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Today we discuss only about wire gauge selection, not about total transformer winding process.
Follow the calculation step by which you select the wire gauge👇
See given below all picture👇
Step3 :- Carefully see the below chart where you found the wire gauge according to ampere(current). 👇
When you construct an Automatic Stabilizer Transformer, the most vital thing is to calculate the wire gauge of the winding. If the wire gauge is not equal with the minimum required rated current according to the output load, you got so far voltage drop to the output within no-load & on-load condition.
This is normal fact in every coil related product that when a load is connect on the coil, some voltage drop must be happen due to coil resistance, this is normal case. That's why when you select the wire gauge for winding a coil, you must maintain the minimum wire gauge according to the rated current with respect of required output load.
If the wire gauge is so lower than required, you found more & more voltage drop within no-load & on-load condition.
Also if the wire gauge is so lower than required, you found more & more temperature difference within no-load & on-load condition. You got maximum temperature from transformer when it's maintain 50%-60% load on output & if the transformer running long time on this situation, you found it's coil can burn out at certain stage.
So, wire gauge selection is a very much essential parameter for any of coil related product, specially applicable in transformer.
In transformer related product, if you want to make a warranty included product & if you want to maintain your goodwill in customer segment with this product, firstly you have no other choice except maintain the proper wire gauge in the coil.
Follow the calculation step by which you select the wire gauge👇
Step1 :- Select the capacity of the stabilizer in VA. After that multiply this value with 0.8, You got actual capacity of this stabilizer (80% performace assume).
Example :- If you want to make 500VA Stabilizer, the actual maximum load capacity of this stabilizer is 400watt (80% performace assume).
Step2 :- Now, this is the most important thing is to identify that which wire gauge is use to make this transformer. Let's see carefully the transformer design according to our 50V kit given bellow👇
In this picture you see that there have 1 common point & after that there have 5 tapping point, mean's 5 coil. We all are well known that an automatic stabilizer transformer work as an step-up & step-down in both situation according to input voltage with respect of output voltage as operated by relay. So, at the low input voltage condition it's work on Boost situation for increasing the output voltage & at the high input voltage condition it's work on Buck situation for decreasing the output voltage. Now here we assume that the common neutral point is A & after that first tapping at 62V point is B, next at 92V point is C, at 136V point is C, at 166V point is D, at 200V point is E.
Now we start calculation of our transformer coil step by step from low voltage.
Calculation stage 1:-
Calculation stage 1:-
Previously you see the calculation in which we find out our transformer capacity which we want to make is 400 Watt. so, when the 400 watt load is apply on output of the stabilizer & is this time the line voltage is just only 62 Volt, at this situation the stabilizer output is 200 Volt which we got practically by our design. so, the current flow through the load is Watt/Voltage which is 400/200 = 2 Amp. At this condition, the input voltage apply in A to B Point which is 62 Volt. The gap (Output - Input) voltage must generate by output coil which is B to F. Generally the load current is obviously flow through the output coil & so it's wire gauge not less than 2 Amp support wire gauge. This is the secondary wire gauge calculation scenario. Follow the wire gauge chart at the bottom. But it's just final for E to F coil wire gauge, not for B to F total coil wire gauge. Don't forget that we get another situation when E to F is only secondary coil & A to E is totally primary coil. So, before doing the calculation we never confirm about the B to E coil wire gauge.
Now let's find-out the primary gauge mean's A to B coil wire gauge. First we calculate the secondary coil load. The secondary coil load is in watt = volt x amp mean's gap (Output - Input) voltage x load current = (200-62) x 2 = 276 watt. Previously we know that this transformer efficiency is 80%, so the secondary coil load is 80% load of primary coil which not include the core loss. So, the primary coil load is 276 x 100/80 = 345 watt at that time. This is the most & most vital point which look-over by maximum manufacturer & that's why their transformer don't have longer life in low voltage. Now it's easy for us to find-out the primary coil current flow which is watt/volt = 345/62 = 5.5645 amp. Now we got just A to B wire gauge. Follow the wire gauge chart at the bottom.
See given below picture👇
See given below picture👇
Calculation stage 2:-
This time the line voltage is just only 92 Volt, at this situation the stabilizer output is 200 Volt which we got practically by our design. so, the current flow through the load is Watt/Voltage which is 400/200 = 2 Amp. At this condition, the input voltage apply in A to C Point which is 92 Volt. The gap (Output - Input) voltage must generate by output coil which is C to F. Generally the load current is obviously flow through the output coil & so it's wire gauge not less than 2 Amp support wire gauge. This is the secondary wire gauge calculation scenario. Follow the wire gauge chart at the bottom. But it's just final for E to F coil wire gauge, not for C to F total coil wire gauge. Don't forget that we get another situation when E to F is only secondary coil & A to E is totally primary coil. So, before doing the calculation we never confirm about the B to E coil wire gauge.
Now let's find-out the primary gauge mean's A to C coil wire gauge. First we calculate the secondary coil load. The secondary coil load is in watt = volt x amp mean's gap (Output - Input) voltage x load current = (200-92) x 2 = 216 watt. Previously we know that this transformer efficiency is 80%, so the secondary coil load is 80% load of primary coil which not include the core loss. So, the primary coil load is 216 x 100/80 = 270 watt at that time. Now the primary coil current flow is watt/volt = 270/92 = 2.9347 amp. Previously we got A to B wire gauge. Now we got just B to C wire gauge. Follow the wire gauge chart at the bottom.
See given below picture👇
Calculation stage 3:-
This time the line voltage is just only 136 Volt, at this situation the stabilizer output is 200 Volt which we got practically by our design. so, the current flow through the load is Watt/Voltage which is 400/200 = 2 Amp. At this condition, the input voltage apply in A to D Point which is 136 Volt. The gap (Output - Input) voltage must generate by output coil which is D to F. Generally the load current is obviously flow through the output coil & so it's wire gauge not less than 2 Amp support wire gauge. This is the secondary wire gauge calculation scenario. Follow the wire gauge chart at the bottom. But it's just final for E to F coil wire gauge, not for D to F total coil wire gauge. Don't forget that we get another situation when E to F is only secondary coil & A to E is totally primary coil. So, before doing the calculation we never confirm about the B to E coil wire gauge.
Now let's find-out the primary gauge mean's A to D coil wire gauge. First we calculate the secondary coil load. The secondary coil load is in watt = volt x amp mean's gap (Output - Input) voltage x load current = (200-136) x 2 = 128 watt. Previously we know that this transformer efficiency is 80%, so the secondary coil load is 80% load of primary coil which not include the core loss. So, the primary coil load is 128 x 100/80 = 160 watt at that time. Now the primary coil current flow is watt/volt = 160/136 = 1.1764 amp. Follow the wire gauge chart at the bottom. Previously we got A to C wire gauge. Now we got just C to D wire gauge. But in this calculation stage we see that our present primary current calculation value is lower than load current value, which never allow for design. so we must maintain the next all coil wire gauge means D to E & E to F equal to our first stage calculation. After that no need to calculate the next coil wire gauge when you got the present primary coil current value is lower than last output coil current value & maintain the equal gauge for all rest coil. Follow the wire gauge chart at the bottom.
See given below all picture👇
Note:- "We well known that the theory never meet the practical due to cheap price demand from customer end".
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