swag,
As they say the truth, in simple English, shall set you free. Thank you. This is the first clear
discussion I see on trafo’s, especially the relationship between changed voltages and currents. I
was particularly concerned about the effect of the changes in current in step-down trafo’s. One
thing that became very clear is that I can imagine any situation and start from there. I can then
practice the formula’s in every way possible to understand all the effects of all the different
designs. This also gives me the ability to reverse engineer existing trafo’s and understand things
even better.
Thank you, I like the way you explain things that I can follow your thinking. That makes it every
easy to turn my own thinking onto something real.
REPLY
Swagatam says
Thanks Christo,
I am glad you found it useful…please keep up the good work!
REPLY
Tolu says

I made a 78va capacity trafo inverter, i load it With 110w appliances, what may bẹ the effect
technically.
REPLY
Swagatam says
Output voltage will drop proportionately
REPLY
Tolu says
I saw a 1.5kva/24v inverter, the trafo guage amperage was 21.2amps for the battery side and the
ac output sise was 2.64amps. please explain how it is so. For this inverter, it is suppose to be
55amps for the battery side which is not feasible
REPLY
Swagatam says
Pleas multiply the primary side voltage with its current, and the secondary side voltage with its
current to get the wattages at the relevant sides of the trafo.
REPLY
Sam says
July 24, 2019 at 1:18 pm (https://www.homemade-circuits.com/how-to-make-
Hi swagtam. I used the turn per voltage formula and fixed these values:
1/(4.44*10^-4*50hz*528mm^2*1.1) giving me a total of 1/12.89376, equals 0.077556895turns per
voltage, please help me calculate it using my values. The 528mm^2 is the core area, and i got it
from tongue width: 1.6cm * tongue depth: 3.3cm. Please help me out
REPLY
Swagatam says
Hi Sam, we have solve it from top towards bottom, meaning start with current and the voltage
of the primary and secondary and so on, it can be very difficult to do the opposite way.
REPLY
Sam says
Please swagtam what unit is there after the 1.152 in the core area formula, help me write it out in
english, my phone displayed the unit as a tiny box (my phone cannot read the unit). Thanks for
the previous reply.
REPLY
Swagatam says
Sam, That’s a square root symbol.
REPLY
Sam says
July 25, 2019 at 3:06 am (https://www.homemade-circuits.com/how-to-make-
Thanks, and also swagtam i have an e core measuring 1.6cm tongue width and 3.3 tongue depth,
i use the turn per volt formula and i get 8.53turns per volt but i think its wrong. Please help me
calculate the turn per volt using my details, the frequency is 50hz, i just want to know if my answer
is right. Please help me calculate it.
REPLY
Swagatam says
Hi Sam, This article is about iron-core step down transformer, it’s not for ecore.
REPLY
Ceaser Molobye says
Ceaser Molobye says

Good day sir
What is the acceptable gap between the lamination of a transformer unit of a 630kva oil cooled
minisub and the bottom of the tank, the voltage is 6600/550v
REPLY
Swagatam says
Good day Ceaser, sorry I have no idea about it…
REPLY
Shashi Kiran says

October 3, 2019 at 1:55 pm (https://www.homemade-circuits.com/how-to-make-
What type of a transformer is used in a mosquito bat ? its a small black with yellow jacket around
it.
REPLY
Swagatam says
It is a calculated ferrite core transformer. The calculation formulas are explained in this article:
https://www.homemade-circuits.com/how-to-design-and-calculate-ferrite-core-transformers-for-
inverters/ (https://www.homemade-circuits.com/how-to-design-and-calculate-ferrite-core-
transformers-for-inverters/)
REPLY
Jan says

Hi Swagatam,
I intend to build my own transformer winding Machine. I find it difficult to find plans to do this even
te d to bu d y o ta so e d g ac e d t d cu t to d p a s to do t s e e
on youtube. Could you perhaps suggest where I can get the necessary info.
Your assistance will be much appreciated.
Regards
Jan
REPLY
Swagatam says
Sorry Jan, presently I do not have any information regarding transformer winding machine. If I
happen to find it I’ll surely update in my blog.
REPLY
Jan says
Thank you Swagatam
REPLY
Ralph Koeniger says

April 5, 2020 at 2:05 am (https://www.homemade-circuits.com/how-to-make-
Hello Swag,
Sincerely appreciate gentlemen like you who help tinkerers like us! I just bought a kiln requiring
208volts and my service is 242volts. The kiln manufacturer tells me I can run the kiln, but the
elements will fail prematurely, replacement cost for 240 elements is $700+. Would you be so kind
as to help me create a drop down transformer either for each leg of 17 or so volts or in combo of
about 32 volts, please? I can make the steel core parts and wind the whole thing by hand – I am
very meticulous. Have more time than money! Hahahaha!!!! I am not the best at math so doing
the calcs myself without guidance from a seasoned vet like you, would not be smart on my part. I
don’t want to blow up the kiln I just invested $500 in. Thank you very much – in advance!
REPLY
Swagatam says
Thank you Ralph, A transformer based design may not be so appropriate since it will be bulky,
difficult to calculate and prone to mistakes. The easiest and the ideal way to provide a
controlled power to a kiln element or any resistive load is through a triac based phase chopper
circuit as explained in the following article:
https://www.homemade-circuits.com/how-to-make-simplest-triac-flasher/
(https://www.homemade-circuits.com/how-to-make-simplest-triac-flasher/)
You can use any of the the last two designs for controlling your kiln element heat very
efficiently and provide a long life to the element.
REPLY
Ralph Koeniger says

April 5, 2020 at 11:26 pm (https://www.homemade-circuits.com/how-to-make-
Hey Swag,
Greatly appreciate the speedy reply. I reviewed your recommendation and think the second
design would be best with just a couple increments (resistors) rather than 4, but I have some
concerns of which may or may not be warranted based on my limited knowledge on the
subject… namely – “minimum transients and spikes” & “generation of lots of RF.” The kiln
draws 53 amps and has a digital controller that ramps up temp, holding times, etc. Will there be
varied voltages, RF emissions that interfere with the controller and are the components capable
of handling 53 amps? Thank you!
REPLY
Swagatam says
Thanks Ralph, there will be RF emission when the load is operated with reduced power,
and the Rf will decrease as the power on the load is increased using the potentiometer.
However the L1, C1 is specifically to cancel these RF, so if these are correctly optimized,
the RF emission can be expected to be minimum. The L1, C1 will also work to absorb
spikes and transients.
53 amps looks very high, so the triac will need to be rated accordingly. Finding a 60 to 100
amp triacs is not easy, so this may be an issue.
To solve this a simpler design could be as shown below:
This design might also work as efficiently as one can expect. The bridge rectifier will also
need to be rated at 60 to 100 amps
REPLY
Ralph Koeniger says

Hello again Swag, I contacted an electronic parts supply company, emailed the schematic you
recommended and they replied:
“In order for us to locate a components on our website, please provide specification for each
component on the diagram.”
So I called the tech support department and they said they need more information on the
individual parts, their values, voltages, style of the caps, etc. I know I am asking a lot, but
could I impose upon you for some detail on those components so the supply house can find
them for me, please? Thank you.
REPLY
Swagatam says
Hello Ralph, In general when the part numbers are without specifications that suggests
any variant and type can be used.
In this circuit, resistors can be 1/4 watt 5%, pot can be any 5K or 10K linear pot, capacitors
can be ceramic disc type, MOSFETs can be IRF740 10nos in parallel.
Bridge rectifier should be 70 to 100 amp rated, IC can be any IC 555
REPLY
Ralph Koeinger says

Thank you so very much, really appreciate you going back and forth with on this. You are
very kind!
ey d
REPLY
Swagatam says
It’s my pleasure, thanks!
REPLY
Ralph Koeniger says

Good afternoon Swag,
Hope you and yours are well.
Got all the components, but the 470R (its on the way). Unfortunately I am a bit confused as
to how to actually make the connections. I am especially confused about how (which
terminals) the two 120v legs from the panel connect to the Rectifier and then how the
dropped voltage (104v) legs go back to the Kiln. The mosfet has three legs, it connects to
the 470R – how? The G leg appears to be an output going to the load, but the load has two
104v legs required to run it? The 1K resistor connects to 4, 8 & +12volt AND pin 7 from the
555 IC? What about the negative12v leg – where does it connect? How does the 5K
connect to the 1N4148, and pins 6 & 2, but how? I laid out the parts, lined them up and
labeled them, took a picture of it, but don’t know how to attach it. Sorry about being such a
neophyte, can’t get this wrong. BTW I have a couple pretty big heat sinks with fans to cool
the rectifier and mosfet. And I’m using a computer 12v pwr supply. Thank you!!!
REPLY
Swagatam says
Hi Ralph,
the connections has to be exactly as shown in my previous diagram. (+) of the bridge
goes to the load, the other leg of the load goes to the MOSFET drain. The bridge (-) and
the 12V (-) must join as a common negative line, which is indicated as the 0V line in the
diagram. So the -12V or the negative of the 12V must connect with the indicated 0V line
of the circuit
of the circuit.
REPLY
Swagatam says
the pot center pin goes to pin6/2 o the IC, and the other outer pins go to the diodes.
REPLY
Ralph Koeniger says

Thank you Sir! I’m on it!
REPLY
Ralph Koeniger says

Hello yet again Swag,
You have been gracious with your time and information. I feel like I need to pay you for this
and will if you wish… On the other hand, if I have “overstayed my welcome” on this forum,
please simply don’t respond, I completely understand. Otherwise, I have just a couple final
questions…
1. The S leg on the mosfet goes to 0V? What about B, the back of the mosfet, does that need
to go to ground or should it be isolated? I will be mounting it to its own heatsink.
2. Does the pot dictate the voltage coming out of leg 3 of the IC, therefore determining the
voltage coming out D leg of the Mosfet? Is there a tolerance for the pot?
3. Will the voltage going to the load, (one leg coming from D, on a 6AWG, and the other
coming from the + side of the bridge also 6AWG), will each leg going to the load be around
104volts AC? The bridge will be mounted to a fan cooled heatsink, should the back be
grounded or isolated?
4. Speaking from my VERY limited knowledge and pardon me for even questioning – but I
don’t understand connecting the neg of the 12v pwr supply to the ground (0V) from the
electrical panel. Could it just connect to the 100n at leg 5 of the IC or does it need the loop
kinda thing? It must frustrate you dealing with neophytes like me. Sorry for troubling you with
these questions, but thank you for helping.
REPLY
REPLY
Swagatam says
Hello Ralph, I’ll try to answer your questions:
1) The back of the MOSFET can remain isolated from the supply lines. Only a heatsink
may be clamped with the MOSFET back.
2) The pot adjusts the pulse widths (https://www.homemade-circuits.com/timer-ic-555-
explained/) of the pin 3 output pulses.
3) THe bridge output will be 104 AC x 1.41 = 146.64 V DC. The back of the bridge can
also remain isolated if it has 4 individual legs on the other side.
4) You can connect the negative of 12V to any point of the shown 0V line.
REPLY
Swagatam says
Hello Devendra, i have a PCB related article posted in my website, you can find it here
https://www.homemade-circuits.com/how-to-make-pcb-at-home/ (https://www.homemade-
circuits.com/how-to-make-pcb-at-home/)
REPLY
DHARNIDHAR KUMAR says

sir apka table no 1 16 ampear tak he ha 40 ampear ka liya kya kar kon swg wire and turn per
square meter use kara
REPLY
Swagatam says

Dharnidhar, the range of the above calculation is 10 amp maximum only, 40 amp cannot be
made using the above calculations
REPLY

May 29, 2020 at 11:48 am (https://www.homemade-circuits.com/how-to-make-
DEAR SIR TO HAM 18V-0-18V,40A PRIMARY TO 0-230V-600V AND 12V AC SECONDRY
TRANSFORMER KAISE BANAEN
REPLY
Swagatam says
Sorry mere pass uska data nahi hai abhi. Ebay se readymade sample kharid kar check kar
sakte ho.
REPLY

DEAR SIR AAPKE PASS KOI FORMULA HAI JISSE KISI BHI TRANSFORMER KA DATA
NIKALA JA SAKTA HAI
REPLY
Swagatam says
You can try this article for the basic formulas!
https://www.homemade-circuits.com/how-transformers-work/ (https://www.homemade-
circuits.com/how-transformers-work/)
REPLY
Ulises Aguilar says

hellow my friend , hope family doing well and taking care , I´m looking for good Zerner tester , to
check the Volt if it could test up to 554 volt
REPLY
Swagatam says
thanks friend, I am good, presently I do not have the mentioned circuit, if possible I’ll try to
update it in the coming days.
REPLY
Skywatcher says
Very useful ideology
REPLY
Satish Vemuri says

Sir,
Hope you’re doing well … !!!
In recent times i have reviewed couple of Youtube videos on HD Step Down Transformers Home
Made, in most of the videos people show calculations in Inch. Where as in your article, shows in
cm. When compared, process is similar, however formulas are different.
Finally when get SWG values from datasheet, in your article data sheet of SWG based on amp
and Turns per Sq Cm, where as others mention, SWG based on Diameter of Inch, MM, MM2,
kg/m
Concern is SWG and its values are different. So which one would you suggest to prefer. In most
of the videos first we should find out Bobbin size and stack size of EI Core.
In your article, its all based on total power (Watts) and when we find out total winding area
subjected to Primary and Secondary, we will find out from table and can know what would be EI
core type for power.
So please tell, how come SWG values are differ.
REPLY
Swagatam says
Satish, it doesn’t matter how the units are calculated or which approach is used for designing
the transformer, ultimately the number of turns and the thickness of the wire will be
approximately the same for all the standard methods of calculations. The transformer
dimension solely depends on the wattage, voltage and current of the transformer.
REPLY
Abdul Latif says

Hello Swagatam,
Thank this useful article. I have a small 110/220 volt transformer that I used as a step down
transformer when I travel to a 220v country. I burnt this transformer one year ago by putting the
110v side into 220volts source. Now, after reading your article, I decided to rebuild the transformer
using your knowledge. But I have a question, the transformer tag says it is 100 watts, core area is
2×2.5 cm. I used the formula Core Area: 1.152 x √P and found the manufacturer’s 100 watts is not
correct.
REPLY
Swagatam says
Hello Abdul, yes the manufacturer normally do not provide the correct wattage, they always
tend to put higher than the real values…
REPLY
Lambhuc says
December 7, 2020 at 8:20 pm (https://www.homemade-circuits.com/how-to-make-

Is there any other simple way to design isolation transformer?
REPLY
Godfrey Godfrey says

Dear sir, please sir, by means of measurement using a meter rule:
1. Is the Core Area = Tongue width x the short length of the center limb(i.e stack height) Or is the
Core Area = Tongue width x the long length of the center limb?
2. Is the I – irons coupled with the E for determining the four measurements (i.e stack height,
tongue width, window area and core area) Or is the four measurements determined only from the
E – irons assembly?
REPLY
Swagatam says
The details are given in the following diagram, the parameters are exactly as shown in the
image:
https://www.homemade-circuits.com/wp-content/uploads/2018/02/core-assembly.png
(https://www.homemade-circuits.com/wp-content/uploads/2018/02/core-assembly.png)
REPLY

Yes sir, I saw the Core Assembly diagram already.
But I was unable to figure out which and which length of the center limb of the core makes up
the Core Area, since you have not indicated using arrows like that of stack height, tongue width
and window area.
So please sir, clarify this for me please:

Is the Core Area = tongue width x the long length of the center limb?
Or is it
Tongue width x the short length of the center limb (which can be imaged as stack height)?
Please sir, the reason I ask the question is that I have a stabilizer(automatic voltage regulator)
transformer I want to disassemble and make new windings on it to become inverter
transformer.
Please sir, the other thing I asked you was :
g y
If the I – irons is included in the Core Assembly diagram for the four measurements (i.e core
area, stack height, window area and tongue width)
Or it is only E – irons?
Please sir, clarify this for me. Thank you very much.
REPLY
Swagatam says
Godfrey, the core area = tongue width x stack height, or simply the L x B of the central pillar
of the E-core.
The dimensions of the I iron laminations will be exactly as per the E-core lamination and
cross section, as shown below:
REPLY
M. says
December 15, 2020 at 1:21 am (https://www.homemade-circuits.com/how-to-make-
Hi every1!
I’m looking for thoose sheets to build a transformer,
-where can i order such?
…without “minimum order: 1 ton / 2000 lbs.”
Thanks!
REPLY

Okay sir, thank you very much sir.
Please sir, in other words, can the L x B of the bobbin be taken as core area?
ease s , ot e o ds, ca t e o t e bobb be ta e as co e a ea
Again, Please sir, am still confused of this point:

For an inverter with 230/12-0-12V, 10A transformer
Is the inverter power rating = 12 x 10 = 120VA or 24 x 10 = 240VA?
Thank you very much sir for your time.
REPLY
Swagatam says
Hello Godfrey, the transformer current rating provides the information regarding the output
current of the unit, which is usually the stepped-down voltage side, so for your example it will
be 12 x 10 = 120 watts.
REPLY
Charles Bonnnici says

January 15, 2021 at 9:50 pm (https://www.homemade-circuits.com/how-to-make-
One of the best websites for DIY transformer. I really thank you. People like you make a big
difference.
REPLY
Swagatam says
January 16, 2021 at 1:15 pm (https://www.homemade-circuits.com/how-to-make-
Thank you very much, glad the post helped you!
REPLY
Charles Bonnici says

Very informative and to the point. Well done God bless you though you are already blessed. You
make a difference.
REPLY
Swagatam says
Thank you for kind feedback!
REPLY
Don Fring says

I have been looking for a way to create a 12VDC to 6VAC 2A output via a full isolation (voltage
only – RFI passing is OK) transformer for over 10 years now and some may have have seen my
requests in various circuit online offerings for going on this long. No takers yet. Seems simple but
must be a catch. There are not even any low-voltage DC to AC buck converter devices I can find
on eBay, Ali, etc. so it must be that I have to make my own. (Seems a crime to use an inefficient
and loss-full 12VDC to 120AC inverter to power a wall adapter that outputs 6VAC with 2A
maximum output, particularly when solar and 12VDC is my only available power source, and with
only 400W of solar providing all individual daily electrical needs.) And while the 12VDC to 120VAC
to 120VAC to 6VAC conversion with commercially available equipment has significantly more
phantom load when not charging than the 2mA one would assume using a conventional DC to DC
buck converter for some DC need. The level of help I am looking for e.g. if there are no
commercial transformers for this project, I could wind one, what is the shell of transformer I should
order and how many wraps of what gauge wire. Also what is a good 555 and couple of MosFETs
perhaps in a push pull at around 60Hz that seem to be a good solution? I think this project is sort
of a “contrary to everything” need because most power transfers demand much more efficient use
of toroid coils and high speed switching circuits and this one is a poky 60hz. There are many other
factors where devices working at such speeds and voltages just aren’t needed that much these
days and are thus of no day to day popular interest.
REPLY
Arthur Francis Zacchia says

August 20, 2021 at 1:56 am (https://www.homemade-circuits.com/how-to-make-
I have a transformer thats 12-0-12 I wound it so no voltage is produced at the 2 wires there is no
24 volt. Is that correct.
REPLY
Swagatam says
If you have applied the mains AC at the primary, and you are not getting any voltage at the
secondary, then it is wrong
REPLY
Arthur Zacchia says

August 20, 2021 at 12:50 pm (https://www.homemade-circuits.com/how-to-make-
I tried to go in to more detail I am not building a step down, this is a inverter transformer. I got
all done and it said I asked the same question. Thanks for your time.
REPLY
Arthur Zacchia says

Thank you for your time, I guess I should have stated I am working on a inverter transformer.
The first time I wound it I started with two wires as the center tap. Then wound both wires
together in the same direction. Now I have two ends and a center tap. I got 12 volts from one
wire using the center tap then got 12 volts from the other lead and center tap. When I measured
the two end and not the center tap I should have 24 volts. The no reading 0 volts. That what I
saw and was told to do for a interverter transformer. Now I tried the other way doing one wire at
a time and putting insulation between the two wires. Now I have 24 volts on the two leads and 12
volts one each side of the center tap. Which one is correct ? Of the two ways of winding. Thanks
REPLY
Swagatam says
24 V voltage across outer leads, and 12 V between the outer and the center tap is the correct
result, and the correct winding.
REPLY
Timileyin says
St d 220 t 12
Step down 220v to 12v

(1) Give turns per voltage 220v
(2)give turns per voltage 12v
when my stack is 12cm and my tongue 5cm
REPLY
Leonardo Togneri says

I am moving to Europe and I have several electric tool that I would like to use there.
The strongest tools are a miter saw and a worm drive circular saw, both using 13 amps at 110
volts, single fase, 60 herts. Italy has 220 volts, 55 herts electricity.
Is it possible to build a transformer to run a circuit sufficient to to use my tools?
REPLY
Swagatam says
Yes that’s definitely possible. The easiest way probably is to buy a 220 x 7 = 1540 watt
transformer, check the resistance of the 220 V side, then remove the secondary side winding
and replace it with a winding that’s identical to the 220V side, but with 50% less resistance
than the 220V side. The thickness of the wire must two times more than that of the 220V side
wire.
REPLY
mohammad reza mokhari says

October 15, 2021 at 12:29 am (https://www.homemade-circuits.com/how-to-make-
dear sir
I calculate low scale transformer as follow But in the this calculate don’t know amounts “K” & delta
1)- S=k * square (p) S is area & p is apparent power in terms of v.a For 100 to 500 watt
transformers
2)- d=1.13 * (square(I/delta)) d is wire Diameter & I is current
Yours sincerely
REPLY
Swagatam says
, p ( p
Hello Mohammad, sorry I do not have any information about the formula suggested by you, so
can’t help you with this.
REPLY
Spyros T says
November 14, 2021 at 10:18 pm (https://www.homemade-circuits.com/how-to-make-
Hello, first thanks very much for sharing your work, it is truly usefull, is there some book or paper i
can find more about this subject?
REPLY
Swagatam says
November 15, 2021 at 8:21 am (https://www.homemade-circuits.com/how-to-make-
You are welcome!, if you search online you may find many relevant information.
From this website you can also refer to the following article:
https://www.homemade-circuits.com/how-transformers-work/ (https://www.homemade-
circuits.com/how-transformers-work/)
REPLY
Eniola says
Hi sir, can the above core area, turns per volt formula work extremely well will an ordinary iron
core also?or just for crgo only?
REPLY
Swagatam says

Yes it can
REPLY
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subject of some experimentation.

Here we will specifically discuss about transformers (https://www.homemade-circuits.com/how-

How to Design and Make Transformers (Iron Core)

Basic Transformer Design

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Core Area: 1.152 x √(output voltage x output current) sq cm.

Calculating Primary Winding

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Primary Turns = Turns per Volt x Primary Volts

Calculating Secondary Winding

Secondary turns = 1.03 (turns per volt x secondary volts)

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Calculating Core size

Table Dimension of Transformer Stamping

For this, the width of the tongue of lamination is

Tongue width = √Gross core area (sq.cm)

Stack Height = Gross Core Area / Actual Tongue Width

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Core Assembly Diagram

How to Assemble the Transformer

How to Apply Shielding

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hello friend long time

yes 220V/30 amp relay will work

February 17, 2018 at 2:33 pm (https://www.homemade-circuits.com/how-to-make-

Sherwin Baptista says

September 3, 2018 at 9:42 pm (https://www.homemade-circuits.com/how-to-make-

Osei Kwame says

May 31, 2019 at 12:29 pm (https://www.homemade-circuits.com/how-to-make-

Osei Kwame says

DEV DATT says

June 26, 2019 at 11:11 am (https://www.homemade-circuits.com/how-to-make-

Ceaser Molobye says

Ceaser Molobye says

Shashi Kiran says

February 20, 2020 at 9:30 pm (https://www.homemade-circuits.com/how-to-make-

Ralph Koeniger says

Ralph Koeniger says

To solve this a simpler design could be as shown below:

Ralph Koeniger says

Bridge rectifier should be 70 to 100 amp rated, IC can be any IC 555

Ralph Koeinger says

April 16, 2020 at 6:47 pm (https://www.homemade-circuits.com/how-to-make-

Ralph Koeniger says

Ralph Koeniger says