Reference Data

Reference Data
Electric Were About surface area effects Three layer insulation electric wire

Table of electric wire types Core Method to create effective gaps Type of tubes

Heat Resistant PVC coated electric wire Type of Insulation and High Temperature Resistance

Input Voltage Pulse Transformer About Shielding Thermo Fuse

Electric Wire
Poly-urethane coated wire (UEW)	Temperature index	120 degrees centigrade	Type E
	This is a type of enamel wire that Poly urethane resin is grazed on surface of Cupper wire. This type of wire has high efficiency of high frequency inductance And used for general purpose equipment as motors and transformer, since connection by soldering can be done without pealing off the insulation layer.
Neo-mare wire (PEW,SMPEW)	Temperature index	130~155 degrees centigrade	Type B~F
	Tele-Phthalic acid type Polyester resin is grazed for insulation. This is popular type as high heat resistance type and widely used for motor and transformers.
Three layer insulated wire (TEX-E) Produced by Furukawa Denko	Temperature index	105~120 degrees centigrade	Type A~E
	Insulation materials are combination of Polyester type high resistance material and poly-amid resin. Wire can solder directly. The coating materials can resist against high voltage, so, in case of multi-layer type winding, tape between layers or barrier can be omitted for compact size design compare to other type of wire.
Hitaester Flat Wire (PEW)	Temperature index	155 degrees centigrade	Type F
	Insulation Coating is mainly polyester based vanish, which is evenly coated on surface of the flat shaped conductor. This is mainly used for magnet wire.

Surface Effect
When Electric Power run through Cupper Wire, large amount our such power currency runs through surface of the wire.
This surface currency effect become more serious with high frequency power, because resistance of power cable does not become equal to diameter or cut dimensional area size.
The parts currency goes through Wire cut illustration of actual effective area of electric currency.

Type of wire table
Nearest Number
of wire gauge Maximum Diameter after Finish Electric Resistance
ohm/km
(20 degrees centigrade) Weight
kg/km
Diameter
(mm) B.S.
(A.W.G) cut section area
(mm) Hormal-Cupper-urethane Poly-urethane wire
Type 0 Type 1 Type 2 Type 1 Type 2
3.2 8 8.04 3.388 3.338 2.221 71.5
3.0 7.06 3.178 3.128 2.514 63.1
2.9 9 6.60 3.078 3.028 2.692 58.9
2.8 6.15 2.978 2.928 2.890 54.9
2.7 5.71 2.878 2.828 3.134 51.0
2.6 10 5.31 2.778 2.728 3.357 47.2
2.5 4.90 2.678 2.628 3.634 43.8
2.4 11 4.52 2.574 2.526 3.948 40.4
2.3 4.15 2.468 2.422 4.303 37.1
2.2 3.80 2.368 2.322 4.709 33.9
2.1 3.46 2.266 2.220 5.175 30.9
2.0 12 3.14 2.162 2.118 5.713 28.0
1.9 13 2.84 2.062 2.018 6.406 25.4
1.8 2.54 1.956 1.914 7.150 22.6
1.7 2.27 1.856 1.814 8.032 20.3
1.6 14 2.01 1.754 1.712 9.088 17.9
1.5 15 1.77 1.654 1.612 1.612 10.37 15.8
1.4 1.54 1.548 1.508 1.508 11.63 13.7
1.3 16 1.32 1.448 1.408 1.408 13.89 11.8
1.2 1.13 1.342 1.304 1.304 16.36 10.1
1.1 17 0.95 1.242 1.204 1.204 19.57 8.47
1.0 18 0.785 1.138 1.102 1.062 1.102 1.062 22.95 7.01
0.95 19 0.707 1.072 1.038 1.008 1.038 1.008 25.85 6.31
0.90 0.635 1.020 0.986 0.956 0.986 0.956 28.28 5.67
0.85 0.568 0.966 0.934 0.904 0.934 0.904 31.75 5.07
0.80 20 0.503 0.914 0.882 0.852 0.882 0.852 35.89 4.45
0.75 21 0.442 0.860 0.830 0.798 0.830 0.798 40.69 3.94
0.70 0.385 0.804 0.776 0.746 0.776 0.746 46.78 3.44
0.65 22 0.332 0.752 0.724 0.694 0.724 0.694 54.35 2.96
0.60 23 0.283 0.698 0.672 0.644 0.672 0.644 63.92 2.51
0.55 24 0.237 0.646 0.620 0.592 0.620 0.592 75.69 2.12
0.50 0.196 0.586 0.560 0.542 0.560 0.542 91.79 1.75
0.45 25 0.159 0.532 0.508 0.490 0.508 0.490 114.8 1.42
0.40 26 0.126 0.480 0.456 0.439 0.456 0.439 145.0 1.12
0.37 0.107 0.446 0.424 0.407 0.424 0.407 169.9 0.96
0.35 0.096 0.424 0.402 0.387 0.402 0.387 190.1 0.86
0.32 28 0.080 0.394 0.372 0.357 0.372 0.357 228.1 0.72
0.30 0.071 0.374 0.352 0.337 0.352 0.337 260.0 0.63
0.29 0.066 0.360 0.340 0.324 0.340 0.324 276.7 0.59
0.28 0.062 0.350 0.330 0.314 0.330 0.314 297.1 0.55
0.27 0.057 0.340 0.320 0.304 0.320 0.304 319.8 0.51
0.26 30 0.053 0.330 0.310 0.294 0.310 0.294 345.3 0.47
0.25 0.049 0.318 0.298 0.284 0.298 0.284 374.0 0.44
0.24 0.045 0.308 0.288 0.274 0.288 0.274 406.3 0.41
0.23 31 0.041 0.298 0.274 0.264 0.278 0.264 443.1 0.37
0.22 0.038 0.286 0.266 0.252 0.266 0.252 485.1 0.34
0.21 0.035 0.276 0.256 0.241 0.256 0.241 528.1 0.31
0.20 32 0.031 0.266 0.246 0.231 0.246 0.231 583.1 0.28
0.19 0.028 0.256 0.236 0.221 0.236 0.221 647.2 0.25
0.18 33 0.025 0.246 0.226 0.211 0.226 0.211 722.4 0.23
0.17 0.023 0.232 0.214 0.199 0.214 0.199 811.4 0.21
0.16 34 0.020 0.222 0.204 0.189 0.204 0.189 918.1 0.18
0.15 0.018 0.210 0.192 0.177 0.192 0.177 1047 0.16
0.14 35 0.015 0.200 0.182 0.167 0.182 0.167 1206 0.14
0.13 0.013 0.190 0.172 0.157 0.172 0.157 1403 0.12
0.12 36 0.011 0.180 0.162 0.147 0.162 0.147 1653 0.10
0.11 0.009 0.166 0.150 0.135 0.150 0.135 1977 0.08
0.10 38 0.008 0.156 0.140 0.125 0.140 0.125 2405 0.07
0.09 0.006 0.113 0.113 3021 0.054
0.08 40 0.005 0.103 0.103 3857 0.05
0.07 41 0.004 0.091 0.091 5094 0.04
0.06 42 0.003 0.081 0.081 7112
0.05 44 0.002 0.069 10460
0.04 45 0.001 0.056 16000
0.03 48 0.044 29470
0.025 50 0.038 43680

Core
Ferrite Shape: EI, EE, EER, EC, PQ EQ, EPC, SMD etc.
Ferrite is a type of Carbon Iron product which is treated under high temperature as 1,000~1,500 degrees centigrade together with metal Oxide (such as Manganese Oxide, Nickel Oxide, Cupper Oxide, Zinc Oxide) to form unique alloy, which has Very high magnetic transparency. High value of Magnetic Flux Saturation, Compare to other metal magnetic materials, Ferrite has higher resistance and popularly used for High Frequency Magnetic Material.

Decide Gap Distance
Spacer Gap

Possible to create any Gap thickness
Center Pole Gap

This middle part is polished and it is difficult to adjust gap distance. Very Low noise due to small leakage of magnetic flux created from the Gap. (Simply change spacer double, the noise does not become same)

Tube
Anti-flamer Silicone Vanish Glass Tube
(Nikkan Industry product)
S-693V VW-1 E55258
S-693-600 200 degrees centigrade 600V VW-1 E72406
Silicone Rubber Injected Tube (Nikkan Industry product)
E-651U-1 200 degrees centigrade 300V VW-1 E88468
E-651U-2 200 degrees centigrade 600V VW-1 E88468
Electric Insulation PBC Tube (Iwase product)
AH-3 105 degrees centigrade 300V VW-1 E56036
AH-6 105 degrees centigrade 600V VW-1 E56036

Heat-resistant plastic wire
UL1007 80 degrees centigrade 300V
UL1015 105 degrees centigrade 600V
UL1430 105 degrees centigrade 300V

Heat Resistant PCB Wire
Type of Insulation Temperature allowance Material Construction
Type Y 90 degrees centigrade For example, Cotton, Silk, Paper combination, without Vanish or oil soaking
Type A 105 degrees centigrade For example, Cotton, Silk, Paper combination with vanish or oil soaking
Type E 120 degrees centigrade Poly-Ethylene type insulator
Type B 130 degrees centigrade For example Mica, Asbestos, Glass Fiber type materials used with resin
Type F 155 degrees centigrade For example Mica, Asbestos, Glass Fiber type materials used with Silicone Alchid resin
Type H 180 degrees centigrade For example Mica, Asbestos, Glass Fiber type materials used with Silicone type of resin or equivalent type of resin ,material. Single use of Rubber type of Solid State Silicone Resin is included
Type C 180 degrees centigrade For example, single use of rare Mica, Asbestos, Ceramic used together with adhesive

Input Voltage Power Line Voltage of the World(AC)
As well as for domestic market, Switching Power Supply is world wide used for AC and DC Power Supply. There are many types and models available. Before use of Switching Power Supply, please check your local Voltage, AC, or DC type, Tolerance of Voltage, method of input Voltage change methods.

Pulse Transformers
This is one type of wide band transformer to transfer pals shape wave accurately. It is necessary to design transformer that core do not get saturated by Pulse signal amplitude and wave width. Also coil must be designed to minimize rush Current and back swing.
E:Peak Pulse Voltage

Zug=B/E x 100%

(1)Excellent Wave Form
(2)Not enough Inductance increase winding turns for improve m or increase core size/
(3)In case magnetic energy transfer is not enough due to pals average currency
(3)Change core time to improve Currency efficiency or change gap distance

About Shielding
Due to it's Physical Construction of transformer, floating capacitance or leakage of magnetic may cause problem to other component parts in circuit. In order to Avoid such problem, there is a method generally used is Shielding the transformer. There are three methods as Common way of Shielding, such as Static Shield, Magnetic Field Shielding and Magnetic Shielding.

Static Shield
Static Capacitance is created at insulation between primary conductance and secondary conductance. Winding width and distance between the primary and secondary, and selection of insulation materials can reduce such static capacitance. To place Cupper foil or other conductive foil can reduce common mode noise about half. This Shielding (S) must be designed to make sure that it will not become short turn.

Electro Magnetic Shielding
Transformer is to create magnetic Field on primary coil and create Voltage at secondary coil by mutual inductive energy relations, however at the same time, without going through core, magnetic energy go through secondary coil.
This leakage of energy can be reduced by changing coil winding method, but situation can be further improved by to wind Cupper foil to same direction as outside coil winding.
This shielding method is called as Electro Magnetic Shielding.
This method is also called as short ring. In this case, it is different from electro static shield. The Cupper foil must be completely short circuited at inside of core. Because the magnetic field which across the Cupper foil become electric currency and become opposite direction magnetic field to make shield effect.

Magnetic Shield
When Magnetic Flux goes through Steel core, a part of magnetic energy leaks from EI core junction point. This magnetic energy may affect component parts used in circuit around transformer. In order to reduce such amount of leakage, it is possible to design junction distance as short as possible for design Bm lower. Generally, core ring or case solves this problem.
Core ring

Use High Magnetic Transparency material to cover the transformer as illustrated drawing. In this case, core ring is magnetically short circuited. There is not high efficiency for high frequency.
To put whole transformer into shield case will make shut out leakage of magnetic noise as well as protecting the transformer from outside noise.

Thermo Fuse
To detect short circuit caused by circuit component parts through lead wire as well as body of transformer and shut out circuit for protection from overheating.
Action Shape

Above is digesting of each detail information

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Surface Effect
When Electric Power run through Cupper Wire, large amount our such power currency runs through surface of the wire. This surface currency effect become more serious with high frequency power, because resistance of power cable does not become equal to diameter or cut dimensional area size.
	The parts currency goes through Wire cut illustration of actual effective area of electric currency.

Example of Three layer wire dimension (Furukawa Electric)
Diameter of Conductive Material (mm)	Tolerance (mm)	Target Diameter (mm)	Maximum Diameter (mm)	Conductive Material Electric Resistance (ohm/km)	Density (kg/km)
0.20	plus minus 0.008	0.380	0.420	307.6	0.383
0.21	plus minus 0.008	0.390	0.430	549.0	0.414
0.22	plus minus 0.008	0.400	0.440	498.4	0.449
0.23	plus minus 0.008	0.410	0.450	454.5	0.484
0.24	plus minus 0.008	0.420	0.460	416.2	0.520
0.25	plus minus 0.008	0.430	0.470	382.5	0.558
0.26	plus minus 0.010	0.440	0.480	358.4	0.597
0.27	plus minus 0.010	0.450	0.490	331.4	0.638
0.28	plus minus 0.010	0.460	0.500	307.3	0.680
0.29	plus minus 0.010	0.470	0.510	285.7	0.723
0.30	plus minus 0.010	0.480	0.540	262.9	0.768
0.32	plus minus 0.010	0.500	0.560	230.0	0.862
0.35	plus minus 0.010	0.530	0.590	191.2	1.013
0.37	plus minus 0.010	0.550	0.610	170.6	1.121
0.40	plus minus 0.010	0.600	0.660	145.3	1.314
0.45	plus minus 0.010	0.650	0.710	114.2	1.630
0.50	plus minus 0.010	0.700	0.760	91.43	1.982
0.55	plus minus 0.020	0.750	0.810	78.15	2.368
0.60	plus minus 0.020	0.800	0.860	65.26	2.789
0.65	plus minus 0.020	0.850	0.910	55.31	3.246
0.70	plus minus 0.020	0.900	0.960	47.47	3.737
0.75	plus minus 0.020	0.950	1.010	41.19	4.263
0.80	plus minus 0.020	1.000	1.060	36.08	4.824
0.85	plus minus 0.020	1.050	1.110	31.87	5.420
0.90	plus minus 0.020	1.100	1.160	28.35	6.050
0.95	plus minus 0.020	1.150	1.210	25.38	6.716
1.00	plus minus 0.030	1.200	1.260	23.33	7.417

Type of wire table
Nearest Number of wire gauge			Maximum Diameter after Finish					Electric Resistance ohm/km (20 degrees centigrade)	Weight kg/km
Diameter (mm)	B.S. (A.W.G)	cut section area (mm)	Hormal-Cupper-urethane			Poly-urethane wire
Diameter (mm)	B.S. (A.W.G)	cut section area (mm)	Type 0	Type 1	Type 2	Type 1	Type 2
3.2	8	8.04	3.388	3.338				2.221	71.5
3.0		7.06	3.178	3.128				2.514	63.1
2.9	9	6.60	3.078	3.028				2.692	58.9
2.8		6.15	2.978	2.928				2.890	54.9
2.7		5.71	2.878	2.828				3.134	51.0
2.6	10	5.31	2.778	2.728				3.357	47.2
2.5		4.90	2.678	2.628				3.634	43.8
2.4	11	4.52	2.574	2.526				3.948	40.4
2.3		4.15	2.468	2.422				4.303	37.1
2.2		3.80	2.368	2.322				4.709	33.9
2.1		3.46	2.266	2.220				5.175	30.9
2.0	12	3.14	2.162	2.118				5.713	28.0
1.9	13	2.84	2.062	2.018				6.406	25.4
1.8		2.54	1.956	1.914				7.150	22.6
1.7		2.27	1.856	1.814				8.032	20.3
1.6	14	2.01	1.754	1.712				9.088	17.9
1.5	15	1.77	1.654	1.612		1.612		10.37	15.8
1.4		1.54	1.548	1.508		1.508		11.63	13.7
1.3	16	1.32	1.448	1.408		1.408		13.89	11.8
1.2		1.13	1.342	1.304		1.304		16.36	10.1
1.1	17	0.95	1.242	1.204		1.204		19.57	8.47
1.0	18	0.785	1.138	1.102	1.062	1.102	1.062	22.95	7.01
0.95	19	0.707	1.072	1.038	1.008	1.038	1.008	25.85	6.31
0.90		0.635	1.020	0.986	0.956	0.986	0.956	28.28	5.67
0.85		0.568	0.966	0.934	0.904	0.934	0.904	31.75	5.07
0.80	20	0.503	0.914	0.882	0.852	0.882	0.852	35.89	4.45
0.75	21	0.442	0.860	0.830	0.798	0.830	0.798	40.69	3.94
0.70		0.385	0.804	0.776	0.746	0.776	0.746	46.78	3.44
0.65	22	0.332	0.752	0.724	0.694	0.724	0.694	54.35	2.96
0.60	23	0.283	0.698	0.672	0.644	0.672	0.644	63.92	2.51
0.55	24	0.237	0.646	0.620	0.592	0.620	0.592	75.69	2.12
0.50		0.196	0.586	0.560	0.542	0.560	0.542	91.79	1.75
0.45	25	0.159	0.532	0.508	0.490	0.508	0.490	114.8	1.42
0.40	26	0.126	0.480	0.456	0.439	0.456	0.439	145.0	1.12
0.37		0.107	0.446	0.424	0.407	0.424	0.407	169.9	0.96
0.35		0.096	0.424	0.402	0.387	0.402	0.387	190.1	0.86
0.32	28	0.080	0.394	0.372	0.357	0.372	0.357	228.1	0.72
0.30		0.071	0.374	0.352	0.337	0.352	0.337	260.0	0.63
0.29		0.066	0.360	0.340	0.324	0.340	0.324	276.7	0.59
0.28		0.062	0.350	0.330	0.314	0.330	0.314	297.1	0.55
0.27		0.057	0.340	0.320	0.304	0.320	0.304	319.8	0.51
0.26	30	0.053	0.330	0.310	0.294	0.310	0.294	345.3	0.47
0.25		0.049	0.318	0.298	0.284	0.298	0.284	374.0	0.44
0.24		0.045	0.308	0.288	0.274	0.288	0.274	406.3	0.41
0.23	31	0.041	0.298	0.274	0.264	0.278	0.264	443.1	0.37
0.22		0.038	0.286	0.266	0.252	0.266	0.252	485.1	0.34
0.21		0.035	0.276	0.256	0.241	0.256	0.241	528.1	0.31
0.20	32	0.031	0.266	0.246	0.231	0.246	0.231	583.1	0.28
0.19		0.028	0.256	0.236	0.221	0.236	0.221	647.2	0.25
0.18	33	0.025	0.246	0.226	0.211	0.226	0.211	722.4	0.23
0.17		0.023	0.232	0.214	0.199	0.214	0.199	811.4	0.21
0.16	34	0.020	0.222	0.204	0.189	0.204	0.189	918.1	0.18
0.15		0.018	0.210	0.192	0.177	0.192	0.177	1047	0.16
0.14	35	0.015	0.200	0.182	0.167	0.182	0.167	1206	0.14
0.13		0.013	0.190	0.172	0.157	0.172	0.157	1403	0.12
0.12	36	0.011	0.180	0.162	0.147	0.162	0.147	1653	0.10
0.11		0.009	0.166	0.150	0.135	0.150	0.135	1977	0.08
0.10	38	0.008	0.156	0.140	0.125	0.140	0.125	2405	0.07
0.09		0.006			0.113		0.113	3021	0.054
0.08	40	0.005			0.103		0.103	3857	0.05
0.07	41	0.004			0.091		0.091	5094	0.04
0.06	42	0.003			0.081		0.081	7112
0.05	44	0.002					0.069	10460
0.04	45	0.001					0.056	16000
0.03	48						0.044	29470
0.025	50						0.038	43680

Core
Ferrite	Shape: EI, EE, EER, EC, PQ EQ, EPC, SMD etc.
	Ferrite is a type of Carbon Iron product which is treated under high temperature as 1,000~1,500 degrees centigrade together with metal Oxide (such as Manganese Oxide, Nickel Oxide, Cupper Oxide, Zinc Oxide) to form unique alloy, which has Very high magnetic transparency. High value of Magnetic Flux Saturation, Compare to other metal magnetic materials, Ferrite has higher resistance and popularly used for High Frequency Magnetic Material.

Decide Gap Distance
	Spacer Gap Possible to create any Gap thickness
	Center Pole Gap This middle part is polished and it is difficult to adjust gap distance. Very Low noise due to small leakage of magnetic flux created from the Gap. (Simply change spacer double, the noise does not become same)

Tube
Anti-flamer Silicone Vanish Glass Tube (Nikkan Industry product)
S-693V			VW-1	E55258
S-693-600	200 degrees centigrade	600V	VW-1	E72406
Silicone Rubber Injected Tube (Nikkan Industry product)
E-651U-1	200 degrees centigrade	300V	VW-1	E88468
E-651U-2	200 degrees centigrade	600V	VW-1	E88468
Electric Insulation PBC Tube (Iwase product)
AH-3	105 degrees centigrade	300V	VW-1	E56036
AH-6	105 degrees centigrade	600V	VW-1	E56036

Heat-resistant plastic wire
UL1007	80 degrees centigrade	300V
UL1015	105 degrees centigrade	600V
UL1430	105 degrees centigrade	300V

Heat Resistant PCB Wire
Type of Insulation	Temperature allowance	Material Construction
Type Y	90 degrees centigrade	For example, Cotton, Silk, Paper combination, without Vanish or oil soaking
Type A	105 degrees centigrade	For example, Cotton, Silk, Paper combination with vanish or oil soaking
Type E	120 degrees centigrade	Poly-Ethylene type insulator
Type B	130 degrees centigrade	For example Mica, Asbestos, Glass Fiber type materials used with resin
Type F	155 degrees centigrade	For example Mica, Asbestos, Glass Fiber type materials used with Silicone Alchid resin
Type H	180 degrees centigrade	For example Mica, Asbestos, Glass Fiber type materials used with Silicone type of resin or equivalent type of resin ,material. Single use of Rubber type of Solid State Silicone Resin is included
Type C	180 degrees centigrade	For example, single use of rare Mica, Asbestos, Ceramic used together with adhesive

Input Voltage	Power Line Voltage of the World(AC)
As well as for domestic market, Switching Power Supply is world wide used for AC and DC Power Supply. There are many types and models available. Before use of Switching Power Supply, please check your local Voltage, AC, or DC type, Tolerance of Voltage, method of input Voltage change methods.

Pulse Transformers
This is one type of wide band transformer to transfer pals shape wave accurately. It is necessary to design transformer that core do not get saturated by Pulse signal amplitude and wave width. Also coil must be designed to minimize rush Current and back swing.
	E:Peak Pulse Voltage Zug=B/E x 100%

	(1)Excellent Wave Form
	(2)Not enough Inductance increase winding turns for improve m or increase core size/
	(3)In case magnetic energy transfer is not enough due to pals average currency
	(3)Change core time to improve Currency efficiency or change gap distance

About Shielding
Due to it's Physical Construction of transformer, floating capacitance or leakage of magnetic may cause problem to other component parts in circuit. In order to Avoid such problem, there is a method generally used is Shielding the transformer. There are three methods as Common way of Shielding, such as Static Shield, Magnetic Field Shielding and Magnetic Shielding.

Static Shield
	Static Capacitance is created at insulation between primary conductance and secondary conductance. Winding width and distance between the primary and secondary, and selection of insulation materials can reduce such static capacitance. To place Cupper foil or other conductive foil can reduce common mode noise about half. This Shielding (S) must be designed to make sure that it will not become short turn.

Magnetic Shield
When Magnetic Flux goes through Steel core, a part of magnetic energy leaks from EI core junction point. This magnetic energy may affect component parts used in circuit around transformer. In order to reduce such amount of leakage, it is possible to design junction distance as short as possible for design Bm lower. Generally, core ring or case solves this problem.
	Core ring Use High Magnetic Transparency material to cover the transformer as illustrated drawing. In this case, core ring is magnetically short circuited. There is not high efficiency for high frequency.
To put whole transformer into shield case will make shut out leakage of magnetic noise as well as protecting the transformer from outside noise.

Thermo Fuse
To detect short circuit caused by circuit component parts through lead wire as well as body of transformer and shut out circuit for protection from overheating.
Action	Shape