1

Design, Construction, and Fabrication of a

220/50 V, 90 W, 60 Hz Step Down Transformer
Adelaine M. Manalo, Student, Mark Harold S. Mendoza, Student,
Ezrael M. Macandog, Student, and Moses Fran J. Mabute III, Student

as well as the frequency. The efficiency of the transformer

I. INTRODUCTION was not included due to the inaccessibility of measuring
devices. Furthermore, in the following sections,
Transformers are devices that transfer electricity from approximations and ideal assumptions were also considered
one alternating-current circuit to one or more other circuits, in the calculations for the designing part.
either as a step-up or step-down transformer, increasing or
decreasing the voltage, respectively. Through Faraday’s II. DESIGN STAGES
Law of Induction, which describes how a magnetic field
will interact with an electric circuit to produce electromotive The calculations for these transformers take into account
force (EMF), voltage transformation is possible [1]. the availability of materials, core area, turns per volt, and
the determination of primary and secondary turns. By
The dynamic interaction of electromagnetic forces, as
considering these factors, it ensures that the selected
demonstrated by EMF, is the fundamental principle
materials meet the necessary specifications for constructing
underlying transformers. When a stationary closed path is
subjected to a time-varying flux, it gives rise to this EMF, the transformer. Furthermore, all the necessary
resulting in the formation of a closed circuit with a current computations and calculations were patterned to this
in accordance with Lenz's law. This induced current opposes reference [4].
the changes in magnetic flux, resulting in a balanced
interaction of electromagnetic phenomena [2]. A. Core Area of the Transformer (A)

In the design, construction, and fabrication of a 220/50 The best possible core area of the transformer is
V, 90 W, 60 Hz step-down transformer, particular objectives computed using the formula:
are taken into account. At the end of the project
implementation, the students should be able to: a.) design a 𝐴 = 1. 152 (𝑉𝑜)(𝐼𝑂)
single-phase AC transformer that can provide the specified
output; b.) fabricate the designed single-phase AC 𝐴 = 1. 152 (𝑃𝑜)
transformer; and c.) prepare documentation about the
project design and the corresponding calculations, as well as 𝐴 = 1. 152 (90 𝑊)
the fabrication of the transformer. 2
𝐴 = 10. 92883159354 𝑐𝑚
Understanding how transformers work is crucial.
Transformers are important in power generation, The ideal core area for the 220/50 V, 90 W, 60 Hz
transmission, and distribution. Step-up transformers of Step Down Transformer is 11 cm2 with a dimension of
considerable size transport power efficiently over long 1.25 inches by 1.25 inches.
distances, while step-down transformers provide for
sub-transmission and distribution. This project aims to B. Turns per volts
design, construct, and fabricate a 220/50V, 90 W, 60 Hz
step-down transformer and explain the principles of its The turns per volts of the transformer is computed
operation. This may also serve as a documentation and using the formula:
comprehensive guide for the construction of a transformer,
1
with the principles underlying it. 𝑇𝑃𝑉 = 4.44 𝑓 𝐵𝑚𝑎𝑥 𝐴

In designing and constructing the transformer, certain where,

project requirements must be met. First, the transformer 𝑓 = 60 𝐻𝑧 ; since this is the usual frequency in
must be a shell-type transformer with an E-I laminated steel the country
core, and its windings must be wound around a transformer 𝐵𝑚𝑎𝑥 = 1. 5 𝑇; since this is the flux density for
bobbin. The transformer must have a primary and secondary
voltage, which in this case is 220 V and 50 V, respectively. iron steel
It must have a power rating of 90 W and operate at a 𝐴 = 0. 03175 𝑚 * 0. 03175 𝑚; since the area
frequency of 60 Hz. The transformer must have a fuse for of the available bobbin is 1.25 in by 1.25 in
1
both the primary and secondary winding that is correctly 𝑇𝑃𝑉 = (4.44) (60 𝐻𝑧) (1.5 𝑇) (0.03175 𝑚 * 0.03175 𝑚)
sized for the conductors used [3].

The scope of designing and fabricating the transformer 𝑇𝑃𝑉 = 2. 48248744746 𝑡𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑣𝑜𝑙𝑡𝑠
mainly includes maintaining the voltage and power rating,

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2
𝐴𝑊𝑃 = 0. 248015873 𝑐𝑚
C. Primary Winding (220 V)

The computation for the primary winding consists

of the number of primary turns (NP), current of the D. Secondary Winding (50 V)
primary winding (IP), the size of the wire (ACP), and the
primary winding area (AWP). The computation for the secondary winding
consists of the number of secondary turns (NS), the
1) Number of Primary Turns current of the secondary winding (IS), the size of the
wire (ACS), and the secondary winding area (AWS).
The number of primary turns is computed
by the formula provided below: 1) Number of Secondary Turns

𝑁𝑃 = 𝑇𝑃𝑉 * 𝑉𝑃 The number of secondary turns is computed by the

𝑁𝑃 = 2. 48248744746 𝑡𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑣𝑜𝑙𝑡𝑠 * 220 𝑉 formula provided below:

𝑁𝑆 = 𝑇𝑃𝑉 * 𝑉𝑆
𝑁𝑃 = 546. 147238441 𝑡𝑢𝑟𝑛𝑠 ≈ 547 𝑡𝑢𝑟𝑛𝑠
𝑁𝑆 = 2. 48248744746 𝑡𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑣𝑜𝑙𝑡𝑠 * 50 𝑉

𝑁𝑆 = 124. 124372373 𝑡𝑢𝑟𝑛𝑠 ≈ 125 𝑡𝑢𝑟𝑛𝑠

2) Current of the Primary Winding

The current of primary winding is

calculated by the formula below: 2) Current of the Secondary Winding
𝑃𝑜 The current of the secondary winding is
𝐼𝑃 = 𝑉𝑃 calculated by the formula below:
90 𝑊
𝐼𝑃 = 220 𝑉 𝑃𝑜
𝐼𝑆 = 𝑉𝑆
𝐼𝑃 = 0. 409090909091 𝐴
90 𝑊
𝐼𝑆 = 50 𝑉

𝐼𝑆 = 1. 8 𝐴
3) Size of the Wire for the Primary Winding

The size of the wire for the primary

winding is computed by assuming that the density 3) Size of the Wire for the Secondary Winding
of the copper wire (J) is 4 A/mm2.
The size of the wire for the secondary
𝐼𝑝 winding is computed by assuming that the density
𝐴𝐶𝑃 = 𝐽 of the copper wire (J) is 4 A/mm2.
0.409090909091 𝐴
𝐴𝐶𝑃 = 𝐴
4 2 𝐼𝑆
𝑚𝑚
𝐴𝐶𝑆 = 𝐽
2 1.8 𝐴
𝐴𝐶𝑃 = 0. 102272727273 𝑚𝑚 ≈ 27 𝐴𝑊𝐺 𝐴𝐶𝑆 = 𝐴
4 2
𝑚𝑚

2
The computed cross-sectional area of the 𝐴𝐶𝑆 = 0. 45 𝑚𝑚 ≈ 21 𝐴𝑊𝐺
wire is 0.1023 mm2. Thus, the wire size is
approximately 27 AWG as per the American Wire
Gauge Conductor Table. The computed cross-sectional area of the
wire is 0.45mm2. Thus, the wire size is
approximately 21 AWG as per the American Wire
4) Primary Winding Area Gauge Conductor Table.

The primary winding area computation is

based on the winding data of the copper wire. 4) Secondary Winding Area
Thus, a 27 AWG wire size has 504 turns per cm2.
The secondary winding area computation
𝑁𝑝
𝐴𝑊𝑃 = is based on the winding data of the copper wire.
2
𝑡𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑐𝑚 Thus, a 21 AWG wire size has 137 turns per cm2.
125 𝑡𝑢𝑟𝑛𝑠
𝐴𝑊𝑃 = 2
504 𝑡𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑐𝑚

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𝑁𝑆 down. This typically means the secondary has a lower
𝐴𝑊𝑆 = 2
𝑇𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑐𝑚 voltage but a higher current. [6]
547 𝑡𝑢𝑟𝑛𝑠
𝐴𝑊𝑆 = 2
137 𝑇𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑐𝑚 III. MATERIALS
2
𝐴𝑊𝑆 = 3. 99270073 𝑐𝑚 For the construction and fabrication of this project, the
essential materials and tools used and their respective
quantities, models/values, descriptions, and costs are as
E. Total Winding Area follows:​​
TABLE I
The total winding area is computed with the
formula below: Overview of the materials used in this project

𝐴𝑊 = (𝐴𝑊𝑃 + 𝐴𝑊𝑆) * 130 Model/

Quantity Material Description Cost
2 2 Value
𝐴𝑊 = (0. 248015873 𝑐𝑚 + 3. 99270073 𝑐𝑚 ) * 130
Transformer Core
2 (E-I): Made up of
𝐴𝑊 = 4. 240716603 𝑐𝑚 laminated iron
sheets; used to
Accurate calculation of the winding area (AW) is minimize Eddy
Transformer Current Losses
crucial in transformer design, as it directly impacts the 1
1.25” by
Core (E-I) with ₱ 368
1.25”
magnetic properties and overall functionality. This Bobbin Transformer
measurement represents the cross-sectional area of the core Bobbin: Serves as
termination and
for magnetic flux. It is important to allocate an extra 30% winding platform
space for the former and insulation beyond the actual for the
transformer
winding area to ensure proper design considerations [4].
Used for the
AWG Copper
F. Fuse Rating ½ kg 21
Wire
secondary side ₱ 550
(50 V)
The fuse rating is calculated using the derived
Used for the
𝑃𝑜 AWG Copper
formula from 𝑃𝑜 = 𝐹𝑅𝑉𝑝 => 𝐹𝑅 = . 1 kg 27 primary side (220 ₱ 980
Wire
𝑉𝑃 V)

1) Primary Winding Used for overload

1 2A Fuse ₱ 10
protection
𝑃𝑜
𝐹𝑅𝑃 = Used for overload
𝑉𝑃 1 1A Fuse ₱ 10
protection
90 𝑊
𝐹𝑅𝑃 = 220 𝑉 Used to hold the
2 - Fuse Holders ₱ 30
fuses
𝐹𝑅𝑃 = 0. 409090909091 𝐴 ≈ 0. 5 𝐴
Used for
1 - Soldering Lead connecting two ₱ 20
wires
For this project, we utilized 1 A since the
0.5 A fuse got busted during the initial testing. Used to insulate
1 1” Masking Tape electrical ₱ 50
2) Secondary Winding connections

𝑃𝑜 Used to insulate
𝐹𝑅𝑆 = 1 ¾” Masking Tape electrical ₱ 50
𝑉𝑆
connections
90 𝑊
𝐹𝑅𝑆 = 50 𝑉 Used to insulate
1 - Electrical Tape electrical ₱ 50
𝐹𝑅𝑆 = 1. 8 𝐴 ≈ 2 𝐴 connections

Lastly, A step down transformer will have the HV Used to remove

1 P60 Sand Paper insulation from ₱ 11
winding on the outside. [5] The step down transformer the copper wires
winding has more turns in the primary winding which serves
as the high voltage winding. As the secondary winding has Used to remove
1 P120 Sand Paper insulation from ₱ 25
lesser turns than the primary winding, the voltage is stepped the copper wires

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Acrylic Glass
IV. CONSTRUCTION
2 6’’ Used for casing Owned
Working Sheet
This part of the paper contains the step-by-step process of
Used for 220V assembling the Transformer.
1 ½m Male plug chord Owned
input voltage port
A. Bobbin Preparation
1 4-pin See-saw switch Used for on/off Owned

Used for the

Solderless
2 - security of Owned
terminal
terminals

Used for
connecting
solderless
1 1.5mm2 Bullet connector
terminals and
Owned
multimeter
probes

Used to protect
⅕m Heat Shrinking the copper wires
1 Owned
(2mm) Tube and soldered
wires

Used to connect
5X200 Figure 1A. Insulated Bobbin
4 Cable Ties acrylic glass Owned
mm
(cover and base)
The bobbin offers structural support, insulation,
TOTAL ₱ 2154 and organization for the windings, ensuring proper
alignment and preventing electrical shorts. To begin, the
bobbin was insulated to maintain efficiency and
All the parts and materials used were sourced from longevity.
Deeco (Dee Hwa Liong Electronics Equipment
Corporation) in Raon, Quiapo, Manila; owned; and online B. Coil Winding
shopping platforms such as Shopee.

​TABLE II

Overview of the tools used in this project

Quantity Tools Description

Used for continuity

1 Multimeter tests and measuring
the output voltage

Used for cutting

1 Pliers
wires

1 Screwdriver Used for screws

Figure 1B. Low Voltage Secondary Winding
1 Wrench Used for nuts
For the winding, to ensure that it is properly
Used for soldering
1 Soldering Iron
wires insulated, the low voltage winding comes first. The 21
AWG wire was manually wound into the bobbin with
Used for heat 125 turns.
1 Lighter
shrinking tube

Used to make holes

1 Hand drill
in acrylic glass.

All the tools used were personally owned by the

students.

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Figure 2B. Secondary Winding Figure 5B. High Voltage Primary Winding

The coil is wound, preferably close and without For the winding (High voltage winding), the
gaps, to maximize efficiency, maintain uniform magnetic primary coil (27 AWG) was subsequently wound onto
fields, and ensure consistent performance. the bobbin with 547 turns.

Figure 3B. Utilization of Counter and Markings Figure 6B. Primary Winding
Counter application and markings were utilized to Repeating the process in the primary winding,
ensure that the number of turns was correct and accurate. counter application, and markings were also utilized.

Figure 4B. Insulating the Transformer Bobbin Figure 7B. Insulating the Transformer Bobbin
After the winding of the 125 turns, a sufficient After the winding of the 547 turns, another layer of
layer of masking tape was carefully applied for added insulation was applied.
insulation.

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C. Transformer Assembly

Figure 4C. Securing the E-I Cores with Bolts and

Screw
Figure 1C. Core Preparation
Bolts and screws were applied to the 4 corners of
The E-I core was prepared for the assembly of the the E-I core that contains screw holes. Ensure that the
transformer. The E-I core was cleaned to avoid screw and bolts are screwed tightly to secure safety and
unnecessary dirt that can affect the core’s assembly. avoid noise during the actual utilization of the device.

D. Strip Insulation

Figure 2C. Inserting E Cores

The E-core pieces were inserted alternately from Figure 1D. Stripping of the Insulation of the Copper
one side to the other side of the bobbin. The E-pieces Wires
were inserted until the maximum number that could fit
into the bobbin. The wire insulation of the wires was removed to
expose the conductor underneath for electrical
connections

E. Fuse Integration

Figure 3C. Inserting I Cores

The I-core pieces were inserted between the spaces

of the inserted E-core pieces. Ensures that the E-I core is
aligned correctly. Figure 1E. Fuse Integration to the Step Down
Transformer

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Fuses were added to the primary and secondary
wires for protection against overcurrent conditions and
to prevent damage to the transformer and connected
equipment. For the low voltage winding, a 1A fuse was
integrated, while 2A for the high voltage winding.

F. Continuity Test

Figure 1H. Schematic Diagram for 220/50V, 60Hz, Step

Down Transformer

Figure 1F. Continuity Test

A continuity test was performed in both windings

to ensure proper functionality and to identify any breaks
or faults in the connection.

G. Final Output

Figure 1H. Schematic Diagram for 220/50V, 60Hz, Step

Down Transformer

V. CONCLUSION AND RECOMMENDATIONS

Transformers are devices that transfer electricity from

one AC circuit to one or more other circuits, with an
increase or decrease in voltage. Through Faraday’s Law of
Induction, which describes how a magnetic field will
interact with an electric circuit to produce electromotive
Figure 1G. Final Output of the 220/50V, 60Hz, Step
force (EMF), voltage transformation is possible [1].
Down Transformer
The fabricated transformer has a shell-type transformer
H. Schematic Diagram
with an E-I laminated steel core, and its windings are wound
around a transformer bobbin. The transformer that was
constructed has a primary and secondary voltage of 220 V
and 50 V, respectively. Its power rating is 90 W and operates
at a frequency of 60 Hz. The transformer also has a fuse for
both the primary and secondary windings that are correctly
sized for the conductors used.

In the process of designing and fabricating a single-phase

transformer, several critical design factors were considered.
Based on the calculations, the ideal core area of the
2
transformer is 10. 93 𝑐𝑚 , where the turns per volt should
be 2. 48 𝑡𝑢𝑟𝑛𝑠 𝑝𝑒𝑟 𝑣𝑜𝑙𝑡𝑠.

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In computing the primary winding, the number of turns, VI. REFERENCES
the current of the winding, the size of the wire, and the
winding area are computed. For the number of primary [1] FIERCE ELECTRONICS, “WHAT IS A TRANSFORMER?”, FIERCE ELECTRONCICS,
17 AUGUST 2021.
turns, the calculated value is approximately 547 𝑡𝑢𝑟𝑛𝑠, HTTPS://WWW.FIERCEELECTRONICS.COM/ELECTRONICS/WHAT-A-TRANSFORMER
wherein the current in this winding is 0. 41 𝐴. The size of
2 [2] Byju’s, “Motional emf, electromotive force, induced emf”, byjus.com,
the wire used was 0. 10 𝑚𝑚 , or 27 AWG, and the winding
2
2020. https://byjus.com/physics/motional-emf/
area is 0. 25 𝑐𝑚 .
[3] A. Maghirang, and E.J. Maguindayao, “EE 61 project: Transformer
For the secondary winding, the same parameters were design and fabrication”, EE 61 Transformer Project, 2023. Department of
also obtained. The number of secondary turns was 125 Electrical Engineering, College of Engineering and Agro-industrial
turns, wherein the current through it was 1.8 A. In Technology, University of the Philippines Los Baños.
computing the size of the wire in the secondary winding, it
[4] Swagatam, “How to Build Step Down Transformers with Calculations,”
is assumed that the density of the copper wire is 4 A/mm2,
2 Homemade Circuit Projects, Feb. 10, 2018.
and the size is 0. 45 𝑚𝑚 approximately 21 𝐴𝑊𝐺 as per the https://www.homemade-circuits.com/how-to-make-transformers/.
American Wire Gauge Conductor Table. Also, the area for
2 [5]“Step up, step down transformers, and reverse feeding,”
the secondary winding is 3. 99 𝑐𝑚 , with a total winding
2
Maddoxtransformer.com, 2023.
area of 4.24 𝑐𝑚 , considering both primary and secondary https://www.maddoxtransformer.com/resources/articles/step-up-step-down-
windings. transformers-and-reverse-feeding

Finally, for safety purposes, a fuse rating was also [6]“How Step up and Step down Transformers Differ from Each Other? |
computed for both primary and secondary windings, which Custom Coils Blog,” Custom Coils Blog | Manufacturer of Transformers
are 1 𝐴 and 2 𝐴, respectively. Other safety measures include and Inductors, 2021.
https://www.customcoils.com/blog/how-step-up-and-step-down-transforme
putting a masking tape for insulation between the primary
rs-differ-from-each-other/#:~:text=On%20the%20contrary%2C%20the%20
and secondary windings. step,voltage%20but%20a%20higher%20current (accessed May 19, 2024).

All these computations were critical in ensuring that the [7] Geeks for Geeks, “Applications of transformers”, geeksforgeeks.org, 23
transformer was performing with the voltage rating in mind. April 2024. https://www.geeksforgeeks.org/applications-of-transformer/
With an input of 220 V, it was tested that the output voltage
was approximately 50 V.

For future reference, the students recommend using a

more suitable insulating material between the primary and
secondary windings, which would ensure better insulation
properties, minimizing the risk of short circuits between the
coils. Furthermore, applying an insulating varnish on the
laminated sheets of the core to preserve the insulation and
protect it from moisture and other contaminants. These are
some of the recommendations to be considered to improve,
and minimize the eddy currents lost.

In designing and fabricating the transformer, the students

understood the wide range of functions of these devices in
power generation, transmission, industrial applications,
voltage regulation, and even electronic devices. Step-up
transformers of considerable size transport power efficiently
over long distances, while step-down transformers provide
for sub-transmission and distribution. The stepping-down
capability of transformers allows for residential usage of
electronic devices. Transformers are also used for regulating
voltages. All in all, transformers find applications in many
fields, where certain voltage requirements, power rating,
frequency of power source, and the types of load it will
power. As the students have learned, different transformer
specifications find various applications in any industry
where it is needed [7].

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