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PCB Mount EI Transformers with Custom Voltage Outputs

PCB Mount EI Transformers with Custom Voltage Outputs

Available with single, dual or multiple secondary windings to meet the power requirements of industrial and electronic control 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 the difference between an open-frame and an encapsulated PCB transformer?

An open-frame transformer is generally smaller, lighter and more economical. A fully encapsulated transformer provides better protection against moisture, dust and mechanical vibration, but normally has different thermal behavior, dimensions and tooling requirements.

2. Can you match our existing PCB footprint?

We can review your PCB layout, hole positions, keep-out area and maximum component height. Final pin tolerances and PCB hole diameters should be confirmed through an approved dimensional drawing.

3. Can the transformer dimensions be customized?

Yes, within the limits of electrical power, insulation distance, core size and temperature rise. Reducing one dimension may require increasing another dimension or accepting different thermal and regulation performance.

4. What is the typical temperature rise of a PCB transformer?

Temperature rise is not one fixed value for every model. It depends on the VA rating, ambient temperature, enclosure ventilation, core flux density, winding current density and insulation class. ECKO can design to an agreed maximum temperature-rise target and verify it on the sample.

5. Can you reduce no-load current, standby loss or audible hum?

These characteristics can be improved through core selection, increased turns, lower flux density, controlled core assembly, winding arrangement and impregnation. The required limits should be stated before the transformer size and price are finalized.

6. Can you add an electrostatic shield?

A shield can be placed between the primary and secondary windings to reduce capacitive coupling and common-mode noise. The shield lead and grounding method must be shown in the customer’s circuit and pin diagram.

7. Can you install a thermal fuse inside the transformer?

One-shot thermal fuses and resettable thermal protectors can be evaluated according to the operating temperature, insulation system and abnormal-condition strategy. The protection temperature and electrical rating must be specified.

8. Do you perform 100% Hi-Pot testing?

Hi-Pot testing can be included as a 100% routine production test. The test voltage, duration, leakage-current limit and test points are defined by the approved specification and applicable standard.

9. Can you provide UL- or CE-related documentation?

Compliance and certification are model-specific. ECKO can evaluate the construction against relevant IEC, EN or UL requirements and provide available material declarations, test records or certification documents for the approved model. Certification scope should be confirmed before ordering.

10. What is the typical sample lead time?

Custom engineering samples are commonly completed within approximately 7–15 working days after the specification and drawing are approved. The exact schedule depends on bobbin availability, tooling, encapsulation requirements and qualification testing.

11. Can you replace an obsolete or discontinued PCB transformer?

Please provide an original sample, electrical ratings, pin diagram, PCB footprint and application information. A physical sample alone may not contain enough information to determine the required insulation system, temperature rise or safety classification.