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Re: Thanks, Sean ...

With minimal current draw, core saturation and transformer noise isn't really going to come into play. As such, using a larger core of equivalent grade can / will lower the distortion of a transformer under heavy demands that are of a dynamic nature. Hysterisis distortion is much more common than many would like to think.

On top of that, most common designs of today are toroidal designs. These are inferior to a high quality "old school" transformer in most every aspect. That is, except for lowering production costs and weight. Since lower weight makes the need for a heavier, more rigid chassis less important that too helps save money. The reduced transformer weight and reduced chassis weight also reduces shipping and packaging costs as their is a lot of transit involved in most audio products. If you think about it, the amp manufacturer has to pay to ship the transformers from the supplier to their manufacturing facility. From there, the manufacturer has to ship the finished component to the distributor and the distributor has to ship the product to the dealer. As you can see, cutting shipping weight can DRASTICALLY affect the cost of a product. If using a toroidal transformer can knock 5 - 20 lbs off of each unit manufactured and shipped, we are talking about a HUGE increase in profit margins. As such, you can see why manufacturers are willing to sacrifice the quality of their AC systems for increased profit margins / reduced shipping weight / less potential for damage in transit.

As a side note, i've got some VERY heavy duty -146 dB Ultra-Isolation transformers that i used to use to filter the AC with. These are 3 KVA units wound on the cores of 5 KVA transformers. These transformers alone weigh something like 112 lbs apiece. As such, the windings would burn out before the cores themselves would saturate. Only problem is, they are a real bitch to transport. Luckily, i don't have to move them around at all : ) Sean
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