Reducing Core and Winding Heating in 450V 70A Transformer for Battery Charging

A transformer designed for 450 V and 70 A output to charge battery plates is experiencing excessive heating in both core and windings despite using high-quality copper wire of gauges 10 and 11. The continuous load nature of battery charging, with a constant current characteristic where current decreases as battery voltage rises, is noted. Suggestions to reduce heating include verifying correct transformer specifications for the load, as under-sizing can cause overheating. It is recommended to analyze the load for harmonic distortion and power factor issues, since non-linear loads like bridge rectifiers can induce eddy current and hysteresis losses in the transformer core. Testing with appropriate equipment such as oscilloscopes to detect noise and harmonics on the output is advised. Additional cooling methods like forced air may be necessary. Further technical details requested include operating frequency, battery voltage and type, amp-hour rating, core material, winding turns, temperature measurements over time, and harmonic tuning to better diagnose the problem.
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