A custom step up transformer is designed to increase voltage according to the specific electrical and mechanical requirements of an application. While standard transformers are available for common voltage and power requirements, some applications require non-standard voltage ratios, current ratings, insulation, dimensions, mounting arrangements, or winding configurations.
Custom Coils designs and manufactures step up transformers according to application-specific requirements, providing engineering support from initial specifications through manufacturing and testing.
What Is a Custom Step up Transformer?
A custom step up transformer is designed to increase AC voltage while meeting requirements that may not be available in a standard transformer.
In a step up transformer, the secondary winding has more turns than the primary winding. This difference in winding turns causes the secondary voltage to be higher than the primary voltage.
A custom design may be required when an application needs non-standard input or output voltage, a specific turns ratio, unusual current or power requirements, multiple secondary outputs, special insulation, non-standard dimensions or mounting, or specific winding or termination configurations.
The transformer is therefore designed around the actual requirements of the equipment rather than selected solely from a standard catalog.
How Does a Step up Transformer Work?
A step up transformer operates through electromagnetic induction.
When AC voltage is applied to the primary winding, it produces a changing magnetic flux in the transformer core. This changing flux links with the secondary winding and induces an AC voltage.
The secondary winding contains more turns than the primary winding. Because induced voltage is proportional to the number of turns, the secondary produces a higher voltage than the primary.
The basic relationship is:
Vp / Vs = Np / Ns
Where:
- Vp = primary voltage
- Vs = secondary voltage
- Np = primary turns
- Ns = secondary turns
For an ideal transformer, increasing the output voltage results in a corresponding reduction in output current for approximately the same transferred power.
For more detailed transformer operating principles, see the step-up/step-down transformer page.
Step up Transformer Design Requirements
Designing a step up transformer begins with understanding the electrical requirements of the application. The required input and output voltage establish the basic turns ratio, while the current and VA or kVA requirements determine the transformer capacity.
Frequency is also important because the core and winding design must be appropriate for the operating frequency. Insulation requirements become particularly important as voltage increases, while available space can affect the physical construction of the transformer.
The design may therefore need to account for input voltage, output voltage, current, frequency, VA/kVA rating, insulation, dimensions, mounting, and operating environment.
Custom Step up Transformer Configurations
Custom step up transformers can be configured around the requirements of the equipment in which they will be installed.
Customization can involve the input and output voltage combination, turns ratio, number of secondary outputs, winding arrangement, physical dimensions, mounting configuration, insulation system, and lead or terminal arrangement.
This flexibility allows the transformer to be designed for applications where a standard configuration cannot provide the required electrical or mechanical characteristics.
Applications of Custom Step up Transformers
Custom step up transformers are used when equipment or systems require a higher AC voltage than the available input supply provides.
Common step up transformer applications include:
- Industrial equipment
- High-voltage systems
- Power conversion equipment
- Specialized electrical equipment
- Electrical testing equipment
- Application-specific power systems
The exact transformer configuration depends on the voltage level, current requirement, operating frequency, insulation requirements, and physical constraints of the application.
When Do You Need a Custom Step up Transformer?
A custom design is appropriate when an available standard transformer cannot adequately meet the application’s requirements. This may include non-standard input or output voltage, a specific current or VA rating, a particular physical footprint, special insulation, multiple secondary outputs, or a specialized mounting arrangement.
Custom engineering can also be useful when environmental conditions or other application requirements make a standard transformer unsuitable.
Why Choose Custom Coils for Custom Step up Transformers?
Custom Coils provides engineering and manufacturing support for application-specific transformer requirements. The process begins with the customer’s electrical and mechanical specifications and develops the transformer around those requirements rather than adapting the application to a fixed catalog design.
Custom Coils can support requirements involving voltage, current, winding configuration, insulation, dimensions, mounting, and other application-specific considerations.
For applications involving elevated voltage levels, see the high voltage transformer capabilities available from Custom Coils.
For a project-specific requirement, request a quote from Custom Coils with the available electrical and mechanical specifications.
Frequently Asked Questions
What is a custom step up transformer?
A custom step up transformer is designed to increase AC voltage while meeting application-specific electrical, mechanical, insulation, or dimensional requirements that may not be available with a standard transformer.
When do I need a custom step up transformer?
A custom step up transformer may be required when the application needs a non-standard voltage ratio, unusual current or VA rating, special insulation, multiple outputs, limited dimensions, or specific mounting and connection requirements.
Can a custom step up transformer have multiple outputs?
Yes. A custom transformer can be designed with multiple secondary outputs when the application requires different output voltage levels.
What information is needed to design a custom step up transformer?
Important information includes input voltage, output voltage, frequency, current, VA/kVA, phase, dimensions, mounting requirements, insulation requirements, application, operating environment, and required testing or standards.
What is the difference between a standard and custom step up transformer?
A standard transformer is manufactured around predefined specifications, while a custom step up transformer is designed around the specific electrical and physical requirements of an application.
Can Custom Coils manufacture high-voltage step up transformers?
Custom Coils provides transformer designs for applications requiring elevated voltage levels. The appropriate design depends on the required voltage, current, insulation, dimensions, and other application specifications.