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Transformers are essential components in many industrial electrical systems. They play a critical role in stepping down the voltage to a lower, more manageable level for control circuits, such as those found in machines, panels, or other electrical equipment. In industrial settings, where precise and reliable control of equipment is paramount, these transformers help ensure that control devices like relays, contactors, and timers receive the appropriate voltage to operate safely and efficiently.

Control Design Supply has an great understanding of transformers and our customers needs within them. We have several manufacturers that carry different varieties of transformers to make sure that you are always getting exactly what you need. In addition to the factory stock, we keep stock of our own here to ensure the fastest delivery. Contact us today with any questions or quoting needs!

What is a Control Transformer?

At its core, a control transformer is a type of transformer designed to convert high-voltage electrical power (such as 480V or 240V) to a lower, more usable voltage (typically 120V or 24V) to power control circuits and devices. These transformers are specifically built for low-power applications where the power requirements are lower than what’s needed to drive heavy machinery. The output of a control transformer is used to power devices that manage or regulate industrial processes, such as PLCs (programmable logic controllers), sensors, indicators, or control relays. Often these devices would add significant cost to run at 480V+.

How Control Transformers Work

Control transformers function similarly to other types of transformers, where they step down the input voltage to the desired level through electromagnetic induction. Here’s how they typically work:

Primary Winding: The high voltage (e.g., 480V or 240V) is fed into the primary winding of the transformer.
Magnetic Field: When current flows through the primary winding, it creates a magnetic field that surrounds the winding.
Secondary Winding: This magnetic field induces a lower voltage in the secondary winding of the transformer. The number of turns in the secondary winding determines the voltage reduction, allowing the output to be stepped down to a level suitable for control circuits (commonly 120V or 24V).
Isolation: Control transformers also provide electrical isolation between the control circuit and the main power supply. This isolation is vital for protecting sensitive control equipment from power surges and faults.

Key Features and Benefits

Voltage Reduction: As the name suggests, control transformers are used to step down voltage to a safe and usable level for control circuits. This allows equipment like relays, PLCs, and timers to function correctly without exposure to the higher voltages used in machinery.
Electrical Isolation: By isolating the control circuit from the higher voltages of the main power supply, control transformers help protect sensitive electronic components from voltage spikes or electrical faults. This isolation also enhances safety by preventing operators from coming into contact with high voltages.
Reliability: In industrial settings, reliability is key. Control transformers are built to endure heavy-duty environments and provide consistent voltage to control circuits. They are often designed to be durable, withstand temperature fluctuations, and operate continuously without failure.
Protection: Some control transformers are equipped with built-in fuses or other protective devices to safeguard against overvoltage or short circuits. These features enhance the overall safety of the system by preventing damage to both the transformer and the connected equipment.
Compact and Efficient: Control transformers are generally smaller and more compact than other types of transformers, making them ideal for control panels where space is limited. Despite their small size, they are designed to handle the electrical load efficiently.

Types of Transformers

There are several different types of transformers designed to meet various industrial needs:

Audio and Signal Transformer: At their core, audio transformers and signal transformers both work by transferring an electrical signal from one circuit to another through electromagnetic induction.
Autotransformer: An autotransformer has a single winding that acts as both the primary and the secondary. This design allows the autotransformer to be more compact and efficient for certain applications.
Current Transformer: A current transformer (CT) is a type of transformer used primarily to measure and monitor electrical currents in AC circuits. These devices allow high current values to be safely monitored by stepping down the current to a lower, manageable level.
Power Transformer: A low voltage power transformer is a type of transformer designed to step down electrical voltage from a higher level to a lower level, typically for use in residential, commercial, or light industrial applications. They serve as a critical link between high-voltage power sources and the devices that need lower, safer operating voltages.

Contact CDS Today for Your Transformer Needs

With over five decades of industry experience, we are a trusted and leading supplier of electronic components. Our large inventory of electrical products is designed to provide solutions for every industry. In addition to top-quality electrical components, we offer comprehensive kitting, assembly, and customization services to meet your exact needs. No matter your project or specifications, you can find the right solution at CDS.

Contact us to learn more about our products and services and speak with a knowledgeable team member. Request a quote to get started on your order today.