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120V to 24V 20VA PCB Mount Transformer for Control Boards
Custom-engineered for reliable board-level voltage conversion with copper windings, controlled temperature rise and an application-specific pin layout.
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Custom PCB Transformers Engineered for Your Circuit Board
Compact through-hole PCB transformer with customized input voltage, output windings, rated power, pin layout and insulation construction. ECKO designs each transformer around your load requirements, PCB footprint, temperature-rise target and applicable safety requirements.
From initial electrical calculations to approved drawings, controlled production and routine electrical testing, we help OEM customers integrate reliable mains-frequency power conversion directly into their PCB assemblies.
Typical PCB Transformer Specifications
| Parameter | Typical Range / Available Options |
|---|---|
| Product Type | Open-frame, vacuum-impregnated or fully encapsulated PCB transformer |
| Rated Power | 0.5 VA to 100 VA typical; higher ratings subject to engineering review |
| Primary Voltage | 100V, 110V, 115V, 120V, 200V, 220V, 230V or 240V AC; single or dual primary |
| Secondary Voltage | 3V to 48V AC per winding typical; other voltages available |
| Output Configuration | Single, center-tapped, dual or multiple secondary windings |
| Frequency | 50Hz, 60Hz or 50/60Hz |
| Core Material | EI laminated electrical steel core selected according to power and temperature-rise requirements |
| Winding Material | Copper winding wire |
| Insulation Class | Class B 130°C or Class F 155°C |
| Dielectric Strength | Project-specific; 3.0–4.0kVAC primary-to-secondary options commonly available |
| Temperature Rise | Defined according to rated load, ambient temperature, enclosure and insulation class |
| Mounting Method | Through-hole PCB pins |
| Pin Configuration | Custom pin count, pitch, row spacing, diameter, length and polarity marking |
| Protection Options | Thermal fuse, resettable thermal protector or external PTC coordination |
| Shielding Options | Electrostatic shield, inter-winding shield or magnetic shielding where required |
| Operating Temperature | Typical design range from -20°C to +70°C, depending on the material system |
| Compliance Options | Construction designed for applicable IEC, EN or UL requirements; approval is model-specific |
Specification notice: The values above represent typical engineering capabilities rather than one fixed catalog model. Final electrical ratings, dimensions, tolerances and test limits are defined by the customer-approved specification and dimensional drawing.
PCB Transformer Product Advantages
PCB Footprint Designed Around Your BoardPin spacing, row distance, pin diameter, seated height and maximum external dimensions can be developed from your PCB layout. This helps reduce board redesign and improves first-fit integration during prototype assembly. |
Stable Output Under Actual Load ConditionsThe transformer is calculated according to the required output voltage, current, duty cycle and acceptable regulation. Output performance is verified under the agreed input voltage, frequency and rated-load conditions. |
Controlled Temperature RiseCore size, magnetic flux density, copper current density, winding arrangement and insulation materials are selected together. This provides a practical thermal margin for enclosed control boards and continuously operated equipment. |
Low No-Load Current and Reduced Core LossThe number of turns, core stack and operating flux density are optimized for the specified mains frequency. This helps control standby loss, excitation current and unnecessary heating. |
Application-Specific Insulation DesignThe bobbin, winding barriers, insulation tape, creepage distance, clearance distance and dielectric-strength level are reviewed according to the end-product requirements. Functional, basic, supplementary or reinforced insulation can be evaluated. |
Quiet and Repeatable ProductionControlled winding tension, core assembly, impregnation or encapsulation help reduce mechanical vibration and audible hum. Approved drawings, BOMs and test limits improve consistency between samples and production batches. |
PCB Transformer Customization Options
| Customization Area | Available Options |
| Electrical Input | Primary voltage, voltage range, 50Hz/60Hz frequency, single primary or dual primary |
| Electrical Output | Single output, dual output, multiple windings, center tap, series/parallel connection |
| Rated Power | VA rating calculated according to each secondary load and operating duty cycle |
| Voltage Regulation | Output voltage adjusted according to the required full-load voltage |
| PCB Footprint | Custom pin position, pitch, row spacing, mounting grid and keep-out area |
| Product Dimensions | Maximum length, width, height, seated height and weight |
| Insulation System | Class B or Class F; functional, basic, supplementary or reinforced insulation |
| Dielectric Strength | Customer-defined or standard-based Hi-Pot level and test duration |
| Thermal Protection | Internal thermal fuse, resettable protector or external protection coordination |
| EMI Control | Electrostatic shield, inter-winding shield and optimized winding arrangement |
| Environmental Protection | Open-frame, vacuum impregnation, tape wrapping or fully encapsulated construction |
| Noise Control | Reduced flux-density design, controlled core assembly and impregnation |
| Identification | Customer part number, polarity mark, date code, batch code and private label |
| Documentation | Product specification, dimensional drawing, pin diagram, test report and material declarations |
| Packaging | Individual trays, partitioned cartons, export cartons and pallet packaging |
Why Choose ECKO for Custom PCB Transformers?
Engineering Design Based on the Complete ApplicationECKO evaluates the input range, frequency, output load, voltage regulation, temperature rise, PCB space, enclosure ventilation and insulation requirements before releasing a design. The transformer is developed as part of the customer’s power circuit rather than selected only by voltage and VA. |
Controlled Specifications, Drawings and RevisionsEach approved project can be managed through a controlled product specification, dimensional drawing, pin diagram, BOM, process instruction and inspection plan. Engineering changes are recorded by revision, approval status and effective production lot. |
Qualified and Traceable Raw MaterialsCopper wire, electrical steel, bobbins, insulation tape, thermal protectors, terminals and encapsulation materials are purchased according to approved specifications. Incoming inspection and batch records help prevent unauthorized material substitution. |
Production Capacity with Process ControlEstablished in 2000, ECKO operates three workshops covering approximately 5,000m² with around 150 skilled workers. Winding, soldering, core assembly, impregnation, encapsulation and electrical testing are managed through defined production and inspection procedures. |
Quality Control from Sample to Mass ProductionCritical electrical parameters are confirmed during sample verification and transferred into the production test specification. Routine testing and batch traceability support stable repeat orders and more efficient customer incoming inspection. |
PCB Transformer Tests and Reference Standards
Routine Production Tests
| Test Item | Test Purpose | Typical Inspection Plan |
| Visual Inspection | Workmanship, label, polarity mark, pin condition and product appearance | Routine or sampling |
| Dimensional Inspection | Outline dimensions, seated height, pin pitch and pin position | Sampling or critical dimensions |
| Winding Resistance | Checks conductor continuity and winding consistency | Routine |
| Turns Ratio / Output Voltage | Verifies output voltage and winding polarity at the specified input | 100% routine test |
| No-Load Current | Confirms excitation current, core assembly and winding consistency | 100% or agreed inspection plan |
| No-Load Loss | Evaluates standby core and winding loss | Sampling or qualification |
| Load Voltage and Regulation | Confirms rated-load output voltage and voltage drop | Sample and periodic verification |
| Insulation Resistance | Checks insulation between windings and accessible conductive parts | Routine or sampling |
| Dielectric Strength / Hi-Pot | Verifies the specified insulation withstand level | 100% at the approved test level |
| Temperature Rise | Confirms thermal performance under defined mounting and load conditions | Type or qualification test |
| Audible Noise | Evaluates hum and mechanical vibration at the specified input | When controlled by the specification |
| Solderability | Confirms PCB pin wetting and resistance to soldering heat | Qualification or sampling |
Custom PCB Transformer Development Process
Step 1: Submit the Application RequirementsProvide the primary voltage, frequency, secondary voltage and current, available PCB space, operating environment, annual quantity and applicable safety requirements. |
Step 2: Engineering Feasibility ReviewECKO reviews the VA requirement, winding arrangement, core size, temperature-rise target, insulation construction, PCB footprint and potential technical risks. |
Step 3: Technical Proposal and QuotationWe provide a proposed electrical configuration, construction type, estimated dimensions, testing plan, tooling requirements and commercial quotation. |
Step 4: Specification and Drawing ApprovalThe customer reviews the electrical specification, outline drawing, PCB footprint, pin assignment, polarity and critical tolerances before sample production. |
Step 5: Prototype ManufacturingSamples are produced using the approved materials and process route. Electrical and dimensional test records can be provided according to the agreed project plan. |
Step 6: Sample Verification and Customer ApprovalOutput voltage, load regulation, no-load current, temperature rise, dielectric strength, dimensions and PCB fit are confirmed before production release. |
Step 7: Controlled Mass ProductionThe approved BOM, drawing revision, winding data, process instructions and test limits are released to production. Routine tests and batch identification are applied according to the inspection plan. |
PCB Transformer FAQ
1. Can you match our existing PCB footprint and pin layout?
ECKO can review your PCB hole positions, pin pitch, row spacing, component height and keep-out area. The final footprint must be confirmed through an approved dimensional drawing because pin tolerances and recommended PCB hole diameters can affect assembly.
2. Can the transformer height be reduced to fit a low-profile enclosure?
The height can often be adjusted by selecting a different core, bobbin or winding construction. However, reducing the height may increase the length, width, temperature rise or material cost. Our engineers will evaluate the available PCB area and recommend a practical dimensional arrangement.
3. How is the temperature rise of a PCB transformer determined?
Temperature rise depends on the rated load, input frequency, core flux density, copper current density, ambient temperature, mounting method and enclosure ventilation. It should be verified at rated load under conditions that represent the final equipment as closely as possible.
4. Does potting always reduce the transformer temperature?
Not necessarily. Encapsulation improves mechanical stability and resistance to moisture, dust and vibration, but it also changes how heat is transferred from the windings. The resin system, transformer dimensions and surrounding airflow must be considered during the thermal design.
5. What insulation classes are available for PCB transformers?
Class B 130°C and Class F 155°C insulation systems are commonly available. The selected insulation class does not by itself define the permitted temperature rise; ambient temperature, component ratings, safety standards and the final equipment’s thermal limits must also be considered.
6. Can you design reinforced insulation between the primary and secondary?
Yes, subject to the working voltage, required safety standard, pollution degree, material group, installation altitude and available dimensions. The bobbin construction, insulation barriers, creepage distance, clearance distance and dielectric-strength requirement must be reviewed together.
7. Do you perform 100% Hi-Pot testing on PCB transformers?
Hi-Pot testing can be included as a 100% routine production test. The test voltage, duration, leakage-current limit and test points are defined according to the approved product specification and applicable safety requirements.
8. Can a thermal fuse be built into the PCB transformer?
A one-shot thermal fuse or resettable thermal protector can be incorporated when required. Its operating temperature, current rating, installation position and coordination with the end-product protection system must be confirmed during the design stage.
9. How can audible hum and vibration be reduced?
Audible noise can be reduced through appropriate flux-density selection, accurate core assembly, controlled winding tension and vacuum impregnation or encapsulation. The final equipment enclosure and PCB mounting can also amplify vibration, so any specific noise limit should be stated before sample development.
10. Can ECKO replace an obsolete PCB transformer?
Please provide the original transformer sample, electrical ratings, PCB footprint, pin diagram, application information and any available drawings or test data. A replacement should be verified electrically, mechanically and thermally in the final equipment before mass production.
