Division Spang Company DESIGN MANUAL TWC-500 ABOUT MAGNETICS
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TAPE WOUND CORES
Division Spang Company
DESIGN MANUAL TWC-500
ABOUT MAGNETICS
Since 1949 Magnetics, division Spang Company, been leading world supplier precision, high permeability magnetic components materials electronics industry. Applications these products range from simple chokes transformers, used telephone equipment, sophisticated devices aerospace electronics. Staffed with high degree technical talent, having modern research facilities, Magnetics followed carefully charted course find fill specialized industrial needs, same time pioneering designs, product developments, innovations manufacturing methods. Many these developments have resulted acceptance industry standards tape wound cores, powder cores ferrite cores products Magnetics. critical importance tape wound cores described this catalog magnetic alloy. sister division, Spang Specialty Metals, originally established manufacture reroll soft magnetic alloys used these cores. Spang Specialty Metals pioneered development unique powder metallurgy techniques which contributed superiority MAGNETICS cores. provide best fastest service obtainable, Magnetics sales offices strategically located serve you. Application assistance also readily available. Many standard parts stocked; custom parts also obtainable.
INDEX
SPANG TECHNOLOGY CENTER
Spang Technology Center well-equipped well-staffed multi-disciplinary laboratory whose main area expertise development evaluation materials high technology applications. laboratory personnel made high calibre people; functions split into areas: determine composition processing conditions invention improved materials, maintain equipment procedures evaluate pertinent properties these materials. Special Measurements Section equipped make most magnetic electrical measurements frequencies several megahertz both high power levels. chemical analytical laboratory analyze wide range inorganic elements, both metallic non-metallic. Other features laboratory include Electron Microscope various mechanical testing machines addition pilot production facilities that duplicate existing production major manufacturing areas.
INTRODUCTION History applications GENERAL CORE CONSTRUCTION. What makes MAGNETICS® tape wound core TESTING Test methods used establishing core parameters CORE SELECTION. Various core boxes available their advantages DESCRIPTION MAGNETIC MATERIALS Various magnetic materials available, their advantages properties ORDER. Designations regular miniature cores what they mean ordering CORE SELECTION Procedure proper core selection application WINDING DATA Procedures estimating greatest number turns cores APPLICATIONS Four applications their design considerations Conventional Converter Inverter Design. Thyristor Protection. Current Transformers. Output Regulators Switched-Mode Power Converters. DESIGN CURVES 34-57 Complete design curves showing characteristics alloys tape thicknesses under various conditions TYPICAL HYSTERESIS LOOPS. CURVES FLUX DENSITY VARIATION TEMPERATURE SQUARENESS TEMPERATURE. 46-47 CORE LOSS CURVES TYPICAL IMPEDANCE PERMEABILITY CURVES. CORE SIZES SELECTION TABLES Complete tables cores their dimensions WIRE WINDING DATA Tables curves proper winding toroidal cores DEFINITIONS CONVERSION FACTORS OTHER PRODUCTS
MAGNETICS registered trademark Magnetics Div., Spang Company, Butler,
INTRODUCTION
Although groundwork formation modern magnetic devices laid Germans World after World that tape wound cores their beginnings when electronics opened weapons systems. Naval Ordnance Laboratory Washington, turned attention facets magnetism devices where vacuum tube serious drawback fragility. Navy constantly looking device with vacuum tube's precise ability control with none physical limitations. device, magnetic amplifier, became subject study. engineers scientists assigned this work began deeply into function core plays, particularly what could done using newer nickel-iron alloys. discovered that some alloys would reach saturation with very magnetizing currents. This started beginning science high permeability magnetics. Magnetics established 1949 when commercial market high permeability magnetic materials virtually nonexistent development this field just taking root. simplicity reliability with which magnetic components could used opened many doors field electronics. Magnetics quickly positioned leader this field remained ever since. first tape cores were used applications where they were superior fragile vacuum tubes. Tape wound core applications grew rapidly because these magnetic components performed better environmental operational advantages. They contained parts wear burn out; effects shock, vibration temperature were small compared other components. Tape cores also afforded advantages electrical isolation signal mixing easily obtainable from other electric parts.
MATERIALS APPLICATIONS
Some magnetic devices early applications have since been replaced transistors integrated circuits; however, host applications requirements core materials have emerged. Magnetic cores often parts complicated electronic circuitry found highly reliable airborne space computers, telephone systems, radar installations, engine controls, power supplies nuclear reactors. Tape wound cores made from high permeability magnetic strip alloys (.0005" .014" thick) nickel-iron (80% nickel), silicon-iron, cobalt-iron various amorphous metals. They provided protective cases epoxy encapsulated. Tape wound cores produced small .375" more than over 1400 sizes. Bobbin cores miniature tape cores made from ultra-thin (.000125" .001" thick) strip wound non-magnetic stainless steel bobbins. Covered with protective caps then epoxy coated, bobbin cores made small .050" with strip widths down .032". Tape Bobbin Cores Cores Applications Converters Current transformers Electronic transformers Ground fault interruptors High frequency counters Inverters Magnetic amplifiers Magnetometers Memory cores Oscillators Power transformers Pulse transformers Reactors Regulators Saturating transformers Static magnetic devices Switching regulators Timers
VERTICAL INTEGRATION
components manufactured Magnetics process-controlled from alloying materials producing finished cores. This total in-house capability, coupled with "Zero Defects" Quality control process, assures user that high-tech applications will performance guaranteed. addition, unexcelled service includes expert engineering assistance, software package recommendations, finished parts inventories satisfy both prototyping volume deliveries.
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GENERAL CORE CONSTRUCTION
From basic steel finished core, strict quality control assures ultimate reliability designs, specifications, necessary tolerances followed through production.
evaluation used selection special materials special cores needed critical applications where standard guaranteed limits wide.
Core Winding Basic Steel
basic steel used within tolerance nominal thickness. Particular attention placed physical selection proper steel. Reasons rejection basic steel tape wound cores include poor physical characteristics, holes, pits, creases, blisters, wrinkles poor magnetic properties such flux density poor squareness ratio. Coil camber held minimum obtain optimum magnetic characteristics finished core. Each basic coil material identified with coil number, thickness, material description, width, weight. This identification carried throughout manufacturing process that complete history every tape wound core available. tape wound cores wound accurate dimensions, weights, winding tensions maintain uniformity finished product.
Steel Evaluation
Each coil tested basic properties winding standard cores processing them under various conditions determine optimum processing that particular coil. process specified that coil becomes part history which travels with that coil made into production cores. your assurance that ultimate tight, guaranteed electrical limits will obtained product. addition, electrical data obtained basic coil
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SPECIFICS CORE CONSTRUCTION
Protective Boxes
tape wound cores made from nickel-iron materials encased protect them from mechanical strains which affect magnetic properties. Silicon-iron cores somewhat less affected, obtained with without protective boxes. Between core there inert silicone cushioning damping compound, amount which pre-determined each core size. This compound prevents movement core provides additional protection from external stresses. Boxes either aluminum phenolic, made minimum dimensions (see "Core Selection", page designed that they strained temperatures pressure from copper windings. Aluminum core boxes greatly minimize these dangers; types uncoated (guaranteed voltage breakdown). guaranteed voltage breakdown finish seals capable withstanding least 1,000 volts cycles between copper windings bare case. permits winding directly core without prior taping. cores checked also leaks their ability operate extreme temperature environments. Each core carries identifying number (see "How Order", page 15). addition, number also stamped box. This number indexes central quality control file which identifies: basic coil steel used manufacturing core; heat treating cycle; date core manufactured; number cores manufactured that lot; electrical data lot.
Annealing
Using most modern automatic furnaces, cores annealed hydrogen atmosphere remove strains impurities from tape. Critical timetemperature characteristics cooling rates accurately controlled. Temperatures corresponding evaluation basic steel previously described used.
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TESTING
Magnetics uses testing methods determining dynamic characteristics tape wound cores. These methods include Constant Current Flux Reset Tester Sine Current Loop Tester, both which normally operated frequency Hertz. (Information regarding operation other frequencies obtained contacting Magnetics Sales Department.) Constant Current Flux Reset test method been chosen standard IEEE (Standards Paper #393) Magnetics because measures parameters which valuable predicting core performance many magnetic amplifier circuits. Figure shows operational diagram Constant Current Flux Reset Tester.
excitation circuit provides magnetizing force from source either half wave rectified current full wave current, depending parameter measured. constant current reset magnetizing force supplied from source direct current which incremental direct current added. Output core integrated measured terms electrical output integrating system composed attenuator, electronic integrator, amplifier, peak voltage detector circuit, output meter bridge balance system. attenuating system compensates core area that flux density output meter dial readings always proportional.
Measurements made applying proper excitation, with reset pick windings placed core. core excited sinusoidal full wave current adjusted IEEE requirements. This drives core around major dynamic hysteresis loop from positive negative saturation, flux density measured. Next, core excited half wave (rectified) source which drives core into saturation during half cycle. This permits flux return residual flux density level during "off" portion cycle. Output core read (Bm- Br), providing indication squareness core. From these values residual flux density squareness ratio computed.
EXCITATION WINDING
EXCITATION SUPPLY
D-CRESET WINDING D-CRESET SUPPLY
INCREMENTAL RESET SUPPLY
OUTPUT METER
PEAK VOLTAGE DETECTOR
AMPLIFIER
ELECTRONIC INTEGRATOR
ATTENUATING SYSTEM
PICK WINDING
FIG. Operational Diagram Magnetics Reset Tester
MAGNETICS Butler,
When negative applied reset winding with positive half wave excitation (Figure total flux change within cycle will increase because core reset driven down back side hysteresis loop (Figure With core being excited positive half wave source, only enough negative introduced reset flux value equal one-third saturation flux density. reset magnetizing force required accomplish this indication loop width (H1). increment reset magnetizing force added initial reset force will further reset flux from flux density Bm/3 flux density m/3. This incremental magnetizing force function slope linear portion dynamic hysteresis loop defined Core gain determined from formula where incremental flux reset. Standard measurements discussed above summarized illustrated Figures also fully covered IEEE Standards Paper #393.
Loop Testing
supplementary dynamic testing method employed Magnetics uses Sine Current Loop Tester which measures coercive force peak differential permeability under sine current excitation. using synchronous switches, following four patterns displayed simultaneously oscilloscope: PATTERN 1-E-I loop core, with signals proportional induced core voltage magnetizing current being displayed vertical axis horizontal axis respectively. PATTERN 2-An elliptical pattern which locus constant permeability. PATTERN zero magnetizing force reference marker.
PATTERN 4-An adjustable vertical magnetizing force line. test made exciting core with sinusoidal drive. Then, means precision potentiometers calibrated units permeability magnetizing force, position patterns made coincide with peak loop (pattern Peak differential permeability coercive force read from potentiometer dials. excitation current includes provide both full wave sinusoidal current. tronic integrator, therefore measure rectifiers half wave elecpossible
FIG. Typical Integrator Output Increasing Reset Current
FIG. Standard Reset Tester Measurements
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residual flux density squareness ratio, calculated from these measurements. simplified schematic drawing Sine Current Loop Tester shown Figure summary measurements illustration patterns oscilloscope appear Figure also covered IEEE Standards Paper #393.
CORE SINUSOIDAL CURRENT SUPPLY
PHASE SHIFTER
DIAL
SYNCHRONOUS SWITCHING REFERENCE VOLTAGE
DIAL
FIG. Schematic design sine current Loop Tester. Half wave supply circuit voltage integrator shown.
Core Matching
standard core matching method used Magnetics consists visual comparison Hertz loops cores displayed simultaneously oscilloscope.* Oscilloscope controls adjusted that half each loops will occupy screen. Only when loops coincide points within five cent peak horizontal vertical deflections they shipped "five cent match." Experience proves that this method results best possible match over entire loop. permits detection wave forms normally rejected differential measure. While this matching method does give numerical results, such results obtained standard test basis mutually acceptable limits. illustration oscilloscope display shown Figure
*For matching other frequencies, please write Magnetics Sales Department.
OSCILLOSCOPE
FIG. Standard sine current Loop Measurements.
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Supermalloy Testing
Supermalloy tape wound cores often used applications requiring high initial permeabilities core losses over wide range frequencies. insure proper operation these applications, Magnetics performs impedance permeability test Supermalloy cores. Impedance permeability correlates well with magnetizing currents flowing result core losses inductive reactance wound cores. equal where determined from total magnetizing current determined from voltage induced pick-up winding core. MAGNETICS Supermalloy cores manufactured minimum limits each material thickness. test performed gauss high frequency where core losses material permeability have equal effect measured Special precautions should taken demagnetize Supermalloy cores before performing level permeability tests. This insures that core permeability being measured around initial "zero state around remanence point.
Constant Current Flux Reset Matching
supplementary core matching method used Magnetics consists matching parameters obtained from Constant Current Flux Reset Tester. These characteristics matched within while matched within 10%. While this test will produce numerical recorded results, cores matched with this method insure that only four distinct test points being matched. Matching these four points does insure that other points hysteresis loops matched same degree. Since performance core will affected windings placed Magnetics cannot guarantee degree match after winding. very critical applications there substitute matching completed reactor assemblies.
Fluxmeter Testing
help maintain constant high quality core materials, Magnetics uses conventional fluxmeter methods measuring magnetic parameters under static (dc) conditions. Although production test, this method part established quality control procedure. Parameters which determined from fluxmeter measurements certain less square materials, initial maximum permeability. Because proven reliability, this test used reference other types flux density measurement equipment.
FIG. Typical matching patterns
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CORE SELECTION
Encapsulated Cores Unboxed Cores
Because extreme sensitivity nickel-iron cores winding stresses pressures, such cores available unboxed state. Magnesil cores susceptible these pressures available without boxes. Magnesil cobalt-based amorphous cores only available encapsulated form. This protection tough, hard, epoxy which adheres rigidly core, allowing winder wind directly over core without prior taping. smooth radius prevents wire insulation from being scraped.
advantages unboxed core are:
advantages encapsulated cores are:
Maximum window area available. Where slight deterioration properties after winding potting tolerated, slightly smaller package somewhat lower cost yielded. minimum voltage breakdown 1,000 volts from core winding guaranteed. temperature rating this finish 125°C (257°F) free air. taping required core prior winding.
FIG. Unboxed core cross section. Unboxed cores available Magnesil.
FIG. Cross section encapsulated core. Epoxy coating. Core.
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Non-Metallic Boxes
superior electrical properties, wearing qualities high strength, non-metallic boxes widely used protection core material against winding stresses pressures. Tough resilient, they come types: where production quantities justify them, boxes made molded glass-filled nylon, volume production quantities, phenolic fabrics used. Both types meet minimum 2,000 volt breakdown requirement. glassfilled nylon types withstand temperatures 200°C without softening, while phenolic materials will withstand temperatures 125°C. sizes that tooled glass-filled nylon shown Core Size Table, pages 58-61.
FIG. Phenolic Core Construction
Phenolic (plastic) case, tough resilient, high electrical resistance. Phenolic insert, accurately cut, pressure fitted tight seal. Inert cushioning, high temperature silicone compound. Magnetic materials, selection commercially available high permeability alloys.
FIG. Nylon Core Construction
Nylon case, tough resilient, high electrical resistance. Nylon insert, accurately cut, pressure fitted tight seal. Inert cushioning, high temperature silicone compound. Magnetic materials, selection commercially available high permeability alloys.
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Aluminum Boxes
Aluminum core boxes have great structural strength. glass epoxy insert, which aluminum case mechanically bonded, forms air-tight seal. These core boxes will withstand temperatures 200°C (392°F), critical factor design compact airborne equipment. Advantages aluminum are: Core boxes will withstand temperatures 200°C (392°F). This important designing extreme environmental conditions. page core material temperature limits. Magnetic properties will changed coil winding. strong aluminum construction will prevent distortion core box, thus preserving guaranteed magnetic properties core within. Effects vibration shock minimized because tape cushioned inert silicone compound.
FIG. Aluminum Core Construction
Aluminum case greatest structural strength ever attained. Silicone glass malamine insert, break electrical path around ctore. Inert cushioning, high temperature silicone compound. Magnetic materials, selection commercially available high permeability alloys
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Aluminum Cases with
This case same basic construction aluminum box, addition thin, epoxy-type, protective coating surrounding case. This finish adds more than .015" subtracts more than .015" from adds more than .020" height.
Miniature Tape Wound Cores
cores previously described used primarily circuits operating available mainly tape thicknesses from mils, depending certain ID's also available tape. higher frequency operation, miniature cores made from Orthonol® Permalloy available thicknesses from mil. These standard miniature cores coated with provide hermetic seal guarantee minimum voltage breakdown volts. Miniature tape wound cores, available wide range standard flux capacities, very useful operating frequencies kHz. advantage that their size much smaller than that obtained boxed cores. Miniature tape wound core sizes part numbers listed page FIG. Cross section GVB. Basically same aluminum case, thin epoxy-type coating around case.
Advantages finish are: guaranteed 1,000 volts minimum breakdown from wire case.
finish will cold flow under winding tensions. case sufficiently tight seal normal vacuum varnish impregnation. high vacuum conditions guaranteed leakproof seal, contact factory. core permits direct winding copper case without prior taping. coating will withstand temperatures high 200°C -65°C with operating life 20,000 hours. Applications include high performance aircraft specialized shipboard use, well surface-to-air air-to-air missiles. Storage does affect finish. encased core ideal majority applications where rigid military specifications involve extreme environments under vibration temperatures. complete information guarantees which caver extreme environmental conditions, refer Magnetics Sales Department.
FIG. Cross section miniature tape wound core. Protective cap. Stainless steel bobbin. Ultra-thin tape.
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DESCRIPTION USES AVAILABLE SOFT MAGNETIC MATERIALS
Magnetics soft magnetic core materials available applications saturating high sensitivity magnetic circuits. These materials especially selected processed meet exacting magnetic circuit requirements, manufactured tight guaranteed tolerances according IEEE test procedures* other common industry test methods.
MAGNESIL(MATERIAL CODE LETTER "K") This material grain-oriented siliconiron alloy available .001", .002", .004" .012" thicknesses. processed annealed develop high squareness core loss. usually used high quality toroidal power transformers, current transformers high power saturable reactors magnetic amplifiers. exhibits high saturation flux density with high squareness comparatively high coercive force core loss. With high Curie temperature, quite useful magnetic devices which exposed temperatures between 200°C 500°C. higher temperatures, flux density, however, must reduced appropriately. page Also higher temperatures, unboxed cores only should used temperature limitations.
ALLOY
(MATERIAL CODE LETTER "H") This material, nickel-iron alloy, round loop available .002", .004" ,014" thicknesses. exhibits lower Saturation Flux Density, Squareness, Coercive Force, core Gain than Orthonol types. However, when used proportioning magnetic amplifiers, eliminates possibilities triggering. useful devices requiring lower coercive force losses such special transformers, saturable reactors, proportioning magnetic amplifiers.
SQUARE PERMALLOY
(MATERIAL CODE LETTER "D") This material non-oriented nickeliron alloy available .0005", .001", .002", .004" .014" thicknesses tape wound cores .000125", .00025" .0005" thicknesses bobbin cores. manufactured meet high Squareness, high core Gain requirements magnetic preamplifiers modulators. especially useful converters inverters where high voltage power levels required, where circuit losses must kept minimum. Square Permalloy Saturation Flux Density approximately that Orthonol's, Coercive Force values that oriented nickel-iron alloys. Core Gain Square Permalloy higher approximately times core Gain Orthonol.
SQUARE ORTHONOL (MATERIAL CODE LETTER "A") This material grain-oriented nickel-iron alloy available thicknesses .0005", .001", .002", .004" .014" tape wound cores, .00025" .0005" thicknesses bobbin cores. manufactured meet exacting circuit requirements very high squareness high core gain, usually used saturable reactors, high gain magnetic amplifiers, bistable switching devices, power inverter-converter applications. Other applications such time delays, flux counters transductors demanding extremely square hysteresis loops require setection Square Orthonol.
*Tested IEEE Std. using Constant Curent Flux Reset Test Method Hertz.
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ROUND PERMALLOY
(MATERIAL CODE LETTER "R") This material non-oriented nickeliron alloy available thicknesses .001", .002" .004". processed develop high Initial Permeability Coercive Force. lower Squareness core Gain than Square type, these characteristics sacrified produce high Initial Permeability Coercive Force properties. This material especially useful designing highly sensitive input inter-stage transformers where signals extremely currents present. also useful types current transformers where losses must kept minimum, high accuracy necessity. Initial Permeability this material usually between 20,000 50,000 with Coercive Force values about that Square Permalloy
SUPERMENDUR
(MATERIAL CODE LETTER "S") This material, available small quantity special order, highly refined cobalt-iron alloy, available ,002" .004" thicknesses. specially processed annealed develop high Squareness high Saturation Flux Density. serve well devices requiring extreme miniaturization high operating temperatures. used same types applications Magnesil; however, higher Flux Density (approximately 21,000 gausses), reduction core size weight accomplished. highest Curie temperature available square loop alloys, will find applications high temperature work.
AMORPHOUS (Iron-based) Round Loop
(MATERIAL CODE LETTER "G") This amorphous alloy annealed obtain round loop which results very core losses high frequencies. Because high saturation induction relative ferrites permalloys, alloy offers significant size reductions high frequency devices. suitable wide temperature ranges without cracking showing large drops usable flux density. This alloy relatively constant impedance permeability over wide frequency range; this property useful signal transformers current transformers. Losses material reduced under square wave excitation, making ideal switched-mode power supplies.
AMORPHOUS (Cobalt-based) AMORPHOUS (Iron-based) Square Loop
(MATERIAL CODE LETTER "B") (MATERIAL CODE LETTER "E") material, cobalt-based alloy, losses, vety high permeability, high squareness coercive force. These characteristics make alloy most ideal SMPS applications such magnetic amplifiers, semiconductor noise suppressors high frequency transformers. also finds high sensitivity matching transformers ultra-sensitive current transformers. This alloy near-zero magnetostriction, high corrosion resistance high insensitivity mechanical stress.
SUPERMALLOY
(MATERIAL CODE LETTER "F") This material highly refined specially processed nickel-iron alloy available .0005", .001", .002" ,004" thicknesses. manufactured develop ultimate high Initial Permeability losses. Initial Permeability ranges from 60,000 100,000 while Coercive Force about that Square Permalloy This material very useful ultra-sensitive transformers, especially pulse transformers, ultra-sensitive magnetic amplifiers where extremely loss mandatory.
This amorphous material square loop material comparable Orthonol having core losses. alloy finds applications pulse transformers, magnetic amplifiers, power transformers, current transducers, other devices requiring square loop, high saturation material. offers unique combination high resistivity, high saturation induction, extremely core loss, making suitable from very high frequencies. This alloy ideal pulse applications which require high squareness high pulse rates. achieve high flux swings with very core loss.
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PHYSICAL PROPERTIES
TABLE TYPICAL PROPERTIES MAGNETIC ALLOYS
AMORPHOUS ALLOYS PROPERTY Nickel Cobalt Iron Silicon Molybdenum Other Density (gms/cm Melting point (°C) Curie Temp. (°C) Specific heat (Cal./°Cgm) Resistivity (miorohm-cm) Coeff. Expansion (x10 /°C) Rockwell hardness SIFE ALLOYS 7.65 1,475 B-84 NIFE ALLOYS 1,425 B-90 NIFE ALLOYS 1,425 .118 12.9 B-95 COFE ALLOYS 1,480 .118 B-98 Iron-based (ATOMIC 13.5B 7.32 1,100 C-69 Cobalt-based (ATOMIC 7.59 1,000 205* 12.7 C-69
Effective continuous operating temperature 90°C.
MATERIALS COMPARISON
TABLE MAGNETIC CHARACTERISTICS COMPARISON*
COERCIVE FORCE FLUX DENSITY MAT'L CODE MATERIAL TYPE Magnesil Square Orthonol Alloy Square Permalloy Round Permalloy Supermalloy Supermendur Amorphous Amorphous Amorphous (KILOGAUSSES) 15.0-18.0 14.2-15.8 11.5-14.0 6.6-8.2 6.6-8.2 6.5-8.2 19-22 15-16 5-6.5 14.5-15.8 (TESLAS) 1.5-1.8 1.42-1.58 1.15-1.40 .66-.82 .66-.82 .65-.82 1.9-2.2 1.5-1.6 .5-.65 1.45-1.58 SQUARENESS .80-.92 .45-.75 .40-.70 OERSTEDS .4-.6 .1-.2 .05-.15 .02-.04 .008-.02 .003-.008 .15-.35 .03-.08 .008-.02 31.8-47.8 7.9-15.9 4-12 1.6-3.2 .64-1.6 .24-.64 12-27.9 2.4-6.4 .64-3.2 HERTZ CCFR**
OERSTEDS
.45-.65 .15-.25 .08-.15 .022-.044 .008-.026 .004-.015 .50-.70 .04-.1 .01-.025
35.8-51.7 11.9-19.9 6.4-12 1.75-3.50 .64-2.07 .32-1.19 39.8-55.7 3.2-7.9 .79-2
GAIN*** 130-220 310-715 280-550 550-1650 250-715 250-715 85-135 400-900 750-2,500
Core loss w/lb. 10kHz,
*Values listed typical .002" thick materials types shown.
*400 Hertz CCFR Coercive Force defined reset characteristics escribed Constant Current Flux Reset Test Method IEEE Std. #393. *Gain Hertz core Gain described Constant Current Flux Reset Test Method IEEE Std. cores with ID/OD .80.
MAGNETICS
ORDER
ORDER REGULAR TAPE WOUND CORES
Magnetics manufactures Performance Proved" tape wound cores using high permeability alloys shown below. Each core coded part number which describes detail. Knowing code will simplify purchasing. typical number
ORDER MINIATURE TAPE WOUND CORES
Magnetics available line miniature stainless steel bobbin cores high frequency magnetic amplifiers. These cores recommended amplifiers whose operating frequency between kHz. Each miniature core number which describes Material coded part
TABLE MATERIAL CROSS REFERENCES AVAILABLE TAPE THICKNESSES
Magnetics Trade Names Square Letter Code
Thickness mills Size description Type
531-
High frequency magnetic amplifier core Permalloy material
Thickness Available .0005" .001" .002" .004" .014"
Similar Trade Names Orthonik Deltamax Hipernik Square
Orthonol
50000 series cores non-metallic boxes 51000 series cores aluminum boxes
tape thickness Stainless steel size number Bobbin core 80500 80999 cores stainless steel bobbins. Single material. letter code describes
Square Permalloy
.0005" .001" .002" .004" .014"
Square Super Square 4-79 Permalloy Square Permalloy Mo-permalloy Carpenter Allegheny 4750 Hipernik Alloy
52000 series cores aluminum with finish 53000 series (Magnesil boxed cores
Round Permalloy Alloy
same mat'l .002" .004" .014"
only)
54000 series encapsulated cores Orthonol 56000 series (ring lamination cores) nylon boxes Permalloy
Supermalloy .0005" .001" .002"
Supermalloy
Following basic series number another number which describes tape thickness mils. Thickness codes
Number preceding thickness mils.
letter
tape
Magnesil
.004" .001" .002" Silectron Microsil Hypersil Supersil Supermendur
Thickness codes are:
Amorphous Supermendur
.004" .012" .002" .004" .001"
METGLAS
Alloy 2605SC
final letter describes desired magnetic material, table Size listings shown Magnetics literature show non-metallic boxes, such 50029. order other type box, just change first digits. example, aluminum 51029; aluminum 52029. Unboxed 53029. page size listings available cores.
Double letter designation following material code special high frequen magnetic amplifier core code. Core sizes flux capacities other than those listed Table Page obtained special order.
Amorphous
.001"
METGLAS
Alloy 2605S-3 Amorphous .001" METGLAS
Alloy 2714A Round Permalloy used high initial permeability requirements, usually transformers. Square Permalloy used high gain devices where high squareness, coercive force with high gain properties desired.
MAGNETICS
TRANSFORMER DESIGN
following procedure useful selecting core designing transformer using tape wound cores. This discussion general applications frequencies between 60Hz 300kHz.
CORE SELECTION
From circuit requirements determine following transformer specifications: operating frequency Hertz primary current amperes transformer saturating type, flux density used must saturation value. This number shown chart below modified because operating temperature (Figure page 45). transformer more common nonsaturating type, flux density usually reduced less saturation value. additional requirement selecting operating flux density non-saturating transformer limit core losses resulting temperature rise core. This accomplished selecting flux used higher frequencies than noted here operating less flux density than saturation value.
primary voltage volts
From wire chart (page Table select wire size handle primary current above note wire area (Aw) From materials chart below, select material tape thickness corresponding operating frequency. upper frequency limit column chart based material being used near saturation flux density. materi-
density that produces core losses between watts pound depending ratio weight magnetic material outside surface area. Large cores that weigh pounds usually have high weight ratio limit core loss watts pound. Smaller cores weighing little grams will have weight ratio operate core loss watts pound higher. Using above considerations, select operating flux density (Bm) solve following equation WaAc:
AwEp
MAGNETIC CHARACTERISTICS TAPE WOUND CORE MATERIALS Saturation Flux Density Kilogauss 16.5
values noted above winding area core effective core cross section area winding factor
Magnetic Material MAGNESIL SiFe)
Curie Temp.°C
Upper Frequency Limit* Tape Thickness (in.) .012 .006 .004 .002 .004 .002 .001 .004 .002 .001 .0005 .001 .001 .001 Frequency 100Hz 250Hz 1KHz 2KHz 1.5KHz 4KHz 8KHz 4KHz 10KHz 20KHz 40KHz 20KHz 100KHz 300KHz
ORTHONOL (50% PERMALLOY (80%
Factor common winding transformer. transformer selfsaturating Royer Jensen type inverter, because space required switching windings. Factor denominator used square wave excitation. sine wave, this number 4.44. transformer core that meets above conditions, select with WaAc value equal greater than solution equation (1). WaAc Magnetics tape wound cores listed pages 58-61 this catalog.
AMORPHOUS AMORPHOUS AMORPHOUS
15.5 5.75
*Frequency limit based material being used flux density equal near material saturation. higher frequency useable with lower flux densities text.
MAGNETICS Butler,
Transformer Design
From chart with tape wound core chosen above, note cross section area core. this value following transformer equation solve number primary turns (Np).
units Teslas Then equation WaAc same equation (1), equations are:
WaAc
Magnetizing Current
Many transformer designs will require limit magnetizing current (Im). find value current above design, determine material core loss watts pound from curves pages through weight core selected above found from information page Multiply material core loss watts pound core weight find core loss watts. Core loss closely approximates voltamperes (VA) substituted PCL). Magnetizing current (Im) calculated using following equation:
MAGNETICS Butler,
FLUX TURNS/VOLT FREQUENCY NOMOGRAM
This nomogram designed solve Faraday's equation sine wave excitation. determine operating frequency core flux capacity maxwells. (See procedure used select toroidal cores Page Core Selection section.) With straight-edge, align these points nomogram read turns/volt from center scale. Knowing applied voltage, proper turns calculated quickly multiplying turn/volt applied voltage.
FIGURE
FLUX
(MAXWELLS) (WEBERS)
TURNS VOLT
FREQUENCY HERTZ
FLUX
TURNS VOLT
FREQUENCY HERTZ
MAGNETICS Butler,
WINDING DATA
DETERMINE APPROXIMATE NUMBER TURNS WIRE THAT WOUND TOROIDAL CORES
estimate greatest number turns that machine-wound toroidal core made taking several factors into consideration. These factors based core diameter height, type machine shuttle used, size wire used. These variables expressed formula which takes above points into account. This expression Effective Window Area Area Turn Wire Insulation window area remaining after core wound maximum winding machine. Subtract area residual hole, found Step from core case window area from Step This gives useable window area core. Determine effective window area multiplying useable window area .60.
Max. Number Turns
Note:
ratio Effective Window Area Useable Window Area
solve this expression, several quantities must known: core size wound, winding machine shuttle being used, proper wire size. Knowing these quantities, solution found from tables graphs included herein. procedure: Determine window area core wound. This quantity found each core Table page Identify shuttle size diameter used. Table lists various widths diameters popular shuttles along with range applicable wire sizes, page Using Figure find case height core being used abscissa. Read intersection applicable shuttle curve. Follow horizontally left from this intersection point find estimated area residual hole ordinate. residual hole amount
varies according type winding used, size wire, tension shuttle. Random-wound cores give ratio high while progressive sector wound cores give ratio .55. exact ratio must determined each machine, operator, wire size core size being used. estimating purposes, .60. Using effective window area from Step area turn proper size wire from Wire Data Section, maximum number turns wire found. Effective Window Area Max. Turns Wire Area Turn Wire
MAGNETICS Butler,
APPLICATIONS
TRANSISTOR INVERTER
APPLICATIONS
transistor inverter/converter made appearance 1955, become popular until 1970's. Since then, usage exploded into industry power conversion equipment. Figure shows original, still use, self-saturating (Royer Inverter) circuit. also known multivibrator oscillator because transistor conducts current while opposite does not; then reverse occurs. transformer core saturates each half cycle, causing each transistor switch case Figure shows modification this circuit (known Jensen circuit). differs from Figure mainly because transformers. Here, transformer saturates, causing switching transistor, while does not. There many other circuits being used. However, these circuits still popular frequencies 20kHz using tape wound cores military applications. Above 20kHz applications often commercial, using ferrite cores. transistors Figure operate switches serve same function switch contacts mechanical vibrator. energy required operate transistors switches supplied feedback windings, bases transistors. magnetic core transformer utilized fully that flux driven positive negative saturation alternate half cycles induces, windings, alternating square wave voltage. This square wave delivered load directly rectified (full wave) voltage higher lower) than battery voltage depending upon turns ratio voltage spike leading edge each pulse produced inductive kickback switch opening inductive circuit, this case transistor turning off. This voltage pulse generated transistor turning means which other transistor turned hence serves useful purpose. this pulse high, however, there danger damaging transistors. this reason, desirable magnetic materials having rectangular hysteresis loop that, saturation, windings exhibit inductance little kickback. Because gain transistors, there usually problem kickback being small, whereas disastrous transistors when pulse excessively large.
FIG.
FIG.
MAGNETICS Butler,
TRANSISTOR DESIGN FACTORS Transistor Selection
maximum voltage rating transistor must least twice battery voltage. When transistor transistor which must block battery voltage, plus induced battery voltage primary winding, plus transient spike which, light loads, high battery voltage. addition buffer capacitor desirable time, converter operate unloaded. maximize efficiency power converter under load, transistor should switch maximum voltage possible. Because junction heating, there maximum collector current which switched which independent supply voltage. Therefore, with given collector current, power output will increase directly with increased supply voltage. Assuming circuit losses (core, copper, transistor) fixed, then efficiency, under load, increased with increased supply voltage. Improved efficiency also results with transistors having high current gain since driving power feed back base must supplied from source through primary windings necessary provide current limiting resistor base circuit, losses this resistance should small achieve high efficiencies. Hence, ratio should high possible, must adequate
provide sufficient voltage current saturate transistor high collector currents. frequency cut-off characteristics transistor must high compared actual switching frequency. transistor cannot switch rapidly between states saturation cut-off, excessive junction heating will result. Therefore, frequency cut-off characteristics transistor should from five times frequency oscillation. When transistor characteristic times frequency multivibrator, output wave form would more nearly square wave than frequency were only five times that multivibrator.
best choice Orthonol. choosing higher flux density material, less iron copper required; thus, smallest size high efficiency achieved. Efficiency high because core losses small compared high output power achievable. interesting note that high efficiencies attained high audio frequencies because frequency increased, core size decreased; increased core losses offset reduction core volume frequency goes other hand, when converter design calls voltage power levels where high efficiencies desired under light load conditions, operating frequency above 10kHz, Permalloy should selected. When frequency approaches 50kHz higher, amorphous Alloy preferred because lower core losses even though flux density lower than other materials. Usually such equipment designed portable where high efficiencies light loads desired conserve battery power. this application, core losses greater than power delivered load unless cores having extremely losses used, hence, choice core material having lowest losses. effects windings circuit characteristics should considered converter designer either windings, or(b) excessive windings. appreciation this direct designer selection appropriate core size particular application.
MAGNETIC CORE CHARACTERISTICS
choice core material converter design simplified considering three materials: Ni-Fe grain oriented (Orthonol) Hz-10kHz Ni-Fe non-oriented (Permalloy 80), 5kHz-50kHz AMORPHOUS Alloy 25kHz-250kHz Orthonol high maximum flux density with losses; Permalloy about half maximum flux density Orthonol, much lower losses (only one-tenth losses Orthonol). converter designer, this means that most power applications where given voltage frequency required,
MAGNETICS Butler,
circuit Figure operates magnetic-coupled multivibrator where switching initiated core saturation. change impedance core from unsaturated saturated state produces rapid increase collector current. same time, induced voltage supplying base current reduced, producing rapid turn-off transistor. Thus, proper operation, there must significant change impedance core proceeds into saturation. this reason, there must sufficient number turns core produce this change impedance. Primary windings should turns greater, should five turns greater insure proper circuit operation. excessive number turns result apparent increase magnetizing current interwinding capacitance. Winding capacitance further evidenced ringing spurious oscillations which produced when core excited with square wave input; some this effect reduced progressive sector winding, best limit windings maximum about 2,500 turns. optimum design resulting minimum core winding cost (based keeping output turns below 2,500) result economical efficient unit.
When simple conversion required operating frequency specified, higher operating frequency will provide smaller unit. However, many cases, increasing frequency will dictate need more expensive material. Most often, either size cost specified, compromise between must made. design transformer either Royer Jensen type circuit, steps starting page followed, keeping mind preceding remarks materials winding techniques.
REFERENCES:
Mogen, Donald "Operation Saturable Core Square Wave Oscillator" Proceedings National Conference Aeronautical Electronics, 1956 (Copies obtained from Honeywell Transistor Division, Minneapolis, Minnesota). Bright, Pittman, Rogers "Transistors On-Off Switches Saturable-Core Circuits" Electrical manufacturing, December 1954. Stoner, Donald "Transistors" C.Q., March 1958 75-79. Sommerfield, E.H. "The Look DC-DC Power Conversion" C.Q., March 1958, following.
MAGNETICS Butler,
THYRISTOR PROTECTION
Toroidal tape wound cores ideal thyristor protection immediately after switching switching device. function core plays delay voltage thyristor hence adjust current that gradually increases. After current through thyristor reaches safe level, core saturates effectively circuit. (See Figures 17). square wave voltage pulse needs delayed length time, following equation used determine core size. where where 100Vt larger flux swing, reset winding used core switches from remanence polarity saturation opposite polarity. reset winding used, Orthonol material) recommended. flux swing 25,000 Gauss used Orthonol.
CURRENT I(no inductor)
(with inductor)
DELAY TIME
Prior saturation, core presents inductance adjusts current waveform according Ampere's law:
TIME inductor saturation time)
FIG.
current Amperes magnetic path length
peak voltage volts delay time µsec number turns effective core cross section area
change magnetizing force Oersteds
number turns
INDUCTOR THYRISTOR LOAD
change flux density gauss
Turns kept very low, most cases, only turn used. larger volt-time capacity required, taller core used cores stacked together turn applied stack. Since waveform unipolar, amorphous material recommended because largest flux swing from remanence saturation (Bm-Br). conservative value this flux swing material 8000 Gauss.
FIG.
MAGNETICS Butler,
CURRENT TRANSFORMER APPLICATIONS
Current transformers fall into general category known instrument transformers. Their main purpose produce, from primary current, proportional secondary current which easily measured used contral various circuits. shown Figure primary winding connected series with source current measured. secondary winding normally connected meter, relay, burden resistor develop level voltage that amplified control purposes. optimum current transformer operation, following conditions should met: Constant load impedance. Zero leakage flux. Zero exciting current. Infinite flux density. first condition, constant load impedance, usually current transformer applications. should also pointed that load impedance usually kept possible, since increase load impedance increases core flux which thereby increases exciting current. second condition, zero leakage flux, influenced both magnetic core material physical winding configuration. With high permeability cores proper winding techniques, this condition approximated errors small. most satisfactory cores current transformers toroids with both
INPUT
OUTPUT
CURRENT TRANSFORMER
FIG.
primary secondary windings encircling entire core. This affords very close coupling core links both windings, thus achieving negligible leakage flux. third condition, zero exciting current, never fully achieved. There will always some exciting current, minimized larger and/or more expensive cores. fourth condition infinite flux density also never achieved. larger cores will allow approaching this condition greater cost space. Current transformer designs normally involve trade-offs accuracy, size cost. Although square loop materials used near saturation minimum size required, most current transformers round loop materials such Magnesil, Alloy Supermalloy. materials usually operated less than saturation flux density order obtain good current transformer accuracy.
basic theory current transformer same other iron-core types. There are, however, subtle differences that change design procedures core selection method used. primary normally single turn least small number turns) while secondary large number turns; turns ratio 1000 more common.
Accuracy
high turns ratio generally causes high leakage inductance. This causes secondary output less than that predicted from primary voltage times resulting turns ratio output error. High permeability materials toroidal shapes afford close core coupling link both windings minimize leakage flux. Coupling increased primary winding several turns; however, satisfactory results obtained with only single turn. best
MAGNETICS Butler,
results, secondary winding should evenly spaced completely around core. exciting current determines maximum accuracy that achieved with current transformer. Exciting current defined portion primary current which satisfies hysteresis eddy current losses core. This becomes second source error because secondary current proportional primary current minus exciting current. secondary current therefore, exact measure primary current, magnitude this error directly proportional ratio magnetizing current primary current. High permeability core loss materials toroidal shapes recommended reduce errors leakage flux high magnetizing currents.
Transformer Design
design current transformer begins examining load requirements. burden transformer determines resistance current maximum output. load current, which secondary current coupled with load resistance determines transformer's secondary voltage
winding. value have reduced high voltages being used (more insulation between windings and, therefore, more winding area will needed). From (4), magnetic core used selected from charts pages 58-61 this catalog.
Saturation
primary current current measured controlled. Therefore, ratio primary secondary currents inversely proportional turns ratio: Using secondary voltage number turns secondary winding transformer equation, flux density core determined follows: 4.44
where
flux density (gauss) frequency (Hz) effective core area
Material Selection
Material selection current transformer depends operating frequency, accuracy cost. accuracy important, material thickness steel strip should follow chart page chart does include ferrites; however, they must considered frequencies over 20kHz. This discussion does include them. power frequencies 400Hz, chart indicates uses silicon steel where typical accuracy current transformer from Alloy improves accuracy .5%. Further improvement results from Permalloy Supermalloy materials, where accuracies less typical. These improved accuracies result from increased permeabilities that lower magnetizing current; they based using toroids manufacturing techniques reduce leakage flux.
most cases, single turn primary used; hence, primary current equal
Using value secondary current wire chart page wire size cross-sectional area should determined. winding area required secondary turns
Flux density from this equation should checked less than maximum flux density material that chosen. not, core with larger cross section (keeping same larger winding area) must selected checked saturation. Conversely, calculated flux density much less than maximum material selected, core with smaller cross section possibly used.
winding factor, function empty space between wires, insulation wires between layers. winding factor conservative, will usually result finished transformer utilizing nearly full winding area. also accounts having both secondary primary
MAGNETICS Butler,
Magnetizing Current
check accuracy current transformer design, necessary calculate amount magnetizing current. Using flux density from equation (5), primary voltage (Ep) from
current transformers used measure large currents 100A), size cost become appreciable, Permalloy generally used except extremely accurate applications. majority high current applications, Magnesil usually chosen because lower cost.
rather that this comparative accuracy various core materials. major factors contributing error current transformer are: leakage flux, losses windings, core losses. error leakage flux negligible most current transformers made toroidal cores with proper winding methods. copper losses made quite small proper design core size wire size. exciting current compensated adjusting turns ratio. actual accuracy expected, therefore, better than than shown table comparison page
core material, determine
material core loss watts pound from curves pages through Core weights found from information pages 58-61. Multiply material core loss (W/lb.) core weight find core loss watts. Core loss closely approximates (voltampere capacity) material substituted Magnetizing current calculated from:
MATERIAL COMPARISONS
following study made compare results obtained from various core materials available, when used typical current transformer applications. show true comparison core materials, following assumptions were made: Core Configuration toroid core structure will used since this optimum core configuration current transformers. affords essentially zero structure which minimizes leakage flux. Turns Ratio same turns ratio wire size will used materials. Core Material Typical magnetic characteristics will used Permalloy Alloy, Magnesil cores. Core Size core size will different each material. will held constant because their effect exciting current. width tape (height core) will varied compensate different flux densities three materials. materials, ratio flux density used maximum flux density will kept constant. accuracy calculated each case based exciting current core. assumed that this ultimate accuracy which could obtained,
Summary.
From previous discussion, main core requirements current transformer applications summarized follows: core configuration should such provide closed magnetic path which windings placed with close coupling minimize leakage flux; ideally toroid. core material should have high permeability, low-loss characteristics minimize effects exciting current. core should have high usable flux density minimize size core.
This value divided total primary current multiplied measure accuracy transformer percent; lower number, more accurate transformer.
Best Material Choice
best choice core materials current transformers based factors: accuracy, size. necessary compromise these factors reach optimum design. current transformers used measure small currents, size cost small, Permalloy best choice better inherent accuracy.
MAGNETICS Butler,
comparison effects core materials 200/2 ampere Hertz current transformer
.004" MAGNESIL INPUT OUTPUT BURDEN RATED CORE CORE SIZE (in.) EXCITING CURRENT ACCURACY COST RATIO AMP/1 TURN AMP/100 TURNS OHMS 50252-4K 1.50 2.25 .500 2.75 AMPS 1.4% .002" ALLOY AMP/1 TURN AMP/100 TURNS OHMS 50252-2H 1.50 2.25 .500 0.5% .002" SUPERMALLOY AMP/1 TURN AMP/100 TURNS OHMS 50088-2F 1.50 2.25 1.00 0.1%
MAGNETICS Butler,
OUTPUT REGULATORS SWITCHED-MODE POWER CONVERTERS
popular effective application Square Permalloy tape wound cores occurs multiple-output switched-mode power supplies. using such squareloop core provide controllable delay leading edge pulses secondary transformer, more outputs independently precisely regulated without losses inherent linear regulators complexity conventional switching regulators. cases where load currents subordinate outputs high excess amps), advantages saturable-core regulators become more more significant. Figure shows block diagram typical multi-output supply this type, while Figure illustrates regulation scheme. simplicity this example, forward converter topology shown, technique equally useful flyback push-pull converters. Typical waveforms shown Figure 19A. pulse width modulator (PWM), primary pulse width controlled sensing output, comparing reference, using error signal adjust pulse duration. there were saturable core (SC) circuit, output would "semiregulated," since primary control loop would provide line regulation. output would vary with load temperature. produce output, average value rectified waveform applied input inductor must 15V. Given pulse height repetition period required width positive pulse must (15V/50V) Because input pulse wide, saturable core must delay leading edge Since amplitude pulse 50V, that core must "withstand" volt-microseconds. accomplish this, core reset this amount during each alternate half cycle. waveform illustrates this. input core swings negative, diode conducts allows error amplifier "clamp" output side core -37.5V. result that core subjected reverse voltage -37.5V duration producing reset
design saturable reactor requires three steps: Determine withstand volt-seconds delay leading edge pulse achieve required output voltage. Here, designer must decide whether output must capable independent "shutdown" (for short-circuit protection turn-off from external logic signal), simply regulated fixed value. Withstand Excluded Pulse Area
Where pulse amplitude, delay leading edge.
Case Shutdown. required withstand simply area under entire positive input pulse. circuit Figure 19A, would Voltmicroseconds. Case Regulation only. Assuming that output inductor been designed continuous conduction, reactor must only reduce input pulse width enough furnish required average value (equal output voltage) input filter inductor.
both cases, must allow "headroom" accommodate load transients. This comment relates choice turns secondary winding transformer which feeds regulator, which must precede calculation volt-seconds which reactor must support. example, might design control range allow pulse width
12.5V
withsand)
output varies, error amplifier will alter this value ensure that output regulated spite changes rectifier voltage drops, etc. waveform primary current, shows increase current when core saturates begins deliver current output inductor. This incidental bonus: primary switching transistor already turned saturated, hence output does contribute turn-on switching losses transistor.
FIG. Multiple-output switched-mode power supply.
FIG. 19A. Regulation scheme.
MAGNETICS Butler,
increase decrease when load current steps down. allow pulse width increase, input pulse width must greater than nominal pulse output reactor. Depending operating frequency core used, must allow additional margin risetime current core after saturates. This typically order microsecond. This implies that secondary voltage least higher than would produce desired output voltage saturable reactor were present. allow pulse width decrease, reactor must withstand additional volt-seconds reduce pulse width below nominal value. circuit Figure 19A, "regulation only" design would require withstand
Pick wire size, based current. reasonable value circular mils current (rms) temperature rise degrees core sizes inch o.d. This yields crosssectional area conductor. Choose core material, determine saturation flux density, this application, Square Permalloy good choice, since coercive force very square loop. approximately 7000 gauss. Choose fill factor using with lower values power applications. Calculate WaAc follows: cir. mils
sectional area, 2581 c.m. Again, using "regulation only case, WaAc follows: 2581
WaAc
7000 .011 c.m.
Note that fill factor been used, since wire size relatively large. Since converter frequency KHz, tape thickness .0005" perhaps wise choice. consulting table page WaAc figures must altered factor approximately .013/.022 (the typical ratio cross sectional areas cores with .0005" .002" tape thicknesses), according Note bottom page. most convenient this alter value desired WaAc, then find appropriate core table. Using this approach, listed value must least .011 (.022/.013) .019 logical candidates 5_374 5_063 cores, whose WaAc values .028 .026, respectively. purpose this example 5_063 core chosen. effective core cross sectional area, .050 mean length magnetic path, 5.98 These values noted future use. Determine number turns. number turns determined withstand, produce desired output regulator:
20%,
Choose core. There popular methods determining size required core. Each results minimum area product, WaAc, provide necessary withstand accommodate wire size (which determines temperature rise). begins with desired temperature rise power handled (withstood), core geometry, fill factor. other requires initial choice wire size, which must estimated based intuition about ultimate temperature rise. Although latter admittedly pragmatic, popular because simplicity. latter method, steps follows:
WaAc
Select core from selection table 58-61 with least this area product. doing tape thickness must chosen, values WaAc column must modified according Note bottom page. Tape thicknesses .0005 .001 inch recommended frequencies KHz, with thinner tapes found bobbin-wound core catalog preferred higher frequencies. circuit Figure 19A, current during conduction core 10A, duty ratio 15/50, Thus current 5.5A. appropriate wire size gauge, since cross-
FIG. 19B. Alternative control circuit.
FIG. Full-wave saturable core regulator.
MAGNETICS Butler,
turns
alternative control circuit given Figure 19B. notable features: resetting control current derived from output, providing "preload" means preventing magnetizing current reactor from raising output voltage zero load. core reset from current source, rather than voltage source. This been shown minimize phase shift control transfer function. this circuit, degenerates transconductance transistor, making transfer function more independent transistor. simply shift level amplifier's output, which unnecessary amplifier powered from voltage higher than output. compensation networks, designed using techniques conventional buck-derived regulators.
Where:
withstand, volt-seconds
Saturation flux density gausses Core cross-sectional area
Note, however, that this circuit actually feedback loops- through error amplifier, directly from output through transistor. Full-wave outputs handled same manner forward converter discussed earlier. circuit Figure illustrates this application. Finally, sometimes useful able translate voltage required reset core, change level, trade voltage current. these cases, second winding placed core, with larger smaller number turns than powerhandling winding, with opposite control transistor being returned convenient bias voltage. example, control winding with less turns will exhibit less voltage swing will require more control current than main winding.
control circuit designed. doing helpful estimate current required reset core thus calculate average control current based duty ratio resetting (negative portion) input pulse. current related magnetizing force follows: amps
Where: Magnetizing force Oersteds Magnetic path length simply coercive force, rather value corresponding flux swing frequency, given curves pages through Note "loop widening effect" force increases with frequency. Again, using circuit Figure chosen core, required number turns 8.57 turns 7000 .050 (round turns) 10-6
CURRENT MODE CONTROL
Another configuration control circuitry shown Figure equally useful half-wave full-wave applications, shown here half-wave case simplicity. This circuit particularly advantageous when independent current limiting output) desired. Unlike current-limiting methods past, where output overcurrent detector comparator "ORed" with error amplifier output, this method "embeds" current-monitoring function feedback loop. Thus, always active provides exceptionally smooth transitions output loaded beyond current limit then returned normal load conditions.
estimate simple data supplied curves core loss, which reflects widening loop. Permalloy this formula applied: .6x106(W/lb.)
Completing above example, core loss Permalloy W/lb. 100kHz. .6x10 =.214 7000x105
Thus, magnetizing current will have typical value .794 .214 5.98 .11A
FIG. regulator with current mode control.
using cobalt-based amorphous material, formula .525x10 6(W/lb.)
MAGNETICS Butler,
Amplifier current error amplifier, whose input circuit comprised resistors R12. output most important input this network, since result output voltage error. output voltage, also introduced (via R12) bias shape current foldback characteristics, desired. Resistor samples regulator's output current, resultant voltage applied error amplifier through resistor Resistors determine gain amplifier; gain R5)/R5. visualize operation this circuit, first assume that output stationary during change current. increase current causes increase voltage drop across Since regulator output treated arbitrary ground reference, this increase current evidenced downward voltage swing junction This amplified without inversion applied reset transistor, through increase reset current decreases pulse width output thus opposes increase current which sensed voltage feedback loop begins with input resistor voltage error amplifier, U1A. Biasing resistor part transient response analysis, since voltage doesn't change (the inverting input virtual ground remains stationary). Resistor capacitor form feedback network U1A, making integrator with zero frequency where C1`s reactance equals R11. output then applied through other amplifier, U1B, which amplifies applies reset transistor. increase output voltage, inverted amplifier ultimately increases amp's reset current supplied This corrects perturbation. Diode limits positive voltage swing output U1A. Since U1's output voltage "reference" current limiter, clamping action determines maximum output current.
design philosophy have current-mode feedback determine phase shift unity-gain crossover frequency, since maximum degrees. feedback paths combine vector sum, thus dominant will determine phase shift. recommended that current-mode loop cross unitygain axis around one-tenth switching frequency, voltage-mode feedback cross over least three octaves below current-mode loop. References describe design output regulators more detail. Circuits using these square-loop cores have appeared power converters operating frequencies MHZ3. only they perform output regulation, also they used primary circuits control frequency converter. Applications practically limitless hands designer with imagination firm concept these interesting "volt-second" components.
ADDITIONALREFERENCE MATERIAL
Graetzer, "Transductor-Regulators Switched-Mode Power Supplies," IEEE Transactions Magnetics, MAG-16, 922, 1980. Hiramatsu, Hirada Ninomiya, "Switch Mode Converter Using High-Frequency Magnetic Amplifier," Powerconversion International, March-April, 1980. International Telephone Telegraph Corp., Reference Data Radio Engineers, Fourth Ed., American-Book-Stratford Press, Inc., York, 1964. Middlebrook Slobodan Cuk, Advances Switched-Mode Power Conversion, Volumes Ill, TESLAco, Pasadena, 1981-1983. I.Pressman, Switching Linear Power ply, Power Converter Design, Hayden, Rochelle Park, Jersey, 1977. Dean Venable, "Practical Techniques Analyzing, Measuring, Stabilizing Feedback Control Loops Switching Regulators Converters," Proceedings Seventh National Solid-State Power Conversion Conference, Powercon Record, I-12.1 I-12.17, March, 1980. Watson, Applications Magnetism, Wiley, York, 1980. Taylor, "Optimizing High Frequency Control MagAmp Design," Proceedings Powercon March 1983. Mullett, "Designing Saturable Core Output Regulators", Seminar Supplement, Power Electronics Design Conference, October 1985. Hiramatsu Mullet, "Recent Advances High Frequency MagAmps", Proceedings High Frequency Power Conversion Conference, April 1987. Hightman, "Efficiency `MagAmp' Post Regulation", Powertechnics, October 1986, 26-33. Mullett, "New Amorphous Materials Improve High-Frequency Saturable Reactor Output Regulators", Power Conversion Intelligent Motion, July 1986, 28-35. Panasuk, "Magnetic Amplifier Juices Efficiency Switching Power Supply", Electronic Design, September 1985. Hiramatsu, Hasada Sassda, Magnetic Power Controller Amorphus Cores Switching Regulator"
REFERENCES
Colonel William McLyman, Transformer Inductor Design Handbook, Dekker, York, 1978. R.D. Middlebrook, "Describing Function Properties Magnetic Pulse-Width Modulator,"IEEE Power Electronics Specialists Conference, 1972 record, 21-35. Hiramatsu Mullett, "Using Saturable Reactor Control Converter Design," Proceedings Tenth National Solid-State Power Conversion Conference, Powercon record, F-2.1-F.2.10. R.M. Tedder, "Limitations Magamp Regulator Improved Magamp Choke Design Procedure, "Powertechnics, November December, 1988. Jamerson, "Calculation Magnetic Amplifier Post Regulator Voltage Control Loop Parameters," Proceedings Second International High Frequency Conference, 222-234, Washington, D.C., April, 1987. D.Y. Chen, Lee, Jamerson, Simple Model Predicts Small-Signal Control Loop Behavior Magamp Post Regulator," Proceedings 1988 High Frequency Power Conversion International, 69-84, Diego, May, 1988.
PAGES CORE SIZES
MAGNETICS Butler.
HIGH FREQUENCY CORES
These cores specifically designed this application. permalloy, permalloy, amorphous, cobalt-based). DIMENSIONS I.D. core Part Number 50B10-5D 50B10-1D 50B10-1E 50B11-5D 50B11-1D 50B11-1E 50B12-5D 50B12-1D 50B12-1E 50B45-5D 50B45-1D 50B45-1E 50B66-5D 50B66-1D 50B66-1E .500 12.7 .430 10.9 .750 19.1 .820 20.8 .125 3.18 .200 5.08 .182 .075 .076 .076 .500 12.7 .430 10.9 .750 19.1 .820 20.8 .250 6.35 .325 8.26 .363 .149 .097 4.99 .151 .151 .050 194,000 .984 .375 9.53 .305 7.75 .500 12.7 .570 14.5 .125 3.18 .200 5.08 .500 12.7 .430 10.9 .625 15.9 .695 17.6 .125 3.18 .200 5.08 .083 .034 .035 .066 .027 .194 4.99 3.49 .038 .038 .025 .038 .038 .101 194,000 .984 99,000 .650 16.5 case (Min.) .580 14.7 O.D. core .900 22.9 case (Max.) .970 24.6 core .125 3.18 case (Max.) .200 5.08 .220 .092 .044 4.49 .076 .076 .025 194,000 1.04 Core loss 50KHz, 2000 gauss (Max.) .118 6.18 .051 Note 348,000 1.76 Core grams Note .0177 .0897 .0264 .1340 .0264 .1340 .0048 .0243 .0074 .0375 .0074 .0375 .0025 .0127 .0038 .0193 .0038 .0193 .0143 .0725 .0214 .1080 .0214 .1080 .0071 .0360 .0108 .0548 .0108 .0548 circ. mils. Bottom circ. mils. Bottom
Above "50000" series cores provided nylon boxes. "1E" cores supplied "54000" series (encapsulated, box). Dimensions 54000 series cores shown right. Additional "1E" cores listed p.33
CORE
54B10-1E 54B11-1E 54B12-1E 54B45-1E 54B66-1E
I.D. (min.)
.585 14.86 .435 11.05 .310 7.87 .435 11.05 .435 11.05
O.D. (max.)
.965 24.51 .690 17.53 .565 14.35 .815 20.70 .815 20.70
(max.)
.175 4.45 .175 4.45 .175 4.45 .300 7.62 .175 4.45
(see Note
372,000 1.89 211,600 1.07 112,225 .569 211,600 1.07 211,600 1.07
circ. mils Bottom
MAGNETICS Butler.
HIGH FREQUENCY CORES (encapsulated) AMORPHOUS ALLOY
DIMENSIONS Part Number core 54C90-1E 54C70-1E 54D26-1E 54D27-1E 54C91-1E 54319-1E 54C88-1E 54942-1E 54632-1E 54904-1E 54C89-1E 54094-1E 54C92-1E 54168-1E 54C17-1E 54029-1E 54932-1E .312 7.92 .375 9.53 .375 9.53 .375 9.53 .375 9.53 .375 9.53 .500 12.7 .500 12.7 .500 12.7 .500 12.7 .550 13.97 .625 15.88 .688 17.48 .750 19.05 .800 20.32 1.000 25.4 1.000 25.4 I.D. coated (Min.) .247 6.27 .310 7.87 .310 7.87 .310 7.87 .310 7.87 .310 7.87 .435 11.05 .435 11.05 .435 11.05 .435 11.05 .485 12.32 .560 14.22 .588 14.94 .650 16.51 .700 17.78 .900 22.86 .900 22.86 core .500 12.7 .500 12.7 .547 13.9 .594 15.1 .625 15.9 .625 15.9 .590 .700 17.8 .750 19.1 .750 19.1 .825 1.000 25.4 .875 22.23 1.000 25.4 1.205 30.61 1.375 34.93 1.625 41.28 O.D. coated (Max.) .565 14.35 .565 14.35 .612 15.54 .659 16.74 .690 17.53 .690 17.53 .655 16.64 .765 19.43 .815 20.70 .815 20.70 .890 22.61 1.065 27.05 .975 24.77 1.100 27.94 1.305 33.15 1.475 37.47 1.725 43.82 core .188 4.77 .188 4.77 .188 4.77 .188 4.77 .188 4.77 .250 6.35 .188 4.77 .188 4.77 .188 4.77 .312 7.92 .188 4.77 .375 9.53 .188 4.77 .375 9.53 .375 9.53 .250 6.35 .625 15.88 coated (Max.) .238 6.05 .238 6.05 .238 6.05 .238 6.05 .238 6.05 .300 7.62 .238 6.05 .238 6.05 .238 6.05 .362 9.19 .238 6.05 .425 10.8 .258 6.55 .445 11.30 .445 11.30 .320 8.13 .695 17.65 circ. mils. Bottom
Core loss (w)@ 50KHz, 2000 gauss (Max.) .055
Note
Core grams
Note
3.24
.085
97,000 .491
2.09
.008 .041
.040
3.49
.057
141,000 .715
1.51
.008 .041
.061
3.67
.083
141,000 .715
2.31
.012 .061
.085
3.87
.110
141,000 .715
3.23
.016 .081
.090
3.99
.113
141,000 .715
3.42
.016 .081
.119
3.99
.150
141,000 .715
4.52
.021 1.06
.034
4.35
.040
250,000 1.27
1.32
.010 .051
.873
4.79
.091
250,000 1.27
3.30
.023 .117
.113
4.99
.113
250,000 1.27
4.27
.028 .142
.188
4.99
.188
250,000 1.27
7.11
.047 .239
.137
5.48
.125
303,000 1.54
5.19
.038 1.93
.440
6.48
.339
391,000 1.98
16.64
.133 .674
.106
6.23
.085
473,000 2.40
4.01
.040 .203
.316
6.98
.226
563,000 2.85
11.95
.127 .644
.586
8.00
.366
640,000 3.24
22.18
.234 1.19
.505
9.47
.226
1,000,000 5.07
19.08
.226 1.15
1.98
10.47
.942
1,000,000 5.07
74.71
.942 4.78
circ. mils. Bottom
other core sizes pages 58-61.
MAGNETICS Butler.
INTRODUCTION DESIGN CURVES
reference purposes, Magnetics collected information which used design magnetic circuits selection toroidal cores used these circuits. Included this catalog dynamic Sine Voltage Hysteresis Loops various materials available from Magnetics. Especially selected circuit loss analysis, bias feedback circuit design sensitive transformer design curves core loss versus flux density, versus curves using constant current (dc) reset determine incremental values being reset, permeability versus flux density Permalloy alloy types which useful transformer design. design higher frequency circuits, square wave drive pulse drive commonly used. Since this common mode operation, Magnetics included magnetization curves showing increase magnetizing force required frequency increases. data curves included herein, contact Magnetics Sales Department.
MAGNETICS Butler,
TYPICAL HYSTERESIS LOOPS
FIG. Typical Hysteresis Loops Alloy Orthonol
(A/m) MAGNETICS Butler,
TYPICAL HYSTERESIS LOOPS
FIG. Typical Hysteresis Loops Square Permalloy Supermalloy
(A/m)
MAGNETICS Butler,
FIG. Typical Hysteresis Loops Magnesil Supermendur
MAGNETICS Butler,
(A/m)
FIG. Hysteresis Loops Orthonol
(A/m)
MAGNETICS Butler,
FIG. Hysteresis Loops Square Permalloy
(A/m) MAGNETICS Butler,
FIG. Hysteresis Loops Square Permalloy
(A/m)
MAGNETICS Butler,
FIG. Hysteresis Loops Square Permalloy
MAGNETICS Butler,
(A/m)
FIG. Hysteresis Loops Amorphous Alloy (Cobalt-base)
(A/m)
MAGNETICS Butler,
TYPICAL HYSTERESIS LOOPS
FIG. Typical Hysteresis Loops Amorphous alloys
MAGNETICS Butler,
(A/m)
FIG. Supermalloy, Round Permalloy Square Permalloy
(Gausses)
(Teslas)
MAGNETICS Butler,
VARIATION MAGNETIC PROPERTIES WITH TEMPERATURE
with ferro-magnetic material, high permeability alloys show changes coercive force induction level with variations ambient temperatures. These variations quite similar different lots material. degree sensitivity changes ambient temperatures will depend upon composition basic alloy impurity levels present. will depend also upon processing alloy from ingot through finished strip. following curves presented guide only, constitute guarantee. Data presented which will indicate typical changes various magnetic characteristics over range temperatures normally employed magnetic circuit work. Also included general curve showing typical change Flux Density temperature materials raised above normal ambient conditions Curie temperature. NOTE Variations with temperature Supermendur dependent peak temperature previously encountered operation cooling rate from that temperature. Much deterioration noted core operated above 500°C then returned lower temperature. NOTE Magnesil will show effects disorientation when cycled 500°C, giving reduction Squareness ratio. Also heavy rusting oxidation noticed which also degrades magnetic characteristics. Above 500°C reduces more rapid rate Curie Temperature, disorientation becomes more pronounced.
Reference:
Electrical Manufacturing, October 1959, "Effects Temperature Magnetic Core Materials", Pasnak Lundsten.
FIGURE Typical Variation Flux Density (Bm) with Temperature
Temperature (°C)
MAGNETICS Butler,
FIGURE Typical Variation Flux Density with Temperature
Temperature (°C)
FIGURE Typical Variation Flux Density (Bm) with Temperature
Temperature
(°C)
FIGURE Typical Variation Squareness Ratio with Temperature
Temperature (°C)
MAGNETICS Butler,
FIGURE Typical Variation Squareness Ratio with Temperature
Temperature (°C)
FIGURE Typical Variation (C.C.F.R. Test) with Temperature
Temperature (°C)
FIGURE Typical Variation (C.C.F.R. Test) with Temperature
Temperature (°C)
MAGNETICS Butler,
SATURATION FREQUENCY
FIGURE Average Required Saturate Permalloy Frequency (Square Wave Current Drive)
FREQUENCY (Hertz)
MAGNETICS Butler,
FIGURE Average Required Saturate Orthonol Frequency (Square Wave Current Drive)
FREQUENCY (Hertz)
MAGNETICS Butler,
CORE LOSS INDUCTION LEVEL
FIGURE Alloy FIGURE Orthonol
Flux Density (Gauss)
Flux Density (Gauss)
FIGURE Orthonol
FIGURE Orthonol
Flux Density (Gauss)
Flux Density (Gauss)
MAGNETICS Butler,
FIGURE Square Permalloy
FIGURE Square Permalloy
Flux Density (Gauss)
Flux Density (Gauss)
FIGURE Square Permalloy
FIGURE Supermalloy
Flux Density (Gauss)
Flux Density (Gauss)
MAGNETICS Butler,
CORE LOSS INDUCTION LEVEL
FIGURE Supermalloy FIGURE Supermalloy
Flux Density (Gauss)
Flux Density (Gauss)
FIGURE Magnesil
FIGURE Magnesil
Flux Density (Gauss)
Flux Density (Gauss)
MAGNETICS Butler,
FIGURE Supermendur
FIGURE Supermendur
Flux Density (Gauss)
Flux Density (Gauss)
FIGURE Amorphous Alloy
FIGURE Amorphous Alloy
Flux Density (Gauss)
Flux Density (Gauss)
MAGNETICS Butler,
IMPEDANCE PERMEABILITY
Impedance permeability equal where determined from total magnetizing current determined from voltage produced across inductor. differs from other permeabilities that takes into consideration magnetizing current which result both core losses inductive reactance material permeability) inductor. usually measured placing voltmeter across inductor ammeter series with Using equations here, calculated, then
4.44
where peak value flux density gauss volts across inductor number turns frequency inductor, Hertz effective cross section area magnetic core
peak value current through inductor effective magnetic path length core
FIGURE Typical Impedance Permeability Orthonol
Frequency Hertz
MAGNETICS Butler,
FIGURE Typical Impedance Permeability Square Permalloy
Frequency Hertz
FIGURE Typical Impedance Permeability Supermalloy
Frequency Hertz
MAGNETICS Butler,
FIGURE Typical Impedance Permeability Alloy
Frequency Hertz
FIGURE Typical Impedance Permeability Supermendur
Frequency Hertz
MAGNETICS Butler,
FIGURE Typical Impedance Permeability Magnesil
Frequency Hertz
FIGURE Typical Impedance Permeability Curves Amorphous (cobalt-base)
FIGURE Typical Impedance Permeability Curves Amorphous (iron-base)
FREQUENCY (kHz)
FREQUENCY (kHz)
MAGNETICS Butler,
CORE SIZES SELECTION TABLES
TABLE Magnetics Tape Wound Core Sizes continued (See page "How Order".)**
Nominal Core Dimensions Core Note 5_403 5_485 5_143 5_374 5_086 5_063 5_134 5_459 5_666 5_454 5_691 5_654 5_632 5_115 5_039 I.D. .375 9.53 .500 12.7 .563 14.3 .625 15.88 .687 17.45 .375 9.53 .438 11.13 .500 12.7 .625 15.88 .750 19.05 .875 22.23 1.000 25.4 .500 12.7 .625 15.88 .650 16.51 .750 19.05 .875 22.23 1.00 25.4 1.125 28.58 1.500 38.1 1.625 41.28 1.750 44.45 2.500 63.5 .438 11.13 .500 12.7 .500 12.7 .625 15.88 .750 19.05 1.00 25.4 1.125 28.58 1.25 31.75 O.D. .438 11.13 .563 14.3 .625 15.88 .687 17.45 .750 19.05 .500 12.7 .563 14.3 .625 15.88 .750 19.05 .875 22.23 1.000 25.4 1.125 28.58 .750 19.05 .875 22.23 .900 22.86 1.00 25.4 1.125 28.58 1.25 31.75 1.375 34.93 1.750 44.45 1.875 47.63 2.000 50.8 2.750 69.85 .563 14.3 .750 19.05 .750 19.05 .875 22.23 1.00 25.4 1.25 31.75 1.375 34.93 1.50 38.1 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .125 3.18 .250 6.35 .188 4.78 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 I.D. Min. .285 7.24 .410 10.41 .475 12.07 .535 13.59 .600 15.24 .285 7.24 .350 8.89 .410 10.41 .535 13.59 .655 16.64 .780 19.81 .905 22.99 .410 10.41 .535 13.59 .560 14.22 .655 16.64 .780 19.81 .900 22.86 1.029 26.14 1.394 35.41 1.519 38.58 1.644 41.76 2.380 60.45 .348 8.84 .410 10.41 .410 10.41 .535 13.59 .655 16.64 .900 22.86 1.030 26.16 1.155 29.34 Listing Case Dimensions (See Note O.D. Max. .530 13.46 .650 16.51 .715 18.16 .780 19.81 .840 21.34 .590 14.99 .650 16.51 .715 18.16 .840 21.34 .965 24.51 1.095 27.81 1.220 30.99 .840 21.34 .965 24.51 .990 25.15 1.095 27.81 1.220 30.99 1.350 34.29 1.471 37.36 1.854 47.09 1.981 50.32 2.106 53.49 2.870 72.90 .653 16.59 .840 21.34 .840 21.34 .965 24.51 1.095 27.81 1.350 34.29 1.470 37.34 1.595 40.51 Mean Length Magnetic Path (cm) 3.25 4.24 4.74 5.24 5.73 3.49 3.99 4.49 5.48 6.48 7.48 8.47 4.99 5.98 6.18 6.98 7.98 8.97 9.97 12.96 13.96 14.96 20.94 3.99 4.99 4.99 5.98 6.98 8.97 9.97 10.97 Case Window Area (Top) Circular mils 106) (Bottom) 0.090 0.456 0.181 0.916 0.240 1.215 0.303 1.534 0.378 1.914 0.090 0.456 0.133 0.673 0.181 0.916 0.303 1.534 0.449 2.273 0.632 3.200 0.846 4.284 0.181 0.916 0.303 1.534 0.331 1.676 0.449 2.273 0.632 3.200 0.837 4.238 1.121 5.676 2.033 10.294 2.399 12.147 2.802 14.187 5.808 29.407 0.143 0.724 0.194 0.982 0.181 0.916 0.303 1.534 0.449 2.273 0.837 4.238 1.092 5.529 1.369 6.932 Effective Core Cross Sectional Area .012 .0005 .001 .002 .004 .014 .013 .019 .022 .023 .025 .038 .043 .045 .050 .076 .086 .091 .050 .076 .086 .091 .076 .101 .114 .151 .129 .171 .137 .182 (See Note 0.002 0.010 0.004 0.020 0.005 0.025 0.007 0.035 0.008 0.041 0.004 0.020 0.006 0.030 0.008 0.041 0.013 0.066 0.019 0.096 0.027 0.137 0.036 0.182 0.016 0.081 0.026 0.132 0.028 0.142 0.039 0.197 0.054 0.273 0.072 0.365 0.096 0.486 0.175 0.886 0.206 1.043 0.241 1.220 0.499 2.527 0.012 0.061 0.025 0.127 0.031 0.157 0.052 0.263 0.077 0.390 0.143 0.724 0.187 0.947 0.234 1.185 (See Note .000061 .000108 .000131 .000157 .000192 .000225 .000314 .000402 .000606 .000818 .00105 .00130 .00145 .00221 .00237 .00299 .00390 .00478 .00646 .00959 .0106 .0118 .0185 .00122 .00355 .00483 .00748 .0103 .0168 .0206 .0245 Max. .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .240 6.10 .365 9.27 .300 7.62 .365 9.27 .365 9.27 .365 9.27 .365 9.27 .365 9.27 .365 9.27 ID/OD Ratio .852 .888 .901 .906 .916 .750 .778 .800 .833 .857 .875 .889 .667 .714 .722 .750 .778 .800 .818 .857 .867 .875 .909 .778 .667 .667 .714 .750 .800 .818 .833
NOTE Core number must include core designation specify type construction required. Each core number should include digits plus material type thickness designation. page "How Order *IEEE Standard Sizes **For more complete list core sizes, consult factory. page These cores available sizes. boxes available.
NOTE Dimensions coated aluminum boxed cores (52000 series). Without coating, these factors apply: .015", OD-.015", HT-.020".
NOTE Product window area (nominal) effective core cross-sectional area calculated 2mil (.002") material. circ. mils Bottom NOTE Core geometry coefficient described "Transformer Inductor Design Handbook", Colonel McLyman.
calculate bare core weight, page
MAGNETICS Butler,
TABLE Magnetics Tape Wound Core Sizes continued (See page "How Order".)**
Nominal Core Dimensions I.D. O.D. .625 15.88 .750 19.05 1.125 28.58 1.625 41.28 .600 15.24 2.500 63.5 .625 15.88 .750 19.05 .875 22.23 1.00 25.4 1.625 41.28 .750 19.05 1.125 28.58 .625 15.88 .750 19.05 1.00 25.4 1.25 31.75 1.000 25.4 1.00 25.4 1.125 28.58 1.50 38.1 2.000 50.8 .900 22.86 2.800 71.12 1.000 25.4 1.125 28.58 1.250 31.75 1.375 34.93 2.000 50.8 1.00 25.4 1.375 34.93 1.125 28.58 1.25 31.75 1.50 38.1 1.75 44.45 1.250 31.75 .188 4.78 .188 4.78 .188 4.78 .188 4.78 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .375 9.53 .375 9.53 .250 6.35 .250 6.35 .250 6.35 .250 6.35 .500 12.7 Listing Case Dimensions (See Note O.D. Max. 1.100 27.94 1.220 30.99 1.595 40.51 2.130 54.10 .990 25.15 2.920 74.17 1.100 27.94 1.220 30.99 1.350 34.29 1.475 37.47 2.130 54.10 1.095 27.81 1.470 37.34 1.220 30.99 1.345 34.16 1.600 40.64 1.855 47.12 1.344 34.14 Mean Length Magnetic Path (cm) 6.48 7.48 10.47 14.46 5.98 21.14 6.48 7.48 8.47 9.47 14.46 6.98 9.97 6.98 7.98 9.97 11.96 8.97 Case Window Area (Top) Circular mils (Bottom) 0.292 1.478 0.449 2.273 1.092 5.529 2.280 11.544 0.292 1.478 5.808 29.407 0.292 1.478 0.449 2.273 0.624 3.160 0.837 4.438 2.280 11.544 0.449 2.273 1.092 5.529 0.297 1.504 0.449 2.273 0.837 4.238 1.346 6.815 0.876 4.435 .202 .303 .343 .363 .151 .227 .257 .272 .121 .182 .206 .218 Effective Core Cross Sectional Area .0005 .001 .002 .004 .012 (See Note .014 .113 .171 .193 .205 0.056 0.284 0.087 0.441 .0211 1.068 0.440 2.228 0.060 0.304 1.196 6.056 0.075 0.380 0.115 0.582 0.160 0.810 0.215 1.089 0.586 2.967 0.115 0.582 0.281 1.423 0.102 0.516 0.154 0.780 0.287 1.453 0.462 2.239 0.300 1.519 NOTE Product window area (nominal) effective core cross-sectional area calculated 2mil (.002") material. circ. mils Bottom NOTE Core geometry coefficient described "Transformer Inductor Design Handbook", Colonel McLyman. .800 .0596 .600 .667 .714 .0360 .0597 .0859 .818 .556 .0416 .0254 .813 .750 .0739 .0203 .625 .667 .700 .727 .0150 .0216 .0281 .0355 .667 .893 .0111 .0975 .813 .0438 (See Note .00915 .0131 .0263
Core Note 5_076* 5_106* 5_392 5_393 5_007* 5_285 5_029* 5_018 5_168* 5_228 5_167 5_318 5_032* 5_030* 5_391
I.D. Min. .525 13.34 .655 16.64 1.030 26.16 1.495 37.97 .510 12.95 2.380 60.45 .525 13.34 .655 16.64 .775 19.69 .900 22.86 1.495 37.97 .655 16.64 1.030 26.16 .530 13.46 .655 16.64 .900 22.86 1.145 29.08 .906 23.01
Max. .300 7.62 .300 7.62 .300 7.62 .305 7.75 .365 9.27 .365 9.27 .365 9.27 .365 9.27 .365 9.27 .365 9.27 .370 9.40 .490 12.45 .490 12.45 .365 9.27 .365 9.27 .365 9.27 .370 9.40 .640 16.26
ID/OD Ratio .625 .667 .750
NOTE Core number must include core designation specify type construction required. Each core number should include digits plus material type thickness designation. page "How Order *IEEE Standard Sizes **For more complete list core sizes, consult factory. page These cores available sizes.
NOTE Dimensions coated aluminum boxed cores (52000 series). Without coating, these factors apply: .015", OD-.015", HT-.020".
calculate bare core weight, page
Nylon boxes available.
TABLE Alloys Thicknesses Available
Alloy Type Square Permalloy Round Permalloy Orthonol Thickness Available .0005 .001 .002 .004 .014 .0005 .001 .002 .004 .001 Alloy Type Alloy Thickness Available .002 .004 .014 .001 .002 .004 .012 .002 .004
TABLE Case Designations
Case Type Non-Metallic Aluminum Aluminum Uncased Magnesil Encapsulated Magnesil Series Code 50000 51000 52000 53000 54000
Magnesil
Supermalloy
Supermendur
Amorphous Alloys
Table cont. page
MAGNETICS Butler,
TABLE Magnetics Tape Wound Core Sizes continued (See page "How Order".)**
Nominal Core Dimensions I.D. O.D. .625 15.88 .750 19.05 .875 22.23 1.00 25.4 1.125 28.58 1.375 34.93 .650 16.51 .750 19.05 .875 22.23 1.00 25.4 1.25 31.75 1.50 38.1 .750 19.05 1.00 25.4 1.125 28.58 1.25 31.75 1.375 34.93 1.50 38.1 1.75 44.45 2.00 50.8 2.50 63.5 .750 19.05 1.250 31.75 2.00 50.8 3.00 76.2 1.00 25.4 1.25 31.75 1.50 38.1 1.75 44.45 1.00 25.4 1.125 28.58 1.250 31.75 1.375 34.93 1.500 38.1 1.75 44.45 1.150 29.21 1.25 31.75 1.375 34.98 1.50 38.1 1.75 44.45 2.00 50.8 1.25 31.75 1.50 38.1 1.625 41.28 1.75 44.45 1.875 47.63 2.00 50.8 2.25 57.15 2.50 63.5 3.00 76.2 1.50 38.1 2.00 50.8 2.75 69.85 3.75 95.25 1.75 44.45 2.00 50.8 2.25 57.15 2.50 63.5 .375 9.53 .375 9.53 .375 9.53 .375 9.53 .375 9.53 .375 9.53 .375 9.53 .375 9.53 .375 9.53 .375 9.53 .375 9.53 .375 9.53 .500 12.7 .500 12.7 .500 12.7 .500 12.7 .500 12.7 .500 12.7 .500 12.7 .500 12.7 .500 12.7 .375 9.53 .375 9.53 .375 9.53 .375 9.53 .500 12.7 .500 12.7 .500 12.7 .550 13.97 Listing Case Dimensions (See Note O.D. Max. 1.095 27.81 1.220 30.99 1.350 34.29 1.475 37.47 1.600 40.64 1.855 47.12 1.240 31.50 1.350 34.29 1.475 37.47 1.600 40.64 1.855 47.12 2.110 53.59 1.350 34.29 1.600 40.64 1.730 43.94 1.855 47.12 1.980 50.29 2.115 53.72 2.365 60.07 2.620 66.55 3.125 79.38 1.600 40.64 2.105 53.47 2.875 73.03 3.895 98.93 1.860 47.24 2.125 53.98 2.365 60.07 2.620 66.55 Mean Length Magnetic Path (cm) 6.48 7.48 8.47 9.47 10.47 12.46 7.18 7.98 8.97 9.97 11.96 13.96 7.98 9.97 10.97 11.96 12.96 13.96 15.95 17.95 21.93 8.97 12.96 18.94 26.92 10.97 12.96 14.96 16.95 Case Window Area (Top) Circular mils (Bottom) 0.303 1.534 0.449 2.273 0.624 3.160 0.837 4.238 1.082 5.478 1.651 8.359 .0331 1.676 0.442 2.238 0.624 3.160 0.837 4.238 1.346 6.815 1.974 9.995 0.449 2.273 0.837 4.238 1.071 5.423 1.346 6.815 1.651 8.359 1.960 9.924 2.723 13.787 3.591 18.182 5.712 28.921 0.442 2.238 1.346 6.815 3.572 18.086 8.237 41.706 0.819 4.147 1.323 6.699 1.960 9.924 2.706 13.701 .597 .907 1.028 1.089 1.149 .862 .448 .681 .771 .817 .766 .398 .605 .686 .726 .575 .299 .454 .514 .545 Effective Core Cross Sectional Area .0005 .001 .002 .004 .012 .014 .224 .340 .386 .408 (See Note 0.117 0.592 0.173 0.876 0.241 1.220 0.323 1.635 0.418 2.116 0.637 3.225 0.170 0.861 0.227 1.149 0.321 1.625 0.430 2.177 0.692 3.504 1.015 5.139 0.308 1.559 0.574 2.906 .0735 3.721 0.923 4.673 1.133 5.737 1.345 6.810 1.868 9.458 2.463 12.471 3.918 19.838 0.341 1.727 1.038 5.256 2.754 13.944 6.351 32.157 0.842 4.263 1.360 6.886 2.015 10.202 2.782 14.086 NOTE Product window area (nominal) effective core cross-sectional area calculated 2mil (.002") material. circ. mils Bottom NOTE Core geometry coefficient described "Transformer Inductor Design Handbook", Colonel McLyman. .571 .625 .667 .700 .389 .578 .799 1.027 .800 1.378 .727 .7619 .625 .3623 .800 .883 .500 .6059 .8519 .1427 .778 .4920 .733 .750 .3353 .3819 .692 .714 .2368 .2853 .600 .667 .1144 .1943 .714 .750 .1760 .2366 .667 .1210 .636 .0949 .600 .0709 .565 .0557 .786 .1215 .750 .0879 .727 .0716 (See Note .0307 .0430 .0563
Core Note 5_094 5_553 5_315 5_188 5_026* 5_098 5_139 5_481 5_038* 5_091 5_035* 5_559 5_017* 5_031* 5_514 5_425* 5_066 5_067 5_190 5_169 5_252 5_222
I.D. Min. .535 13.59 .655 16.64 .775 19.69 .900 22.86 1.025 26.04 1.270 32.26 .560 14.22 .650 16.51 .775 19.69 .900 22.86 1.145 29.08 1.390 35.31 .655 16.64 .900 22.86 1.020 25.91 1.145 29.08 1.270 32.28 1.385 35.18 1.635 41.53 1.880 47.75 2.375 60.33 .650 16.51 1.145 29.08 1.875 47.63 2.855 72.52 .890 22.61 1.135 28.83 1.385 35.18 1.630 41.40
Max. .490 12.45 .490 12.45 .490 12.45 .490 12.45 .490 12.45 .495 12.57 .490 12.45 .490 12.45 .490 12.45 .490 12.45 .495 12.57 .495 12.57 .625 15.88 .625 15.88 .630 16.0 .630 16.0 .635 16.13 .635 16.13 .640 16.26 .640 16.26 .640 16.26 .500 12.70 .500 12.70 .515 13.08 .535 13.59 .635 16.13 .635 16.13 .635 16.13 .640 16.26
ID/OD Ratio .625 .667 .700
NOTE Core number must include core designation specify type construction required. Each core number should include digits plus material type thickness designation. page "How Order *IEEE Standard Sizes **For more complete list core sizes, consult factory. page These cores available sizes.
NOTE Dimensions coated aluminum boxed cores (52000 series). Without coating, these factors apply: .015", OD-.015", HT-.020".
Nylon boxes available.
calculate bare core weight, page
MAGNETICS Butler,
TABLE Magnetics Tape Wound Core Sizes continued (See page "How Order".)*
Nominal Core Dimensions I.D. O.D. 1.25 31.75 1.50 38.1 2.00 50.8 2.50 63.5 1.000 25.4 1.25 31.75 1.50 38.1 1.25 31.75 1.50 38.1 2.00 50.8 2.50 63.5 1.75 44.45 2.00 50.8 2.25 57.15 2.50 63.5 3.25 82.55 4.50 114.3 4.00 101.6 4.00 101.6 2.25 57.14 2.50 63.5 3.00 76.2 3.50 88.9 1.50 38.1 1.75 44.45 2.00 50.8 2.000 50.8 2.50 63.5 3.00 76.2 3.50 88.9 3.00 76.2 3.25 82.55 3.50 88.9 3.75 95.25 4.75 120.7 6.00 152.4 5.25 133.4 6.00 152.4 .500 12.7 .500 12.7 .500 12.7 .500 12.7 1.00 25.4 1.00 25.4 1.00 25.4 1.00 25.4 1.00 25.4 1.00 25.4 1.00 25.4 1.00 25.4 1.00 25.4 1.00 25.4 1.50 38.1 1.50 38.1 1.50 38.1 2.00 50.8 2.00 50.8 Listing Case Dimensions (See Note O.D. Max. 2.365 60.07 2.625 66.68 3.135 79.63 3.635 92.33 1.600 40.64 1.855 47.12 2.120 53.85 2.125 53.98 2.635 66.93 3.135 79.63 3.635 92.33 3.135 79.63 3.390 86.11 3.635 92.33 3.905 99.19 4.920 124.97 6.190 157.23 5.430 137.92 6.190 157.23 Mean Length Magnetic Path (cm) 13.96 15.95 19.94 23.93 9.97 11.96 13.96 12.96 15.95 19.94 23.93 18.94 20.94 22.93 24.93 31.90 41.87 36.89 39.88 Case Window Area (Top) Circular mils (Bottom) 1.323 6.699 1.904 9.640 3.534 17.894 5.664 28.678 0.837 4.238 1.346 6.815 1.946 9.853 1.323 6.699 1.904 9.640 3.534 17.894 5.664 28.678 2.657 13.453 3.572 18.086 4.580 23.190 5.570 28.202 9.610 48.657 18.706 94.713 14.707 74.465 14.631 72.455 9.678 10.968 11.614 12.259 4.537 5.444 5.444 6.049 5.142 6.170 6.170 6.855 5.444 6.533 6.533 7.259 5.746 6.896 6.896 7.662 1.990 3.024 3.428 3.629 3.831 1.195 1.590 1.815 2.420 2.057 2.742 2.178 2.903 3.065 .796 1.210 1.371 1.452 1.532 Effective Core Cross Sectional Area .0005 .001 .002 .004 .012 .014 .796 1.210 1.371 1.452 1.532 (See Note 1.814 9.185 2.610 13.215 4.845 24.531 7.765 39.316 1.148 5.813 1.845 9.342 2.668 13.509 2.721 13.777 5.221 26.435 9.690 49.063 15.531 78.637 9.108 46.116 12.245 61.999 15.697 79.478 28.641 145.02 59.294 300.2 115.416 584.4 100.816 510.5 160.473 812.5 .667 229.571 .667 .684 .750 .762 28.193 60.957 102.773 97.119 .583 .615 .643 8.040 10.219 12.515 .714 9.983 .625 .600 .667 1.779 4.076 6.845 .667 .714 .750 .573 .860 1.168 (See Note .956 1.284 2.099 3.006
Core Note 5_012 5_036 5_013 5_022* 5_448 5_261 5_100* 5_101 5_516 5_112* 5_426*
I.D. Min. 1.135 28.83 1.365 34.67 1.865 47.37 2.365 60.07 .900 22.86 1.145 29.08 1.380 35.05 1.135 28.83 1.365 34.67 1.865 47.37 2.365 60.07 1.615 41.02 1.860 47.24 2.110 53.59 2.345 59.56 3.085 78.36 4.310 109.47 3.820 97.03 3.810 96.77
Max. .640 16.26 .640 16.26 .645 16.38 .655 16.64 1.125 28.58 1.130 28.70 1.130 28.70 1.135 28.83 1.135 28.83 1.140 28.96 1.155 29.34 1.140 28.96 1.140 28.96 1.150 29.21 1.680 42.67 1.710 43.43 1.715 43.56 2.225 56.52 2.225 56.52
ID/OD Ratio .556 .600 .667 .714
NOTE Core number must include core designation specify type construction required. Each core number should include digits plus material type thickness designation. page "How Order *IEEE Standard Sizes **For more complete list core sizes, consult factory. page These cores available sizes.
NOTE Dimensions coated aluminum boxed cores (52000 series). Without coating, these factors apply: .015", OD-.015", HT-.020".
NOTE Product window area (nominal) effective core cross-sectional area calculated 2mil (.002") material. circ. mils Bottom NOTE Core geometry coefficient described "Transformer Inductor Design Handbook", Colonel McLyman.
Nylon boxes available.
calculate bare core weight, page
TABLE Alloys Thicknesses Available
Alloy Type Square Permalloy Round Permalloy Orthonol Thickness Available .0005 .001 .002 .004 .014 .0005 .001 .002 .004 .001 Alloy Type Alloy Thickness Available .002 .004 .014 .001 .002 .004 .012 .002 .004
TABLE Case Designations
Case Type Non-Metallic Aluminum Aluminum Uncased Magnesil Encapsulated Magnesil Series Code 50000 51000 52000 53000 54000
Magnesil
Supermalloy
Supermendur
Amorphous Alloys
MAGNETICS Butler,
TABLE Miniature Tape Wound Core Sizes High Frequency Applications
Case Dimensions** Core 80521-(*)MA 80550-(*)MA 80505-(*)MA 80512-(*)MA 80529-(*)MA 80544-(*)MA 80523-(*)MA 80530-(*) 80524-(*)MA 80531-(*)MA 80608-(*)MA 80609-(*)MA 80558-(*)MA 80581-(*)MA 80610-(*)MA 80611-(*)MA 80598-(*)MA 80516-(*)MA 80612-(*)MA 80588-(*)MA I.D. .097 2.41 .128 3.18 .160 4.06 .222 5.59 .097 2.41 .125 3.18 .160 4.06 .222 5.59 .285 7.24 .345 8.76 .405 10.29 .470 11.94 .222 5.59 .285 7.24 .345 8.76 .220 5.59 .285 7.24 .345 8.76 .405 10.29 .470 11.94 O.D. .225 5.72 .255 6.48 .290 7.37 .350 8.89 .225 5.72 .255 6.48 .290 7.37 .350 8.89 .415 10.54 .480 12.19 .540 13.72 .605 15.37 .385 9.78 .445 11.30 .505 12.83 .415 10.54 .480 12.19 .540 13.72 .605 15.37 .665 16.89 .120 2.67 .120 2.67 .120 2.67 .120 2.67 .185 4.45 .185 4.45 .185 4.45 .185 4.45 .185 4.45 .185 4.45 .185 4.45 .185 4.45 .185 4.45 .185 4.45 .185 4.45 .185 4.45 .185 4.45 .185 4.48 .185 4.45 .185 4.45 2.30 2.80 3.30 2.40 2.90 3.40 3.90 4.40 Mean Length (cm) 1.20 1.45 1.70 2.20 1.20 1.45 1.70 2.20 2.70 3.20 3.70 4.20 Window Area (See Note .0100 .0506 .0170 .0860 .0270 .137 .0505 .255 .0100 .0506 .0170 .0860 .0270 .136 .0505 .255 .0840 .425 .1225 .620 .1680 .850 .2260 1.14 .0505 .255 .0840 .425 .1225 .620 .0505 .255 .0840 .425 .1225 .620 .1680 .850 .2260 1.14 (.008) (.0133) (.021) (.0264) (.0133) (.021) (.0264) (.006) (.01) (.016) (.0198) (.01) (.016) (.0198) (.004) (.0066) (.0105) (.0132) (.0066) (.0105) (.0132) Permalloy Flux Capacity (Maxwells)***
Orthonol Flux Capacity (Maxwells)
(.002)
(.0033)
(.0053)
(.0066)
(.0033)
(.0053)
(.0066)
*Add material type thickness code when ordering. page Note cir. mils *These dimensions minimum I.D. maximum O.D. Bottom *Standard tolerance flux capacity 15%. other magnetic characteristics, please contact Magnetics Sales Department. Effective cross sectional area shown cm2.
VOLTAGE BREAKDOWN GUARANTEE
coating guaranteed hermetically seal bobbin withstand inch mercury vacuum with leakage. (This feature allows bobbins vacuum impregnated, encapsulated, etc., with shifts core properties.) addition, finish guaranteed withstand volts Hertz between bare winding stainless steel bobbin. special request finish applied tested seal bobbin withstand inches mercury vacuum. bobbins supplied with epoxy (Guaranteed Voltage Breakdown) coating. Additional information available Bobbin Cores Catalog BOBCAT 100.
MAGNETICS Butler,
TABLE Miniature Tape Wound Core Sizes High Frequency Applications
Case Dimensions** Core 80613-(*)MA 80606-(*)MA 80614-(*)MA 80615-(*)MA 80560-(*)MA 80539-(*)MA 80517-(*)MA 80616-(*)MA 80617-(*)MA 80600-(*)MA 80618-(*)MA 80619-(*)MA 80525-(*)MA I.D. .285 7.24 .345 8.76 .405 10.29 .470 11.94 .217 5.46 .280 7.11 .342 8.64 .400 10.16 .465 11.81 .280 7.11 .340 8.64 .400 10.16 .465 11.81 O.D. .510 12.95 .570 14.48 .630 16.00 .695 17.65 .385 9.78 .445 11.30 .510 12.95 .570 14.48 .630 16.00 .480 12.19 .540 13.72 .605 15.37 .665 16.89 .185 4.45 .185 4.45 .185 4.45 .185 4.45 .320 7.87 .320 7.87 .320 7.87 .320 .787 .320 7.87 .320 7.87 .320 7.87 .320 7.87 .320 7.87 Mean Length (cm) 3.00 3.50 4.00 4.50 2.30 2.80 3.30 3.80 4.30 2.90 3.40 3.90 4.40 Window Area (See Note .0840 .425 .1225 .620 .1680 .850 .2260 1.14 .0485 .245 .0810 .410 .1190 .602 .1640 .830 .2210 1.12 .0810 .410 .1190 .602 .1640 .830 .2210 1.12 Permalloy Flux Capacity (Maxwells)***
Orthonol Flux Capacity (Maxwells) 1000
(.01)
(.0165)
(.0265)
(.033)
(.0165)
(.0265)
(.033) 1200
(.012)
(.02)
(.032)
(.0395)
(.02)
(.032) 1280
(.0395) 1600
(.016)
(.0265)
(.042)
(.053)
(.0265)
(.042)
(.053)
*Add material type thickness code when ordering. page Note cir. mils *These dimensions minimum I.D. maximum O.D. Bottom *Standard tolerance flux capacity 15%. other magnetic characteristics, please contact Magnetics Sales Department. Effective cross sectional area shown cm2.
TABLE Ring Cores Ground Fault Interrupters
following cores specifically designed applications. Permalloy stamped rings (.014" thick) comprise core material. Rings processed accomplish minimum permeability 38,000 from -35°C +65°C. Case material (56xxx series) nylon, glassfilled. Core Dimensions Core 56037-7D 56822-7D 56153-7D 56054-7D 56154-7D 56000-7D 56106-7D 56392-7D 56055-7D I.D. 0.305 0.348 0.375 0.438 11.1 0.438 11.1 0.500 12.7 0.750 19.0 1.125 28.6 1.625 41.3 O.D. 0.405 10.3 0.480 12.2 0.500 12.7 0.562 14.3 0.562 14.3 0.750 19.0 1.125 28.6 1.500 38.1 2.000 50.8 0.098 0.056 0.126 0.084 0.126 0.126 0.196 0.196 0.504 12.8 Case Dimensions I.D. min. 0.255 0.291 0.313 0.369 0.369 0.431 10.9 0.671 17.0 1.036 26.3 1.401 35.6 O.D. max. 0.462 11.7 0.539 13.7 0.569 14.5 0.632 16.1 0.632 16.1 0.819 20.8 1.204 30.6 1,599 40.6 2.099 53.3 0.165 0.118 .0199 0.153 0.199 0.199 0.272 0.292 0.604 15.3 Mean Length Magnetic Path (cm) 2.833 3.304 3.491 3.990 3.990 4.987 7.481 10.47 14.46 Effective Core Cross Sectional Area 0.032 0.024 0.051 0.034 0.050 0.102 0.237 0.237 0.610
MAGNETICS Butler,
WIRE WINDING DATA
TABLE Sizes, Areas, Resistance Current Capacities Synthetic Film Insulated Wire
Wire Area (Max) Heavy Triple Quad Wire Size Current (MA) (circ. mils) (circ. mils) (circ. mils) Ohms/1000' Capacity (**) 18,010 91.21 18,360 92.98 18,960 96.02 .6281 16,510 14,350 72.68 14,670 74.30 15,200 76.98 .7925 13,090 11,470 58.13 11,750 59.51 12,230 61.94 .9987 10,380 9,158 46.42 9,390 47.56 9,821 49.74 1.261 8,226 7,310 37.05 7,517 38.07 7,885 39.93 1.588 6,529 5,852 29.66 6,022 30.50 6,336 32.09 2.001 5,184 4,679 23.72 4,830 24.46 5,112 25.89 2.524 4,109 3,758 19.05 3,894 19.72 4,147 21.00 3.181 3,260 3,003 15.22 3,114 15.77 3,329 16.86 4.020 2,581 2,421 12.27 2,520 12.76 2,704 13.69 5.054 2,052 1,936 9.812 2,025 10.26 2,190 11.09 6.386 1,624 1,560 7.907 1,632 8.265 1,781 9.020 8.046 1,289 1,246 6.315 1,310 6.635 1,436 7.273 10.13 1,024 1,005 5.094 1,063 5.384 1,170 5.925 12.77 812.3 4.090 4.320 4.806 16.20 640.1 3.294 3.505 3.940 20.30 510.8 2.656 2.846 3.216 25.67 404.0 2.149 2.320 2.634 32.37 320.4 1.733 1.869 2.147 41.02 252.8 1.379 1.499 1.733 51.44 201.6 1.110 1.215 1.398 65.31 158.8 0.9123 1.008 1.170 81.21 127.7 0.7298 0.8154 0.9521 103.7 100.0 0.5930 0.6685 0.7799 130.9 79.21 96.0 0.4866 0.5571 0.6483 162.0 64.00 77.4 0.3923 90.2 0.4568 0.5267 205.7 50.41 60.8 0.3082 70.6 0.3576 82.8 0.4193 261.3 39.69 49.0 0.2484 57.8 0.2927 67.2 0.3403 330.7 31.36 39.7 0.2012 47.6 0.2410 54.8 0.2775 414.8 25.00 32.5 0.1647 38.4 0.1945 44.9 0.2274 512.1 20.25 26.0 0.1318 31.4 0.1590 36.0 0.1823 648.2 16.00 20.2 0.1024 25.0 0.1266 28.1 0.1423 846.6 12.25 16.0 0.0810 19.4 0.0983 22.1 0.1119 1079.6 9.61 13.0 0.0659 16.0 0.0810 1323. 7.85 10.2 0.0517 13.0 0.0659 1659. 6.25 0.0426 10.2 0.0517 2143. 4.84 0.037 0.0456 2593. 4.00 *Areas maximum wire area plus maximum insulation buildup. **Based 1,000 cir. mils/amp., current capacity will vary according geometry unit range from 1200 cir. mils/amp. Includes Formvar Poly-Thermaleze types.
TABLE Toroidal Winder Information
Figure opposite page Width Diameter Shuttle Shuttle Shuttle Wire Sizes .218 32-42 .250 26-42 .300 26-42 .313 25-40 .218 32-42 .350 26-42 .417 23-37 .438 26-42 .500 22-40 .300 26-42 .500 22-40 .750 20-38 .875 16-30 Shuttles listed above typical shuttle sizes used with popular types automatic toroidal winding machines.
MAGNETICS Butler,
FIGURE Residual Hole Height Standard Shuttle Sizes
HEIGHT (inches)
MAGNETICS Butler,
TABLE Temperature Correction Factors Copper Windings
Resistance determined
Find Resistance -55°C -50°C -45°C -40°C -35°C -30°C -25°C -20°C -15°C -10°C 10°C 15°C 20°C 25°C 30°C 35°C 40°C 45°C 50°C
Multiply .749 .761 .772 .784 .797 .810 .822 .836 .850 .865 .879 .895 .928 .945 .963 .980 .000 1.0197 1.0393 1.059 1.0785 1.0983
Find Resistance 55°C 60°C 65°C 70°C 75°C 80°C 85°C 90°C 95°C 100°C 105°C 110°C 115°C 120°C 125°C 130°C 135°C 140°C 145°C 150°C 155°C
Multiply 1.118 1.138 1.157 1.177 1.197 1.216 1.236 1.256 1.275 1.295 1.314 1.334 1.354 1.373 1.393 1.413 1.432 1.452 1.471 1.491 1.511
DEFINITIONS
Faraday's Defines relationship voltage flux sinusoidal voltage conditions, written: 2.22
where:
Magnetizing force oersteds Number turns Current through turns Magnetic path length core. Magnetic Flux product magnetic induction, crosssectional area, when magnetic induction uniformly distributed normal plane cross-section. Maxwell unit magnetic flux electromagnetic system. maxwell equals 10-8 webers. Gauss unit magnetic induction electromagnetic system. gauss equal maxwell square centimeter. Oersted unit magnetizing force electromagnetic system. oersted equals magneto-motive force gilbert centimeter path length.
Coercive Force that value magnetizing force required reduce flux density zero. (Hc). Residual Flux that value magnetic induction that remains magnetic circuit when magneto-motive force reduced zero. Squareness Ratio ratio residual flux density maximum (saturation) flux density. Permeability general, ratio changes magnetic induction changes magnetizing force called permeability represented symbol Window Area area hole core. (Wa) Winding Factor ratio total area copper wire center hole toroid window area toroid.
4.44
where
Voltage desired Flux density material gausses
Total flux capacity core
Effective core cross-sectional area Design frequency Number turns
Ampere's Defines relationship between magnetizing force current. commonly written
MAGNETICS Butler,
CONVERSION FACTORS
TABLE Selected Conversion Factors
MULTIPLY WEIGHT Pounds Pounds Grams Kilograms 453.59 0.45359 0.0022046 2.2046 LENGTH Feet Inches Centimeters Centimeters Inches Meters 30.480 2.5400 0.032808 0.39370 0.025400 39.370 AREA Circular Circular Square Square Square Square Square Square Square Square Square Square mils mils feet inches centimeters centimeters centimeters inches inches meters centimeters meters 5.067 7.854 929.04 6.4516 1.974 1.0764 0.15500 1.273 6.4516 1.5500 SINUSOIDAL Peak current voltage Peak current voltage current voltage current voltage Average current voltage Average current voltage square square square square circular square square circular square square square square centimeters inches centimeters centimeters mils feet inches mils meters inches meters centimeters centimeters centimeters feet inches meters inches grams kilograms pounds pounds Oersteds Oersteds Oersteds Ampere-turns Ampere-turns Ampere-turns Ampere-turns Ampere-turns OBTAIN MULTIPLY MAGNET
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