AUDIO

TRNSF10R$MER

DESIGN MANUAL

ROBERT G. WOLPERT

AUDIO

TRSFORSMER

DESI6N MANUAL

ROBERT G. WOLPERT

PREFACE

This manual is intended to show how to design and manufacture audio

transformers.
It will explain the various th ings that have to be considered and the
problems that will be encountered in achieving the desi red resu lts. It will
show how to design to meet the requirements and give examples and test
results.
It will also give methods of manufacturing to ach ieve the results desired,
with some of the th ings that will prevent the design from being
successfu I.
Th is manual is written with the assumption that the designer has
experience in the design of power transformers. Therefore, it covers only
those manufacturing techniques that are different and necessary to
achieve the proper results in an audio transformer.
If the designer needs more information on the construction methods, the
TRANSFORMER DESIGN AND MANUFACTURING MANUAL publ ished by the
author in 1 984, or some other publication, should be consulted .
The appendix will have various tables and charts to assist in the design of
the transformers.

Robert G. Wol pert

page 1

TABLE OF CONTE NTS

PART I.

DESIGN CONSIDERATIO NS

CHAPTER

1.0
1.1
1 .2
1.3
1 .4
1.5
1.6
1.7
1.8

GENERAL REQUIREMENTS
Frequency response
I m pedances
Power level
Total harmonic distortion
Direct current in windings
Hum reduction
Longitudinal balance
Insertion loss

CHAPTER

2.0
2. 1
2.2
2.3
2.4

LOW FREQ UENCY RES PONSE

Open circuit inductance
Pri mary voltage and current
Secondary voltage and current
Core size and material

CHAPTER

3.0
3.1
3.2

H IGH FREQUENCY RES PONS E

Interleaving the winding
Leakage inductance

CHAPTER

4.0
4. 1
4.2
4.3
4.4

SPECIAL REQUIREMENTS
Total harmonic distortion
Shield ing for hum reduction
Longitudinal balance
Insertion loss

CHAPTER

5.0
5.1
5.2
5.3

DESIGN METHODS
Flux density
Construction suggestions
Calculating the physical parameters

page 2

PART II. DESIGN EXA M PLES

Example 1 :

Voice frequency telephone transformer

Example 2 :

Aud io output transformer

Example 3 :

Line to voice coil transformer

APPEN DIX

Symbols used
DB-Watts table
Wire table
Lamination table
Total harmonic d istortion table
Wire size - turns - lamination tables

page

PART I. DESIGN CONSIDERATIONS

page 4

PART I.

DESIGN CONSID E RATIONS

CHAPTER 1. GENERAL REQUI REM E NTS

By definition, an audio transformer is designed to operate within the

aud io range of frequencies. However, the upper and lower limits are
extended beyond the audio range for many uses.
For example, usage in h igh fidel ity ci rcuits might desire a range from
1 0 Hz to 3 0 0 0 0 Hz or h igher, while a telephone transformer could have a
range from 3 0 Hz to 3 0 0 0 Hz.
The frequency range, both high and low l i m its, will determine to a great
extent, the design and method of manufacture .
Transformers designed to work at aud io frequencies can be put into three
general categories. These are input, output and i m pedance match ing.
Actually, the only differences between these are the usage and the
im pedance ratios. They all can be considered as i m pedance matching
transformers, as they are used to transmit signals from one impedance to
another impedance either h igher or lower or sometimes, when isolation
only is desired, between equal impedances.
There are several things to be considered in the design of audio
transformers :
a.
b.
c.
d.
e.
f.
g.
h.

Frequency response
Impedances
Power level
TH D o r total harmonic distortion
Value of D.C. in windings, if any
Hum reduction level, if required
Longitudinal balance
Insertion loss

In addition, the flux density of the core material must be considered in

order to not operate the core into saturation.

page 5

1.1

Frequency Response

The frequency response of a transformer is that range of frequencies that

is desired to be passed.
It is desirable to have the same response or voltage level of all
frequencies within this range. The extremes of the range will fall off.
These are usually cal l ed out as a range of DB, such as 3 DB or 1 DB,
etc. This means that all the voltages between the two extremes will not
vary more than the l i m its shown.
The variations
the center of
transformers.
1000 Hz, then
of 3 DB or 1

cal led out will usually be referred to a certain frequency in

the response. Usua l ly this wi l l be 1 000 Hz for audio
Thus, if a certain voltage or DB level is called out for
all frequencies within the range should be within the lim its
DB or whatever is required.

The -3 DB frequencies will have a voltage level that is 70. 7/o of the
voltage at the m iddle of the frequency range.
The best way to measure the response is to use a meter that is cal ibrated
in DB rather than trying to calculate the DB from the voltage levels.
However, the DB can be calculated from the voltages by using the
following formula :

DB= 20 LOG

Eo
ErN

The lower limit of the frequency range is controlled by the primary

inductance. This will fal l off 3 DB at the frequency where the inductive
reactance of the primary equals the primary im pedance. It will fal l off
1 DB at two times the primary im pedance and 0 . 5 DB at approximately
4 times the primary im pedance.

page 6

The following formulas are used :

L -

Where:

- 3 DB

- -0 . 5 DB

L
Z
F1

=
=
=

- 1 DB

pri mary inductance

primary im pedance
lower frequency desired

The upper frequency will be down 3 DB where the normalized impedance

equals the reactance of the leakage inductance.
The frequency response can be measured using the circuit in Figure 1 .

Figure 1

Rs

the i mpedance of the primary

Ri

the i mpedance of the secondary

page 7

The voltage of E1 must be held constant for all frequencies. The output
voltage, E2 , is then set for a middle frequency, usually 1000 Hz, and the
deviation from this voltage is the response over the frequency range.

1.2

Impedances

The im pedances of both the primary and the secondary must be known or
can be calculated . The i m pedance ratio is equal to the turns ratio
squared and also equal to the voltage ratio squared.
2

2
=

1.3

Power Level

The operating power level is usually called out. This can be sine wave
power or music power. Sine wave power will be approximately three
times the effective music power.
The transformer must be able to handle the full voltage and current at
any frequency within the operating range for sine wave power. For music
power it must hand le the ful l voltage but only one third of the current for
heating purposes. This will al low the use of smal ler magnet wire and will
result in a smaller unit.
1.4

Total Harmonic Distortion

The total harmonic distortion is mainly a function of the operating flux

density in the core at the lowest operating frequency. Reducing the flux
density will reduce the d istortion.
The distortion at a given frequency and flux density will vary with the
type of magnetic material used .

page 8

1.5

Direct Current in the Windings

When one or more of the windings is required to carry unbalanced direct

current, it is necessary to design that winding for the proper inductance
the same way you would design an inductor carrying d i rect current. The
proper air gap spacer must be put in the magnetic path . This will result
in a larger unit than one that does not carry unbalanced d i rect current.
1.6

Hum Reduction

When designing for low level usage, it is often necessary to keep the
external flux fields at a very low level. Levels of -60 DB to -80 DB
requirements are not unusual .
This is accomplished by enclosing the unit in a case o r cases using high
permeability materials. 80/o nickel is often used for this app lication . A
single case or a nest of cases using alternate cases of high permeabil ity
material and copper may be needed .
1.7

Longitudinal Bal ance

Longitudinal balance is a measure of a transformer's balance and ability

to prevent longitud inal signals or signals that have been induced in the
power l ine from being transferred into the secondary of the transformer.
1.8

Insertion Loss

Insertion loss is a measure of the power available out of the transformer

versus the power induced into the transformer.

page 9

CHAPTER 2. LOW FREQUENCY RESPONSE

The requirements of an audio transformer a re a l l inte r- related and must

a l l be considered in the design. The first step is to design for the low
frequency. This will esta blish the size of the core and the num ber of
turns needed. It is a l so the easiest part of the design.
2. 1

Open circuit inductance

Calculate the i nducta nce necessary. Assuming a -3 DB requirement at

the low frequency end, the inducta nce needed will be :
L =

For - 1 DB and -0 . 5 DB requirements, the formula is cha nged accordingly,

as cal led out in 1 . 1 .
It ca n now be seen that the h igher the prima ry i m pedance, the larger the
inducta nce needed. This translates to a larger core a nd/or more turns. It
also makes it more difficult to obta in the h igher frequency l i m it as will be
seen later.
2.2

Primary voltage and current

Calculate the p ri ma ry voltage a nd current.

This depends on the
information given. If the power (wattage) is given a nd the impedance is
known, Ohm's law may be used to ca lculate the voltage a nd current.

AND

Ii =

If the power is given in DB or DBm, the power in watts must be either

ca lculated or ta ken fro m a chart. A chart of DB versus watts is in the
Append ix. DBm is DB for a 600 ohm im pedance.

page 10

2.3

Secondary voltage and current

Calculate the secondary voltage and current. The seconda ry voltage can
be calcul ated from the im pedance ratio. By rearranging the formula from
1 . 2:

The current ratios a re inversely proportiona l to the voltage ratios so the

seconda ry current can be ca lculated by rearranging the equation :

--

2.4

Core size and material

The core material will depend largely on the a pplication.

If the
transformer is a small, low- level unit, the materia l can be either 50/o or
80/o nickel. These a re h igh permeabil ity materials and wi ll require fewer
turns than 4/o sil icon steel. If a h igher level unit is desi red, 4/o sil icon
steel will probably be the best choice as the cost of nickel la minations will
be prohibitive in l a rger units. Al so, the operating flux density can be
h igher in silicon steel , which will result in a smal ler unit.
The power requirements will help choose the core size. If the core size is
ca l l ed out, there is no choice. If not, then experience from past designs,
or an adjustment to the information from the 60 Hz tabl es will have to be
used.
For exa m ple, a 1 50 watt, 60 Hz core will probably be a bout right for a
50 watt, 20 Hz aud io transformer. This will be a good starting point. See
the table in the Appendix.
The core size o btained in this manner is an a pproximation and
adjustments will have to be made to get the proper fill. When the turns
are calculated in the next step and the wire sizes a re chosen, the fit in
the core can be calcul ated.

page 11

When the core has been chosen, an easy and quick way to calculate the
turns needed to give the required inductance for a ny given core size and
magnetic material is to refer to a lamination cata log put out by the
various manufacturers. A formula is given for inductance fo r each size of
core. This can be turned a round to find the turns. The only other
requirement is that the permea bility of the material must be known. This
can al so be obta ined from data published by the manufacturers.
For exam ple, from a cata log, a core size of EI- 1 00, with a squa re stack,
has an in ductance formula :
L = . 5289 x 10

AND

x Kx

UA c

L x 10

. 5289 x K x

Where :

x N

UA c

K is the stacking factor

UA c

is the permea bility of the material

The wire size is determi ned by the current. The prima ry current will be
as calculated in 2.2. The secondary current can be calculated from 2. 3.
If the requirement is for sine wave power, the size of the wire should be
from 650 to 1 00 0 circular- mils per a m pere. This will be determined by
the insertion loss allowed . In genera l , 800 CM/A will be a bout right, and
will be used as a starting point in this manual. If music power is called
for, the size can be reduced to about 300 CM/A.
The core size and wire sizes have now been determined. By referring to
the ta bles in the Appendix (wi re sizes and turns versus lamination sizes),
the fi l l can be checked before going any further. In genera l , the primary
wire should use up half the fi ll and the secondary the other ha lf.
This chapter should pretty well tie down the core size, turns and wire
sizes for both the p ri ma ry and secondary. It may be necessa ry to make
adjustments if i nterleaving is necessa ry to meet the h igh frequency
response.

page 12

CHAPTER 3. HIGH FREQUE NCY RESPONSE

The l i m it of the high frequency response is controlled by the leakage

inductance and the i m pedances.
The leakage inductance is proportional to the square of the turns, thus, it
is possible to reduce this value greatly by reducing the turns, but since
the lower frequency l i m it depends on the pri mary inductance and that is
controlled by the turns and the type of magnetic material used in the
core, the turns are pretty well set. Also, care must be taken that the
maximum flux density of the material is not exceeded in reducing the
turns. The leakage can be reduced by interleaving the primary and
secondary windings.
3. 1

Interleaving the winding

As mentioned before, the high frequency response is determined by the

leakage inductance and the winding im pedances.
In order to reduce the leakage inductance, it is sometimes necessary to
interleave the windings. That is, split the windings and wind one part
primary, one part secondary, one part primary, etc. This can result in
1 : 2, 2 : 3 , 3 : 4, etc, interleaving .
The exam ples will show designs with this interleaving used . A 3 : 2
interleave would be 1/3 primary, 1/2 secondary, 1/3 pri mary, 1/2
secondary and 1/3 primary, and so on . In some cases interleavings of
5 : 4, 6 : 5 and more are used.
3.2

Leakage inductance

The leakage inductance of a transformer can be calculated in many ways.

Some of these are extre mely complicated .
A good com pro mise for a transformer that is wound concentrical ly, that is
one winding over the other, is the following :
LL =

10.6 x N 2 x MLT x (2 x S x T + H)
52 x WL x 109

HYS

page 13

Where :

N
MLT
H
WL
T
s

= number of turns
= mean length turn
winding height
winding length
= insulation space
= number of interleaves
=
=

The high frequency response can now be calculated by using the values of
leakage inductance and the normalized im pedance . The upper frequency
limit will be :

ZT

[:]

2
x Z2 + Z1

page 14

CHAPTER 4. SPECIAL REQUIREM ENTS

4. 1

Total harmonic distortion

If TH D is cal l ed out, the flux density in the core and the type of core
material must be considered . This may require the core size or turns or
both be modified .
The distortion is normally only of concern at the lowest frequency as it
fal l s off rapidly as the frequency increases.
If you consider the three most commonly used types of materials, 80/o
nickel, 50/o nickel, and silicon steel, the flux densities will vary from the
lowest for the 80/o nickel to the h ig hest for the sil icon steel . A table in
the Appendix will give some representative values fo r the three materials
at various flux levels. These numbers will al low you to estimate the
distortion that can be expected at the flux level and frequency of
operation.
4.2

Shielding for hum reduction

Many low l evel transformers are required to function within an external

field without pic king up that field and transmitting it into the operating
circuit.
The transformer can be enclosed within a case or cases to achieve the
desired results . For example, a sing le case of steel will give about 10 DB
of shield ing . A case made of 50/o nickel will give about 20 DB. A case
made of 80/o nickel will g ive 30 DB. A nest of cases consisting of an
80/o nickel case, a copper case and another 80/o nickel case will g ive
60 DB of shielding . If this is extended to three 80/o nickel cases with two
copper cases in between, it will give 90 DB of sh ield ing .
These 80/o nickel cases must be properly annealed and the copper cases
must be soft copper to obtain the desired results.
Care must be taken that the external field is not so h i g h as to saturate
the 80/o nickel or the expected results wi l l not be o btained . If this
occurs, a steel case on the outside may be used to reduce the field to a
level that can be tolerated .
These methods will also apply when the transformer is placed in a very
sensitive circuit and the external flux of the transformer must be reduced .

1989, ROBERT G. WOLPERT, Rev. 2004

page 15

4.3

Longitudinal balance

A longitudinal signal is one that is induced along the power lines and
enters the transformer in both the primary leads as if they were one lead .
This signal must be prevented from passing throug h the transformer as a
signal in the output.
To prevent the passing throug h , the transformer must be balanced so
that it has the same coupling from the input leads to the output
terminations. See Figure 2.

Figure 2

This coupling is represented by the two capacitors, C 1 and C2 .

If c 1

equals C 2 then there is no feed through and no im balance. Of course,

this is a simplification as the coupling can occur anywhere within the
windings.
There are several ways to reduce i m balance .
shown later.

Some of these will be

Figure 3 shows a method of measuring the longitudinal balance.

,5Ra

Figure 3

page 16

.5 R 1 + . 5 R1 = primary Z and must be match ed to within 0 .1/o for a

40 DB balance and to be within 0 . 0 1/o if 60 DB of balance is required . R2
will be equal to the i m pedance of the secondary. The core should be
connected to g round. If a shield is used it should be connected to the
core and g round .
E2 should be a voltmeter with a DB scale.

E2 reads zero.

Perfect balance will be when

When measuring E2, there should be no voltmeter

connected to read Ei .

Short direct wiring should be used to minimize

capacitance unbalance. The level of E i should be the operating level of

the transformer, or as cal l ed out by the customer.
4.4

Insertion loss

The insertion loss of a transformer is a measure of the efficiency as it

shows how much power is consumed by the transformer. Thus, it is
im portant to keep these losses as low as possible.
The most obvious of these losses is the DC resistance of the wind ings.
The larger the size of the wire that can be used, the lower the losses.
The losses in the magnetic material can also contri bute to the total loss.
The magnetic material losses can usually be ignored if the flux density is
kept within reasonable l i m its .
The following method can be used to determine the approxi mate insertion
loss before building the unit. The total or normalized winding resistance,
that is the resistance of the secondary referred to the primary, or the
primary referred to the secondary, will normally be 1 0 to 20/o of the load
resistance. If it is 1 0/o, it wi l l have a loss of approximately 0 . 5 DB and , if
20/o, it will be approximate ly 1 . 0 DB.
By using the calculated values of the winding resistances, the calculation
of the normalized resistance can be done as follows :
2

page 17

Then the percentage loss will be :

x 100

Where :

Ri

DC resistance of the pri mary winding

R2 = DC resistance of the secondary winding

Figure 4 shows how to measure the insertion loss.

Figure 4

Where :

Ei

E2

Ri
R2

Voltage across the pri mary

Load voltage

=
=

Primary i m pedance
Secondary i m pedance

It should be noted that the insertion loss test circuit is the same as the
frequency response circuit, except that the primary voltage is taken after
the primary resistor instead of across the generator.
Then the insertion loss is :

20 LOG

Ei
E2

The voltages obtained from this test can be used to calculate the insertion
loss at any given frequency.

page 18

CHAPTER 5.

DESIGN M ETHODS

Before the design of any transformer can begin, it is necessary to

understand the general construction and how to calculate the turns,
winding fil l and DC resistances of the winding .
The following will show the methods used to determine these values.
5.1

Flux density

The formula for calculating the open circuit primary inductance needed to
meet the low frequency response is given on page 7. In this formula, no
provision is made for the flux density. It is always necessary to calculate
the flux density to be sure that the core will not be operating in saturation
and adjustments made to the turns, if necessary. Th is may result in
more turns than the minimum needed for the required inductance . The
resulting inductance may be higher than is necessary.
The operational flux density for the various core materials can be
obtained from a core manufacturer's catalog . For the purposes of this
manual , the maximum flux densities used will be 17 kilo - gauss for 29M6
material, 8 kilo-gauss for 50/o nickel and 5 kilo-gauss for 8 0/o nickel. If
other materials or flux densities are desirable, the literature should be
consulted .
The formula for determining the turns for a given core is :
Np =
4. 44 x Ac x F x B

Where :

Np
E

= Number of turns
= Voltage appl ied

Ac = Effective core area in square inches

= Lowest frequency of operation
F
Flux density in lines per square inch
B
(Gauss x 6.45 = lines per square inch)
4.44 is a constant
=

page 19

5.2

Construction suggestions

The construction of an audio transformer differs from a regular power

transforme r in that the leakage inductance must be kept as low as
possible.
The interleaving h a s been covered for the lea kage inductance, but the
advantages of interleaving can be offset by i m p roper or sloppy winding .
The windings must be d i rectly a bove one another. The ma rg ins ca l led out
must be ma intained and the winding lengths must be fu lly uti lized . If the
turns a re not sufficient to fil l out the winding length, then the wire must
be spiraled to fil l it out. The ma rg ins for a l l windings must be the same.
If one size wire calls for a 1/4" m a rg in, for instance, then a l l windings
must have 1/4" m a rg ins.
The windings, when layer- wound, must be even and no cross-overs
a l lowed . In bobbin windings, they cannot be in perfect layers, but they
should be wound as evenly as possible.
In genera l , good, high qua l ity workmans h ip is essential for an audio
transformer to m eet the design goals. No matter how g ood the design is,
sloppy construction techniques can result in a failed transformer.
These methods should be cal led out in the construction specifications.
5.3

Calculating the physical parameters

The following design exa m ple is for a simple power transformer. This is
used in order to conserve space. It will demonstrate the princi ples used
for calculations of the turns, winding fi l l and DC resistances of the magnet
wire the same a s for an audio transformer.
It is desired to design a transformer to operate from a 1 1 5 volt line at
60 Hertz and to deliver 6 . 3 volts at 1 0 a m pe res AC. The physica l size is
not g iven .

page

20

Write down a l l information known.

115 v
60 HZ

6.3 v
10 A

Schematic diagram

Ep = 1 1 5 V
60 Hz
F
Es
6.3 V
Is = 1 0 A
=

Calculate the tota l VA :

VA

Es x Is = 6 . 3 x 1 0

63

Calculate the pri m a ry current :

Ip = (VA x 1 . 1 1 ) I Ep = (63 x 1 . 1 1 ) I 1 1 5 = 0 . 0608 A
Choose a core from the La m ination Table in the Appendix. 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 65. This should be a good core for this transformer.

page 21

The manufacturers will g ive the core losses at flux densities in kilo-gauss.
This can be converted to l ines by multi plying by 6.45.
For exa mple, 1 5 K G o r 1 5 0 0 0 gauss x 6.45 = 96750 l ines
The conversion can be done directly in the formula for primary turns by
using the gauss number and adding the 6.45 factor below the line.
The window of the l a m ination is 9/16" x 1 1 1/16" .
area is 1 . 164 square inch.

The effective core

We will choose to try 29M6 g rade laminations with a flux density of 95000
l ines as a starting point. This is 14. 72 KG.
Calculate the pri ma ry turns.

Np =

115 x 10
-------

4.44 x Ac x F x B

4.44 x 1 .1 64 x 60 x 95000

390 T

Calculate the secondary turns.

Ns

N p / Ep x 1 . 0 5 x Es = 390 / 1 1 5 x 1 . 0 5 x 6.3 = 22 .4 turns

Change the turns to an even number or 22 turns.

Choose the wire sizes.
The primary wire should be .608 x 800 circular mils = 486.4. For this we
wil l see that #23 wire is the closest with 509 . 5 c m . See Wire Table in the
Appendix.
The seconda ry wire should be 1 0 x 800 cm
8 0 0 0 . # 1 1 wire has
8234 cm and will be used. It should be noted that this is conservative
and in practice there is room for adjustment up or down, if needed. The
only l i miting factors will be temperature rise and regulation.
=

page 22

Calculate the turns per layer and number of layers.

The window length is 1 1 1/16" long . In order to fit, the coil length should
be 1/16" shorter or 1 5/8" long. From the wire table, it is seen that the
margin for #23 wire should be 1/8" on each end . The ma rgin for # 1 1
wire should be 1/4" on each end. The turns per layer is determined by
the winding length x the turns per inch for that wire size. This is a lso
obta ined from the wire table. The va lues should be put down on the work
sheet clearly to show the construction of the coil .
With a coil length of 1 5/8" , the winding length for #23 wire will be 1 3/8"
and a m a rgin of 1/8" on each end.
The turns per layer will be :
1 3/8" x 37.4 (turns per inch from table) = 52 turns.
Layers = 390 / 52 = 7 . 5 layers. Use 8 .
# 1 1 wire winding length = 1/8", margins 1/4" each end.
Turns per layer = 1 1/8" x 1 0 . 2 = 1 1 turns
Layers = 22 I 1 1 = 2
It should be noted that for a power transformer, the ma rg ins of the
windings do not have to be the same for a l l wind ings.
Figure 5 shows the cross section of a coil with 4 layers. The space
between the layers is, for practical purposes, the layer insulation and the
impregnating compound . The mean length turn is the distance a round
the winding at the center. See Figure 6. In Figure 6, the mean length
turn would be between layers 2 and 3.

lrMLT

-----

Figure 5

Figure 6

page

23

Ca lculate the fil l of the window. This is done by a dding up a l l the various
thicknesses of winding tube, wire diameter, layer insulation and
wrappers. The layer insulation is determined by the thickness needed to
support that particular wire size. Th is is ca lled out in the Wire Table in
the Appendix.
The winding tube thickness is determined by what is needed to support
the co i l . Smal l coils with fine wire need less support than l a rger coils with
heavy wire. This can vary from . 020" to . 070" or more. A coil for the
size used in this exa mple will genera lly 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 exam ple we will use . 0 1 0 " thick insulation, as this is the
value needed to support the # 1 1 wire and, since there a re no unusual l y
high voltages involved, it will be used .
It is now necessa ry to put down on paper the va rious thicknesses, add
them up and ca lcul ate the percentage of available space in the window
that is needed .
This l a m ination h a s a window width of 9/ 16" or, in deci ma ls, . 5625" .
Figure 7 s hows the size of the la mination ( El- 1 12).
1"

32

DIA. HOLES

-ICD ff)ICO
rt')

C\I

Figure 7

page 24

The fi l l can now be calculated :

Winding tube
8 layers #23
Layer ins.
Wra pper
2 layers # 1 1
Layer ins.
Wra pper
Total fi l l

= . 04 0 0
. 1 920
= . 02 1 0
= . 0 10 0
= . 1 858
= . 0 10 0
= . 0 10 0
=

. 4688 I . 5625 x 1 0 0 = 8 3 . 3 /o

This is an acceptable fi l l .
The voltage d ro ps and resistances can now be ca lculated . In order to
obta in the voltage d ro ps in each winding, it is first necessa ry to picture
the build-up of the coil as ca lculated above in the fil l . This build-up is
acco m plished in the fol lowing order:
1.
2.
3.
4.
5.

Winding tube
Pri m a ry wire separated by the layer insulation
Wra pper between windings
Seconda ry wire separated by the layer insulation
Fina l ly , t h e outside wra pper.

The mean length turn can be determined by ta king the bui ld-up and
adding up the va rious sections.
Figure 8 shows a view of the tube upon which the wire is wound .

. 040"

1 1 /8"

.040"

1 1/8,,

Figure 8

page 25

In order to simplify the ca lcul ations it is advisable to reduce the winding

tube to a squa re if it is not a l ready one. This is done by ta king the tota l
distance a round and dividing it by 4.
This wi ll give an equiva lent
dimension of one side only.
For exa m ple, a winding tube that is 1 1/2" x 1 3/4" would be :
1 1/2" x 2 + 1 3/4" x 2
square.

3" + 3 . 5" = 6 . 5 " I 4

1 .625" equiva lent

In the exa mple used the winding tube is a l ready a square so the 1 1/8"
dimension will be the starting point.
Starting with the size of the lamination and adding the winding tube
thickness to each side, the actual dimension of the winding form will be
obtained. The wire and insulation is added on top of this.
Lamination
Tube x 2
8 - #23 wire
Insulation

= 1 . 1250
- . 08 0 0
. 1 920
= . 02 1 0

Tota l

( 1 1/8")

1 .4 1 80

This gives the bui ld-up in one direction of the pri m a ry winding . When this
number is multi pl ied by 4, it will give the length of one turn in the center
of the winding, o r the mean length turn of the pri ma ry wire. Thus,
3 . 75 Ohms. The 1 .6966 is the
1 .4180 x 4 x 390 x 1 .6966 I 1 0 0 0
resistance of this size wire per 1 0 0 0 inches.
=

It should be noted here that this mean length turn va lue is used in the
ca lculation of the winding lea kage inductance of an audio transformer.
The value, 1 .4180, is the bui ld-up to the center of the prima ry winding,
so the primary values must be added in again to get to the sta rt of the
secondary winding . The entire build-up is now repeated to clearly show
the ca lculations.

page 26

Lam .
Tube
8 - #23
Insul

1 . 1250
. 08 0 0
. 1 920
.0210
1 .4 1 8 0 x 4 x 390 x 1 .6966 I 1 00 0

8 - #23
Insul
Wra p
2 - #11
Insul

=
=

3 . 75 x .608

2.28 v

. 1 920
. 02 1 0
. 0 1 00
. 1 858
. 0 1 00
1 . 8368 x 4 x 22 x . 1 0 5 0 I 1 0 0 0

. 0 169 x 1 0

. 169 v

These va lues can be used to determine the output voltage under loaded
conditions. This is done by subtracting the prima ry voltage d rop from the
input voltage and, fro m the turns ratio, obta in the seconda ry voltage.
The secondary voltage d rop is then subtracted from this va lue to obta in
the loaded voltage.
1 1 5 - 2.28

1 12 . 72 v

This is the effective input voltage.

From the turns ratio, 1 12 . 72 / 390 x 22

6.358 V

Subtracting the seconda ry voltage d rop, 6. 358 - . 169

6. 189 V

This is lower than the 6 . 3 V desired so adjustments must be made. This

can be done by adjusting either the primary turns down or the secondary
turns up. This will not be carried any further a s the purpose of this
exa mple is to show how to calcul ate the fill and the resistances of the
windings.
The weight of the wire can be obtained by using the DC resistances.
Referring to the wire table, the weights are given in O h m s per pound.
For exam ple, #23 wire is 12.88 Ohms per pound .
Then the weight is 3 . 75 / 12.88

.29 1 pounds.

page 27

As indicated previously, this exam ple was used only to s h ow the methods
of ca lculating the winding l ayers, turns per layer, fil l and DC resistance.
It can a lso be used as a guide for designing power transformers.
The com plete d esign and construction of power transformer and inductors
can be found in the TRANSFORM ER DESIGN AND MAN UFACTURING
MAN UAL published by the author in 1984.
The methods described above will be used in the foll owing exa mples of
audio transformers.

page 28

PART II. DESIGN EXAMPLES

page 29

PART II. DESIGN EXAMPLES

In the actua l design of an audio transformer it is necessa ry to consider a l l

of the requirements one a t a t i m e . However, many o f these requirements
interact and this w i l l affect the results so they must a l l be kept in mind
while doing the design.
The exam ples that fol low will cover a broad range of aud io transformers.
Some of them will be relatively easy to design and some will be more
difficult and time consuming .
An attempt wi l l be made to go throug h each design, step-by-step,
explaining the thinking as the design progresses.
The calculations of the various parameters will be given and then the
actual transfo rmer will be built and tested. The results will be co mpa red
with the cal cul ated values.
In order to demonstrate the results of interleaving , a design for a 600
watt transformer has been made and built for a 4 Ohm to 200 volt l ine
transformer.
The complete design will not be s hown as the following designs will
thorough ly demonstrate the design and construction of enough types of
audio transformers to suffice.
The l a m ination size is El- 2 1/8" with a 2 1/8" stack. The first design was
not interleaved . It was built with the prima ry first and then the
seconda ry.
The h ig h frequency response was ca lcul ated to be down 3 D B at 9600 Hz.
The measured response was down 3 D B at 1 1 0 0 0 Hz.
The unit was then redesigned and built with a 2: 1 interleaving . The
seconda ry was split in half and the prima ry was put in the center.
The ca lculated 3 DB down-point was 26400 Hz and the measured
frequency was down 3 DB at 3 0 0 0 0 Hz.
The low frequency response was not affected .
The following designs have been ch osen to demonstrate the three most
representative types of aud io transformers.

page 30

EXAMPLE 1: VOICE FREQUENCY TELE P H O N E TRANSFORMER

This exam ple will be for an audio transformer used in a telephone circuit
that has a voice frequency response requirement.
5
600 OHMS

600 OHMS

40---

-.....ge

Circuit Diagram

The pola rity dots indicate the instantaneous pola rity of the windings. This
is im portant in m any audio transformers.
The specifications c a l l for the following:
I m pedances a re 600 Ohms to 600 Ohms
Frequency response is 1 . 0 DB from 300 Hz to 3 5 0 0 H z
Insertion loss i s 1 . 0 D B maximum
Longitudina l ba lance is 60 DB m inimum from 20 Hz to 1 00 0 Hz and
40 DB at 4 0 0 0 H z
Operating level is + 1 0 DBM
TH D at 300 H z = 0 . 5/o maximum
Primary DC current is . 09 0 a m peres
Physica l size is g iven as EI- 3/8" lam ination with a squa re stack to be
wound on a printed circuit bobbin
Primary DC resistance = 5 0 Ohms maximum
Seconda ry DC resistance = 65 Ohms maximum
From page 7, the inductance needed is:

L=

7t F

1989, ROBERT G. WOLPERT, Rev. 2004

600
7t x 3 0 0

---

= .636 HY

page 31

The design for tu rns on the prima ry is done the sa me as for an

ind uctance that ca rries di rect cu rrent. Any method for obtaining the
proper result is satisfactory.
In this case Hanna's cu rves were used to ca lculate the turns and air gap
needed to obtain the proper inductance .
This transformer can be constructed using either 29M6, 50/o nickel or
80/o nickel. 29M6 is the preferred choice, if it will result in the proper
ind uctance and the wire sizes will meet the specification for resistance,
because it is the least expensive.
29M6 will be chosen to sta rt the turns ca lcu lations. From Hanna's curves
for 29M6 core material, the turns will be 1 0 0 0 and the g a p spacer needed
is . 00 5 " .
Since the gap s pacer i s put across both legs and the center E, the spacer
is divided by 2 for a thickness of . 0 025". A spacer of . 00 3 " will be used to
sta rt as this is a standard th ickness of insu lating pa per. This va lue may
have to be a dj u sted when the unit is tested .
The flux density in the core m ust be checked . + 1 0 DBM (+ 1 0 DB in 600
Ohms) is the power leve l . By checking the DB Expressed in Watts Ta ble
in the Appendix, the power level is seen to be . 0 1 watts. The voltage is :
E

\/0 . 0 1 x 600

2.45 V

The flux density i s ca lculated :

B

2.45 x 1 0

4.44

. 13 3 6

300

1000

1376 li nes

213 ga uss

This is a low flux density. In genera l, when using Hanna 's curves, it is
not necessary to calcu late the fl ux density as they a re designed to keep it
within the proper range.
The curves in the Tota l Ha rmonic Distortion Ta ble in the Appendix show
the expected THD for this material and fl ux density. They show that the
THD will be less than . 03/o . This is lower than the required 0 . 5/o.

page 32

The cu rrent is . 0 1 watts d ivided by 2.45 V, which is . 0 04 a m peres.

The . 090 ADC in the pri m a ry and the requ i red resistance will determine
the wire sizes to be used :
. 0 9 x 0 . 7 = . 063 ( 0 . 7 is 700 CM/A)
From the Wire Ta ble in the Ap pendix, #32 AWG can be used, however,
the customer has cal led out the DC resistance and to meet this
requirement, the EI-375 La m ination tu rns ta ble s h ows that #33 AWG will
fit and should m eet the resistance requirement. #34 AWG will be used
for the seconda ry .
I t can be seen from these calculations that 29M6 m aterial will meet the
ind uctance and OCR requirements.
The frequency response will not be difficult to meet, but the longitudinal
balance m ust be considered. This wi ll call for spl itting the prima ry in two
parts a s a 2 : 1 interleave. This will be wound on a bobbin as required by
the customer.
The fo l lowing calculations a re expla ined in Section 5.3
physical pa rameters .

Calculating the

The fill will not be calculated :

The window of the lamination is 5/16" x 3/4"
The winding length of the bobbin is .673" (from manufacturer's cata log)
#33 wire turns per layer = 75 layers

500 / 75 = 6 .66 (use 7)

#34 wire tu rns per layer = 84 layers = 1 00 0 / 84

Bobbin
7- #33
Wra p
12- #34
Wra p
7- #33
Wra p

1 1 . 9 (use 12)

= . 03 0 0
= . 0553
= . 0 060
. 0 840
= . 0 060
= . 0553
= . 0 060
=

. 2426 I . 3 125 = . 776 x 1 0 0

78/o fill

page

33

Ca lculating the DC resistances .

. 3750
. 0600
. 0553
.4903 x 4 x 5 0 0 / 1000 x 1 7.2416
. 0553
. 0 060
. 0840

.6356 x 4 x 1 0 0 0 / 1 00 0 x 2 1 . 7416
. 0840
. 0 060
. 0553
. 7809 x 4 x 5 0 0 I 1000 x 1 7.2416

16.9 Ohms

55.27 Ohms

26.92 Ohms

This is 16.9 + 26. 92

43 . 82 O h ms tota l for the primary, 55.27 Ohms for
the seconda ry . These a re in conform ity with the requirements.
=

The customer ca lled for a 1: 1 turns ratio so the turns cannot be adjusted .
The insertion loss is calculated using the formula from page 1 7:
2

Since the tu rns a re equal, the first va lu e becomes 1 .

page 34

Then:
RT = R2 + Ri = 5 5 .27 + 43 .82

IL =

RT

99 . 09
600

99 . 09

X 1 00 = 16.5/o

If this is interpolated, it wi l l be . 75 DB for 1 5/o , so it is a pproximately

. 82 DB for 1 6 . 5 /o . The requ i rement of 1 . 0 DB will be met. See page 1 7 .
The next requirement to be considered i s the longitud ina l balance. This is
a small transfo rmer with i mpedances of 600 Ohms for both windings.
The size and the low i mpedance makes it easier to meet the
requirements.
There is no easy way to calculate the long itud inal balance, so past
experience mu st be ca l led on. A 2: 1 interleave h a s been chosen. The
high frequency response is only 3 5 00 Hz so that should be no problem
and can be met without interleaving, but the bal ance will require that
voltage g radients be considered.
The 2: 1 interleave will split one winding so that the voltage g rad ient on
each side of the center winding is sma l l .

ov

.sv
ov

I V

I V

If the start of the pri m a ry winding is 0 volt and the finish is 1 volt and the
seconda ry will be the same since they have the same number of turns,
then the center of the pri m a ry will be 0 . 5 volt to 0 volts on the start of
the secondary and a lso 0 . 5 volt to 1 volt to the finish of the seconda ry.
This will result in a difference of 0 . 5 volt from the pri ma ry to both the
start and finish of the second a ry. This will provide a fai rly equ al voltage
g radient. Of cou rse, there a re other paths that can upset a perfect
balance, fo r exa mp le, from windings to core and the d ressing of the
leads.
page

35

Another way to increase the balance is to put sh ields in between the

windings and connect these to g round .
A fu rther increase can be
accomplished by putting in additiona l sh ields and using box shields that
completely enclose both wind ings. These methods a re used in instrument
transformers, where maxi m u m isolation is necessa ry .
This interleaving will resu lt i n a frequency response m uch h igh er than
requ i red for this transformer.
The frequency response can now be ca lculated.
The leakage inductance is calculated using the formula from page 13.
Where:
N
MLT
s

T
H
WL

=
=

=
-

1000
2. 54"
2
. 006"
. 2692"
.673"

Assigning the proper values:

LL -

10 . 6

1000 2

2 . 54

(2

2 x . 006 + .2692)

= .00293

2
9
2 x .673 x 1 0

page 36

The high frequency l i m it is ca lculated :

zT

[J

2
x 600 + 600 = 1 2 0 0

0
1-2 -0_

--

_
_

2 7t x . 00293

652 1 5 H Z

The transformer manufacturing specifications can now be written up and

the unit built and tested .
The frequency response test results were plotted on the curve shown on
page 43. These were run without DC on the pri m a ry and no a i r gap and
with DC and the necessary a i r g a p . They com p a re favorably with the
calculated resu lts .
The insertion l oss measurements were tested to be 0 . 78 DB.
The calculated value was a pproxi mately 0 .82 DB.
The total h a rm onic d i stortion from the curves is 0 . 0 3 /o . The measured
distortion was a p proximately 0 . 0 3/o . This com pa red to the requirement
of 0 . 5/o maxi m u m .
The longitud inal balance test was measured a s - 7 5 DB at 3 0 0 Hz.
requirement was for a m inim u m of - 60 DB.

The

This same transformer was constructed with shields between the primary
ha lves and the secondary to show the i m provement that can be obta ined.
This resulted in a measurement of - 86 DB, an increase of 1 1 DB .

page

37

ROBERT G. WOLPERT

TRANSFORMER DESIGN SERVICES

WINDING SHEET
1

PAGE
SPEC NO.
ENGINEER.
TYPE

OF --=5'---- PAGES

TELEPHONE TRANSFORMER
RGW

DATE 6/24/89

AUDIO 600 OHMS TO 600 OHMS

5/16" x 3/4"
78 O/o NET GROSS
3/8" X 3/8" BOBBIN

WINDOW
COIL BUILD
TUBE ( N ET GROSS)
OVER TUBE

218 GAUSS
300 H Z

DENSITY
FREQUENCY
AREA

0. 1 29
+10 DBM

AT

IN

VOLTS

TERMINALS

-----

r .673"--t
COIL 1

A
A
2

CONN ECT A 'S TOGETH E R AND BLI N D

WINDING
WIRE SIZE
TOTAL TURNS

#33
500

#34
1000

#33
500

.673
BOBBIN WIND

.673
- N O MARGINS

.673

TAPS
WINDING LENGTH
MARGIN
TURNS PER LAYER
%

RANDOM WIND IN

LAYER AS CLOSE

AS POSSIBLE

FILL

NO. OF LAYERS
LAYER INSULATION
WRAPPER
TERM COIL

2L MYLAR
1-A

TAPE
3-4

A-2

START AT

page 38

ROBERT G. WOLPERT

TRANSFORMER DESIGN SERVICES

MATERIAL SHEET
PAG E
SPEC NO.

CORE

PART N O .

AMT.

EI- 3/ 8"
29M6

.1 10#

OF ----'5=--- PAGES

TELEPHONE TRANSFORMER

TO PRICE

TO PRICE

TO PRICE

COPPER

.034#
.026#

#33 MAGNET WIRE

#34 MAGNET WIRE
CAN
LID-T
LID-B
TERMINALS
BOBBIN

3/8" x 3/8"

3/8" x 3/8"

TERM BOARD
LUG PANEL
BKT
LEADS

#1
#2
#3
#4

HORIZ. FRAME
#22 SLW x 7"
LONG

BLACK
BROWN
RED
GREEN

1
1
1
1

NOTES:

page

39

ROBERT G. WOLPERT

TRANSFORMER DESIGN SERVICES

FI NISHING
PAGE
SPEC NO.

LEADS SIZE

#22
#22
#22
#22

SLW
SLW
SLW
SLW

COLOR

BLACK
BROWN
RED
GREEN

OF _s=--- PAG ES

TELEPHONE TRANSFORMER

LENGTH OUT
OF COIL

LEAD#

6"
6"
6"
6"

1
2
3
4

LUGS OR LUG PAN E L :

PART#

LEAD#

SPECIAL INSTRUCTIONS:

page 40

ROBERT G. WOLPERT

TRANSFORMER DESIGN SERVICES

STACKING & ASSEMBLY

PAGE
SPEC NO.

OF

__

PAGES

TELEPHONE TRANSFORMER

LAMINATION :

EI- 3/8"
29M6
3/8"
1x1

SIZ E :
GRADE :
STACK HEIGHT:
INTERLEAVE :
KEEPERS:
CUT OFF E'S :
GAP SPACER:

.003K

BRUISERS:
SIZ E :
SHIELD:
U INSULATO RS :
SIZ E :
BRACKETS -

QTY:

3/8" x 3/8" HORIZONTAL FRAME

HARDWARE :
QTY:
QTY:
QTY:
TO BE REMOV E D

NO

SPECIAL IN STRUCTIONS:
BUTT STACK WITH .003" GAP SPACER
VACUUM VARNISH AFTER ADJUSTING FOR PROPER IN DUCTANCE - LEADS OUT BOTTO M.

page 41

ROBERT G. WOLPERT

TRANSFORMER DESIGN SERVICES

TEST INSTRUCTIO NS
PAGE
SPEC NO.

OF

=
5

__

PAGES

TELEPHONE TRANSFORMER

PROCEDURE
lST TEST

2, 6

2ND TEST

7
s, 6

3RD TEST {AFTER VARNISH)

2, 6, 7

FINAL TEST
1.

NO LOAD VOLTAGE RATIO

HZ TO TERM .

APPLY

MAX.

lex

V TER M .

READ

V TER M .
V TERM.

2.

INDUCTANCE TEST
APPLY

1.0

READ " L"

3.

1000

.636 HY

HZ TO TERM .

1-2

&

0.090

A.D.C.

MIN.

INDUCED VOLTAGE TEST

APPLY

4.

MUST MEG.

5.

H I POT

H Z TO TER M .

FOR

MEGOHMS M I N .

VOLTS D.C.

LEAD NO.
1

TO
3

VOLTS
100

1, 3

CORE
CASE

100

6.

CONTI N U ITY

7.

SPECIAL TESTS

S EC.

Rs
600 o h m s
RL = 6 0 0 o h m s
Frequency response
=

page 42

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..

EXAM PLE 2: AUDIO OUTPUT T RA N S FORMER

Audio a m pl ifiers using vacu um tu bes a re again in favor after a period

where tra nsistors were used excl usively.
Vacuum tubes have a h i g h plate-to- pl ate im pedance while transistor
impeda nces a re usua lly qu ite low. This ma kes the design of tra nsformers
for use with vacu u m tu bes much more d ifficult. The i m peda nces can be
1 00 0 0 oh ms, p late-to-plate and a bove and a re therefore a more difficult
design in order to o bta i n the h i g h frequency response.
The output tra nsformer chosen for this exa mple is a 1 0 0 watt, sine wave
power, unit with a pri m a ry pl ate-to- p late i m pedance of 1250 ohms. The
secondary m ust del iver power to 16, 8, and 4 o h m i m pedances.
The frequency response is to be 1 DB from 20 Hz to 200 0 0 Hz.
The primary is to ha ve screen ta ps for ultra -linear o perati o n . These taps
a re at the 60/o point of the pri m a ry from the center ta p . That is, 60/o of
the plate voltage is a ppl ied to the screens.
See the circuit d i a g ra m .

PLATE
SCREEN

16

SCREEN

OHM

O HM
OHM

COM.

PLATE
Circuit Diagram

page 44

Fi rst it is necessary to choose a core size, if it is not ca l led out by the

customer. As expla ined in page 1 1 , the core size will be a bout the same
a s for a 3 0 0 watt, 60 Hz transformer. Since the wind ings m ust be
interleaved, it will need to have a slightly l a rger core. An EI 1 . 75
lamination with a square stack will be tried.
Area = 1 . 75 x 1 . 7 5 x .92 = 2 . 8 1
The inductance needed will be:
L -

1250

= 1 9 . 89 HY

7t x 20

We will design for 20 HY.

Referring to a m a nufacturer's catalog, the formula for ind uctance for this
l a m ination i s :
L

. 9283 x 1 0

-8

x K x UAc x N

Then using a permea bil ity of 4 0 0 0 for 29M6 materia l :

N =

20

. 9283 x 10

-8

x . 92 x 4000

= 765

A permea bil ity of 4 0 0 0 is a bout rig ht for 29M6 l a minations. The primary
voltage for 1 0 0 watts, 1250 ohms will be :
2

E
W = -_
R
E=

\j 100 x 1250

= 353 V

page 45

The turns for a maxi m u m flux density of 1 7 KG at 20 Hz will be :

N =

3 5 3 x 1 08
4 .44 x 2 . 8 1 x 20 x 1 7000 x 6 . 45

= 1290 T

1 3 0 0 turns w i l l be used.
In this case the turns needed for the ind uctance a re less than those
necessa ry for the fl ux density so the 1 3 0 0 turns w i l l have to be used .
The B+ voltag e will be a pplied to the center of the winding . 60/o of the
voltage will be at 1 3 0 0 / 2 = 650 x .60 = 3 9 0 turns from the center ta p .
This w i l l be 6 5 0 - 3 9 0 = 260 turns from the plate end o f t h e windings.
Seconda ry voltages will be :
16 O H M E =

8 OHM E

4 OHM E

v 1 0 0 x 16
v
v

100 x 8

100 x 4

40 V

28.28 V

20 V

The seconda ry turns will be :

1 300
353

x 1 . 0 5 x 40 = 1 5 5 T
x 28.28 = 1 1 0 T
x 20 = 78 T

The 1 . 05 factor is to compensate for the losses.

page 46

Pri m a ry current :

I =

w
E

Ip =

100

- .283 A

353
Seconda ry cu rrents :

16 OHM -

8 OHM =

4 OHM -

100
40

= 2.5 A

100
= 3 . 53 A
28 . 78

100
20

5.0 A

The configuration must be chosen. This is for the most pa rt, a guessing
ga me, using past experience. A 4 to 5 interleave will be tried for this
design since the pri m a ry can natura l l y be divided into 4 sections in series
and the seconda ry will be wound in 5 sections that will be put in paral lel .
The l a m ination size, the number of turns and the cu rrents a re known and
the configuration has been decided upon, the wire sizes can be chosen.
The primary current is .283 a mperes.
Using 750 CM/A, .283 x . 7 5 0
will be chosen.

.212, so #27 wire with 20 1 circu lar mils

page 47

The seconda ry is d ivided into 5 parts. The l a rgest cu rrent for any one
winding will be for the 4 o h m winding, 5 a m peres d ivided by 5 or 1 A. per
section. Then, 1 x 7 5 0 = . 7 5 0. So #2 1 wire with 8 1 0 circu lary mils will
be used.
.

The following circuit d i agram will s h ow how the wind ing wi l l be done. The
circled num bers indicate the winding sequence.

Winding Diagram

The lead n u mbers shown will be connected so that like n u mbered leads
a re connected together and brought out as one lea d .
For the pri m a ry, leads num bered 1 and 5 will b e the plates. Leads
numbered 2 and 4 will be the screen ta ps. Lea ds n u m bered 3 will be the
center ta p for the B+ voltage.

page 48

For the seconda ry, leads n u m bered 6 will be for the 16 o h m winding .
Leads num bered 7 will be for the 8 o h m winding . Leads num bered 8 will
be for the 4 ohm winding and the nu m ber 9 leads wi l l be the common
point lea d .
The fi l l can now b e calcu lated . The window for the EI 1 . 75 l a m ination is
7/8" wide by 2 5/8" long . The coi l length w i l l be 1/ 16" less than the
window length or 2 9/ 16".
Using the m ethods shown in the exa mple in Section 5 . 3 :
The fi l l w i l l be calcu lated using the winding order a s sh own in the circuit
diagra m on page 48.

page 49

The total turns for the seconda ry a re 1 5 5 . This will be on each seconda ry
winding as they a re to be put in para l l e l . The turns for the prima ry are
split a s s hown on page 47. The circuit dia g ra m s h ows h ow this is done.
The winding length is 2 9/ 16".
1
2
3
4
5
6
7
8
9

#21
#27
#21
#27
#21
#27
#21
#27
#21

wire
wire
wire
wire
wire
wire
wire
wire
wire

turns
turns
turns
turns
turns
turns
turns
turns
turns

per
per
per
per
per
per
per
per
per

layer
layer
layer
layer
layer
layer
layer
layer
layer

=
=
=
=
=

=
=
=
=

52
130
52
130
52
130
52
130
52

Layers
Layers
Layers
Layers
Layers
Layers
Layers
Layers
Layers

=
=
=
=
=
=
=

155 /
260 /
155 /
390 /
1 55 /
390 /
155 /
260 /
= 155 /
=

52
130
52
130
52
130
52
130
52

= 3
= 2
= 3
3
= 3
= 3
= 3
= 2
= 3
=

The winding tu be wi l l be made up of . 040" thick m ate ri a l .

Winding tube
3 layers #21
Layer ins.
Wrapper
2 layers #27
Layer ins.
Wrapper
3 layers #21
Layer ins.
Wrapper
3 layers #27
Layer ins.
Wrapper
3 layers #21
Layer ins.
Wrapper
Layer ins.
3 layers #27
Layer ins.
Wrapper
3 layers #21
Layer ins.
Wrapper
2 layers #27
Layer ins.
Wrapper
3 layers # 2 1 =
Layer ins.
Wrapper
Tota l

=
=
=
=
=
=
=

=
=
=
=
=
=
=

=
=
=

=
=

=
=

=
=

. 0400
. 0903
. 0 100 (2 layers of .005" Kraft pa per)
.0050
.0308
.0020
.0050
. 0903
. 0 1 00
.0050
. 0462
. 0040
.0050
. 0903
. 0 1 00
.0050
. 0 1 00
.0462
.0040
. 0050
.0903
. 0 100
.0050
.0308
. 0020
.0050
.0903
. 0 1 00
. 0 1 00
. 7675 I .8750 x 100 = 86.5/o fi l l

page 50

This fi l l is h ig her than the 85/o idea l, but it will fit with a g ood winding
job.
An audio transformer that is layer wound m u st be wound careful ly. The
margins at the ends of the windings must be ma intained even if it is
necessary to spira l the winding s . This is so that the windings a re d i rectly
above on another and not staggered. Staggering will g reatly increase the
leakage inductance and throw off the ca lculations .
For this transformer the #21 wire at 52 tu rns per layer on the
seconda ries will ta ke 52 x . 0 3 0 1 = 1 . 565" of winding space.
Then, 1 . 565 / 2 . 3 1 25 = 67/o fi l l . So the seconda ry windings will have to
be spira led, h owever, each secondary will have 2 ta ps b rought out and
that will ta ke u p som e space. A little experimentation on the first winding
will result in a properly filled winding space.
The pri m ary windings a re 1 3 0 tu rns per layer of #27 wire .
1 3 0 x . 0 1 54 = 2. 0 02" I 2 . 3 125

86 . 5/o fi ll

Thi is a bout rig ht and there should be no problem in hold ing the
m a rgins .
The DC resistance of the windings can now be ca lculated .
exa m ple on page 27.

See the

1 . 7500
.0800
. 0903
. 0 1 00
1 . 93 0 3 x 4 x 1 5 5 x 1 . 0666 / 1 0 0 0 = 1 . 276 o h m s
. 0 1 00
.0903
. 00 5 0
. 0308
. 0020
2. 0684

page 51

DC resistance calculations, conti nu ed

2. 0684 x 4 x 260 x 4.2891 / 1 0 0 0

9. 226 o h m s

. 0020
. 0308
.0050
. 09 0 3
.0100
2.2065 x 4 x 1 5 5 x 1 . 0666 I 1 0 0 0 = 1 .459 o h m s
. 0 10 0
. 09 0 3
.0050
. 0462
. 0 04 0
2. 3620 x 4 x 3 9 0 x 4.2891 / 1 0 0 0 = 1 5 . 8 0 o h m s
. 0 04 0
. 0462
.0050
. 09 0 3
. 0 10 0
2. 5 1 75 x 4 x 1 5 5 x 1 . 0666 / 1 00 0 = 1 .664 o h m s
. 0 10 0
. 09 0 3
.0050
. 0 462
. 0 040
2.6730 x 4 x 390 x 4.2891 / 1 0 0 0

1 7.88 o h ms

. 0 04 0
. 0462
.0050
. 09 0 3
. 0 10 0
2 . 8285

page

52

DC resistance ca l c u lations, continued

2 . 8285 x 4 x 1 5 5 x 1 . 0666 I 1 0 0 0 = 1 . 87 o h m s
.0100
.0903
.0050
. 0308
. 0 020
2 . 9666 x 4 x 260 x 4.289 1 I 1 0 0 0

1 3 .23 o h ms

2.053 ohms

. 0 020
. 03 0 8
.0050
. 09 0 3
. 0100
3 . 1 047 x 4 x 1 5 5 x 1 . 0666 / 1 0 0 0
The tota l pri m a ry resistance is :
9 . 226 + 1 5 . 80 + 1 7 . 88 + 1 3 .23

56. 13 o h ms.

The voltage d ro p in the pri m a ry is 56. 14 x .283 = 1 5 .88 V.

The seconda ries a re all in para l lel so that the s u m of t h e wind ings will be :
Rs

1
=

--

--

1 . 276

1 . 459

1 .664

1 . 87

2.053

= . 323 OHMS

This will b e for t h e 16 o h m winding .

Calcu late the output voltage :
( 3 5 3 - 1 5 . 88 ) I 1 3 0 0 x 1 5 5 = 40 . 1 9 5 - .809 = 3 9 . 3 8 v
In order to increase the output to the desired 4 0 volts, the secondary
turns should be increased to 1 57 . Then the output w i l l be 3 9 . 9 V .

page 53

The other ta ps can be calculated rapidly by ta king a percentage of the

total wind ing .
For the 8 o h m wind ing it will be 1 1 0 I 1 57 x . 323
. 226 o h m s .
Then .226 x 3 . 53 = . 798 V d rop.
(353 - 1 5 . 88) / 1 3 0 0 x 1 1 0 = 28 . 52 - . 798
2 7 . 72 v.
Adjusting for 28.28 V = 1 12 turns.
=

For the 4 o h m winding it wil l be 78 / 1 57 x . 32 3 = . 16 0 o h m s

Then, . 1 60 x 5
.802 V d ro p .
( 3 5 3 - 1 5 . 88 ) I 1 3 0 0 x 78 = 20 .22 - . 8 02 = 1 9 .42 v .
Adjusting for 2 0 V
8 0 turns.
=

These a dj ustments w i l l result in a s m a l l change in the DC resistances, but

it won't be necessa ry to go back and m a ke a l l the new calculations.
Calculate the leakage ind uctance using the formu l a from page 1 3 .
N
MLT

WL
s
T

LL

1300
2 . 5 1 75 x 4 = 1 0 . 07
2.3125
4 ( interleaves)
.005
. 7675

(from the center winding )

2
1 0 .6 x 1 3 0 0 x 1 0 . 0 7 x (2 x 4 x . 00 5
2
9
4 x 2 . 3 125 x 1 0

. 7675)

. 003 93 HY

For the h i g h frequency response :

2
1300
1 57

7t

x 16 + 1250 = 2347

2347
= 9 5 095
x . 00 3 9 3

page 54

This calculates to be 0 . K .
The design is now ready to write u p th e manufacturing specifications and
build and test the unit.
The g ra p h on page 61 shows the frequency response test results.

page 55

ROBERT G. WOLPERT

TRANSFORMER DESIGN SERVICES

WINDING SH EET
PAG E

1 - OF -=
S

_
_

__

PAG ES

SPEC NO. AU_D_I_O_OUTP_UT

ENGINEER.

DATE 6_/25/_8_9-

RGW

TYPE 1 250 OHMS TO 16, 8, 4 O H MS. 100 WATTS

7 /8" x 2 5/8"

WINDOW

86 O/o

COIL BUILD

NET G ROSS

1 3/4" x 1 3 / 4" x .040

TUBE (NET GROSS)

OVER TUBE
D ENSITY

17 KG

FREQUENCY

20 HZ

AREA

2.81

AT

IN

353
r-2 9/ 16'

_,,,.- s

-.....

VOLTS

1- -1

COIL 1

4
4
2
2

3
3

3/4

CONN ECT LIKE NUMB ERED LEADS TOGETHER; WHEN WINDING #21 WIRE, HOLD TO
1/8" MARGINS EVEN IF YOU HAVE TO SPIRAL WIND. HOLD ALL MARGINS TO 1/8".
WINDING
WIRE SIZE
TOTAL TURNS
TAPS
WINDING
LENGTH
MARGIN
TURNS PER
LAYER
% FILL
NO. OF
LAYERS
LAYER
INSULATION
WRAPPER
TERM COIL

#21
157
82,1 10

#27
260

#21
157
82,1 10

#27
390

#21
157
82,1 10

#27
390

#21
157
82,110

#27
260

#21
157
82,1 10

2 5/16"

2 5/16"

2 5/16"

2 5/16"

2 5/16"

2 5/16"

2 5/16"

2 5/16"

2 5/16"

1/8"

1/8"

1/8"

1/8"

1/8"

1/8"

1/8"

1/8"

1/8"

53

130

53

130

53

130

53

130

53

700/o

87/o

70/o

87%

70%

87/o

70/o

87/o

70%

.005K

.002K

.005K

.002K

.005K

.002K

.005K

.002K

.005K

--

--

--

--

ll -

ll -

ll -

ll -

ll -

ll -

ll -

ll -

ll -

.005K
6, 7,
8, 9

.005K
1-2

.005K
6, 7,
8, 9

.005K
2-3

.005K
6, , 7,
8, 9

.005K
3-4

.005K
6, 7,
8, 9

.005K

.005K
6, 7,
8, 9

4-5

START AT

page 56

RO BERT G. WOLP ERT

TRANSFORMER DESIGN SERVICES

MATERIAL SH EET
PAGE
SPEC N O .

CORE

PART N O .

AMT.

EI- 1 3/4"
29M6

8.7#

OF

__

PAGES

A
D IO
U
U
=-=..
O""""
...._.. U
....T

.. P
....
T

.. -

_
_
_

TO
PRICE

TO PRICE

TO PRICE

COPPER

1.63#
0.68#

#21 MAGNET WIRE

#27 MAGNET WIRE

CAN
LID-T
LI D - B
TERMINALS
TUBE

1 3/4" x 1 3/4" x .040

x 2 9 / 1 6" LONG

TERM BOARD
LUG PAN E L
BKT
BOLTS
NUTS
WASH ERS
WAS H E RS
LEADS

#1
#2
#3
#4
#5
#6
#7
#8
#9

1 3/4" HORIZ. "L"

#10 x 2"
#10
# 1 0 STEEL
#10 FIBER

4
4
4
8
4

#20 SLW x 10" LONG

BLACK
BROWN
RED
YELLOW
G REEN
BLUE
ORANGE
W H ITE
VIOLET

1
1
1
1
1
1
1
1
1

NOTES:

page 57

ROBERT G. WOLPERT

TRANSFORMER DESIGN SERVICES

FINISHING
PAG E

OF --=5.___ PAG ES

SPEC N O . -

--=A
..:.U
:.
.; =
D
.: =
I0
:-.
0;..;:
.: U
....
T
'--=. P....;:
U
::...
: T.__
.:: _

LEADS SIZE

#20 SLW
#20 SLW
#20 SLW
#20 SLW
#20 SLW
#20 SLW
#20 SLW
#20 SLW
#20 SLW

COLOR

LEN GTH OUT

OF COIL

LEAD#

8"
8"
8"
8"
8"
8"
8"
8"
8"

1
2
3
4
5
6
7
8
9

BLACK
BROWN
RED
YELLOW
GREEN
BLUE
ORANGE
WHITE
VIOLET

LUGS OR LUG PAN EL:

PART#

LEAD#

SPECIAL IN STRUCTI O N S :

FINISH ALL LIKE NUMBERED LEADS TOGETHER.

page 58

ROBERT G. WOLPERT

TRANSFORMER DESIGN SERVICES

STACKING & ASS EMBLY

PAGE
SPEC NO.

=
5__ PAGES

"""'""
D__
I"' o
""""-=
o....
u....
.. T
....
.P
....
... U
._.
.. T
AU

_
__

_
_
_

LAMINATION:
SIZE :

OF

_
_

EI- 1 3/4"
29M 6
1 3/4"
lxl
2

GRADE:
STACK H EIGHT:
INTERLEAVE:
KEEPERS:
CUT OFF E'S:
GAP SPACER:
BRUISERS:
SIZE:
SHIELD:
U INSULATORS:
SIZE:
BRACKETS -

QTY:

1 3/4" HORIZONTAL "L"

QTY:
QTY:

4
4
8
4

BOLTS #10-32
NUTS # 10-32
WASHERS # 10 STEEL
WASH ERS #10 FIBER
NO

HARDWARE:

QTY:
QTY:
TO BE REMOVED

SPECIAL INSTRUCTIONS:

VACUUM VARNISH

page 59

ROBERT G. WOLPERT

TRANSFORMER DESIGN SERVICES

TEST INSTRUCTIONS
PAGE

OF

-=
S_
_ PAGES

SPEC NO. -------=A=U=D=IO:.....:=OUT!..:.P..,UT:...-_

PROCEDURE
6

1ST TEST
2ND TEST
3RD TEST
FINAL TEST (AFTER VARN ISH)
1.

7
--

s,

NO LOAD VOLTAGE RATIO

APPLY

H Z TO TERM .

READ

lex

MAX.

V TERM.
V TERM.
V TERM.

2.

INDUCTANCE TEST
APPLY

READ " L"

HZ TO TERM .

&

A.D.C.

MIN.

I N DUCED VOLTA G E TEST

3.

APPLY
4.

M UST M EG .

5.

HI POT

LEAD NO.
1

6.

CONTI N UITY

7.

SPECIAL TESTS :

FOR

M EGOHMS M I N .

1, 6

Rs

H Z TO TER M .

VO LTS D.C.

TO

VOLTS
1000

CORE
CASE

1000

SEC.

1250 ohms

RL = 1 6 ohms
Test is made across the entire secondary.
Test results on the fo l lowing page.

page 60

>
u
z
w
::::>
O'
w
a:
I.Lo

-1-1-4--'--+- 1 -' -

t:=I----

2 .

>- .
'
1-- -

10 1
9._

r::-

:: """"
;_...:._
- -=

7
" .... -

- ._ f

!. _.:C .-

++-'-++++;
a
- --r-r 1:---

+T
...!- ! -

J -

- .

.. ... t

-++-+-+-t--+-t

"!''

!.

...... .... ........

._ __,
--

-- .

_l

.. L.
r..

,.

.I

, _ - ..._

0
'l"4

- - --i---

__

- __

'f .::

:;

>--- - ---- I------- --

-1-i- -

. . . : t = ...

..

::: :...-

.... =

...

0
N
I

-:::: -

:=. .:.:.!.:: .

..... : ::.:-
::.:..:: :.;::::::: =:::t=
.

--

--

__

f--. --

. ... .

. . ..

--.

EXA M PLE 3:

LIN E -TO-VOICE COIL TRANSFO R M E R

Li ne-to-voice co i l t ransformers a re widely used in the tra nsm ission of

m usic and for pu blic a d d ress systems . A d esign for this ty pe transformer
is one of the m ost d ifficult to o bta i n . The foll owing exa m ple will s h ow the
design of a typ ica l l i n e-to-voice coil tra nsformer.
The req u i re ments for this u n it a re :
7 0 . 7 volt l i n e to 4 , 8 a n d 16 o h m s output with power ratings o f 8, 16 a nd
32 watts. The freq uency response is 1 D B from 3 0 Hz to 1 5 000 H z.
Insertion loss of 0 . 5 D B ma xi m u m .

---0

16 OHMS

lo------o 8

OHMS

Circuit Diagram

Connections to the a ppro p riate leads will g ive the desired wattage and
output im pedance.
Since this unit w i l l be a bout 3 DB down at 15 Hz ( - 1 DB at 30 Hz), it will
require a l a m i nation that ca n support a bout 32 watts x 4
1 28 VA at 60
Hz.
=

By dividing 60 H z by 15 Hz, a factor of 4 is o bta ined for power

req uire ments of the l a m ination for this transformer.
From the La m ination Table in the Appendix, E l- 1 1/4" x 1 1/4" is good
for 90 VA.
A 1 1/2" stack of this size l a m ination should be a bout rig ht as a starting
point for 1 28 VA.

page 62

The pri m a ry i m peda n ces ca n be ca lculated from O h m 's law.

Z =

70.7
32

70.7
16

70.7
8

2
=

156

312

625

Then calcu late the pri m a ry ind ucta nce necessary, from page 7 . For the
32 watt prim a ry . Thi s winding is used as it will h a ve the least n u m ber of
tu rns a n d , as s h own later, the maxi m u m flux density m u st be ca lculated
for this wi nding .
L

---

7t

1 56

30

7t

= 1 . 65 HY

30

From the m a n u factu rer's cata log for this l a m ination :

L

. 66 5 x 1 0

-8

x K x UAc x N

For a 1 1/2" stack it will be cha nged

This form ula is for a square stack.

by a ratio of 1 . 5 / 1 . 2 5
1 .2.
=

The formu l a wil l then be :

L

. 665 x 1 0

-8

x 1 . 2 x K x UAc x N

Using a perm e a b i lity of 4000 for M6 l a mination :

N

/.-

1 . 665

. 665 x 1 . 2 x . 9 2 x 4000 x l O

237

page 63

These a re the tu rns n eeded for the 3 2 watt winding to obtain the proper
ind ucta nce.
The a rea of this core is 1 1/4 x 1 1/2 x .92 = 1 . 725 sq. i n .
A reasona bl e fl ux density i s a bout 1 5 KG o r 96750 lines . Using this flux
density and ca lcu lating the tu rns needed from the formula on page 1 9 :
70.7 x 10

N =

= 318

4 . 44 x 1 . 7 2 5 x 30 x 96750
It ca n be seen that 237 turns as calcu lated for the inducta nce will result
in too high a flux density, so the 3 1 S turns must be used for the 32 watt
wind i n g . As m entioned before, this winding has the lowest n u m ber of
tu rns a n d 70. 7 volts wi l l be a pplied to a l l the pri m a ry windings as they
a re used .
By ta king 3 1 S turns for the 32 watt winding, since the tu rns ratio is the
sq uare root of the i mpeda nces ratio, the tu rns for the other ta ps on the
pri m a ry wil l be :

x 3 1 S = 450
\! ---&---

16 w =

S W =

\/
-Tst- x 3 1 S = 636

The turns for the secondaries ca n now be ca lculated . By ta king the 3 1 S

turns fo r 32 watts, t h e tu rns for the secondaries wil l be :

\/
x 3 1S = 5 1

4 0H M =

\/;---;156 - x 3 1 S = 72

S OH M =

--N- x 3 1 S = 1 0 2
\/

16 0HM =

page 64

The confi g u ration a s shown later will resu lt i n a cha nge of turns in both
the pri m a ry a n d secondary .
The configuration m ust now be considered . It is advisable to split the
pri m a ry so that a 2 : 1 i nterleave is achieved . By spl itting the primary in
the center of the low i m pedan ce winding (32 watts) and adj usting the
winding confi g u ration of the pri m a ry and secondary, the m i n i m u m voltage
g radient ca n be o bta i n ed .
If the 3 1 8 turns ca n be s p l it into 159 + 1 59 a nd then put the 4 watt
winding in between . The 4 watt winding is 52 turns.
This is s p l it i nto 26 + 2 6 .
So we now have 1 59 T pri m a ry ; 2 6 T secondary
pri m a ry.

26 T secondary ; 159 T

We need 3 1 8 turns mo re on the pri m a ry a nd 52 mo re tu rns on

secondary. In o rd e r to p reserve the voltage g ra d ients a nd split
windings even ly, the additional pri m a ry turns should be d ivided
added at each e n d . The additional secondary turns should be put in
center of the secondary .

the
the
and
the

Then the winding configuration w i l l be :

1 59 T + 1 5 9 T; 26 T + 2 6 T + 2 6 T + 2 6 T; 1 59 T + 1 59 T.
This will give the tota l pri m a ry turns and seco n d a ry turns. It re mains to
n u m ber these windings so they wi l l be connected p roperl y .

1 5 9 + 1 59;

26 + 26 + 26 +

2-3

7-B

3-A

5-6

6 -7

26;
B-8

1 5 9 + 159
A-4

1-2

0 0 0 0 0

page 65

This circu it d i a g ra m will show how the wind ing s a re interleaved. The
ci rcled n u m bers in the d i a g ra m show the o rder i n w h ich the windings will
be woun d .

Circuit Diagram

The p ri m a ry w i l l be :
3-A, A-4 = 3 1 8 turns for 3 2 watts
2-3-A-4 = 477 turns for 1 6 watts
1 - 2 - 3-A-4

6 3 6 turns for 8 watts

Si nce 2 - 3 3-A a re together they ca n be wound a s o ne winding of 3 1 8

turns ta p ped a t 1 5 9 t u rns a n d not be separate wind ing s .
The secondary w i l l be :
5 - 6 + 6 - 7 + 7 - B + B-8
6-7 + 7 - B + B-8

1 04 turns for 1 6 o h m s

7 8 t u rns for 8 o h m s

7 - B + B-8 = 5 2 turns for 4 o h ms

This will resu lt i n t h e correct turns for the 8 watt a n d 3 2 watt windings,
but the 1 6 watt w i l l be 477 turns. This is a d eviation of 6/o wh ich is
acceptable. Also, the secondary tu rns have a l so been adjusted and will
result i n a d eviation for the 8 ohm winding of a pprox i mately 6 /o .

page 66

The next step is to determine the wire sizes a nd ca lculate the fi l l .

The highest cu rrent i n the pri ma ry wi l l be i n the 3 2 watt winding .
I =

w
--

32
70 . 7

= . 4 5 2A 3 2 W

16
70.7

= . 2 2 6A 1 6 w

8
70.7

= . 1 1 3A 8 W

The h ig hest cu rrent in the secondary winding w i l l b e th e 4 o h m winding

and at 32 watts.

I =

(32
V u;-

= 2 .82 A 4 0 H M

= 2.0 A B OHM

= 1 .41 A 1 6 OHM

#26 AWG wire wi l l be 254 / 452 = 562 CM/A for the pri m a ry .
# 1 6 AWG wire wi l l be 1 . 6 24 / 2 . 8 2 = 575 CM/A for the secondary .

These sizes a re s m a ller than suggested previously, b u t w i l l be sufficient,

as they a re worst case for 32 watts and 4 o h m s .

page 67

CALCU LATE THE FILL

The window for this size l a m i nation is 5/8 " x 1 7 /8".
should be 1/32" s h o rter tha n the window.
Coil length

The coil length

1 27/32"

#26 winding length

1 1 9/32", the m a rgins wi ll be 1/8" each end .
Turns per layer
8 0 (from the Wire Ta ble in the Appendix)
4
Layers
3 1 8 I 80
=

# 1 6 winding length
1 19/32", the m a rg ins will be 1/8" each end .
Turns per layer
26
Layers
26 / 26
1
=

# 1 6,
# 1 6,
# 1 6,
#26,
#26,

26
26
26
80
80

turns
1 layer
turns
1 layer
turns
1 layer
tu rns per layer
tu rns per layer
=
=

=
=

159 I 80
159 I 80

=
=

2 layers
2 layers

The fi l l ca n now be ca lculated using the configuration o n page 67.

=

Winding tube
4 L #26 wire
Layer ins.
Wrap
1 L # 1 6 wire
Wra p
1 L # 1 6 wire
Wra p
1 L # 1 6 wire
Wra p
2 L #26 wire
Layer ins.
Wrap
2 L #26 wire
Layer ins.
Wrap
Total

=
=
=

=
=
=
=
=
=
=
=
=
=
=
=

. 0400
. 0 684
. 0090
. 0 100
. 0527
. 0 100
. 0527
. 0 100
. 0527
. 0 100
. 0 342
. 0060
. 0 100
. 0 342
. 0060
.0100

( 3 layers of . 0 0 3 " Kraft pa per)

K
K
K
K
K
K
K
K

.4265 I . 62 5

100

70/o fi ll

This fi l l is 0. K.

page 68

The winding resista nces can now be ca lculated (see page 2 6 ) .

From t h e fi l l figu res a n d t h e l a m ination size :
The equivalent of a square tube will be 1 . 2 5 + 1 . 5
Core

2.75 / 2

1 . 3 75.

1 . 3750
. 0800
.0684
.0900
1 . 5 324

318 / 1000

26 / 1000

. 3 346

. 0 582 ohms

26 / 1000

. 3 346

. 0 612 ohms

2 6 / 1000

. 3 346

.0652 ohms

26 / 1000

. 3 346

. 0693 ohms

159 / 1000

3 .4008

4 . 5 2 3 ohms

159 I 1000

3 . 4008

4 . 706 ohms

3 .4005

6 . 628 o h m s

. 0090
.0684
.0100
. 0 527
1 . 6725
.0527
. 0 100
.0527
1 . 7609
. 0 527
. 0 100
.0527
1 . 8763
. 0 527
. 0 100
.0527
1.9917
.0527
. 0 100
. 0342
.0030
2.0916
.0030
. 0342
. 0 100
. 0342
.0030
2 . 1 760

page 69

The mean length turn wi l l be i n the center of the windings wh ich wi l l be

7.5".
This will be used in calcul ating the leakage
1 . 8 763 x 4
inducta nce.
=

This winding confi g u ration has a l l of the seconda ries in between the
pri m a ries, so a 2 to 1 interleave wi l l be used .
From page 1 3, the form ula for leakage ind ucta nce, using the val ues for
this tra nsformer is:

10.6

(636) 2

7.5
22

1 . 593

109

(2

. 0 10

.4265)
=

.00235

W h ere :
5

WL
T
H
M LT

2
1 1 9/32
.010
.4265
7.5
636 (the tota l pri m a ry turns)

The high frequency response ca n be ca lculated using this value of leakage

ind uctance.

ZT

F2 -

636
1 04

1 6 + 625

1 2 23
2

7t

x .00235

1 223

82895 HZ

page

70

It should be noted that this h a s been ca lcul ated using the entire pri mary
and secondary . W h e n taps a re used for different wattages and outputs,
the h i g h freq uency res ponse will not be as g ood .
This is d ue to the windings that a re not used ca using the effective
leakage inductance to be d ifferent. This is difficult to calcu late a nd , when
the u pper end is beyond the req uirements, it wi l l not be attempted .
However, it wi l l be tested a n d the results put on the frequency response
g ra p h to show the diffe re nce.
The in sertion loss requ i rement is for 0 . 5 DB m a xi m u m . From page 64,
the tota l pri m a ry turns a re 636. The tota l secondary turns a re 1 04 .
By adding t h e resistances, as ca lcu lated o n page 6 9 , t h e total primary
resista nce is 6 . 28 + 4 . 523 + 4. 706
1 5 . 5 ohms.
=

The total seco n d a ry resista nce is :

. 0582 + . 0 6 1 2

RT

. 0652 + . 0693

t:rx
IL

RT
Z1

R2 + R i

X 100

25
625

. 2539 .

tr
636
104

x 100

x . 2 54 + 1 5 . 5

25

410

Referring to page 1 7 , this being less than 1 010 , it w i l l m eet the 0 . 5 DB

maxi m u m .
The insertion l oss will be different for the d ifferent ta ps. This makes it
necessa ry to ca lcul ate what probably is the worst case. This is for 32
watts a n d 4 o h ms as they a re the windings that w i l l ca rry the hig hest
cu rrent.

page 71

Using the resista nce of the 3 2 watt winding, 3-A, A-4 :

3-A w i l l be 6 . 628 / 3 1 8 x 1 59 = 3 . 3 1 4
A-4 is 4. 523
The tota l will be 3 . 3 1 4 + 4 . 523 = 7 . 84 ohms. Th is is for 3 1 8 tu rns.
The 4 o h m winding is 7 - B, B-8.
7-B = . 0 582
B-8 = . 0 693
. 0 582

. 0693

. 1 2 7 5 o h ms.

This is for 5 2 turns. The i m peda nce for 32 watt is 1 56 o h m s .

Then :

RT

IL

[ ]
52
L J

31s

12.60
156

x . 1 2 7 5 + 7 . 84 = 1 2 . 6 0

100

8. 08/o

This is a lso less t ha n 1 0 /o for the 0 . 5 DB m a xi m u m .

The design i s now co m plete a n d the man ufactu rin g s pecifications ca n be
written up, the u n i t built a n d tested .

page

72

ROBERT G. WOLPERT

TRANSFORMER DESIGN SERVICES

WINDING SH EET
PAGE

5__ PAGES
OF -

SPEC N O . ----=L=l=N=E,_T.::...;O=-=V....;::O=l=C=E--=C=O=l=L=--ENGINEER.
TYPE

DATE

RGW

6/20/89

AUDIO
32W. 1 6W, SW TO 4, 8, 16 OHMS

5/8" x 1 7/8"
70 O/o NET GROSS
1 1/4" X 1 1 / 2" X .040 K

WINDOW
COIL BUILD
TUBE ( N ET GROSS)
OVER TUBE

15 KG
30 HZ

DENSITY
FREQUENCY
AREA

1.725
70.7

AT

IN

VOLTS

TERMINALS

1 27/32"

2
2
3
A
A
4

7
8

----

COIL 1

B
B

----

1- - 1

6
A

HOLD ALL MARGINS TO 1/8"

A's, B's, 2's &. 7's CON N ECT TOGETHER
WINDING
WIRE SIZE
TOTAL TURNS
TAPS
WINDING LENGTH
MARGIN
TURNS PER LAYER
% FILL
NO. OF LAYERS
LAYER
INSULATION
WRAPPER
TERM COIL
START AT

#2 6

# 16

# 16

#1 6

# 16

#2 6

#2 6

3 18

26

26

26

26

159

159

159
1 19/32"

--

--

--

--

--

1 19/32"

1 19/32"

1 19/32"

1 19/32"

1 19/32"

1 19/32"

1 8"

1 8"

1 8"

1 8"

1 8"

1 8"

1 8"

80

26
86/o

26

26

86%

26
86/o

86%

86%

80
86/o

86%

.003K

--

--

--

--

.003K

.003K

ll -

ll .OlOK

ll .OlOK

ll .OlOK

1L .OlOK

ll .OlOK

7-B

5-6

6-7

B -8

A-4

ll .OlOK
1 -2

.OlOK
2-3-A

--

80

page

73

ROBERT G. WOLPERT

TRANSFORMER DESIGN SERVICES

MATERIAL SHEET
PAGE

OF _5""--- PAGES

SPEC N O . =L=INE=-=-TOVO==IC=E=-=C=O=IL=---

CORE

PART NO.

AMT.

EI- 1 1/4"
29M6

3.75#

COPPER
#26 MAGNET WIRE
#16 MAGNET WIRE
CAN

TO
PRICE

TO
PRICE

TO
PRICE

0.3#
0.5#

LID-T
LID-B
TERMINALS
TUBE

1 1/4" x 1 1/2" x .040

x 1 27/3 2" LONG

1 1/4" HORIZ. "L"

#8-32 X 2" LONG
#8-32
#8 STEEL
#8 FIBER

4
4
4
8
4

TERM BOARD
LUG PAN EL
BKT
BOLTS
N UTS
WASHERS
WASHERS
LEADS

#1
#2
#3
#4
LEADS

#5
#6
#7
#8

#20 SLW

BLACK
BROWN
RED
O RANGE
# 16 SLW
YELLOW
G RE E N
BLUE
VIOLET

10" LONG

1
1
1
1

10" LONG

1
1
1
1

NOTES :

page 74

ROBERT G. WOLPERT

TRANSFORMER DESIGN SERVICES

FIN ISHING
PAGE

O F ----'5=-- PAGES

SPEC N O . --=L=IN=ETOVO=I=C=EC=O=I=L=--LEADS SIZE

#20 SLW
#20 SLW
#20 SLW
#20 SLW
# 1 6 SLW
#16 SLW
# 1 6 SLW
# 1 6 SLW

COLOR

BLACK
BROWN
RED
ORANGE
YELLOW
GREEN
BLUE
VIOLET

LENGTH OUT
O F COIL

LEAD #

8"
8"
8"
8"

1
2
3
4
5
6
7
8

LUGS OR LUG PAN EL:

PART #

LEAD #

SPECIAL INSTRUCTIONS:

CONNECT ALL LIKE NUM BERED AND LETTERED LEADS TOG ETHER.
BLIND A's & B's

page 75

ROBERT G. WOLPERT

TRANSFORMER DESIGN SERVICES

STACKING & ASS E M BLY

PAGE
SPEC N O .
LAMI NATION:

O F 5- PAGES

I.. L--LI
-..-N
....-.
E.. TO
-=--....-. V
....
O
....
.. I..
.. C....,. E....C
=... O
....=

_
_
__

EI- 1 1/4"
29M6
1 1 / 2"
1x1
2

SIZE:
GRADE :
STACK H EIGHT:
INTERLEAVE:
KEEPERS :
CUT OFF E'S:
GAP SPACER :
BRUISERS:
SIZE:
SHIELD :
U INSULATORS:
SIZE :
BRACKETS -

QTY:

1 1/4" HORIZONTAL " L"

Q TY:
Q TY:

4
4
8
4

BOLTS 8-32 x 2"

NUTS 8- 32
#8 WASHERS, STEEL
#8 WASHERS, FIBER
NO

HARDWARE:

QTY:
QTY:
TO BE REMOVED

SPECIAL INSTRUCTI O N S :

VACUU M VARNISH

page 76

ROBERT G. WOLPERT

TRANSFORMER DESIGN SERVICES

TEST INSTRUCTIO NS
PAGE
SPEC N O .

OF -=
5

__

PAGES

I=

L=
IN
..
E
...=. T

O
==
IC
="'"-"'
E C
OV
O
L

_
_

PROCEDURE
6

1ST TEST

2ND TEST

--

3RD TEST

6, 5

FINAL TEST (AFTER VARNISH)

NO LOAD VOLTAGE RATIO

1.

APPLY

HZ TO TER M .

lex

MAX.

V TERM.

READ

V TERM.
V TERM.

2.

INDUCTANCE TEST
APPLY
READ " L"

APPLY
4.

M UST M EG .

5.

H I POT

A. D.C.

MIN.

VOLTS
500

1,5

CORE
CASE

500

SPECIAL TESTS:

SEC.
VOLTS D.C.

TO
5

7.

FOR

LEAD NO.
1

CONTINUITY

H Z TO TERM .
M EGOHMS M I N .

6.

RL

&

INDUCED VOLTAGE TEST

3.

Rs

H Z TO TERM .

625 ohms
16 ohms

Test across the total primary and secondary.

Test results on the fol lowing page.

page 77

i i

--- .

_-r-r
.__ r
- --

- -

-t.:..t-

1-

-r'

. t.

f.
-

, _

I-

>
u
z
w
:::>
O'
w
a:
u..

'

- t.._ - + +--
-

-1 -1,__ -'---

-. !-- - -

:t.

I-

1 1-+->--<-1- - I

a::i
Q

_,

}-

f
.

.__t-I-

__

r. - -- ;

..

. t-t-:t-1---.
t- t-
t--r-t--1
-;- -r- I- -t'
- --

--

__.. _
.. ..
-....

-t-

- .. __ --

..:._-._.:f.::t:=_t= -

_..__L-1-- - +
++
..,
r-1-+
--1
'-1 ........
..... ,....
............

1
....j
l....
1
'
1
.
..
-=
:.::
.
1- 1-1-1.-, l-l-l. .
-1I t
f
- -- -

0
N
I

A PPEN DIX

page 7 9

SYMBOLS U S E D
Ac
B

Ei

E2

Fi

F2

11

12

K
L
LL

Effective area of core in sq. inches.

Flux density in Gauss
P rimary voltage
Secondary voltage
Freq uency
Low frequency limit
High frequency limit
Winding build - u p
Primary cu rrent in am peres
Secondary cu rrent in am peres
Stacking factor
Primary open circuit ind uctance in Henrys
Leakage ind uctance in Henrys

MLT=

Mean length turn in inches

Ni

Prim ary turns

N2
n
Ri
R2
RT

s
T

Secondary turns
N u m ber of layers
DC resistance of primary
D C resistance of secondary
Total or normalized resistance
N u m ber of sections or interleaves
Thickness of insu lation in inches

UAc =

Incremental permeability of core m aterial

Power in Watts

WL =

Winding length in inches

Z1

Primary i mpedance

Secondary im pedance

Total or norm alized imped ance

Z2
ZT

page 80

D B EXPRESSE D I N WATTS

DB

M IC RO-WATTS

-80
-70
-60

0 . 0000 1
0 . 00 0 1
0.001
0.01
0.1
1.0
10.0
1 2 . 26
lS.9
20.0
2S . 1
31.6
39.8
S0. 1
63 . 1
7 9. 4
100.0
126.0
159.0
200.0
2S1.0
3 1 6.0
398 . 0
SOl.O
63 1 . 0
794. 0
1 000 . 0

-so

-40
-30
-20
- 19
-18
-17
- 16
-ls
-14
-13
-12
-11
-10
- 9
- 8
- 7
- 6
- s
- 4
- 3
- 2
- 1
- 0

DB

0.0
1.0
2.0
3.0
4.0
s.o

6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
lS.O
16.0
17.0
18.0
19.0
20.0
30.0
40.0
so.a

60. 0
70.0
80.0

WATTS

0 . 00 1
0 . 00 1 3
0 . 00 1 6
0.002
0 . 002S
0 . 0032
0 . 004
o . oos

0 . 0063
0 . 0 079
0.01
0 . 0 126
0 . 0 1 S9
0.02
0 . 02S
0.0316
0 . 0398
o . oso

0 . 063
0 . 079
0.10
1.0
10.0
100.0
1 0 0 0 .0
10 000. 0
1 00000. 0

page 81

WIRE TABLE

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

OHM S/
1000"
1 39 . 0 0
1 10 . 2 5
87.42
69.32
54.97
43.59
34. 56
27.42
21 . 74
1 7 . 24
13.67
1 0 . 84
8.60
6.82
5.41
4 . 29
3 .40
2 . 70
2 . 14
1 . 70
1 . 34 5
1 . 067
. 8458
. 6709
.5320
.4220
. 3 346
. 26 5 3
. 2 1 04
. 1 669
. 1323
. 1 050
.0833
.0660
. 0 5 24

I NS U L

. 0007
. 0007
. 0007
. 0007
.001
.001
.001
.001
.001
.0015
.0015
.0015
.0015
.0015
.0015
.002
.002
.002
. 002
.003
.003
. 003
.005
.005
.007
.007
.010
.010
.010
.010
.010
.010
.010
.010
.010

MARGIN

1/ 16
1/ 16
1/16
1/16
1/ 16
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

CM
AREA
6.25
7.8
9.9
12.5
15.7
19.8
25.0
31.52
39.75
50. 1 3
63.2
79.7
100.5
126.7
1 59 . 8
201 . 3
254. 1
320.4
404 . 0
509 . 5
642 .4
810 . 1
1022 . 0
1288 . 0
1624 . 0
2045 . 0
2533.0
3257.0
4107.0
5778 . 0
6530.0
8234 . 0
10380 . 0
1 3090 . 0
16510.0

DIA

. 0028
. 0032
. 0036
. 0040
. 0045
.005 1
.0056
. 0062
. 0070
. 0079
. 0089
. 0099
.0110
.0123
. 0 1 37
. 0 1 54
. 0 171
. 0 192
.0215
. 0 240
.0268
.0301
.0336
.0376
.0421
.0471
.0527
.0590
.0661
.0 741
. 0829
. 0929
. 1 042
. 1 168
. 13 10

TU RNS/
IN
304.0
267.0
239.0
215.0
19 2 . 3
170.4
155.5
142.0
125.6
1 10.4
99.0
88.9
81.0
72.5
63.0
57.6
52.0
45.9
4 1 .9
37.4
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

OH MS/LB

84648 . 0
54045 . 0
35610.0
22047 . 0
12887 . 0
8077 . 0
5248 . 0
3375.0
2 1 06.0
1305.0
810.0
530.0
333.4
204.6
132.5
82.5
52.7
32.7
20.7
12.9
8.22
5.12
3.23
2 . 04
1 . 29
.805
.5101
. 3 193
. 20 1 6
. 1 258
.0794
.0 500
.0315
. 0 198
. 0 1 25

page 82

LAMI NATION TABLE

VA

AREA

WINDOW

WEIGHT
LBS .
.015

SIZE

STACK HT

EI- 187

3/ 16

0.5

. 0 35

3/16 x 7/ 16

EE-24-25

1/4

1.0

. 0625

1/4 x 1/2

.0 34

EI-3/8

3/8

3.0

. 1406

5/16 x 3/4

. 1 08

EI-5/8

5/8

7.0

. 390

5/16 x 15/16

. 392

EI-3/4

3/4

14.0

. 5625

3/8 x 1 1/8

. 678

EI-3/4

1.0

19.0

. 75

3/8

1 1/8

. 9 04

EI-7/8

7/8

30.0

. 765

7/ 1 6

1 5/16

1 .05

EI-7/8

1.0

32.0

.8 75

7/ 1 6 x 1 5/16

1 . 20

EI- 1

1.0

45 . 0

1 .0 0

1/2 x 1 1/2

1 . 55

EI- 1

1 1/4

50.0

1 .25

1/2

1 . 94

EI - 1 1/8

1 1/8

65 . 0

1 . 265

EI- 1 1/4

1 1/4

90.0

1 . 5 625

EI- 1 3/8

1 3/8

125.0

EI- 1 1/2

1 1/2

EI- 1 3/8

1 1/2

9/ 16 x 1 1 1/16

2 . 24

5/8 x 1 7/8

3 . 08

1 . 89

1 1/ 1 6 x 2 1/16

4.17

1 60 . 0

2.25

3/4 x 2 1/4

5.3 5

1 3/4

160 . 0

2 . 40

1 1/16 x 2 1/16

5.31

EI- 1 1/2

2 1/2

300.0

3 . 75

3/4 x 2 1/4

8.9 1

EI- 1 3/4

1 3/4

340. 0

3 . 06

7/8 x 2 5/8

8.61

EI- 1 3/4

2.0

400. 0

3 . 50

7/8 x 2 5/8

9.84

EI- 1 5/8

2.0

450 . 0

3 . 25

1 1/4

x 2 5/8

7 . 78

Note : Va l ues shown for a rea and weight must be modified by the stacking
fa ctor K.

page 83

TOTAL HARM O N IC DISTORTION TABLES

The following ta bles a re the results of testing actua l transformers. They

should only be used as g u idel in es for esti mating the distortion that can be
expected using th ese th ree materia ls at different flux levels.
The hysteresis cu rves of these material s show that the distortion
increases as the fl ux level a pproaches the knee of the curve .

FLUX ( KG)

SOO/o NICKEL (O/o)

800/o NICKEL (O/o)

29 M 6

(O/o)

.01

.012

. 03

.01

.03

. 03

. 066

.06

. 03

.10

. 18

. 03

. 12

.45

. 04

. 14

1 . 45

.05

. 16

1.6

. 10

.46

2.3

.15

. 75

.25

10

.30

11

.36

12

.41

13

. 66

14

98

15

1.25

16

1 .65

17

2.10

18

2.55

page 84

The fo l lowing tab l es show the turns of each size of w i re that ca n be fitted
into diffe rent sizes of l a m i nations, both layer wou n d a n d bobbin wou n d .
These ta bles w i l l be a h e l p i n d etermi n i n g the poss ib il ity o f fit in a design
after the t u rns and w i re sizes a re c h osen a n d before spending a lot of
tim e ca lculating t h e fi l l .
For exa m ple, i f t h e design s h own i n 5 . 3 , pages 2 0 a n d 2 1 , was stop ped at
the point, page 23, wh ere 390 turns of # 2 3 w i re was determined for the
p ri m a ry a n d the EI- 1 1 2 La m ination Ta b le in t h e Appendix is consu lted, it
ca n be s h own that it w i l l fit, 390 / 848 x 1 0 0
46/o. This is less than
1/2 of the ava i l a b l e space and is a bout rig h t for the p ri m a ry winding in a
norm a l d esig n .
=

These ta bles can save a lot of d esig n time that m ig h t b e necessa ry in

juggling between turns, w i re sizes a n d l a m i nation sizes. H owever, where
extensive i nterleav i n g i s used , 46/o fi ll for the pri m a ry winding might
resu lt i n a tig ht fit.

page 85

EE-28-29 LAM I NATIO N

MAXI M U M TU RNS FOR LAYER WOU N D COILS
COIL LENGTH = 1 9/64"
WIN DOW WI DTH
1/8"
0 . 98"
MEAN LENGTH TU RN
=

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

1 1 - .003K

21

.0345

24

1 1 - .002K

28

.0587

25

1 1 - .002K

32

.086

26

1 1 - .002K

45

. 1 50

27

1 1 - .002K

11

55

.231

28

1 1 - .002K

12

72

.381

29

1 1 - . 00 1 5 K

13

91

.608

30

1 1 - . 00 1 5 K

15

1 20

1 .01 1

31

1 1 - .001 K

17

1 36

1 .445

32

1 1 - .001 K

19

1 71

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

35 1

9.431

36

1 1 - .001 K

30

14

420

1 4 .228

37

1 1 - .001 K

34

16

544

23.24

38

1 1 - .001 K

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 86

EI- 186 LAMI NATION

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

Wire
Gage

M i n . Layer
Insu lation

Turns/
Layer

Max.
Layers

Max.
Turns

Resistance
square stack

22

1 1 - .003K

20

.0374

23

1 1 - .003K

4.5

22

.0512

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 - .00 1 5 K

10

90

.853

30

1 1 - .001 K

10

12

1 20

1 .435

31

1 1 - .001 K

11

13

1 43

2. 1 55

32

1 1 - .001 K

1 2.5

14

1 75

3.326

33

1 1 - .001 K

14

16

224

5.368

34

1 1 - .00 1 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

21.14

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

2115

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

page 87

EI- 1 8 7 LAMI NATION

MAXIM U M TUR N S FOR LAYER WOU N D COILS
COIL LENGTH = 1 3/32"
WI N DOW WIDTH = 3/ 1 6 "
M EAN LENGTH TU RN
1 . 39"
=

Wire
Gage

M i n . Layer
Insulation

Turns/
Layer

Max.
Layers

Resistance
s q u a re stack

Max.
Turns

22

1 1 - . 0025K

45

.0841

23

1 1 - . 003K

10

50

. 1 1 65

24

1 1 - . 002K

1 1 .5

69

.2052

25

1 1 - . 002K

13

78

.2925

26

1 1 - . 002K

1 4.5

1 01

.4774

27

1 1 - . 002K

16

1 28

.7631

28

1 1 - .001 5K

18

1 62

1 .218

29

1 1 - .001 5K

20

10

200

1 . 895

30

1 1 - . 001 K

23

12

276

3.30

31

1 1 - . 001 K

25.5

13

331

5.00

32

1 1 - .001 K

28

14

392

7.45

33

1 1 - .001 K

3 1 .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

1 1 - .001 K

45

21

945

45.41

37

1 1 - . 001 K

50 .5

24

1 21 2

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

7 1 6.30

43

1 1 - .00075K

1 01

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

page 88

E E-24-25 LAMINATI O N
MAXI M U M TUR NS FOR LAYE R WOU N D COILS
COIL LENGTH
1 5/32"
WI N DOW WIDTH
1/4"
M EAN LENGTH TU RN
1 . 87 "
=

Wire
Gage

M i n . Layer
Insulation

Turns/
Layer

Max.
Layers

Max.
Turns

Resista nce
square stack

22

1 1 - . 003K

11

66

. 1 660

23

1 1 - . 003K

13

91

.2887

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

1 1 - . 001 K

31

17

527

1 0.68

32

1 1 - .001 K

34

18

612

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 51 .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

43

3827

625.50

41

1 1 - . 00075K

98

50

4900

1 0 1 0.00

42

1 1 - .0005K

1 08

54

5832

1 520.00

43

1 1 - .0005K

1 23

61

7503

2460.00

44

1 1 - .0005K

1 40

68

9520

3963.00

45

1 1 - .0005K

1 55

73

1 1315

5902.00

46

1 1 - .0005K

1 72

80

1 3760

901 9.00

page 89

E E - 26-27 LAM I NATION

MAXIM U M TU RNS FOR LAYE R WO U N D COILS
COIL LENGTH = 2 1/ 3 2 "
WIN DOW WI DTH = 1/4"
MEAN LENGTH TU RN = 2 .42"
Wire
Gage

M i n . La yer
Insulation

Tu rns/
Layer

M a x.
Layers

Max.
Turns

Resistance
square stack

22

1 1 - . 003K

16

96

.3125

23

1 1 - .003K

18

1 08

.4435

24

1 1 - . 002K

20

1 40

.7250

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 - . 00 1 5K

33

12

396

5. 1 84

29

1 1 - . 00 1 5K

36

13

468

7.724

30

1 1 - .001 K

40

16

640

1 2.47

31

1 1 - .001 K

45

16

720

1 8.89

32

1 1 - .001 K

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

1 661 3.00

page 90

EI-375 LAM I NATIO N

MAXIM U M TU RNS FOR LAYER WOU N D COILS
COIL LENGTH = 1/2"
WINDOW WIDTH = 3/4"
M EAN LENGTH TU RN = 2 . 75"
Wire
Gage

M i n . Layer
Insu lation

Turns/
Layer

Max.
Layers

Max.
Turns

Resistance
square stack

20

1 1 - . 005K

13

78

. 1 81 0

21

1 1 - . 005K

15

1 05

.3079

22

1 1 - . 003K

16

1 28

.4734

23

1 1 - . 003K

18

1 62

.7558

24

1 1 - . 002K

21

10

210

1 .235

25

1 1 - . 002K

23

11

253

1 . 8767

26

1 1 - . 002K

26

12

312

2.917

27

1 1 - . 002K

29

15

435

5. 1 30

28

1 1 - .00 1 5K

31

16

496

7.376

29

1 1 - .001 5K

36

17

612

1 1 .476

30

1 1 - .001 K

40

20

800

1 8.92

31

1 1 - .001 K

44

22

968

28.86

32

1 1 - . 001 K

49

24

1 1 76

44.224

33

1 1 - .001 K

55

27

1 485

70.41

34

1 1 - .001 K

63

30

1 890

1 1 3.0

35

1 1 - .001 K

71

34

241 4

1 82.0

36

1 1 - .001 K

78

37

2886

274.33

37

1 1 - . 001 K

85

40

3400

407.58

38

1 1 - . 00 1 K

96

44

4224

638.48

39

1 1 - .00075K

1 07

51

5457

1 040.21

40

1 1 - . 00075K

119

56

6664

1 602.0

41

1 1 - .0005K

1 33

66

8778

266 1 .37

42

1 1 - . 0005K

1 52

74

1 1 248

4300.0

page 9 1

EI- 2 1 LAMI NATION

MAXI M U M TU RNS FOR LAYER WOUND COILS
COIL LE NGTH = 2 5/32"
WIN DOW WI DTH = 5/ 1 6 "
M EAN LEN GTH TU RN = 3 . 1 2 "
Wire
Gage

M i n . Layer
Insu lation

Turns/
Layer

M a x.
Layers

Max.
Turns

Resistance
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

5.91 5

28

1 1 - .001 5K

39

15

585

9.87

29

1 1 - .001 5K

43

17

731

1 5.55

30

1 1 - . 001 K

48

19

912

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

1 19

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 92

EI-625 LAMINATION
MAXI M U M TU RNS FOR LAYE R WO U N D COILS
COIL LENGTH = 29/3 2 "
WIN DOW WIDTH = 5/ 16"
M EAN LENGTH TU R N
3 . 62 "
=

Wire
Gage

M i n . Layer
Insulation

Tu rns/
Layer

M a x.
Layers

Max.
Turns

Resistance
square 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

23

1 84

.896

23

1 1 - .003K

25

225

1 . 382

24

1 1 - .002K

31

10

310

2.40

25

1 1 - . 002 K

35

11

385

3.76

26

1 1 - . 002K

39

12

468

5.76

27

1 1 - . 002K

43

13

559

8.68

28

1 1 - . 00 1 5K

49

15

735

14.39

29

1 1 - . 00 1 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

1 428

56 . 1 0

32

1 1 - .001 K

75

23

1 725

85.40

33

1 1 - .001 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

2 1 83.00

40

1 1 - .00075K

1 94

55

1 0670

3377.00

41

1 1 - .0005K

21 3

64

1 3632

5441 .00

42

1 1 - .0005K

236

70

1 6520

8338.00

page 93

EI-75 LAMINATIO N
MAXI M U M TU RNS FOR LAYER WOU N D COI LS
1 1/16"
COIL LENGTH
WIN DOW WIDTH
3/8"
MEAN LENGTH TU R N
4 . 3 3"
=

Wire
Gage

M i n . La yer
Insu lation

Turns/
Layer

M a x.
Layers

Max.
Turns

Resistance
square stack

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

28

252

1 .467

23

1 1 - .003K

32

10

320

2.31

24

1 1 - .002K

36

12

432

4.00

25

1 1 - . 002K

40

13

520

6.07

26

1 1 - . 002K

46

15

690

1 0. 1 6

27

1 1 - .002K

51

16

816

1 5. 1 5

28

1 1 - .001 5K

57

18

1 026

24.00

29

1 1 - .00 1 5 K

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

112

35

3920

369.00

35

1 1 - .001 K

1 26

39

4914

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

3716.00

40

1 1 - .00075K

227

67

1 5209

5756.00

41

1 1 - .0005K

248

77

1 9096

9 1 1 5.00

42

1 1 - .0005K

275

85

23375

1 4 1 1 0.00

page 94

EI-87 LAMINATIO N
MAXI M U M TURNS FO R LAYER WOU N D COILS
COIL LENGTH = 1 1/4"
WIN DOW WIDTH = 7/ 1 6"
M EAN LENGTH TU RN = 5 . 04"
Wire
Gage

M i n . Layer
Insulation

Tu rns/
Layer

Max.
Layers

M a x.
Turns

Resista nce
square 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

1 1 - .003K

31

10

310

1 .666

22

1 1 - .003K

35

11

385

1 .97

23

1 1 - .003K

39

12

468

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

1 6.03

27

1 1 - .002K

61

19

1 1 59

25.06

28

1 1 - .00 1 5 K

69

22

1 51 8

41 .38

29

1 1 - .001 5K

77

24

1 848

63.51

30

1 1 - .001 K

86

28

2408

1 04.40

31

1 1 - .001 K

95

31

2945

1 60.90

32

1 1 - .001 K

1 06

34

3604

248.40

33

1 1 - .001 K

1 20

38

4560

396.30

34

1 1 - .001 K

1 36

42

571 2

6 1 5.00

35

1 1 - .001 K

1 53

47

7191

993.70

36

1 1 - .001 K

1 70

51

8670

1 5 1 0.50

37

1 1 - .001 K

1 91

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

page 95

EI- 100 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 TU RN
5. 7 1 "
=

Wire
Gage

M i n . Layer
Insu lation

Tu rns/
Layer

M a x.
Layers

M a x.
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

1 1 - .003K

33

10

330

1 .60

21

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

10.16

25

1 1 - .002K

58

18

1 044

1 6.08

26

1 1 - .002K

65

20

1 300

25.24

27

1 1 - .001 K

72

22

1 584

38.80

28

1 1 - .001 5K

81

25

2025

62.53

29

1 1 - .00 1 5 K

90

27

2430

94.61

30

1 1 - .001 K

1 02

32

3264

1 60.27

31

1 1 - .001 K

1 13

35

3955

244.80

32

1 1 - . 00 1 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

1 471 6.00

page 96

EI- 1 1 2 LAM I NATIO N

MAXIM U M TURNS F O R LAYE R WOU N D COILS
COIL LENGTH
1 5/8"
WIN DOW W I DTH
9/ 1 6 "
M EAN LENGTH TU R N = 6 . 60 "
=

Wire
Gage

M i n . Layer
Insu lation

Turns/
Layer

Max.
Layers

Max.
Turns

Resistance
square stac k

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 - . 002 K

59

18

1 062

1 5.00

25

1 1 - . 002 K

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 - . 001 5K

94

29

2726

97.30

29

1 1 - . 00 1 5 K

1 04

32

3328

1 49.78

30

1 1 - .001 K

1 17

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 - . 00 1 K

1 62

49

7938

903.30

34

1 1 - .001 K

1 84

55

1 0 1 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 - .001 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 97

EI- 1 2 5 LAMINATIO N
MAXIM U M TU RNS FOR LAYE R WOU N D COILS
COIL LENGTH
1 13/16"
WIN DOW WIDTH
5/8 "
M EAN LENGTH TU RN = 7 . 2 1 "
=

Wire
Gage

M i n . Layer
Insulation

Turns/
Layer

Max.
Layers

Max.
Turns

Resista nce
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

559

3.41

21

1 1 - . 003K

48

14

672

5.17

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

1 1 - .002K

75

22

1 650

32. 1 0

26

1 1 - . 002K

85

25

2 1 25

52 .02

27

1 1 - . 002K

94

27

2538

78.48

28

1 1 - .00 1 5 K

1 06

31

3286

1 28 . 1 0

29

1 1 - .001 5K

1 17

34

3978

1 93.20

30

1 1 - . 00 1 K

1 32

40

5280

327.40

31

1 1 - . 00 1 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 - .001 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

39 1 04

1 9542.00

40

1 1 - . 00075K

421

1 14

47994

30248.00

page 98

EI- 1 38 LAMINATION
MAXI M U M TURNS FOR LAYER WOU N D COILS
COIL LENGTH = 2 "
WI N DOW WIDTH
1 1/ 1 6"
M EAN LENGTH TUR N = 7 . 66"
=

Wire
Gage

M i n . Layer
Insulation

Turns/
Layer

Max.
Layers

M a x.
Turns

Resistance
square stack

13

1 1 - . 0 1 0K

19

1 14

. 1 46

14

1 1 - . 0 1 0K

21

1 47

.24

15

1 1 - . 0 1 0K

24

1 92

.39

16

1 1 - . 007K

29

232

.60

17

1 1 - . 007K

33

10

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

62

18

1 1 16

1 1 .50

23

1 1 - .005K

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 - .001 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

191

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

page 99

EI- 1 50 LAM I NATION

MAXI M U M TURNS FOR LAYER WOU N D COILS
COIL LENGTH = 1 7/ 1 6"
WIN DOW WIDTH
1/2"
M EAN LENGTH TU RN = 8 . 4 "
=

Wire
Gage

M i n . Layer
Insu lation

Turns/
Layer

Max.
Layers

M a x.
Turns

Resistance
square stack

13

1 1 - .010K

21

1 47

.21

14

1 1 - .001 K

24

1 92

. 34

15

1 1 - .001 K

27

216

.48

16

1 1 - .007K

33

297

.84

17

1 1 - . 006K

37

11

407

1 .44

18

1 1 - .007K

41

12

492

2.20

19

1 1 - .005K

47

13

61 1

3.45

20

1 1 - .005K

53

15

795

5.60

21

1 1 - .005K

59

17

1 003

9.00

22

1 1 - . 003K

69

20

1 380

1 5.60

23

1 1 - . 003K

77

22

1 694

24.00

24

1 1 - . 002K

86

26

2236

4 1 .00

25

1 1 - .002 K

97

28

2716

63.50

26

1 1 - .002K

1 09

32

3488

1 00.00

27

1 1 - .002K

121

35

4235

1 53.00

28

1 1 - .001 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 1 2

583.00

31

1 1 - .001 K

1 90

54

1 0260

933.00

32

1 1 - .001 K

215

58

1 2528

1435.00

page 100

E E- 28-29 LA M INATI O N
MAXIM U M TU R N S FOR BOBBIN WOU N D COILS (85/o FILL)
M EAN LENGTH TU RN

.930"

W i re
Gage

Turns/
Layer

20

14

. 0 1 21

21

16

. 0 1 74

22

27

.0373

23

10

30

.0520

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

3 1 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

Max.
Layers

Max.
Tu rns

Resistance
squa re stack

page

10 1

EI- 1 86 LAMINATIO N
MAXIM U M TU R N S FOR BOBBIN WOU N D COILS ( 8 5 /o FILL)
M EAN LENGTH TU RN

1 . 4"
Max.
Layers

Max.
Turns

Resistance
square stack

Wire
Gage

Turns/
Layer

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 5.91

35

28

21

588

25.00

36

31

23

71 3

38.40

37

35

26

91 0

59.70

38

38

29

1 1 02

91 .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 102

EI- 1 8 7 LA M INATI O N
MAXI M U M TU R N S FOR BOBBIN WO U N D COILS (85/o FILL)
M EAN LENGTH TU RN

1 .35"
Max.
Layers

Max.
Tu rns

Resistance
s q u a re stack

W i re
Gage

Tu rns/
Layer

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

518

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

2944

278.00

40

92

35

3220

429.00

41

1 03

40

4 1 20

673.50

42

1 14

44

50 1 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 103

EI-375 LAM I NATIO N

MAXIM U M TURNS FO R BOBBIN WOU N D COILS (85/o FILL)
M EAN LENGTH TU R N = 2 . 49"
Max.
Layers

Max.
Turns

Resista nce
square stack

Wire
Gage

Turns/
Layer

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

2.18

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

1 113

26.40

31

60

24

1 440

43.59

32

66

26

1 71 6

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

116

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 104

E E-24-25 LAM I NATION

MAXI M U M TU R N S FO R BOBBIN WO U N D COILS ( 8 5 /o FI LL)
M EAN LENGTH TURN

1 . 86"
Max.
Layers

Max.
Turns

Resista nce
sq u a re stack

W i re
Gage

Tu rns/
Layer

20

11

55

.0946

21

12

72

.1618

22

14

84

.2308

23

15

1 05

.3624

24

17

1 36

.6 1 6

25

19

1 71

.954

26

22

10

220

1 .54

27

24

11

264

2.315

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 08 1

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

1 001 1

3663.00

44

1 60

81

1 2960

5870. 00

45

1 86

94

1 7484

91 70.00

page 105

EI- 2 1 LAMINATIO N
MAXIM U M TU R N S FO R BO BBIN WO U N D COILS ( 8 5 /o FI LL)
M EAN LENGTH TU R N

3.01"
Max.
Layers

Max.
Turns

W i re
Gage

Turns/
Layer

20

19

1 14

.319

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

29 1 2

21 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

1 40

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 31 30.00

44

281

1 02

28662

20430. 00

45

325

118

38350

32200 .00

Resistan ce
s q u a re stack

page 106

EI-625 LAMINATIO N
MAXI M U M TU R N S FOR BOBBIN WO U N D COILS (85/o FILL)
M EAN LENGTH TURN

3 . 53 "
Max.
Layers

Max.
Turns

Wire
Gage

Turns/
Layer

17

16

80

. 1 1 89

18

18

90

. 1 68

19

20

1 20

.284

20

21

1 26

.41 35

21

23

1 61

.656

22

26

208

1 . 085

23

30

270

1 . 773

24

33

10

330

2.743

25

37

11

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

73

22

1 606

68.7

32

81

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

143

44

6292

1 040.00

38

1 59

49

7791

1 630.00

39

1 83

56

1 0248

2830.00

40

204

63

1 2852

4480.00

41

227

71

1 61 1 7

6750.00

42

255

79

20145

1 0800.00

Resistance
s q u a re stack

page 107

EI-75 LAM I NATIO N

MAXI M U M TURNS FOR BOBBIN WOU N D COILS ( 8 5 /o FILL)
M EAN LENGTH TU R N

4 . 202"
M a x.
Layers

Max.
Turns

Resistance
squ a re stack

Wire
Gage

Turns/
Layer

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

5 1 .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

5 1 48

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

205 1 4

851 0.00

page 108

EI-87 LAM I N ATION

MAXIM U M TUR N S FOR BOBBIN WOU N D COILS ( 8 5 /o FILL)
M EAN LENGTH TU R N

5 . 04"
Max.
Layers

Max.
Tu rn s

Resista nce
s q u a re stack

Wire
Gage

Turns/
Layer

16

20

1 20

.202

17

23

1 61

. 342

18

25

200

.536

19

28

252

.852

20

32

10

320

1 .36

21

36

11

396

2.1 3

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

2 1 .59

27

70

22

1 540

33.29

28

79

25

1 975

53.83

29

88

27

2376

81 .65

30

98

31

3088

1 3 1 .68

31

1 09

34

3706

202.50

32

1 22

38

4626

3 1 9 .40

33

1 37

43

5891

51 2.00

34

1 55

48

7440

81 5.20

35

1 75

55

9625

1 329.60

36

1 93

61

1 1 773

2051 . 00

37

212

67

1 4204

3 1 20.00

38

222

76

1 6872

4673.50

39

271

85

23035

8046.60

40

301

95

28595

1 2597.00

page 109

EI- 1 0 0 LAM I N ATION

MAXIM U M TURNS FOR BOBBIN WO U N D COILS (85/o FILL)
M EAN LENGTH TU RN

5 . 57"
M a x.
Layers

Max.
Turns

Resistance
s q u a re stack

Wire
Gage

Turns/
La yer

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

61

19

1 1 59

1 3.81

25

69

21

1 449

2 1 .77

26

77

24

1 848

35.00

27

86

26

2236

53.42

28

96

30

2880

86.75

29

1 07

33

3531

1 34. 1 0

30

1 20

37

4440

2 1 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

2 1 06 0

51 1 3.00

38

294

92

27048

8281 .00

39

331

1 03

34093

1 3 1 63.00

40

368

115

42320

20606 .00

page 110

EI- 1 1 2 LAMINATIO N
MAXI M U M TU R N S FO R BOBBI N WOU N D COILS ( 8 5 /o FILL)
M EAN LENGTH T U R N

6 . 60 "

W i re
Gage

Tu rns/
Layer

13

19

1 14

. 1 26

14

22

1 54

.2 1 4

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

918

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

3 1 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

Max.
Layers

Max.
Tu rns

Resista nce
s q u a re stack

page 1 1 1

EI- 1 2 5 LAM I NATI O N

MAXIM U M TU R N S F O R BOBBIN WOU N D COILS ( 8 5 /o FILL)
M EAN LENGTH T U R N

7.21"

W i re
Gage

Tu rns/
Layer

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

1 140

1 1 .00

23

67

21

1 407

1 7.2 1

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

1 31

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

2 1 924

4333.80

36

289

94

2 7 1 66

6770.00

Max.
Layers

Max.
Turns

Resista nce
s q u a re sta ck

page 1 1 2

EI- 1 38 LAM INATI O N

MAXI M U M T U R N S FOR BOBBIN WOU N D COILS ( 8 5 /o FILL)
M EAN LE N GTH TURN

7 . 66"
M a x.
Layers

Wire
Gage

Turns/
Layer

11

17

1 02

.082

12

19

1 33

. 1 35

13

21

1 47

. 1 88

14

24

1 92

.3 1 0

15

27

243

.494

16

30

11

330

.846

17

34

12

408

1 . 32

18

38

13

494

2.01

19

42

15

630

3.24

20

47

17

799

5.17

21

53

19

1 007

8.23

22

59

21

1 239

1 2.76

23

66

24

1 584

20.58

24

74

27

2268

37. 1 6

25

83

30

2490

51 .45

26

93

34

3 1 62

82.37

27

1 03

37

381 1

1 25.20

28

116

42

4872

201 .80

29

1 30

47

6110

3 1 9 .25

30

1 45

53

7685

506.25

31

1 61

58

9338

775.50

32

1 79

65

1 1 635

1 21 8.80

33

202

73

1 4746

1 947.50

34

228

83

1 8924

3 1 5 1 .60

35

258

94

24252

5093.20

36

285

1 04

29640

7848.00

Max.
Turns

Resista nce
s q u a re stack

page 113

EI- 1 5 0 LAM I N ATION

MAXI M U M TURNS FOR BOBBIN WOU N D COILS ( 8 5 /o FILL)
M EAN L E N GTH TU RN

8 .40"

W i re
Gage

Turns/
Layer

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

1 1 02

7.82

21

64

21

1 344

1 2.04

22

72

23

1 656

1 8. 70

23

81

26

2 1 06

30.00

24

96

29

2784

50. 00

25

101

33

3333

75.52

26

1 14

37

421 8

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

82 1 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

Max.
Layers

M a x.
Turn s

Resistance
squ a re stack

page 114