chapter 3 magnetic cores - university of north carolina … and dimensional data for ui laminations...

Chapter 3

Magnetic Cores

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

Table of Contents

1. Introduction

2. Core Type and Shell Type Construction

3. Types of Core Materials

4. Eddy Currents and Insulation

5. Laminations

6. Annealing and Stress-Relief

7. Stacking Laminations and Polarity

8. Flux Crowding

9. Exciting Current

10. Tape Wound C, EE, and Toroidal Cores

11. Tape Toroidal Cores

12. Toroidal, Powder Core

13. Stacking Factors

14. Design and Dimensional Data for El Laminations

15. Design and Dimensional Data for UI Laminations

16. Design and Dimensional Data for LL Laminations

17. Design and Dimensional Data for DU Laminations

18. Design and Dimensional Data for Three Phase Laminations

19. Design and Dimensional Data for Tape Wound C Cores

20. Dimensional Outline for Tape Wound EE Cores

21. Design and Dimensional Data for Tape Wound Toroidal Cores

22. Design and Dimensional Data for EE and El Ferrite Cores

23. Design and Dimensional Data for EE and El Planar, Ferrite Cores

24. Design and Dimensional Data for EC, Ferrite Cores

25. Design and Dimensional Data for ETD, Ferrite Cores

26. Design and Dimensional Data for ETD/(low profile), Ferrite Cores

27. Design and Dimensional Data for ER, Ferrite Cores

28. Design and Dimensional Data for EFD, Ferrite Cores

29. Design and Dimensional Data for EPC, Ferrite Cores

30. Design and Dimensional Data for PC, Ferrite Cores

31. Design and Dimensional Data for EP, Ferrite Cores

32. Design and Dimensional Data for PQ, Ferrite Cores

33. Design and Dimensional Data for PQ/(low profile), Ferrite Cores

34. Design and Dimensional Data for RM, Ferrite Cores


35. Design and Dimensional Data for RM/(Iow profile), Ferrite Cores

36. Design and Dimensional Data for DS, Ferrite Cores

37. Design and Dimensional Data for UUR, Ferrite Cores

38. Design and Dimensional Data for UUS, Ferrite Cores

39. Design and Dimensional Data for Toroidal, Ferrite Cores

40. Design and Dimensional Data for Toroidal, MPP Powder Cores

41. Design and Dimensional Data for Toroidal, Iron Powder Cores

42. Design and Dimensional Data for Toroidal, Sendust Powder Cores

43. Design and Dimensional Data for Toroidal, High Flux Powder Cores

44. Design and Dimensional Data for EE, Iron Powder Cores

45. Design and Dimensional Data for EE, Sendust Powder Cores

46. References


Introduction

The key ingredient in a magnetic device is the magnetic field (flux) created when current is passed through

a coiled wire. The ability to control (channel, predict, conduct), the magnetic field (flux) is critical to

controlling 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 for

the 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 vital

keys 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, <t

Magnetic Core

Figure 3-2. Magnetic Core Confines the Magnetic Field.

Core Type and Shell Type Construction

There are two types of construction for magnetic cores, core type and shell type. The shell type

construction is shown in Figure 3-3, and the core type construction is shown in Figure 3-4. In the shell type,

shown in Figure 3-3, the core surrounds the coil. Here the magnetic fields are around the outside of the

coil. The advantage of this configuration is that it requires only one coil. In the core type of construction,

shown in Figure 3-4, the coils are outside of the core. A good example of this is a toroid, where the coil is

wound on the outside of a core.

Flux,

Coil

\E-I Core

Figure 3-3. Shell Type Construction: the Core Surrounds the Coil.

Flux, <X> CCore

Coils

\

Figure 3-4. Core Type Construction the Coil Surrounds the Core.


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 hot

and cold rolling. The rolling process produces a sheet of material with a thickness ranging from 0.004 to

0.031 inches that can be punched into laminations. It can be further rolled to thicknesses ranging from

0.002 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 into

toroids, EE cores and slugs. Powder core processing starts at the ingot, then goes through various steps of

grinding until the powder is the right consistency for the required performance. Normally, powder cores are

not 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 per

square inch and fired at temperatures above 2000 degrees F. After the parts are made, they are usually

rumbled to remove burrs and sharp edges, which are characteristic of this process. Ferrites can be

machined 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 adequate

resistivity. Also, it needs to be rolled to a specific thickness, and it needs effective electrical insulation or

coating of the magnetic material.

If an alternating voltage is applied to the primary winding, as shown in Figure 3-5, it will induce an

alternating 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 produce

currents 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 the

lamination 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, is

governed by flux, per lamination and resistance of the lamination. It is, therefore, dependent on lamination

width, 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 primarily

dependent 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. The

insulating coating is applied to reduce eddy currents. The American Iron and Steel Institute (AISI) has set

up insulation standards for transformer steels used in different applications. High permeability, nickel-iron

cores are very strain sensitive. Manufacturers of these cores normally have their own proprietary,

insulating material.


Laminations

Laminations are available in scores of different shapes and sizes. The punch press technology for

fabricating 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. The

laminations differ from each other by the location of the cut in the magnetic path length. This cut

introduces an air gap, which results in the loss of permeability. To minimize the resulting air gap, the

laminations 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 is

the scrapless. The name, scrapless, is derived from shapes that are punched with minimum waste, as shown

in 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 the

magnetic materials will have an impact on the permeability. The resulting stress could cause higher

magnetizing current, or a lower inductance. When the transformer is being assembled (in the stacking

process), and a lamination is bent (does not return to its original shape), that lamination has been stressed

and 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 materials

by annealing. Basically, stress relief is accomplished by heating (annealing) the magnetic material to

prescribed temperature, (depending on the material), followed by cooling to room temperature. The entire

annealing 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 of

the steel.

Stacking Laminations and Polarity

The edges of the magnetic material that have been stamped, sheared, or slit, will have a burr, as shown in

Figure 3-9. The quality of the equipment will keep the burr to a minimum. This burr now gives the

lamination a polarity. When a transformer is being stacked, the lamination build is normally sized by

dimensions, 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 are

stacked 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. This

could 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 as

an 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 would

be in groups of two or more. This is done to cut assembly time. The loss in performance in stacking, other

than 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 is

caused by the difference in spacing between the E, I, and the adjacent lamination. The adjacent lamination

has a minimum air gap, which translates into a higher permeability.

Laminations E and I

g \

-\>

\^

,%!/i

\

:= ===

i i= == =

II

r

,ii \i

53S

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 flux

crowding in that lamination. Eventually, this crowding will cause saturation in that portion of the

lamination, and the excitation current will rise. After that portion of the lamination has saturated, the flux

will migrate back to the lower permeability segment of the lamination from where it left. This effect can be

easily viewed by observing the B-H loops at low and high flux densities, and comparing them with a

toroidal core of the same material, with a minimum air gap, as shown in Figure 3-12. The B-H loop, along

with the magnetizing current, Im, of a toroidal core, is shown in Figure 3-12A. The toroidal core, with its

inherit 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 flux

densities. 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, a

channel bracket or maybe a bolt through the mounting holes to the chassis. When transformers are being

assembled, 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 and

degrade 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, shown

in 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 and

nut. Also, included in this hardware, should be fiber shoulder washers and proper sleeving to cover the bolt

threads. If insulating hardware is not used, there is a good chance of a partial, shorted turn. The continuity

for this partial turn can be created through the bolts and bracket, or the bolts, bracket, and the chassis. This

partial 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 a

preslit 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). The

advantage of this type of construction is that the flux is parallel with the direction of rolling of the magnetic

material. This provides the maximum utilization of flux with the minimum of magnetizing force. There

are 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 smooth

mating 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 this

procedure 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 many

configurations in the design of a magnetic component, as shown in Figure 3-17. The EE cores are

constructed 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 <-ore

Coil

ji

Figure 3-17. Three Different C Core Configurations.

Overwind

C Core

7^

-•

V.

X

V

^

^

"\

/

s~

V

s

/

\

J

Band -

Buckle

Core —

^/JE"\ ( rCoil

*( (V

V — —

TCnil

^

-\1 I

Coil

) IJ

Figure 3-18. Three-Phase, Cut EE Core. Figure 3-19. Typical, Assembled EE Cut Core.

Tape Toroidal Cores

Tape toroidal cores are constructed in the same way as tape C cores, by winding the magnetic material

around a mandrel, in the form of a preslit tape. This tape material comes in all of the iron alloys, plus the

amorphous materials. The tape thickness varies from 0.000125 inch (0.00318 mm) to 0.012 inch (0.305

mm). The tape toroid is normally offered in two configurations, cased and encapsulated, as shown in

Figure 3-20. The cased toroid offers superior electrical properties and stress protection against winding.

The encapsulated cores are used when not all of the fine magnetic properties are important to the design,

such as in power transformers.


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 the

initial design. Powder cores have a built-in air gap. They come in a variety of materials and are very stable

with time and temperature. The cores are manufactured with good engineering aids. Manufacturers

provide catalogs for their cores, listing not only the size, but also permeability and Millihenrys per 1000

turns. The data is presented to the engineer in such a way that it takes the minimum amount of time to have

a design that will function.

OD

Figure 3-21. Outline of a Powder Toroidal Core.

Stacking Factors

The standard stacking factors for tape cores, wound cut cotes and laminations are shown in Table 3-1.

Table 3-1. Standard Stacking Factors.

Thickness

mils0.1250.2500.5001.0002.0004.0006.00012.00014.00018.00025.000

Tape Cores

0.2500.3750.5000.7500.8500.900

0.9400.940

Wound Cut Cores

0.8300.8900.9000.9000.9500.950

Laminations

Butt 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 for

El laminations and an assembled transformer is shown in Figure 3-22. Dimensional data for El laminations

is 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

MLTcm6.78.29.511.213.014.816.518.320.122.025.632.7

MPLcm7.38.39.511.413.315.217.219.121.022.926.734.3

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

AP

cm4

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 Laminations

The 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

oF

oF

^ ^

F

i

1

1

1

1

1

, H

G

H

D

e

Coil#l Coil#2

e e

UI, Laminations

Side 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

Wtfe

grams173300585138427254702749117692

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

Ac

cm2

1.5321.9393.4486.1299.57713.79019.85835.303

wacm2

4.83911.99610.88719.35530.24243.54852.25892.903

AP4cm

7.41423.26337.534

118.626289.614600.544

1037.7403279.770

KK

cm5

0.5921.8394.614

19.70960.647

150.318313.636

1331.997

A,cm2

11020924743968598712962304


Design and Dimensional Data for LL Laminations

The 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

ii

t

\

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

MLTcm4.95.95.97.37.78.78.88.78.89.810.2

MPLcm10.812.716.513.315.216.520.222.519.721.023.2

waAc

9.4732.8844.5323.8673.1594.7377.1938.4884.4196.1875.474

Ac

cm2

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

AP4cm

1.3902.9434.6245.3227.41411.12116.88519.92516.61723.26331.375

Kg

cm5

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

i

t

G\

tH

^

i

i

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

MLTcm1.52.43.33.94.44.45.77.29.714.221.021.3

MPLcm3.25.27.38.99.913.313.317.222.834.351.441.4

waAc

10.5005.9064.6883.1595.1339.6343.1588.4208.4228.4208.4215.389

Ac

cm2

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

AP

cm4

0.0060.0540.2170.4630.7531.3902.3466.25619.771

100.091506.709494.275

KB

cm3

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

i

F1

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 mil

PartNo.

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 .OOOEI

1.200EI

1.500E1

1 .800EI

2.400EI

3.600EI

wtcugrams

57134242403600125525942178426673261723058144

wtfegrams

541543244217061743275135466957120172863496805

MLTcm4.36.28.28.810.113.916.717.622.026.334.852.2

wa2AC

3.2512.3391.8102.2132.3341.8092.3681.3161.3161.3161.3161.316

Ac

cm2

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

AP

cm4

1.435.2112.7424.8840.13119.53266.91307.48750.681556.614919.6624905.75

KR

cm5

0.0510.2890.9552.1873.81616.18739.06761.727187.898470.4531997.99515174.600

At

cm531021592072754877307251132163028996522


Design and Dimensional Data for Tape Wound C Cores

The dimensional outline for C cores is shown in Figure 3-27. Dimensional data for C cores is given in

Table 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

wvvtcu

grams13.019.827.258.473.595.1137.7160.5176.2254.5315.6471.7

wtfegrams13.022.645.272.5120.8121.7170.4255.6149.1478.4530.5600.1

MLTcm3.63.95.45.77.27.47.79.07.911.411.411.9

MPLcm6.48.38.311.811.812.715.615.615.617.519.421.9

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

AP

cm4

0.2710.5071.0132.3233.8714.5587.23610.8547.915

22.62628.05340.170

K8

cm5

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 Cores

The 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 mil

PartNo.

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

Wtfe

grams6861073142218032899442045976544

MLTcm11.212.813.415.117.321.320.322.0

wa2AC

0.7891.1581.1480.8460.8220.5851.6020.574

AC

cm3.4484.3105.2666.7059.19413.79010.73016.860

wacm5.449.9812.1011.3415.1216.1334.3819.35

AP

cm4

28.1664.5395.561 14.06208.50333.64553.15489.40

KR

cm5

3.4618.68614.97720.20344..43S86.347117.079150.340

A,cm2

261324400468613737993956


Design and Dimensional Data for Tape Wound Toroidal Cores

The dimensional outline for tape wound Toroidal cores is shown in Figure 3-29. Dimensional data for

cased 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

AC

cm0.0220.0220.0430.0430.0430.0860.0860.1710.1710.1710.1930.257

wacm2

0.4120.8510.4120.8511.4510.8510.6140.8512.1754.1041.3981.398

AP

cm4

0.009060.018720.017700.036600.062370.073200.052780.145540.371870.701840.269750.35920

Kg

cm5

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


G

>\

\

^ fe-c

Ac i

1

i

\

i

E

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

Wvvtcu

grams6.813.936.447.364.4111.1

wtfegrams

4.49.533.057.0103.0179.0

MLTcm3.84.96.68.19.411.2

MPLcm

4.014.856.947.758.9010.70

waAc

2.2192.0681.8751.1030.8080.826

Ac

cm2

0.2280.3840.8211.4902.3903.390

wacm

0.5060.7941.5391.6431.9302.799

AP4cm4

0.1160.3051.2642.4484.6169.487

Kg

cm5

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

Wvvtcu

grams1.53.13.87.88.917.829.759.4

wtfegrams

4.14.910.413.022.026.058.070.8

MLTcm4.74.76.56.58.98.911.911.9

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)

AP4cm

0.03660.07150.13190.27090.36490.72991.58923.1784

KB

cm5

0.001240.002480.006510.013370.021260.042530.120850.24170

A,cm10.411.617.820.533.437.965.475.3

*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

X

Wvv

\\

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)Part

No.

EC-35

EC-41

EC-52

EC-70

wtcugrams

35.1

55.4

97.8

256.7

wtfegrams

36.0

52.0

111.0

253.0

MLT

cm

6.3

7.5

9.0

11.7

MPL

cm

7.59

8.76

10.30

14.10

wa

Ac

2.213

1.964

2.156

2.927

AC

cm2

0.710

1.060

1.410

2.110

wa

cm2

1.571

2.082

3.040

6.177

Ap

cm4

1.115

2.207

4.287

13.034

Kgcm5

0.050

0.125

0.267

0.941

A,

cm2

50.2

67.6

106.5

201.7

*AL

rnh/lK

1000

1233

1680

1920

*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 Cores

The dimensional outline for ETD ferrite cores is shown in Figure 3-33. Dimensional data for ETD ferrite


G

C

B A

\

ETD Ferrite Core

4 *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

MPLcm7.207.879.2210.3011.4012.7013.90

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

AP

cm4

1.08001.66652.93304.85207.245312.612919.0698

KR

cm5

0.05170.09110.17660.35950.59171.21042.1271

At

cm42.553.469.987.9107.9133.7163.1

*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 ~vva

ETD-lp Ferrite CoreD

Perspective 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)

Part

No.ETD34(lp)

ETD39(lp)

ETD44(lp)

ETD49(lp)

Acm

3.421

3.909

4.399

4.869

Bcm

2.631

3.010

3.330

3.701

Ccm

1.804

1.798

1.920

2.082

Dcm

1.080

1.250

1.481

1.631

Ecm

1.080

1.250

1.481

1.631

Gcm

0.762

0.762

0.762

0.762

Table 3-27. Design Data for ETD/lp Ferrite Cores.

ETD/lp, Ferrite Cores (TSC Ferrite International)

Part

No.

ETD34(lp)

ETD39(lp)

ETD44(lp)

ETD49(lp)

Wvvtcu

grams

15.1

20.0

24.6

29.1

Wtfc

grams

32.7

46.3

72.1

95.0

MLT

cm

7.2

8.4

9.5

10.4

MPL

cm

4.65

5.03

5.40

5.85

waAc

0.609

0.559

0.420

0.374

Ac

cm2

0.970

1.200

1.730

2.110

wa

cm2

0.591

0.671

0.727

0.789

Ap

cm4

0.5732

0.8047

1.2583

1.6641

Kg

cm5

0.0310

0.0461

0.0914

0.1353

A,

cm2

33.1

39.6

48.4

58.2

*AL

mh/lK

2382

2838

3659

4120*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 Cores

Surface 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

DPerspective View

Figure 3-35. Dimension Outline for ER Ferrite Cores.

Table 3-28. Dimensional Data for ER Ferrite Cores.

ER, Ferrite Cores (Ferroxcube)

Part

No.

ER9.5

E R 1 1

ER35

A

cm

0.950

1.100

3.500

B

cm

0.750

0.870

2.615

C

cm

0.490

0.490

4.140

D

cm

0.500

0.600

1.140

E

cm

0.350

0.425

1.130

G

cm

0.320

0.300

2.950

Part

No.

ER42

ER48

ER54

A

cm

4.200

4.800

5.350

B

cm

3.005

3.800

4.065

C

cm

4.480

4.220

3.660

D

cm

1.560

2.100

1.795

E

cm

1.550

1.800

1.790

G

cm

3.090

2.940

2.220

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

Wtfe

grams0.71.0

46.096.0128.0122.0

MLTcm

2.7003.2007.3009.10011.5001 1 .400

MPLcm1.421.479.089.8810.009.18

waAc

0.8420.6502.1901.1891.1851.052

Ac

cm2

0.0760.1031.0001.8902.4802.400

wacm2

0.06400.06702.19002.24802.94002.5250

AP

cm4

0.004860.006882.190374.248677.291206.06060

KB

cm5

0.0000540.0000900.1203400.3524440.6262450.512544

A,cm3.03.7

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 Cores


The EFD cores, (Economic Flat Design), offer a significant advance in power transformer circuit

miniaturization. The dimensional outline for EFD ferrite cores is shown in Figure 3-36. Dimensional data

for 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)

Part

No.

EFD- 10

EFD- 15

EFD-20

EFD-25

EFD-30

wtcugrams

0.8

3.0

6.8

11.5

17.0

wtfegrams

0.90

2.80

7.00

16.00

24.00

MLT

cm

1.8

2.7

3.8

4.8

5.5

MPL

cm

2.37

3.40

4.70

5.70

6.80

waAc

1.611

2.093

1.616

1.171

1.267

Ac

cm2

0.072

0.150

0.310

0.580

0.690

wacm2

0.116

0.314

0.501

0.679

0.874

AP

cm4

0.00837

0.04703

0.15516

0.39376

0.60278

Kscm5

0.00013

0.00105

0.00506

0.01911

0.03047

At

cm2

3.3

7.3

13.3

21.6

28.9

*AL

mh/lK

254

413

565

957

913*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 Cores


The dimensional outline for EPC ferrite cores is shown in Figure 3-37. Dimensional data for EPC ferrite


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

Wvvtcu

grams0.52.04.96.914.818.821.9

wtfegrams

1.12.14.55.313.018.023.0

MLTcm1.92.53.43.75.05.15.5

MPLcm1.783.064.024.615.927.318.16

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

AP4cm

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

MLTcm1.92.93.74.45.36.37.58.6

MPLcm1.251.972.593.123.764.505.296.85

waAC

0.6500.6310.6200.6120.5760.5500.4990.686

Ac

cm2

0.1000.2490.4290.6390.9311.3602.0202.660

wacm2

0.0650.1570.2660.3910.5360.7481.0071.826

AP4cm

0.006520.039040.114130.249850.499130.971752.034954.85663

K*5cm0.0001340.0013310.0052870.0143600.0351140.0804080.2203470.600289

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 Cores

The EP ferrite cores are typically used in transformer applications. The shape of the assembly is almost

cubical, allowing high package densities on the PCB. The dimensional outline for EP ferrite cores is shown

in 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

MLTcm1.82.12.42.94.2

MPLcm1.571.922.422.853.98

waAC

0.9221.8321.2000.9500.637

Ac

cm2

0.1030.1130.1950.3390.780

wacm2

0.0950.2070.2340.3220.497

AP

cm4

0.009790.023390.045580.109150.38737

KB

cm5

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. The

dimensional outline for PQ ferrite cores is shown in Figure 3-40. Dimensional data for PQ ferrite cores is

given 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

Wvvtcu

grams7.410.431.017.018.935.559.097.2158.5

Wtfe

grams13.015.031.036.042.055.073.095.0195.0

MLTcm4.44.45.65.76.66.77.58.410.3

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

Ap4cm

0.2940.4080.7180.9971.3732.4094.3246.55214.209

KE

cm5

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 substantially

reduced total height. The dimensional outline for PQ ferrite cores is shown in Figure 3-41. Dimensional

data 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)

Part

No.PQ20-14-141p

PQ26-16-191p

PQ32-17-221p

PQ35-17-261p

PQ40-18-281p

wttugrams

5.4

7.912.5

17.8

24.9

wtfegrams

12.5

28.0

39.4

44.9

63.5

MLT

cm4.4

5.66.6

7.4

8.3

MPL

cm3.2

3.94.8

5.3

5.8

wa

AC

0.563

0.336

0.315

0.343

0.419

Ac

cm2

0.620

1.190

1.700

1.960

2.010

wacm2

0.349

0.400

0.535

0.672

0.842

AP4cm

0.217

0.477

0.909

1.318

1.692

KS

cm5

0.0123

0.0407

0.0937

0.1389

0.1637

A,

cm2

15.4

25.4

32.9

40.4

48.0

*AL

mh/lK

1948

3170

3659

3893

3850This 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 RM, Ferrite Cores

The RM cores, (Rectangular Modular), were developed for high Printed Circuit Board, (PCB), packing

densities. 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

Ccm1.041.041.241.64

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

Ccm1.862.352.88

Ecm1.071.261.47

Gcm1.271.712.11

Table 3-43. Design Data for RM Ferrite Cores.

RM, Ferrite Cores (TDK)PartNo.

RM-4RM-5RM-6RM-8RM-10RM-12RM-14

wvvtcu

grams1.11.62.97.313.224.439.9

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

Ac

cm0.1400.2370.3660.6400.9801.4001.880

wacm

0.1570.1820.2600.4900.6951.1031.561

AP

cm4

0.02190.04310.09530.31330.68141.54402.7790

Ks

cm5

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 Cores


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

Wvvtcu

grams0.60.91.52.33.76.411.919.5

Wtfe

grams1.52.24.26.010.017.034.055.0

MLTcm2.02.53.13.64.25.26.17.1

MPLcm1.731.752.182.352.873.394.205.09

waAc

0.7700.5250.4330.4440.4490.4260.4390.463

Ac

cm2

0.1130.1810.3120.3960.5540.8091.2501.680

wacm2

0.0870.0950.1350.1760.2490.3450.5490.777

AP

cm4

0.009840.017270.042120.069790.138100.279150.686251.30536

KK

cm5

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 many

strands of wire, which is convenient for high power and multiple outputs. The dimensional outline for DS

ferrite cores is shown in Figure 3-44. Dimensional data for DS ferrite cores is given in Table 3-46; design

data 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

Wvvtcu

grams4.79.110.116.726.656.0

wtfegrams10.013.015.022.037.078.0

MLTcm4.54.65.36.37.58.6

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

AP4cm

0.1100.2270.3360.7171.2533.255

KB5cm

0.003680.008000.015930.043800.084040.26917

A,2cm

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


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)

Part

No.

UUR-44121

UUR-44119

UUR-44125

UUR-44130

wtcugrams

119.0146.2

171.3227.0

Wtfe

grams

55.054.0

64.0

75.0

MLTcm

8.0

8.08.0

8.0

MPLcm

11.312.1

13.315.3

waAc

4.215

5.6196.070

8.043

Ac

cm2

0.988

0.911

0.988

0.988

wa

cm4.164

5.1195.997

7.946

AP

cm4

4.114

4.663

5.925

7.850

Kg

cm5

0.202

0.211

0.291

0.386

A,

cm98.5

102.9

116.1134.9

*ALmh/lK

616

710702

610*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 0-08-03

U20-16-07U25-20-13U30-25-16U67-27-14

U93-76-16

Wvvtcu

grams3.5

16.4

41.6

83.9

435.01875.2

Wtfe

grams1.8

19.047.0

86.0

170.0

800.0

MLTcm

2.2

4.4

6.1

7.5

12.4

15.2

MPLcm

3.8

6.8

8.8

11.117.3

35.4

waAc

5.3701.8961.841

1.943

4.831

7.757

Ac

cm2

0.081

0.560

1.040

1.610

2.0404.480

wacm2

0.4351.062

1.915

3.129

9.85534.752

Ap

cm4

0.03520.59491.99205.0380

20.1050155.6890

KEcm5

0.0005100.0306610.1356690.430427

1.32166118.386023

A,

cm2

8.1

29.5

51.1

82.5

240.2605.3

*AL

mh/lK213

826

1261

1609

1652

1478*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 flux

path is completely enclosed within the magnetic structure. The toroidal structure fully exploits the

capabilities 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

wvvtcu

grams0.81.41.23.24.011.213.733.738.063.647.2740.1

Wtfe

grams1.21.63.32.42.85.46.412.929.426.451.7

203.0

MLTcm1.72.02.22.22.22.82.93.74.24.75.39.1

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

Ac

cm2

0.1070.1350.2210.1460.1530.2310.2500.3580.6280.5701.1501.870

Wa

cm2

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

Ks

cm5

0.0003660.0006870.0014430.0016380.0022400.0084820.0112210.0358690.0935050.1072830.2523943.496437

A,cm2

5.36.68.610.212.822.725.844.661.268.571.0

348.0

*ALmh/lK

657752113059154860060063087888316651091

This AL value has been normalized for a permeability of IK. For a close approximation of AL for other values ofpermeability, multiply this AL value by the new permeability in kilo-perm. If the new permeability is 2500, then use2.5.


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)

Part

No.55021

55281

55291

55041

5513155051

55121

ODcm

0.699

1.0291.0291.0801.1811.3461.740

IDcm

0.229

0.427

0.427

0.457

0.584

0.699

0.953

HTcm

0.343

0.3810.460

0.460

0.460

0.5510.711

Part

No.55381

55848

55059

55351

55894

55071

55586

ODcm

1.8032.1102.360

2.430

2.770

3.380

3.520

IDcm

0.902

1.2071.3341.3771.4101.9302.260

HTcm

0.7110.7110.838

0.965

1.1941.1430.978

Part

No.55076

55083

55439

55090

55716

55110

ODcm

3.670

4.080

4.760

4.760

5.1705.800

IDcm

2.1502.330

2.330

2.790

3.090

3.470

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

MLTcm1.101.401.601.601.702.002.502.602.803.203.504.104.504.404.805.706.806.406.407.00

MPLcm1.362.182.182.382.693.124.114.145.095.675.886.358.158.958.989.8410.7411.6312.7314.300

waAc

0.7231.7291.3761.5002.7593.1753.5632.6344.8984.0973.7272.3204.2638.6815.2553.9102.1064.4975.9176.474

Ac

cm2

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

AP

cm4

0.0016100.0097570.0123590.0149980.0227350.0412790.1312670.1417470.2500920.4488570.5611530.9924231.9254201.7891282.4158974.4927098.3400108.0752119.26026813.498792

Kg

cm5

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

MPLcm1.151.501.471.842.312.182.683.193.744.235.145.975.786.498.287.967.729.149.3811.20

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

AP

cm4

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

I

Figure 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

MLTcm1.101.401.601.601.702.002.502.602.803.203.504.104.504.404.805.706.806.406.407.00

MPLcm1.362.182.182.382.693.124.114.145.095.675.886.358.158.958.989.8410.7411.6312.73

14.300

waAc

0.7231.7291.3761.5002.7593.1753.5632.6344.8984.0973.7272.3204.2638.6815.2553.9102.1064.4975.9176.474

Ac

cm2

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

AP

cm4

0.0016100.0097570.0123590.0149980.0227350.0412790.1312670.1417470.2500920.4488570.5611530.9924231.9254201.7891282.4158974.4927098.3400108.0752119.26026813.498792

KR

cm5

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

I

Figure 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

MLTcm1.101.401.601.60

rr.702.002.502.602.803.203.504.104.504.404.805.706.806.406.407.00

MPLcm1.362.182.182.382.693.124.114.145.095.675.886.358.158.958.989.8410.7411.6312.7314.300

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

AP

cm4

0.0016100.0097570.0123590.0149980.0227350.0412790.1312670.1417470.2500920.4488570.5611530.9924231.9254201.7891282.4158974.4927098.3400108.0752119.26026813.498792

KB

cm0.0000270.0002040.0003010.0003750.0004920.0009610.0039850.0050990.0080010.0184060.0249690.0629160.1141790.0741660.1378770.3366080.9712440.6774850.7204351.111049

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

\

_^ ^D

EE 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

Wtfe

grams5.35.512.240.180.8112.4149.6141.1283.7245.8

MLTcm3.33.85.06.78.28.99.99.411.611.2

MPLcm

3.984.105.107.408.4010.4010.409.513.211.5

waAC

1.7902.4512.0101.7141.0711.5861.1910.7851.1330.778

Ac

cm2

0.2240.2260.4030.9071.6101.8102.4102.4803.6003.580

wacm2

0.4010.5540.8101.5551.7252.8702.8701.9484.0792.784

AP

cm4

0.0900.1250.3261.4112.7775.1966.9184.83114.6849.9667

Ks

cm5

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

\

i

Er

\

Xy,

\

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

Wtfe

grams6.413.140.882.6126.0163.0302.0

MLTcm3.85.06.78.28.99.911.6

MPLcm

4.014.856.947.759.849.8412.3

waAc

2.4512.0101.7141.0711.5861.1911.133

Ac

cm0.2260.4030.9071.6101.8102.4103.600

wacm2

0.5540.8101.5551.7252.8702.8704.079

AP

cm4

0.1250.3261.4112.7775.1966.91814.684

KK

cm5

0.002970.010620.076240.218520.420500.670541.82699

A,cm14.423.546.863.384.492.9141.3

ALmh/lK

4870102163150194219


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chapter 3 magnetic cores - university of north carolina … and dimensional data for ui laminations...

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