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Custom EI PCB Transformers for Compact Power Supply Designs

Custom EI PCB Transformers for Compact Power Supply Designs

Engineered with customized input voltage, output windings, rated power and pin layout for reliable integration into OEM circuit boards.

Overview
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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 Board

Pin 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 Conditions

The 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 Rise

Core 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 Loss

The 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 Design

The 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 Production

Controlled 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 Application

ECKO 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 Revisions

Each 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 Materials

Copper 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 Control

Established 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 Production

Critical 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 Requirements

Provide the primary voltage, frequency, secondary voltage and current, available PCB space, operating environment, annual quantity and applicable safety requirements.

Step 2: Engineering Feasibility Review

ECKO reviews the VA requirement, winding arrangement, core size, temperature-rise target, insulation construction, PCB footprint and potential technical risks.

Step 3: Technical Proposal and Quotation

We provide a proposed electrical configuration, construction type, estimated dimensions, testing plan, tooling requirements and commercial quotation.

Step 4: Specification and Drawing Approval

The customer reviews the electrical specification, outline drawing, PCB footprint, pin assignment, polarity and critical tolerances before sample production.

Step 5: Prototype Manufacturing

Samples 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 Approval

Output voltage, load regulation, no-load current, temperature rise, dielectric strength, dimensions and PCB fit are confirmed before production release.

Step 7: Controlled Mass Production

The 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. What is a PCB transformer?

A PCB transformer is a compact, mains-frequency transformer designed for direct through-hole mounting on a printed circuit board. It converts the input voltage to one or more lower AC output voltages while providing the required electrical isolation between the primary and secondary circuits.

2. What information should I provide when requesting a custom PCB transformer?

Please provide the input voltage and frequency, each secondary voltage and current, load type, operating duty cycle, maximum dimensions, PCB footprint, ambient temperature, insulation requirements and estimated annual quantity. A PCB layout, dimensional drawing or existing transformer sample will help us evaluate the project more accurately.

3. How do I select the correct VA rating for a PCB transformer?

The basic VA requirement is calculated by multiplying each secondary voltage by its rated current and adding the results together. Additional design margin may be required for rectifier circuits, capacitive loads, peak currents, voltage-regulation requirements and elevated ambient temperatures.

4. Should I specify the secondary voltage at no load or full load?

For most custom projects, the required secondary voltage should be specified at the actual operating load. A transformer’s no-load voltage is normally higher than its rated-load voltage because of winding resistance and internal voltage drop. Please provide both values if your circuit has a strict voltage range.

5. Why is the measured no-load voltage higher than the rated output voltage?

The rated secondary voltage is usually defined at a specified load. When the transformer operates without a load, there is almost no voltage drop across the windings, so the measured output voltage increases. The difference between the no-load and full-load voltage is described as voltage regulation.

6. Can a PCB transformer be designed for a bridge rectifier and filter capacitor?

However, a rectifier-capacitor input draws short, high-current charging pulses rather than a smooth sinusoidal current. Please provide the required DC output voltage, DC load current, rectifier arrangement and filter capacitance so that the transformer can be sized correctly for winding heating and voltage regulation.

7. Can you manufacture PCB transformers with multiple secondary windings?

A PCB transformer can be designed with single, dual, center-tapped or multiple independent secondary windings. Each winding’s voltage, current, insulation relationship and connection method should be clearly defined in the approved electrical specification.

8. Can the secondary windings be connected in series or parallel?

Identical secondary windings may be designed for series or parallel connection. Series connection increases the available voltage, while parallel connection increases the available current. Correct winding polarity must be followed, and only windings specifically designed with matching characteristics should be connected in parallel.

9. Can you produce a PCB transformer with dual 115V/230V primary windings?

Two matched primary windings can be connected in parallel for approximately 115V operation or in series for approximately 230V operation. The required connection diagram, pin assignment and safety instructions will be defined on the approved drawing.

10. Can the same PCB transformer operate at both 50Hz and 60Hz?

Yes, if it is designed and rated for 50/60Hz operation. A transformer designed only for 60Hz may experience excessive magnetic flux, no-load current and heating if operated at 50Hz at the same voltage. The lowest intended operating frequency should therefore be stated before design approval.