/ IRON POWDER CORES Introduction General Properties Tolerances. Physical Properties Toroidal Cores. Composite Cores. E Cores EF Cores, EM Cores F Core Bobbins Bus Bar, U Cores Pot Core Assemblies Bobbin Assemblies Plain Cores Magnetic Characteristics Magnetization Curves. Curve Fit Formulas. Core Losses Des 9 Software CONTENTS Thermal Aging Considerations. 1 DC Application Notes 4 Graphic Design Aid. Core Selection Examples 5 DC Inductor Table 14 E Core Gapping 15 Effects of Ripple on OC Chokes. 19 AC Application Notes Toroidal Core Caps...20 Power Factor Core Loss Calculations. 21 60 Hz Filter Inductor. Cote Selection Example. 23 (60 Hz Inductor Table. 28 Winding Table Packaging Size and Weights. 25 Glossary. Addition Sales Contacts 58 0 62 a 64 66 67 68 6 MICROMETALS, INC established in 1951, is committed to supplying high quality iron powder cores to meet the needs of the electronics industry. As the technology has changed, new shapes, sizes and materials have been roduced to become industry standards. TEL. (714) 970-9400 FAX (714) 970-0400 INTRODUCTION be used in place of f MICROMETALS incidental or conseque The iton powder cores described in this ¢ return of parts and repayment of price; or replacement of Within 30 days after delivery: Before using these products, buyer agrees to determine suitability of the product for their intended use or application. Micrometals shall not be liable for any other loss or damage, including but not limited to smely well-suited for a variety of ene atalog are typically used for DC output chokes, differ Ikon powder as a core material has been widely used in RF applications for years. The distributed air gap properties inherent in iron powder cores also make them ¢ Iron powder is a cost-effective design alternative to molypermalloy powder (MPP), high flux, or sendust cores. It can also rites and iron-alloy laminations requiring a gap. y storage inductor applications. intial-mode input chokes, power factor correction inductors, continuous-mode flyback inductors, light dimmer chokes and other EMI RFI applications. WARRANTY Parts are warranted to conform to the specifications in the latest issue of this catalog. Micrometals’ liability is limited to parts, Notice of nonconformance must be madeGENERAL MATERIAL PROPERTIES INTRODUCTION Material Reference Material Relative Color No. Permeability Density Cost Code Ww) (gem) 2 To 30 27 RediCTear 8 35 65 50 Yellow/Red 4 14 5.2 36 Black/Red “18 35. 66 34 Green/Red -26 75 70 10 Yellow/White “30° 2 6.0 14 Green/Gray oat 3 62 15 Gray/Blue 35" 3 63 14 Yellow/Gray 238 8 7A u Gray/Black “40. 60. 69 10 GreenYellow “45 100 7.2 26 Black/Black “52 75 70 12 Green/Blue "The G0 Materal was developed as a lower cost, lower loss alernate fo the -28 Matera Similar, he G4 & 5 Malerals war eveloped to replace the 33 Material. The -28 & “33 Materials are not kisted inthis catalog but ave‘stil availabe ‘CORE LOSS COMPARISON (mW/em’) PERMEABILITY WITH DC BIAS Material 60 Hz IkHz —10kHz = 50kHz = 100kHz 500kHz HDC = 50 Oersteds Mix No. @5000G @1500G @500G @225G @140G _@50G owe effective =z cha = 5 Tz Too TOT 8 45 6459 50 28 a1 31.9 4 19% 32% 32 29 17 100 140 18 48 72 70 63 37 74 40.7 "26 32 60 7589 9 51 383 “30 37 80 120149 129 91 20.0 234 29 6187 100 78 84 277 “35 33 73 109137 123 84 277 “38 31 577299 217 51 434 -40 29 62 93 130 223 62 37.2 “45 26 49° 6069 92 46 46.0 “52 30 56 6872 63 59) 443 * Low frequency core loss is extrapolated rom data measured at high frequency MATERIAL APPLICATIONS. [60 Az Difterential-mode FMT Tine Chokes [DC Chokes: ) MICROMETAIS A. MAGNETIC DIMENSIONS Part No. nH/N® A B c D F G cA Vv OW (Bobbin) (Ref. Size)_in/mm___in/mm __in/mm__in/mm__in/mm__in/mm__cm_cm’_cm’ cm? oa 205 500/127 —A7/M.A 125/518 3127793 1258.18 373155 2.86 101 288.252 9-0 290 9.26 380 49532 380 Bad) US TAME 28.29) £5026 420 S0S/128 SOWI28 14876 3540899 1491878 3541899 3.08 145 401 254 032 70 NoBobbin INT34) tere £658 205 645/164 640/163 10S? A7Y/I2O 162K.62 AALS 61 399 teste 380 tsa 10 tos S60 (NoBobbin IN: 165) tere VAS 750191 635/61 1877S A556 187.75 562N43 4.20226 936.551 BS oo $30 380 (W875) WS AWEIIB7) ko wo 0795202 7e4199 2305.4 200584 57546 4.84 333 1.63.613 f0-26 70 toes no (880) BIN 2019) e008 510 1.00025. 1.000254 2877.29 287729 $9577 608 548 3.38.908 fo9.26 960 932 960 (859) @IN257) e102 21.0 1.000254 7509.1 2506.35 50027 250635 7519.1. 5.08 40s 205.806 00-8 ‘ao foots 30 10026 520 fiona) 810 floes? 50 (BION) SLAM: Ee2425) e112 50 1.020259 7509.1 555/181 3500889 765)194 393 895 2.36.58 Mtehing Coe HOT XX ENe26 900 1.185701 118501 27H7.00 702199 —-27A/.06 70x99 7.14 498 460 127 fined 0.0 fiss2 900 eri) (oIN307) TEL, (714) 970-9400 FAX (714) 970-0400 (9) =) i is (i) S O (om So =TEL. (714) 970-9400 FAX (714) 970-0400 MICROMETALS E CORES oto cont vm paw fea i a F meat PART NO. 3. ee E168 -26A/G015 118 Greene ¥ J 26 Yellow vhite * “A dimension in 100th inches: 30 GreenGray a I ‘Micrometals Mix No, St, A G F _eterideates Alternate “C dimension 3 Gilet | f—tndiateConterley gop per han 001 inches —— Besa | 2 same” 1 S32 Greenflue ape ft CORES ORDERED PER HALF MICROMETALS At MAGNETIC DIMENSIONS Part No. nH/N? A B c D F G tA VW (Bobbin) (Ref. Size)_in/mm __in/mm __in/mm _in/mm _in/mm _in/mm _cm_em!_cm! cm’ 125-26 134.0 1.25531. 1.21508 3789.60 835/21.2 3789.00 885225 7.45 922 6821.37 125-40, 1130 (No Bobbin (US LAM: EE-27-36) Available) 5137-2 320 1375/49 1.14529.1 37553 770/196 3758.53 1.000254 7.40 5137-6 670 5137-18 100.0 2137-26 1340 5137-40 113.0 5137-52 1310 8137) (US LAM: E1375) 2145-18 1120 1.455/97.0 1.370848 425/108 .950/24.1 425/10.8 1.035/26.3 8.50 1.17 9.89 1.88 £145.26 146.0 14552 146.0 (No Bobbin Available) 162-8 105.0 1.625/41.3 1.342/34.1 500/27 842/214 500/127 1.125/28.6 B41 1.61 13.61.70 162-18, 149.0 £162-26 2100 162-40 175.0 162-52 1990 (P8162) (US LAM: £121) 168-2 43.5 1.685/42.8 1.660/42.2 5905.0 1.210807 475/120 1.210307 10.4 1.81 18.52.87 F160-8 970 168-18, 135.0 168-26 195.0 168-40 163.0 168-52 1790 (8168) (OIN: 42/15) £168-26/G015 125.0 E168-40/G015 114.0 E168-52/GO15._ 125.0 Gapped £168 with center gap .030in/.76mm per set 168.2, 55.0 1.685/42.8 1.660/42.2 .787/20.0 1.210307 475/120 1.210/30.7 104 2.41 24.6 2.87 168-84 1160 168-184 1700 E168-264 232.0 168-404 196.0 E168-52A 230.0 (PBI68A) (DIN: 42/20) E168-52NGOIS 161.0 1,685/42.8 1.660/42.2 787/200 1.210307 475/120 1210/3107 104 241 2462.87 Gapped E1G8A with center gap .030in/.76mm per set 16 -E CORES Coton cope jo jc TRIAL PART NO. ies E 168 -26A/G015 Satie Co) FL rtmensen nasi |_| Geeencioy ; Micrometas Mit No. Say A G F _Leterindictes Aternate“C" dimension Cray . Insts Center gp pe alo 001 inches ei | T since I = Coie E CORES ORDERED PER HALF MICROMETALS Av MAGNETIC DIMENSIONS Part No. nH/N* A B gE D F G t A Vv WwW Gobbimy (Ret. Size) in/mm __in/mm —_in/mm _infmm __in/mm _in/mm _cm_cm* em’ cm* F678 148.0 1.805/47.4 1.55294 62015.7 952242 620157 1.250/318 9.53 2.48 2331.95 fete 30 187-25 ©2650 e740 240.0 1752650 ate (US Tawi t-625) £220-2 69.0 2.210/56.1 2.180554 820208 1.510/58.3 680/173 1520386 132 3.00 477 409 F220 13.0 F220-18 1960 E02 2750 #220530, 1070 £22034 1360 F240 2400 fas? 3520 (P5220) ‘Din! s5/20 £220.20/6020 1830 E22080/G020 168.0 £220-52/6020 185.0 Gapped £220 with center gap 040 ind 2mm per set 225.2 760 2240/569 1.875/476 745/189 11407290 745/189 1.500/381 11.5 358 40.82.76 e238 130 Gusie 400 £252 4150 E2540 2000 £225.32 325.0 (P8223) (US LAM Et 750 30575 3.051775 933/287 211853.8 939/237 2.118538 185 562 104 8.10 1360 m20 ero i240. 6058 1500 B0540 350, 605522070 (P8303 or PB305N0) £305-2616050 165.0 £305-5216050 165.0 Gapped £305 wih center gap 100 in /2.54 mm per set 630584 208.0 051/775 3.051/77.5 1.244/316218538 954727 2.118538 15 749 139 8.10 Gios@A 2800, 6305-268 4820 6305-508 10650 Bossa 5390 E3055 4820 PBIO5A) 217 (VAKOTSXOU ASME 55 (313) 320-0380TEL. (714) 970-9400 FAX (714) 970-0400 MICROMETALS E CORES ‘coLoR cope I Ned Cleae L_s— © TYPICAL PART NO. paces E168 -26 A/G 015 ce Seite : 1 mesma soins! Soe | Scared sare INS At" doan ee, ¢ |] ee ¢ |] 6 Smee piper et aes aur | [Cj E CORES ORDERED PER HALF MICROMETALS Av MAGNETIC DIMENSIONS PartNo. nH/N? A B c D F G oA VW Bobbin) (Ref. Size) _infmm —__in/mm —_in/mm _infmm _infmm __in/mm__cm_cm*_cm'_cm* £305-26NGO50 219.0 3.051/77.5 3051/75 1.244/31.6 2.118/53.8 933/237 2.118/53.8 18.5 7.49 139 8.10 305-52NG050 219.0 Gapped E305A with center gap .100 in/2.54 mm per set 450.2 132.0 4.500/114 3.636924 1,375/34.9 2.250/57.2 1.375/34.9 3.12079.3 22.9 12.2 280 12.7 450-8 260.0 450-18 400.0 450-26 540.0 450.30 235.0 £45034 300.0 450-40 4800 450-52 500.0 (PB450/V0) (US LAM: E1-30) 450.8 140.0 4.500/114 3.636924 .689/17.5 2.250/57.2 1.37549 3.120793 22.9 6.1 140 12.7 £430-18H 200.0 E45052H 270.0 (PB450/V0 for double stack) £610-2" 163.0 6.102/155 6.102/1551,866/47-4 4.236/108 1.86/47. £610.26" 588.0 £610.34" 3140 4.236/108 37.0 22.5 832 32.4 * Proposed E-core size, please check with factory for status. Tolerances to be determined, BANDING, STRAPPING AND MOUNTING PRECAUTIONS ron powder as a core material is susceptible to performance changes when wrapped with a ferrous material. Iron powder cores are manufactured with a distributed air gap and occasionally a center leg gap. When a ferrous material is added to this type of magnetic structure the core is essentially “shorted out” decreasing the overall “Q” of the coil This decrease in "Q" indicates an increase in core loss which will result in a higher than expected operating temperature. This effect will be more significant with the lower permeability materials. Micrometals suggests using the following nonferrous materials to mount and band iron powder cores: 1. Phosphor bronze or nonmagnetic stainless steel banding material 2. Brass hardware 3. Various electrical tapes 4. Cable Tie wraps 5. Filled epoxy or filled super glue -18-EF CORES TYPICAL PART NO. EF 60 - 52 imension in 100th inches. ometals Mix No, EF CORES ORDERED PER HALF [MAGNETIC DIMENSIONS MICROMETALS Av A 8 c D E F Gc t A Vw PartNo. nH/N? in/mm —in/mm —_infmm —_in/mm —_in/mm —_in/mm —_in/mm cm cm? cm! em? £F60-52 34.0 597/15.2 .590/15.0 .183/4.65 .430/10.9 .095/241 .209/5.31.425/10.8 3.40 .150 550 .300 Bobbin: EFD15 Equivalents 80-52 48.0 794/20.2764/19.9 .264/6.71 606/154 .144/3.66 .351/8.92.606/15.4 4.70.290 1.46 498 Bobbin: EFO20 Equivalents EM CORES ‘cotor cove pl lc Tut tcat parr no. 26 YellowAWhite EM 168 - 26A/G 015 40 Green/Yeliow I “52. Green Blue Fr =A" dimension in 100th inches— | ‘Micrometals Mix No.- A G F Letter indicates Alternate C* dimension “ASA Indicates Centerteg gap per hain O01 inches, ¥ I 4 erable EM CORES ORDERED PER HALF eiertemas 3 a0: f+ —| ‘appropriate *F” dimensions. MAGNETIC DIMENSIONS MICROMETALS Ay A B c D H G to A Vow PartNo. nH/N?in/mm —_in/mm —_in/mm —_in/mm —_infmm _in/mm _cm_cm?_cm! cm? €M145-18 95.0 1.455/37.0 1.37034.8 425/108 950/24.1 425/108 1.035/26.3 8.50 915 9.28 1.84 EM145-26 125.0 EMI45-52 125.0 £M220-26 230.0 -2.210/56.1 2.180/55.4 820/208 1.510/38.3 7809.8 1520386 13.2 2.90 45.0 4.09 FM220-40 196.0 £M220-26/G020 173.0 £M220-40/G020 143.0, ‘Gapped EM220 with center gap .040 inJ1.02mm per set 219 MOLSON T=MMAUMESY 550213) 320.3300TEL, (714) 970-9400 FAX (714) 970-0400 MICROMETALS E CORE BOBBINS TYPICAL PART NO. Moe oh — 1 ) coe PB 168A i {|| + (—5 ‘ J |e TREY FORGET ponds to Core ——] rt==Jl tt — ae pid i (Cg e = = FANGES “FANGES FLANGE Typical Tolerance #010 Materia: 6/6 Nylon 1303, HOSA. 6/6 Nylon Glass Filled Bobbin Notes: All bobbins are composed of 6/6 Nylon material except PB305, PB305A and any bobbin with the suffix “/V0". The PB305 and PB305A are composed of 6/6 Nylon Glass Filled. The "VO" indicates a material that is rated for UL 94 VO flame class. Micrometals also offers bobbins for the following metric and custom E-core sizes for sample and small quantity orders; E80, E99. Their part numbers are, respectively, PB8O, and PB99. WKOMEIS Ak ‘ FG lage Pathe iam vam ifm in in n/m infirm "Nak rei 3609.14 auoo14 1309.30 430830 3077.99 Aea.06 Jea4406 ony 4 res SNE BBN, ages even avin” oes soess Sayles 1 morene Saye oias eee 7) Grdess “euiei egeas Sowers isan 1 reise” ey e920 e878 Seavey ‘Soars “ania “aawiia) “onvana pica 1100279 1300379 510130 san. 799202 ssnae onsen 1 ries (3sue8 Henaos otes wna sansa Sates ‘eai'ss fiega aeyaes trsppes ‘Sovaos aouas tan foes ‘ues 3 Pier 1aighos tiasand “eaehea auatoa "aasans jisnas iviad oavas reno ou/sn7 1438862 migra ants ratanee 750192 9204 OHS 2 fas Mave tanoase esina Sustaa thse ‘aesars “higals ayaa 3 pisos anus s boausrs Gesans aeanes dawns vosvaos voseaes ome 2 Fesegno Sonnets doanets ‘sedans vanes owt tossen tossaes Ooms 2 rosa 230592 2020513 127924 684s OHSS LosKa6e 136547 wns 2 massono soars Somers Vaasa vatasa ios Vaaaas eete | TOROIDAL CORE CAPS ymca 8 80. . Te 400 ff oregon ooo ——} t | ‘pc hits ance 98 in Sein mtn ‘Material type: Rynite FRS30 (UL 94-VO) ‘Typical Applications: The toroidal core caps can be used as an alternate to the standard insulating coating when winding cores with very heavy gauge wire or when a greater dielectric strength is required. Core caps will fit either coated or uncoated cores. To specify a core that is uncoated add the suffix “/18” to standard part numbers. (Example: 400-26 is a standard part which includes coating, T400-26/18 specifies a standard part without coating.) MICROMETALS op 1D Ht THICKNESS PART NO. in/rm in/rmm. infrmon injowm TC400 4.030/102.4 2.235/56.8 -250/6.35 030/.762 10520 5.250/133.4 3.062/77.8 250/6.35 (030/.762 = 20BUS BAR CORES color cope A Red ICAL PART NO. 26 Yellow 2 Green HS 300 - 26 A/ T Code To Indicate Man. Current o ‘Mierometals Mix No. Letter Indicates Alternate Length 4 Code Area For Other Characteristics 1 HS CORES ORDERED PER HALF MAGNETIC DIMENSIONS, MICROMETALS Ae A B L D E t A v Part No. nH/N? infmm in/mm in/fmm in/mm infmm cm ocm* cm 300-8 68 1.020259 650165 500127 —52013.2 1408.56 5.92 806 461 Hs300260 149 Hs30052 14? 115300-8a 83 1.020259 650765 625/19 520132 140.56 5.92 1015.77 Hs300204 179 HS300524 179 1300-88 95 1.020259 650/165 75019.1 5203.2 1403.56 5.92 1.21 692 208 208 Hsa00.8¢ 1071020259 650765 875/222 520932 .140/3.56 141 8.06 Hs3o0-26c 232 Hsioosze 232 Hss00-26 221 1.50038.1 960244 7509.1 765/94 205/521. 8.71 1.78 Hsavozea 2a ¥.00025.4 239 Hs400-208 335, 125081'8 296 Hsdo0-26¢ 371 1500/36.1 356 ase om 25 tun tt wind * U CORES k TYPICAL PART NO. 7 U80-26A/ A" din. 100th inches — G Micrometals Mix No - {eter ndicates Alternate °C di JIT Code Area For Other Charact Ce U-CORES ORDERED PER HALF MAGNETIC DIMENSIONS MICROMETALS A A B c E F G roa PartNo. nH/N*_in/mm _in/mm __in/mm _in/mm _in/mm _in/mm __cm__cm’_cm’ 61-26 710 6105.5 900/229 .250/6.35 .510/13.0 .195/4,95 2105.33 5.66 3151.81 80-8 42.4 800/20.3 1.250/31.8 .250/6.35 .750/19.1 2506.35 3007.62 7.87 403 3.18 80-26 710 (U80-28 375 Us0-30 a0 U80-52 700 U350-40, 235.5 3.500/88.9 5.750/146 1.000/25.4 3.250/82.6 1.000/25.4 1.500/38.1 35.6 6.45 250 a TEL, (714) 970-9400 FAX (714) 970-0400 MICROMETALS(WW KeT see rey re 13) 2.0300 POT CORE ASSEMBLIES The Pot Core Assemblies, provide a closed-path ct —o0—> structure for high current designs where the round —rn — winding form and efficient packaging shape are beneficial The geometry also provides the added flexibility of using lower permeability materials for { } oo} the hollow core instead of gapping the structure. J Typical assemblies are illustrated. This configura. u 1 S tion is not available assembled. Order 2 Disks, 1 Hollow Core and 1 sleeve per set. SLEEVE DISC HOLLOW CORE = Av L Window AY Part No. Part No. Part No. nH/N? in/mm cm cm __ cm _ cm’ $101-1040 D101-1040 2526-1040 600" 3.150/80.0 2.402/61.0 5.49 15.3, 204 S101-1002 _D101-1002—-H2526-1002 165.8" SLEEVE —1— 0D») TYPICAL PART NO. |_| if oN 0 th intes ——] stor b oe entre charac aa ‘eromeae MeN Typical Tolerance #050 inches SLEEVE oD ID L Part No. in/mm info in/mm 101-1040, 3.150/80.0 2.680/68.1 1.615/81.0 760/19.3 101-1002 DISC TYPICAL PART NO. D 101-10 40 0D in 1000h Ce ee asad +a Typical Tolerance + 030 inches DISC oD cB 1D t h Part No. in/mm in/mm info n/m inf DroT-1040———3.150780.0, 1.614/41.0 250/6.35 3947100 3749.50 Di01-1002 HOLLOW CORE TYPICAL PART NO. ne H 25 26-10 40 TF To ovin shines, — rk i Length in Toth inches nde area for other charactersis | Micrometals Mix No. HOLLOW CORE op 1D L Part No. info info info 526-1040 1.60040.6 250/6.35 1.615!41.0 f 2526-1002 value i approximate ad is for indication only disBOBBIN ASSEMBLIES Various bobbins can be assembled from the Hollow Cores and Discs shown on the following page. These bobbin assemblies provide an alternative shape tor high current choke applications oD Which can tolerate some electro-magnetic radiation, This Configuration can be especially effective for high power speaker Crossover Coils ‘Typical assemblies. are illustrated. This configuration is not <1 aNailable assembled. Order 2 Discs and 1 Hollow Core per se. DISC HOLLOW Core At oD L Window Part No. Part No. n/N in/mm in/mm cm? 45-1040 Har1-1140, 85 1.420/36.1 877238 184 45-1040 817-1140. 60 1:420/36.1 13RAI3 295, 59-1040 11015-1040 100 1.845/46.9 1250/31: 3.43 59-1040 H1021-1040 80 11845/46.9 V6 25/413 490 40-2040 H1217-1040 130 2'500/03:5 1375/49 5.66, 0-200 11225-1040 95 2:500/63:5 1875/47.6 349 * A, value listed is approximate and is for indication only HOLLOW CORES Core outside and inside Standard with variations in tength possible TYPICAL PART NO. H 10 20 - 10 40 \ we wticte — + jf Se a} mom MICROMETALS oD 1D Length Part No. in/mm infmm in/mm H1616-1040, 1,000/25.4 250/6.35, 1.000/25. DISCS cura 1o™~\ 4 on IN cowmmtnore —_| | Sone om ©) ) He eee 4 tL} cats Ta other MICROMETALS oD cB ID T Part No. infmm infmm infmm in/mm “23 TEL, (714) 970-9400 FAX (714) 970-0400 MICROMETALSPLAIN CORES Seveccen P46 32-440 ‘possible upon request. t nen — | Code area for other characteristics ‘Micrometals Mix No. Note: Fr information on Mx 1 5 4,6,7, 10, 12,117, 42, and 0 see Micrometals Catalog 3 for RF Applications MICROMETALS. Ac oD Length Part No. nH/N? infenm infmm, 825-140 76 136/3.45, P1224-140 125 190/485, Pr624-140 16.0 016.35 1632-140 16.0 250/6:35 1680-240 150 255/648 1250/91 8 2032-240 200 313/7.98 1.00025.4 2080-240 200 33/795 1250818 2432-240 255 375/058 Vo0025:4 2440-240 265 375/953 4.250818 2448-240 350 375/9.53 150088.1 2456-240 225 375/9.53 1 750/48.5 3340-140 343 500/12.7 1:25031.8 3248-140 a0 500/127 V500/30.1 3256-140 320 500/12.7 175085 3264-140 310 500712.7 2000508 4040-140 375 625/159 1.250/31.8 P404s-140 15 625/159 1300881 4876-140 495, 750/19.1 2.375603 Pod6s-180 B00 000025: 2.000/50.8 CYLINDRICAL CORE APPLICATIONS The inductance and required number of turns for cylindrical shapes such as plain and hollow cores can be closely approximated from the following equations: ffective permeability of core (See graph below) Radius of coil (inches) ameter of core (inches) Length of coil/core (inches) Coil build SINGLE-LAYER COIL MULTILAYER COIL Meg (NY (0.8) Hag IPN} Or + 10 * r+ 9¢+10b 2 or or u 1 fuse + 1007]! ye 1 fltor+ 9e+10bi]'* RE r e FL 08K Hey? ZZ WHERE: BE 1 inductance microhenies) N= Number of tur a The family of curves to the left shows how the effective permeability (Wer) of a wound cylindrical core is a function of the core’s wound length to diameter ratio (VD) as well as the initial material permeability (). These curves indicate that in many cases variations in the lengthidiameter ratio will more significantly afiect the effective permeability than increases in permeability of the core material. This group of curves was calculated using a cylindrical core with a single layer winding closely wound over 95% of its length. is also possible to use as a fair approximation of the effective permeability for multi-layer windings. MICROMETALS -24-MAGNETIC CHARACTERISTICS INTRODUCTION TO MAGNETIC CHARACTERISTICS General Information: The magnetic characteristics shown ongpanes 26:46) result te lal cores. The apeie ton cine os 7thave a typical tolerance of +20%, -10%. Oth ations such as Cores and U Cores will produce slightly clfferent results due tothe effects of leakage associated with the geometry. These characteristics were measured at room temperature, The temperature coefficient of initial permeability for each ‘material is listed on page 3. The temperature coefficient of percent permeability versus both DC magnetizing force and peak AC flux density ranges from -100 to ~400 ppnvC* The combination of these coefficients will generally result in an increase in inductance with increasing temperature even under biased conditions. The percent change in permeability is directly proportional to the percent change in A. value. The cores are ‘manufactured to the A. value rather than to the referenced permeability Since iron powder cores are normally used in inductor auplicatigns the magnetization curves provided on page are in relation to permeability. B-H curves are low. DC Magnetization: The curves at thd horton of page 26: illustrate the effect of DC Magnetizi per initial permeability for the materials shown. As the level of| DC magnetizing force increases, the materials gradually experience a reduction in. permeability. This “soft saturation characteristic results from the distributed air gap in the iron powder core materials, The formula in the body of the graph is used to calculate the DC Magnetizing Force in oersteds. The mean magnetic path (0 for each core is included in the part number listing, These curves are based on a peak AC flux density of 10 gauss (1 mT). The response to DC magnetizing force is affected by the level of peak AC flux density present. AC Magnetization: The curves at thetiop_a( Baa illustrate the effect of Peak AC Flux Density on percent initial permeability. As. the level of peak AC flux density increases, the materials experience an increase in permeability up to an AC flux density of between 3000 and (6000 gauss. Beyond this level, the material begins to saturate. These curves are the result of tests performed from 60 Hz to 10 kHz. The formula in the body of the graph is used to calculate the peak AC flux density in gauss. The Cross-Sectional Area (A) for each core is included in the part number listing The A. values listed are based on a peak AC flux density of 10 gauss (1 mi). Testing cores at a higher flux density can have a significant effect on measured results, Frequency Response: The curves at thé/vuinl obi show how the permeability of each material is affected by frequency. A typical coil wound with multiple turns will have a measurable amount of intenwinding capacitance which acts in parallel with the coil. This interwinding capacitance will cause the coil to become self-resonant. In order to avoid this effect, the data at the highest frequencies was taken with a single tur. BH CURVES 8 Material -34/-35 Materials] 12500 gauss Bn = 11000 gavss 3 460 pause Br = "300 gains 500 enteds = 500 fered wm 92 aenteds 3.1 oxreds -2 Material -30 Materials 5000 gauss fn = 9740 gave 36 gauss 8” = "200 paus 50 erste He = 500 ese 15 ered | HEE “30 costes 26 Material “52 Material Gn = 13000 gauss MY By = 14000 gauns 3 y= 11750 gauss? fe B= "1450 fe? : Hn = "250 urteds sa Hg = "250 Oeste so HOD 35 cersteds HOE “63 conte 40 Matera 16 Materia Sy = 10300 gauss en ease Be e380 ne os) see Hg = 250 oursteds tee 9s Sees HOD “Bh certeds TEL, (714) 970-9400 FAX (714) 970-0400 a =) Ke pis if = (e} [rg s =MAGNETIC CHARACTERISTICS FF titi Permeability (x) DC Magnetizing Force* 1-52 iy = 79) i E ae east LE -26 (ig = 75) SH Nh il ia a 1 Sete angen eec Inductors in active power factor correction boost topologies do not have the simple steady state waveform presented before. Rather, the high frequency signal (typically 100 kHz) is such that both the peak voltage across the inductor (E) and the “on” time (1) are constantly changing throughout the period of the fundamental line frequency (50 or 60 Hz). The core loss in this case will be the time-averaged core loss of the individual pulses forthe period of the line frequency. Pleas! le 16 i538 And SBior information on the PEC inductors, -30-CORE LOSS. wm 200501000 amo 500 10,000, Peak AC Flux Density (gauss) NOTE: tesla = gauss x 10° tow mqeny caro exacted am amend a hgh ey TEL. (714) 970-9400 FAX (714) 970-0400 wm 20001000 atm 500 1,000 Ba Peak AC Flux Demy (gauss) NOTE: tesla = gous «10° 7) = Ke F rf (eo) oc © 31FAX (714) 970-0400 TEL, (714) 970-9400 (9) aad xs & ni ps o ig © CORE LOSS 14 Material ont Core Loss (W/cm) w 2m 5001000 2000 S000 10.080 ‘Ba Peak AC Fux Density gauss) NOTE tesla = gauss» 10° “tow imagens carton eae am ats mee tee 18 Material yo wm am 500mm 0000010. Bu Peak AC Flux Deny (gauss) NOTE: tesla = gauss x 10° -32-CORE LOSS Core Lose (W/cm) om 1mm 5001000 2000 stm 4000 Ba Peak AC Fh Density (gauss) NOTE: tesla = gaus x 10° 30 Material woe f= i FAX (714) 970-0400 ‘Core Loss mW’) TEL. CROMETALS wm mm 500000 00 RO Ba Peak AC Flux Density (gauss) NOTE: fsla = gauss «10° -33-CORE LOSS Cove Loss m/c) TEL, (714) 970-9400 FAX (714) 970-0400 3 = ie fm (i) ie MICR30 Material jo 1B. Peak AC Flax Density (gauss) NOTE: tesla = gauss x 10° Core toss mem) wm 2m 500000 2009 s00 18.00 Bu Peak AC Flax Density (gauss) NOTE: tsa = gauss «10° 235. CORE LOSS. TEL, (714) 970-9400 FAX (714) 970-0400 a) = 10,000,000 =| eS Table 1 =39-TEL, (714) 970-9400 FAX (714) 970-0400 ln Lal Ee IE (a) = (eo) [ra iS CORE LOSS ‘The third design example is a PFC boost choke operating at 100 kHz with the following requirements: Lmin = 250 wH Ide = 7. Epk In = 120V Ede Out = 400V Referring to Table 1, you can sce that design Solution #1 is a design that is dominated by 9.06 watts of core loss with only 0.87 watts of copper loss. This results in a temperature rise of 65C°. Figure 3 indicates that with an ambient of 55°C, this part will have thermal runaway in less than 2 years, Solution #2 demonstrates that with the same core, by simply increasing the number of turns with the required smaller wire size, the core and copper losses will become ‘more balanced. This results in improved efficiency (saving 4.3 watts), a lower operating temperature (AT=41C%), and a dramatic improvement in thermal life (almost 2 orders of magnitude). While it may seem obvious that solution #1 is a poor design, this is a fairly common mistake Ifthe higher inductance produced by adding turns in solution #2 is unacceptable in the circuit, the core and ‘copper losses can also be better balance by selecting a lower permeability material. Solution #3 illustrates how the Micrometals 10, (-2 Material) performs. This choke will be the most efficient and reliable, but this material type is more expensive than the $2 Material option Tea Jog compar a8 a 5 Core Operating Temp ('C) g23 Another important thermal aging consideration is the source of the iron powder cores, in other words, beware of “equivalent” iron powder cores. As demonstrated above, different materials will thermally age at different rates. This is also true with different manufacturers of core ‘materials. In many cases, the term “equivalent core” is solely based on dimensional and permeability characteristics. Figure 4 illustrates the thermal aging characteristic of Micrometals T90-26 at 7SkHz with 633 as well as the same winding on an “equivalent” competitor. The Micrometals core will safely operate for 300,000 hours whereas the competitor will runaway in less than 30,000 hours. Clearly, both cores are thermally aging at different rates. on Powser Aging Comparison ae rT iN Figure 4 Less obvious is the variation of initial core operating temperatures between the Micrometals and competitor cores. The competitors increased initial core temperature isa result of higher core losses, In another example, the ambient temperature for the Micrometals winding was increased to 60 °C to match the initial core operating temperature of the competitor. Again, the predicted difference in thermal life is dramatic. As the example above demonstrate, evaluating one manufacturers core and substituting another at a later time ‘can be a critical error. It is also very important to regulate the supply chain and monitor that sub-suppliers are not ‘making any unknown core substitutions. =40-DC APPLICATIONS IRON POWDER CORES IN DC APPLICATIONS: ‘The design software described on the previous page is an extremely useful tool for selecting Micrometals iron powder cores for DC applications and compliments the energy storage curves provided here. DC energy storage inductors are an ideal application for ‘Micrometals iron powder cores. In this application the core must support a significant DC current while maintaining an inductance adequate to filter high frequency signals. The amount of energy stored is a function ofinductanceand current. Specifically, energy storage for an inductor is described: Energy = Yo LE aN Microjoules Microhenries Amperes wh uh) fa) Energy storage isproportional to theflux density squared divided by the effective permeability of the structure. Be Energy ~ H etccive The introduction of a discreet air gap significantly lowers the effective permeability of core structures. made from ferrites and iron alloys. This increases the energy storage capabilities of the core by allowing additional energy to be stored in the gap. Iron powder cores contain inherent minute air gaps which are distributed throughout the core body. This distributed air gap characteristic makes iron powder well-suited for energy storage inductors. DC inductors, most commonly, fall into one of 3 basic categories: 1. Those specifically designed to maintain a relatively constant inductance from zero to full rated load. 2. ‘Those specifically designed to have greater inductance, under minimum load conditions (swing). 3. Thosesimply requiringa minimum inductance, Micrometals Energy Storage Curves are presented for a numberof coresizesin eachmaterial (except-2 Material due to its low permeability) to assistin the design of such inductors. These curves are shown both in terms of ampere-turns (NI) at the top portion of each page, and percent saturation (100% -% initial permeability) at the bottom portion of each page. The curves shown on pages 42-51 are based on a peak AC flux density of 10 gauss (1 mT). This will typically represent a ripple current of less than 1%. Under this condition, the only heat generated results irom the resistive winding (copper) losses. The energy storage limits for 10C, 25C®, and 40C® temperature rise (in free-standing air) resulting from winding losses are shown on each graph. When significantly greater AC or ripple flux density is present, the cores will produce higher inductance due to the AC magnetization characteristics shown at the topofpage 25. Underthis condition, the high frequency Core losses must also be taken into account as described on pages 29-36. Refer to pages 56-57 for additional information. The -8, -18, and -52 Materials should be considered for DC chokes operating above 100kHz due to their lower core loss characteristics at high frequency. The importance of the swing of the inductor must be determined betore the appropriate core material can be selected 1. The -8, -18, -30, -34 and -35 Materials (or a gapped E Core, see pages 54-55) should be considered if the inductor must maintain a relatively constant inductance from minimum, tofull-rated current, These materials are able to store high energy with a minimum of saturation. 2, The-26, -38,-40, -45 and -52 Materials should be considered if the inductor should “swing” (increase in inductance as current decreases) a moderate amount. These materials have higher permeability and can produce a 2:1 swing (50% saturation point. The Composite Cores should be considered if a swing of greater than 3:1 is required. Refer to pages 14 and 51 3. The-26,-38,-40, and-52 Materialsare generally recommended for designs concerned with minimum inductance because they are the most cost effective. The temperature rise of the wound unit, aside from saturation, is the primary limiting factor in inductor design. Inthe case of DC inductors with very low level ‘AC ripple, this temperature rise is a result of copper loss in the winding. (DC flux does not have a noticeable effect on core loss.) For single-layer windings on toroidal cores, the current handling capability of a wire size as a function of temperature rise is relatively independent of core size. ‘Making use ofthis, asingle-layerwindingtable hasbeen developed giving current ratings for temperature rises of 10C®, 25C*, and 40C° in free-standing air. (page 64) Forfull windings (45% toroid inside diameter remaining) asimilartable hasbeen developed (page 65). Inthe case of full windings, the current handling capability of a given wire size is no longer independent of core size. However, for any particular core size, an ampere-turn rating for a given temperature rise does become a constant. These ampere-turn constants are included in the full winding table. Refer to page 56 for design examples using the Energy Storage Curves, <41- 14) 970-9400 FAX (714) 970-0400 TEL, 2) an é a0 “| a bs | i y A ite E 20 otic fA fi 7 Se onesies w “52 Material we aa % ol i 100 fom 5010-200. -500, 1000 bo. sto. 18000 20000 somo 100 00m0 1.0m0W DC Energy Storage — 50+Percent Saturation DC APPLICATIONS ‘Composite Toroids iia: aa a ai i Stjaedavee=t| ai 10 20-5 100-200-500 1000 2000 5000 10,000 20,000 50,000 100,000 300,000 1,000,000, DC Energy Storage — Ys LF crjoues) ‘sThooae7 | smI02736 PARTNO. n 1s AYVALUE EE swine 1% 50100200500. 1000 2000 5000 10,000 20.000 50,000 100,000 300,000 1,000,000 [DC Energy Storage — Ya LP (Micros) ot e) a Eq FE [en O} cc o TEL, (714) 970-9400 FAX (714) 970-0400TEL. (714) 970-9400 FAX (714) 970-0400 oO =] KS F in E (e) oc MIC DC APPLICATIONS DC INDUCTOR DESIGN EXAMPLES Requirements: 45 4H at 7.5 amps DC (-<1% ripple current) Example #1: Design Priorities cost temperature rise component size Requirements: 45 4H at 7.5 amps DC 60uH max at 0 amps DC (25% saturation max) (1% ripple current) Example #2: Design Priorities component size temperature rise cost 52, and -40 Material should be considered since ductor requirements do not limit swing and these materials are the most cost effective. -8,-18, -30,-34 and-35 Materials should be considered, because of the limited swing requirement = (/0) (45) (7.5) = 1266 wh YALE = (hs) (45) (7.57 = 1266 ph -26, Material will be used in this example, ik y Storage table on page 44, The T106 ‘size toroid will be selected in order to keep the winding, “simple” and the temperature rise around 25C°. The £137 is also an attractive choice if bobbin winding is preferred. ‘The-8 Material is the best choice since component size 8486 43 indicates that the iS the smallest core able to meet the energy storage requirements at <40C° temperature rise, We must also check the % saturation curvest{page bottom) to verity that this core will be operating at less than 25% saturation. The curve at helio 6f pase 4d indicates the T106 will require 217 ampere-turns to produce 1266 Therefore, Nl = 217 or N = 217/7. = 29 turns Inthe case of the £137 core, the curves indicate that 162 ampere-turns will be required to produce 1266 i. Therefore, NI = 162 of N= 162/7.5 = 22 tums The curves atthebotiong iZindicatethattheT94 will be operating at 84.5% of initial permeability (15.5% saturation) to produce 1266 ji. Use the following, formula to calculate turns: Nel desired tint) ] (Ao (on) 45, ~ N=} 43.000) a6 twins (25.0) (85) In the case of the T106 toroidal core, the “simple’ Winding limits are close estimates of typical single layer ngs, refer to the Single Layer Winding Table on 4: This table shows that #17 wirewill fitinasingle dresultina 25C° temperature rise from thewire. the £137, referring to the Full Winding indicates that up to #13 wire can be 1106-26 with 29 turns #17 or £137-26 with 22 turns #14 Solution Since a “full” winding was required to keep the temperature rise “194 below 40C°, refer to the winding table onjpage 64} This table indicates that #16 wire should be use This table also contains the information necessary to calculate the DC resistance of a winding Part number T94-8/90 with 46 turns #16, Solution: SzeDC APPLICATIONS 0060-026 (PLZ) xv 0066-026 (LZ) TAL eh AE itel=rel ii $5090 04299 0 W284 en Xe YO sajdwexg 40199puy 3a Tara] SWAT] Shae SRE] REF] a] amare] — svar oe noe | Htoze | Hoge | Hoo. | Hite | HMosz | HMoso'r | Hiooc'i | O° san sawnraz | swwnace | ssannre swans | swanzorr | swanecie Hio'e Hivir | Hora | Hsor | Hose | Hozr'L | Hoo | SP sawn sewaz | sxwani | syne | swvrrer | swwrnee | swan] swanrcia Hizo | Hire Hice | Hues: | Higsz | Horo | Here | Hose | 4U os wos wos mvt omveie omy rie omv eur amvoce | yg sdwe oo, | sduegg | sduwog | sdwegz | sduecy | sduwe or | sduegs | sdwe cz |. intino 90 SONIGNIM NigHOA TIAA 'SHHOD san Suarez] —snwnzon | sawn er | snararont | —swwan toe] senna) snare Hio6r | Hire | Hmo6s | Hioso’L | Hro9z't | Hoole | HM 069's | HMooI'9e | “Ot ‘SNWAL LE ‘SNwnL I ‘SNWAL 6S swwnn co SAYA 9 swwntaor | sNwni zi ‘swan oe Hizor | Hicor | Hizee | Hrives | Haze | Hiozz't | Hto96'r | Hiooe'r | OS swan | sawn sxunzae | swvazos | —snanute | sawaaie | sxwnaeer | svar zor Hiore | Hdoso | Hm | Hdoiz | Hisre | Hmbzo | Ho6z’t | HMoor's | “Te swaniee | swwnnar | swwnnet | snarnos | sworn | swan | swwnneer | snr vor - Hiciz | Hivor | Hices | Hizer | Hmeiz | Hoge | Hro6o': | Hoze’s | “tt snare | sxynzer | — ssanare | —sworuce | swan ir | sarees] — swans] swana en Hive | Higa: | Hieee | Hoes | Hizor | Heer | Hoss | Hos | “iH | ~sxanztr | swans snore] swwnece | swannor snare | swwrrez | swan Higs | Hiri | Hmeiz | Hose | Higes | Hmezi | Hmzoe | Hiogo | “2! sani | swwaust | snynzoe | snynree | swwarre | snwaure | swannee swan sri Hie Hiec | uno | Hioez | Hieor | HNote | Hitze | Hro89 ok Sao # swore | ~ swan sani | swaarae | —snaror —] —snaraz rz Higo | Hie Hil yp Hizot | Hise | Hrigie | Hose | Yee ‘SNYNL E SNL D SNYUE SNIN TE sNynL LE SNAIL 6S - Hizo | Hizo | Hel Hizor | Hicoe | Hie eras omvour owveir uw eut omy ou" mv aie mw oce omy ree omvece | yg sdue o¢ sduue 07 sduie ¢| sdue OL sdwe ¢ 7 sdwe 0g sdue ¢°Z sdwe ort |. aa inwano 2a SONIGNIM AVI TTONIS 53409 IWAIONOL -53-TEL, (714) 970-9400 FAX (714) 970-0400 MICROMETALS DC APPLICATIONS GAPPING IRON POWDER E CORES Gapping iron powder E Cores increases energy storage capabilities beyond that inherent in the distributed air gap structure that is characteristic of the material. Gapping of E Cores in advantageous only in the higher permeability -26, -40, and -52 Materials due to ampere- turn temperature rise limitations. The graphs below and to the right illustrate the typical effect of gapping on the basic magnetic characteristics, of-26 Material. The magnetization curves or the E Core geometry vary somewhat from curves or toroidal cores, Thisdifference isdue tothe variationin leakage between the geometries. Similarly, some variation will exist between particular E Cores sizes. These curves are for reference only. Similar results occur for -40 and -52 Materials. While -40 Material has an initial permeability approximately 20% lower than -26 and -52 Materials, when the two ‘materialsare gapped the resulting efiective permeabilities are much closer to one another. In addition to increasing energy storage, gapping also significantly reduces the swing of these materials with DC bias resulting in performance similar to -8, -18,-30, -34, and -35 Materials without a gap. Since -26, -40, and -52 Materials are less expensive than -8, -18, 30, -34 and -35 Materials this offers an attractive design alternative. 7] e168 Ungapped 9050 | 0075 [0095 ‘ovo | 01s [019 Percent Effective Permeability Be Peak AC Flux Density (gauss) An additional discrete gap in iron powder does not have ‘a dramatic impacton effective permeability as illustrated by the graph to the upper right. Asa result, the gapping, of iron powder E Cores is relatively non-critical when ‘compared to ferrites and iron alloy lamitations. Energy Storage Curves for optimum butt-gapped E Cores in -26 material are shown at the bottom of the following page. Similar or slightly higher energy storage will result with -52 Material while slightly lower energy storage will result for -40 Material with the same windings. ‘Theterm butt-gap hasbeen used to indicate the physical separation of two standard E Cores (that are butted up against a spacer). By example, a set of cores with all three legs separated by .010 inches has a butt-gap of 010 inches. This creates and effective discrete gap of {020 inches. A butt-gap of .010 inches is equivalent to a total center-leg gap of .020 inches. The £168, E16BA, £220, and E305 size E cores, are leg gaps as detailed in the E 8 0, aE, The E16B and E168A are available wilh a centerleg gap of .015 inches per halt. A Set made up of two of these gapped cores will produce a Center-leg gap of .030 inches. The £220 is available with a center leg ap of .020 inches per half. NOTE: tesla = gauss x 10° 545Percent Permeability Ampere - Turns (ND DC APPLICATIONS -26 Material ‘recent Pees 2c Magis Force era? | e168 | e220 Ungspped 0050 [075 [0085 -a10 | 01s | 019 ‘uit-ap in inches 2 5 w » so wo 20 DC Magnetizing Force (ersteds) NOTE: A/em « oersteds x 7958, -26 Material Agee De oy Sra at Oban Cbd VE TEM? Se IL WN Eee] we] we] oe = a. aa | am | ‘oe | | sn 2a0 ‘Note: indicated Gap b “Butl-Gap” in inches. x | To rz ‘Maxime Suing 25% i za | ea] 30) sa 200 sw 100 00050010000 2000 S000 10,000 DC Energy Storage — '/ LI (microjoules) sSb< TEL. (714) 970-9400 FAX (714) 970-0400 @) a KS te Lu fe) oc [ej Ww‘TEL. (714) 970-9400 FAX (714) 970-0400 in =) 20 kHz) this is of no concer. In certain 60 Hz applications, however, core buzzing can be noticeable. This condition will be more noticeable with E Cores than with toroids. It will also be more significant with signals which have been chopped (light dimmers, motor controllers) than with normal sinewaves. Itis also dependent on operating AC flux density Energy storage inductor design is limited by temperature rise resulting from the combined copper and cote loss, and core saturation. While the -8, -18, and -52 Materials have the lowest core losses at frequencies about 25 kHz, the -26 and -40 Materials have lower core losses at 60 Hz. Further, the higher core loss characteristics of the -26 and -40 Materials at frequencies above 25 KHz will produce a coil with low Q at high frequency. This characteristic is an additional | suppress the unwanted signals. The -26 and -40 Materials maintain good permeability versus AC flux density characteristics as illustrated at the "2. The significant increase in percent ‘permeability Tor these materials can be a considerable advantage. It appears that this increase in permeability is experienced in applications such as light dimmers. Tests performed with a low-level 10 KHz sinewave superimposed over a 60 Hz signal of increasing level did indicate that the high frequency signal experienced an increase in inductance as the 60 Hz signal was increased. While this may be the case for a continuous time averaged signal, itis not clear if this isthe case for instantaneous noise signals. Energy Storage Curves for 60 Hz filtering applications for -26 and -40 Materials are shown on page 61. These curves take into account th in permeability illustrated by the curves at thetiop of page 34. The AC flux density levels have been reerenced. These fux densily references can be useful in approximating core loss as well as determining how the inductance will vary with current. ‘The representation of per AC flux density at thetiog of page 22 shows how the permeability (inductance) will change with voltage across the coil, but it does not provide a clear view of how the inductance will vary with current. The graphs at the top of page 62 are an attempt to illustrate (in relative terms only) how the relative inductance will change with changes in current. lity versus peak Energy storage limits for temperature rises of 10C°, 25C°, and 40C° are also listed for 60 Hz applications for a num- ber of ditierent core sizes. For the same temperature rises, all core sizes operate at a similar flux density, but the loss distribution differs. With physically large cores, the major- ity of the loss is due to the core losses, while with the physically small cores the majority of the loss is due to the losses in the winding, This phenomenon not unique to iron powder. AA design example can be found atthe bottom of ia ‘pase! For applications where itis unclearifthe high frequency signal will experience the same increase in permeability as the 60 Hz signal, itis recommended that the 60 Hz signal be treated as DC current. This will produce a significantly different result but will be the most conservative approach = 60-Ampere Turns (NI) "26 Material 100 500 1000 2000 5000 10,000 20,000 AC Energy Storage — LE (Microjutes) -61- AC APPLICATIONS. 50,000 100,000 300,000 1,000,000, 14) 970-9400 3 Z z z Ez MICROMETALSFAX (714) 970-0400 TEL. (714) 970-9400 ad Eq - i = (e) [ra lO = AC APPLICATIONS Caren inductance 3s Function of crix Deny 26 Material Relative Current) Relative Inductance (%) Relative inductance (%) 60 Hz INDUCTOR DESIGN Requirements: 500 LH minimum from 1 to 5 amps of 60 Hz Current. For this example, the inductor must maintain 500HH minimum from 1 to 5 amperes, or down to 20% of full-rated current (I max). The importance of this consideration is illustrated by the graph above. This shaws thal, in the case of -40 Material, ifthe inductor is designed to operate at 10 kG at | max, that the inductance will be greater than or equal to Lat I max down to 2.5 + 42 = 6.0% of I max. Likewise, ifthe inductor operates at 8 kG at I max, the inductor can only be operated down to 4.6 + 19.5 = 25% of I max before lower inductance will result. “PL = (9 (500) (59 = 6250 4} In this example -40 Material will be used. In order to maintain a minimum inductance down to 1 amp (20% of 1 max), the inductor must be designed to operate at greater than & kG at I max. This requires a core no larger than the E137 core of T131 toroidal core. To keep temperature rise down, the T131 will be selected. At 6250 tl, he T131-40 indicates 235 ampere-turns. NI = 235 N = 235/5 = 47 tums inding results are a rough approximation of typical single-layer windings, the Single Layer ‘Jble-on page Gdican be used as a guide in selecting the wire size. #19 will fit in a single layer and yield about temperature rise due to the winding losses. 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