I am currently building a step down transformer with multiple secondaries and a single primary. The core material is standard silicon steel EI laminations.
The primary is spec'd out to use 127 turns of magnet wire with the secondaries being proportional to that in the normal way for voltages. I have 3d printed a custom bobbin made out of abs plastic.
The problem is after I wind the entire transformer and plug it in for some reason under no load 8 amps of current are drawn on the primary which leads to A LOT of heating requiring me to shut down the transformer to prevent damage. What are some possible reasons for this high current draw when the transformer under max load was designed to draw no more than a single amp on the primary?
EDIT: Detailed Design
The core is made of silicon steel rated to 2T with a center leg width of 22.23mm and a stack height of 90mm.
Primary - 127 Turns of 24AWG
Secondary 1 - 14 Turns of 18AWG
Secondary 2 - 9 Turns of 18AWG
Secondary 3 - 6 Turns of 24AWG
Secondary 4 - 17 Turns - Center tap - 9 Turns - Tap - 17 Turns
simulate this circuit – Schematic created using CircuitLab
Above is the basic test schematic, just insert the additional secondaries which were also open.
