transformer and inductor design handbook chapter 3
TRANSCRIPT
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Chapter 3
Magnetic Cores
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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Table of Contents
1. Introduction2. Core Type and Shell Type Construction3. Types of Core Materials4. Eddy Currents and Insulation5. Laminations6. Annealing and Stress-Relief7. Stacking Laminations and Polarity8. Flux Crowding9. Exciting Current10. Tape Wound C, EE, and Toroidal Cores11. Tape Toroidal Cores12. Toroidal, Powder Core13. Stacking Factors14. Design and Dimensional Data for El Laminations15. Design and Dimensional Data for UI Laminations16. Design and Dimensional Data for LL Laminations17. Design and Dimensional Data for DU Laminations18. Design and Dimensional Data for Three Phase Laminations19. Design and Dimensional Data for Tape Wound C Cores20. Dimensional Outline for Tape Wound EE Cores21. Design and Dimensional Data for Tape Wound Toroidal Cores22. Design and Dimensional Data for EE and El Ferrite Cores23. Design and Dimensional Data for EE and El Planar, Ferrite Cores24. Design and Dimensional Data for EC, Ferrite Cores25. Design and Dimensional Data for ETD, Ferrite Cores26. Design and Dimensional Data for ETD/(low profile), Ferrite Cores27. Design and Dimensional Data for ER, Ferrite Cores28. Design and Dimensional Data for EFD, Ferrite Cores29. Design and Dimensional Data for EPC, Ferrite Cores30. Design and Dimensional Data for PC, Ferrite Cores31. Design and Dimensional Data for EP, Ferrite Cores32. Design and Dimensional Data for PQ, Ferrite Cores33. Design and Dimensional Data for PQ/(low profile), Ferrite Cores34. Design and Dimensional Data for RM, Ferrite Cores
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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35. Design and Dimensional Data for RM/(Iow profile), Ferrite Cores36. Design and Dimensional Data for DS, Ferrite Cores37. Design and Dimensional Data for UUR, Ferrite Cores38. Design and Dimensional Data for UUS, Ferrite Cores39. Design and Dimensional Data for Toroidal, Ferrite Cores40. Design and Dimensional Data for Toroidal, MPP Powder Cores41. Design and Dimensional Data for Toroidal, Iron Powder Cores42. Design and Dimensional Data for Toroidal, Sendust Powder Cores43. Design and Dimensional Data for Toroidal, High Flux Powder Cores44. Design and Dimensional Data for EE, Iron Powder Cores45. Design and Dimensional Data for EE, Sendust Powder Cores46. References
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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Introduction
The key ingredient in a magnetic device is the magnetic field (flux) created when current is passed througha coiled wire. The ability to control (channel, predict, conduct), the magnetic field (flux) is critical tocontrolling the operation of the magnetic device.
The ability of a material to conduct magnetic flux is defined as permeability. A vacuum is defined as
having a permeability of 1.0 and the permeability of all other materials is measured against this baseline.
Most materials such as air, paper, and wood are poor conductors of magnetic flux, in that they have low
permeability. If wire is wound on a dowel, it exhibits a magnetic field exactly, as shown in Figure 3-1.
There are a few materials, such as iron, nickel, cobalt, and their alloys that have high permeabilities,
sometimes ranging into the hundreds of thousands. These materials and their alloys are used as the base
materials for all core materials.
Magnetic Flux, O
Current, I
Coil
Dowel
Figure 3-1. Air Core with an Intensified Magnetic Field.
The main purpose of the core is to contain the magnetic flux and create a well-defined, predictable path forthe flux. This flux path, and the mean distance covered by the flux within the magnetic material, is defined
as the Magnetic Path Length (MPL) (see Figure 3-2). The Magnetic Path Length and permeability are vitalkeys in predicting the operation characteristic of a magnetic device. Selection of a core material and
geometry are usually based on a compromise between conflicting requirements, such as size, weight,temperature rise, flux density, core loss, and operating frequency.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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agnetic Path Length
Flux,
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Types of Core Materials
Magnetic cores are made of three basic materials. The first is bulk metal, the second is powdered materials,
and the third is ferrite material.
The bulk metals are processed from the furnace into ingots. Then, the material is put into a process of hotand cold rolling. The rolling process produces a sheet of material with a thickness ranging from 0.004 to0.031 inches that can be punched into laminations. It can be further rolled to thicknesses ranging from0.002 to 0.000125 inches, then slit and wound into tape cores, such as C cores, E cores and toroids.
The powder cores, such as powder molypermalloy and powdered iron materials, are die-pressed intotoroids, EE cores and slugs. Powder core processing starts at the ingot, then goes through various steps ofgrinding until the powder is the right consistency for the required performance. Normally, powder cores arenot machined after processing.
Ferrites are ceramic materials of iron oxide, alloyed with oxides or carbonate of manganese, zinc, nickel,magnesium, or cobalt. Alloys are selected and mixed, based on the required permeability of the core.Then, these mixtures are molded into the desired shape with pressure of approximately 150-200 tons persquare inch and fired at temperatures above 2000 degrees F. After the parts are made, they are usuallyrumbled to remove burrs and sharp edges, which are characteristic of this process. Ferrites can bemachined to almost any shape to meet the engineer's needs.
Eddy Currents and Insulation
Transformers, operating at moderate frequency, require the reduction of eddy current losses in the magnetic
material. To reduce the eddy current losses to a reasonable value requires electrical steel to have adequateresistivity. Also, it needs to be rolled to a specific thickness, and it needs effective electrical insulation orcoating of the magnetic material.
If an alternating voltage is applied to the primary winding, as shown in Figure 3-5, it will induce analternating flux in the core. The alternating flux will, in turn, induce a voltage on the secondary winding.This alternating flux also induces a small alternating voltage in the core material. These voltages producecurrents called eddy currents, which are proportional to the voltage. The magnitude of these eddy currents
is also limited by the resistivity of the material. The alternating flux is proportional to the applied voltage.
Doubling the applied voltage will double the eddy currents. This will raise the core loss by a factor of four.
Eddy currents not only flow in the lamination itself, but could flow within the core as a unit, if thelamination is not properly stamped, and if the lamination is not adequately insulated, as shown in Figure 3-6.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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Applied VoltageMagnetic Core
Secondary Voltage
Figure 3-5. Applied Alternating Voltage Induces an Alternating Flux.
There are two eddy currents, as shown in Figure 3-6, ia and ib. The intralaminar eddy current, ia, isgoverned by flux, per lamination and resistance of the lamination. It is, therefore, dependent on laminationwidth, thickness, and volume resistivity.
Insulation, (Coating)
Eddy Current, ia
Eddy Current, z
Figure 3-6. Insulation is Required Between Laminations to Reduce Eddy Currents.
The interlaminar eddy current, ib, is governed by total flux and resistance of the core stack. It is primarilydependent upon stack width and height, the number of laminations, and the surface insulation resistance,
per lamination.
The magnetic materials used for tape cores and laminations are coated with an insulating material. Theinsulating coating is applied to reduce eddy currents. The American Iron and Steel Institute (AISI) has setup insulation standards for transformer steels used in different applications. High permeability, nickel-ironcores are very strain sensitive. Manufacturers of these cores normally have their own proprietary,
insulating material.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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LaminationsLaminations are available in scores of different shapes and sizes. The punch press technology forfabricating laminations has been well-developed. Most lamination sizes have been around forever. The
most commonly used laminations are the El, EE, FF, UI, LL, and the DU, as shown in Figure 3-7. Thelaminations differ from each other by the location of the cut in the magnetic path length. This cutintroduces an air gap, which results in the loss of permeability. To minimize the resulting air gap, thelaminations are generally stacked in such a way the air gaps in each layer are staggered.
El, Laminations EE, Laminations FF, Laminations
UI, Laminations LL, Laminations DU, Laminations
Figure 3-7. Commonly Used, Lamination Shapes.
There are bobbins and brackets for almost all standard stacking dimensions. Most of the El lamination isthe scrapless. The name, scrapless, is derived from shapes that are punched with minimum waste, as shownin Figure 3-8.
i A I
El, Laminations E, Laminations
Laminations
Figure 3-8. Typical, Scrapless El Lamination.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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Annealing and Stress-Relief
One of the most important parameters in transformer steels is permeability. Any stress or strain of themagnetic materials will have an impact on the permeability. The resulting stress could cause highermagnetizing current, or a lower inductance. When the transformer is being assembled (in the stackingprocess), and a lamination is bent (does not return to its original shape), that lamination has been stressedand should be replaced.
Some of the important magnetic properties are lost due to stress and strain after stamping, shearing and
slitting. These properties that have been lost or seriously reduced can be restored to the magnetic materialsby annealing. Basically, stress relief is accomplished by heating (annealing) the magnetic material toprescribed temperature, (depending on the material), followed by cooling to room temperature. The entireannealing process is a delicate operation. The annealing must be done under controlled conditions of time,
temperature and the ambient atmosphere that will avoid, even minute, adverse changes in the chemistry ofthe steel.
Stacking Laminations and Polarity
The edges of the magnetic material that have been stamped, sheared, or slit, will have a burr, as shown inFigure 3-9. The quality of the equipment will keep the burr to a minimum. This burr now gives thelamination a polarity. When a transformer is being stacked, the lamination build is normally sized bydimensions, or it just fills the bobbin.
LaminationWorn Die
Expanded View
=tBun-
Figure 3-9. Expanded View, Showing Lamination Burr.
If the laminations are stacked correctly, all of the burred ends will be aligned. If the laminations arestacked randomly, such as the burr ends facing each other, then, the stacking factor would be affected. The
stacking factor has a direct impact on the cross-section of the core. The end result would be less iron. Thiscould lead to premature saturation, as an increase in the magnetizing current, or a loss of inductance.
There are several methods used in stacking transformer laminations. The most common technique used in
stacking laminations is the alternate method. The alternate method is where one set of laminations, such asan E and an I, are assembled. Then, the laminations are reversed, as shown in Figure 3-10. This technique,
used in stacking, provides the lowest air gap and the highest permeability. Another method for stacking
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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laminations is to interleave two-by-two, also shown in Figure 3-10. The second method of stacking wouldbe in groups of two or more. This is done to cut assembly time. The loss in performance in stacking, otherthan one by one, is the increase in magnetizing current and a loss of permeability.
Laminations E and I
Interleave 1 x 1 Interleave 2 x 2
Figure 3-10. Methods for Stacking Laminations.
Flux Crowding
When laminations are stacked, as shown in Figure 3-11, there is flux crowding. This flux crowding iscaused by the difference in spacing between the E, I, and the adjacent lamination. The adjacent laminationhas a minimum air gap, which translates into a higher permeability.
Laminations E and I
g \
-
\>
\^,
%!/i
\
:= ===
i i= == =
IIr
,
ii \i53S
I
L
-
i
-|
J
i
1
"
Flux Crowding
Minute Air Gap ^~ ' jli izi |1{ ^
Flux
Figure 3-11. Flux Crowding, when Laminations are Interleaved.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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Exciting Current
The flux will skirt the low permeability air gap and migrate into the adjacent lamination, causing fluxcrowding in that lamination. Eventually, this crowding will cause saturation in that portion of thelamination, and the excitation current will rise. After that portion of the lamination has saturated, the fluxwill migrate back to the lower permeability segment of the lamination from where it left. This effect can beeasily viewed by observing the B-H loops at low and high flux densities, and comparing them with atoroidal core of the same material, with a minimum air gap, as shown in Figure 3-12. The B-H loop, alongwith the magnetizing current, Im, of a toroidal core, is shown in Figure 3-12A. The toroidal core, with itsinherit minimum air gap, will have almost a square of current. Using the same material in lamination form
will exhibit a B-H loop, and a magnetizing current, Im, similar to Figure 3-12B operating at low fluxdensities. Increasing the excitation will cause premature saturation of the lamination, as seen by the non-linear, exciting current, as shown in Figure 3-12C
B
ABH
B
C
Figure 3-12. Comparing the Exciting Currents and Three B-H Loops.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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Most finished transformers or inductors will have some sort of bracket, such as an L bracket, end bells, achannel bracket or maybe a bolt through the mounting holes to the chassis. When transformers are beingassembled, there is a certain amount of attention that has to be used to get proper performance. The
insulation material used to coat the lamination is normally very durable, but it can be scratched off anddegrade the performance. When brackets are used in the transformer assembly, as shown in Figure 3-13,care must be taken on how the bolts and brackets are put together. The transformer assembly bolts, shownin Figure 3-13, should be the recommended size for the mounting hole and use all of the required hardware.This hardware should include the correct bolt size and length, and correct surface washer, lock washer andnut. Also, included in this hardware, should be fiber shoulder washers and proper sleeving to cover the boltthreads. If insulating hardware is not used, there is a good chance of a partial, shorted turn. The continuityfor this partial turn can be created through the bolts and bracket, or the bolts, bracket, and the chassis. Thispartial shorted turn will downgrade the performance of the transformer.
Sleeving Laminations
Bolt
Air Gap Material
Mounting Bracket
Shoulder Washer
Fringing Flux
Mounting Bracket
Butt Stack
Figure 3-13. Lamination Mounting Hardware.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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Tape Wound C, EE, and Toroidal Cores
Tape wound cores are constructed by winding around a mandrel, a magnetic material in the form of apreslit tape, as shown in Figure 3-14. This tape material comes in all of the iron alloys, plus the amorphous
materials. The tape thickness varies from 0.0005 inch (0.0127 mm) to 0.012 inch (0.305 mm). Theadvantage of this type of construction is that the flux is parallel with the direction of rolling of the magneticmaterial. This provides the maximum utilization of flux with the minimum of magnetizing force. Thereare two disadvantages in this type of construction. When the core is cut in half, as shown in Figure 3-15,the mating surface has to be ground, lapped, and then, acid-etched. This is done to provide a smoothmating surface with the minimum of air gap and the maximum of permeability. The other disadvantage is
when the cores are reassembled, the method used is normally done with a band and buckle, and thisprocedure requires a little skill to provide the right alignment and correct tension, as shown in Figure 3-16.The C cores are impregnated for strength, prior to being cut. The cut C core can be used in manyconfigurations in the design of a magnetic component, as shown in Figure 3-17. The EE cores areconstructed in the same way as C cores, but they have an additional overwind, as shown in Figure 3-18.The assembled three-phase transformer is shown in Figure 3-19.
Magnetic Material (Tape)
C Core Construction
Mandrel
Magnetic Material (Tape)
Toroidal CoreConstruction "
Mandrel
Figure 3-14. Tape Cores Being Wound on a Mandrel.
Cut C Core
Mating Surface
Figure 3-15. Two Halves of a Cut C Core.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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Banding Material
Buckle
Cut C Core
Figure 3-16. Banding the Cut C Core.
Single Core, Single Coil
Core
Coil
'
Single Core, Dual Coils
cDual Cores, Single Coil
Coil Coil
core y
-
EnclosureCased Toroid Caseless Toroid
Figure 3-20. Outline of a Cased and a Caseless Toroidal Core.
Toroidal, Powder Core
Powder cores, as shown in Figure 3-21, are very unique. They give the engineer another tool to speed theinitial design. Powder cores have a built-in air gap. They come in a variety of materials and are very stablewith time and temperature. The cores are manufactured with good engineering aids. Manufacturersprovide catalogs for their cores, listing not only the size, but also permeability and Millihenrys per 1000turns. The data is presented to the engineer in such a way that it takes the minimum amount of time to havea design that will function.
OD
Figure 3-21. Outline of a Powder Toroidal Core.
Stacking FactorsThe standard stacking factors for tape cores, wound cut cotes and laminations are shown in Table 3-1.
Table 3-1. Standard Stacking Factors.
Thicknessmils
0.1250.2500.5001.0002.0004.0006.00012.00014.00018.00025.000
Tape Cores
0.2500.3750.5000.7500.8500.900
0.9400.940
Wound Cut Cores
0.8300.8900.9000.9000.9500.950
LaminationsButt Stack
0.9000.900
0.9500.9500.950
Interleave 1x1
0.8000.850
0.9000.9000.920
(S.F.)2
0.0620.1410.2500.5620.7220.8100.8100.8840.9020.8100.846
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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Design and Dimensional Data for El Laminations
Laminations are still one of the most widely-used cores in power conversion. The dimensional outline forEl laminations and an assembled transformer is shown in Figure 3-22. Dimensional data for El laminationsis given in Table 3-2; design data is given in Table 3-3.
i . G i I D
Coil
E and I, Laminations Channel Bracket Assembly
Figure 3-22. El Lamination Outline.
Table 3-2. Dimensional Data for El Laminations.
El, Laminations, (Tempel) 14 milPartNo.
EI-375EI-021EI-625EI-750EI-875El- 100
Dcm
0.9531.2701.5881.9052.2232.540
Ecm
0.9531.2701.5881.9052.2232.540
Fcm
0.7940.7940.7940.9531.1111.270
Gcm
1.9052.0642.3812.8573.3333.810
PartNo.
EM 12El- 125EI-138El- 150El- 175EI-225
Dcm
2.8573.1753.4933.8104.4455.715
Ecm
2.8573.1753.4933.8104.4455.715
Fcm
1.4291.5881.7461.9052.2232.858
Gcm
4.2864.7635.2395.7156.6688.573
Table 3-3. Design Data for 14 mil El Laminations.
El, Laminations, (Tempel) 14 milPartNo.
EI-375EI-021EI-625EI-750EI-875El- 100El-112El- 125EI-138EI-150El- 175EI-225
wtcugrams36.147.663.5108.8171.0254.0360.0492.0653.0853.01348.02844.0
wtfegrams47.294.3170.0296.0457.0676.0976.01343.01786.02334.03711.07976.0
MLTcm
6.78.29.511.213.014.816.518.320.122.025.632.7
MPLcm
7.38.39.511.413.315.217.219.121.022.926.734.3
waAc
1.7541.0750.4180.7900.7890.7900.7890.7890.7890.7890.7890.789
Ac
cm0.8621.5232.3943.4484.6936.1297.7579.57711.58813.79018.77031.028
wacm2
1.5121.6381.8902.7233.7054.8396.1247.5609.14810.88714.81824.496
APcm4
1.3032.5104.5259.38417.38429.65647.50472.404106.006150.136278.145760.064
Kgcm5
0.0670.1880.4591.1532.5134.9278.92015.16224.49237.57981.656
288.936
A,cm46.262.183.2120.0163.0212.9269.4333.0403.0479.0652.01078.0
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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Design and Dimensional Data for UI LaminationsThe dimensional outline for UI laminations and an assembled transformer is shown in Figure 3-23.
Dimensional data for UI laminations is given in Table 3-4; design data is given in Table 3-5.
W,
o o
o
F
o
F^ ^
F
i
11
111
, H
G
H
D
e
Coil#l Coil#2
e e
UI, LaminationsSide View End View
UI Transformer Assembled
Figure 3-23. UI Lamination Outline.
Table 3-4. Dimensional Data for UI Laminations.
UI, Standard Laminations 14 milPartNo.
50UI60UI75UI100UI
Dcm
1.2701.4291.9052.540
Ecm
1.2701.4291.9052.540
Fcm
1.2702.2231.9052.540
Gcm
3.8105.3985.7157.620
Hcm
1.2701.4291.9052.540
PartNo.
125UI150UI180UI240UI
Dcm
3.1753.8104.5726.096
Ecm
3.1753.8104.5726.096
Fcm
3.1753.8104.5726.096
Gcm
9.52511.43011.43015.240
Hcm
3.1753.8104.5726.096
Table 3-5. Design Data for 14 mil UI Laminations.
UI, Standard Laminations 14 milPartNo.
50UI60UI75U1100UI125UI150UI180UI240UI
wtcugrams
132418434101619673413488411487
Wtfegrams
173300585138427254702749117692
MLTcm
7.689.8111.2214.7618.2922.0426.2834.77
MPLcm
15.2418.1022.8630.4838.1045.7250.2967.06
waAc
3.1596.1873.1573.1583.1583.1582.6322.632
Accm2
1.5321.9393.4486.1299.57713.79019.85835.303
wacm2
4.83911.99610.88719.35530.24243.54852.25892.903
AP4
cm
7.41423.26337.534
118.626289.614600.544
1037.7403279.770
KKcm5
0.5921.8394.614
19.70960.647
150.318313.636
1331.997
A,cm2
11020924743968598712962304
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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Design and Dimensional Data for LL LaminationsThe dimensional outline for LL laminations and an assembled transformer is shown in Figure 3-24.
Dimensional data for LL laminations is given in Table 3-6; design data is given in Table 3-7.
o
o-* *-
E
O
^
-^ *-
F
O-^ fc-
E
iit
\i1
H
H
LL, Laminations
D
Coil#l Coil#2
LL Transformer Assembly
Figure 3-24. LL Lamination Outline.
Table 3-6. Dimensional Data for 14 mil LL Laminations.
LL, Standard Laminations 14 milPartNo.
141L108L250L101L7L4L
Dcm
0.6351.0311.0311.1111.2701.270
Ecm
0.6351.0311.0311.1111.2701.270
Fcm
1.2700.8740.8741.5881.2701.905
Gcm
2.8583.3345.2392.8583.8103.810
Hcm
0.6351.1111.1111.1111.2701.270
PartNumber
104L105L102L106L107L
Dcm
1.2701.2701.4291. 4291.588
Ecm
1.2701.2701.4291.4291.588
Fcm
1.9841.9051.5882.2232.064
Gcm
5.5556.8265.3985.3986.350
Hcm
1.2701.2701.4291.4291.588
Table 3-7. Design Data for 14 mil LL Laminations.
LL, Standard Laminations 14 milPartNo.
141L108L250L101L7L4L
104L105L102L106L107L
wtcugrams63.861.296.1118.5132.2224.0344.9401.3268.6418.6475.2
wtftgrams31.397.9127.1115.9173.9185.2228.0256.5284.1302.1409.5
MLTcm
4.95.95.97.37.78.78.88.78.89.810.2
MPLcm
10.812.716.513.315.216.520.222.519.721.023.2
waAc
9.4732.8844.5323.8673.1594.7377.1938.4884.4196.1875.474
Accm2
0.3831.0101.0101.1731.5321.5321.5321.5321.9391.9392.394
wa2
cm3.6292.9134.5774.5364.8397.25811.02013.0048.56911.99613.105
AP4
cm1.3902.9434.6245.3227.41411.12116.88519.92516.61723.26331.375
Kgcm5
0.0430.2010.3160.3400.5920.7851.1761.4071.4621.8392.946
A,cm2
55.270.392.097.3109.7141.9180.2199.4167.6208.8235.8
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
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Design and Dimensional Data for DU Laminations
The dimensional outline for DU laminations and an assembled transformer is shown in Figure 3-25.
Dimensional data for DU laminations is given in Table 3-8; design data is given in Table 3-9.
tH
it
G\t
H^
ii
I
r
k
r
+*
o
E F
0
E 4
O
O'
^t
o
H = 2E
^a
A
/: | =
DU, Laminations DU Transformer Assembly
Figure 3-25. DU Lamination Outline.
Table 3-8. Dimensional Data for 14 mil DU Laminations.
DU, Standard Laminations 14 milPartNo.
DU-63DU-124DU-18DU-26DU-25DU-1
Dcm
0.1590.3180.4760.6350.6350.635
Ecm
0.1590.3180.4760.6350.6350.635
Fcm
0.3180.4760.6350.6350.9530.953
Gcm
0.7941.1911.5881.9052.0643.810
Hcm
0.3180.6350.9531.2701.2701.270
PartNo.
DU-39DU-37DU-50DU-75
DU-1 125DU-125
Dcm
0.9530.9531.2701.9052.8583.175
Ecm
0.9530.9531.2701.9052.8583.175
Fcm
0.9531.9052.5403.8105.7155.080
Gcm
2.8583.8105.0807.62011.43010.160
Hcm
1.9051.9052.5403.8105.7156.350
Table 3-9. Design Data for 14 mil DU Laminations.
DU, Standard Laminations 14 milPartNo.
DU-63DU-124DU-18DU-26DU-25DU-1DU-39DU-37DU-50DU-75DU-1 125DU-125
wtcugrams
1.44.911.917.031.157.355.3186.0443.91467.04880.03906.0
wtregrams
0.64.313.528.930.442.4104.5124.5287.8985.23246.03966.0
MLTcm
1.52.43.33.94.44.45.77.29.714.221.021.3
MPLcm
3.25.27.38.99.913.313.317.222.834.351.441.4
waAc
10.5005.9064.6883.1595.1339.6343.1588.4208.4228.4208.4215.389
Accm2
0.0240.0960.2150.3830.3830.3830.8620.8621.5323.4487.7579.577
wacm2
0.2520.5671.0081.2101.9663.6302.7227.25812.90329.03265.32251.610
APcm4
0.0060.0540.2170.4630.7531.3902.3466.25619.771
100.091506.709494.275
KBcm3
0.000030.00090.00570.01800.02600.04790.14160.29921.25249.7136
74.830288.9599
A,cm2
4.211.823.433.944.360.976.2134.3238.0537.11208.01147.0
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for Three Phase Laminations
The dimensional outline for 3Phase El laminations and an assembled transformer is shown in Figure 3-26.
Dimensional data for 3Phase El laminations is given in Table 3-10; design data is given in Table 3-11.
tE T
iF
1
W i
o
o
o
-
G ,.
o
o
o
D
e e e
Coil #1 Coil #2 Coil #3
e e e
3Phase Laminations 3Phase Transformer Assembly
Figure 3-26. El Three Phase Laminations Outline.
Table 3-10. Dimensional Data for 14 mil El Three Phase Laminations.
3Phase, Standard Laminations, Thomas & Skinner 14 milPartNo.
0.250EI0.375EI0.500EI0.562EI0.625EI0.875EI
Dcm
0.6350.9531.2701.4271.5882.223
Ecm
0.6350.9531.2701.4271.5882.223
Fcm
0.8711.2701.5881.5881.9842.779
Gcm
2.8583.1753.4935.3985.6346.111
PartNo.
l.OOOEI1.200EI1.500EI1.800EI2.400EI3.600EI
Dcm
2.5403.0483.8104.5726.0969.144
Ecm
2.5403.0483.8104.5726.0969.144
Fcm
3.8103.0483.8104.5726.0969.144
Gcm
7.6207.6209.52511.43015.24022.860
Table 3-11. Design Data for 14 mil El Three Phase Laminations.
3Phase, Standard Laminations, Thomas & Skinner 14 milPartNo.
0.250EI0.375EI0.500EI0.562EI0.625EI0.875EI1 .OOOEI1.200EI1.500E11 .800EI2.400EI3.600EI
wtcugrams
57134242403600125525942178426673261723058144
wtfegrams
541543244217061743275135466957120172863496805
MLTcm
4.36.28.28.810.113.916.717.622.026.334.852.2
wa2AC
3.2512.3391.8102.2132.3341.8092.3681.3161.3161.3161.3161.316
Accm2
0.3830.8621.5321.9362.3944.6936.1298.82613.79019.85835.30379.432
wacm2
2.494.035.548.5711.1816.9829.0323.2336.2952.2692.90209.03
APcm4
1.435.2112.7424.8840.13119.53266.91307.48750.681556.614919.6624905.75
KRcm5
0.0510.2890.9552.1873.81616.18739.06761.727187.898470.4531997.99515174.600
Atcm
531021592072754877307251132163028996522
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for Tape Wound C CoresThe dimensional outline for C cores is shown in Figure 3-27. Dimensional data for C cores is given inTable 3-12; design data is given in Table 3-13.
D
Figure 3-27. Tape C Core Dimensional Outline.
Table 3-12. Dimensional Data for Tape C Cores.
C Cores, Magnetic Metals, 2 milPartNo.
ML-002ML-004ML-006ML-008ML-010ML-012
Dcm
0.6350.6351.2700.9531.5881.270
Ecm
0.4760.6350.6350.9530.9531.111
Fcm
0.6350.6350.6350.9530.9531.270
Gcm
1.5882.2232.2233.0163.0162.858
PartNo.
ML-014ML-016ML-018ML-020ML-022ML-024
Dcm
1.2701.9051.2702.5402.5402.450
Ecm
1.2701.2701.1111.5881.5881.588
Fcm
1.2701.2701.5881.5881.5881.905
Gcm
3.9693.9693.9693.9694.9215.874
Table 3-13. Design Data for Tape C Cores.
C Cores, Magnetic Metals, 2 milPartNo.
ML-002ML-004ML-006ML-008ML-010ML-012ML-014ML-016ML-018ML-020ML-022ML-024
wvvtcugrams13.019.827.258.473.595.1137.7160.5176.2254.5315.6471.7
wtfegrams13.022.645.272.5120.8121.7170.4255.6149.1478.4530.5600.1
MLTcm
3.63.95.45.77.27.47.79.07.911.411.411.9
MPLcm
6.48.38.311.811.812.715.615.615.617.519.421.9
waAc
3.7473.9331.9673.5562.1342.8913.5132.3415.0191.7562.1773.117
Ac
cm2
0.2690.3590.7180.8081.3471.2561.4352.1531.2563.5903.5903.590
wacm2
1.0081.4121.4122.8742.8743.6305.0415.0416.3036.3037.81511.190
APcm4
0.2710.5071.0132.3233.8714.5587.23610.8547.915
22.62628.05340.170
K8cm5
0.00800.01840.05370.13140.29020.31090.54081 .04430.50562.86073.54694.8656
A,cm2
21.029.837.563.674.787.1112.1126.8118.9182.0202.0244.8
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Dimensional Outline for Tape Wound EE CoresThe dimensional outline for EE cores is shown in Figure 3-28. Dimensional data for EE cores is given in
Table 3-14; design data is given in Table 3-15.
1
1
G
Ac
D
Figure 3-28. Tape EE Core Dimensional Outline.
Table 3-14. Dimensional Data for Tape EE Cores.
3Phase E Cores, National-Arnold Magnetics, 14 milPartNo.
CTA-25CTA-22CTA-17CTA-14
Dcm
1.9053.1753.1753.175
Ecm
1.9051.4291.7462.223
Fcm
1.9051.9051.9052.381
Gcm
2.8585.2396.3504.763
PartNo.
CTA-12CTA-20CTA-03CTA-15
Dcm
3.8105.7154.4455.080
Ecm
2.5402.5402.5403.493
Fcm
2.3812.5403.4932.540
Gcm
6.3506.3509.8437.620
Table 3-15. Design Data for Tape EE Cores.
3Phase E Cores, National-Arnold Magnetics, 14 milPartNo.
CTA-25CTA-22CTA-17CTA-14CTA-12CTA-20CTA-03CTA-15
wtcugrams3266828679161391183437172266
Wtfegrams6861073142218032899442045976544
MLTcm
11.212.813.415.117.321.320.322.0
wa2AC
0.7891.1581.1480.8460.8220.5851.6020.574
ACcm
3.4484.3105.2666.7059.19413.79010.73016.860
wacm5.449.9812.1011.3415.1216.1334.3819.35
APcm4
28.1664.5395.561 14.06208.50333.64553.15489.40
KRcm5
3.4618.68614.97720.20344..43S86.347117.079150.340
A,cm2
261324400468613737993956
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for Tape Wound Toroidal CoresThe dimensional outline for tape wound Toroidal cores is shown in Figure 3-29. Dimensional data forcased tape wound Toroidal cores is given in Table 3-16; design data is given in Table 3-17.
Enclosure
Wa
OD
Cased Toroid Caseless Toroid
Figure 3-29. Tape Toroidal Core Dimensional Outline.
Table 3-16. Dimensional Data for Tape Toroidal Cores.
Toroidal Tape Cores, MagPartNo.
52402521075215352056
ODcm
1.3461.6511.4991.816
IDcm
0.7241.0410.7241.041
HTcm
0.6100.6100.6100.610
PartNo.
52057520005215552176
netics 2 mil Iron Alloy (cased and coated)ODcm
2.1342.1341.6592.134
IDcm
1.3591.0410.8841.041
HTcm
0.6100.6100.9270.927
PartNo.
52061520045207652007
ODcm
2.7813.4292.7942.794
IDcm
1.6642.2861.3341.334
HTcm
0.9270.9270.7620.927
Table 3-17. Design Data for Tape Toroidal Cores.
Toroidal Tape Cores, Magnetics 2 mil Iron Alloy (cased)PartNo.
524025210752153520565205752000521555217652061520045207652007
wtcugrams2.846.763.207.4013.808.106.109.70
28.7061.7017.2018.50
wtfcgrams0.500.701.101.501.803.302.606.509.1011.709.5012.70
MLTcm
2.162.302.202.402.702.702.803.203.704.203.503.70
MPLcm
3.254.243.494.495.484.993.994.996.988.976.486.48
waAc
18.72738.6829.58119.79133.7449.8957.1404.97712.71924.0007.2445.440
ACcm
0.0220.0220.0430.0430.0430.0860.0860.1710.1710.1710.1930.257
wacm2
0.4120.8510.4120.8511.4510.8510.6140.8512.1754.1041.3981.398
APcm4
0.009060.018720.017700.036600.062370.073200.052780.145540.371870.701840.269750.35920
Kgcm5
0.00003880.00007170.00014000.00025920.00039980.00093840.00064610.00312030.00685970.01135850.00602840.0099305
A,cm2
9.8015.5011.2016.8023.7020.6016.0023.3040.3062.2034.6036.40
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for EE Ferrite Cores
The dimensional outline for EE ferrite cores is shown in Figure 3-30. Dimensional data for EE ferrite cores
is given in Table 3-18; design data is given in Table 3-19.
G
>\
\
^ fe-c
Ac i
1
i
\
iE
r
\
\V
\
B A
\
L
\
r
ra
\
^ ^D
EE Ferrite Cores Perspective View
Figure 3-30. Dimension Outline for EE Ferrite Cores.
Table 3-18. Dimensional Data for EE Ferrite Cores.
EE, Ferrite Cores (Magnetics)PartNo.
EE-187EE-2425EE-375
Acm
1.9302.5153.454
Bcm
1.3921.8802.527
Ccm
1.6201.9062.820
Dcm
0.4780.6530.935
Ecm
0.4780.6100.932
Gcm
1.1081.2501.930
PartNo.
EE-21EE-625EE-75
Acm
4.0874.7125.657
Bcm
2.8323.1623.810
Ccm
3.3003.9404.720
Dcm
1.2521.5671.880
Ecm
1.2521.5671.880
Gcm
2.0802.4202.900
Table 3-19. Design Data for EE Ferrite Cores.
EE, Ferrite Cores (Magnetics)PartNo.
EE-187EE-2425EE-375EE-21EE-625EE-75
Wvvtcugrams
6.813.936.447.364.4111.1
wtfegrams
4.49.533.057.0103.0179.0
MLTcm
3.84.96.68.19.411.2
MPLcm
4.014.856.947.758.9010.70
waAc
2.2192.0681.8751.1030.8080.826
Accm2
0.2280.3840.8211.4902.3903.390
wacm
0.5060.7941.5391.6431.9302.799
AP4cm4
0.1160.3051.2642.4484.6169.487
Kgcm5
0.00280.00950.06240.18020.47001.1527
A,cm2
14.423.545.360.981.8118.0
*ALmh/lK
5007671167196727673467
*This AL value has been normalized for a permeability of IK. For a close approximation of AL for othervalues of permeability, multiply this AL value by the new permeability in kilo-perm. If the newpermeability is 2500, then use 2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for EE and El Planar, Ferrite Cores
The dimensional outline for EE and El planar ferrite cores is shown in Figure 3-31. Dimensional data for
EE and El planar ferrite cores is given in Table 3-20; design data is given in Table 3-21.
B A
Matting SetAc
E o r l
*
D
>-C
EE or El Planar Ferrite Cores Perspective View
Figure 3-31. Dimension Outline for EE, El Planar Ferrite Cores.
Table 3-20. Dimensional Data for EE, El Planar Ferrite Cores.
EE&EI/LP, Ferrite Cores (Magnetics)PartNo.
EI-41805EE-41805EI-42216EE-42216
Acm
1.8001.8002.1602.160
Bcm
1.3701.3701.6101.610
Ccm
0.6380.7960.8671.144
Dcm
1.0001.0001.5901.590
Ecm
0.3980.3980.5080.508
Gcm
0.1880.3760.2970.610
PartNo.
EI-43208EE-43208EI-44310EE-44310
Acm
3.1753.1754.3184.318
Bcm
2.4902.4903.4403.440
Ccm
0.9531.2701.3951.906
Dcm
2.0322.0322.7902.790
Ecm
0.6350.6350.8130.813
Gcm
0.3050.6100.5331.066
Table 3-21. Design Data for EE, El Planar Ferrite Cores.
EE&EI/LP, Ferrite Cores (MagPartNo.
EI-41805EE-41805EI-42216EE-42216EI-43208EE-43208EI-44310EE-44310
Wvvtcugrams
1.53.13.87.88.917.829.759.4
wtfegrams
4.14.910.413.022.026.058.070.8
MLTcm
4.74.76.56.58.98.911.911.9
MPLcm
2.032.422.583.213.544.175.066.15
waAc
0.22690.45640.20350.41690.2240.43880.30840.6167
Ac
cm2
0.4010.4010.8060.8061.2901.2902.2702.270
wacm
0.0910.1830.1640.3360.2890.5660.7001.400
netics)AP
4cm
0.03660.07150.13190.27090.36490.72991.58923.1784
KBcm5
0.001240.002480.006510.013370.021260.042530.120850.24170
A,cm
10.411.617.820.533.437.965.475.3
*ALmh/lK17371460259220833438291542673483
This AL value has been normalized for a permeability of 1 K. For a close approximation of AL for other values ofpermeability, multiply this AL value by the new permeability in kilo-perm. If the new permeability is 2500, thenuse 2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for EC, Ferrite Cores
The dimensional outline for EC ferrite cores is shown in Figure 3-32. Dimensional data for EC ferrite
cores is given in Table 3-22; design data is given in Table 3-23.
G
XWvv
\\
B A
u
EC Ferrite CoreD
Perspective View
Figure 3-32. Dimension Outline for EC Ferrite Cores.
Table 3-22. Dimensional Data for EC Ferrite Cores.
EC, Ferrite Cores (Magnetics)PartNo.
EC-35EC-41EC-52EC-70
Acm
3.4504.0605.2207.000
Bcm
2.2702.7053.3024.450
Ccm
3.4603.9014.8416.900
Dcm
0.9501.1611.3401.638
Ecm
0.9501.1611.3401.638
Gcm
2.3802.6973.0994.465
Table 3-23. Design Data for EC Ferrite Cores.
EC, Ferrite Cores (Magnetics)PartNo.
EC-35EC-41EC-52EC-70
wtcugrams35.155.497.8
256.7
wtfegrams36.052.0111.0253.0
MLTcm
6.37.59.011.7
MPLcm
7.598.7610.3014.10
waAc
2.2131.9642.1562.927
ACcm2
0.7101.0601.4102.110
wacm2
1.5712.0823.0406.177
Apcm4
1.1152.2074.28713.034
Kgcm5
0.0500.1250.2670.941
A,cm2
50.267.6106.5201.7
*ALrnh/lK1000123316801920
*This AL value has been normalized for a permeability of 1 K. For a close approximation of AL for othervalues of permeability, multiply this AL value by the new permeability in kilo-perm. If the new permeabilityis 2500, then use 2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for ETD, Ferrite CoresThe dimensional outline for ETD ferrite cores is shown in Figure 3-33. Dimensional data for ETD ferrite
cores is given in Table 3-24; design data is given in Table 3-25.
G
C
B A
\
ETD Ferrite Core4 *
D Perspective View
Figure 3-33. Dimension Outline for ETD Ferrite Cores.
Table 3-24. Dimensional Data for ETD Ferrite Cores.
ETD, Ferrite Cores (Ferroxcube)PartNo.
ETD-29ETD-34ETD-39ETD-44
Acm
3.0603.5004.0004.500
Bcm
2.2702.5602.9303.250
Ccm
3.1603.4603.9604.460
Dcm
0.9801.1101.2801.520
Ecm
0.9801.1101.2801.520
Gcm
2.2002.3602.8403.220
PartNo.
ETD-49ETD-54ETD-59
Acm
4.9805,4505.980
Bcm
3.6104.1204.470
Ccm
4.9405.5206.200
Dcm
1.6701.8902.165
Ecm
1.6701.8902.165
Gcm
3.5404.0404.500
Table 3-25. Design Data for ETD Ferrite Cores.
ETD, Ferrite Cores (Ferroxcube)PartNo.
ETD-29ETD-34ETD-39ETD-44ETD-49ETD-54ETD-59
wtcugrams32.143.469.393.2126.2186.9237.7
wtfegrams28.040.060.094.0124.0180.0260.0
MLTcm6.47.18.39.410.311.712.9
MPLcm
7.207.879.2210.3011.4012.7013.90
waAc
1.8651.7571.8711.5991.6271.6091.410
Ac
cm2
0.7610.9741.2521.7422.1102.8003.677
wacm2
1.4191.7112.3432.7853.4344.5055.186
APcm4
1.08001.66652.93304.85207.245312.612919.0698
KRcm5
0.05170.09110.17660.35950.59171.21042.1271
Atcm42.553.469.987.9107.9133.7163.1
*ALmh/lK1000118213181682190922732727
*This AL value has been normalized for a permeability of IK. For a close approximation of AL for other values ofpermeability, multiply this AL value by the new permeability in kilo-perm. If the new permeability is 2500, then use2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for ETD/(low profile), Ferrite Cores
The dimensional outline for ETD/lp low profile ferrite cores is shown in Figure 3-34. Dimensional data for
ETD/lp low profile ferrite cores is given in Table 3-26; design data is given in Table 3-27.
X
c
B
w ~vvaETD-lp Ferrite Core
DPerspective View
Figure 3-34. Dimension Outline for ETD/lp Ferrite Cores.
Table 3-26. Dimensional Data for ETD/lp Ferrite Cores.
ETD/lp, Ferrite Cores (TSC Ferrite International)PartNo.
ETD34(lp)ETD39(lp)ETD44(lp)ETD49(lp)
Acm
3.4213.9094.3994.869
Bcm
2.6313.0103.3303.701
Ccm
1.8041.7981.9202.082
Dcm
1.0801.2501.4811.631
Ecm
1.0801.2501.4811.631
Gcm
0.7620.7620.7620.762
Table 3-27. Design Data for ETD/lp Ferrite Cores.
ETD/lp, Ferrite Cores (TSC Ferrite International)PartNo.
ETD34(lp)ETD39(lp)ETD44(lp)ETD49(lp)
Wvvtcugrams15.120.024.629.1
Wtfc
grams32.746.372.195.0
MLTcm
7.28.49.510.4
MPLcm
4.655.035.405.85
waAc
0.6090.5590.4200.374
Accm2
0.9701.2001.7302.110
wacm2
0.5910.6710.7270.789
Apcm4
0.57320.80471.25831.6641
Kgcm5
0.03100.04610.09140.1353
A,cm2
33.139.648.458.2
*ALmh/lK2382283836594120
*This AL value has been normalized for a permeability of 1 K. For a close approximation of AL for other valuesof permeability, multiply this AL value by the new permeability in kilo-perm. If the new permeability is 2500,then use 2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for ER, Ferrite CoresSurface Mount Device, SMD
The dimensional outline for ER ferrite cores is shown in Figure 3-35. Dimensional data for ER ferrite
cores is given in Table 3-28; design data is given in Table 3-29.
B
cER Ferrite Core D Perspective View
Figure 3-35. Dimension Outline for ER Ferrite Cores.
Table 3-28. Dimensional Data for ER Ferrite Cores.
ER, Ferrite Cores (Ferroxcube)PartNo.
ER9.5E R 1 1ER35
Acm
0.9501.1003.500
Bcm
0.7500.8702.615
Ccm
0.4900.4904.140
Dcm
0.5000.6001.140
Ecm
0.3500.4251.130
Gcm
0.3200.3002.950
PartNo.
ER42ER48ER54
Acm
4.2004.8005.350
Bcm
3.0053.8004.065
Ccm
4.4804.2203.660
Dcm
1.5602.1001.795
Ecm
1.5501.8001.790
Gcm
3.0902.9402.220
Table 3-29. Design Data for ER Ferrite Cores.
ER, Ferrite Cores (Ferroxcube)PartNo.
ER9.5E R 1 1ER35ER42ER48ER54
wtcugrams
0.60.756.772.9120.7101.9
Wtfegrams
0.71.0
46.096.0128.0122.0
MLTcm
2.7003.2007.3009.10011.5001 1 .400
MPLcm
1.421.479.089.8810.009.18
waAc
0.8420.6502.1901.1891.1851.052
Accm2
0.0760.1031.0001.8902.4802.400
wacm2
0.06400.06702.19002.24802.94002.5250
APcm4
0.004860.006882.190374.248677.291206.06060
KBcm5
0.0000540.0000900.1203400.3524440.6262450.512544
A,cm
3.03.7
62.481.0100.196.2
*ALmh/lK
4356091217200024782652
*This AL value has been normalized for a permeability of 1 K. For a close approximation of AL for other valuesof permeability, multiply this AL value by the new permeability in kilo-perm. If the new permeability is 2500,then use 2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for EFD, Ferrite CoresSurface Mount Device, SMD
The EFD cores, (Economic Flat Design), offer a significant advance in power transformer circuitminiaturization. The dimensional outline for EFD ferrite cores is shown in Figure 3-36. Dimensional datafor EFD ferrite cores is given in Table 3-30; design data is given in Table 3-31.
EFD Ferrite Core Perspective View
Figure 3-36. Dimension Outline for EFD Ferrite Cores.
Table 3-30. Dimensional Data for EFD Ferrite Cores.
EFD, Ferrite Cores (Ferroxcube)PartNo.
EFD- 10EFD- 15EFD-20EFD-25EFD-30
Acm
1.0501.5002.0002.5003.000
Bcm
0.7651.1001.5401.8702.240
Ccm
0.2700.4650.6650.9100.910
Dcm
1.0401.5002.0002.5003.000
Ecm
0.4550.5300.8901.1401.460
Gcm
0.7501.1001.5401.8602.240
Hcm
0.1450.2400.3600.5200.490
Table 3-31. Design Data for EFD Ferrite Cores.
EFD, Ferrite Cores (Ferroxcube)PartNo.
EFD- 10EFD- 15EFD-20EFD-25EFD-30
wtcugrams
0.83.06.811.517.0
wtfegrams0.902.807.0016.0024.00
MLTcm
1.82.73.84.85.5
MPLcm
2.373.404.705.706.80
waAc
1.6112.0931.6161.1711.267
Accm2
0.0720.1500.3100.5800.690
wacm2
0.1160.3140.5010.6790.874
APcm4
0.008370.047030.155160.393760.60278
Ks
cm5
0.000130.001050.005060.019110.03047
Atcm2
3.37.313.321.628.9
*ALmh/lK
254413565957913
*This AL value has been normalized for a permeability of IK. For a close approximation of AL for othervalues of permeability, multiply this AL value by the new permeability in kilo-perm. If the new permeabilityis 2500, then use 2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for EPC, Ferrite CoresSurface Mount Device, SMD
The dimensional outline for EPC ferrite cores is shown in Figure 3-37. Dimensional data for EPC ferritecores is given in Table 3-32; design data is given in Table 3-33.
EPC Ferrite Core Perspective View
Figure 3-37. Dimension Outline for EPC Ferrite Cores.
Table 3-32. Dimensional Data for EPC Ferrite Cores.
EPC, Ferrite Cores (TDK)PartNo.
EPC- 10EPC- 13EPC- 17EPC- 19EPC-25EPC-27EPC-30
Acm
1.0201.3251.7601.9102.5102.7103.010
Bcm
0.7601.0501.4301.5802.0402.1602.360
Ccm
0.3400.4600.6000.6000.8000.8000.800
Dcm
0.8101.3201.7101.9502.5003.2003.500
Ecm
0.5000.5600.7700.8501.1501.3001.500
Gcm
0.5300.9001.2101.4501.8002.4002.600
Hcm
0.1900.2050.2800.2500.4000.4000.400
Table 3-33. Design Data for EPC Ferrite Cores.
EPC, Ferrite Cores (TDK)PartNo.
EPC- 10EPC- 13EPC-17EPC- 19EPC-25EPC-27EPC-30
Wvvtcugrams
0.52.04.96.914.818.821.9
wtfegrams
1.12.14.55.313.018.023.0
MLTcm
1.92.53.43.75.05.15.5
MPLcm
1.783.064.024.615.927.318.16
waAC
0.7351.7681.7502.3301.8041.8901.833
ACcm
0.0940.1250.2280.2270.4640.5460.610
wacm
0.0690.2210.3990.5290.8371.0321.118
AP4
cm
0.006470.027560.091040.120140.388370.563470.68198
Kgcm
0.0001280.0005490.0024280.0029810.0145320.0240360.030145
A,cm"
2.95.910.212.120.626.831.5
*ALmh/lK
416363479392650642654
This AL value has been normalized for a permeability of IK. For a close approximation of AL for other values ofpermeability, multiply this AL value by the new permeability in kilo-perm. If the new permeability is 2500, then use2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for PC, Ferrite Cores
The dimensional outline for PC ferrite pot cores is shown in Figure 3-38. Dimensional data for PC ferrite
pot cores is given in Table 3-34; design data is given in Table 3-35.
Ferrite Pot Core
B
Perspective View
Figure 3-38. Dimension Outline for PC Ferrite Cores.
Table 3-34. Dimensional Data for PC Ferrite Cores.
PC, Ferrite Cores (Magnetics)PartNo.
PC-40905PC-41408PC-41811PC-42213
Acm
0.9141.4001.8002.160
Bcm
0.7491.1601.4981.790
Ccm
0.5260.8481.0671.340
Ecm
0.3880.5990.7590.940
Gcm
0.3610.5590.7200.920
PartNumber
PC-42616PC-43019PC-43622PC-44229
Acm
2.5503.0003.5604.240
Bcm
2.1212.5002.9903.560
Ccm
1.6101.8802.2002.960
Ecm
1.1481.3501.6101.770
Gcm
1.1021.3001.4602.040
Table 3-35. Design Data for PC Ferrite Cores.
PC, Ferrite Cores (Magnetics)PartNo.
PC-40905PC-41408PC-41811PC-42213PC-42616PC-43019PC-43622PC-44229
wtcugrams
0.51.63.56.210.116.726.755.9
Wtf,grams
1.03.27.313.020.034.057.0104.0
MLTcm
1.92.93.74.45.36.37.58.6
MPLcm
1.251.972.593.123.764.505.296.85
waAC
0.6500.6310.6200.6120.5760.5500.4990.686
Accm2
0.1000.2490.4290.6390.9311.3602.0202.660
wacm2
0.0650.1570.2660.3910.5360.7481.0071.826
AP4
cm0.006520.039040.114130.249850.499130.971752.034954.85663
K*5
cm0.0001340.0013310.0052870.0143600.0351140.0804080.2203470.600289
A,cm2
2.86.811.116.423.131.944.567.7
*ALmh/lK
455933133316332116270034004000
"This AL value has been normalized for a permeability of IK. For a close approximation of AL for other values ofpermeability, multiply this AL value by the new permeability in kilo-perm. If the new permeability is 2500, then use2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for EP, Ferrite CoresThe EP ferrite cores are typically used in transformer applications. The shape of the assembly is almostcubical, allowing high package densities on the PCB. The dimensional outline for EP ferrite cores is shownin Figure 3-39. Dimensional data for EP ferrite cores is given in Table 3-36; design data is given in Table
3-37.
A, D
EP Ferrite Core Perspective View
Figure 3-39. Dimension Outline for EP Ferrite Cores.
Table 3-36. Dimensional Data for EP Ferrite Cores.
EP, Ferrite Cores (Magnetics)PartNo.
EP-07EP-10EP-13EP-17EP-20
Acm
0.9201.1501.2501.7982.400
Bcm
0.7200.9200.9721.1601.610
Ccm
0.6350.7600.8801.1001.495
Dcm
0.7401.0301.2901.6802.139
Ecm
0.3400.3450.4520.5840.899
Gcm
0.5000.7200.8991.1181.397
Table 3-37. Design Data for EP Ferrite Cores.
EP, Ferrite Cores (Magnetics)PartNo.
EP-07EP-10EP-13EP-17EP-20
wtcugrams
1.41.62.011.67.4
wtfegrams
1.42.85.111.627.6
MLTcm
1.82.12.42.94.2
MPLcm
1.571.922.422.853.98
waAC
0.9221.8321.2000.9500.637
Accm2
0.1030.1130.1950.3390.780
wacm2
0.0950.2070.2340.3220.497
APcm4
0.009790.023390.045580.109150.38737
KBcm5
0.000220.000490.001480.005100.02892
A,cm2
3.55.77.713.723.8
*ALmh/lK
41340066710331667
*This AL value has been normalized for a permeability of 1 K. For a close approximation of AL for othervalues of permeability, multiply this AL value by the new permeability in kilo-perm. If the new permeability is2500, then use 2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for PQ, Ferrite Cores
The PQ ferrite cores, (Power Quality), feature round center legs with rather small cross-sections. Thedimensional outline for PQ ferrite cores is shown in Figure 3-40. Dimensional data for PQ ferrite cores isgiven in Table 3-38; design data is given in Table 3-39.
E B
^
i
B
1
\i
r
*--
s
r
-i
i L
A
PQ Ferrite Core Perspective View
Figure 3-40. Dimension Outline for PQ Ferrite Cores.
Table 3-38. Dimensional Data for PQ Ferrite Cores.
PQ, Ferrite Cores (TDK)PartNo.
PQ20/16PQ20/20PQ26/20PQ26/25PQ32/20
Acm
2.0502.0502.6502.6503.200
Bcm
1.8001.8002.2502.2502.750
Ccm
1.6202.0202.0152.4752.055
Dcm
1.4001.4001.9001.9002.200
Ecm
0.8800.8801.2001.2001.345
Gcm
.030
.430
.150
.610
.150
PartNo.
PQ32/30PQ35/35PQ40/40PQ50/50
Acm
3.2003.5104.0505.000
Bcm
2.7503.2003.7004.400
Ccm
3.0353.4753.9754.995
Dcm
2.2002.6002.8003.200
Ecm
1.3451.4351.4902.000
Gcm
2.1302.5002.9503.610
Table 3-39. Design Data for PQ Ferrite Cores.
PQ, Ferrite Cores (TDK)PartNo.
PQ20/16PQ20/20PQ26/20PQ26/25PQ32/20PQ32/30PQ35/35PQ40/40PQ50/50
Wvvtcugrams
7.410.431.017.018.935.559.097.2158.5
Wtfegrams13.015.031.036.042.055.073.095.0195.0
MLTcm
4.44.45.65.76.66.77.58.410.3
MPLcm
3.744.544.635.555.557.468.7910.2011.30
waAc
0.7651.0610.5080.7160.4750.9291.1261.6221.321
Ac
cm0.6200.6201.1901.1801.7001.6101.9602.0103.280
wacm2
0.4740.6580.6040.8450.8081.4962.2063.2604.332
Ap4
cm0.2940.4080.7180.9971.3732.4094.3246.55214.209
KEcm5
0.01670.02270.06130.08320.14170.23260.45100.62801.8120
A,cm2
16.919.728.432.636.346.960.777.1113.9
*ALmh/lK161713132571218730462142202517922800
*This AL value has been normalized for a permeability of IK. For a close approximation of AL for other values ofpermeability, multiply this AL value by the new permeability in kilo-perm. If the new permeability is 2500, thenuse 2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for PQ/(low profile), Ferrite Cores
The PQ/lp cores are a cut down version of the standard PQ cores. The PQ/lp cores have a substantiallyreduced total height. The dimensional outline for PQ ferrite cores is shown in Figure 3-41. Dimensionaldata for PQ ferrite cores is given in Table 3-40; design data is given in Table 3-41.
1
1
\t
B
r
s-*
^
-
i
i I
A
DPQ Ferrite Core, low profile Perspective View
Figure 3-41. Dimension Outline for PQ/lp Ferrite Cores.
Table 3-40. Dimensional Data for PQ/lp Ferrite Cores.
PQ/1PartNo.
PQ20-14-141pPQ26-16-141pPQ32-17-221pPQ35-17-261ppQ40-18-281p
>, Ferrite Cores (Ferrite International)Acm
2.1252.7243.3023.6124.148
Bcm
1.8012.2502.7513.2003.701
Ccm
1.3521.6301.6701.7381.784
Dcm
1.4001.9002.2002.6012.799
Ecm
0.8841.1991.3481.4351.491
Gcm
0.7620.7620.7620.7620.762
Table 3-41. Design Data for PQ/lp Ferrite Cores.
PQ/lp, Ferrite Cores (TSC Ferrite International)PartNo.
PQ20-14-141pPQ26-16-191pPQ32-17-221pPQ35-17-261pPQ40-18-281p
wttugrams
5.47.912.517.824.9
wtfegrams12.528.039.444.963.5
MLTcm
4.45.66.67.48.3
MPLcm
3.23.94.85.35.8
waAC
0.5630.3360.3150.3430.419
Ac
cm2
0.6201.1901.7001.9602.010
wacm2
0.3490.4000.5350.6720.842
AP4
cm
0.2170.4770.9091.3181.692
KScm5
0.01230.04070.09370.13890.1637
A,cm2
15.425.432.940.448.0
*ALmh/lK
19483170365938933850
This AL value has been normalized for a permeability of IK. For a close approximation of AL for other values ofpermeability, multiply this AL value by the new permeability in kilo-perm. If the new permeability is 2500, then use2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for RM, Ferrite Cores
The RM cores, (Rectangular Modular), were developed for high Printed Circuit Board, (PCB), packingdensities. The dimensional outline for RM ferrite cores is shown in Figure 3-42. Dimensional data for RM
ferrite cores is given in Table 3-42; design data is given in Table 3-43.
RM Ferrite Core
Figure 3-42. Dimension Outline for RM Ferrite Cores.
Table 3-42. Dimensional Data for RM Ferrite Cores.
Perspective View
RM, Ferrite Cores (TDK)PartNo.
RM-4RM-5RM-6RM-8
Acm
0.9631.2051.44
1.935
Bcm
0.8151.04
1.2651.73
Ccm
1.041.041.241.64
Ecm
0.380.480.630.84
Gcm
0.720.650.821.1
PartNo.
RM-10RM-12RM-14
Acm
2.4152.9253.42
Bcm
2.1652.552.95
Ccm
1.862.352.88
Ecm
1.071.261.47
Gcm
1.271.712.11
Table 3-43. Design Data for RM Ferrite Cores.
RM, Ferrite Cores (TDK)PartNo.
RM-4RM-5RM-6RM-8RM-10RM-12RM-14
wvvtcugrams
1.11.62.97.313.224.439.9
wtfegrams
1.73.05.513.023.042.070.0
MLTcm2.02.53.14.25.36.27.2
MPLcm
2.272.242.863.804.405.696.90
waAc
1.1210.7680.7100.7660.7090.7880.830
Accm
0.1400.2370.3660.6400.9801.4001.880
wacm
0.1570.1820.2600.4900.6951.1031.561
APcm4
0.02190.04310.09530.31330.68141.54402.7790
Kscm5
0.00060.00160.00440.01910.05020.13890.2755
A,cm2
5.97.911.320.229.644.662.8
*ALmh/lK
48986911301233183324342869
*This AL value has been normalized for a permeability of IK. For a close approximation of AL for othervalues of permeability, multiply this AL value by the new permeability in kilo-perm. If the new permeabilityis 2500, then use 2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for RM/(low profile), Ferrite CoresSurface Mount Device, SMD
The RM/lp ferrite cores are a cut down version of the standard RM cores. The dimensional outline for
RM/lp ferrite cores is shown in Figure 3-43. Dimensional data for RM/lp ferrite cores is given in Table 3-
44; design data is given in Table 3-45.
RM Ferrite Core, low profile Perspective View
Figure 3-43. Dimension Outline for RM/lp Ferrite Cores.
Table 3-44. Dimensional Data for RM/lp Ferrite Cores.
RM/lp, Ferrite Cores (Ferroxcube)PartNo.
RM4/ILPRM5/ILPRM6S/LPRM7/1LP
Acm
0.9801.2301.4701.720
Bcm
0.7951.0201.2401.475
Ccm
0.7800.7800.9000.980
Ecm
0.3900.4900.6400.725
Gcm
0.4300.3600.4500.470
PartNo.
RM8/ILPRM10/ILPRM12/ILPRM14/ILP
Acm
1.9702.4702.9803.470
Bcm
1.7002.1202.5002.900
Ccm
1.1601.3001.6802.050
Ecm
0.8551.0901.2801.500
Gcm
0.5900.6700.9001.110
Table 3-45. Design Data for RM/lp Ferrite Cores.
RM/lp, Ferrite Cores (Ferroxcube)PartNo.
RM4/ILPRM5/ILPRM6S/LPRM7/ILPRM8/ILP
RM10/ILPRM12/ILPRM14/ILP
Wvvtcugrams
0.60.91.52.33.76.411.919.5
Wtfegrams
1.52.24.26.010.017.034.055.0
MLTcm
2.02.53.13.64.25.26.17.1
MPLcm
1.731.752.182.352.873.394.205.09
waAc
0.7700.5250.4330.4440.4490.4260.4390.463
Accm2
0.1130.1810.3120.3960.5540.8091.2501.680
wacm2
0.0870.0950.1350.1760.2490.3450.5490.777
APcm4
0.009840.017270.042120.069790.138100.279150.686251.30536
KKcm5
0.000220.000490.001690.003060.007330.017360.056270.12404
A,cm2
5.06.99.612.716.925.037.852.5
ALmh/lK
6091022138015871783243530873652
*This AL value has been normalized for a permeability of 1 K. For a close approximation of AL for other values ofpermeability, multiply this AL value by the new permeability in kilo-perm. If the new permeability is 2500, thenuse 2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for DS, Ferrite Cores
The DS ferrite cores are similar to standard Pot Cores. These cores have a large opening to bring out manystrands of wire, which is convenient for high power and multiple outputs. The dimensional outline for DSferrite cores is shown in Figure 3-44. Dimensional data for DS ferrite cores is given in Table 3-46; designdata is given in Table 3-47.
G
B
DS Ferrite Core Perspective View
Figure 3-44. Dimension Outline for DS Ferrite Cores.
Table 3-46. Dimensional Data for DS Ferrite Cores.
DS, Ferrite Cores (Magnetics)PartNo.
DS-42311DS-42318DS-42616DS-43019DS-43622DS-44229
Acm
2.2862.2862.5503.0003.5614.240
Bcm
1.7931.7932.1212.5002.9853.561
Ccm
1.1081.8001.6101.8802.1702.960
Dcm
1.5401.5401.7091.7092.3852.840
Ecm
0.9900.9901.1481.3511.6101.770
Gcm
0.7261.3861.1021.3001.4582.042
Table 3-47. Design Data for DS Ferrite Cores.
DS, Ferrite Cores (Magnetics)PartNo.
DS-42311DS-42318DS-42616DS-43019DS-43622DS-44229
Wvvtcugrams
4.79.110.116.726.656.0
wtfegrams10.013.015.022.037.078.0
MLTcm
4.54.65.36.37.58.6
MPLcm
2.683.993.894.625.287.17
waAc
0.7701.3660.8550.7780.8021.028
Ac
cm0.3780.4070.6270.9601.2501.780
wacm2
0.2910.5560.5360.7471.0021.829
AP4
cm
0.1100.2270.3360.7171.2533.255
KB5
cm
0.003680.008000.015930.043800.084040.26917
A,2
cm
16.221.123.131.944.267.7
*ALmh/lK148712671667193323332800
*This AL value has been normalized for a permeability of 1 K. For a close approximation of AL for other values ofpermeability, multiply this AL value by the new permeability in kilo-perm. If the new permeability is 2500, thenuse 2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for UUR, Ferrite Cores
The UUR ferrite cores feature round legs with rather small cross sections. The round legs allow easy
winding with either wire or foil. U cores are used for power, pulse and high-voltage transformers. The
dimensional outline for UUR ferrite cores is shown in Figure 3-45. Dimensional data for UUR ferrite cores
is given in Table 3-48; design data is given in Table 3-49.
c
r
\
1
F
1
/
X
Gr
/\
J
/j
i
wa
A
AC
.
D
1
mUUR Ferrite Cores Perspective View
Figure 3-45. Dimension Outline for UUR Ferrite Cores.
Table 3-48. Dimensional Data for UUR Ferrite Cores.
UUR, Ferrite Cores (Magnetics)PartNo.
UUR-44121UUR-44119UUR-44125UUR-44130
Acm
4.1964.1964.1964.196
Ccm
4.1204.1805.0806.100
Dcm
1.1701.1701.1701.170
Fcm
1.9101.9101.9101.910
Gcm
2.1802.6803.1404.160
Table 3-49. Design Data for UUR Ferrite Cores.
UUR, Ferrite Cores (Magnetics)PartNo.
UUR-44121UUR-44119UUR-44125UUR-44130
wtcugrams119.0146.2171.3227.0
Wtfegrams55.054.064.075.0
MLTcm
8.08.08.08.0
MPLcm
11.312.113.315.3
waAc
4.2155.6196.0708.043
Accm2
0.9880.9110.9880.988
wacm
4.1645.1195.9977.946
APcm4
4.1144.6635.9257.850
Kgcm5
0.2020.2110.2910.386
A,cm
98.5102.9116.1134.9
*ALmh/lK
616710702610
*This AL value has been normalized for a permeability of 1 K. For a close approximation of AL for othervalues of permeability, multiply this AL value by the new permeability in kilo-perm. If the new permeability is2500, then use 2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for UUS, Ferrite Cores
The UUS ferrite cores feature square or rectangular legs. U cores are used for power, pulse and high-
voltage transformers. The dimensional outline for UUS ferrite cores is shown in Figure 3-46. Dimensional
data for UUS ferrite cores is given in Table 3-50; design data is given in Table 3-51.
1F
i
i
r (J
J
1
L
A
r
W.
UUS Ferrite Core Perspective View
Figure 3-46. Dimension Outline for UUS Ferrite Cores.
Table 3-50. Dimensional Data for UUS Ferrite Cores.
UUS, Ferrite Cores (Ferroxcube)PartNo.
U10-08-03U20- 16-07U25-20-13U30-25-16U67-27-14U93-76-16
Acm
1.0002.0802.4803.1306.7309.300
Ccm
1.6403.1203.9205.0605.40015.200
Dcm
0.2900.7501.2701.6001.4301.600
Fcm
0.4350.6400.8401.0503.8803.620
Gcm
1.0001.6602.2802.9802.5409.600
Table 3-51. Design Data for UUS Ferrite Cores.
UUS, Ferrite Cores (Ferroxcube)PartNo.
Ul 0-08-03U20-16-07U25-20-13U30-25-16U67-27-14U93-76-16
Wvvtcugrams
3.516.441.683.9
435.01875.2
Wtfegrams
1.819.047.086.0170.0800.0
MLTcm
2.24.46.17.512.415.2
MPLcm
3.86.88.811.117.335.4
waAc
5.3701.8961.8411.9434.8317.757
Accm2
0.0810.5601.0401.6102.0404.480
wacm2
0.4351.0621.9153.1299.85534.752
Apcm4
0.03520.59491.99205.0380
20.1050155.6890
KEcm5
0.0005100.0306610.1356690.4304271.32166118.386023
A,cm2
8.129.551.182.5
240.2605.3
*ALmh/lK
2138261261160916521478
*This AL value has been normalized for a permeability of 1 K. For a close approximation of AL for other values ofpermeability, multiply this AL value by the new permeability in kilo-perm. If the new permeability is 2500, then use2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for Toroidal, Ferrite Cores
The toroidal ferrite core has the best possible shape from the magnetic point of view. The magnetic fluxpath is completely enclosed within the magnetic structure. The toroidal structure fully exploits thecapabilities of a ferrite material. The dimensional outline for toroidal ferrite cores is shown in Figure 3-47.Dimensional data for toroidal ferrite cores is given in Table 3-52; design data is given in Table 3-53.
Wa *"
\O.D
i r
HT.,^ fi,
-*
A
i
\
k
I.D.
r
Toroidal Ferrite Core
Perspective View
Figure 3-47. Dimension Outline for Toroidal Ferrite Cores.
Table 3-52. Dimensional Data for Toroidal Ferrite Cores.
Toroidal, Ferrite Z Coated Cores (Magnetics)PartNo.
TC-40907TC-41005TC-41206TC-41306TC-41605TC-42106
ODcm
1.0161.0161.3341.3341.6642.134
IDcm
0.4950.4110.4520.7290.8121.193
HTcm
0.7680.5290.6910.6910.5210.691
PartNo.
TC-42206TC-42908TC-43806TC-43610TC-43813TC-48613
ODcm
2.2862.9903.9253.6893.9258.738
IDcm
1.2951.8111.7902.2121.7905.389
HTcm
0.6910.8060.6911.0651.3341.334
Table 3-53. Design Data for Toroidal Ferrite Cores.
Toroidal, Ferrite Cores (Magnetics)PartNo.
TC-41005TC-40907TC-41206TC-41306TC-41605TC-42106TC-42206TC-42908TC-43806TC-43610TC-43813TC-48613
wvvtcugrams
0.81.41.23.24.011.213.733.738.063.647.2740.1
Wtfegrams
1.21.63.32.42.85.46.412.929.426.451.7
203.0
MLTcm
1.72.02.22.22.22.82.93.74.24.75.39.1
MPLcm
2.072.272.463.123.685.005.427.328.978.308.30
21.50
waAc
1.2431.4220.7242.8563.3864.8405.2687.1964.0066.7422.18812.197
Accm2
0.1070.1350.2210.1460.1530.2310.2500.3580.6280.5701.1501.870
Wacm2
0.1330.1920.1600.4170.5181.1181.3172.5762.5163.8432.51622.809
APcm4
0.0141960.0259800.0354620.0609390.0792310.2582160.3292830.9221671.5803572.1904562.893966
42.652794
Kscm5
0.0003660.0006870.0014430.0016380.0022400.0084820.0112210.0358690.0935050.1072830.2523943.496437
A,cm2
5.36.68.610.212.822.725.844.661.268.571.0
348.0
*ALmh/lK
657752113059154860060063087888316651091
This AL value has been normalized for a permeability of IK. For a close approximation of AL for other values ofpermeability, multiply this AL value by the new permeability in kilo-perm. If the new permeability is 2500, then use2.5.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for Toroidal, MPP Powder Cores
The dimensional outline for MPP powder cores is shown in Figure 3-48. Dimensional data for MPP
powder cores is given in Table 3-54; design data is given in Table 3-55. For more information, see Chapter
2.
HT.-
tOD
Figure 3-48. Dimension Outline for Toroidal MPP Powder Cores.
Table 3-54. Dimensional Data for Toroidal MPP Powder Cores.
MPP Powder Cores, Magnetics 60 mu (coated)PartNo.
55021552815529155041551315505155121
ODcm
0.6991.0291.0291.0801.1811.3461.740
IDcm
0.2290.4270.4270.4570.5840.6990.953
HTcm
0.3430.3810.4600.4600.4600.5510.711
PartNo.
55381558485505955351558945507155586
ODcm
1.8032.1102.3602.4302.7703.3803.520
IDcm
0.9021.2071.3341.3771.4101.9302.260
HTcm
0.7110.7110.8380.9651.1941.1430.978
PartNo.
550765508355439550905571655110
ODcm
3.6704.0804.7604.7605.1705.800
IDcm
2.1502.3302.3302.7903.0903.470
HTcm
1.1351.5371.8921.6131.4351.486
Table 3-55. Design Data for Toroidal MPP Powder Cores.
MPP Powder Cores, Magnetics 60 mu (coated)PartNo.
5502155281552915504155131550515512155381558485505955351558945507155586550765508355439550905571655110
wtcugrams0.100.700.700.901.502.506.105.6011.1015.2017.9022.3046.2061.4060.2085.30101.90136.90169.30233.30
wtfegrams0.5531.3071.6451.7951.9932.8866.3737.6708.83614.99318.70633.65244.08632.80648.69286.198170.140122.576132.540164.500
MLTcm
1.101.401.601.601.702.002.502.602.803.203.504.104.504.404.805.706.806.406.407.00
MPLcm
1.362.182.182.382.693.124.114.145.095.675.886.358.158.958.989.8410.7411.6312.7314.300
waAc
0.7231.7291.3761.5002.7593.1753.5632.6344.8984.0973.7272.3204.2638.6815.2553.9102.1064.4975.9176.474
Accm2
0.0470.0750.0950.1000.0910.1140.1920.2320.2260.3310.3880.6540.6720.4540.6781.0721.9901.3401.2511.444
wacm
0.0340.1300.1300.1500.2500.3620.6840.6111.1071.3561.4461.5172.8653.9413.5634.1914.1916.0267.4029.348
APcm4
0.0016100.0097570.0123590.0149980.0227350.0412790.1312670.1417470.2500920.4488570.5611530.9924231.9254201.7891282.4158974.4927098.3400108.0752119.26026813.498792
Kgcm5
0.0000270.0002040.0003010.0003750.0004920.0009610.0039850.0050990.0080010.0184060.0249690.0629160.1141790.0741660.1378770.3366080.9712440.6774850.7204351.111049
A,cm2.304.805.105.606.909.3016.0016.3022.7028.6031.4039.8058.3064.4068.0087.50112.60117.20133.10164.70
ALmh/lK
24253232262735433243517561385681135867375
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for Toroidal, Iron Powder Cores
The dimensional outline for Iron powder cores is shown in Figure 3-49. Dimensional data for Iron powder
cores is given in Table 3-56; design data is given in Table 3-57. For more information, see Chapter 2.
Figure 3-49. Dimension Outline for Toroidal Iron Powder Cores.
Table 3-56. Dimensional Data for Toroidal Iron Powder Cores.
Iron Powder Cores, Micrometals 75 mu (coated)PartNo.
T20-26T25-26T26-26T30-26T37-26T38-26T44-26
ODcm
0.5080.6480.6730.7800.9530.9531.120
IDcm
0.2240.3050.2670.3840.5210.4450.582
HTcm
0.1780.2440.4830.3250.3250.4830.404
PartNo.
T50-26T60-26T68-26T80-26T94-26T90-26
T 106-26
ODcm
1.2701.5201.7502.0202.3902.2902.690
IDcm
0.7700.8530.9401.2601.4201.4001.450
HTcm
0.4830.5940.4830.6350.7920.9531.110
PartNo.
T130-26T 132-26T131-26T141-26T 150-26T175-26
ODcm
3.3003.3003.3003.5903.8404.450
IDcm
1.9801.7801.6302.2402.1502.720
HTcm
1.1101.1101.1101.0501.1101.650
Table 3-57. Design Data for Toroidal Iron Powder Cores.Iron Powder Cores, Micrometals 75 mu (coated)
PartNo.
T20-26T25-26T26-26T30-26T37-26T38-26T44-26T50-26T60-26T68-26T80-26T94-26T90-26
T 106-26T 130-26T 132-26T131-26T141-26T 150-26T 175-26
wtcugrams0.100.240.260.470.970.851.462.964.405.3611.6617.4418.3723.0548.3339.0532.7562.7062.55128.04
wtregrams0.190.390.930.771.041.741.862.504.895.308.3115.1315.9829.9440.4644.8547.8345.7058.24105.05
MLTcm
0.700.901.301.141.281.501.501.802.202.172.633.103.403.934.404.404.404.604.856.20
MPLcm
1.151.501.471.842.312.182.683.193.744.235.145.975.786.498.287.967.729.149.3811.20
waAC
1.7131.9730.6441.9333.3281.3602.6874.0713.0533.8775.3944.3733.8942.5044.4083.0892.3575.7434.0914.334
AC
cm2
0.0230.0370.0900.0600.0640.1140.0990.1120.1870.1790.2310.3620.3950.6590.6980.8050.8850.6740.8871.340
wacm2
0.0390.0730.0580.1160.2130.1550.2660.4560.5710.6941.2461.5831.5381.6503.0772.4872.0863.8713.6295.808
APcm4
0.0009000.0027000.0050300.0069400.0136300.0177000.0263200.0521200.1068000.1241500.2878800.5730000.6077401.0876602.1488002.0021901.8458202.6088873.2186207.782300
Kgcm5
0.0000100.0000380.0001300.0001400.0002700.0005200.0006700.0013000.0036800.0040900.0101000.0267700.0296000.0729900.1358100.1459900.1479600.1545160.2355500.672790
A,cm2
1.22.02.63.14.54.86.28.812.214.421.429.629.438.056.953.951.766.671.6107.4
ALmh/lK
18.524.557
33.528.549373350
43.546607093811031167596105
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for Toroidal, Sendust Powder Cores
The dimensional outline for Sendust powder cores is shown in Figure 3-50. Dimensional data for Sendust
powder cores is given in Table 3-58; design data is given in Table 3-59. For more information, see Chapter
2.
HT.- ^^
OD
IFigure 3-50. Dimension Outline for Toroidal Sendust Powder Cores.
Table 3-58. Dimensional Data for Toroidal Sendust Powder Cores.
Sendust Powder Cores, Magnetics 60 mu (coated)PartNo.
77021772817729177041771317705177121
ODcm
0.6991.0291.0291.0801.1811.3461.740
IDcm
0.2290.4270.4270.4570.5840.6990.953
HTcm
0.3430.3810.4600.4600.4600.5510.711
PartNo.
77381778487705977351778947707177586
ODcm
1.8032.1102.3602.4302.7703.3803.520
IDcm
0.9021.2071.3341.3771.4101.9302.260
HTcm
0.7110.7110.8380.9651.1941.1430.978
PartNo.
770767708377439770907771677110
ODcm
3.6704.0804.7604.7605.1705.800
IDcm
2.1502.3302.3302.7903.0903.470
HTcm
1.1351.5371.8921.6131.4351.486
Table 3-59. Design Data for Toroidal Sendust Powder Cores.
Sendust Powder Cores, Magnetics 60 mu (coated)PartNo.
7702177281772917704177131770517712177381778487705977351778947707177586770767708377439770907771677110
wtcugrams0.100.700.700.901.502.506.105.6011.1015.2017.9022.3046.2061.4060.2085.30101.90136.90169.30233.30
wtfegrams0.4481.1481.4421.6661.7062.4905.5246.7238.05213.13715.97029.07038.33828.44342.61973.839149.608109.089111.477144.544
MLTcm
1.101.401.601.601.702.002.502.602.803.203.504.104.504.404.805.706.806.406.407.00
MPLcm
1.362.182.182.382.693.124.114.145.095.675.886.358.158.958.989.8410.7411.6312.73
14.300
waAc
0.7231.7291.3761.5002.7593.1753.5632.6344.8984.0973.7272.3204.2638.6815.2553.9102.1064.4975.9176.474
Accm2
0.0470.0750.0950.1000.0910.1140.1920.2320.2260.3310.3880.6540.6720.4540.6781.0721.9901.3401.2511.444
wacm2
0.0340.1300.1300.1500.2500.3620.6840.6111.1071.3561.4461.5172.8653.9413.5634.1914.1916.0267.4029.348
APcm4
0.0016100.0097570.0123590.0149980.0227350.0412790.1312670.1417470.2500920.4488570.5611530.9924231.9254201.7891282.4158974.4927098.3400108.0752119.26026813.498792
KRcm5
0.0000270.0002040.0003010.0003750.0004920.0009610.0039850.0050990.0080010.0184060.0249690.0629160.1141790.0741660.1378770.3366080.9712440.6774850.7204351.111049
A,cm2
2.304.805.105.606.909.3016.0016.3022.7028.6031.4039.8058.3064.4068.0087.50112.60117.20133.10164.70
ALmh/lK
24253232262735433243517561385681135867375
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for Toroidal, High Flux Powder Cores
The dimensional outline for High Flux powder cores is shown in Figure 3-51. Dimensional data for High
Flux powder cores is given in Table 3-60; design data is given in Table 3-61. For more information, see
Chapter 2.
HT.I
tOD
IFigure 3-51. Dimension Outline for Toroidal High Flux Powder Cores.
Table 3-60. Dimensional Data for Toroidal High Flux Powder Cores.
High Flux Powder Cores, Magnetics 60 mu (coated)PartNo.
58021582815829158041581315805158121
ODcm
0.6991.0291.0291.0801.1811.3461.740
IDcm
0.2290.4270.4270.4570.5840.6990.953
HTcm
0.3430.3810.4600.4600.4600.5510.711
PartNo.
58381588485805958351588945807158586
ODcm
1.8032.1102.3602.4302.7703.3803.520
IDcm
0.9021.2071.3341.3771.4101.9302.260
HTcm
0.7110.7110.8380.9651.1941.1430.978
PartNo.
580765808358439580905871658110
ODcm
3.6704.0804.7604.7605.1705.800
IDcm
2.1502.3302.3302.7903.0903.470
HTcm
1.1351.5371.8921.6131.4351.486
Table 3-61. Design Data for Toroidal High Flux Powder Cores.
High Flux Powder Cores, Magnetics 60 mu (coated)PartNo.
5802158281582915804158131580515812158381588485805958351588945807158586580765808358439580905871658110
wtcugrams0.100.700.700.901.502.506.105.6011.1015.2017.9022.3046.2061.4060.2085.30101.90136.90169.30233.30
Wtfegrams0.5041.2221.5981.6921.8802.7266.0167.2388.36614.10017.67231.77241.54830.92645.96681.310160.740115.620125.020155.100
MLTcm
1.101.401.601.60
rr.702.002.502.602.803.203.504.104.504.404.805.706.806.406.407.00
MPLcm
1.362.182.182.382.693.124.114.145.095.675.886.358.158.958.989.8410.7411.6312.7314.300
waAc
0.7231.7291.3761.5002.7593.1753.5632.6344.8984.0973.7272.3204.2638.6815.2553.9102.1064.4975.9176.474
Ac
cm0.0470.0750.0950.1000.0910.1140.1920.2320.2260.3310.3880.6540.6720.4540.6781.0721.9901.3401.2511.444
wacm2
0.0340.1300.1300.1500.2500.3620.6840.6111.1071.3561.4461.5172.8653.9413.5634.1914.1916.0267.4029.348
APcm4
0.0016100.0097570.0123590.0149980.0227350.0412790.1312670.1417470.2500920.4488570.5611530.9924231.9254201.7891282.4158974.4927098.3400108.0752119.26026813.498792
KBcm
0.0000270.0002040.0003010.0003750.0004920.0009610.0039850.0050990.0080010.0184060.0249690.0629160.1141790.0741660.1378770.3366080.9712440.6774850.7204351.111049
A,cm2.304.805.105.606.909.3016.00
^ 16.3022.7028.6031.4039.8058.3064.4068.0087.50112.60117.20133.10164.70
ALmh/lK
24253232262735433243517561385681135867375
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for EE, Iron Powder Cores
The dimensional outline for EE iron powder cores is shown in Figure 3-52. Dimensional data for EE iron
powder cores is given in Table 3-62; design data is given in Table 3-63. For more information, see Chapter
2.
G
>
^
^ ^c
AC 'i
t
\
1
EF
\
\V
i \
B A
F
\
L
\
'
a
\
_^ ^
DEE Iron Powder Cores Perspective View
Figure 3-52. Dimension Outline for EE Iron Powder Cores.
Table 3-62. Dimensional Data for EE Iron Powder Cores.
EE, Iron Powder Cores (Micrometals) 75 mu Mix-26PartNo.
DIN- 16-5EI-187EE-24-25EI-375EI-21
Acm
1.6401.9102.5403.4904.130
Bcm
1.1301.4301.9102.5402.860
Ccm
1.6301.6101.9102.9103.410
Dcm
0.4620.4750.6350.9531.270
Ecm
0.4620.4750.6350.9531.270
Gcm
1.2001.1601.2701.9602.140
PartNo.
DIN-42-15DIN-42-20EI-625DIN-55-21EI-75
Acm
4.2804.2804.7405.6105.690
Bcm
3.0703.0703.1803.8603.810
Ccm
4.2204.2203.9405.5404.760
Dcm
1.5002.0001.5702.0801.890
Ecm
1.2001.2001.5701.7301.890
Gcm
3.0703.0702.4203.8302.900
Table 3-63. Design Data for EE Iron Powder Cores.
EE, Iron Powder Cores (Micrometals) 75 mu Mix-26PartNo.
DIN- 16-5EI-187El -24-25EI-375EI-21DIN-42-15DIN-42-20EI-625DIN-55-21EI-75
wtcugrams
4.77.514.337.150.291.3101.565.2167.9110.7
Wtfegrams
5.35.512.240.180.8112.4149.6141.1283.7245.8
MLTcm
3.33.85.06.78.28.99.99.411.611.2
MPLcm
3.984.105.107.408.4010.4010.409.513.211.5
waAC
1.7902.4512.0101.7141.0711.5861.1910.7851.1330.778
Accm2
0.2240.2260.4030.9071.6101.8102.4102.4803.6003.580
wacm2
0.4010.5540.8101.5551.7252.8702.8701.9484.0792.784
APcm4
0.0900.1250.3261.4112.7775.1966.9184.83114.6849.9667
Kscm5
0.002430.002970.010620.076240.218520.420500.670540.508941.826991.27615
A,cm2
11.514.423.546.863.384.492.982.4141.3119.3
ALmh/lK
586492134210195232265275325
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
Design and Dimensional Data for EE, Sendust Powder Cores
The dimensional outline for EE Sendust cores is shown in Figure 3-53. Dimensional data for EE Sendust
powder cores is given in Table 3-64; design data is given in Table 3-65. For more information, see Chapter
2.
G
>, \\
^ te-c
Ac '
i
i
\
iE
r
\
X y,
\
B A
r
1
i
\
a
\
^ ^-D
EE Sendust Powder Cores Perspective View
Figure 3-53. Dimension Outline for EE Sendust Powder Cores.
Table 3-64. Dimensional Data for EE Sendust Powder Cores.
EE, Sendust Powder Cores (Magnetics) 60 muPartNo.
EI-187EE-24-25EI-375EI-21
Acm
1.9102.5403.4904.130
Bcm
1.4301.9102.5402.860
Ccm
1.6101.9102.9103.410
Dcm
0.4750.6350.9531.270
Ecm
0.4750.6350.9531.270
Gcm
1.1601.2701.9602.140
PartNo.
DIN-42-15DIN-42-20DIN-55-21
Acm
4.2804.2805.610
Bcm
3.0703.0703.860
Ccm
4.2204.2205.540
Dcm
1.5002.0002.080
Ecm
1.2001.2001.730
Gcm
3.0703.0703.830
Table 3-65. Design Data for EE Sendust Powder Cores.
EE, Sendust Powder Cores (Magnetics) 60 muPartNo.
EI-187El -24-25EI-375EI-21DIN-42-15DIN-42-20DIN-55-21
wtcugrams
7.514.337.150.291.3101.5167.9
Wtfegrams
6.413.140.882.6126.0163.0302.0
MLTcm
3.85.06.78.28.99.911.6
MPLcm
4.014.856.947.759.849.8412.3
waAc
2.4512.0101.7141.0711.5861.1911.133
Accm
0.2260.4030.9071.6101.8102.4103.600
wacm2
0.5540.8101.5551.7252.8702.8704.079
APcm4
0.1250.3261.4112.7775.1966.91814.684
KKcm5
0.002970.010620.076240.218520.420500.670541.82699
A,cm14.423.546.863.384.492.9141.3
ALmh/lK
4870102163150194219
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
-
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C o p y r i g h t 2 0 0 4 b y M a r c e l D e k k e r , I n c . A l l R i g h t s R e s e r v e d .
CONTENTS CHAPTER 3: MAGNETIC CORESINTRODUCTIONCORE TYPE AND SHELL TYPE CONSTRUCTIONTYPES OF CORE MATERIALSEDDY CURRENTS AND INSULATIONLAMINATIONSANNEALING AND STRESS-RELIEFSTACKING LAMINATIONS AND POLARITYFLUX CROWDINGEXCITING CURRENTTAPE WOUND C, EE, AND TOROIDAL CORESTAPE TOROIDAL CORESTOROIDAL, POWDER CORESTACKING FACTORSDESIGN AND DIMENSIONAL DATA FOR EL LAMINATIONSDESIGN AND DIMENSIONAL DATA FOR UI LAMINATIONSDESIGN AND DIMENSIONAL DATA FOR LL LAMINATIONSDESIGN AND DIMENSIONAL DATA FOR DU LAMINATIONSDESIGN AND DIMENSIONAL DATA FOR THREE PHASE LAMINATIONSDESIGN AND DIMENSIONAL DATA FOR TAPE WOUND C CORESDIMENSIONAL OUTLINE FOR TAPE WOUND EE CORESDESIGN AND DIMENSIONAL DATA FOR TAPE WOUND TOROIDAL CORESDESIGN AND DIMENSIONAL DATA FOR EE FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR EE AND EL PLANAR, FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR EC, FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR ETD, FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR ETD/(LOW PROFILE), FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR ER, FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR EFD, FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR EPC, FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR PC, FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR EP, FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR PQ, FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR PQ/(LOW PROFILE), FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR RM, FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR RM/(LOW PROFILE), FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR DS, FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR UUR, FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR UUS, FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR TOROIDAL, FERRITE CORESDESIGN AND DIMENSIONAL DATA FOR TOROIDAL, MPP POWDER CORESDESIGN AND DIMENSIONAL DATA FOR TOROIDAL, IRON POWDER CORESDESIGN AND DIMENSIONAL DATA FOR TOROIDAL, SENDUST POWDER CORESDESIGN AND DIMENSIONAL DATA FOR TOROIDAL, HIGH FLUX POWDER CORESDESIGN AND DIMENSIONAL DATA FOR EE, IRON POWDER CORESDESIGN AND DIMENSIONAL DATA FOR EE, SENDUST POWDER CORESREFERENCES