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Toroidal Transformer
Customized

Customized toroidal transformers can be designed within the following limits.

Specifications:
Power:
Frequency:
Primary:
Secondary:
Temperature:
Dimensions:
Approvals:

5 - 10.000 VA
10 - 2.000 Hz
< 1.000 VAC
< 1.000 VAC
Customer specified
Customer specified
EN61558-1, UL506,
UL60601-1
Below are listed some different design possibilities, that can be used as inspiration when designing the toroidal transformer. The design inspiration is divided into the following areas:
Transformer Type and Size
Safety transformer, protective transformer, separating transformer or autotransformer. "High and narrow" or "low and wide".
Mounting
Vertical or horizontal. Moulded into housing, DIN-rail mounted, metal disc mounted, centre-potted with through-hole or flange mounted.
Connections
Solid wires in a sleeve or Stranded flexible wires. Open ended or terminated with terminals or connecters.
Safety
Thermal switches and fuses.
Standards and Approvals
In accordance with EN, UL, UL-Medico, VDE, DEMKO.

Transformer Type and Size
The toroidal transformer can be designed with seperated primary and secondary windings for safety transformers, protective transformers and separating transformers.

Another possibility is to design the transformer as an autotransformer where the primary and secondary outlets are directly connected. Using an autotransformer will reduce the size of the transformer when compared to a transformer with separated windings.

Using different core designs can greatly vary the height and diameter of the toroidal transformer, as long as the cross section area of the core is held constant. Below is shown an example of three transformers with the same effect but three different designs.


Low and wide

Standard

High and narrow

The standard transformer is designed so that the diameter of the transformer is approximately
2 - 2,5 times larger then the height of the transformer.

Mounting
The mounting of the toroidal transformer can be made in different ways. Below are shown five different mounting solutions.


Metal disk mounted

Centre potted with a thru-hole

Flange Mounted

DIN-Rail bracket

Encapsulated

All standard transformers are delivered with 2 rubber and 1 metal disk. This mounting style will of cause add to the total height of the transformer.

Another solution is to make a centre potting with a through hole which can be used for the mounting. The centre potting can be kept below the edge of the transformer, hence not adding to the height of the transformer.

Other types of mounting for the toroidal transformer include flange mounting for vertical mounting or the transformer can be fitted with a DIN-Rail bracket for quick snap in mounting.

The transformer can also be encapsulated in a cylindrically or square housing with various mounting solutions. Using a encapsulation will protect the transformer and add different possibilities when it comes to connections

Connections
The toroidal transformer can be supplied with a variety of different wires and connectors.

The connection to the transformer can be made with different types of solid or stranded flexible wires in the length specified by the customer. Standard transformers are supplied with open ended wires in a length of 250 mm.

The wires from the transformer can be terminated with different connectors. Below are listed some of the connecters commonly used for customized transformers.

AMP / Tyco Electronics
(www.tycoelectronics.com)
Molex
(www.molex.com)
Adels-contact
(www.adels-contact.de)
Wago
(www.wago.com)
Phoenix Contact
(www.phoenixcontact.com)
Other types of connectors include PCB-pins when using housing, cables with moulded mains connectors (e.g. EU-plug or US-plug) or if required customer specified terminals.

Safety
The toroidal transformer can be designed with different types of thermal switches and electrical fuses integrated in the transformer, thereby insuring a shut down of the transformer and connected circuit in case of overheating or overload.

Inserting a thermal switch directly in the primary winding will allow the transformer to automatically turn of if it becomes overheated.

Standards and Approvals
The toroidal transformers can be made in accordance with national and international standards such as; EN, UL, CSA, VDE and DEMKO. Custom designed toroidal transformers can furthermore be UL certified with family approvals for Speciality Transformers UL 506 and transformers for medical electrical equipment UL 60601-1.

Scandinavian Transformer Sp.zo.o.   ·   Tel.: +48 (0) 46 832 47 09 / +45 9858 1022   ·   E-mail: sk@skandinaviantransformer.com.pl