TRANSFOREIR DE 16N

AND
MANUFACTURI1N6 MANUAL

ROBERT G. WOLPERT

1984, ROBERT G. WOLPERT, Rev. 2004

TRSFORSMER DESIGN
AND

MANUFACTURING MANUAL

ROBERT G. WOLPERT

1984,

ROBERT G. WOLPERT, Rev. 2004

A PRACTICAL APPROACH TO THE DESIGN AND MANUFACTURE OF

ELECTRONIC TRANSFORMERS AND INDUCTORS

ROBERT G. WOLPERT

PREFACE

The first part of this manual is intended to serve as a sta rting point in
lea rn ing a method of designing transformers and other wire wound
magnetic co m ponents. The second part is included to show the new
designer, and others, how the tra nsformer is manufactured .
The design g u i des, if followed carefu lly, will result in a design that will
work as intended . There will be very little attem pt to explain the theories
or justify the method or formulas used . I have used these methods
successfu l ly for many years in both the designing of tra nsformers and in
the training of new designers.
I suggest that additional study into the theory of magnetism and
transformer operation be conducted by the serious engineer.
The second part concerns the actual manufactu ring of the transformer
after it is desig ned . The methods shown here have been used extensively
for many years in the man ufactu re of transformers and other wire wound
magnetic com ponents. They have proven very useful as training aids for
new employees and as manufacturing procedu res for sta ndard shop
practices.
The man ufacturing methods a re also an aid to the new designer in
showing how the transformer is actually put together and a help in
choosing the proper materials for construction .

Robert G . Wol pert

page 1

TABLE OF CONTE NTS

PART I . TRANSFORM ER DESIGN PROCEDURES

CHAPTER

1.0

TRANSFORMER OPERATION THEORY

CHAPTER

2.0
2.1
2.2
2.3
2.4
2.5

SINGLE PHASE POWER TRANS FORM ER DESIGN

Design proced ure
Design example
Sam ple man ufacturing specifications
La mination table
Wire table

CHAPTER

3.0
3.1
3.1.1
3.2
3.2.2
3.3
3.3.1
3.3.2
3 .4

THREE PHASE POWE R TRANS FORM ER DESIGN

The Wye configuration
Wye example
The Delta configuration
Delta exa m ple
Three phase design exa mple
Temperature rise
Reg ulation
Interconnections

CHAPTER

4.0
4. 1
4.2

AUTO TRAN SFORMERS

Design procedu re
Design example

CHAPTER

5.0
5.1
5. 1 . 1
5.1.2
5.1.3
5.1.4
5.2
5.2.1

POWER TRANSFORM ERS USI NG CAPACITIVE FILTERS

Types of rectifier circuits
Full wave center-ta pped circuit
Example
Full wave bridge circuit
Full wave bridge center-ta pped circuit
Correcting the efficiency
Exa mple

CHAPTER

6.0
6. 1
6.2
6.3
6.4
6.4. 1
6.5

CONVERTER TRANSFORMERS
The saturating tra nsformer
Core material
Control winding voltage
Design criteria
Design re-ca p
The non-saturating tra nsformer

....

page 2

TABLE OF CONTENTS, conti n ued

CHAPTER

7.0
7.1
7.1.1
7.2

S H I E LDING I N POWER TRA N S FORM ERS

Electrostatic shields
Box shields
Electro-magnetic shields

CHAPTER

8.0
8. 1
8.2
8.3

IRON CORE FILTER CHOKES

Chokes that ca rry a direct current
Chokes with no direct current
Configurations other tha n E I l a m i n ations

CHAPTER

9.0
9.1
9.2

AIR CORE I N D UCTORS AND SOLENOIDS

The single layer solenoid
M u lti ple layer solenoid

page 3

PART II. MAN UFACTU RI NG PROCESSES

CHAPTER

10.0
10.1
10.2

LAYE R WINDING O N A SINGLE COIL FORM

Electrostatic shield
W i re table

CHAPTER

1 1.0

BOBBI N WINDING

CHAPTER

12.0
12. 1
12.2

LEAD FINISHING
Stra nded lead wire term inations
Solder lug termi nations

CHAPTER

13.0
13.1
13.2
13.3

ASS EM BLY AN D STACKING O F MAGN ETIC CORES

Stacking of laminated cores
Asse m bly and bracketing
Asse m bly with a fl ux shield

CHAPTER

14.0

I M P REG NATION

CHAPTER

15.0

TESTIN G TH E TRANS FORM E R

CHAPTER

16.0

I N S U LATION MATERIALS

APPEN DIX TABLES FOR TURNS AN D WIRE SIZES VERSUS

LAMINATION SIZES

page 4

PART I.

TRANSFORMER DESIGN PROCEDURES

page 5

CHAPTER 1 . TRANSFORM ER OPERATION TH EORY

An ideal transformer, (one in which there are no losses) , will transform

AC voltage directly proportional to the tu rns ratio and will transform
current inversely proportional to the tu rns ratio.
Thus, the voltage of the secondary d ivided by the volta ge of the primary
is equal to the turns of the secondary divided by the tu rns of the prima ry
and the cu rrent of the secondary divided by the cu rrent of the primary is
equal to the turns of the primary divided by the tu rns of the secondary.
Es/Ep

Ns/Np and Is/Ip

Np/NS

Where :
Es
Ep
Is
Ip

=
=

Ns Np -

Secondary voltage
Primary voltage
Secondary current
Pri m a ry current
Secondary turns
Pri m a ry turns

The total VA of the p rimary will be equal to the total VA of the secondary.
Thus, the voltage of the primary m u ltiplied by the current of the primary
is eq ual to the voltage of the secondary m u ltipl ied by the current of the
secondary.
Ep x I p

Es x Is

Ep

Es

Ip

Is

Figure 1

page 6

For a transformer with more than one secondary, the tota l VA of the
primary will be equal to the sum of the VA's of the secondaries.
Ep x Ip - Es1 x Is1 + Es2 x Is2, etc.

The turns ratio w i l l be :

Es1 I Ep

N s1 I N p a n d Es3 I E p

Ns2 /Np, etc.

In other words, the voltage of secondary # 1 divided by the voltage of the

primary is equal to the turns of secondary # 1 d ivided by the tu rns of the
primary and so on for all secondaries.
The pola rity dots of Fig u re 2 show insta ntaneous pola rity of the voltages .

Es1

3
ls1

Ep

Ip

5
Es2

Is2
6

Fig ure 2

If arbitrary values a re assigned to the windi ngs:

Let :

Ep
Np
Es1
Is1
Es2
Is2

1 1 5 volts
230 turns
6 . 5 volts
5 . 0 a mperes
4 5 volts
1 . 0 a mperes

page 7

Ns/Np to Np/Ep
Ns/Es, we will have a formula
By transposing Es/Ep
for turns per volt. Thus, the turns of the primary divided by the voltage
of the primary is equal to the turns of the secondary divided by the
voltage of the secondary. By fi ll ing in the assigned val ues, the secondary
tu rns can be ca lcu lated.
=

230 I 1 1 5

Nsl I 6.5

Solving for seconda ry tu rns : Ns1

And Ns2

( 230 x 45) I 1 1 5

(230 x 6 . 5 ) / 1 1 5 - 1 3 tu rns

90 turns

The total VA of the transformer is :

6.5 V x 5.0 A
45 V x 1 . 0 A
Tota l

Then the primary cu rrent, Ip

77.5 / 1 1 5

- 32.5
- 45.0
- 77.5 VA

0 . 67 a m peres

These ca lculations neglect any losses in the windings and the core .
Pola rity dots shown by each winding in the schematic diagra m indicate
the polarity at any given instant of time and will dictate the winding
direction. Therefore, if it is desired to determ ine the pola rity or winding
direction by measu rement, connect the windings of Fig u re 2 as shown
below in Fig u re 3 . This then becomes an auto transformer.
1

2
3
4
5
6

Figure 3

page 8

If 1 1 5 volts is applied to # 1 and #2, then you wil l read :

From # 1 to #4, 1 1 5 / 230 x (230 + 1 3 )
1 2 1 . 5 volts
From # 1 to #6, 1 15 / 230 x (230 + 1 3 + 90)
1 6 6 . 5 volts
=

If the pola rity is reversed on #3 and #4, then you will read :
From # 1 to #4, 1 1 5 / 230 x (230 - 13)
1 0 8 . 5 volts
From # 1 to #6, 1 1 5 / 230 x (230 - 13 + 9 0 )
1 5 3 . 5 volts
=

A center ta pped winding can be treated l i ke two sepa rate windings for
determining the tu rns ratios and polarities.
These methods shown here will apply to a l l tra nsfo rmers that a re being
tested without a loa d . If loaded voltages and cu rrents a re needed, it is
necessary to go th rough a much more sophisticated method of
determining the losses in the windings and lamination and calculate the
voltage d rops. This is explained fu lly in the followi ng cha pters.

page 9

CHAPTER 2. SINGLE PHASE POWER TRAN SFORM ER DESIGN

This cha pter will give a step-by-step design procedu re for a single- phase
power transformer of the type genera l ly used in O E M electronic
equipment.
The user's specifications will ca ll out what is desired . Sometimes this will
only be the i n put voltage and freq uency and the req uired output voltage
and current. If this is the case, the designer ca n choose the size of the
core that will best fit. In other cases, the size is a lso given along with
temperature rise and regulatio n . This is more restrictive and will require
more time and ca lculations to fit the req uire ments.
The procedure that follows will enable the designer to a rrive at a design
that will fit the req uirements if the steps a re followed ca refully .
Providing, of course, that the specifications a re not so restrictive that
they are im possible to meet.
2.1

Desig n proced u re

This is a step- by-step proced u re for the design of a power tra nsformer for
use in electrical and electronic eq uipment. If the procedure is followed
carefully, it will result in a transformer that w i l l function as desired .
The design proced u re is first given and then a n exa mple is shown using
the procedu re.
Step # 1
Assemble and put down o n paper all the information available on the unit
to be designed .
Step # 2
Calcu late the tota l VA a n d the primary cu rrent.
Ip = VAX 1 . 1 1
Ep

VA = Es x Is
Where :

Ep
Es
Ip
Is

primary voltage
secondary voltage
primary current
secondary cu rrent

1 . 1 1 is used as a factor to cover losses for a 90/o efficient tra nsformer.

page 10

Step # 3
Choose a core size from the VA colu m n of the l a m i n ation ta ble a t the end
of this cha pter. Record the window size and core a rea of the lamination
chosen. Calculate the effective a rea of the core.
Aeff = Ac x K
Where :

Ac = a rea of the core (Tongue width x stack height)

K = the sta cking factor ( Use . 92 for 1 x 1
interleave and . 95 for a butt stack)

Step #4
Calculate the pri m a ry turns for th is core and voltage desired .
Ep x 1 08
Np =
4.44 x B x A x F
Where :

4.44 is a constant for sine wave operation

E p - primary voltage from the power sou rce
- flux density in lines per square inch . (This
B
value will depend on the grade of steel used . )
A
effective area of the core
F
line freq uency

Step #5
Calcu late the turns for the secondary or secondaries.
Ns = JiQ_ x 1 . 05 x Es
Ep
Where : Np - pri m a ry turns
Ns - secondary turns
1 .0 5 is a factor used to adjust the tu rns to compensate for the losses.
This will vary with the size of the transformer and the desired regulation .

page 1 1

Step # 6
Choose the wire sizes. Use 800 circu lar mils per a m pere for a sta rti ng
point. Refer to the wire table to find the sizes needed . Fo r exa m ple, if a
cu rrent of 1 a m pere is required , then AWG # 2 1 would be chosen as it has
a volume of 8 1 0 ci rcular mils.
Step # 7
Determine coil length, winding length, m a rg ins, turns per layer and
n u m ber of layers. ( See wire ta ble on page 3 6 . )
Step #8
Calculate fil l . This is done by adding up the various elements of the
win d i n g . These a re the winding tube thickness, diameter of the wire
mu ltiplied by the n u m ber of layers, layer insulation thickness and inter
winding insu lation th ickness. An accepta ble fil l is from 80 to 90/o .
If fill is not a ccepta ble, adj u stments m ust be made. This can be done in
several different ways, either by more or less core stack, a change in core
size, turns adj ustment, which will change the flux density or wire sizes.
In any case, if adj u stments a re made, you m ust be careful that all other
pa rameters a re considered to keep from exceeding any a l lowable limits.
Step # 9
Calculate wire resistances a n d voltage d rops in each wind i n g . These may
lead to further adj u stments to bri n g the secondary voltage to the desired
values.
Step # 10
Calculate the copper and lam in ation weig hts.
Step # 1 1
Calcu late the losses.

page 12

Step # 1 2
Calculate the a pproximate tem perature rise. Temperature rise i n degrees
centigrade:

TOTAL LOSSES (WATTS)

TOTAL WEIGHT
0.1
2/3
1.073

The tota l losses a re the combined copper losses and the lami nation or
iron losses. The weig ht is the weight of the copper wire plus the weight
of the lami nation plus 15/o for insu lation, winding tube, brackets, etc.

Step # 1 3
Calcu late the regulation. The regulation is the secondary fu ll load voltage
subtracted from the n o load voltage and that result divided by the fu ll
load voltage.
010 Reg u lation -

No load - fu l l load
Full load

x 100

Now proceed to 2 . 2 and the exa mple, following the a bove steps.

page 13

2.2

Design exa m ple

Step # 1
It is desired to design a tra nsformer to operate from a 1 1 5 Volt line at 60
Hertz and to deliver 6 . 3 Volts at 10 a m peres AC, center tapped . The
physical size is not give n . Record a l l informatio n .

115

6 0 Hz.

6 . 3 V c.t.
@
1 0. 0 A

Schematic d iagram

Ep
F
Es
Is

=
=
=
=

1 1 5 V.
60 Hz
6 . 3 V c.t.
10 A

Step #2
Calcu late total VA
VA = Es x Is - 6 . 3 x 10 - 63

Calculate primary current

Ip

VA x 1 . 1 1
Ep

63 x 1 . 1 1
115

- 0 . 608 A.

page 14

Step # 3
Choose a core from the lamination table.
From the VA column it
is seen that
EI- 1 1/8 size with a 1 1/8" stack height has a VA rating of 6 5 . This
should be a good core for th is transformer.
The effective a rea is 1 1/8 x 1 1/8

1 . 265 sq . i n . x K.

Assu ming a 1 x 1 interleave, it will be 1 . 265 x .92

1 . 164 sq . in.

At this time it becomes necessary to explain the d ifferent types and

grades of lami nations availa ble.
The sta ndard EI lamination is ca l led out by the thickness and grade of
steel used . Thus, 29 M6 is a lamination of 29 gauge ( . 0 14" thick) and
made of a g rade M 6 g rain-oriented stee l .
There a re several g rades and th ickness of laminations available, but, in
most electronic transformers, and in this treatise, we will consider only
th ree. These a re M6, M 19 and M22 g rades and the thicknesses used a re
29 gauge ( .014"), 26 ga uge ( . 0 1 8") and 24 gauge ( . 025") . Only the M6
grade is g rain - oriented and th us can be used at a higher fl ux density and
will result in a smal ler u n it. This grade of steel a lso costs more per
pou nd, so a com promise is sometimes necessary between size and cost.
The core loss table will show the fl ux densities that ca n be safely used
and the losses per pound that will result with each of the different grades
of lamination. More extensive data can be obta ined from the various
manufacturers of the l a m inations. The data given here is only intended
to serve as g u ideli nes for the beginning designer.
For our pu rposes, only two levels of fl ux density will be shown .
Saturation w i l l occur at approximately 18 kilo-ga uss ( 1 1 6, 1 0 0 lines ) . Th is
should be considered the limiting va lue.

page 15

Step #3, continued

The manufacturers will give the core losses at fl ux densities in kilo-ga uss.
This can be converted to lines by mu ltiplying by 6.45.
For example, 15 KG or 1 5000 Gauss x 6 .45 = 96750 lines.
This, of cou rse, ca n be converted directly in the form ula for primary turns
by using the Gauss figure and adding the 6.45 factor below the line.
The window of the lamination is 9/1 6" x 1 1 1/16".
The effective core area is 1 . 164 sq . i n .
We will choose to try 2 6 M 19 laminations with a fl ux density o f 85000
lines as a starting point.
Th is is 1 3 . 17 KG .
Step #4
Calculate the pri m a ry turns.
Np =

Ep

108
-

4.44 x B x A x F

4.44

115
85000

10 8
x 1 .164

60

436

turns

Step # 5
Calculate the secondary tu rns.
Ns = N p / Ep x 1 .05 x Es = 436 / 1 1 5 x 1 .05 x 6.3

25 . 1 turns

Since the secondary must have a center ta p, we should change the turns
to an even n u m ber or 26 turns. Actua lly, a half-turn ca n be obtained in a
transformer using this lamination by bringing out the lead on the opposite
side of the core. This is usua lly not done unless absol utely necessary. In
order to have a fu ll turn, the wire must pass through both sides of the
window. A half-turn will pass th rough only one side. If the customer
calls out the lead position, the decision will be made for you .

page 16

Step #6
Choose the wire sizes.
The primary wire should be . 608 A x 800 circular mils

486 . 4

For this we will see that # 2 3 wire is closest with 509 . 5 cm (see the wire
ta ble).
The secondary wire should be 10 A x 800 cm .
8000 cm . # 1 1 wire has
8234 cm and will be chosen for this. It should be noted that th is is
conservative and in practice there is room for adj ustment up or down if
needed . The only l i m iting factors will be temperature rise and reg ulatio n .
=

Step # 7
Calcu late the turns per layer a n d n u m ber of layers. The window length is
1 1 1/1 6" long . In order to fit, the coil length should be 1/ 16" shorter or
1 5/8" long . From the wire ta ble, it is seen that the marg i n for #23 wire
should be 1/8" on each end . The margin for # 1 1 wire should be 1/4" on
each end. The turns per layer is determined by the winding length times
the tu rns per inch for that wire size. This is also obtained from the wire
ta ble. The va l ues should be put down on the work sheet clearly to show
the construction of the coil .
Fig ure 4 shows the size of the lami nation and the way the coil is
constructed ( El- 1 1/8 " ) .

o,f!Q

wnmw

1-lao

_j

VDIDOll

1'>1

Figu re 4

page 17

Window = 9/ 1 6" x 1 1 1/ 1 6"

Coil length = 1 5/8"
#23 wire winding length = 1 3/8"
Margins = 1/8" each end
Turns per layer = 1 3/8" x 3 7 . 4 (turns per inch from ta ble) = 52 turns
Layers = 436 / 52 = 8 . 4 layers (use 9)
# 1 1 wire winding length = 1 1/8"
Margins = 1/4" each end
Tu rns per layer = 1 1/8" x 1 0 . 2 = 11 turns
Layers = 26 / 1 1 = 2 . 3 6 layers ( use 3 )
Step #8
Calcu late the fill of the wi ndow by adding up all the various thicknesses of
the winding tube, wire d iameter, layer insu lations and wrappers (See
Fig u re 4 ) .
The layer insu lation is determined by the thickness needed to support
that pa rticu l a r wire size . This is cal led out in the wire ta ble.
The winding tube thickness is determ ined by what is needed to support
the coi l . S m a l l coils with fine wire need less support than l a rger coils with
heavy wire. This ca n vary from . 020" to . 0 70 " or more. A coil of the size
used in this exa mple will generally use a winding tube thickness of . 030"
to . 040".
The wra pper is the insulation used between windings. This is determined
by the voltage isolation needed and the support needed for the next
winding . For this example we will use . 0 10" thick insulation, as this is the
va lue for suppo rt of # 1 1 wire.
It is now necessary to put down on paper the various thicknesses, add
them up and calcu late the percentage of ava ilable space in the window
that is used . This l a mination has a window width of 9/ 1 6" or, in decimals,
.5625".

page 18

Winding tube =
9-#23 wire Layer insu l . Wra pper
3 - # 1 1 wire Layer insu l . Wra pper

. 0400
. 2 160
. 0240
.0100
. 2787
.0200
.0 150

.6037

Tota l

( 9 x diameter of wire )
(8 layers x . 003" paper from ta ble)

(2 x . 0 10 pa per)
(outside wrapper)

The availa ble space is . 5625"

. 6037 I . 5625 x 1 00 = 107/o
This is obviously too m uch . So some adjustments will have to be made.
As mentioned previo usly, there a re several choices. A larger lamination
can be chosen, a better grade of lamination can be used, or a larger stack
of the same l a m i nation ca n be used . The choice is not always left to the
designer. If the customer has cal led out this size, then the choice will be
a higher g rade of l a mination . This will al low a higher fl ux density to be
used and therefore fewer turns. We will choose to use a higher grade of
lamination of the same size and return to Step #4 to mod ify.
Modify design

Step #4
Reca lcu late the pri m a ry turns using a new fl ux density of 95000
lines. This is 1 4 . 7 KG and is an a rbitra ry choice. It cou l d go as high as
17 KG and sti ll be a cceptable.
Np

4.44 x

115 x 108
95000 x 1.164

60

= 390 turns

Step # 5
Ns = 390 / 1 1 5 x 1 .0 5 x 6 . 3

2 2 . 4 turns (use 22)

Step #6
Wire sizes will not change for this modification; #23 and # 1 1 will sti ll be
used .

page 19

Step # 7
Coil lengths a n d margins will be the same. Also, the turns per layer will
remain the sa me.
#23 wire will have 390 / 52
7 . 5 layers (use 8)
#11 wire will have 22 / 11
2 layers
=

Step #8
Reca lculate the fil l
Tube
8-#23 wire
Insu l .
Wrap
2-#11 wire
Insu l .
Wrap
Tota l

. 0400
.1920
. 0 210
. 0100
. 1858
. 0100
. 0150
.4738

. 4738 I . 5626 x 100

84/o

This is an accepta ble fil l .

Step # 9
This step is to calculate the voltage d rops ca used by the DC resista nce of
the windings and adjust the turns, if necessary, to obtain the proper
voltage under loa d .
I n order to get the voltage d rop i n each winding, it i s fi rst necessa ry to
picture the build-up of the coil as calcu lated i n Step #8. This build-up is
accomplished in the following order:
1.
2.
3.
4.
5.

Winding tube
Pri m a ry wire separated by the layer insu lation
Wrapper between windings
Secondary wire sepa rated by the layer insu lation
Fin a l ly, the outside wrapper

page 20

If we take the b u i l d - u p a nd add u p the various sections, we ca n arrive at

a mean length turn for each winding.
Fig u re 5 shows a view of the tube on which the wire is wound .

.040"

1"
-

1"
.040"

Figure 5

In order to simplify the ca lculations, it is advisable to reduce the winding

tube to a squ a re, if it is not a l ready one. This is done by ta king the tota l
distance a round a n d d ividing by 4 . This will give you a n equiva lent
dimension of one side.
For exa m ple, a winding tube that is 1 1/2" x 1 3/4" would be :
1 . 625" equ ivalent squa re.
1 1/2 x 2 + 1 3/4 x 2
3 + 3 . 5 or 6 . 5 / 4
=

In our exam ple, the tube is a l ready square so we will ta ke the 1 1/8"
dimension and build - u p from there.
Sta rti ng with the size of the lamination and adding the winding tube
thickness to each side, the actua l dimension of the winding will be
obtained . The wire and insu lation is added on top of this.
Lamination
Tube x 2
8-#23 wire
Insu l .
Tota l

1 . 1 2 50 ( 1 1/8")
. 0800
. 1920
.0210
1 .4 1 80

page 2 1

This gives the build-up in one direction of the pri m a ry winding. When this
number is mu ltiplied by 4, it will give the length of one turn in the center
of the winding, or the mea n length turn of the pri m a ry wire. Thus,
1 .4 180 x 4 x 390 turns will give the length of the wire in inches. If th is is
multiplied by the resista nce per 1 000 inches from the wire ta ble and
divided by 1000, it will result in the DC resista nce of the winding .
1 . 41 80 x 4 x 390 x 1 . 6966 I 1 000

3 .75 Ohms

This value, 1 . 4 1 80, is the build-up to the center of the primary winding,
so the primary va l ues must be added i n again to g et to the start of the
secondary windi n g . The entire build-up is now repeated to clea rly show
the ca lcu lations.
La m .
Tube
8-#23
Insu l .
Total

8-#23
Insul .
Wra p
2-# 1 1
Insu l .
Tota l

1 . 1250
. 0800
. 1 920
.0210
1.4180 x 4 x 390

1.6966 I 1000

3. 75 x .608

2.28 v drop

. 1 920
.0210
.0100
. 1858
.0100
1 . 8368 x 4 x 2 2 x . 1 050 I 1 000

. 0 1 69 x 1 0

. 1 69 V drop

These voltage d rops can now be used to determine the output voltage
under loaded conditions. Th is is done by su btracting the primary drop
from the input voltage and, from the tu rns ratio, obta in the secondary
voltage. The secondary voltage d rop is then subtracted from this va lue to
obtain the loaded voltage.
Thus: 1 1 5 - 2 . 28

1 1 2 . 72 V. This is the effective i n put voltage.

From the turns ratio : 1 1 2 . 72 / 390 x 22

6.358 V.

Subtracting the secondary drop: 6 . 358 - . 1 69

6 . 1 89 V.

This is lower tha n the 6 . 3 volts desired so adjustments m ust be made.

page 22

Since the secondary m ust be center-tapped and an even n u m ber of tu rns

is desired, it wil l be better to adjust the primary turns. This is done by
dividing the ca lculated voltage by the desired voltage a n d m u ltiplying this
by the primary turns.
6.189 I 6 . 3

. 982 x 390

383 turns.

Reca lculating the loaded volta g e :

1 1 2 . 72 / 3 8 3 x 2 2

6 .474 - . 1 69

6 . 30 5 volts

It should be noted that this al so changes the fl ux density by a factor of

390 I 383 .
This will result in a fl ux density of:
95000 x 390 / 383

96736 lines or 1 5 KG.

This is wel l with in the l i m itations of M6 materia l .

The secondary turns ca n also be cha nged by this method .
It is
sometimes necessary to adjust both the p rimary and secondary tu rns
when there is more th an one secondary with a s m a l l n u m ber of tu rns.
This ca n result in a juggling of tu rns back and forth to get the desired
resu lts.
This small change in turns will not change the winding layers or
configuration .
Step # 10
The wire and l a m i n ation weights can now be ca lculated. The wire weight
is obtained by usi ng the calcu lated resistance a n d , referring to the wire
table for #23 wire, it is seen that it has 1 2 . 88 Ohms per pound. By
dividing the ca lculated pri m a ry resista nce by this val ue, we will get the
weight of the wire. The sa me is done for the # 1 1 wire of the secondary.
For the #23 pri m a ry wire : 3. 75 / 1 2 . 88
. 29 1 pounds
For the # 1 1 secondary wire : . 0 1 69 / . 0500
. 338 pounds
=

page 23

The weight of the lamination is obta ined from the l a m ination table or a
manufactu rer's cata log . For a sq uare stack of EI- 1 1/8" lamination, the
ta ble shows a weight of 2 . 24 pounds. This m ust be modified by the
stacki ng factor. This is . 9 2 for 1 x 1 interleaving .
2 . 24 x . 9 2

2 . 06 pounds of lamination

Step # 1 1
The losses ca n now be ca lculated . The core loss is obtained from the
man ufacturer's cata logs. Some of these a re listed at the bottom of the
wire table. It can be seen that M6 lamination at 1 5 KG is . 66 watts per
1 . 3 6 watts.
pound. Then the loss will be: 2 . 06 x .66
=

The winding or copper losses a re obta ined by multiplying the voltage drop
by the load cu rrent.
Primary
2 . 28 x . 608
Secondary
. 1 69 x 1 0
=

=
=

1 . 39 watts
1 . 69 watts

Adding the losses :

Core loss
Pri. loss
Sec. loss
Total

1 . 36
1 .39
1 . 69
4 . 44 watts

The tota l weight is :

Core
#23 wire
# 1 1 wire
Total

2 . 060
0.291
0 . 3 38
2 . 689 x 1 . 1 5

3 . 09 pounds

The 1 . 1 5 is the 1 5/o added for insu lation, brackets, etc.

page 24

Step # 1 2
The temperature rise ca n now be ca lcul ated .

0. 1

4. 44
3 . 09
1 . 073

2 /3

- 2 1 . 93 degrees C rise
-

This is very conservative. Normal transfo rmer material ca n sta nd a tota l

temperature of 1 0 5C.
This includes the tem perature of the
su rrou ndings, or a m bient temperature, plus the tem perature rise of the
transformer. For exa m ple, if the am bient is 50 degrees, then the rise can
be 55 deg rees. M ost specifications will call out either the a m bient or the
maxi m u m tem perature rise accepta ble, or both .
Step # 1 3
Calcu late the reg u lation . This i s the secondary n o load voltage minus the
fu ll load voltage, d ivided by the fu ll load voltage. The no-load voltage has
not been ca lculated previously so it m ust be done now. This is done by
calculating the turns ratio without any voltage d rops :
1 15 I 383 x 22

6 . 605 V no load

Then 6 . 605 - 6 . 3 0 5

. 30 / 6.305

. 047 x 1 0 0

4. 710 reg u lation .

A normal tra nsformer of this size would probably be desired to be within

the 5 to 1010 ra nge of reg ulatio n . This will a lso norma lly be ca l led out in
the specification if it is critica I.
This exa m ple is one of the simplest designs, but it clea rly shows the
design method . More complicated desig ns ca n readily be accompl ished
by followi ng the steps a n d adapting them to fit the requirements.

page 25

2.2. 1 Bobbin construction method of design

The design example was shown as being a layer wound coi l . This could
also have been designed on a bobbin .
A bobbin-wound u n it can be smaller than a layer wou n d unit because
there is no need for end margins as the bobbin fla nges protect the
windings from the lamination, and a lso, bobbins a re usua lly ra ndom
wound which e l i m i n ates the need for layer insulation . Wra p pers between
windings a re sti l l necessary for electrical isolatio n .
Some extra
preca utions m ust be taken in man ufactu rin g . This w i l l be discussed in
Chapter 1 1 on bobbin winding.
To demonstrate the differences, let us return to the desig n exa mple that
resulted in a fill of 1 07/o. The bobbin for this size lamination will have a
winding length inside the flanges of 1 . 545 inches (see the m a n u facturer's
catalog ) .
Turns per l ayer for # 2 3 wire will be 37.4 x 1 . 545
Layers
436 I 58
8
=

5 8 turns

1 5 turns

Tu rns per layer for # 1 1 wire will be 1 0 . 2

Layers
26 I 15
2
=

1 . 545

Reca lcu lating the fill and eliminating the layer insulation :
Winding tube
8-#23
Wra pper
2-# 1 1
Wrapper
Tota l

. 0400 (bobbin)
. 1 920
.0100
. 1 858
. 0 1 50
.4428 I . 5625 x 100

79/o fill

As you can see, the use of a bobbi n in this tra nsformer would result in
being a ble to use a lower g rade of lamination, since the flux density can
be lower.

page 26

A more d ra m atic change can be obta i ned by red ucing the core one size
and increasing the fl ux density. This might result in using smal ler sizes of
wire and therefore hig her copper losses. The tem perature rise would
have to be ca lcu lated to see if this is acceptable. Care m ust be. ta ken to
conform to the customer's req uirements and to not exceed good design
practices.
2.3

Frequencies other than 60 Hertz

The lamination table gives the approximate sizes to be used as sta rting
points for a particular VA ratin g . This ta ble is for 60 Hertz operatio n . If
the frequency is other than 60 Hertz, adjustments m ust be made.
From the tra nsformer turns formu l a , it would seem that the size would be
inversely proportional to the freq uency . A look at the manufacturer's
core loss curves show that this is not true.
As a rule of th u m b, a 400 Hertz unit will be a pp roxi mately one-half the
size of a 60 Hertz unit, and a 50 Hertz u n it will be a pproximately 10/o
larger than the 60 Hertz unit. These a re only a pproximations and a re to
be used for choosing a lami nation size as a starting point in the design.
2.4

Excitation cu rrent

The excitation cu rrent, or the cu rrent needed to d rive the core to the
proper flux density, has not been previously d iscussed . Some customers
will put a maxi m u m excitation current l i mitation in their specifications. If
this is the case, this cu rrent m ust be calculated .
The man ufactu rer's cata logs will give some val ues or have curves that
show the va lues to be expected for various fl ux densities. Unfortunately,
these curves usually a re test results of the core material under idea l
conditions. The val ues obtai ned from these curves must be modified to
accom modate the actua l conditions.

page 27

Consideri ng the th ree previously mentioned g rades of l a m i nations, and an

interleave of 1 x 1 , the fol lowing mu ltipliers should be used :
For 29M6 materia l at 1 5 KG, use 3 times the value show n .
For 1 8 KG, use 10 times the val ues.
For 26M 19 a n d 24M22 materials at 10 KG, use 1 . 5 times the val ues
shown.
For 14 KG, use 3 times the val ues.
For va lues of fl ux densities in between those g iven . it will be necessary to
interpolate.
There a re many things that will cause the exciting cu rrent to va ry other
tha n the flux density and the grade of the core material.
For exa mple, if the lami nations are bent or not stacked tig htly to reduce
the gaps, the exciting current will increase d rastica lly. U nfortunately, the
gu idelines a bove a re a pproxi mations. Experience will result in a better
feel for what to expect u nder actua l conditions.
The following pages conta i n the wire and l a m i nation ta bles and a
complete man ufactu ring specification for the layer wound transformer
that was designed .

page 28

WINDING S H E ET EXPLANATIONS

(1)

The tube size is given as 1 . 1 5 " x 1 . 1 5 " x . 040". This size i s . 025"
larger than the core to a l l ow the l a m i n ations to be inserted without
digging into the tube. The . 040" is the thickness of the tu be.

(2)

The leads a re shown coming out of the coi l . Notice that the primary
winding is 8 layers, therefore, the start a n d the fin ish will both
come out on the sa me end . The seco n d a ry winding a lso has an
even n u m ber of layers, 2, but the ta p is at the end of the first layer.
Therefore, the start, #3 and the finish, # 5 , will come out on the
same end, but #4 will come out the o pposite e n d . This is the result
of the tap coming at the end of the first layer. A look at the
winding m ethod of Cha pter 10 w i l l m a ke this clear. The finishing
instructions on sheet #3 of this specification ca lls for the #4 lead to
be finished across the coil in order for a l l the secondary leads to
come out on the same end when fi nished .
Note the li nes d rawn i n to represent the l a m i nations. This is done
to indicate to the winders the areas that m u st be free of leads.

(3)

It is customary t o p u t a n outside wra p on the coil w h e n it i s wound

and a lso an addition a l wra p of g u mmed pa per or ta pe is put on
after fi nishing the leads.

(4)

Th is indicates at which end of the coil the winding is sta rted . The
"A" end is at the left a n d the "B" end is at the rig h t .

(5)

This d imension is to be fil led-in if a maxi m u m coi l size is called out

on the fin ished coil .

page 2 9

ROBERT G. WOLPERT
TRANSFORMER DESIGN SERVICES

WINDING S H E ET
1

PAGE

-5

__

PAGES

SA MPLE DESIGN

SPEC NO.
RGW

ENGINEER.

DATE

-----

POWER

TYPE
WINDOW
COIL BUILD
TUBE
OVER TUBE
DENSITY
FREQUENCY
AREA
AT
TERMINALS

OF

9/16" x 1 1/16"
NET GROSS
84 Ofo
1.15" x 1.15" x .040" (1)
None
96750 lines
60 HZ
IN2
1.164
VOLTS
115
1-2

5/8" -t 1-<5)- I
COIL 1

(2)

A
1 u----

115v

6.3 V c.t.

60 Hz.
2

@
10.0 A

See page 29 for explanation .

WINDING NO
WIRE SIZE
TOTAL TURNS

1
#23
383

TAPS
WINDING LENGTH
MARGIN
TURNS PER LAYER
% FILL
NO. OF LAYERS
LAYER INSULATION

WRAPPER

TERM COIL
START AT

1 3/8"
1/8"
48
84/o
8
1L - .007K
1 -layer .01 OK
1-2
A

2
#11
22
11
1 1/8"
1/4"
11
91/o
2
1L - .01 K
1 - layer .01 OK
1 layer .005 GK {by
finishing) (3)
3-4-5
A (4)

page 30

MATERIAL SHEET
PAGE
SPEC NO.

CORE
COPPER

OF --==5

_
_

PAGES

__,S=A...._MP=LE=-=DE
= S
= I
= G=.:.;:N

___

PART NO.

AMT.

EI- 1 1 /8 "
2 9M6 arade

2 . 06#

#23 SINGLE COATED

#1 1 HEAVY COATED

TO
PRICE

TO
PRICE

TO
PRICE

0 . 2 9#
0 . 338#

CAN
LID-T
LID-B
TERMINALS
TUBE

1 . 1 5x 1 . 1 5x .0 40
x 1 5/8 " long

1 1 /8 " HORIZ. "L"

TERM BOARD
LUG PANEL
BKT
LEADS
Black
Green
Yellow

BOLTS
NUTS
WASHERS
WASHERS

#20 AWG PVC

#12 AWG PVC
#12 AWG PVC
6 6 #6
#6

x
x
x

811 LON G
811 LON G
811 LON G

32 x 1 1 /2 "
32
steel
fiber

2
2
1
4
4
4
4

NOTES:

page 3 1

FINISHING
3

PAGE
SPEC NO.

5__ PAGES
OF -
.
S
-.. A..-....
M P=L
.._ -E D-=-= E=S=I--G....
N,__

___...

___

COLOR

LENGTH OUT
OF COIL

LEAD#

#20 AWG PVC

BLACK

6"

1 &2

#1 2 AWG PVC

GREEN

6"

3&5

#1 2 AWG PVC

YELLOW

6"

LEADS SIZE

LUGS OR LUG PANEL:

PART#

LEAD#

SPECIAL INSTRUCTIONS:
Finish as shown. Yellow lead, #4, is finished across the coil.

BLACK 2

3 GREEN

page 32

STAC KI NG & ASS E M B LY

4

PAGE

OF -=5

__

PAGES

SPEC NO. ----S=A=MPL=E"'-=D=E=SIG=N.....__

LAMINATION:
EI

SIZE:

1 1/8 "

GRADE:

2 9M6

STACK HEIGHT:

1 1/8 "
1x 1

INTERLEAVE:

KEEPERS:
CUT OFF E'S:
GAP SPACER:
BRUISERS:
SIZE:

No

SHIELD:
U INSULATORS:
SIZE:
BRACKETS:
HARDWARE

QTY: 4
Q TY:
QTY:
QTY:
QTY:

4
4

1 1/8 " H orizontal "L "

6

32 x 1 1/2 " bolts

6

3 2 nuts

#6 steel washers

#6 fiber washers

SPECIAL INSTRUCTIONS:
Assemble as shown . Fiber washers to go under bolt heads .
core.
Vacuum varnish completed unit .

Mark on top of

w = 3 3/8"
D= 2 3/8"
H = 2 13/16"
MH = 13/64" X 3/8" slot
MW= 2 13/16"
MD= 2 1/8"

page 33

TEST INSTRUCTIONS
PAGE -5- OF
SPEC NO.

PAGES

SAMP_LE
-DE
-. SIG..
N _
.._

__.

___

PROCEDURE
1ST TEST

2ND TEST
3RD TEST
FINAL TEST

1.

NO LOAD VOLTAGE RATIO

115

APPLY
READ

2.

60

HZ TO TERM.

--'
==3 3'"----0
=--=- 3'""'
3
. ......._

--

BLK-BLK

V TERM.

__

____

V TERM.

______

V TERM.

lex _..._N=-A.:.-_ MAX.

GREEN-YELLOW-GREEN

INDUCTANCE TEST
APPLY
READ "L"

3.

5, 6

NA

__

----

HZ TO TERM.

&

___

A. D. C.

MIN.

INDUCED VOLTAGE TEST

APPLY

NA

4.

MUST MEG.

5.

HIPOT

___

NA

HZ TO TERM.

FOR

___

MEGOHMS MIN.

VOLTS D. C.

LEAD NO.

TO

VOLTS

BLACK

GREEN

1500

BLK,GRN

CORE
CASE

1500

6.

CONTINUITY

7.

SPECIAL TESTS

SEC.

page 34

LAMINATION TABLE
SIZE

STACK HT.

VA

AREA

EI-187

3L16

0.5

.0 3 5

3L16

EE-24-25

1L4

1.0

.0625

1L4

EI-3L8

3L8

3.0

. 1406

5L16

3L4

. 108

EI-5L8

5L8

7.0

.390

5L16

15L16

. 392

EI-3L4

3L4

14. 0

.5625

3L8

1 1L8

.678

EI-3L4

1.0

19 . 0

. 75

3L8

1 1L8

.9 04

EI-7L8

7L8

30.0

. 765

7L16

1 5L16

1.05

EI-7L8

1.0

32.0

. 875

7L16

1 5L16

1.20

EI-1

1.0

45.0

1.00

1L2

1 1L2

1.55

EI-1

1 1L4

50.0

1.25

1L2

1 1L2

1.94

EI-1 1L8

1 1L8

65.0

1.265

9L16

EI-1 1L4

1 1L4

90.0

1.5625

5L8

EI-1 3L8

1 3L8

125.0

1.89

11L16

EI-1 1L2

1 1L2

160.0

2.25

3L4

2 1L4

EI-1 3L8

1 3L4

160 .0

2 .40

11L16

EI-1 1L2

2 1L2

300.0

3 . 75

3 L4

2 1L4

8 .91

EI-1 3L4

1 3L4

340 .0

3 . 06

7L8

2 5L8

8 . 61

EI-1 3L4

2.0

400 .0

3.50

7L8

2 5L8

9 . 84

EI-1 5L8

2.0

450.0

3.25

1 1L4

WINDOW
x

WEIGHT (lbs . )

7L16

.015

1L2

.034

1 11L16

1 7L8

2.24
3 . 08

2 1L16

4 . 17
5.35

2 1L16

2 5L8

5 . 31

7.78

Note : Va l ues shown for a rea and weig ht must be modified by the stacking
factor K.
REPRESENTATIVE CORE LOSS

CORE LOSS IN WATTS PER LB.

GRADE

10 KG (64500 lines)

29 M6

15 KG (96750 lines)
0 . 66

26 M19

0.83

2 . 00

24 M22

1.10

2 . 60

Note:

Core losses shown a re from manufactu rer's cata logs and a re

typica l . The cata logs should be consu lted for more detai led data .
page 3 5

WIRE TABLE
SIZE OHMSL1000" INSUL MARGIN

42 139 .00
41 110. 25
87.42
40
69. 32
39
54.97
38
37
43.59
34. 56
36
27.42
35
21. 74
34
17. 24
33
13. 67
32
10.84
31
30
8.60
6.82
29
5.41
28
27
4.29
3.40
26
2.70
25
2.14
24
23
1.70
22
1. 345
21
1. 067
20
.8458
. 6709
19
18
. 5 320
.4220
17
16
. 3 346
15
. 26 5 3
. 2104
14
. 1669
13
12
.1323
11
. 1050
10
.0 833
9
. 0660
8
. 0 524

.0 007
.0 007
.0 007
.0 007
.0 01
.0 01
.0 01
.0 01
.0 01
. 0015
. 0015
. 0015
. 0015
.0015
. 0015
.002
.002
.002
.002
.003
.0 03
.0 03
.0 05
.005
.007
.007
. 010
. 010
. 010
. 010
. 010
. 010
. 010
.010
.010

CM AREA

6.25
1L16
7.8
1L16
9.9
1L16
12. 5
1L16
15.7
1L16
19 . 8
3L32
25.0
3L32
31. 5 2
3L32
39.75
3L32
50.13
3L32
63.2
3L32
79.7
3L32
100.5
3L32
126.7
1L8
159.8
1L8
201.3
1L8
254.1
1L8
320.4
1L8
404.0
1L8
509.5
1L8
1L8
642.4
810.1
1L8
10 22. 0
1L8
1288.0
1L8
1624.0
1L8
204 5 . 0
1L8
253 3.0
1L4
1L4
3257.0
4107.0
1L4
5778.0
1L4
6530.0
1L4
1L4
8234.0
1L4 10 380. 0
1L4 13090.0
1L4 16 510.0

DIA

TURNSLIN

.0028
.0032
.0036
.0040
.0045
.0051
.0056
.0062
.0070
.0079
.0089
.0099
.0110
.0123
.0137
.0154
.0171
.0192
.0215
.0240
.0268
. 0301
. 0336
. 03 76
.0421
.0471
.0 527
. 0 590
.0661
.0741
.0829
. 0929
. 1042
.1168
.1310

304.0
267.0
239.0
215.0
192.3
170.4
15 5.5
142.0
125.6
110.4
99.0
88.9
81. 0
72. 5
63.0
57.6
52.0
45.9
41. 9
3 7.4
33.6
30.3
26.7
24.3
21.7
19. 3
17.6
15.9
14.2
12 .8
11. 5
10. 2
9. 5
8.2
7.2

OHMS[LB

84648.0
54045.0
3 5610 .0
22047.0
12887.0
8077. 0
5248.0
3 375. 0
2106.0
1305.0
810.0
530.0
3 3 3.4
204.6
13 2 . 5
82.5
52.7
32.7
20.7
12.9
8.22
5.12
3.23
2.04
1. 29
.805
.5101
.3193
. 2016
.1258
.0794
. 0500
. 0315
.0198
. 0125

page 36

CHAPTER 3 . THREE PHASE TRANSFORMER D ESIGN

Three phase tra nsformers can be designed using a similar method to the
single phase transformer design in Chapter 2 . There a re differences in
the methods of ca lculating the voltages and cu rrents. In general, a th ree
phase unit ca n be considered as three single ph ase u n its connected
together.
Three phase transformers ca n be connected in several configurations.
They a re Delta - Delta, Delta - Wye, Wye - Delta and Wye - Wye. The
Wye is also ca l led a Sta r configuration.
Before the tra nsformer ca n be designed, it m ust be determ ined what the
configuration will be, and also the various relationships between voltages
and currents.
3.1

The Wye configuration

The line voltage is usually given for the primary and secondary. To
obtain the phase voltage, d ivide the line voltage by the square root of 3,
which is 1. 732. It can be shown that this is derived from the fact that the
three voltages a re 1 2 0 degrees out of phase.
Let

E<l>
EL
I<l>
IL

Then E<l>

phase voltage
line voltage
phase current
line cu rrent
E L I 1 . 732.

This is the voltage that must be used in ca lculating the turns necessary
for a given core.
The phase current is equal to the line current I<l>
The phase power is eq ual to E<l> x I<l>
The total power is equal to the phase power x 3 or

IL
E<l>

I<l> x 3

To demonstrate this, refer to Fig ure 6.

page 37

FIGU RE 6

The line to line voltage will be the voltage applied between 1 & 2, 1 & 3,
and 2 & 3. These voltages a re 120 degrees a pa rt. The ph ase voltage will
be the voltage between each line and the neutral ( N ) . The neutra l is not
always used, but is shown here for clarity . It ca n now be seen that the
tu rns in each ph ase will be ca lculated using the phase voltage and the
wire size m ust be chosen using the phase cu rrent. The neutral line will
carry no current if the l ines a re bala nced.

3.1.1 Example
A Wye secondary has a line voltage of 200 V. a n d a power rating of 120
VA. To find the phase voltage : E<t>
200 / 1 . 732
115.4 v
=

The phase cu rrent is equal to the line cu rrent.

The tota l power is 1 2 0 VA which is eq ual to
Solving for the phase current: let>

let> x E<t> x 3 .

120 / (115.4

3)

0 .347 A .

If this transformer also has a Wye primary with a 208 volt line voltage,
the primary ph ase voltage will be : E<t>
208 / 1. 732
120 v.
=

The primary tota l power will be : 120 x 1.11

The primary cu rrent will be : 133.2 / (120 x 3)

=
=

133 .2 VA.
0.37 A.

The per phase power for the primary for calculating the size of the core
needed will be: 120 / 3
40.
=

page 38

Th is ca n be considered as th ree tra nsformers each capa ble of handling 40

VA in choosi ng the core size. In this case, from the lamination ta ble,
Chapter 2.4, it is seen that a 40 VA single phase transformer will need
about 1 square inch of core. Th is would be a 1" stack of EI-1 lamination.
However, the window width is larger in the three phase than in the single
phase la mination, so a smaller size will probably suffice. Therefore, a
7/8"_ lamination with a 7/8" stack will be used as a sta rting point. A
manufacturer's catalog should be consu lted for available sizes.
The desig n gu ide for single phase transformers ca n now be followed with
the difference being only 1/2 of the window width can be used for each
coil .
Figure 7 shows an outl ine drawing of a typica l th ree phase
transformer. Fig u re 8 shows a three phase lam ination of the size used in
this desig n .

-----

3192

-----

2
31/2
1
132
11 - 32
3
3
3
.----_
_ -.---....2"""'.
2

1....3...

__ _

__

-e-

32
7

DIA

--.-----""'

5
312

FIGURE 7

-e-

- 35
l64

64

(4)

-e3 1/2

FIG U RE 8

page 39

3.2

The Delta configu ration

The Delta configuration differs only in the way the windings a re

connected. This cha nges the relationships between the voltages and
currents. See Fig u re 9 .
1

2
3
FIGU RE 9

In the Delta con nections the phase voltage is equal to the line voltage.
The phase current is equal to the line cu rrent divided by the square root
of three.
If you examine Fig u res 6 and 9 it ca n be seen that the line voltage is
appl ied directly across the per phase tu rns in the Delta configuration,
while it is not in the Wye . Also, the line cu rrent mu st flow th rough the
turns directly in the Wye and is divided in the Delta .

3.2.2 Delta exa mple

If the sa me specifications used in the Wye exa mple a re used for the
Delta :
Line voltage
2 0 0 V.
Power
120 VA
=

The phase voltage is equal to the l i ne voltage, 200 V. The phase cu rrent
is equal to the line current divided by 1. 732.
The line current
.02 I 1 . 732

120 / ( 200

3)

0 . 2 and the phase current will be :

0 . 1 1 5 A.

The turns are ca lculated using 200 V. and the wire size from the 0 . 115 A.

page 40

3.3

Th ree phase design exa mple

The previous exam ples a re used for a co m plete desig n . This will be a
transformer with a Wye primary and a Delta seconda ry . See Fig u re 1 0 .

1
1

ST

ST

ST

F
200 v

L-L

@
120 VA
208 V

L-L

@
60 Hz

, ST

F
ST

F
3

ST

FIGURE 10

As has been shown previously, the secondary current per phase will be
. 1 15 A. The pri m a ry VA = 1 2 0 x 1 . 1 1 = 1 3 3 . 2 . The pri m a ry line voltage
is 208 V., then the per phase voltage will be 1 2 0 V. and the per phase
current = 0 . 3 7 A.
A starting point for the core size will be EI-7/8 with a 7/8" stack. The
effective core a rea is 7/8" x 7/8" x . 92 = 0. 704 " .
Ca lculating the pri m a ry turns for 2 9 M 6 lami nation a n d 60 H z . at
15 Kiloga uss (96750 li nes ) :

Np =

4.44

10 8

120

60

. 704

96750

661 turns

Calculating the seconda ry turns:

661 / 120 x 1 . 05 x 200 = 1 1 57 turns.
The wire size needed for the primary cu rrent of 0 . 3 7 A will be # 2 5 .
The wire size for the secondary cu rrent of 0 . 1 1 5 A will be # 3 0 .

page 4 1

Calculating the fil l:

Window
1 3/32" x 2 1 3/32"
Coil Length
2 1/4"
#25 winding length
2"; margins
1/8"
Tu rns per layer
95 (this is more than the chart shows, but w i l l fit with a
winding layer fill of 9 1 /o)
=

7
Layers
661 I 9 5
#30 winding length
2"; margins
1/8"
Turns per layer
1 66 (a winding fi ll of 9 1 /o)
Layers
1 1 57 I 1 66
7
=

Winding tube
7-#25
Insu lation
Wrapper
7-#30
Insu lation
Wrapper

. 0300
. 1 344
. 0 1 20 (6 layers of . 002" paper)
. 0 1 00
. 0 770
.0090 (6 layers of . 0 0 1 5 pa per)
.0 150

Tota l

.2874 x 2

. 5748 I 1 . 094 x 100

52/o

This is too small a fil l . An adjustment ca n be made by using less

expensive l a m i n ation o r a smaller size. The next s m a l le r size is 5/8",
which is probably too s m a l l , so 26M 1 9 lamination wil l be tried using a flux
density of 1 0 KG ( 64500 lines) .
The primary tu rns will be increased by the ratio of 1 5 KG divided by 10
KG : 661 x 1 5 / 10
992 turns
=

Secondary turns

992 / 120 x 1 . 0 5 x 200

1736

The sam e wire sizes a n d turns per layer will be used.

#25 layers
992 I 95
11
#30 layers
1736 / 166
11
=

page 42

Recalculati ng the fill:

Tube
. 0300
.2117
1 1- # 2 5
. 0 20 0
Insu l .
.0100
Wrap
. 1210
11-#30
. 0 1 50
Insu l .
Wrap
. 0 1 50
-

.4227 x 2

Total

.8454 I 1 . 094 x 100

78/o

This is sufficient fi l l for this tra nsformer.

Calculating the
Core
Tube x 2 1 1- # 2 5
Insul .

voltage drops (from the single phase exam ple) :

.8750
.0600
.2117
. 0 20 0
1 . 1667

Wrap
1 1- # 30
Insu l .

992

1736

2 . 69 7/1000

1 2 .48 O h m s

.37

8 . 6 / 1000

9 2 . 2 3 Ohms

.115

4 . 62

. 0200
.2117
.0100
. 1210
. 0 1 50
1 . 5444

10.6

Ca lculating the loaded voltage per phase:

120 - 4 . 62

1 1 5 . 38 I 9 9 2 x 1 73 6

20 1 . 9 1 - 1 0 . 6

19 1 . 3 1 v .

This is lower than the 2 0 0 V needed. Therefore, i t will be necessa ry to

adjust the seco n da ry turns by the ratio of 2 0 0 / 1 9 1 . 3 .
This i s 1 . 045 x 1 736

1815.

page 43

Recalculating the voltage drop i n the seconda ry with this new number of
turns:
92 . 23 Ohms x 1 8 1 5 / 1736
1 1 5 . 38 I 992 x 1 8 1 5

96.43 Ohms x . 1 1 5

2 1 i . 10 - 1 1 .09

1 1 . 0 9 V drop.

200 . 0 1 v .

Th is is the complete design:

Primary
992 turns of #25 wire
Secondary
1 8 1 5 turns of # 3 0 wire per coi l for three identica l coils.
=

3.3. 1 Temperature rise

The tem perature rise of a small three phase transformer is ca lculated in
the sa me manner as the single phase tra nsformer except that the tota l
weight a n d total losses a re both divided by three before the calcu lations.
The weight of the core (from the manufacturer's catalog) is 4 . 0 5 pounds.
The actua l weight is 4 . 0 5 x 9 2
3. 73 pou nds.
=

The weight of the wire is:

#25
#30

=
=

12.48 I 3 2 . 69
92.23 / 3 3 3 . 4

=
=

. 3 8 1 pou nds per coil x 3

. 2 7 7 pounds per coil x 3

=
=

1 . 145 pou n ds
. 8 3 1 pounds

The tota l weig ht:

Core 3.73
1 . 145
#25
.831
#30
Total

5 . 706 x 1 . 1 5

The core loss

Primary loss
Secondary loss

=
=
=

6 . 56 pounds (adding 1 5/o )

3 . 73 x .83 (from chart page 24)

4.62 x . 3 7
1 . 7094 per coil x 3
1 1 . 09 x . 1 1 5
1 .28 per coil x 3
=

Tota l losses
Dividing the weight by 3 : 6 . 56 / 3
Dividing the losses by 3 : 1 2 . 04 / 3

=
=

3.09
5 . 128
3 . 826
1 2 . 04

2 . 19 pou nds
4 . 0 1 5 watts

page 44

Using the tem perature rise formula from Chapter 2 :

0. 1

4.015
2.2
1 .073

3 . 3 . 2 Reg u lation

) 2/3

24.87 degrees rise

The no-load voltage = 1 2 0 / 992 x 1 8 1 5 = 2 1 9 . 55 V

The ful l load volta ge = 200 . 0 1 V
Regu lation = ( 2 1 9 . 55 - 200 . 0 1 ) / 2 00 . 0 1 x 1 0 0 = 9 . 77/o
3.4

Interconnections

The manufacturing specifications for a three phase tra nsfo rmer will be
similar to the single phase specifications. The three phase u n it will need
three coi ls wound. The interconnections between the coils will be as
shown in the Fig u re 1 0 diag ra m . All fin ishes on the Wye configu ration will
connect together a n d go to the neutra l , if desired . The sta rts connect to
the finishes i n the Delta configuration . The A, B, C coils a re called out to
keep the windings stra ight.
When ta ps a re req u i red on th ree phase tra nsformers, it is simple to put
ta ps in the Wye configuratio n . This is done just l i ke the single phase
units. Ta ps in the Delta configuration must be ha ndled differently. If a
ta p is put in the Delta configuration without changing the connections, it
will result in circu lating cu rrents. In order to overcome this, an open
Delta is used. See Fig u re 1 1 .
1

1
1

3
c

FIGURE 1 1

page 4 5

Referring to Fig u re 1 1 , for normal operation, con nect:

# 1 of coil A to # 3 of coi l B
# 1 of coil B to # 3 of coil C
# 1 of coil C to # 3 of coil A
When the taps a re used, the # l 's a re left disconnected a n d the #2's are
connected to the # 3 's instead of the # 1 's.
The material list m ust show the wire weight for all three coils.

page 46

CHAPTE R 4. AUTO TRANSFORM E RS

An a uto transformer can be used when pri m a ry to secondary isolation is

not necessa ry. It can be either a step-u p or a step-down volta ge ratio.
A distinct size a dva ntage is g a i ned if the ratio of voltag es is not too large.
It can be shown that the size of an auto tra nsformer will va ry
approximately from a reg ular tra nsformer by the form u la: ( E 1 - E2) I E i .
Where :

E1
E2

=
=

h i gher voltage
lower voltage

For exa m ple, if E i

230 V a n d E2
1 1 5 V, then the size will be
approximately 1/2 that of a reg ular tra nsformer. The size adva ntage is
lost if the ratio becomes more than 3/4, wh ich is a voltage ratio of 4 to 1 .
=

4. 1

Design proced u re

In the design of an a uto transformer consider Fig u re 1 2 .

I
1 0-----....-----<J 3 --

n-------v 5 --

I
FIG U RE 1 2

If the line voltage i s a pplied to 1 a n d 2 a n d the load is a p plied to 3 and 5,

then the load current flow in 3 and 5 will be directly drawn through the
in put li nes, 1 a n d 2, a n d a transformer will not be needed. However, if a
load is placed a cross 3 a n d 4, then the load current flow will be from 1 to
3, through the load resista nce to 4 and back through a portion of the
tu rns to 2 . See Fig u re 1 3 . The a rrows represent the cu rrent flow
direction at any given i nsta nt.

page 47

If the dia g ra m of Fig u re 1 3 is followed, it is readily seen that the tu rns

from 4 to 2 is the only portion of the transformer that m ust carry the load
cu rrent. The bala n ce of the turns will carry the difference between the
primary current a n d the load cu rrent.
The turns from 1 to 2 m ust carry the exciting current plus the difference
of the two other currents. Thus the turns from 4 to 2 must ca rry the load
cu rrent plus the exciti ng current. The exciti ng cu rrent is usually so m uch
smaller than the load cu rrent and also is not directly in phase with the
load so that it usually ca n be disrega rded in calculating the wire sizes.

Ei

RL E 2

FIG URE 1 3

4.2

Design exa mple

An a uto tra nsformer is desired to change 120 volts to 50 volts at 1 . 0

am peres. This is 5 0 x 1 = 5 0 VA.
From the l a m ination table of 2 . 4 it is seen that a regu l a r transformer will
be about the same size as the exa m ple of Chapter 2, which is 1 1/8". For
an a uto tra nsformer this will be : ( 1 20 - 5 0 ) / 120 = a p p roximately 60/o
of the size or 38 VA. From the table this will be a core size of EI 7/8" x 1"
for a starting point.
Using 29M6 g ra de laminations:
The tu rns =

4.44

1 08

120

60

.805

96750

= 578

The seconda ry turns = 578 / 1 20 x 1 . 08 x 50 = 260

The current for the i n put windi n g will be: 50 x 1 . 1 1 / 1 2 0 = .462 A.
Then the current for 3 - 4 will be 1 - .462 = . 53 2 A.

page 48

The wire size fo r this part of the winding will be # 2 5 . The load cu rrent of
1 . 0 a m peres will require # 2 2 wire. It should be noted here that this is
642 circula r mils per a m pere a n d is smaller tha n in dicated in Cha pter 2 .
It w i l l be seen later that i t w i l l be sufficient for a reasona ble tem perature
rise.
The turns for the # 2 5 wire will be : 578 - 260

318

Using a bobbin for this design, check the table for EI-87 La mination i n the
Appendix to see if the tu rns will fit in this core size.
The maxi m u m turns for # 2 5 wire are 952 tu rns,
then 3 18 / 952
. 34 x 1 0 0
34/o.
=

The maxi m u m turns for #22 wire are 480 turns,

then 260 / 480
. 5 3 x 100
53/o . The tota l is 34 + 53
=

87/o.

This should fit as the tables a re conservative.

Calculati n g the fil l :
Core window
Winding length
#25 turns per layer
Layers
#22 turns per layer
Layers
Winding tube
6 - #25
Wrapper
7 - #22
Wrapper

7/ 1 6" x 1 5/ 1 6"
1 3/ 16"
54
3 18 I 54
5 . 8 o r 6 layers
34
260 I 34
6 . 6 o r 7 layers
. 0400 (bobbin)
. 1 1 52
. 0600 ( Mylar tape)
. 1876
. 0060

Tota l fil l

. 3547 / .4375

100

8 1 /o

Calculating the voltage drops :

Core
.9375
Tu be
.0800
6 - #25
. 1 1 52
1 . 1 3 27 x 4

318

2 . 6975 / 1000

260

1 . 345 / 10 00

3 . 88 O h m s

. 1 152
.0060

7 - #22

. 1876
1 .4414

2 . 0 1 Ohms

page 49

The voltage drop for 3 - 4

2 . 0 1 x . 532
1 . 0 7 volts.
The voltage drop for 4 - 2 will be 3 . 88 x 1
3 . 88 volts.
The tota l voltage drop across the in put will be 1 . 07 + 3 . 88
=

120 - 4 . 9 5

1 1 5 . 0 5 I 578

. 1 99 x 260

5 1 . 75 - 1 . 07

4 . 9 5 volts .

5 0 . 68 v .

This is close enoug h to the desired 50 volts for this exa m ple. If a closer
voltage is desired, the turns ca n be adjusted to :
50 / 5 0 . 68 x 260

257 turns

This w i l l not change the other ca lculations enough to m a ke a significant

difference.

4.2.1 Temperature rise

Core weig ht
#25 weight
# 2 2 weight

1 .20 x .92
3 . 88 I 3 2 . 7
2.01 I 8.22

- 1 . 1 04
.012
. 244

Tota l

- 1 . 36

x 1.15

1 . 564 pou nds

Losses :
Core #25 #22 -

1 . 1 04 x . 66
3 .88 x 1 . 0
1 . 0 7 x . 532
Total

Tem perature rise :

- 0 . 638
- 3 .88
- 0 . 569

5 . 087 Watts

5.087
0.1 (1.564 ) 2/3 - 39.56 degrees
1.073
4.2.2 Reg u lation

No-load voltage
1 20 / 578 x 260
53.97 V
(53.97 - 5 0 . 68 ) / 5 0 . 68
.0649 x 100
6 . 49/o reg u lation
=

This is a very usable desig n . It m ust be noted, however, that the size
form ula is approxi mate a n d is o n l y a starti ng point. Adjustments may
have to be m ade j u st as in the reg ular transformer designs.

page 50

CHAPTER 5 . POWE R TRANSFORM E RS USI N G CAPACITOR FILTE RS

When a tra nsformer is used in a rectifie r circuit, it is sometimes necessary

for the tra nsformer desig ne r to ca lcu late the RM S vo ltages a n d cu rrents
needed when the DC va lues a re g iven . Th is chapter will show a method
of ca lcu lati ng these va lues.
In the past, i n ductive fi lters were genera l ly used. There is m uch written
on methods used to calculate this type of filter a n d w i l l not be covered.
The most com mo n l y used filter now is the ca pacita nce i n put filter. This is
the type of filter circuit that wil l be considered.
The complete ca lcu lations for the capacitor fi lter tra nsformer a re
compl icated a n d will not be shown . The method used here is a close
a pproxi mation a n d the resu lts a re very satisfactory in m ost cases.
When the req u i rements a re g iven for a DC load, it m u st a l so be known
what type of rectifier circuit will be used a n d a lso the value(s ) of the
ca pacitor filter.
5.1

Types of rectifier ci rcu its

There a re severa l types of rectifier circu its. These a re fu ll wave center

tapped, fu l l wave bridge, fu ll wave bridge center-ta pped, half wave, etc.
In this desig n g u ide o n l y the fi rst three circu its will be considered.
5 . 1 . 1 Full wave center-tapped

If the circuit of Fig u re 1 4 is exa m i ned, it can be seen that the secon da ry
of the tran sformer w i l l s u p pl y power first in one direction a n d then in the
other. Th is causes the secondary to furnish power one half at a time.
This a l lows the wire size to be cut in half as the duty cycle is 50/o .
H owever, the turns m u st be doubled as the voltage delivered is from only
half of the winding ; this m ust be kept in mind when designing the u nit.

FIGURE 1 4

page 5 1

When the output DC voltages and cu rrents a re given, it is necessary to

ca lculate the RMS voltages a n d cu rrents in order to design the
transformer. Aga i n , there will be no atte m pt to explain why certa in
things a re done. The theory can be studied by the designer at a later
date, if desired.
The RMS voltage needed is eq ual to the DC voltage divided by 1 .4 1 4 and
a n u m be r representi ng the efficiency of the entire system . To th is
n u m ber is a dded the voltage drop in the rectifiers.
Erms = V / ( 1 . 4 1 4 x eff. ) + Ed.
Where:

Erms
V
1.414
eff.
Ed

=
=
-

the seconda ry voltage of the transformer.

the DC voltage given
a constant
the efficiency of the system
the voltage drop i n the diodes . This value will be
considered to be 0 . 7 volts per diode u nless
otherwise specified

As a sta rting point i n the desig n a n efficiency of 85/o w i l l be assumed.

Thus, . 8 5 will be the value used i n the a bove form u la .
In this circuit there a re two diodes but only one per transformer leg . That
is, there is only one diode in use at a time, a n d a voltage drop of O. 7 volts
will be used.
The RMS cu rrent is equal to the DC cu rrent multipl ied by 1 . 6 .
I = A x 1.6
Where:

I
A
1.6

= RMS cu rrent
= DC current
= a consta nt

page 52

5. 1 . 2 Exa mple

Assume the following para m eters:

DC voltage
DC cu rrent

=
=

40 V
1.0 A

The RMS volta ge that m ust be delivered by the tra nsformer will be :
E
40 / ( 1 .4 1 4 x . 8 5 )
3 3 . 28 + 0 . 7
3 3 . 98 or 34 volts
The RMS cu rrent w i l l be : I
1.0 x 1.6
1 . 6 Am peres
The VA will be 34 x 1 . 6
54.4 VA
=

The transformer will now be desig ned to deliver 34 x 2

68 volts center
ta pped at a current of 1 . 6 Am peres. Since the secondary will deliver the
tota l current only half of the time, the wire in the seconda ry will be
chosen for one half of 1 . 6 or 0 . 8 Am peres. The pri m a ry will be designed
using the 54.4 VA as this will be the tota l VA delivered by the
transformer.
=

If the above calcu lations a re considered, it will be seen that the

seconda ry voltage drops and regulation will be l a rger than for a u n it with
a resistive load of the sa me VA, as the wire size is for a cu rrent of one
half the amount delivered. The tem perature rise will be ca lculated using
the entire seco n da ry and one half of the cu rrent. The design method of
Chapter 2 can now be used in designing th is type tra nsformer.
5 . 1 . 3 Full wave bridge circuit

FIG U RE 1 5

page 53

This circuit utilizes the e ntire secondary of the tra nsformer for calculating
the voltages. Th us, there will be one half of the turns of the previous
exam ple, however, it will have to deliver the fu ll cu rrent 1 00/o of the
time. It will a lso be noticed that there a re 4 diodes, 2 that a re used at
one time. Thi s w i l l result in a diode d rop of 2 x 0 . 7
1 . 4 Volts.
=

E
I

=
=

V I ( 1 .4 1 4 x . 8 5 ) + 1 . 4
1.6 x A

If the va lues from the previous exa mple a re used :

E
I
VA

=
=
=

40 I ( 1 .4 14 x .85) + 1 .4
1.6 x 1
1 . 6 Am peres
34.68 x 1 . 6
54.49 VA

34.68 Volts

From this point o n , the tra nsformer will be designed the sa me as a

reg ular tra nsformer having these req uirements.
5. 1.4 Full wave bridge cente r-ta pped

The ful l wave bridge center-tapped circuit is the same as the ful l wave
bridge circuit except it has a center tap a n d will supply a plus and a
minus voltag e at the load. This req uires two capacitors. If the loads and
capacitors a re the same, it is calculated as if there were no center ta p
and the load was across the entire output.
Many times the loads a re different. If this is the case, the tota l VA is
calcul ated as if there were two windings with sepa rate loads. However,
each half of the winding will have to supply first one load and then the
other. This may al low a smaller wire size if one load is m uch less. The
wire size ca n be considered as su pplying the larger load plus the smal ler
load d ivided by 2. This is a guide only and the other req uirements, such
as regu lation a n d tem peratu re rise, will govern . There a re two diodes per
leg as in the fu ll wave bridge circu it. See Fig u re 1 6 .

FIGURE 1 6
page 54

5.2

Correcting the efficiency

The above exa mples show how to design a tra nsformer using an
estimated efficiency , without considering the va lue of the filter capacitor
or the driving source i m pedances. The foll owi ng is a method that will
g ive a more accurate result by taking these values into consideration .
A transformer is first designed using the methods previously show n . This
will result in a circuit with 85/o efficiency. The val ues of this tra nsformer
can then be used to determine the actual efficiency, and corrections can
be made, if necessa ry, that will resu lt in obta i n i ng voltages closer to the
desired val ues.
5 . 2 . 1 Exam ple

As an exa mple ta ke the va l ues of Fig u re 1 5 . An actua l design was made

for this tra nsformer. The design will not be shown, but the va lues
obta ined will be used . The core used is EI- 1 " with a 1 " stack on a bobbi n .
The values a re :
Np Ns Rp
Rs -

495 turns
1 6 1 turns
6. 94 Ohms
.914 Ohms

From Fig u re 15, the capacitor is 5000 ufd

Ri

Ri

The load resistance. This ca n be calcu lated by d ividing the load

voltage by the load current.
40 I 1
4 0 Ohms
=

From these val ues, the d riving sou rce resistance, Rt, the equ iva lent
resistance, Req, a n d the equ iva lent ca pacita nce, Ceq, can be determ ined.
The d riving source resista nce, Rt, consists of the tra nsformer resista nce
referred to the seco ndary plus the diode resista nce. The d iode resista nce
is usually in the order of 0 . 0 5 Ohms. Req is the load resista nce divided
by Rt.

page SS

To determine Rt, divide the secondary turns, Ns, by the pri m a ry turns, N p
a n d squ a re that va l u e . This is then m u ltiplied b y the pri m a ry resista nce,
Rp, and added to the secondary resista nce, RS, a nd the d i ode resista nce,
Rd .
Rt
Req

=
=

( Ns/Np) 2 x Rp
R l I Rt

Rs

Rd

The equ iva lent capacita nce is eq ual to the d riving sou rce resista nce
m u ltiplied by the capacita nce and this value m u ltiplied by f / 60. Where
f is the power line frequency. This value is 1 if the freq uency is 60
Hertz.
11

11

Ceq

Rt x C x f I 60

Su bstituti ng the actual values :

Rt
Req
Ceq

=
=
=

. 1 06 x 6 . 94
( 16 1 I 4 9 5 )
40 I 1 . 7 5
22.85
5000 x 1 . 75 x 1
8 7 5 0 ufd
=

. 734 + . 9 1 4

2 ( . 05 )

1 . 75 Ohms

With these val ues the actual efficiency ca n be obta ined with the use of
the curves of Fig u re 1 7 .
The value fa lls between the 80/o a n d 86/o lines . By interpolating, it can
be seen that it wi l l be a bout 84.5/o . If this value is used :
34.68 - 1 .4

3 3 . 28 x 1 .4 1 4 x .845

39. 76 VDC

This is probably close enough to the desired 40 V.

adjust the voltage, the following proced ure is used :

If it is desired to

Going back to the orig inal ca lcu lations for the RMS voltage of the
transformer seco n d a ry and using the new efficiency n u m ber, the va lue is :
E

40 I ( 1 .4 1 4 x .84 5 ) + 1 . 4

34.88 Volts

The turns can then be adjusted to obtain this volta ge instead of the 34.68
Volts previously obtained . Results as close as this will not requ ire any
adjustment other than the turns, however, if there is a large difference, it
may be necessary to change the design of the transformer and
reca lcu late all the val ues and refer back to the curves fo r the proper
results.

page 56

It should be noted that this is a very efficient transformer. If the physica l

size of the tra nsformer is small or the regulation is large, it ca n result in
efficiencies of 60 to 70/o . When th is occu rs the use of the curves and
reca lculations will be necessary to obta in voltages desi red . Experience
with this type of design will result in using an efficiency closer to the
actual value in the original calculations.

page 57

1000

II
1 00

II

93.5%

Miii:

s:

0
-

10

96%

II
Ill

90%

II

II

86%
80%

"'
""'"

II

70%
60%

II

50%

40%
1

1 00

'

1 9 '

"

1 0,000

1 000

Ceq (Microfarads)

y.

0 9

1 00,000

CHAPTER 6. CONVERTER TRANSFORM ERS

Before a converter transformer ca n be designed, it is necessary to

understa nd how it is to be used . Only the basics will be covered . The
transformer designer must study and explore the many different circu its
and relationships on his own, if further knowledge is desired .
A converter tran sformer is used in a circuit to change a D .C. voltage into
an A.C. voltage, which ca n be rectified into a nother level of D . C . voltage,
if desired. The freq uency of operation is determined by the design of the
transformer in the case of the satu rating tra nsfo rmer circuit. If the
transistors a re satu rated, then the tra nsformer tra nsfers the voltages and
currents in a norm a l manner similar to the standard power tra nsformer.
6.1

The saturating transformer

A simple form of the Royer circuit is shown in Fig u re 1 8 . This circuit uses
P N P tra nsistors, however, N PN tra nsistors can be used by changing the
circuitry with no effect on the transformer. S i n ce we are concerned with
the transformer only, this exam ple will suffice.

1/2 FB

OUTPUT

1/2 FB

FIG URE 18

page 5 9

Looking at the circu it, it ca n be seen that a D . C . voltage source is

conn ected to the center ta p of the p ri m a ry wind ing . The transistors,
when cond ucting, will a l low cu rrent to flow in the winding from the D . C .
sou rce. It i s desired that cu rrent wi l l flow in o n e h a lf o f the primary a t a
time a n d a lternate between ha lves. This will set u p a fl ux in the core
similar to an A.C. voltage in a normal power tra nsformer except that this
will be a sq u a re wave instead of a sine wave. The feed-back winding
which is con nected to the bases of the transistors, controls the switching
of the transistors, a nd a l lows the D . C . current to flow i n an alternating
fashion . This is a very simplified expla nation, but is a l l that is necessa ry
for the tra nsformer to be desig ned .
The tra nsformer m ust be desig ned so that the core will saturate at the
desired voltage level and operating freq uency. If the sta ndard form ula
for pri m a ry turns is exam ined, it can be seen that the fl ux density, core
a rea, frequency a n d volta ge a l l i nteract to give the n u m ber of turns. It
must be noted that i n this type of tra nsformer the voltage is a pplied to
only one half of the turns in the pri m a ry winding at one time and thus the
turns m ust be calcul ated with th is in m i n d .
Np =

E x 1 08
4.0 x F x A x B

------

The 4 . 44 constant for sine waves is changed to 4 . 0 for sq uare wave

operation .
If the voltage is fixed a nd the core a rea and saturati ng fl ux have been
chosen, then the only vari a bles left to be determi ned a re the turns and
the frequency, o r conversely, if the frequency a nd voltage is g iven, then
the core a n d the turns m ust be chosen to give the proper results .
The frequency of o peration a n d losses will determ ine the type of core
material to be use d . It will now be advisa ble to explore some of the
materia ls used in these designs.

page 60

6.2

Core materials

The idea l material will have a very na rrow, sq u a re hystersis loop, as this
will determine the switching losses and efficiency. All m a g netic materials
will saturate at som e value of fl ux density at a g iven freq uency . The core
losses at these val ues, a long with the copper losses, will determine the
efficiency of the circuit.
These val ues a re usually given in the
man ufacturer's catalogs and a re too extensive to be shown here. The
catalogs listed at the end of this cha pter should be studied ca refu lly.
Ta pe wound to roidal cores have been used extensively for this pu rpose.
The type a n d thickness of the material a re chosen, depending on the
desired freq uency. Originally the freq uency of operation was fairly low,
1 KHz to 5 KHz, beca use of the u navailability of high frequency switching
transistors. This is no longer a problem and switching frequencies of
20-50 KHz a n d a bove a re now common. Two ( 2 ) a nd fou r (4) mil thick
ta pe cores a re sufficient for frequencies below 5 KHz. Th inner materials
must be used for higher frequencies and sq uare loop ferrite cores a re now
used extensively fo r frequencies above 20 KHz. M a n ufacturer's catalogs
and other ava i l a ble literature will assist in choosing the proper core and
materi a l .
M a ny times the operating frequency ra nge will be determined by the
physica l size req u i rements or by the customer. Th is will remove one
option from the transformer desig ner.
6.3

Control wi nding voltage

The control winding voltage will be determ ined by the a m ou nt of voltage

necessa ry to switch the tra nsistors. Th is wil l vary depending on the
tra nsistors used . This volta ge will be either given by the customer or will
have to be determ i ned fro m the req u irements of the tra nsistors used .
This can be obta ined from the publ ished data on the tra nsistors.
6.4

Design criteria

The actual design of the tra nsformer will proceed according to the
g u idelines shown p reviously in the power transformer design method of
Cha pter 2. The pri m a ry tu rns, feed- back turns, a n d the output windings
will all be ca lculated . The construction will be d ifferent as it is necessary
to have close cou pling between halves of the pri m a ry windi ngs.

page 6 1

This is acco mplished by winding the primary ha lves i n para llel . Also,
cou pling between the primary and feed back windings is i mportant. This
can be accomplished by winding one half of the feedback winding first,
then the pri m a ry and then the other half of the feedback winding.
The output, or secondary windings, ca n be wound on top of these
windings. If the step up voltage ratios a re large and the frequencies a re
high, it is sometimes necessary to interleave the output with the pri mary
and feedback windings. In the case of large step-up ratios, it may be
advisa ble to use two transformers, one for the converter circuit with a
small step-up ratio and a second transformer to further step-up the
voltage. In th is case the step-up transformer is designed l i ke a typica l
non-saturati ng u n it for sq uare wave voltages.
In the case of high power converters, it is sometimes advisable to use
two transformers, one small transformer using square loop materia l to
switch the transistors and a larger transformer using less expensive
material for the power handling. The designs of these transformers will
follow the same g u idelines as previously covered. The ci rcuits to be used
and the para m eters req uired must be furnished by the customer for this
type of desig n .
The losses of the transformers must b e kept low i f a high efficiency
system is to be obta ined. The losses of the core material has been
covered . The copper losses must a lso be kept low. This is a ccomplished
by using larger sizes of wire tha n would ordinarily be requ ired. As a rule
of thumb, the wire size should be a m i n i m u m of 1000 circu lar mils per
am pere of current in a l l windings. If size is limited , the primary winding
wire can be adjusted to ta ke into account the fact that it is cond ucting
current only one half of the time.

page 62

6.4. 1 Design reca p

Reviewing the i m porta nt points :

1.

The transformer i s designed using the reg ular turns form ula with
the exception of using 4.0 instead of the 4.44 constant.

2.

Wire sizes should be 1000 circular mils per a mpere minimum for
copper losses.

3.

Flux density used will be the saturating flux density of the material .

4.

The primary windings should be wou nd bifilar to reduce coupling

losses. That is, the two halves of the winding a re wound in parallel.
The feed back winding ha lves a re interleaved with the primary
wind i n g . The primary and feedback windings a re connected as
shown in Fig u re 1 7 so they a re in series.

5.

The seconda ry, o r output winding, can be put o n over the primary
and feed back windi ngs or it can be wound first before the other
windi ngs, whichever is more convenient.

6.5

The non-saturati ng tra nsformer

The non-saturating transformer needs little coverage as it is sim ilar to a

regular power transformer operating on a sq uare wave voltage and at a
frequency specified by the customer. Ca re m ust be taken in choosing the
core size and material to accommodate the req uirements.
There have been many a rticles published on converter ci rcuits and their
design, therefore the methods shown here to desig n the transformer is all
that needs to be covered.

page 63

Man ufacturers' catalogs covering the information necessary for choosi ng

cores and core m aterials can be obtained from the following compan ies :

MAGN ETIC M ETALS COM PANY

CAM D E N , NJ 0 8 1 1 0
MAGN ETICS
BUTLER, PA 1 60 0 1
ARNOLD ENGI N E E RING COM PANY
300 WEST STREET
MARENGO, I L 6 0 1 5 2
FERROXCU B E CORPO RATIO N
SAUGERTIES, NY 1 2477

page 64

CHAPTE R 7 . SHIELDING IN POW ER TRANSFORMERS

There a re two types of shields used in power tra nsformers. These are
electrostatic shields and electro-mag netic shields. They a re both used to
reduce interference and noise from being either generated or tra nsm itted.
7. 1

Electrostatic sh ields

Electrostatic sh ields a re used to reduce noise or interference in the power

source from passi ng through the transformer and i nto the load ci rcuit and
also to red uce noise and interference from passi ng from the load circuit
back through the tra nsformer and into the power lines.
The most used type of electrostatic shield is placed between the primary
or pri m a ries a n d the secondaries. It is usua l ly a 2 or 5 mil thick copper
sheet, however, a cl ose wound layer of fine wire can be used, but will be
less effective.
The shield must be wel l insulated from both the pri m a ry and secondary
windings and m ust not short out on itself, otherwise it will result in a
shorted turn . A lead wire of some type will be soldered to the shield and
brought out as a lead or be connected to the core as a g rou n d .
7. 1 . 1 Box shields

Box shields a re electrostatic shields that com pletely enclose the windin g .
These a re used when extremely high isolation o f interference i s desired .
Sometimes more than one shield is used over the primaries o r
secondaries o r both . The shield lead and the coil leads a re brought out
through shielded ca ble to keep from picking up noise on the lead wires.
Box shields ca n be constructed using copper sheet or stri p or a l u m i n u m
sheet o r strip. Alu m i n u m is easier to use as it is softer and conforms to
the conto u r of the winding easier, however, it is more difficult to attach
the lead to the a l u m i n u m .
Care must be taken to insu late the shields from the windings and each
other. Shorted tu rns a re difficu lt to prevent in this type of shield and
great care m ust be ta ken .

page 65

7.2

Electro-magnetic shields

Electro-mag netic shields are used to reduce the external flux from the
core from rad iating out and interfering with other circuits. This type of
shield ca n be anything from a simple end cover, which is only marginally
effective, to a copper strap a round the core and coil, which is the normal
type of shield.
Also, a sheet of magnetic material can be put a round the periphery of the
core to reduce the external fl ux. The maxi m u m shielding can be obtained
by enclosing the transformer in a nest of shield ca ns. This will consist of
several layers of enclosures made of high permea bil ity material
interleaved with copper enclosures.
The a mount of s h ielding necessa ry will dictate the type of shield that is to
be used .

page 66

C HAPTER 8. IRON CORE FILTER CH OKES

Iron core filter chokes usua lly fit into two categories.
direct cu rrent in their windings and those that do not.

Those that carry

M uch has been written on the desig n of these u n its a n d mag netic material
man ufacturer's cata logs give very adeq uate design methods for their
various materials. For this reason, it is only necessary to cover some of
the importa nt poi nts and some of the pitfa l ls to avoid .
8.1

Chokes that carry a d i rect cu rrent

A filter choke is usua lly desig ned to have a certa in inducta nce with a
particu lar va lue of direct current flowing in the wind i n g . There a lso is
usua lly a limitation on the resista nce of the windi ngs, either im posed by
the specification, o r l i mited by the al lowa ble tem peratu re rise.
The direct cu rrent will satu rate the core if some adjustments are not
made. If an air gap is introduced into the magnetic path, the effect of the
direct cu rrent flux is reduced . By adjusting the length of this gap with
regard to the tota l length of the mag netic path, the opti m u m permeabil ity
for this particu lar design ca n be obtained .
C. R. Hanna publ ished in 1 927, a simple method of desig ning this type of
choke. It is stil l a very popu lar and easy method to use. I would suggest
a copy of this paper be obtained .
A sta rti ng point for the physical size ca n be obtained by the formula :
VA = 188 LI

Where VA - The VA of an eq uivalent 60 Hertz tra nsformer

- The inductance desired
L
- The direct current flowing i n the winding
I
The lam ination ta ble in Cha pter 2 ca n be used to find a core size that will
handle this VA. Using this core size for a starting point and Hanna's
curves or other method, a design ca n be derived .

page 67

It should be poi nted out that EI laminations have two pa ral lel mag netic
paths around both legs of the E and so will also have two gaps if a gap
spacer is put in between the E's and I's. This is with a butt stack. See
Fig u re 3 5 in Chapter 1 3 o n lam inating methods.
8.2

Chokes with no d i rect cu rrent

Chokes that d o not ca rry d i rect c u rrent ca n be designed using the

sta ndard form ula for ind uctance :
L=

Where L
N
A
u
I
7t

0.4 x

x A x N2 x u
I x 1 08
7t

Inducta n ce in henries
N u m ber of turns
Net core a rea
Core permea bility
M a g netic path length of the core
3. 1416

A l l of the a bove values can readily be obta ined from the sizes listed in the
m a n ufacturer's cata logs except for the core permea bility.
The
permea bility w i l l vary with the type of core m ateria l used . This can be
determined from the pu blished data for that particular m aterial. This ca n
va ry from 14 or less for powdered material up to 40,000 or more for 80/o
nickel a n d other materials.
Some manufacturer's cata logs give an
inducta nce form u l a for each size of lam ination . This form ula, a long with
the material permea bil ity, w i l l result in a n easy desig n .
It should be noted that many sizes of cores can be used for any particular
inducta nce value. However, it is necessa ry to ca lculate the fl ux density to
determine that the core is not saturating and a l so to determine that the
resista nce of the winding is not too high to meet the requ i rements.

page 68

8.3

Configurations other than EI lami nations

There are many core configurations that can be used for chokes, both
with and without direct current flowing in their windings. These include
such cores as toroids, pot cores, H cores, and many others .
These will not b e covered a s the man ufacturer's cata logs and publ ished
design data m a ke their design exceedingly sim ple.

page 69

CHAPTER 9 . AIR CORE IN D UCTORS AN D SOLENOIDS

The previous cha pters have dealt with iron core components.
It is
sometimes desirous to have an inductor designed using no mag netic core.
These a re referred to as air core indu ctors.
The basic form ula for inducta nce a ppl ies to this type u n it, except for the
fact that there is no magnetic path for the fl ux, a n d for this reason the
flux path will radiate out i nto space around the coi l . This m a kes the
usage of the stan d a rd form ula more difficult.
This chapter will deal with two configurations of a i r core coi ls and an easy
way to design them . These a re the single layer solenoid a nd the multiple
l ayer solenoid.
9.1

The single layer solenoid

A single layer solenoid is wound using only one laye r of mag net wire
similar to a screen door spri n g . It is usua lly wound o n a coil form and
held in place with ta pe or cement. See Fig u re 1 9 .

'ofJJJJJJJ1-'
FIG U RE 19

Many times a high resista nce carbon resistor is used

sma ll u n its. This works out very well if the resista nce
as to not affect the results . La rger coil forms can be
from various materials and will work fi ne if they a re
non-conducti ng.

as a coil form for

is sufficiently high
obtai ned or made
non-magnetic and

It is im porta nt that the length to diameter ratio not be too large or the
ind ucta nce wi l l not increase as desired with addition al turns. If possible
the length to diameter ratio should be no more tha n 3 to 1 for accu rate
results.

page 70

It should be noted that i n a l l coils the ind uctance w i l l increase as the

turns squared . For exa m ple, if the turns a re dou bled, the inducta nce will
increase by a ratio of 2 sq uared or 4 times.
If th is formula is exam ined, it ca n be seen that it is necessary to have the
size of the coil a n d the d esired va lue of inducta nce before startin g .
N =

Where : L
N
a
I

\/L x ((9 x a )

( 1 0 x I))

a
Inducta nce desired (in micro-henries)
- N u m ber of turns
- Radius of the coil
- Length of the coi l
-

For exa mple, if val ues a re assig ned to the varia bles :
Let :

L
a
I

- 20 m icro-henries
- .5"
1"

Then the req uired n u m ber of turns will be :

N =

\/20 x ((9 x . 5 )
.5

(10 x 1))

= 34 turns

So 34 turns will be needed. In order to m a ke a close wound coil with 34

turns on a 1 " winding, it is necessa ry to choose a wire size that will have
34 turns per i n c h . If the wire ta ble of Chapter 2 is consu lted it can be
seen that # 2 2 AWG wire will fill the req uirement. If this wire size is large
enough to ca rry the current, then the design is complete. Sometimes it
will be necessary to increase the size and reca lcu late . Increasing the
dia meter of the winding will g ive a larger ind ucta nce with less turns so a
larger wire can be used .

page 7 1

9.2

M u ltiple layer solenoid

The mu ltiple layer solenoid has one more d imension to be considered .

This is the build u p of the wire . See Fig u re 2 0 .

FIG U RE 20

The ind uctance form ula for this coil is :

L =

Where L
N
a
I
c

0 . 8 a2 N 2
Ga + 91 + 10c
Inductance desired (in micro-henries)
N u m ber of tu rns needed
Rad i u s of the coil
Length of the coil
Build of the winding

In this case the value of "a" is measu red to the center of the wire build up
instead of the rad i u s of the coil .
From here on it is a matter of calculating the desired n u m ber of turns and
determining the wire size that will fit into the a l lotted space.
If
adjustments need to be made, the new sizes ca n be used to recalculate
the turns or the ind ucta nce can be ca lculated to d etermine how close it is
to the desired value.

page 7 2

9.2

Summary

As can be seen, it is q u ite possi ble that more tha n one try will be needed
to a rrive at the exact v a lues desired. H owever, the form ulas d o work and
a re very handle in the design of these types of i n d u ctors .
In the construction of the solenoids, the wire ca n be wound on a bobbin
with end fla nges or can be layer wound using layer insu lation. In either
case the actual winding length of the wire m ust be used for calculating
pu rposes.

page 7 3

PART II. MAN U FACTU RI N G PROCESSES

The following sta n d a rd processes and proced u res a re d esig ned to show
shop personnel a n d new engineers how to build and assemble the
magnetic parts. These methods, if ca refu lly followed , will result in a
com ponent that will m eet the customer's req uire ments. The individual
specifications, as cal led out by the designer, m ust be followed in all
cases, where other th an standard procedures a re needed .
The material to be used for insu lation, the type of magnet wire, and other
materials m ust be called out in the m a n u facturing specifications.

page 74

CHAPTER 1 0 . LAYER WINDING ON A SINGLE COIL FORM

Winding a single coil on a winding tube without flan ges req u i res the wire
to be wound i n laye rs with individu a l turns side by side and with no
crossovers. Individual layers must be sepa rated with i nsu lation heavy
enough to su pport the coil wire without it pulling down between the wires
of the previous layer. A marg i n m ust be m a i ntained at each end of the
coil wide enough to prevent the turns from fal l ing off the ends.
The insu lation thickness and m i n i m u m marg i n s needed for each size of
wire is ca lled out in the wire table in th is cha pter. Fig u re 2 1 shows a
cross sectio n of a coi l wound on a winding tube a n d layer insu lation .

MARGINS
LAYER INSULATION

---- COIL LEN GTH

..,

_
_
_

FIG U RE 2 1

A wrapper is put o n over the com pleted winding, sufficiently thick to

support the next w i n d i n g . The thickness and materia l of this wrapper is
determine by the electrical requ irements of the design a n d a lso the size
of the wire. This will be ca l led out on the winding specification by the
designer.
Before sta rting the winding it is necessary to correctly a nchor down the
sta rt of the coil wire.
The coil wire is a nchored with a stri p of electrica l ta pe, ad hesive side up.
The start of the coi l wire is placed on the tube a n d a nchored down a
dista nce from the end equal to the m a rg i n , as ca lled out on the
specificatio n . Th is stri p is folded over and held down with an additional
strip of ta pe. The end of the coil wire is left long enough to accom plish
Usually 3 or 4 inches is
the finishing process as described later.
sufficient. Fig u re 22 shows this process.

page 7 5

FIG U RE 22

The coil wire is then wound on evenly a n d closely without bunching or

crossing over, mainta i n i ng the proper margins at each e n d .
At the e n d o f each layer the insu lation i s p u t on a nd the winding
contin ued back in the other direction . The i nsu lation will be the same
width as the coi l form a n d the thickness as ca lled out on the specification .
The insu lation is ta ped down under the last turn of the layer, wra pped
around the coil a n d ta ped down again. This beco m es the coil form for the
next layer. Figu re 23 shows this p rocess.

FIGURE 23

page 76

This winding and insu lation process is continued unti l the proper number
of turns have been wound. If a ta p is req uired within the winding, it is
brought out at the proper n u m ber of turns, as shown in Fig u re 24.

ANCHOR TAPE

OVER TAPE

UNDER INSUL.

r
FIGU RE 24

The procedure is as follows :

Place two anchor tapes, adhesive side up, a few tu rns (2 or 3) before the
ta p is to be brought out.
Sepa rate them enough to accommodate the loop for the ta p.
Continue the winding over this tape until the proper n u m ber of turns has
been reached .
Fold the first ta pe over to hold the wire in place, pull a loop in the wire
long enough for the lead and then bring the wire back to the second
a nchor tape and fold the ta pe over.
A piece of insulation is placed under the loop and a piece of tape is placed
over the loop to hold it in place and also protect it from the wire as the
winding is continued.
If the wire is too heavy for the anchor tapes alone to hold it in place, it
may be necessary to place an additional piece of ta pe over the anchors
after they a re folded back.
After the proper n u m ber of tu rns have been put on, the end of the
winding is again anchored down in a similar manner to the ta p . A piece
of tape is placed u nder the wire, ad hesive side up, a few turns from the
end .
page 77

The winding is contin ued until the proper n u m ber of tu rns has been
reached and then the tape is folded over and taped dow n . See Figure 25.
The wra pper is then put on over th is winding and taped dow n . It is now
ready for the next winding to be put on.

FIG URE 2 5
1 0 . 1 Electrostatic sh ield

Some transformers req uire an electrostatic shield be placed between

windings. This is usually a 1, 2 or 5 mil thick copper foil winding. This is
0 . 0 0 1 , 0 . 002, or 0 . 005 inches thick. The shield is made the same width
length . That is the tube length minus the margins. The length of the
shield is made long enough to wra p a round the coil with a minimum
overlap of 1/8 " .
The shield lead will usua lly be # 2 0 o r # 2 2 AWG tin ned copper. If other
types of leads a re required, it will be ca lled out on the specification.
Figu re 26 shows a typical electrostatic shield before it is put on the coil .
The method of putting on the shield is as follows :
The start of the shield is taped down with the lead coming out at the
proper place on the coil, accord ing to the specificatio n .
A strip of insu lation wide enough to cover the overla p is placed over the
start end of the shield so that the finish of the shield will not touch the
start.

page 78

If the start and fin ish touch, a shorted turn will res u lt a n d the coil will
have to be rewou n d or d iscarded .
A wrapper is then put on over the shield and the coil is ready for the next
windi ng.

Winding width

Solder
SHIELD CONSTRUCTION

_..--- Lead wire

FIG URE 26

Fig ure 2 7 shows th is process.

Shield

FIG URE 27

page 79

1 0 . 2 Wire ta ble

Wire Size
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8

Minimum
Insu lation
0.0007
0.0007
0.0007
0.0007
0.001
0.001
0.001
0.001
0.001
0.001 5
0.00 1 5
0.001 5
0.00 1 5
0.00 1 5
0.00 1 5
0.002
0.002
0.002
0.002
0.003
0.003
0.003
0.005
0.005
0.007
0.007
0.01 0
0.0 1 0
0.0 1 0
0.0 1 0
0.010
0.0 1 0
0.010
0.01 0
0.0 1 0

Minimum
M a rg i n
1/16
1/16
1/16
1 /1 6
1 /1 6
3/32
3/32
3/32
3/32
3/32
3/32
3/32
3/32
1 /8
1 /8
1 /8
1 /8
1 /8
1 /8
1 /8
1 /8
1 /8
1 /8
1 /8
1 /8
1 /8
1 /4
1 /4
1 /4
1 /4
1 /4
1 /4
1 /4
1 /4
1 /4

Tu rns/Inch
304
267
239
215
1 93
171
1 56
1 42
1 26
111
99
89
81
73
63
58
52
46
42
38
34
31
27
25
22
19
18
16
14
13
11
10
9
8
7

The turns per inch a re given for a 90/o fil l factor.

page 80

CHAPTER 1 1 . BOBBIN WIN DING

A bobbin is a winding form that has fl anges on each end to conta in the
winding turns without a marg i n .
When windi n g o n a bobbin it i s not necessa ry to be as careful a s with the
layer winding. M ost bobbins a re ra ndom wou nd. This mea ns that the
wire is spread evenly on the bobbi n, but not in exact layers. No layer
insulation is used un less ca lled for in the specification . If layer insu lation
is cal led for, the proced ure is the sa me as descri bed for layer windi ng.

FIG U RE 28

Fig ure 28 shows the method of anchoring down the sta rt lead. This is
similar to the layer winding anchor except that no marg i n is req uired .
The wire is placed as close to the fla nge as possible. A strip of insu lation
is placed over the coi l wire as it is brought up the side of the flange to
protect it from the turns as the wire is wou nd.
When using fine wire it is also good practice to insu late under this lead
wire to keep it from breaking when bent over the edge of the fla nge. All
taps and leads a re insu lated up the sides of the bobbin in this manner as
they are brought out.

page 81

The winding then proceeds. The wire is wound as evenly as possible

without atte m pting to layer wind. Any taps, if req u i red, a re brought out
using the same procedu re as described for the layer wind i n g .
Interwinding insu lation or wrappers a re used . Bobbin winding usua lly
uses a flexi ble insulating material to better conform to the contour of the
winding. Th is insu lation should com pletely cover the winding so that the
subsequent windi ngs ca nnot pull down at the ends and contact the turns
of another windi ng.
It is someti mes desira ble to use a th ree flange bobbin . This is a bobbin
with two winding a reas. In this case the primary(s) a re usually put in one
space a n d the secondary(s) a re put i n the other. This elimi nates the
need for insu lation between the primaries and the seconda ries since the
center flange provides the insu latio n . Also, an electrostatic shield is
usua lly not needed with this type of bobbin . The winding procedu re will
be the sam e as with the standard bobbin. Fig u re 29 shows an end and
side view of a three fla nge bobbi n.

.....- -

...._

_ _ ......

- -

___

_ ..

FIGURE 29

page 82

CHAPTER

12.

LEAD FINISHING

1 2 . 1 Stra nded lead wire term ination .

After a coil is wound it is necessa ry to have term inations that are usable
by the customer. Sometimes, in the case of heavy wire of #26 AWG or
larger, addition al leads a re not necessary. This is ca lled out in the
specification. However many times it is desira ble to atta ch additional
lead wire to the coi l terminations. This ca n be insulated, stranded lead

wire or a length of tinned copper wire. The col ors, sizes and lengths are
ca lled in the specificatio n .
Coils that a re layer wound o n a former without fla nges a re finished i n the
following manner:
A piece of insu lation (tab) is placed on the end of the coil under the coil
wires. This can be a na rrow strip of ta pe as shown in Figu re 30 or a
wider piece of tape to accommodate more than one lea d . The wires are
then brought out o n top of these tabs and a piece of tape put over them
for protection and to hold them in place.

SADDLE

FIG U RE 30

page 83

A sadd le of suita ble material, such as kraft paper, fish pa per, or tape is
put on the end of the coil and the coil wire is taped in place on top of this
saddle. Care must be taken to keep the leads a pa rt so no short circuit
can result. See Fig u re 3 0 .
The leads a re then soldered to the coil wire. The coil wire and lead wire
are twisted together to m a ke a mecha nical joint before soldering .
Another piece of ta pe is then put over the leads to hold them in place,
leaving approxi mately 1/2 inch exposed below this ta pe. The lead wire is
then bent up over the tape and another piece of ta pe is put over the
entire end of the coi l to over the solder joints. This is shown in Fig u re 3 1 .

4-

c-

SADDLE

FIG URE 3 1

Care m ust be taken d u ring this process to leave a little slack i n the coil
wire so that it won't end up in tension and cause a brea kage during
handling .
The bending over of the lead wires is to keep them from pulling out when
handling du ring the rest of the man ufacturing process and by the
customer.

page 84

If there a re too many leads for the size of the coil to space them safely,
without da nger of touch ing, it will be necessary to alternate the ta ping
process and accom plish this in more than one step. This a lso ca n be
done by putting tape over and under leads when they are bent up.
If leads from another winding a re to be placed on the same surface,
another saddle should be put on over the first set of leads and the same
procedu re followed .
The fi nal wrapper is then placed a round the entire coi l .
This same procedure is fol lowed for coi ls wound on bobbins, except that
the tabs will not be necessary.
1 2 . 2 Solder lug terminations
A solder lug is a piece of meta l , usua lly copper or brass with a tin coating,
that is attached to the coil and the coil wire, then soldered to it. These
lugs a re usually attached to strips of insu lating paper and then th is is
taped to the coil . This strip is cal led a lug panel .
These lugs can be one of several different confi g u rations and sizes, such
as solder lugs, fasten lugs, etc. Figure 32 shows a loose solder lug and
a lso a lug panel that has been made up using the loose lugs and a strip of
insulating pa per.

FIGURE 32

page 85

Before attaching the lug to the coi l, a saddle is placed on the coil in a
similar man ner previously described . The lug panel is then taped in place
with the swagged side of the lugs away from the coil . A ta b is placed
under the lead and it is then brought out and wra pped a round the lug to
make a good mecha nical joint, and then soldered . See Fig u re 3 3 .

HOLD DOWN TAPE

LUG PANEL
COIL INSULATION (SADDLE)

FIG URE 3 3

In both of the a bove processes noth ing has been said about the soldering
process. There a re m a ny different types of coating used on mag net wire.
Some a re of a material that will solder without any stripping . This type is
the most com monly used beca use the soldering process is accompl ished
with a minimum of work. Other types of coati ng req uire that it be
stripped off before it ca n be soldered . These types of coati ng are usually
high temperature materials and a re normally used in special
circumsta nces. The stripping process is an additional operation that
should be avoided un less it is absolutely necessary.

page 86

CHAPTER 1 3 . ASSEMBLY AND STACKING OF MAG N ETIC CORES

1 3 . 1 Stacking of lam inated cores

The lamination type core is made by laminati ng thin layers of electrical
g rade steel that has been sta m ped into various sha pes. These include EI,
EE, D U , F a n d others. The exa mples g iven here show the EI type
sta m ping . This is the most commonly used configurati o n . The other
configurations can easily be und erstood from these exam ples.
Interleaved construction is demonstrated in Fig u re 34.

FIG URE 34

This shows a n interleaving of 1 x 1 . The laminations a re inserted in the

coil one at a tim e and a re alternated with E's and I's from one end and
then from the other end. This ca n be done 2 x 2, 3 x 3 or other, as cal led
out in the specificatio n . Care m ust be ta ken that the l a m i nations do not
cut into the coil former and short out the turns.

page 87

The laminating process must result in a structure that is tightly stacked

with a m i n i m u m of gapping between the ends of the E's and I's.
Some specifications ca l l for butt stacki n g .
inductors that ca rry direct cu rrent.

Th is is usually used for

Butt stacking is when the entire qua ntity of E's a re assem bled from one
end of the coil and the I's from the other. A gap spacer may be called for
between the E's and I's. Fig ure 35 shows this method of stacki ng.

GAP SPACERS

FIGURE 35

The gap thickness and materia l to be used will be ca lled out in the
specification.

page 88

1 3 . 2 Assembly a n d bracketing
Several methods of holding the laminations together ca n be used . Most
of the methods a re a lso the mou nti ng method of the completed
com ponent. When bolts a re used, it is sometimes desired to insu late the
bolt from the l a m i nations. This can be accompl ished by putting an
insu lating sleeve over the bolt or a fiber shoul der washer u nder the head
of the bolt. If the bolts short out the various leaves of the l a m ination
stack, it can resu lt in the exciti ng current increasing a n d the bolts will get
very hot.
The fol lowing a re several of the mou nting a nd asse m bling methods
commonly used . Figu re 36 shows a horizontal and vertical channel frame
constructio n .

FIG URE 36

Fig u re 37 shows horizonta l and vertical "L" brackets.

FIG URE 37

page 89

Fig ure 38 shows a n end bel l constructio n . These end bells completely
enclose the coil except fo r lead holes out of the mou nting surface.

FIG URE 38

Fig u re 39 shows a half shell constructio n . This ca n be one or two half

shells. It is norma lly mou nted on the chassis by the l a mination bolts,
with the coil protruding through the chassis.

MO

W I

FIG URE 39

page 90

1 3 . 3 Assem bly with a fl ux shield

It is often desired to reduce the externa l flux of a magnetic device. This
is especially true when the transformer is operated near a sensitive
device or circuit. Th is cou ld be a cathode ray tube or a high gain
amplifier.
One way to accom plish th is is to use a mag netic fl ux shiel d . This consists
of a heavy copper stra p wrapped a round the core and coil. The copper
strap thickness will va ry from 0 . 0 1 0" to 0 . 060" . This will be called out in
the specifications. Fig u re 40 shows this construction.

FIG URE 40

The width of the strap should be the same as the length of the coil .
The strap i s formed to closely follow the contour of the core and coil.
Insulation is placed under the shield to prevent shorting to the terminal
lugs or leads. The ends of the strap are soldered together with a good
solid solder joint. Pre -tinning of the ends is customary and they are
sweated together with a heavy soldering iron.
The stra p is usual ly put on before the impregnating process.

page 9 1

CHAPTER 14. I M PREG NATION

The completed com ponent, in order to be moistu re resista nt and last for
many hours of operation, is usually impregnated with a moistu re resistant
materia l .
The impregnation ca n be accom plished by di pping or vacu u m
im preg nati n g . The large units, using large size wire, can be dipped with
good resu lts, however, when fine wire, #26 or smal ler, is used, it is
better to vacuum impregnate . Th is will result in better penetration
th roughout the windings.
Before the impregnation process is done, the u n it should be ba ked in an
oven to drive out the moistu re in the insu lation . This is an im portant
process. If the u n it is impregnated with moistu re sealed in it can cause
corrosion and fa i l u re over a period of time. The u n it should be baked at a
temperature at or a bove 100c ( 2 1 2F) to boil out the moisture. The
length of baking will va ry with the size of the un it. The time must be long
enoug h to a l l ow the entire unit to reach the baking tem perature.
There a re many types of impregnating materials. The most often used is
an electrical g rade of varnish. Military and other special appl ications can
req uire that an epoxy i mpregnate be used . There are many brands of
varnish and epoxy on the ma rket that are suita ble for this used . It wou ld
be impractica l to list them here. Some are what is known as air dry, or
room temperature curing, which means that the unit will cure without
baking. Others a re listed as a baking type that means that the unit will
never cure without it being raised to a temperature that cures the
impregnate. These u n its may skin over on the outside and appea r to be
cured, but inside they will remain wet and will eventually cause failures
by attacking the magnet wire coverin g .
The methods of impreg nating a n d curing also a re n u merous.
Most
manufacturers furnish the properties and impreg nating and curing
conditions for their materia ls, so it is not necessary to incl ude them here.
These instructions m ust be followed carefully if satisfactory results a re to
be obtained .
Materia ls used and the impregnating and baking processes will dictate the
methods needed and the results obtained .

page 92

CHAPTER 1 5 . TESTING THE TRAN SFORM ER

Tra nsformers m ust be tested after they a re manufactured in order to be

sure the resu lts meet the desired objectives.
The first un it of any design should be tested completely by a test
technician (or the desig ner) under loaded conditions to assure that the
design meets the req uirements of the customer's specificatio n . Th is
should be accompl ished before production is started . This first unit can
usua lly be tested before im pregnation so that any adjustments, if needed,
can be made without d isca rding the enti re u n it. However, in the case of
high voltage u n its, it is sometimes necessary to impregnate the
transformer in order to pass all tests.
Sheet # 5 of the m a nufacturing specification example of Cha pter 2 ca lls
out the electrica l tests needed. Sheet #4 is used to check the physical
req uirements.
Referring to Sheet # 5 :
1.

The no- load voltage ratio tests a re made to check that the proper
n u m ber of turns have been put on each windi n g . If a maximum
exciting current is ca lled out, it can a lso be checked at the same
time by putti ng a cu rrent meter in the primary circuit.

2.

Inductance tests a re not normally req uired for power transformers.

If they a re required, an inducta nce or impeda nce bridge is usua lly
used .

3.

The induced voltage test and the hipot tests a re usua lly used to be
sure there a re no electrica l shorts between the sepa rate windi ngs
and the windings and the core. They will also determine if the
proper size and type of insulation has been used .
Some
specifications ca l l for induced voltage tests, but usua lly the hipot
tests a re used .

4.

Megohm tests a re sometimes ca l led for.

These a re done to
measure leakage cu rrent th rough the insu lation and in the margins
and fi nishing operation. This test is sometimes used in military and
medica l equipment. A megohm meter is used for this test.

page 93

5.

The value of the hipot tests a re often cal led out b y the customer's
specification or other specifications referred to on the specification.
These cou l d be Underwriters Laboratories, Mil ita ry specifications or
others. The test voltage on most power transformers will be 1000
to 1500 volts between the primary and secondaries and to the core .
Low voltage windings ca n be tested to each other and the core at
500 volts. Un less otherwise specified, these tests will run at 60 Hz.

6.

If other than normal operation is required, such as some u n its that

may operate at a high voltage above ground, the test voltage
should be 1 3 0/o of the working voltage plus 1 000 volts.
For
exam ple, if a u n it has a working voltage of 5000 volts, the hi pot
test will be 1 . 3 x 5000
6500 + 1 000
7500 volts.
=

7.

Special tests m ust be called out showing a test circu it, if needed, in
the event oth er than normal tests are needed .

Production testing will norm a l ly be accompl ished before im pregnation on

all but the hipot and final continu ity tests. This is done so that any
production errors can be caught and corrected without discarding all the
units.
If the un it has been impregnated it is a l most impossible to
salvage.

page 94

CHAPTER 16. INSULATION MATERIALS

In choosing the proper materials for insu lation with in a tra nsformer or
inductor, it is necessary to consider both the thickness for support of the
windings as well as the diel ectric strength needed to withsta nd the
voltage stresses.
The wire ta ble of page 37 gives the m i n i m u m thickness needed for
support of each size wire. These va lues a re for Kraft pa per, but also may
be used for most sta ndard insu lating materia ls.
The thickness needed to withsta nd the test voltages must be determined ,
considering the type of insu lating material chosen.
The tests referred to a re the brea kdown tests between windings and
between windings and the core and not with i n a winding . A normal
tra nsformer will not have voltages within a winding that will req uire
special insu lation . In the case of very high voltages req uiring many turns
and layers, it may be necessary to consider the layer to layer voltages in
choosing the insu lation th ickness.
If a dielectric or h i g h potential test is not ca lled out in the customer's
req uirement, the designer must choose a test voltage that will insure a
reliable component. The sta ndard is usually 1 . 3 times the working
voltage plus 1000 volts at 60 Hz.
For exa m p l e :
A 1 1 5 volt tra nsformer would be tested a t 1 1 5 x 1 . 3 + 1000 volts
1 149. 5 or 1200 volts. A commonly used test for this type of power
tra nsformer is 1 5 0 0 volts at 60 Hz.
=

page 95

The following is a partia l list of materials com monly used in power

transformers. This list gives the dielectric strength in volts/m i l . (volts per
. 0 0 1 inches).
Material
Kraft paper, dry
Kraft paper, varn ished
Fish paper, d ry
Fish paper, varnished
Pressboard, dry
Pressboard, varnished
Mylar

Dielectric strenqth volts/mil

1 1 0 - 230
600 - 1000
1 1 0 - 230
600 - 1000
200
300
4 0 0 0 (2 mil)

The insulating properties of the many types of electrical tapes are too
extensive to be included here.
They can readily be found in the
man ufacturer's literature.
These values a re the puncture values and should be modified for actual
use. For example, Kraft paper, the most commo n ly used insulation,
would normally be used at 1 5 0 volts per mil when varnish treated. Thus
1 0 mils of insulation would be the minimum for a 1 5 0 0 volt test. It is
possible that pin holes cou ld occur in the insu lation, therefore, I would
suggest that two layers of 5 mil material be used rather than one layer of
1 0 mil to reduce the cha nce that a brea kdown could occur due to pin
holes.

page 96

APPEN DIX

The following ta bles show the tu rns of each size of wire that ca n be fitted
into different sizes of l a m inations, both layer wound and bobbin wound.
These tables will be a help in determining the possibility of fit in a desig n
after the turns a n d wire sizes are chosen and before spending a lot of
time ca lculating the fil l .
For exam ple, if the desig n proced ure shown i n 2 . 2 Design exa mple was
stopped at the point after Step #4 where 436 turns of #23 wire was
determined for the primary and the EI- 1 1 2 La m i n ation ta ble was
consu lted , it ca n be shown that it will be a tight fit a n d cha nges need to
be made :
436 I 848 x 1 0 0

5 1 .4/o

This is more than 1/2 of the ava i l a ble space and is more than ca n be used
for the pri m a ry winding in a normal design. A review of the design is
necessary at th is point to either reduce the turns o r wire size as shown in
the exa mple.
Another a lternative is to use a bobbi n . The EI- 1 0 0 Lam ination ta ble
shows that 1 1 59 turns of # 24 wire will fit. This i s :
436 I 1 1 59 x 1 0 0

3 7 . 6/o ,

so a bobbin could be used for th is desi g n . These tables can save a lot of
design time that m ight be necessary in juggling between turns, wire sizes
and lamination sizes.
Another use for these ta bles is in determ i n ing the turns, wire size and
core size needed in designing chokes.
The standard ind ucta nce form ula on page 68 ca n be used for calculating
the turns for an AC ind uctor. Then, by using the ta ble for the size
lamination chosen, it can readily be seen what size wire can be used and
if it is the rig ht size and if the resista nce is correct for what is needed .

page 97

A quick way to estimate the size for a choke ca rrying DC is to use the
form ula on page 68 and the ta ble for that lamination size. Experience
has shown that the permea bility for this type of choke will usually be in
the ra nge of 190 - 200. A permeability of 200 ca n be put in the
inducta nce form ula to find the turns needed .
The table for that
lami nation will show what wire size ca n be used and what the resista nce
will be. If these va l ues agree with what is needed , then the design ca n
be continued or a quotation ca n be made without going through a
complete desig n .
In using Hanna's curves for chokes ca rrying DC, it is easy to determine if
the proper size wire will fit and what the resista nce will be, after
determining the turns a n d before spending a lot of time ca lculating the
fil l .

page 98

EE-28-29 LAMINATION
MAXIM U M TURNS FOR LAYER WOU N D COILS
COIL LENGTH
1 9/64"
WIN DOW WIDTH
1/8"
M EAN LENGTH TURN
0 . 98"
=

Wire
Gage

M i n . Layer
Insu lation

Tu rns/
Layer

Max.
Layers

Max.
Turns

Resistance
square stack

22

1 1 - .003K

18

.0237

23

21

.0345

24

1 1 - .003K
1 1 - .002K

28

.0587

25

1 1 - .002K

32

.086

26
27

1 1 - .002K

45

. 1 50

1 1 - .002K

9
11

55

.231

28

1 1 - .00 1 5K

12

72

.381

29

1 1 - .00 1 5K

13

91

.608

30

1 1 - .001 K

15

1 20

1 .01 1

31

1 1 - .001 K

17

1 36

1 .445

32

1 1 - .001 K

19

171

2.292

33

1 1 - .001 K

21

10

210

3.548

34

1 1 - .001 K

24

11

264

5.625

35

1 1 - .001 K

27

13

351

9.431

36

1 1 - .001 K

30

14

420

1 4.228

37

1 1 - .001 K

16

544

23.24

38

1 1 - .001 K

34
37

18

666

35.87

39

1 1 - .00075K

43

20

860

58.42

40

1 1 - .00075K

48

22

1 056

90.47

41

1 1 - .0005K

53

26

1 378

1 48.89

42

1 1 - .0005K

59

28

1 652

225.72

43

1 1 - .0005K

67

31

2077

356.88

44

1 1 - .0005K

77

35

2695

588.1 0

45

1 1 - .0005K

85

38

3230

883. 1 0

46

1 1 - .0005K

94

41

3854

1 324. 1 0

page 99

EI- 186 LAMINATIO N

MAXI M U M TU RNS FOR LAYER WOU N D COILS
COIL LENGTH
1 5/64"
WIN DOW WIDTH
3/1 6 "
M EAN LENGTH TU RN
1 . 39"
=

Wire
Gage

M i n . Layer
Insu lation

Tu rns/
Layer

Max.
Layers

Max.
Turns

22

1 1 - .003K

20

.0374

23

1 1 - .003K

4.5

22

.05 1 2

24

1 1 - .002K

30

. 0892

25

1 1 - .002K

36

. 1 35

26

1 1 - .002K

6.5

45

.212

27

1 1 - .002K

56

.334

28

1 1 - .001 5K

72

.541

29

1 1 - .001 5K

10

90

.853

30

1 1 - .001 K

10

12

1 20

1 .435

31
32

1 1 - .001 K
1 1 - .001 K

11
1 2. 5

13
14

1 43
1 75

2 . 1 55

33

1 1 - .001 K

14

16

224

5.368

34

1 1 - .001 K

16

18

288

8.71

35

1 1 - .001 K

18

20

360

1 3. 72

36

1 1 - .001 K

20

22

440

21 . 1 4

37

1 1 - .001 K

22.5

24

540

32.72

38

1 1 - .001 K

25

27

675

51 .57

39

1 1 - .00075K

29

31

899

86.62

40

1 1 - .00075K

32

34

1 088

1 32.20

41

1 1 - .0005K

35

39

1 365

209.20

42

1 1 - .0005K

39

42

1 638

31 7.40

43

1 1 - .0005K

45

47

21 1 5

51 5.40

44

1 1 - .0005K

51

53

2703

836.60

45

1 1 - . 0005K

56

57

3 1 92

1 237.90

46

1 1 - .0005K

63

62

3906

1 903.40

Resista nce
square stack

3.326

page 100

EI- 187 LAMINATIO N

MAXIM U M TU RNS FOR LAYER WOU N D COILS
COIL LENGTH
1 3/32"
WINDOW WIDTH
3/ 16"
M EAN LENGTH TURN
1 . 39"
=

Wire
Gage

M i n . Layer
Insu lation

Turns/
Layer

Max.
Layers

Max.
Tu rns

Resistance
sq uare stack

22

1 1 - .0025K

45

.0841

23
24

1 1 - . 003K

10

50

. 1 1 65

1 1 .5

13

27

1 1 - .002K

1 4.5
16

6
7

69
78
1 01

.2052

25
26

1 1 - .002K
1 1 - . 002K
1 1 - .002K

1 28

.7631

28
29

1 1 - .00 1 5K

18

1 62

1 .2 1 8

1 1 - .001 5K

20

10

200

1 .895

30
31
32

1 1 - .001 K

23

12

276

3.30

1 1 - .001 K
1 1 - .001 K

25.5
28

13
14

331
392

5.00
7.45

33

1 1 - .001 K

31 .5

16

504

1 2.08

34

1 1 - .001 K

36

18

648

1 9.58

35

1 1 - .001 K

40.5

20

810

30.87

36
37

1 1 - .001 K

45

21

945

45.41

1 1 - .001 K

50.5

24

1212

73.44

38

1 1 - .00075K

56

27

1 51 2

1 1 5.50

39

1 1 - .00075K

65

31

201 5

1 94.20

40

1 1 - .00075K

73

34

2482

301 .60

41

1 1 - .00075K

80

39

3 1 20

478.00

42

1 1 - .00075K

88

42

3696

71 6.30

43

1 1 - .00075K

101

47

4747

1 1 57.00

44

1 1 - .0005K

115

53

6095

1 886.50

45

1 1 - . 0005K

1 27

57

7239

2807.40

46

1 1 - .0005K

141

62

8742

4260.00

.2925
.4774

page 101

EE-24-25 LAMINATIO N
MAXI M U M TU RNS FOR LAYER WOU N D COILS
COIL LENGTH
1 5/32"
WINDOW WIDTH
1/4"
M EAN LENGTH TURN
1 . 87"
=

Wire
Gage

M i n . Layer
Insu lation

Turns/
Layer

Resistance
square stack

Max.
Layers

Max.
Turns
66
91

. 1 660

22

1 1 - .003K

11

23

1 1 - .003K

13

6
7

24

1 1 - .002K

14

1 12

.4480

25

1 1 - .002K

16

1 28

.6422

26

1 1 - .002K

18

1 62

1 .03

27

1 1 - .002K

20

10

200

1 .602

28

1 1 - .001 5K

22

12

264

2.67

29

1 1 - .001 5K

25

13

325

4 . 1 43

30

1 1 - .001 K

28

15

420

6.753

31
32

1 1 - .001 K
1 1 - .001 K

31
34

17
18

527
612

1 0.68
1 5.64

33

1 1 - .001 K

39

20

780

25. 1 4

34

1 1 - .001 K

44

23

1 01 2

41 . 1 4

35

1 1 - .001 K

50

25

1 250

64. 1 0

36

1 1 - .001 K

55

28

1 540

99.52

37

1 1 - .001 K

62

30

1 860

1 5 1 .60

38

1 1 - .00075K

69

35

241 5

248.20

39

1 1 - .00075K

80

39

3 1 20

404.30

40

1 1 - .00075K

89

3827

625.50

41

1 1 - .00075K

98

43
50

4900

1 01 0.00

42
43

1 1 - .0005K

1 08

54

5832

1 520.00

1 1 - .0005K

1 23

61

7503

2460.00

44

1 40

68

1 55

73 .

9520
1 1 31 5

3963.00

45

1 1 - .0005K
1 1 - .0005K

5902.00

46

1 1 - .0005K

1 72

80

1 3760

901 9.00

.2887

page 102

E E-26-27 LAMI NATION

MAXI M U M TU RNS FOR LAYER WOU N D COI LS
COIL LENGTH
2 1/32"
WIN DOW WIDTH
1/4"
MEAN LENGTH TURN
2 . 42"
=

Max.
Turns

Resista nce
sq u a re stack

96

. 3 1 25

18

1 08

.4435

1 1 - .002K

20

1 40

.725

25

1 1 - .002K

23

1 84

1 .201

26

1 1 - .002K

26

234

1 .926

27

1 1 - . 002K

29

10

290

3.01

28

1 1 - .001 5K

33

12

396

5. 1 84

29

1 1 - .001 5K

36

13

468

7.724

30

1 1 - .001 K

40

16

640

1 2.47

31
32

1 1 - .001 K

16

720

1 8.89

1 1 - .00 1 K

45
50

18

900

29.80

33

1 1 - .001 K

56

20

1 1 20

46.74

34

1 1 - .001 K

64

22

1 408

58.76

35

1 1 - .001 K

72

25

1 800

1 1 9.45

36

1 1 - .001 K

80

27

2 1 60

1 80.70

37

1 1 - .001 K

90

30

2700

284.90

38

1 1 - .001 K

1 00

34

3400

452.30

39

1 1 - .00075K

1 16

38

4408

739.60

40

1 1 - .00075K

1 29

42

541 8

1 093.00

41

1 1 - .0005K

1 42

49

6958

1 857.00

42

1 1 - .0005K

1 57

53

8321

2808.00

43

1 1 - .0005K

1 80

59

1 0620

4507.00

44

1 1 - .0005K

205

66

1 3530

7300.00

45

1 1 - . 0005K

226

71

1 6046

1 0836.00

46

1 1 - .0005K

251

78

1 9578

1 66 1 3 .00

Turns/
Layer

Wire
Gage

M i n . Layer
Insu lation

22

1 1 - .003K

16

23

1 1 - .003K

24

Max.
Layers

page 103

EI- 2 1 LAM INATIO N

MAXI M U M TURNS FOR LAYER WOU N D COILS
COIL LENGTH
2 5/32"
WIN DOW WI DTH
5/ 1 6 "
M EAN LENGTH TU RN
3. 12"
=

Wire
Gage

M i n . Layer
Insu lation

Tu rns/
Layer

Max.
Layers

Max.
Turns

Resista nce
square stack

20

1 1 - .003K

15

90

.2375

21

1 1 - . 003K

17

119

.396

22

1 1 - . 003K

20

1 60

.6714

23

1 1 - . 003K

22

1 98

1 .048

24

1 1 - . 002K

24

10

240

1 .602

25

1 1 - . 002K

27

11

297

2.50

26

1 1 - .002K

31

12

372

3.947

27

1 1 - . 002K

34

13

442

5.9 1 5

28

1 1 - .001 5K

39

15

585

9.87

29
30

1 1 - .001 5K
1 1 - .001 K

43
48

17
19

731
912

1 5.55
24.47

31

1 1 - .001 K

54

21

1 1 34

38.36

32

1 1 - .001 K

59

23

1 357

58. 1 0

33

1 1 - . 001 K

67

26

1 742

93.71

34

1 1 - .001 K

76

29

2204

1 1 8.60

35

1 1 - .001 K

86

32

2752

235.40

36

1 1 - .001 K

95

35

3325

358.60

37

1 1 - .001 K

1 07

39

4 1 73

567.60

38

1 1 - .00075K

119

45

5805

995.50

39

1 1 - .00075K

1 27

50

6350

1 373.30

40

1 1 - .00075K

1 54

55

8470

231 0.00

41

1 1 - .00075K

1 68

64

1 0752

3698.50

42

1 1 - . 0005K

1 87

70

1 3090

5694.00

43

1 1 - .0005K

214

78

1 6692

9 1 31 .00

44

1 1 - .0005K

243

87

21 141

1 4687.00

page 104

EI-625 LAMINATION
MAXI M U M TURNS FOR LAYER WOU N D COILS
COIL LENGTH
29/32"
WIN DOW WIDTH
5/ 16"
M EAN LENGTH TURN
3 . 62"
=

Wire
Gage

M i n . Layer
Insu lation

Turns/
Layer

Max.
Layers

Max.
Turns

Resistance
squ a re stack

18

1 1 - .003K

15

75

. 1 45

19

1 1 - .003K

16

80

. 1 94

20

1 1 - .003K

18

1 08

.330

21

1 1 - .003K

20

1 40

.541

22

1 1 - .003K
1 1 - .003K
1 1 - .002K

23

1 84

. 896

25

8
9

225

1 .382

31

10

310

2.40

25
26

1 1 - .002K

35

11

385

3.76

1 1 - .002K

39

12

468

5.76

27

43

13

559

8.68

28

1 1 - .002K
1 1 - .00 1 5K

49

15

735

14.39

29

1 1 - .001 5K

54

17

918

22.66

30

1 1 - .001 K

61

19

1 1 59

36. 1 0

31

1 1 - .001 K

68

21

1428

56. 1 0

32

1 1 - .001 K

75

23

1 725

85.40

33

1 1 - .00 1 K

85

26

221 0

1 37.95

34

1 1 - .001 K

96

29

2784

2 1 9. 1 0

35

1 1 - .001 K

1 08

32

3456

343.00

36

1 1 - .001 K

1 20

35

4200

525.60

37

1 1 - .001 K

1 35

39

5265

831 .00

38

1 1 - .00075K

1 50

45

6750

1 343.00

39

1 1 - .00075K

1 74

50

8700

21 83.00

40

1 1 - .00075K

1 94

55

1 0670

3377.00

41

1 1 - .0005K

213

64

1 3632

5441 . 00

. 42

1 1 - .0005K

236

70

1 6520

8338.00

23
24

page 105

EI-75 LAMINATION
MAXI M U M TURNS FOR LAYER WOU N D COILS
COIL LENGTH
1 1/ 1 6"
WIN DOW WIDTH
3/8"
M EAN LENGTH TURN
4.33"
=

Max.
Layers

Max.
Turns

Resistance
square stack

Wire
Gage

M i n . Layer
Insu lation

Turns/
Layer

18

1 1 - .003K

18

1 08

.249

19

1 1 - .003K

20

1 40

.51 3

20

1 1 - .003K

23

161

.590

21

1 1 - .003K

26

208

.960

22

1 1 - .003K

252

1 .467

23

1 1 - .003K

28
32

10

320

2.31

24

1 1 - .002K

12

432

4.00

25

1 1 - .002K

36
40

13

520

6.07

26

1 1 - .002K

46

15

690

1 0. 1 6

27
28

1 1 - .002K
1 1 - .001 5K

51
57

16
18

816
1 026

15.15
24.00

29

1 1 - .00 1 5K

63

20

1 260

37.20

30

1 1 - .001 K

71

24

1 704

63.45

31

1 1 - .001 K

79

26

2054

96.41

32

1 1 - . 001 K

87

29

2523

1 49.38

33

1 1 - . 001 K

99

32

3 1 68

236.50

34

1 1 - .001 K

1 12

35

3920

369.00

35

1 1 - .001 K

1 26

39

491 4

583.30

36

1 1 - .001 K

1 40

43

6020

901 .00

37

1 1 - .001 K

1 57

47

7379

1 396.00

38

1 1 - .00075K

1 75

54

9450

2249.00

39

1 1 - .00075K

203

61

1 2383

371 6.00

40

1 1 - .00075K

227

67

1 5209

5756.00

41

1 1 - .0005K

248

77

1 9096

91 1 5.00

. 42

1 1 - .0005K

275

85

23375

1 4 1 1 0.00

page 106

EI-87 LAMI NATION

MAXI M U M TU RNS FOR LAYER WOU N D COILS
COIL LENGTH
1 1/4"
WIN DOW WIDTH
7/16"
M EAN LENGTH TURN
5 . 04"
=

Wire
Gage

M i n . Layer
Insu lation

Turns/
Layer

Max.
Layers

Max.
Turns

Resistance
sq uare stack

18

1 1 - .003K

22

1 54

.386

19

1 1 - .003K

25

200

.6763

20

1 1 - .003K

28

252

1 .074

21
22

1 1 - .003K

31

9
10

310

35
39

11

23

1 1 - . 003K
1 1 - .003K

12

385
468

1 .666
1 .97
3.96

24

1 1 - .002K

44

14

616

6.64

25

1 1 - .002K

49

16

784

1 0.66

26

1 1 - . 002K

55

17

935

27

1 1 - . 002K

61

19

1 1 59

16.03
25.06

28

1 1 - .001 5K

69

22

1 51 8

4 1 .38

29

1 1 - .00 1 5K

77

24

1 848

63.51

30

1 1 - .001 K

86

28

2408

1 04.40

31
32

1 1 - .001 K

95

31

2945

1 60.90

1 1 - .001 K

1 06
1 20

34
38

3604
4560

248.40
396.30

1 36

42

571 2

61 5.00

34

1 1 - .001 K
1 1 - .001 K

35

1 1 - .001 K

1 53

47

7191

993.70

36

1 1 - .001 K

1 70

51

8670

1 51 0.50

37

1 1 - .001 K

191

57

1 0887

2392.00

38

1 1 - .00075K

213

65

1 3845

3835.50

39

1 1 - .00075K

246

74

1 8204

6360.00

40

1 1 - .00075K

275

81

22275

9814.00

41

1 1 - .0005K

302

93

28086

1 5606.00

42

1 1 - .0005K

334

1 02

34068

23939.00

33

page 107

EI- 1 0 0 LAMINATION
MAXI M U M TU RNS FOR LAYER WOU N D COILS
COIL LENGTH
1 7/ 1 6 "
WIN DOW WIDTH
1/2"
M EAN LENGTH TURN
5.71"
=

Wire
Gage

M i n . Layer
Insu lation

Turns/
Layer

Max.
Layers

Max.
Turns

Resistance
square stack

16

1 1 - .005K

21

1 26

.241

17

1 1 - .005K

23

161

.388

18

1 1 - . 003K

26

208

.632

19

1 1 - .003K

29

261

1 .00

20

33

10

330

1 .60

21

1 1 - .003K
1 1 - .003K

37

11

407

2.48

22

1 1 - .003K

41

13

533

4. 1 0

23

1 1 - .003K

46

14

644

6.24

24

1 1 - .002K

52

16

832

1 0. 1 6

25
26

1 1 - .002K
1 1 - .002K

58

18

65

20

1 044
1 300

1 6.08
25.24

27

1 1 - .002K

72

22

1 548

38.80

28

1 1 - .001 5K

81

25

2025

62.53

29

1 1 - .001 5K

90

27

2430

94.61

30

1 1 - .001 K

1 02

32

3264

1 60.27

31

1 1 - .001 K

113

35

3955

244.80

32

1 1 - .001 K

1 25

38

4750

370.90

33

1 1 - .001 K

141

43

6063

597.00

34

1 1 - .001 K

1 59

48

7632

947.40

35

1 1 - .001 K

1 80

53

9540

1 493.40

36

1 1 - .001 K

200

58

1 1 600

2289.40

37

1 1 - .001 K

225

64

1 4400

3584.00

38

1 1 - .00075K

250

73

1 8250

5728.00

39

1 1 - .00075K

290

83

24070

9526.00

40

1 1 - .00075K

324

91

29484

1 4716.00

page 108

EI- 1 1 2 LAMINATIO N
MAXI M U M TURNS FOR LAYER WOUN D COILS
COIL LENGTH
1 5/8"
WIN DOW WIDTH
9/ 16"
MEAN LENGTH TURN
6 . 60 "
=

Wire
Gage

M i n . Layer
Insu lation

Turns/
Layer

Max.
Layers

Max.
Turns

Resista nce
sq uare stack

16

1 1 - .005K

24

1 68

.371

17

1 1 - . 005K

27

216

.602

18

1 1 - .003K

30

10

300

.984

19

1 1 - .003K

34

11

374

1 .656

20

1 1 - .003K

38

12

456

2.55

21

1 1 - .003K

42.5

13

552

3.89

22

1 1 - .003K

47.5

15

712

6.32

23

1 1 - .003K

53

16

848

9.38

24

1 1 - .002K

59

18

1 062

1 5.00

25

1 1 - . 002K

67

20

1 340

23.86

26

1 1 - .002K

75

23

1 725

38.72

27

1 1 - .002K

83

25

2075

58.74

28

1 1 - .00 1 5K

94

29

2726

97.30

29

1 1 - .00 1 5K

1 04

32

3328

1 49.78

30

1 1 - .001 K

117

37

4329

245.70

31

1 1 - .001 K

1 31

41

5371

384.30

32

1 1 - .001 K

1 44

44

6336

571 .90

33

1 1 - .001 K

1 62

49

7938

903.30

34

1 1 - .001 K

1 84

55

1 01 20

1 452.20

35

1 1 - .001 K

208

61

1 2688

2296.00

36

1 1 - .001 K

230

67

1 54 1 0

351 5.70

37

1 1 - . 00 1 K

258

74

1 9092

5493.00

38

1 1 - . 00075K

288

85

24480

8881 .00

39

1 1 - .00075K

333

96

3 1 968

1 4625.00

40

1 1 - . 00075K

372

1 05

39060

22535.00

page 109

EI- 1 2 5 LAMINATION
MAXI M U M TU RNS FOR LAYER WOU N D COI LS
COIL LENGTH
1 1 3/ 1 6"
WIN DOW WIDTH
5/8"
M EAN LENGTH TU RN
7.21"
=

Wire
Gage

M i n . Layer
Insu lation

Turns/
Layer

Max.
Layers

Max.
Turns

Resistance
square stack

16

1 1 - .005K

27

216

.521

17

1 1 - .005K

30

270

.822

18

1 1 - .003K

34

10

340

1 .304

19

1 1 - .003K

38

11

418

2.022

20

1 1 - .003K

43

13

3.41

21

1 1 - .003K

48

14

559
672

22

1 1 - .003K

54

16

864

8.38

23

1 1 - .003K

60

18

1 080

1 3.21

24

1 1 - .002K

67

20

1 340

20.67

25
26

1 1 - .002K
1 1 - .002K

75
85

22
25

1 650

32. 1 0

2 1 25

52.02

27

1 1 - .002K

94

27

2538

78.48

28

1 1 - .001 5K

1 06

31

3286

1 28. 1 0

29

1 1 - .001 5K

1 17

34

3978

1 93.20

30

1 1 - .001 K

1 32

40

5280

327.40

31

1 1 - .001 K

1 47

44

6468

505.60

32

1 1 - .001 K

1 62

48

7776

766.60

33

1 1 - .00 1 K

1 83

54

9882

1 228.40

34

1 1 - .00 1 K

207

60

1 2420

1 946.80

35

1 1 - .00 1 K

234

67

1 5678

3099.00

36

1 1 - .001 K

260

73

1 8980

4730.00

37

1 1 - .001 K

292

80

23360

7341 .00

38

1 1 - .00075K

325

92

29900

1 1 849.00

39

1 1 - .00075K

376

1 04

391 04

1 9542.00

40

1 1 - .00075K

421

1 14

47994

30248.00

5. 1 7

page 110

EI- 1 3 8 LAMINATION
MAXI M U M TU RNS FOR LAYER W O U N D COILS
COIL LENGTH
2"
WIN DOW WIDTH
1 1/ 1 6"
M EAN LENGTH TURN
7 . 66"
=

Resista nce
square stack

Max.
Layers

Max.
Turns

19

1 14

. 1 46

1 1 - .01 0K

21

1 47

.24

15

1 1 - . 0 1 0K

24

1 92

.39

16

29

.60

33

8
10

232

17

1 1 - .007K
1 1 - .007K

330

1 .07

18

1 1 - .007K

37

11

407

1 .66

19

1 1 - .005K

43

12

516

2.65

20

1 1 - .005K

48

14

672

4.35

21

1 1 - .005K

54

15

810

6.60

22

1 1 - .005K

18

1 1 16

1 1 .50

23

1 1 - .005K

62
69

20

1 380

1 7.90

24

1 1 - .003

78

23

1 794

29.50

25

1 1 - . 003

88

26

2288

47.20

26

1 1 - .003

98

29

2842

74.00

27

1 1 - .003

110

32

3520

1 1 6.00

28

1 1 - . 00 1 5

1 23

37

4551

1 89.00

29

1 1 - .001 5

1 36

40

5440

287.00

30

1 1 - .001 K

1 53

44

6732

445.00

31

1 1 - .001 K

1 72

49

8428

700.00

32

1 1 - .001 K

1 91

53

1 02 1 3

1 060.00

33

1 1 - .001 K

213

58

1 2354

1 630.00

34

1 1 - .001 K

241

69

1 6629

2765.00

Wire
Gage

M i n . Layer
Insu lation

13

1 1 - .01 0K

14

Turns/
Layer

page 1 1 1

El- 1 5 0 LAMINATIO N
MAXIM U M TU RNS FOR LAYER WOU N D COI LS
COIL LENGTH
1 7/ 1 6 "
WIN DOW WIDTH
1/2"
MEAN LENGTH TURN
8.4"
=

Wire
Gage

M i n . Layer
Insu lation

Turns/
Layer

Max.
Layers

Max.
Turns

Resistance
sq uare stack

147
1 92

.21

24

7
8

1 1 - .001 K

27

216

.48

16

1 1 - . 007K

33

297

.84

17
18

1 1 - .006K

37

11

407

1 .44

1 1 - .007K

41

12

492

2.20

19

1 1 - .005K

47

13

61 1

3.45

20

1 1 - . 005K

15

795

5.60

21

1 1 - . 005K

53
59

17

1 003

9.00

22
23

1 1 - . 003K
1 1 - .003K

69
77

20
22

1 380
1 694

1 5.60
24.00

24

1 1 - .002K

86

26

2236

41 .00

25

1 1 - .002K

63.50

1 1 - .002 K

28
32

2716

26

97
1 09

3488

1 00.00

27

1 1 - .002K

121

35

4235

1 53.00

28

1 1 - .00 1 5K

1 36

40

5440

247.00

29

1 1 - .00 1 5K

1 51

44

6644

381 .00

30

1 1 - .001 K

1 69

48

81 12

583.00

31

1 1 - .001 K

1 90

1 0260

933.00

32

1 1 - .001 K

215

54
58

1 2528

1435.00

21

14

1 1 - . 0 1 0K
1 1 - .001 K

15

13

.34

page 1 1 2

E E-28-29 LAMINATION
MAXI M U M TURNS FOR BOBBIN WOU N D COILS (85/o FILL)
M EAN LENGTH TU RN
Wire
Gage

.930"

Turns/
Layer

Max.
Layers

Max.
Turns

Resistance
square stack

20

14

.0121

21

16

. 0 1 74

22

27

.0373

23

10

30

.052

24

11

33

.0723

25

12

48

. 1 325

26

14

56

. 1 96

27

15

75

.325

28

17

85

.469

29

19

1 14

.955

30

21

1 47

1 .286

31

24

1 92

2. 1 1 7

32

26

208

2.841

33

30

10

300

5.20

34

33

11

363

5.69

35

37

12

444

1 2.35

36

41

14

574

20.80

37

46

15

690

29.73

38

51

17

867

47.00

39

58

20

1 1 60

82.80

40

65

22

1 430

1 1 1 .60

41

73

25

1 825

1 64.80

42

80

28

2240

31 2.70

43

90

31

2790

450.00

44

1 02

35

3570

780.00

45

118

41

4838

1 369.00

46

1 23

43

5289

1 878.00

page 113

EI- 186 LAMINATIO N

MAXI M U M T U R N S F O R BOBBIN WO U N D COILS (85/o FILL)
M EAN LENGTH TU RN
W i re
Gage

1 .4 "

Turns/
Layer

Max.
Layers

Max.
Turns

Resista nce
square stack

20

20

.026

21

24

.039

22

30

.062

23

35

.091

24

48

. 1 58

25

63

.262

26

10

70

.369

27

11

88

.572

28

13

1 17

1 .42

29

14

10

1 40

2 . 09

30

16

12

1 92

2.875

31

18

13

234

3.93

32

20

15

300

6.25

33

22

17

374

9.89

34

25

19

475

1 5. 9 1

35

28

21

588

25.00

36

31

23

713

38.40

37

35

26

910

59.70

38

38

29

1 1 02

9 1 .40

39

44

34

1 496

1 62 . 1 0

40

49

38

1 862

258.00

41

55

43

2365

402.90

42

61

47

2867

609.00

43

68

53

3604

990.00

44

77

60

4620

1 540.00

page 114

EI- 187 LAMI NATION

MAXI M U M TURNS FO R BOBBIN WO U N D COILS (85/o FILL)
M EAN LENGTH TU RN
Wire
Gage

1 .35"

Tu rns/
Layer

Max.
Layers

Max.
Turns

Resista nce
square stack

20

10

30

.0376

21

11

44

.070

22

12

48

.0963

23

14

70

. 1 76

24

15

75

.2382

25

17

1 02

.408

26

19

1 33

.675

27

21

1 68

1 .07

28

24

216

1 .72

29

27

10

270

2.72

30

30

11

330

4.24

31

34

12

408

6.58

32

37

14

51 8

1 0.40

33

42

16

672

1 6.72

34

47

17

799

25.80

35

53

20

1 060

43.35

36

58

22

1 276

65.40

37

65

25

1 625

1 02.90

38

72

27

2656

1 55.90

39

83

32

2994

278.00

40

92

35

3220

429.00

41

1 03

40

4 1 20

673.50

42

1 14

44

501 6

1 029.00

43

1 27

50

6350

1 683.00

44

1 45

57

8265

241 3.00

45

1 67

66

1 1 022

4640.00

page 1 1 5

EI-375 LAMI NATION

MAXI M U M TURNS FOR BOBBIN WO U N D COILS ( 8 5 /o FILL)
M EAN LENGTH TU RN
Wire
Gage

2 . 49"

Turns/
Layer

Max.
Layers

Max.
Turns

Resista nce
square stack

20

18

1 08

.25

21

20

1 40

.423

22

22

1 76

.646

23

25

225

1 .043

24

28

10

280

1 .642

25

31

12

372

2. 1 8

26

35

13

455

4.48

27

38

15

570

6.68

28

43

17

731

1 0. 86

29

48

18

864

1 6. 00

30

53

21

1 1 13

26.40

31
32

60

24

1 440

43.59

66

26

1716

6 1 . 30

33

75

29

2 1 75

1 02 . 1 0

34

84

33

2772

1 65.00

35

94

37

3478

262.00

36

1 03

41

4223

398.00

37

1 16

47

5452

636.00

38

1 28

51

6528

965.00

39

1 47

59

8673

1 672.00

40

1 63

66

1 0758

2663.00

41

1 82

74

1 3468

4660.00

42

202

83

1 6766

6330.00

43

226

92

20792

1 01 60.00

44

257

1 05

26985

1 5900.00

45

298

1 22

36356

25230.00

page 1 1 6

EE-24-25 LAMINATION
MAXI M U M TURNS FO R BOBBIN WOU N D COILS (85/o FILL)
M EAN LENGTH TURN
Wire
Gage

1 . 86"

Tu rns/
Layer

Max.
Layers

Max.
Turn s

Resistance
square stack

20

11

55

.0946

21

12

72

.1618

22

14

84

.2308

23

15

1 05

.3624

24

17

1 36

.616

25

19

1 71

.954

26

22

10

220

1 .54

27

24

11

264

2.31 5

28

27

13

351

3.94

29

30

14

420

5.81

30

34

16

544

9.63

31

37

18

666

1 5.00

32

41

20

820

22.70

33

47

23

1 081

37.9

34

52

25

1 300

57.85

35

59

28

1 652

93.20

36

64

32

2048

1 44.50

37

72

35

2520

223.00

38

80

39

3 1 20

344.00

39

91

46

4 1 86

604.00

40

1 02

51

5202

956.00

41

1 14

57

6498

1 573. 00

42

1 26

63

7938

2241 .00

43

141

71

1 00 1 1

3663.00

44

1 60

81

1 2960

5870.00

45

1 86

94

1 7484

91 70.00

page 1 1 7

EI- 2 1 LAMINATION
MAXI M U M TURNS FOR BOBBIN WOU N D COILS (85/o FILL)
M EAN LEN GTH TURN
W i re
Gage

3.01"

Tu rns/
Layer

Max.
Layers

Max.
Turns

Resistance
square stack

20

19

1 14

.31 9

21

21

1 47

.5345

22

24

1 92

. 856

23

27

243

1 .36

24

30

10

300

2 . 1 23

25

34

11

374

3.34

26

38

14

532

5.60

27

42

14

588

8.49

28

47

16

752

1 3.50

29

52

18

936

20.75

30

58

20

1 1 60

33.22

31

66

23

1518

55.53

32

72

25

1 800

86.00

33

82

28

2296

1 30.00

34

91

32

2912

2 1 0.00

35

1 03

36

3708

328.00

36

1 12

40

4480

51 2.50

37

1 26

45

5670

800.00

38

140

50

7000

1 250.00

39

1 60

58

9280

2830.00

40

1 78

64

1 1 392

3385.00

41

1 99

72

1 4328

5240.00

42

220

80

1 7600

8 1 28.00

43

247

90

22230

1 3 1 30.00

44

281

1 02

28662

20430.00

45

325

118

38350

32200.00

page 1 1 8

EI-625 LAMINATION
MAXIM U M TURNS FOR BOBBIN WO U N D COILS (85/o FILL)
M EAN LENGTH TU RN
W i re
Gage

3.53"

Turns/
Layer

Max.
Layers

Max.
Turns

Resista nce
square stack

17

16

80

. 1 1 89

18

18

90

. 1 68

19

20

1 20

.284

20

21

6
6

1 26

.41 35

21
22

23

.656

26

161
208

24

30
33

25

1 .085
1 .773
2.743

37

10
11

270
330
407

4.265

26

42

13

546

7.25

27

46

14

644

1 0.52

28

52

16

832

1 7.50

29

58

18

1 044

27.40

30

65

20

1 300

43.60

31
32

73
81

22

1 606

68.7

25

2025

1 06.50

33

91

28

2548

1 69.30

34

101

31

3 1 31

264.50

35

115

35

4025

430.50

36

1 28

39

4992

670.00

37

1 43

44

6292

1 040.00

38

1 59

49

7791

1 630.00

39

56
63

1 0248

2830.00

40

1 83
204

1 2852

4480.00

41

227

71

161 17

6750.00

42

255

79

20145

1 0800.00

23

page 1 19

EI-75 LAMINATIO N
MAXI M U M T U R N S F O R BOBBIN WOU N D COILS (85/o FILL)
M EAN LENGTH TU RN
Wire
Gage

4 . 202"

Turns/
Layer

Max.
Layers

Max.
Tu rns

Resistance
square stack

16

17

1 02

. 1 435

17

20

1 20

.21 3

18

22

1 54

.349

19

25

200

.564

20

27

216

.8425

21

30

270

1 .37

22

34

10

340

2 . 1 57

23

38

11

418

3.27

24

43

12

516

5. 1 0

25

48

14

672

8.36

26

54

16

864

1 4.60

27

60

17

1 020

20.20

28

67

20

1 340

33.60

29

75

22

1 650

51 .60

30

84

25

2 1 00

84.00

31

95

28

2660

1 35.80

32

1 04

31

3224

201 .50

33

1 18

35

4 1 30

327.00

34

1 32

39

5148

51 6.50

35

1 48

44

651 2

830.00

36

1 65

49

8085

1 290.00

37

1 84

54

9936

1 959.00

38

205

61

1 2505

3 1 2 1 .00

39

236

70

1 6520

5370.00

40

263

78

20514

851 0.00

page 1 20

EI-87 LAMINATIO N
MAXI M U M TURNS FOR BOBBIN WO U N D COILS ( 8 5 /o FILL)
M EAN LENGTH TU RN
Wire
Gage

5 . 04"

Turns/
Layer

Max.
Layers

Max.
Turns

Resistance
sq uare stack

16

20

1 20

.202

17

23

161

.342

18

25

200

.536

19

28

252

.852

20

32

10

320

1 .36

21

36

11

396

2.13

22

40

12

480

3.25

23

45

14

630

5.39

24

50

16

800

8.63

25

56

17

952

1 2.94

26

63

20

1 260

21 .59

27

70

22

1 540

33.29

28

79

25

1 975

53.83

29

88

27

2376

8 1 .65

30

98

31

3088

1 31 .68

31

1 09

34

3706

202.50

32

1 22

38

4626

31 9.40

33

1 37

43

5891

5 1 2 .00

34

1 55

48

7440

8 1 5.20

35

1 75

55

9625

1 329.60

36

1 93

61

1 1 773

2051 .00

37

212

67

1 4204

31 20.00

38

222

76

1 6872

4673.50

39

271

85

23035

8046.60

40

301

95

28595

1 2597.00

page 121

EI- 1 0 0 LAMI NATION

MAXI M U M TU RNS FOR BOBBIN WOU N D COILS (85/o FILL)
M EAN LENGTH TURN
W i re
Gage

5 . 57"

Tu rns/
Layer

Max.
Layers

Max.
Turns

Resista nce
square stack

15

22

1 54

.227

16

25

1 75

. 326

17

28

224

. 526

18

31

279

.826

19

35

11

385

1 .44

20

39

12

468

2.20

21

44

13

572

3.40

22

49

15

735

5.50

23

55

17

935

8.83

24
25

61

19

1 1 59

1 3.81

69

21

1 449

21 .77

26

77

24

1 848

35.00

27

86

26

2236

53.42

28
29

96

2880

86.75

1 07

30
33

3531

1 34. 1 0

30

1 20

37

4440

21 2.70

31

1 33

42

5586

337.30

32

1 48

46

6808

51 8.60

33

1 67

52

8684

834.00

34

1 89

59

1 1 151

1 350.00

35

213

66

1 4085

2 1 46.80

36

236

74

1 7464

3362.40

37

260

81

21 060

51 1 3.00

38

294

92

27048

8281 .00

39

331

1 03

34093

1 31 63.00

40

368

115

42320

20606.00

page 122

EI- 1 1 2 LAMINATION
MAXI M U M TU R N S FOR BOBBIN WOU N D COILS (85/o FILL)
M EAN LENGTH TURN
W i re
Gage

6 . 60"

Turns/
Layer

Max.
Layers

Max.
Tu rns

Resista nce
square stack

13

19

1 14

. 1 26

14

22

1 54

.214

15

24

1 68

.294

16

27

216

.477

17

31

10

310

.863

18

34

11

374

1 .32

19

38

12

456

2.02

20

43

14

602

3.36

21

48

15

720

5.07

22

54

17

91 8

8. 1 5

23

61

19

1 1 59

1 2.97

24

68

21

1 428

20. 1 6

25

76

24

1 824

32.47

26

85

27

2295

51 .51

27

95

30

2850

80.67

28

1 06

34

3604

1 28.60

29

1 19

38

4522

203.50

30

1 33

42

5586

31 7.00

31

1 47

47

6909

494.40

32

1 64

52

8528

769.70

33

1 85

59

1 09 1 5

1 242.00

34

209

67

1 4003

2009.00

35

235

75

1 7625

3 1 89.00

page 123

EI- 1 2 5 LAMI NATIO N

MAXI M U M TU R N S FO R BOBBIN WOU N D COILS (85/o FI LL)
M EAN LENGTH TURN
Wire
Gage

7.21"

Turns/
Layer

Max.
Layers

Max.
Turns

Resista nce
square stack

12

19

1 14

. 1 09

13

21

1 47

. 1 77

14

24

1 92

.291

15

27

243

.465

16

30

10

300

.723

17

34

11

374

1 . 1 38

18

38

12

456

1 .75

19

43

14

602

2.91

20

48

15

720

4.39

21

53

17

901

6.93

22

60

19

1 1 40

1 1 .00

23

67

21

1 407

1 7.21

24

75

24

1 800

27.76

25

84

27

2268

44. 1 0

26

94

30

2820

69. 1 5

27

1 05

34

3570

1 1 0.40

28

1 18

38

4484

1 74.84

29

131

42

5502

270.50

30

1 47

47

6909

428.40

31

1 63

53

8639

675.30

32

1 82

59

1 0738

1 058.60

33

205

66

1 3530

1 682.00

34

231

75

1 7325

271 5.80

35

261

84

21 924

4333.80

36

289

94

271 66

6770.00

page 124

EI- 1 38 LAMINATIO N
MAXI M U M TU R N S FOR BOBBIN WOU N D COILS ( 8 5 /o FILL)
M EAN LENGTH TU RN
Wire
Gage

7 . 66"

Turns/
Layer

Max.
Layers

Max.
Turns

Resistance
square stack

11

17

1 02

.082

12

19

1 33

. 1 35

13

21

1 47

. 1 88

14

24

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15

27

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11

330

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12

408

1 .32

18

38

13

494

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19

42

15

630

3.24

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47

17

799

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21

53

19

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22

59

21

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1 2.76

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66

24

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74

27

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25

83

30

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93

34

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27

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28

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53

7685

506.25

31

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58

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32

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65

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83

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35

258

94

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5093.20

36

285

1 04

29640

7848.00

page 125

EI- 1 50 LAMINATION
MAXI M U M TURNS FOR BOBBIN WOU N D COILS (85/o FILL)
M EAN LENGTH TURN
W i re
Gage

8 . 4"

Tu rns/
Layer

Max.
Layers

Max.
Turns

Resistance
square stack

10

18

1 08

.076

11

20

1 20

. 1 06

12

23

161

. 1 79

13

26

208

.292

14

29

261

.461

15

33

10

330

.735

16

37

12

444

1 .25

17

41

13

533

1 .89

18

46

15

690

3.08

19

51

17

867

4.89

20

58

19

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7.82

21

64

21

1 344

1 2.04

22

72

23

1 656

1 8.70

23

81

26

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30.00

24

96

29

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25

101

33

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37

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1 20.49

27

1 26

41

5 1 66

1 86. 1 0

28

1 42

46

6532

296.70

29

1 58

52

821 6

470.60

30

1 77

58

1 0266

741 .60

31

1 97

64

1 2608

1 1 48.20

32

219

71

1 5549

1 786.00

page 1 26