
A
7/96
AN-18
29
spreadsheet.  26 AWG wire has a bare area of 252.8 circular
mils. Two parallel strands of 26 AWG triple insulated wire have
a current capacity of:
CMA
S
=
×
225
.
=
2
2528
2247
.
.
  circular mils/ampere
This value is within 10% of the primary CMA of 243 circular
mils/ampere, and satisfies the CMA limit of 200-500 circular
mils per ampere.
Bias Wire Size
The bias winding  wire size is chosen to fill as much of the
bobbin width  as possible.  Since there are usually relatively few
turns on the primary bias winding, this is best accomplished by
using a bifilar winding rather than a large diameter wire,
effectively doubling the number of physical turns.
 The required
TC to fill a single layer can be calculated as follows:
TC
N
BW
M
turns cm
15
B
(
=
×
×
×
=
× ×
(
×
=
2
10
2
2
2
12
0
)
)
From the wire table, the closest wire size with a TC  greater than
or equal to this value is 23 AWG, with a TC 
of 15.82 turns/cm.
This wire is too large to use with a small bobbin.  A compromise
is to use the next smallest size, 24 AWG, which will not fill the
bobbin width completely, but is easier to terminate to the
bobbin pins.  Since the output current of this winding is 10 mA
or less, there is no need to consider the current capacity of the
wire.  The wire size in this case is determined by fill factor
requirements rather than current capacity.
Transformer Construction Style
Since this transformer is a triple insulated wire design for a
secondary regulated application, appropriate construction styles
are Figure 7B and 10B.  Because this design is for a 15W
application, a split primary winding as shown in Figure 10B is
not necessary, and the more cost effective single section primary
design of Figure 7B should be used.
Tape Sizes
Since this is a triple insulated design, one size of tape is required
for basic insulation, with a width equal to BW.  From cell (B27)
of the Table 6 spreadsheet, this is 12.0 mm.
Insulating Sleeving Size
Since this is a triple insulated wire design, no sleeving is
required
Gapped Core Inductance Coefficient
The A
 for this transformer design is given in cell (C47) of the
design spreadsheet, and should be used as the center value for
specifying the core A
LG 
on the transformer specification.
Finished Triple Insulated Wire Transformer Design
The information required to assemble a transformer specification
for the triple insulated wire transformer example is summarized
in Table 8.   A completed transformer schematic diagram and
parts list are shown  in  Figure  8.   A  construction  drawing  is
shown  in  Figure 9.