Transformer and Inductor Design Handbook Chapter 3

Chapter 3

Magnetic Cores

Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.

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


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


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.


agnetic Path Length

Flux,

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.


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.


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.


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


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.


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.


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.


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.


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


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


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


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


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


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


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


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


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


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.


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.


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.


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


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.


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.


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


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.


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.


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.


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.


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.


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.


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



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.


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.


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.


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.


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.


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



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


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


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


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


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


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


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


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


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


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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

Documents

Transformer and Inductor Design Handbook Chapter 3