Micrometal Catalog

207037_FCQ1/29/07 7:50 AM Page 3 Power Conversion & Line Filter Applications Issue L February 2007 CONTENTS Introduction General Properties..................................1 Tolerances..............................................4 Physical Properties Toroidal Cores........................................5 Composite Cores...................................14 E Cores..................................................15 EH Cores, EM Cores.............................19 E Core Bobbins, Toroidal Core Caps....20 Bus Bar, U Cores...................................21 Pot Core Assemblies..............................22 Bobbin Assemblies.................................23 Plain Cores.............................................24 Magnetic Characteristics Magnetization Curves.............................25 Curve Fit Formulas.................................28 Core Losses.............................................29 Copyright © 2007, Micrometals Inc., Issue L, Printed February 2007 Design Software....................................................37 Thermal Aging Considerations..............................38 DC Application Notes Graphic Design Aid................................41 Core Selection Examples........................52 DC Inductor Table..................................53 E Core Gapping......................................54 Effects of Ripple on DC Chokes.............56 AC Application Notes Power Factor Core Loss Calculations.....58 60 Hz Filter Inductor..............................60 Core Selection Example..........................62 60 Hz Inductor Table..............................63 Winding Table......................................................64 Packaging Size and Weights.................................66 Glossary................................................................67 Additional Literature.............................................68 Sales Contacts.......................................................69 MICROMETALS, INC. established in 1951, is committed to supplying high quality iron powder cores to meet the needs of the electronics industry. As the technology has changed, new shapes, sizes and materials have been introduced to become industry standards. MICROMETALS TEL. (714) 970-9400 FAX (714) 970-0400 Iron powder as a core material has been widely used in RF applications for years. The distributed air gap properties inherent in iron powder cores also make them extremely well-suited for a variety of energy storage inductor applications. Iron powder is a cost-effective design alternative to molypermalloy powder (MPP), high flux, or sendust cores. It can also be used in place of ferrites and iron-alloy laminations requiring a gap. The iron powder cores described in this catalog are typically used for DC output chokes, differential-mode input chokes, power factor correction inductors, continuous-mode flyback inductors, light dimmer chokes and other EMI/ RFI applications. INTRODUCTION WARRANTY Parts are warranted to conform to the specifications in the latest issue of this catalog. Micrometals’ liability is limited to return of parts and repayment of price; or replacement of nonconforming parts. Notice of nonconformance must be made within 30 days after delivery. Before using these products, buyer agrees to determine suitability of the product for their intended use or application. Micrometals shall not be liable for any other loss or damage, including but not limited to incidental or consequential damages. GENERAL MATERIAL PROPERTIES Material Mix No. -2 -8 -14 -18 -19 -26 -30 -34 -35 -40 -45 -52 Reference Permeability (μ0) 10 35 14 55 55 75 22 33 33 60 100 75 Material Density (g/cm3) 5.0 6.5 5.2 6.6 6.8 7.0 6.0 6.2 6.3 6.9 7.2 7.0 Relative Cost 2.7 5.0 3.6 3.4 1.7 1.0 1.4 1.5 1.4 1.0 2.6 1.2 INTRODUCTION Color* Code Red/Clear Yellow/Red Black/Red Green/Red Red/Green Yellow/White Green/Gray Gray/Blue Yellow/Gray Green/Yellow Black/Black Green/Blue * All Micrometals color codes are protected by US Trademark law. Formal registration numbers have been issued for the -8, -18, -26 and -52 color codes by the United States Patent and Trademark office. CORE LOSS COMPARISON (mW/cm3) Material 60 Hz 1kHz 10kHz 50kHz 100kHz 500kHz Mix No. @5000G @1500G @500G @225G @140G @50G -2 -8 ** -14 -18 -19 -26 -30 -34 -35 -40 -45 -52 19 45 19 48 31 32 37 29 33 29 26 30 32 64 32 72 60 60 80 61 73 62 49 56 32 59 32 70 72 75 120 87 109 93 60 68 28 48 29 63 71 89 149 100 137 130 69 72 19 32 21 46 54 83 129 82 119 127 61 58 12 15 17 37 49 139 129 78 123 223 92 63 PERMEABILITY WITH DC BIAS HDC = 50 Oersteds %μ0 μeffective 99 91 99 74 74 51 91 84 84 62 46 59 10.0 31.9 14.0 40.7 40.7 38.3 20.0 27.7 27.7 37.2 46.0 44.3 ** Revised since last issue. MATERIAL APPLICATIONS Typical Application Light Dimmer Chokes 60 Hz Differential-mode EMI Line Chokes DC Chokes: <50kHz or low Et/N (Buck/Boost) DC Chokes: ≥50kHz or higher Et/N (Buck/Boost) Power Factor Correction Chokes: <50kHz Power Factor Correction Chokes: ≥50kHz Resonant Inductors: ≥50kHz -2 -8 -14 -18 -19 -26 X X X X X X X X X X X -30 -34 -35 -40 X X X X -45 -52 X X X X X MATERIAL DESCRIPTION -2/-14 Materials The low permeability of these materials will result in lower operating AC flux density than with other materials with no additional gap-loss. The -14 Material is similar to -2 Material with slightly higher permeability. -8 Material This material has low core loss and good linearity under high bias conditions. A good high frequency material. The highest cost material. -18 Material This material has low core loss similar to the -8 Material with higher permeability and a lower cost. Good DC saturation characteristics. -19 Material An inexpensive alternate to the -18 Material with the same permeability and somewhat higher core losses. -26 Material The most popular material. It is a cost-effective general purpose material that is useful in a wide variety of power conversion and line filter applications. -30 Material The good linearity, low cost, and relatively low permeability of this material make it popular in large sizes for high power UPS chokes. -34/-35 Materials An inexpensive alternate to the -8 material for applications where high frequency core loss is not critical. Good linearity with high bias. -40 Material The least expensive material. It has characteristics quite similar to the very popular -26 Material. Popular in large sizes. -45 Material The highest permeability material. A high permeability alternate to -52 Material with slightly higher core losses. -52 Material This material has lower core loss at high frequency and the same permeability as the -26 Material. It is very popular for high frequency choke designs. -1- MICROMETALS TEL. (714) 970-9400 FAX (714) 970-0400 X X X X X X X X X X X X X X X X T51C. T80. In addition Micrometals maintains stocking warehouses in Hong Kong and Dietzenbach. delivery and lead-time information as well as technical support are available through our headquarters in Anaheim. (Including Bobbins) 35 Items. 2) Special prototypes can be machined from blocks of material for preliminary evaluation. T37. We recommend the cores remain in the original factory packaging and be sheltered from rain or high humidity since uncoated iron can eventually form surface rust. E450. T50. Several key benefits of iron powder as a core material are. E220. (Including Bobbins) 15 Items. and Zhongshan. T44. E49. T157. T106. (Please refer to page 66 for package increments and weights. Micrometals will gladly produce custom shapes and sizes.INTRODUCTION AVAILABILITY Part numbers in this catalog which appear in bold print are considered standard items and are generally available from stock. dirt. Iron powder cores tend to be heavier than many other products and special consideration must be given to the weight of the carton. Abilene. E225. 425 pieces ENGINEERING KIT #15 T130. E137. Micrometals has factories in Anaheim. E162. 114 pieces ENGINEERING KIT #17 TEL. T175. 1) Custom and proprietary tooling are relatively inexpensive.) Do not stack more than 5 cartons high to avoid crushing the bottom cartons. T90. Texas. T200. Also. California or with any of our local representatives. T184. T131. or with any of our sales representatives. MICROMETALS -2- .com Pricing. T72.O.Leo & Company Ltd. T250. solvents. oil. E305.de@bfioptilas. dust and acids. Shatin Hong Kong Germany: BFI Optilas Assar Gabreilsson Str. T26. and 3) cores can be manufactured in a variety of heights from any of the materials shown without additional tooling charges. 239 pieces T225. Micrometals will gladly extend sample cores to aid in your core selection. E75. Other items are available on a build-to-order basis. E162. T300. E168. Please do not hesitate to contact the factory with any special requests. E100. Special consideration for electrostatic discharge (ESD) is not necessary with iron powder cores since they have a “distributed air gap structure” and will not retain an electrostatic charge.1 63128 Dietzenbach Germany Phone: +852-2604-8222 +49-6074-40980 Fax: +852-2693-2093 +49-6074-4098-10 E-Mail Market@pleo. T225. P. E100. T38. (Including Bobbins) 42 Items. (714) 970-9400 FAX (714) 970-0400 T80. (Including Bobbins) 30 Items. ENGINEERING KITS For a wide selection of cores for engineering design and evaluation. Orders may be placed directly with the factory in Anaheim. T130. Please refer to page 69 for complete list of representatives. The details regarding our warehouses are as follows: Hong Kong: P. China. iron powder cores need to be kept free of metal shavings. as with most magnetic material. E220.com ipe. if individual cores are dropped on a hard surface a crack or chip can result on the core coating. the engineering kits described below are available at a modest charge: ENGINEERING KIT #14 ENGINEERING KIT #16 T20. T68. T25. E187. Germany for immediate delivery to the Far East and Europe. California. Box 175 Fo Tan. T30. CUSTOM SHAPES AND SIZES In addition to the items shown in this catalog. Finally. California. T131. Damage will occur to cores if boxes are handled incorrectly or dropped. 44 pieces HANDLING AND STORAGE CONSIDERATIONS Micrometals has designed standard packaging for shipment to customers around the world. T400. Additionally. T60. Please be aware the cores are quite dense and package size can be deceivingly heavy. core size. Lastly.S.0 nH/N2 To calculate the number of turns required for a desired inductance (L) in nanohenries (nH) use the following formula: desired L (nH) 1/2 Required turns = AL (nH/N2) THERMAL CONSIDERATION Material Mix No. When cores are exposed to or generate elevated temperatures. Please contact us directly to receive a free copy or download directly from our web site at http://www. also known as AL values. A copy of the Yellow card can be provided upon request. we are also pleased to provide free design consultation. frequency. Designs where core loss exceeds copper loss should be avoided. Furthermore. -2 -8 -14 -18 -19 -26 -30 -34 -35 -40 -45 -52 Temp. The toroidal cores can be double or triple coated for greater dielectric strength. of Permeability (+ppm/Cº) 95 255 150 385 650 825 510 565 665 950 1043 650 Coef. All finishes have a minimum dielectric strength of 500 Vrms at 60 Hz and resist most cleaning solvents. -3- MICROMETALS FINISH The toroidal and bus bar cores listed in this catalog are provided with a protective coating. and flux density. a permanent decrease in both inductance and quality factor (Q) will gradually occur. Please contact the factory for information on optional finishes or core caps for larger size toroids. Hysteresis losses are unaffected by the thermal aging process. . T16 and T20 size cores are coated under vacuum with Parylene C. A more thorough and detailed discussion regarding thermal considerations for iron powder core designs is given on pages 38-40 of this catalog.com. Micrometals color codes are protected by U. The extent of these changes is highly dependent on time. Expansion (+ppm/Cº) 10 10 10 11 12 12 11 12 12 11 12 12 Thermal Conductivity (mW/cm-Cº) 10 29 11 21 30 42 20 28 30 36 43 34 TEMPERATURE EFFECTS Micrometals iron powder cores have an organic content and undergo thermal aging. trademark law. of Lin. Micrometals has also incorporated a thermal aging predictor into our standard design software. We can also provide uncoated cores upon special request. Coef.INDUCTANCE RATINGS In this catalog the inductance ratings. are expressed in nanohenries (10-9 Henries) per turn (N) squared (nH/N2). The T14. (714) 970-9400 FAX (714) 970-0400 In high power applications where core loss is contributing to the total temperature. temperature. micrometals. a decrease in quality factor will translate into an increase in eddy current losses which will further heat the core and can lead to thermal runaway. The larger cores are coated with a two color code finish that is UL approved for Flame Class UL94V-0 per file #E140098 (S). TEL. An example of a conversion from mH for 100 turns to nH/N2 is: INTRODUCTION 350 μH for 100 turns = 35. Iron powder cores tolerate temperatures down to -65ºC with no permanent effects. Extended exposure to certain solvents may have detrimental effects. It is essential that these properties are considered in any design operating at or above 75ºC. Micrometals recommends that all uncoated cores should be sheltered from high humidity or rain since they will eventually form surface rust. The E-cores and U-cores are treated to help resist rust. 015 A ±.015 ±.020 A ±.010 ±.HS400 U CORES U61 .010 TOROIDS* T150 .020 T ±.020 ±.015 ±.015 F ±.Hxx25 DISCS D45 .000/-.007 ±.0020 . (714) 970-9400 FAX (714) 970-0400 **OD for T50-8/90 and T50-8B/90 is +.005 OD +. Gap*** .010 H ±.030 ±.T141 COMPOSITE* ST50 ST83 .015 ±. OD ±.010 ±. DIMENSIONAL TOLERANCE (inches) TOROIDS* T14 .010 ±.007 ±.020 ±.040 Ht ±.010 G ±.E118 E125 .Hx12 Hxx14 . Measurements made under other conditions will produce results in accordance with the magnetic curves shown on page 27.TOLERANCES MAGNETIC TOLERANCE Material (Mix No.000 +.005 OD +.020 ±.T650 COMPOSITE* ST150 ST200 E ±.005 +.EM220 PLAIN CORES Pxx24 .015 ±.007 ±.025 C ±.020 ±.005/-.040 B ±.010 ±.T400 T520 .015 ±..T38 T40 .050 Ht ±.020 ±.007 ±.0050 Max.020 OD ±.020 ±.010 ±.0020 .0030 .0015 .030 ±.005 E ±.005/-.000 L ±.025 ±.030 ±.010 ±.D80 *Tolerance includes coating ***Gap per piece. Gap .025 E/H ±.020 D ±.007 OD ±.007 ±.020 D ±.015 ±.010 ±.015 Max.Pxx76 HOLLOW CORES Hx10 .005/-.ST102 BUS BAR* HS300 .030 G ±.030 ±.020 B ±.015 ±.030 ±.015 ID ±.000/-.010 ±.U80 U350 E CORES E49 .010 C ±.T20 T22 .005 ±.010 ±.020 ±.050 L ±.E225 E305 . The toroidal cores are tested with an evenly-spaced full single-layer winding in order to minimize leakage effects.000/-.005 ±.000 +.E450 E610 EH CORES EH220 EM CORES EM145 EM168 .015 C ±.010 ±.0015 .005/-.000/-.015 A ±.030 A ±.040 A ±.010 ±.015 G ±. The Magnetic Characteristic curves shown on pages 26-27 have a typical tolerance of +20%.Pxx40 Pxx48 .015 ±. Iron powder cores tested with a small number of turns which are not evenly distributed will produce higher inductance readings than expected.020 B ±.) -2 AL Tolerance -8 -14 -18 -19 -26 -30 -34 +10% -10% -35 -40 -45 -52 -267 -275 +5% +10% +10% +10% +10% +10% +10% -5% -10% -10% -10% -10% -10% -10% +10% +10% +10% +10% +35% +35% -10% -10% -10% -10% -25% -25% The cores are manufactured to the AL values listed.000 ID +.015 ±. the AL values are based on a peak AC flux density of 10 gauss (1 mT) at a frequency of 10 kHz.010 ±.000 CB +.010 ±.030 G ±.050 ID ±.030 ±.010 ±.E162 E168 .010 Ht ±.010 ±.015 ±.005 +.015 ±.005 C ±.000/-.030 ±.020 L ±.020 F ±.025 ±.015 B ±.030 D ±. In all cases.020 B ±.010 ±. The curves on Core Loss characteristics have a typical tolerance of ±15%.005/-.015 ±.010 ±.-10%.Hxx20 Hxx21 .030 ±.025 Ht ±.0030 ID ±.010 ±. The E Cores are tested with 100 turns.025 D ±.050 OD ±.020 ID +.015 ±.020 ID ±. the permeability for each material is for reference only.T72** T80 .015 ±.T225 T249 .020 ±.015 OD +.040 MICROMETALS TEL.010 ±. Gap*** .0030 Max.005 +.040 ±.015 ±.000/-.015 -4- .025/. 133 .28 1.5 38. MICROMETALS Part No.0 24.25 1.143/3. 6.08 .5 7. 3. Letter Indicates Alternate Height Code Area For Other Characteristics / Note: For information on Mix 0.096/2.71 .5 20.15 .055 . 17.44 1.0 22.128/3.5 17.280/7.5 38.3 14.060/1.160/4.135/3.190/4.5 27.5 11.06 .012 .067/1.5 57.5 4.265/6.5 30.5 18.24 . -66.5 16.2 6.0 18.070/1.52 . -63.84 . (714) 970-9400 FAX (714) 970-0400 .0 40.128/3.83 1.052 .8 13. ID TYPICAL PART NO.200/5.78 1.151/3.060 .5 2.66 .023 .090 .0 22.110 -5- MICROMETALS TEL.48 .84 .067 .98 .307/7.TOROIDAL CORES COLOR CODE -2 Red/Clear -8 Yellow/Red -14 Black/Red -18 Green/Red -19 Red/Green -26 Yellow/White -30 Green/Gray -34 Gray/Blue -35 Yellow/Gray -40 Green/Yellow -45 Black/Black -52 Green/Blue Refer to page 4 for tolerances.3 11.120/3. OD For information on -60.0 17.014 .52 MAGNETIC DIMENSIONS A V cm cm2 cm3 .25 1. and 42 see Micrometals RF Catalog.026 .060/1.015 .05 .4 10.078/1. 7. 10. -61.84 .11 . T14-26A T14-45A T14-52A T16-2 T16-8/90 T16-18 T16-26 T16-40 T16-45 T16-52 T20-2 T20-8/90 T20-18 T20-26 T20-40 T20-45 T20-52 T22-26 T22-52 T25-2 T25-8/90 T25-18 T25-26 T25-40 T25-45 T25-52 T26-8/90 T26-18 T26-26 T26-45 T26-52 T27-2 T27-8/90 T27-18 T27-26 T27-52 T30-2 T30-8/90 T30-18 T30-26 T30-40 T30-45 T30-52 nH/N2 12.80 .047 .151/3.930 .5 14.0 56.5 12.67 . T 106.255/6.0 3.080 .105/2.0 33.0 24.0 9.43 ID in/mm .097/2.5 AL OD in/mm .0 41. 12.47 .70 Ht in/mm .0 13. 15.63 .5 3.5 28. -70 and -M125 see Micrometals 200C Series Catalog.5 17.810 .26 Ht OD in 100th inches Micrometals Mix No.5 2.037 . 1.088/2.73 . 4.0 77.5 31.5 16.0098 .0 23.5 25.50 .223/5.46 . 21 .5 65.0 12.41 2.112 .0 46.7 .114 .14 .0 33.2 .0 41. MICROMETALS Part No.205/5.0 AL OD in/mm .440/11. (714) 970-9400 FAX (714) 970-0400 nH/N2 35.59 .440/11.68 3. T32-52 T37-2 T37-8/90 T37-18 T37-19 T37-26 T37-40 T37-45 T37-52 T38-2 T38-8/90 T38-18 T38-19 T38-26 T38-40 T38-45 T38-52 T40-26 T40-52 T44-2 T44-8/90 T44-14 T44-18 T44-19 T44-26 T44-40 T44-45 T44-52 T44-52C T44-52D T50-2 T50-8/90* T50-14 T50-18 T50-19 T50-26 T50-40 T50-45 T50-52 TEL. -63.83 2.229/5.45 .25 MAGNETIC DIMENSIONS A V cm cm2 cm3 1.5 24.5 34.169/4.68 2.099 . -70 and -M125 see Micrometals 200C Series Catalog.147 . 10.0 19.158/4.205/5. 17.128/3.2 .19 . Letter Indicates Alternate Height Code Area For Other Characteristics / Note: For information on Mix 0.338/8.01 .35 . refer to page 4 for details -6- .0 28.0 36.0 4.0 36.0 33. 3.9 17.82 .266 MICROMETALS .0 31.0 26.0 36.419 .5 37.9 24.400/10.190/4.0 7.70 . T 106.223 . 4.375/9.0 55.TOROIDAL CORES COLOR CODE -2 Red/Clear -8 Yellow/Red -14 Black/Red -18 Green/Red -19 Red/Green -26 Yellow/White -30 Green/Gray -34 Gray/Blue -35 Yellow/Gray -40 Green/Yellow -45 Black/Black -52 Green/Blue Refer to page 4 for tolerances.26 Ht OD in 100th inches Micrometals Mix No.2 18.5 35.358 * Non-Standard dimensional tolerance.5 44.159/4.0 19.0 24. ID TYPICAL PART NO.0 36.229/5.53 . -66. 1.82 .567 .500/12.82 .212 .2 25.83 2. OD For information on -60.5 25. 12.21 Ht in/mm .163/4.303/7.229/5. and 42 see Micrometals RF Catalog.4 20.0 4.96 2.53 ID in/mm .064 .2 .2 .0 29. -61.31 .0 49.157 .29 .04 2.0 5.31 . 6. 15.0 49.190/4.175/4.093 .0 70.073 .0 6.144 .18 .440/11.68 .248 .5 5.375/9.327/8. 7.250/6. 93 .805 .5 28.51 .19 . 12.0 43.7 ID in/mm .196/4.500/12. refer to page 4 for details.0 49.273/6.250/6.470/11.6 .622 .0 75.400 .2 . and 42 see Micrometals RF Catalog.94 3. ID TYPICAL PART NO.148 .0 T68-18 29.7 .0 OD in/mm .70 .TOROIDAL CORES COLOR CODE -2 Red/Clear -8 Yellow/Red -14 Black/Red -18 Green/Red -19 Red/Green -26 Yellow/White -30 Green/Gray -34 Gray/Blue -35 Yellow/Gray -40 Green/Yellow -45 Black/Black -52 Green/Blue Refer to page 4 for tolerances.335/8. Letter Indicates Alternate Height Code Area For Other Characteristics / Note: For information on Mix 0.200 .7 . 17. -70 and -M125 see Micrometals 200C Series Catalog.303/7.70 .3 61.2 .187 .74 .0 67.601 .336/8. (714) 970-9400 FAX (714) 970-0400 .5 38.179 1.35 2.98 .19 3.0 37.375/9.38 3.223 .0 * Non-standard dimensional tolerance.5 34.303/7.0 41.0 43.711 . 6.374 . OD For information on -60. -66.79 .250/6.0 6. -7- MICROMETALS .0 67.0 32.38 3.53 .68 .19 .5 T68-14 7.5 47.08 .0 83.0 97.336/8.303/7.93 .0 T68-45 53.53 3. T50-8B/90* T50-18B T50-19B T50-26B T50-40B T50-45B T50-52B T50-8C/90 T50-26C T50-26D T50-40D T50-52D T51-8C/90 T51-18C T51-26C T51-40C T51-52C T57-45 T57-52 T57-45A T57-52A T60-2 T60-8/90 T60-14 T60-18 T60-19 T60-26 T60-40 T60-52 T60-26D T60-52D AL nH/N2 23. -63.759 T68-2 5. 4.53 .0 94.0 55.0 66.5 88.200/5. 15.471 .690/17.239 .699 TEL.370/9. 1.500/12.5 T68-40 35.0 8.0 T68-52 40.70 Ht in/mm .5 19.26 Ht OD in 100th inches Micrometals Mix No.7 .5 58.0 72.74 4. -61.0 32.600/15.6 .35 MAGNETIC DIMENSIONS A V cm cm2 cm3 3.23 .0 66.637 .9 .573/14.0 T68-26 43.573/14. 7.5 .3 34.263/6.223 . T 106. 3.273/6.190/4.178 .500/12.83 3.0 T68-19 29.500/12.7 .5 50.0 59. 10.40 T68-8/90 19.234/5. MICROMETALS Part No.600/15. 61 1.09 4. 6.349 1.495/12.5 .280/7.0 63.53 4.0 AL OD in/mm . 10.0 83.0 29.2 87.453 2.23 .6 .6 .231 1.720/18.5 46.795/20.0 9.0 5.8 36. T68-2A T68-8A/90 T68-14A T68-18A T68-19A T68-26A T68-40A T68-45A T68-52A T68-2D T68-14D T68-26D T68-40D T68-52D T69-45 T72-2 T72-8/90 T72-18 T72-26 T72-40 T72-52 T80-2 T80-8/90 T80-14 T80-18 T80-19 T80-26 T80-40 T80-45 T80-52 T80-8B/90 T80-14B T80-18B T80-19B T80-26B T80-40B T80-45B T80-52B T80-26D T80-40D T80-52D nH/N2 7.14 . Letter Indicates Alternate Height Code Area For Other Characteristics / Note: For information on Mix 0.5 56.0 120.370/9.0 46.0 11.5 18.5 71.26 Ht OD in 100th inches Micrometals Mix No. -63.0 70.2 .40 .14 . 1.336/8.03 .5 11.53 .2 .TOROIDAL CORES COLOR CODE -2 Red/Clear -8 Yellow/Red -14 Black/Red -18 Green/Red -19 Red/Green -26 Yellow/White -30 Green/Gray -34 Gray/Blue -35 Yellow/Gray -40 Green/Yellow -45 Black/Black -52 Green/Blue Refer to page 4 for tolerances.0 80.358 1.0 7. 3.795/20.5 39.250/6.4 31. T 106.5 58. 4.5 .40 TEL.0 46.690/17.11 .5 39.5 ID in/mm . -70 and -M125 see Micrometals 200C Series Catalog.394 .3 .367/9.500/12.347 1. (714) 970-9400 FAX (714) 970-0400 .690/17.690/17. MICROMETALS Part No.60 4. OD For information on -60.35 MAGNETIC DIMENSIONS A V cm cm2 cm3 4.14 .375/9.7 5. 12.0 71. -61. 17.0 47. 15.2 .6 . ID TYPICAL PART NO.0 60. and 42 see Micrometals RF Catalog.78 .0 59.4 14.23 .0 84.0 79. -66.19 MICROMETALS .250/6.0 82.32 .40 Ht in/mm .0 42.0 39.0 54.370/9.0 31.0 92. 7.33 -8- .0 26.0 71.260/6.795/20.242 1.53 5.495/12.01 .35 5.0 90.495/12.375/9.0 12.52 . 9 .97 .510 .49 .942/23.11 .0 49.0 95.560/14. 4.9 .6 .2 .0 84.0 57.060/26.375/9. ID TYPICAL PART NO.0 70. and 42 see Micrometals RF Catalog.6 6.5 .1 5.570/14.312/7.0 125.92 5.49 .78 .16 .28 .698 3.0 70.92 6.0 AL OD in/mm .0 35. 15.0 85.060/26.0 .28 1. 7.710/18.4 25.0 58.78 -9- MICROMETALS 1.0 67.8 .0 106.312/7.0 17.26 Ht OD in 100th inches Micrometals Mix No.9 .300/33.550/14.0 14.461 3.72 6.570/14.00 TEL.0 91.9 ID in/mm . 3.495/12.942/23.0 49.0 8.575/14.6 1.0 47.858 5. T 106.437/11.0 Ht in/mm .0 42.0 76.5 .55 5.245/31. 6.0 30.0 58.0 10. MICROMETALS Part No.459 . 1.9 .0 57.780/19.57 1.570/14.0 42.0 58.0 40.91 4. -63.1 7. (714) 970-9400 FAX (714) 970-0400 . -70 and -M125 see Micrometals 200C Series Catalog. -66. 17.53 MAGNETIC DIMENSIONS A V cm cm2 cm3 5.0 124.437/11.5 .0 84.395 2.28 .0 67.0 47.0 124.0 93.659 2. OD For information on -60.0 64.0 60.362 2.0 70. 12.0 11.75 8.TOROIDAL CORES COLOR CODE -2 Red/Clear -8 Yellow/Red -14 Black/Red -18 Green/Red -19 Red/Green -26 Yellow/White -30 Green/Gray -34 Gray/Blue -35 Yellow/Gray -40 Green/Yellow -45 Black/Black -52 Green/Blue Refer to page 4 for tolerances.280/7.53 . Letter Indicates Alternate Height Code Area For Other Characteristics / Note: For information on Mix 0.0 91.0 58.5 45.0 13.9 1. 10. -61.0 40.375/9.060/26. T90-8/90 T90-18 T90-19 T90-26 T90-40 T90-45 T90-52 T94-2 T94-8/90 T94-14 T94-18 T94-19 T94-26 T94-40 T94-45 T94-52 T95-26B T95-52B T106-2 T106-8/90 T106-14 T106-18 T106-19 T106-26 T106-30 T106-34 T106-35 T106-40 T106-45 T106-52 T106-18A T106-26A T106-40A T106-52A T106-18B T106-19B T106-26B T106-40B T106-52B T124-26 T130-2 T130-8/90 T130-14 T130-18 T130-19 nH/N2 30.900/22.0 .0 81.49 . 5 43.1 MAGNETIC DIMENSIONS A V cm cm2 cm3 8. 4.0 60.10 - .412/10.72 .9 .26 Ht OD in 100th inches Micrometals Mix No.0 96.0 66.700/17.26 .845/21.0 79.0 41.8 . Letter Indicates Alternate Height Code Area For Other Characteristics / Note: For information on Mix 0.570/39. ID TYPICAL PART NO.96 . 3.TOROIDAL CORES COLOR CODE -2 Red/Clear -8 Yellow/Red -14 Black/Red -18 Green/Red -19 Red/Green -26 Yellow/White -30 Green/Gray -34 Gray/Blue -35 Yellow/Gray -40 Green/Yellow -45 Black/Black -52 Green/Blue Refer to page 4 for tolerances.361 .84 1. -61.640/16.657 1.510/38.5 73.14 .674 6.0 84.1 .437/11.28 7.0 73.0 25.0 95.9 .225/5.5 33.437/11.4 .8 Ht in/mm .0 100.0 78.780/19.300/33.99 6.0 1.0 46. 7.325/8.0 ID in/mm .0 14.300/33.437/11.880/22.38 .5 9. (714) 970-9400 FAX (714) 970-0400 T141-8/90 T141-26 T141-40 T141-52 T150-18 T150-26 T150-40 T150-52 T150-26A T150-45A T157-2 T157-8/90 T157-14 T157-18 T157-19 T157-26 T157-30 T157-34 T157-35 T157-40 T157-45 T157-52 nH/N2 81.300/33. MICROMETALS Part No. -66.0 42.72 .0 52.950/24. 1.0 75. 15.0 33.5 86.5 69.0 105.1 7.0 108. OD For information on -60.5 46.0 83.5 43.0 AL OD in/mm 1.0 17.0 . T 106.698 5.300/33.0 103.570/14.4 1.780/19.0 99.845/21.16 1.510/38.887 8.5 .0 65.5 93.0 116. 6. T130-26 T130-30 T130-34 T130-35 T130-40 T130-45 T130-52 T130-26A T130-40A T131-8/90 T131-18 T131-19 T131-26 T131-34 T131-35 T131-40 T131-52 T132-26 T132-40 T132-52 TEL.1 9.0 31.0 32.38 10.3 .0 79. -70 and -M125 see Micrometals 200C Series Catalog.41 1.885 2. 17.31 MICROMETALS 1.415/35.78 1.805 6.16 10. 12.0 130.1 . and 42 see Micrometals RF Catalog.06 6.8 .0 69.5 . 10. -63.437/11.7 .1 8.5 79.28 .0 89.0 34.0 .5 9.4 . 0 48.550/14.7 .250/31.4 2.8 78.88 21. ID TYPICAL PART NO.0 42. -70 and -M125 see Micrometals 200C Series Catalog.5 120.26 Ht OD in 100th inches Micrometals Mix No.0 70.7 .8 2.11 - MICROMETALS TEL.0 79.0 28.750/44.0 67. (714) 970-9400 FAX (714) 970-0400 .8 .0 24.0 14.000/50. and 42 see Micrometals RF Catalog.0 51. -66.0 72. 4.2 1.0 155. -63.0 224.0 159. T175-2 T175-8/90 T175-18 T175-26 T175-40 T175-52 T184-2 T184-8/90 T184-14 T184-18 T184-19 T184-26 T184-30 T184-34 T184-35 T184-40 T184-52 T200-2 T200-8/90 T200-18 T200-19 T200-26 T200-34 T200-35 T200-40 T200-52 T200-2B T200-8B/90 T200-18B T200-19B T200-26B T200-30B T200-35B T200-40B T200-52B T201-8/90 T201-18 T201-26 T201-40 T201-52 T224-26C T224-52C T225-2 T225-8/90 T225-18 T225-19 nH/N2 15.0 AL OD in/mm 1.0 90.5 ID in/mm 1.0 116.0 1.0 155. 12.0 12.0 92.750/19.5 MAGNETIC DIMENSIONS A V cm cm2 cm3 11.0 42.TOROIDAL CORES COLOR CODE -2 Red/Clear -8 Yellow/Red -14 Black/Red -18 Green/Red -19 Red/Green -26 Yellow/White -30 Green/Gray -34 Gray/Blue -35 Yellow/Gray -40 Green/Yellow -45 Black/Black -52 Green/Blue Refer to page 4 for tolerances.2 2.0 37.2 2.0 155.5 67.0 14.0 37.650/16. 3.1 .000/50.250/31.0 169.2 11. 15.6 2. 6.7 .0 160.81 33.0 104.27 16.5 67.840/46.1 .0 1.250/31.0 74.0 51.0 70.070/27.0 116.1 .0 105.31 1.32 30.8 1.8 .405/35.0 2.0 194.000/25. 1.0 13.34 15.2 1.2 20.0 82.250/57.250/57. T 106.0 164. 10.8 1. 7.42 32.0 105.0 67.0 120. -61. 17.0 11.0 142.8 1.0 12.2 Ht in/mm .4 13.550/14.950/24.0 92.2 1.875/22.0 143.0 2. MICROMETALS Part No.8 1.0 224. OD For information on -60.000/50.950/24.0 21.710/18.0 2. Letter Indicates Alternate Height Code Area For Other Characteristics / Note: For information on Mix 0. 0 37.6 3.0 194.0 142.84 57.000/25.4 19.250/31. Letter Indicates Alternate Height Code Area For Other Characteristics / Note: For information on Mix 0.4 15.7 2. 3.5 1.5 34.0 21.0 58.0 . 10.0 37.0 177.405/35.0 89.7 Ht in/mm .4 37.0 MAGNETIC DIMENSIONS A V cm cm2 cm3 14.500/63.0 11.930/49.4 15.930/49.405/35.0 160.0 113.2 1.500/63.500/12. and 42 see Micrometals RF Catalog.8 28.0 67.0 3.6 2.0 .040/77.0 22.0 242.0 80.0 46. (714) 970-9400 FAX (714) 970-0400 3.42 20.12 - . 4.0 71.0 28.0 242.0 OD in/mm 2.59 37.8 2.5 28.68 33.250/57. 7. -63.5 71. OD For information on -60.7 1. MICROMETALS Part No.2 ID in/mm 1. -70 and -M125 see Micrometals 200C Series Catalog.4 14.5 1. 12.000/25.0 160.550/14. T 106-26 Ht OD in 100th inches Micrometals Mix No.3 2.8 1.0 69.0 80. -61.0 23.0 34.38 67.4 MICROMETALS 3.8 1.250/57.0 155.0 106.0 116. T225-26 T225-30 T225-34 T225-35 T225-40 T225-52 T225-2B T225-14B T225-26B T225-34B T225-52B T249-26 T249-34 T249-52 T250-8/90 T250-14 T250-18 T250-19 T250-26 T250-30 T250-34 T250-40 T250-52 T300-2 T300-8/90 T300-18 T300-19 T300-26 T300-30 T300-34 T300-35 T300-40 T300-52 T300-2D T300-14D T300-18D T300-19D T300-26D T300-30D T300-34D T300-35D T300-40D T300-52D AL nH/N2 98. 17.0 78.36 52.0 160.0 203.405/35.0 58.0 203.7 19.0 116. -66. 6.000/25.7 1.040/77. 15.0 69.000/25.8 3.0 177.0 43.4 TEL.2 1. 1.TOROIDAL CORES COLOR CODE -2 Red/Clear -8 Yellow/Red -14 Black/Red -18 Green/Red -19 Red/Green -26 Yellow/White -30 Green/Gray -34 Gray/Blue -35 Yellow/Gray -40 Green/Yellow -45 Black/Black -52 Green/Blue Refer to page 4 for tolerances. ID TYPICAL PART NO.0 92.0 1.6 1.2 1. 24 173 TEL.0 81. 12.2 Ht in/mm .200/132 3.0 131.1 10.0 5.0 58.000/102 2. 3.650/16.000/102 4.600/40.250/57.0 45.85 133 171 5.0 191. 17.500/165 3.200/132 3.TOROIDAL CORES COLOR CODE -2 Red/Clear -8 Yellow/Red -14 Black/Red -18 Green/Red -19 Red/Green -26 Yellow/White -30 Green/Gray -34 Gray/Blue -35 Yellow/Gray -40 Green/Yellow -45 Black/Black -52 Green/Blue Refer to page 4 for tolerances. MICROMETALS Part No.0 40. 1.9 18.0 60.250/57.0 130. and 42 see Micrometals RF Catalog.0 200.5 MAGNETIC DIMENSIONS A V cm cm2 cm3 25.0 65. OD For information on -60.1 5.3 33.8 39.13 - MICROMETALS .2 1.4 1.0 127.0 65.0 3.0 36.0 AL OD in/mm 4.0 110. 4. 7.2 1. 15.000/25.800/20.0 45.0 25.46 86. 6.080/78.0 110.0 137.0 55. ID TYPICAL PART NO.0 25.0 96.0 149.0 115.0 230.0 191.0 405.080/78.0 90. 10. T400-2* T400-8/90 T400-18 T400-19 T400-26 T400-30 T400-34 T400-35 T400-40 T400-52 T400-26B* T400-2D* T400-14D T400-26D T400-30D T400-34D T400-35D T400-40D T520-2* T520-8/90 T520-26 T520-30 T520-34 T520-35 T520-40 T520-52 T520-30D* T520-34D T520-35D T520-40D T650-2 T650-8/90 T650-26 T650-30 T650-34 T650-35 T650-40 T650-52 nH/N2 18.0 130.5 347 6.0 240.000/102 ID in/mm 2.0 65.0 376. Letter Indicates Alternate Height Code Area For Other Characteristics / Note: For information on Mix 0.6 33.5 262. (714) 970-9400 FAX (714) 970-0400 5.0 434.5 55.9 2.2 .0 20.0 205. -63.000/50.500/88. -66.0 119.250/57. T 106.4 4.35 6.2 2.0 131. -70 and -M125 see Micrometals 200C Series Catalog. Please refer to page 20 for more details .4 734 * T400 and T520 can be provided uncoated by adding the suffix "/18" for use with core covers. -61.26 Ht OD in 100th inches Micrometals Mix No.0 96.300/33. 835/21.835/21.814 1.625/15.525/13.625/15.010/51.4 MICROMETALS TEL.025/26.400/10. ID ST 102 .290/7.475/12.290/7.825/21.240/31.510/13.19 5.3 16.0 .27 .619 .2 .025/26.510/13.280/7.365/9.775/19.01 5.0 .5 Ht in/mm .2 .0 MAGNETIC DIMENSIONS A* V cm cm2 cm3 3. See page 51 for DC energy storage curves.28 12. MICROMETALS Part No.37 6.9 . MATERIAL COMPOSITION Ferrite Core (µ ~ 2300) 33% 25% Micrometals -52 Material (µ = 75) 67% 75% Refer to page 4 for tolerances.010/51.2 .40 13.48 6.31 1.510/13.2 .11 .0 .COMPOSITE CORES COLOR CODE -267 Green -275 Green TYPICAL PART NO.1 2.14 2.48 9. (714) 970-9400 FAX (714) 970-0400 .0 .520/38.0 1.37 5.3 23.7 31. OD -267 -275 Typical Applications: These Ferrite/Iron Powder Composite Cores produce a large change in inductance with DC bias such that 10 to 20 times more inductance will exist at low current than at maximum current.37 .2 75 B Ht OD in 100th inches Code to indicate iron powder mix Indicates percent iron Letter indicates different Ht.600/15.398 .0 13.14 - .835/21.3 .42 .025/26.7 1.83 2.600/15.5 1.189 .1 ID in/mm .240/31.520/38.2 1.510/13.835/21.6 2.6 1.0 1.603 .40 9.0 .9 .81 4.246 . This characteristic is particularly useful for producing DC output chokes for switching power supplies that must maintain continuous operation to very low loads as well as some EMI Filter applications. ST50-267 ST50-275B ST83-267 ST83-275B ST102-267 ST102-275B ST150-267 ST150-275B ST200-267 ST200-275B AL nH/N2 450 475 625 650 800 825 1250 1300 1275 1325 OD in/mm .73 1.786 2.37 . Micrometals "ST" cores are composed of a ferrite and iron powder core and may contain a small gap or parting line between materials.1 .2 .2 1.523 .0 .19 3. 125/3.9 .5 64.455/11.3 4.0 51.182/4.399 .230/5.4 48.0 (US LAM: EI-187) 38.441 .7 .38 .1 33. (714) 970-9400 FAX (714) 970-0400 .8 47.15 - MICROMETALS TEL.5 .0 38.784/19.62 .782/19. -63.26 A / G 015 A G F "A" dimension in 100th inches Micrometals Mix No.76 .312/7.1 .84 .3 .5 .0 38.288 .333 1.500/12.0 1. (Bobbin) E49-8 E49-18 E49-26 E49-52 (PB49) E50-26 E50-52 (No Bobbin Offered) E65-8 E65-26 E65-40 E65-52 (No Bobbin Offered) E75-2 E75-8 E75-26 E75-40 E75-52 (PB75) E80-8 E80-26 E80-52 (PB80) E99-8 E99-26 E99-52 (PB99) E100-2 E100-8 E100-18 E100-26 E100-40 E100-52 (PB100E) E118-26 E118-40 E118-52 (PB118) (Ref.504/12.375/9.5 .287/7.0 (DIN:13/4) 30.06 .403 2.1 .7 29.234 .548 3.182/4.1 .0 (US LAM: EE-28-29) 48.354/8.08 .690/17. -61.8 .0 90.185/30.936 .640/16.4 58.750/19.187/4.0 (DIN: 20/6) 51.437/11.101 .645/16.550/14.001 inches D E CORES ORDERED PER HALF For information on -60.0 .226 .06 .4 96.861 .0 55.575/14.99 .445/11.27 .35 .782/19.750/19.6 .63 .0 1.187/4.0 0.278/7. C E 168 .35 .84 .0 .99 3.29 .505/12.230/5.0 85.18 G in/mm .224 .0 .354/8.252 .278/7.60 1.53 A V W cm cm2 cm3 cm2 2.9 .125/3. -70 and -M125 see Micrometals 200C Series Catalog.75 .0 (DIN: 16/5) 14.250/6.86 .795/20.000/25.471/12.5 .0 1.750/19.149/3.000/25.806 1.0 65.0 96. *E-Core sizes from E49 to E100 do not receive color stripes MICROMETALS Part No.0 56.29 .1 80.75 .0 59.562/14.78 .0 81.635/16. Size) in/mm 20.20 .498 4.2 73.500/12.551 .185/30.0 92.08 .14 .4 .7 6.143 .148/3.1 5. -66.9 7.1 AL nH/N2 C in/mm D in/mm F in/mm .62 .695/17.0 73.E CORES COLOR CODE -2 Red/Clear -8 Yellow/Red -14 Black/Red -18 Green/Red -19 Red/Green -26 Yellow/White -30 Green/Gray -34 Gray/Blue -35 Yellow/Gray -40 Green/Yellow -45 Black/Black -52 Green/Blue B TYPICAL PART NO.08 .93 .0 (DIN: 30/7) MAGNETIC DIMENSIONS A B in/mm .250/6.05 .84 .908 .98 .18 .6 4.287/7.0 (DIN: 25/7) 21.0 (US LAM: EE-24-25) 90.000/25. Letter Indicates Alternate "C" dimension Indicates Center-leg gap per half in .3 3.613 1. Refer to page 4 for tolerances. /.475/12.6 8.378/9.0 170.6 2.0 (US LAM: EI-21) 43.8 .53 1.950/24.210/30.0 134.8 .035/26.0 1.87 E168-52A/G015 161.885/22.26 A / G 015 A G F "A" dimension in 100th inches Micrometals Mix No.3 149.7 10.87 MICROMETALS E168-26/G015 125. (714) 970-9400 FAX (714) 970-0400 E168-2 E168-8 E168-18 E168-26 E168-40 E168-52 (PB168) 1.0 196.0 113.5 1.0 1.787/20.0 1.7 1.590/15.375/9.210/30.5 1.500/12.770/19.70 TEL.2 .342/34.8 97.835/21.50 1.3 8.625/41.0 100.55 E145-18 112.41 1. -61.8 1.125/28.0 (DIN: 42/15) 1.0 179.7 .16 - .7 10.685/42.0 (No Bobbin Available) E162-8 E162-18 E162-26 E162-40 E162-52 (PB162) 1.17 9.4 .6 2.375/9.210/30. -63.660/42.475/12. Letter Indicates Alternate "C" dimension Indicates Center-leg gap per half in . -70 and -M125 see Micrometals 200C Series Catalog.6 1.001 inches D E CORES ORDERED PER HALF For information on -60.425/10.E CORES COLOR CODE -2 Red/Clear -8 Yellow/Red -14 Black/Red -18 Green/Red -19 Red/Green -26 Yellow/White -30 Green/Gray -34 Gray/Blue -35 Yellow/Gray -40 Green/Yellow -45 Black/Black -52 Green/Blue B TYPICAL PART NO.2 ./.89 1.60 . (Bobbin) A (Ref.210/30.0 1. Refer to page 4 for tolerances. MICROMETALS Part No.2 .455/37.210/30.72 1.76mm per set E168-2A E168-8A E168-18A E168-26A E168-40A E168-52A (PB168A) 55.0 131.8 C in/mm D in/mm F in/mm .40 .0 (DIN: 42/20) 1.4 1.60 G in/mm MAGNETIC DIMENSIONS A V W cm cm2 cm3 cm2 7.45 .0 175.8 116.660/42.8 1.2 .81 18.0 E145-52 146. C E 168 .378/9.37 E125-26 E125-40 (No Bobbin Available) E137-2 E137-8 E137-18 E137-26 E137-40 E137-52 (PB137) .7 .76mm per set.5 2.0 AL nH/N2 B in/mm 1.7 Gapped E168A with center gap .1 .255/31.685/42.1 .370/34.425/10.475/12.907 6.0 230.82 1.0 1.0 1.787/20.660/42.0 E168-52/G015 125.9 67.1 . -66.0 E168-40/G015 114.0 1.0 (US LAM: EE-27-38) 32.500/12.0 135.8 113.53 .4 2.0 232.0 E145-26 146.000/25.842/21.210/30.0 195.7 10.61 13.0 1.145/29.0 (US LAM: EI-375) 1.84 105.0 1.030in.41 24.7 .375/34.41 24. .4 7. Size) in/mm 134.922 6.0 199.6 .0 Gapped E168 with center gap .215/30.4 2.030in.0 210.0 163.0 1.685/42.87 .0 1. 001 inches D E CORES ORDERED PER HALF For information on -60.0 325.0 (US LAM: EI-625) 69.0 265.3 1.875/47.745/18. C E 168 .051/77.02mm per set E225-2 E225-8 E225-18 E225-26 E225-40 E225-52 (PB225) 76.0 E220-40/G020 168.745/18.118/53. -61.8 .0 165.180/55.244/31.1 11.140/29.0 1.7 2.9 1.0 2. Letter Indicates Alternate "C" dimension Indicates Center-leg gap per half in .78 E305-26/G050 165.0 275.0 E305-40 255.0 E305-26 287.5 3.0 E305-52 287.49 139 8.0 E220-52/G020 183.2 3.0 E305-18 222.7 2.510/38.100 in. -70 and -M125 see Micrometals 200C Series Catalog.4 213.500/38.10 TEL.552/39.9 1.5 . (Bobbin) A (Ref. -63.933/23.8 .0 262. (714) 970-9400 FAX (714) 970-0400 .250/31.0 Gapped E305 with center gap .0 3.0 (US LAM: EI-75) 3.93 E187-8 E187-18 E187-26 E187-40 E187-52 (PB187) E220-2 E220-8 E220-18 E220-26 E220-30 E220-34 E220-40 E220-52 (PB220) .5 3.865/47.60 47.0 107.620/15.2 .952/24.0 .26 A / G 015 A G F "A" dimension in 100th inches Micrometals Mix No.0 240.7 2.0 136.118/53. Size) in/mm 144.48 23.520/38.0 265.0 (PB305 or PB305/V0) 3.09 E220-26/G020 183.3 .0 325.0 Gapped E220 with center gap .7 1.9 173.0 240.0 240.680/17.0 2.6 13. MICROMETALS Part No.7 4. Refer to page 4 for tolerances.051/77.4 .8 1.0 E305-8 156.240/56.0 E305-52/G050 165.210/56.8 2.0 (DIN: 55/21) AL nH/N2 B in/mm 1.118/53.0 339.0 196.17 - MICROMETALS E305-2 75.5 5. -66.4 C in/mm D in/mm F in/mm G in/mm MAGNETIC DIMENSIONS A V W cm cm2 cm3 cm2 9.118/53.0 E305-34 150.620/15.8 18.7 .6 2.8 18.933/23.3 1.820/20.0 E305-30 124.051/77.0 280.53 2.58 40.E CORES COLOR CODE -2 Red/Clear -8 Yellow/Red -14 Black/Red -18 Green/Red -19 Red/Green -26 Yellow/White -30 Green/Gray -34 Gray/Blue -35 Yellow/Gray -40 Green/Yellow -45 Black/Black -52 Green/Blue B TYPICAL PART NO.933/23.5 7.8 2.10 ./1.0 382.1 143.5 1.0 290.5 1.0 382.6 .040 in./2.54 mm per set E305-8A E305-18A E305-26A E305-30A E305-40A E305-52A (PB305A) 208.62 104 8.051/77. 4 4.250/57.0 235.0 500.8 E305-52A/G050 219.5 1.2 1. Size) in/mm MAGNETIC DIMENSIONS AL nH/N2 A B in/mm C in/mm D in/mm F in/mm G in/mm A V W cm cm2 cm3 cm2 18. Various electrical tapes 4.1 140 12. When a ferrous material is added to this type of magnetic structure the core is essentially “shorted out” decreasing the overall “Q” of the coil.375/34. This decrease in “Q” indicates an increase in core loss which will result in a higher than expected operating temperature.0 (PB450/V0 for double stack) E610-2 E610-26 E610-34 163.500/114 E450-18H 200.688/17. Refer to page 4 for tolerances.49 139 8.7 6.54 mm per set E450-2 E450-8 E450-18 E450-26 E450-30 E450-34 E450-40 E450-52 (PB450/V0) 132.8 1. Phosphor bronze or nonmagnetic stainless steel banding material 2. Cable Tie wraps 5. Brass hardware 3. STRAPPING AND MOUNTING PRECAUTIONS Iron powder as a core material is susceptible to performance changes when wrapped with a ferrous material.2 280 12.051/77.0 4. -66.3 22.0 Gapped E305A with center gap . -63.5 2.26 A / G 015 A G F "A" dimension in 100th inches Micrometals Mix No.0 22.375/34.0 3. -61.7 2.866/47.236/108 1.9 3.2 .9 3.5 3.0 314.244/31.636/92. (714) 970-9400 FAX (714) 970-0400 BANDING. Letter Indicates Alternate "C" dimension Indicates Center-leg gap per half in .10 E305-26A/G050 219.0 480.9 12.250/57.500/114 260.9 2.100 in. C E 168 .102/155 1. This effect will be more significant with the lower permeability materials.118/53.9 6.7 E450-8H 140. Micrometals suggests using the following nonferrous materials to mount and band iron powder cores: 1.5 7.933/23.636/92.102/155 3. (Bobbin) (Ref.0 540.236/108 37.866/47.0 E450-52H 270.120/79.0 4.051/77.120/79.0 (US LAM: EI-30) 3.0 300. Iron powder cores are manufactured with a distributed air gap and occasionally a center leg gap.0 6.6 2. Filled epoxy or filled super glue MICROMETALS .4 .0 588.118/53.4 TEL.4 1.0 400.3 22.18 - . -70 and -M125 see Micrometals 200C Series Catalog.001 inches D E CORES ORDERED PER HALF For information on -60./2.4 4.375/34.5 832 32. MICROMETALS Part No.E CORES COLOR CODE -2 Red/Clear -8 Yellow/Red -14 Black/Red -18 Green/Red -19 Red/Green -26 Yellow/White -30 Green/Gray -34 Gray/Blue -35 Yellow/Gray -40 Green/Yellow -45 Black/Black -52 Green/Blue B TYPICAL PART NO. 05mm per set.6 0.530/38.43 EM126-8 48.8 13.766/19. 2.1 6.6 EM220-26* EM220-40 EM220-26/G020 EM220-40/G020 EM221-8 EM221-40/13 EM221-52 230.1 84.1 1.7 127.000/25.500/38.120 in.3 0.1 2.9 EM145-26 EM145-52 EM150-8 EM150-52 125.4 .90 45.28 13.4 0.0 1. Refer to page 16 and 17 for appropriate "F" Dimensions.1 1./3.0 EM193-40/G060/13 70.140 in.930/49.0 89.700/43.950/24.510/38.800/20.8 1.9 1. EH AND EM CORES ORDERED PER HALF MICROMETALS Part No.676/17.210/56.916/23.915 1.4 Gapped EH220 with center gap.6 13.3 0.0 143.4 0.2 12.3 0. 1.820/20.820/20.6 0.45 1. (714) 970-9400 FAX (714) 970-0400 .3 EM193-8 77.19 29.425/10.780/19.3 1.877/22.0 Gapped EM220 with center gap .0 125.8 1.3 1.19 29.7 1.190/30.9 1.28 7.250/31.7 EM169-8 82.EH/EM CORES TYPICAL PART NO./3.210/56.1 2.26 A / G 015 "A" dimension in 100th inches Micrometals Mix No.570/14.4 0./1.19 - MICROMETALS TEL.56mm per set.250/31.2 0.700/43.500/38.820/20.9 188. Letter Indicates Alternate "C" dimension Indicates Center-leg gap per half in .3 EM169-40/13 148.5 1. Value nH/N2 AL MAGNETIC DIMENSIONS A in/mm B in/mm C in/mm D in/mm E in/mm G in/mm H in/mm cm A cm2 V cm3 EH220-8 EH220-40/13 114.1 0.6 1.800/20.0 EM169-52 151.0 228.780/19. .350/8.00 7.8 1.46 9.79 9.0 2.9 0.02mm per set.0 EM126-52/G040 49.425/10. MICROMETALS Part No.8 1.0 196.3 1.28 27.50 9.080 in.510/38.8 0.8 1. Value nH/N2 AL MAGNETIC DIMENSIONS A in/mm B in/mm C in/mm D in/mm G in/mm H in/mm cm A cm2 V cm3 EM102-8 EM102-52 40.2 1.8 0.7 0.46 0. E 168 .360/34.000/25.200/30.0 EM193-52 168.5 0.040 in.3 0.637 0.7 1.89 1.7 EM126-52 119./2.180/55.1 1.2 2.7 17.200/55.8 1.0 2.1 2.5 Gapped EM193 with center gap .8 1.3 2.500/12.685/42.3 1.520/38.104 in.5 0.0 EM169-40/G052/13 61.760/44.7 8.0 1.22 44.070/27.438/11.204/30.2 191.010/25.0 0.210/56.1 2.1 2.7 0.001 inches Refer to page 4 for tolerances.536/13.580/14.654/42.370/34.520/38.960 4.0 173.930/49.8 13.64mm per set.0 Gapped EM126 with center gap .8 1.180/55.0 Gapped EM169 with center gap .0 63.455/37.520/38.760/44.6 0.750/19.510/38.850/21./2.0 * Center post not completely round on EM220 series.6 1.180/55.8 13. 2.530/38.2 1.90 0.035/26. 1.1 EH220-40/G070/13 76.5 0.780/19.1 2. .4 1.0 0.210/56.7 3.03mm per set.3 1. 8 1.020/.060/1.040/51.) MICROMETALS PART NO.032/.840/21.005 Specified dimensions for reference only.35 .52 .010 Material: 6/6 Nylon PB305.5 1.0 .440/36.6 . (714) 970-9400 FAX (714) 970-0400 TYPICAL PART NO.880/22. (Example: T400-26 is a standard part which includes coating.535/13.845/21.200/55. respectively.275/32.570/14.030/.465/37.635 .35 .68 Flange No.06 .025/.2 1.845/21.3 2.020/51.130/3.5 1.796/20.E CORE BOBBINS TYPICAL PART NO.5 D in/mm .480/37.9 1.425/36.035/.030/102.6 2.050/77.100/27.4 5.8 2.205/5.8 .6 1.6 2.715/18.765/19.5 L in/mm .055/26.3 2.475/12.2 F in/mm .3 .4 .965/24.635 .412/35.050/77.8 2.52 .965/24.544/39.250/6.060/1.813 .740/18.5 3.762 .150/29.865/22.385/9.445/11.920/23.307/7.3 .762 .2 .5 . Micrometals also offers bobbins for the following metric and custom E-core sizes for sample and small quantity orders.250/133.2 .445/11.760/19.040/51.9 TOROIDAL CORE CAPS TEL.305/7. in/mm PB49 PB75 PB100E PB137 PB162 PB168 PB168A PB187 PB220 PB225 PB305 PB305/V0 PB305A PB450/V0 .4 .508 .9 E in/mm .575/14.3 .060/1.055/26.8 1.480/37.2 1.30 . The PB305 and PB305A are composed of 6/6 Nylon Glass Filled.8 1.360/9.3 .130/3.8 1.799/20.385/9.715/18.2 1.3 .265/6.9 1.3 .889 .1 1.5 .305/7.21 .06 .3 .510/13.4 .720/18.142/29.5 .4 .370/34.889 .645/16.6 . P305A 6/6 Nylon Glass Filled Bobbin Notes: All bobbins are composed of 6/6 Nylon material except PB305.5 1.4 .2 2.3 3.330/59.4 .3 2. Core caps will fit either coated or uncoated cores.8 1.5 1.265/6. and PB99.14 .640/16.965/24.157/29.78 .420/10.020/51.645/16.412/35. E80.535/13.8 1.73 .75 .680/17.7 .3 .0 .965/24.78 .020/51.3 .14 . Material type: Rynite FR530 (UL 94V-Ø) UL Yellow Card: #E69578 TC 400 MICROMETALS Thickness Typical Applications: The toroidal core caps can be used as an alternate to the standard insulating coating when winding cores with very heavy gauge wire or when a greater dielectric strength is required.020/51.52 .160/4.7 1.250/6.160/4. OD in/mm ID in/mm Ht in/mm THICKNESS in/mm TC400 TC520 4.765/19.6 .020/51.9 1.575/14.0 1. PB80.030/.225/31. To specify a core that is uncoated add the suffix “/18” to standard part numbers.3 B in/mm .680/17.5 1.965/24.250/6.365/34.80 . E99.490/12.055/26.30 .0 . PB305A and any bobbin with the suffix “/V0”.35 .5 .813 .025/.100/27. MICROMETALS A Part No.6 .250/6. PB 168A Corresponds to E Core Typical Tolerance ± . Ht Corresponds to Toroid OD ID Typical thickness tolerance ± .235/56.4 .8 2.52 .52 .062/77.492/12.7 1.040/51.035/.9 1.640/41.215/30.8 .165/29.060/1.4 2.73 . The “/V0” indicates a material that is rated for UL 94 V0 flame class.4 .2 1.8 3.3 C in/mm . T400-26/18 specifies a standard part without coating.055/26.360/9.115/28.740/18.21 .20 - .544/39. 1 1 1 1 1 2 3 4 2 5 2 2 2 1 2.060/1.066/1.2 G in/mm .925/23. Their part numbers are.060/1.510/13.52 .205/5.570/14.055/26.9 1.0 1.8 .032/.5 .865/22.35 .4 1.1 .75 . BUS BAR CORES COLOR CODE -8 Red -26 Yellow -52 Green TYPICAL PART NO. HS 300 - 26 A / Code To Indicate Max. Current Micrometals Mix No. Letter Indicates Alternate Length Code Area For Other Characteristics Refer to page 4 for tolerances. HS CORES ORDERED PER HALF MICROMETALS Part No. HS300-8 HS300-26 HS300-52 HS300-8A HS300-26A HS300-52A HS300-8B HS300-26B HS300-52B HS300-8C HS300-26C HS300-52C HS400-26 HS400-26A HS400-26B HS400-26C AL* nH/N2 68 147 147 83 179 179 95 208 208 107 232 232 221 286 335 371 A in/mm 1.020/25.9 B in/mm .650/16.5 L in/mm .500/12.7 D in/mm .520/13.2 MAGNETIC DIMENSIONS E A V in/mm cm cm2 cm3 .140/3.56 5.92 .806 4.61 1.020/25.9 .650/16.5 .625/15.9 .520/13.2 .140/3.56 5.92 1.01 5.77 1.020/25.9 .650/16.5 .750/19.1 .520/13.2 .140/3.56 5.92 1.21 6.92 1.020/25.9 .650/16.5 .875/22.2 .520/13.2 .140/3.56 5.92 1.41 8.06 1.500/38.1 .960/24.4 .750/19.1 1.000/25.4 1.250/31.8 1.500/38.1 .765/19.4 .205/5.21 8.71 1.78 2.37 2.96 3.56 15.1 20.1 25.2 30.2 *Based on 25 turn test winding U CORES TYPICAL PART NO. U 80 - 26 A / "A" dim to 1000th inches Micrometals Mix No. Letter Indicates Alternate "C" dim. Code Area For Other Characteristics Refer to page 4 for tolerances. U CORES ORDERED PER HALF MICROMETALS AL Part No. nH/N2 U61-26 U80-8 U80-26 U80-40 U80-52 U350-2 U350-40 71.0 42.4 71.0 64.0 70.0 59.0 235.5 A in/mm .610/15.5 .800/20.3 B in/mm .900/22.9 1.250/31.8 C in/mm E in/mm F in/mm MAGNETIC DIMENSIONS G A V in/mm cm cm2 cm3 5.66 7.87 .315 .403 1.81 3.18 .250/6.35 .510/13.0 .195/4.95 .210/5.33 .250/6.35 .750/19.1 .250/6.35 .300/7.62 3.500/88.9 5.750/146 1.000/25.4 3.250/82.6 1.000/25.4 1.500/38.1 35.6 6.45 250 - 21 - MICROMETALS TEL. (714) 970-9400 FAX (714) 970-0400 POT CORE ASSEMBLIES L OD The Pot Core Assemblies provide a closed-path structure for high current designs where the round winding form and efficient packaging shape are beneficial. The geometry also provides the added flexibility of using lower permeability materials for the hollow core instead of gapping the structure. Typical assemblies are illustrated. This configuration is not available assembled. Order 2 Disks, 1 Hollow Core and 1 sleeve per set. SLEEVE Part No. S101-1002 S101-1040 DISC Part No. D101-1002 D101-1040 HOLLOW CORE AL Part No. nH/N2 H2526-1002 H2526-1040 165.8* 600* OD in/mm 3.150/80.0 L in/mm 2.402/61.0 Window cm2 5.49 cm 15.3 A cm2 12.7 V cm3 204 SLEEVE L OD TYPICAL PART NO. S 101-10 40 ID OD in 100th inches Code area for other characteristics Micrometals Mix No. SLOT Typical Tolerance ± .050 inches SLEEVE Part No. S101-1002 S101-1040 OD in/mm 3.150/80.0 ID in/mm 2.680/68.1 L in/mm 1.615/41.0 Slot in/mm .760/19.3 DISC T1 TYPICAL PART NO. D 101-10 40 OD A OD in 100th inches Code area for other characteristics Micrometals Mix No. CB ID TEL. (714) 970-9400 FAX (714) 970-0400 T2 Typical Tolerance ± .030 inches DISC Part No. D101-1002 D101-1040 OD in/mm 3.150/80.0 CB in/mm 1.614/41.0 ID in/mm .250/6.35 T1 in/mm .394/10.0 T2 in/mm .374/9.50 A in/mm 2.675/67.9 HOLLOW CORE TYPICAL PART NO. MICROMETALS H 25 26 -10 40 ID L ±.030 OD ±.010 OD in 16th inches Length in 16th inches Code area for other characteristics Micrometals Mix No. HOLLOW CORE Part No. H2526-1002 H2526-1040 OD in/mm 1.600/40.6 ID in/mm .250/6.35 L in/mm 1.615/41.0 *AL value is approximate and is for indication only - 22 - BOBBIN ASSEMBLIES Various bobbins can be assembled from the Hollow Cores and Disks shown on the following page. These bobbin assemblies provide an alternative shape for high current choke applications which can tolerate some electro-magnetic radiation. This configuration can be especially effective for high power speaker crossover coils. Typical assemblies are illustrated. This configuration is not available assembled. Order 2 Disks and one Hollow Core per set. OD L DISC Part No. D45-1040 D45-1040 D59-1040 D59-1040 D80-2040 D80-2040 HOLLOW Core Part No. H811-1140 H817-1140 H1015-1040 H1021-1040 H1217-1040 H1225-1040 AL* nH/N2 85 60 100 80 130 95 OD in/mm in/mm 1.420/36.1. 1.420/36.1 1.845/46.9 1.845/46.9 2.500/63.5 2.500/63.5 L in/mm in/mm 937/23.8 1.312/33.3 1.250/31.8 1.625/41.3 1.375/34.9 1.875/47.6 WINDOW in/mm 2 cm 1.84 2.95 3.43 4.90 5.66 8.49 * AL value listed is approximate and is for indication only HOLLOW CORES TYPICAL PART NO. Core outside and inside diameters listed are standard with cariations in length possible upon request. H 10 20-10 40 ID L OD OD in 16th inches Length in 16th inches Code area for other characteristics Micrometals Mix No. Refer to page 4 for tolerances. Note: For information on Mix 1, 3, 4, 6, 7, 10, 12, 15, 17, 42, and 0 see Micrometals RF Catalog MICROMETALS Part. No. H512-1026 H811-1140 H817-1140 H822-1140 H1014-1040 H1015-1040 H1020-1040 H1021-1040 H1217-1040 H1225-1040 H1616-1040 OD in/mm .312/7.95 .500/12.7 .500/12.7 .500/12.7 .625/15.9 .625/15.9 .625/15.9 .625/15.9 .750/19.1 .750/19.1 1.000/25.4 ID in/mm .137/3.48 .172/4.37 .172/4.37 .172/4.34 .219/5.56 .219/5.56 .219/5.56 .219/5.56 .260/6.60 .260/6.60 .250/6.35 Length in/mm .750/19.1 .688/17.5 1.064/27.0 1.375/34.9 .900/22.9 .955/24.3 1.250/31.8 1.330/33.8 1.080/27.4 1.580/40.1 1.000/25.4 DISCS TYPICAL PART NO. OD CB ID OD in 32nd inches Code area for other characteristics Micrometals Mix No. Variations in T are available upon request. Variations in CB possible with a modest tooling charge. Refer to page 4 for tolerances. T MICROMETALS Part No. D45-1040 D59-1040 D80-2040 OD in/mm 1.420/36.1 1.845/46.9 2.500/63.5 CB in/mm .500/12.7 .635/16.1 .755/19.2 ID in/mm .172/4.37 .188/4.78 .255/6.48 T in/mm .156/3.96 .187/4.75 .187/4.75 - 23 - MICROMETALS D 59 -10 40 TEL. (714) 970-9400 FAX (714) 970-0400 750/19.7 .0 32.375/60. 3.53 .500/12.5 26.5 P4876-140 49.1 2.83 .500/12.5 25.250/31.53 .5 33.250/31.0 15.750/19. .313/7.53 .8)( μeff )(rN)2 6r+ 9 + 10b or L(6r + 9 + 10b) (0.250/6. This group of curves was calculated using a cylindrical core with a single layer winding closely wound over 95% of its length.24 - .250/6.0 20.0 20.9 .000/25.500/38.8)( μeff ) μeff (rN)2 9r + 10 or L(9r + 10 ) 1/2 1/2 1 N = r μeff 1 N= r N = Number of turns r = Radius of coil (inches) D = Diameter of core (inches) = Length of coil/core (inches) b = Coil build WHERE: L = Inductance μeff = Effective permeability of core (See graph below) MICROMETALS The family of curves to the left shows how the effective premeability (μeff) of a wound clyindrical core is a function of the core’s wound length to diameter ratio ( /D)as well as the initial material permeability (μeff).5 34.625/15.8 1.500/38.625/15. 7.000/25.255/6.500/12.375/9.5 16.53 .8 1.35 .8 1.8 1.375/9.250/31. and 0 see Micrometals RF Catalog MICROMETALS Part No.7 .7 .5 2. Note: For information on Mix 1.3 2.5 P6464-140 80.750/19. 42.0 OD in/mm . 17.1 1.4 1.000/50.375/9.1 1.0 22. 6. 4.35 .PLAIN CORES Core diameters are standard with variations from listed core lengths possible upon request. 10.000/50.500/12. TYPICAL PART NO.250/31. P816-340 P1224-140 P1624-140 P1632-140 P1640-240 P2032-240 P2040-240 P2432-240 P2440-240 P2448-240 P2456-240 P3240-140 P3248-140 P3256-140 P3264-140 AL* nH/N2 8.250/31.134/3. These curves indicate that in many cases variations in the length/ diameter ratio will more significantly affect the effective permeability than increases in permeability of the core material.190/4.000/25.95 .1 1.8 P4040-140 37.000/25.95 . It is also possible to use as a fair approximation of the effective permeability for multi-layer windings.8 1.1 1. (714) 970-9400 FAX (714) 970-0400 MULTI-LAYER COIL L= (0.1 .4 1.4 1.48 .5 P4048-140 41.4 Length in/mm . 12. P 16 32 -1 40 OD L OD in 64th inches Length in 32nd inches Code area for other characteristics Micrometals Mix No.750/44.5 1.0 16.40 .750/44.375/9. 15.0 12.9 .7 .500/38.7 .8 1.0 * AL is approximate and for reference only CYLINDERICAL CORE APPLICATIONS The inductance and required number of turns for cylindrical shapes such as plain and hollow cores can be closely approximated from the following equations: SINGLE-LAYER COIL L= TEL.313/7.0 25.0 31.500/12. the material begins to saturate. AC Magnetization: The curves at the top of page 27 illustrate the effect of Peak AC Flux Density on percent initial permeability. the data at the highest frequencies was taken with a single turn. The combination of these coefficients will generally result in an increase in inductance with increasing temperature even under biased conditions. These characteristics were measured at room temperature. The cores are manufactured to the AL value rather than to the referenced permeability. The temperature coefficient of initial permeability for each material is listed on page 3. The magnetization curves on pages 26 and 27 have a typical tolerance of +20%. The Cross-Sectional Area (A) for each core is included in the part number listing. -10%. Beyond this level. B-H curves are shown below. As the level of DC magnetizing force increases. A typical coil wound with multiple turns will have a measurable amount of interwinding capacitance which acts in parallel with the coil. These curves are based on a peak AC flux density of 10 gauss (1 mT). The temperature coefficient of percent permeability versus both DC magnetizing force and peak AC flux density ranges from -100 to -400 ppm/ C°. This interwinding capacitance will cause the coil to become self-resonant. The mean magnetic path ( ) for each core is included in the part number listing. This “soft” saturation characteristic results from the distributed air-gap in the iron powder core materials. The formula in the body of the graph is used to calculate the peak AC flux density in gauss. Testing cores at a higher flux density can have a significant effect on measured results. Other configurations such as E Cores and U Cores will produce slightly different results due to the effects of leakage associated with the geometry. As the level of peak AC flux density increases. These curves are the result of tests performed from 60 Hz to 10 kHz. the materials gradually experience a reduction in permeability. Frequency Response: The curves at the bottom of page 27 show how the permeability of each material is affected by frequency. The AL values listed are based on a peak AC flux density of 10 gauss (1 mT). The response to DC magnetizing force is affected by the level of peak AC flux density present. In order to avoid this effect. the materials experience an increase in permeability up to an AC flux density of between 3000 and 6000 gauss.MAGNETIC CHARACTERISTICS INTRODUCTION TO MAGNETIC CHARACTERISTICS General Information: The magnetic characteristics shown on pages 26-36 result from testing toroidal cores. . Since iron powder cores are normally used in inductor applications the magnetization curves provided on page 26 and 27 are in relation to permeability. DC Magnetization: The curves at the bottom of page 26 illustrate the effect of DC Magnetizing force on percent initial permeability for the materials shown. The formula in the body of the graph is used to calculate the DC Magnetizing Force in oersteds. (714) 970-9400 FAX (714) 970-0400 .25 - MICROMETALS TEL. The percent change in permeability is directly proportional to the percent change in AL value. 7958 A/cm * Curve fit formula provided on page 28 .MAGNETIC CHARACTERISTICS H= 0. (714) 970-9400 FAX (714) 970-0400 100 90 Percent Initial Permeability (%µ0) -2 -14 0 10 20 30 40 50 60 70 80 90 100 Percent Saturation 80 70 8/ -1 -1 0 -3 -8 4/-3 35 60 50 40 30 20 10 0 1 MICROMETALS H= 0.4 π NI -4 5 -4 0 9 2 -5 6 -2 H = DC Magnetizing Force (oersteds) N = Number of Turns I = DC Current (ampere) = Mean Magnetic Path Length (cm) 2 5 10 20 50 100 200 350 H-DC Magnetizing Force (oersteds) NOTE: 1 Oe=.26 - .4 π NI H = DC Magnetizing Force (oersteds) N = Number of Turns I = DC Current (ampere) = Mean Magnetic Path Length (cm) Percent Initial Permeability (%µ0) vs DC Magnetizing Force* TEL. (714) 970-9400 FAX (714) 970-0400 -45 .27 - MICROMETALS -18 TEL.MAGNETIC CHARACTIERISTICS Effective Permeability vs Frequency 100 90 80 Effective Permeability -52 -26 -40 -19 70 60 50 40 30 -8 -34 -35 -30 20 10 -14 -2 1 kHz 10 kHz 100 kHz Frequency (hertz) 1 MHz 10 MHz 100 MHz * Curve fit formula provided on page 28 . 7x108 1.99x10-2 -2.0x108 1.2x106 2.7x10-14 1.29 11.82x10-9 2.2 7.0x109 3.3 37.36 3.4 12.5x106 2.71x10-3 Where: %μ0 = Percentage (ie: 90%=90) H = DC Magnetizing Force (oersteds) c d 5.21x10-5 1.9 14.9x10-14 * Curve fit formula valid only for ranges shown on graph.05x10-3 4.3 B1.4 13.0119 .61x10-4 4.0x109 8.0x10-14 1.1x10-13 7.0853 .77x10-4 4.3x108 1.0298 .26x10-3 8.51x10-2 6.26x10-4 1.86x10-6 7.1x108 2.62x10-4 Where: %μ0 = Percentage (ie: 90%=90) B = Peak AC Flux Density (gauss) c 7.4 92.39 12.7 3.0212 .2x10-13 6.01x10-4 7.52x10-4 1.8 45.62x10-5 6.12x10-3 4.0x106 2.1x106 1.8 40.34x10-2 Where: %μ0 = Percentage (ie: 90%=90) B = Peak AC Flux Density (gauss) c d 2.9x10-13 1. .51x10-6 6.29x10-4 -8.2 24.66x10-6 TEL.92x10-4 1.2x107 3.68x10-5 3.0505 .0 b -2.MAGNETIC CHARACTERISTICS PERCENT PERMEABILITY vs DC MAGNETIZING FORCE* .7x108 8.See page 26 FORMULA: %μ0 = ((a+cH+eH2)/(1+bH+dH2))1/2 Material -2 -14 -8 -18/-19 -26 -30 -34/-35 -40 -45 -52 a 10000 10000 10090 9990 10090 10140 10200 10240 10014 10240 b 6.64x10-3 5.45x10-5 9.72x10-6 -3.0x108 3.79x10-3 7.1x109 1.32x10-3 6.6 88.9x109 1.7x106 9.0267 -.See page 27 FORMULA: %μ0 = ((a+cB+eB2)/(1+bB+dB2))1/2 Material -2/-14 -8 -18/-19 -26 -40 a 9970 9990 10270 10600 10480 b 5.30x10-7 1.0x108 1.51x10-9 e -1.18x10-3 -8.43x10-4 -3.3x107 2.0x109 f a + b + c B3 B2.3x107 1.9x106 2.0x108 2.0x10-15 1.1x109 3.58x10-3 -.08 2.77 8.13x10-4 5.0578 -.65 b 3. (714) 970-9400 FAX (714) 970-0400 CORE LOSS vs PEAK AC FLUX DENSITY .70x10-8 -7.1x10-13 1.6x10-14 3.8 d -8.See page 31-36 FORMULA: CL(mW/cm3) = Material -2 -8 ** -14 -18 -19 -26 -30 -34 -35 -40 -45 -52 a 4.5x106 2.1x108 + (d f2 B2) MICROMETALS c 2.74x10-9 -6.3x108 1.0x107 3.75x10-4 e 4.1 -30.7x106 9.4x106 2.2x109 1.68x10-4 5.1x10-14 5.0x109 1.35x10-3 FORMULA: %μ0 = a+bB+cB1/2+dB2 Material -30 -34/-35 -45 -52 a 93.17x10-3 1.80 2.1x10-13 3.0x105 2.0x10-15 5.3 92.56x10-3 -3.0105 PERCENT PERMEABILITY vs PEAK AC FLUX DENSITY* .96x10-8 8.4x107 1.07x10-7 -2.28 - .9x109 4.05 30. ** Revised since last issue.78x10-3 1.36x10-4 5.1x106 d 8.22 5.0x105 2.07x10-3 6. thus lower the operating flux density. resonant inductors in power supplies. It is possible to introduce a discreet air gap into ferrite structures to lower their effective permeability and. eddy current and residual losses in the core material. the following formula is commonly used for a sinewave signal with voltage in rms: . These curves have a typical tolerance of ±15%. In many cases the gap loss will exceed the core loss. Since iron powder cores have a distributed air gap.00. This formula is useful in determining the peak AC flux density (Bpk) to be used with the core loss curves for sinewave applications such as 60 Hz differential-mode line filter inductors. these localized gap losses are essentially eliminated. The relative core loss comparison between materials at other AC flux densities will differ according to each materials response to operating AC flux density. additional turns will be needed to achieve the required inductance. it will reduce the operating AC flux density which will result in lower core loss. This information results from sinewave core loss measurement made on a Clarke-Hesse V-A-W Meter. The greater number of turns on the -2 Material will result in an AC flux density which is about 53% of the -8 Material flux density.CORE LOSS Core losses are a result of an alternating magnetic field in a core material.44 A N f Where: Bpk Erms A N f Peak AC flux density (gauss) RMS AC voltage (volts) Cross-sectional area (cm2) Number of turns frequency (hertz) The factor of 108 is due to the Bpk conversion from tesla to gauss (1 tesla = 104 gauss) and the cross-sectional area (A) conversion from m2 to cm2 (m2 = 104 cm2). The loss generated for a given material is a function of operating frequency and total flux swing (∆B). factor for a square wave is 1. (714) 970-9400 FAX (714) 970-0400 In cgs units. The core losses are due to hysteresis.29 - MICROMETALS TEL. This is typically the case in high frequency resonant inductors. In general. Consequently.36. The formula to calculate the peak AC flux density for an alternating signal based on the average voltage per halfcycle in SI units is: Bpk = Eavg 4ANf In inductor applications where the total losses are dominated by core loss rather than copper loss. However. By utilizing a lower permeability core material (such as -2 Material μ = 10). While additional turns will increase the winding losses. the form factor for a sinewave is 1. a discreet air gap can cause severe localized gap loss problems. consider that an inductor of a given value on -2 Material (μ0 = 10) will require about 87% more turns than an inductor on -8 Material (μ0 = 35). the inductor on the -2 Material will exhibit about 1/4 the core loss of the inductor on the -8 Material. Since the form factor is equal to the rms value divided by the average value for a half-cycle. A Core Loss Comparison Table is shown on page 1. The core loss in milliwatts per cubic centimeter (mW/cm3) as a function of peak AC flux density in gauss is shown for various frequencies. Core loss curves for each material are shown on pages 31. the -2 and -14 Material is recommended for resonant inductor applications. and for the fundamental line frequency signal in power factor correction chokes.44 is due to the form factor of a sinewave. Under this condition. This is particularly true at frequencies above 100 kHz. To illustrate the core loss benefit of a lower permeability material. the core experiences a total peak to peak AC flux density swing (DB) that is twice the value of peak AC flux density (Bpk) calculated with the above formulas as illustrated: Where: Bpk Eavg A N f Peak AC flux density (tesla) Average AC voltage per half-cycle (volts) Cross-sectional area (m2) Number of turns frequency (hertz) Bpk = Erms 108 4. This table provides a quick comparison of core loss in mW/ cm3 at various frequencies for a given AC flux density for each material. The change in constant from 4 to 4. The form . an overall improvement in performance can be achieved by using a lower permeability core material.11 (π/(2√2). . The following diagram describes a typical squarewave voltage across an inductor in a switching power supply: MICROMETALS Since the volt-seconds (Et) during the “on” and “off” portion of a period must be equal in the steady state. the core loss curves provided assume Bpk = ∆B/2. (714) 970-9400 FAX (714) 970-0400 Epk t 108 2AN L ∆I 108 = 2AN Core loss measurements made at the same frequency and total flux density swing (∆B) produce only slightly higher core loss for squarewaves than for sinewaves. Therefore.CORE LOSS One of the most common applications for iron powder cores in switching power supplies is DC output chokes. The following formulas should be used to calculate the value of peak AC flux density to be used with the core loss graphs on pages 31-36 to determine the high frequency core loss in iron powder cores for a variety of DC biased inductor applications: In cgs units: Bpk = TEL. Rather. the high frequency signal (typically 100 kHz) is such that both the peak voltage across the inductor (E) and the “on” time (t) are constantly changing throughout the period of the fundamental line frequency (50 or 60 Hz). the preceding formulas which describe the total peak to peak flux density need to be used to verify operation within the maximum flux density limit of the core material to avoid magnetic saturation. since it is industry practice to show core loss as a function of peak AC flux density with symmetrical operation about zero. the coil is biased with DC current along with a smaller percentage of ripple current which results from a squarewave voltage. The core loss in this case will be the time-averaged core loss of the individual pulses for the period of the line frequency. Please refer to pages 58 and 59 for information on the interpretation of core loss in active PFC inductors. The DC current generates a DC flux density and the squarewave voltage produces an alternating (AC) flux density. In this application. However.30 - . This condition is illustrated: Another representation of this formula which can also be useful for these applications in cgs units is: L ∆I 108 ∆B = AN Where: ∆B L ∆I A N Peak to Peak flux density (gauss) Inductance (Henries) Peak to Peak ripple current (amps) Cross-sectional area (cm2) Number of turns In unipolar applications such as flybacks. It is only the alternating flux density (∆B) that generates core loss. core loss is determined from the graphs by using one-half of the peak to peak flux density at the frequency of the total period where f = 1/tp. the peak to peak flux density for a squarewave (which is not necessarily symmetric) is described by the following formula in cgs units: ∆B = Where: ∆B Epk t A N Epk t 108 AN Peak to Peak flux density (gauss) Peak voltage across coil during “t” (volts) Time of applied voltage (seconds) Cross-sectional area (cm2) Number of turns Where: Bpk Epk t L ∆I A N Peak AC flux density (gauss) Peak voltage across coil during “t” (volts) Time of applied voltage (seconds) Inductance (Henries) Peak to peak ripple current (amps) Cross-sectional area (cm2) Number of turns Inductors in active power factor correction boost topologies do not have the simple steady state waveform presented before. Biasing a magnetic material with DC current will shift the minor alternating BH loop but will not have a noticeable effect on the core loss. 31 - MICROMETALS kH z 250 kH z 100 kH z 50k Hz 25k Hz 10k Hz 5kH z Hz 40 0H z 500 1kH z 1M 60 Hz TEL. (714) 970-9400 FAX (714) 970-0400 2000 1kH 500 Hz z . .Peak AC Flux Density (gauss) 500 1000 2000 5000 NOTE: 1 tesla = 10.000 50 10.000 gauss 10.000 * Revised since last issue.000 5000 Core Loss* vs Peak AC Flux Density -8 Material μo=35 1000 Core Loss (mW/cm3) 500 200 100 50 20 10 20 50 100 200 Bpk .CORE LOSS 10.Peak AC Flux Density (gauss) 500 1000 2000 5000 NOTE: 1 tesla = 10.5 40 20 10 20 50 100 200 Bpk .000 5000 Core Loss vs Peak AC Flux Density -2 Material μo=10 2000 1000 Core Loss (mW/cm3) 500 200 100 MH z kH z 250 kH z 100 kH z 50k Hz 25k Hz 10k Hz 5kH z 1M Hz 0H z 2.000 gauss 60 10. Peak AC Flux Density (gauss) 500 1000 2000 5000 NOTE: 1 tesla = 10.5 20 10 20 50 100 200 Bpk .CORE LOSS 10.000 10. (714) 970-9400 FAX (714) 970-0400 1000 Core Loss (mW/cm3) 500 200 MICROMETALS 100 z z kH kH kH z Hz Hz Hz Hz 250 500 1kH z 5kH 100 20 10 20 50 100 200 Bpk .Peak AC Flux Density (gauss) 500 1000 2000 5000 NOTE: 1 tesla = 10.000 5000 -14 Material Core Loss vs Peak AC Flux Density μo=14 2000 1000 Core Loss (mW/cm3) 500 200 100 MH z kH z z 1M Hz z 100 kH 250 kH Hz Hz Hz 5kH z 0H z 10k 2.000 500 50k 25k z .000 gauss 60 50 25k 40 0 50k 10k Hz z .000 5000 -18 Material Core Loss vs Peak AC Flux Density μo=55 2000 TEL.32 - 60 Hz 10.000 gauss 40 50 1kH 10. 000 50 10.Peak AC Flux Density (gauss) 500 1000 2000 5000 NOTE: 1 tesla = 10.000 5000 -19 Material Core Loss vs Peak AC Flux Density μo=55 2000 1000 Core Loss (mW/cm3) 500 200 100 kH z z 250 kH kH z Hz Hz 5kH z Hz 0H z 500 40 20 10 20 50 100 200 Bpk .CORE LOSS 10.000 .000 5000 -26 Material Core Loss vs Peak AC Flux Density μo=75 1000 Core Loss (mW/cm3) 500 200 100 40 20 10 20 50 100 200 Bpk . (714) 970-9400 FAX (714) 970-0400 2000 50k 1kH z 100 25k 10k Hz .000 gauss 60 10.33 - MICROMETALS z z kH kH kH z z Hz 5kH z 25k H 0H z Hz 500 250 50k 1kH z 100 10k Hz TEL.Peak AC Flux Density (gauss) 500 1000 2000 5000 NOTE: 1 tesla = 10.000 gauss 60 50 10. 000 50 10. (714) 970-9400 FAX (714) 970-0400 2000 1000 Core Loss (mW/cm3) 500 200 MICROMETALS 100 100 kH z 50k Hz 25k Hz z kH z kH 50k z 1kH 100 25k 10k 10k H 0H z z 500 20 10 20 50 100 200 Bpk .CORE LOSS 10.000 gauss 60 10.000 gauss 40 50 250 60 Hz 10.000 5000 -34 Material Core Loss vs Peak AC Flux Density μo=33 TEL.000 5000 -30 Material Core Loss vs Peak AC Flux Density μo=22 2000 1000 Core Loss (mW/cm3) 500 200 100 kH z z 250 kH kH z Hz Hz 0H z Hz z 5kH 500 40 20 10 20 50 100 200 Bpk .000 .Peak AC Flux Density (gauss) 500 1000 2000 5000 NOTE: 1 tesla = 10.34 - 1kH z 5kH Hz z .Peak AC Flux Density (gauss) 500 1000 2000 5000 NOTE: 1 tesla = 10. 000 5000 -40 Material Core Loss vs Peak AC Flux Density μo=60 1000 Core Loss (mW/cm3) 500 200 100 20 10 20 50 100 200 Bpk .000 gauss 40 50 10.000 5kH 10.Peak AC Flux Density (gauss) 500 1000 2000 5000 NOTE: 1 tesla = 10.Peak AC Flux Density (gauss) 500 1000 2000 5000 NOTE: 1 tesla = 10.000 5000 -35 Material Core Loss vs Peak AC Flux Density μo=33 2000 1000 Core Loss (mW/cm3) 500 200 100 kH z z 250 kH kH z Hz Hz Hz 0H z z 500 20 10 20 50 100 200 Bpk . (714) 970-9400 FAX (714) 970-0400 2000 1kH 100 25k 10k z .CORE LOSS 10.35 - MICROMETALS z z kH kH kH z 25k Hz z 10k H 0H z Hz z 500 250 50k 60 Hz 5kH 1kH 100 z TEL.000 .000 gauss 40 50 50k 60 Hz 10. 000 50 10.000 5000 -52 Material Core Loss vs Peak AC Flux Density μo=75 TEL.000 5000 -45 Material Core Loss vs Peak AC Flux Density μo=100 2000 1000 Core Loss (mW/cm3) 500 200 100 z kH z 100 kH kH z Hz 25k Hz z 10k H 0H z z 5kH 500 250 40 20 10 20 50 100 200 Bpk . (714) 970-9400 FAX (714) 970-0400 2000 1000 Core Loss (mW/cm3) 500 200 MICROMETALS 100 z kH z 100 kH kH z Hz 25k Hz 50k z 1kH 10k H 0H z z 5kH 500 250 40 20 10 20 50 100 200 Bpk .Peak AC Flux Density (gauss) 500 1000 2000 5000 NOTE: 1 tesla = 10.Peak AC Flux Density (gauss) 500 1000 2000 5000 NOTE: 1 tesla = 10.CORE LOSS 10.36 - 1kH Hz z Hz z .000 gauss 60 10.000 50 50k .000 gauss 60 10. 2) Design of Controlled Swing inductors where the inductance does not exceed a maximum value at reduced current. The software is a DOS based program with a file size of 320 kB and is available at no charge. 4) Required Number of Turns.000 piece quantity Please contact the factory for technical support. . peak voltage.) 3) Design of Wide Swing inductors where the inductance at low current is typically 5 to 20 times higher than the inductance at maximum DC current.5 inches each The program will automatically calculate the smallest core size possible that will meet the specified needs and will display. output voltage. This application utilizes a ferrite/iron powder composite core as described on page 14 4) Design of Active Power Factor Boost or buck inductors. (714) 970-9400 FAX (714) 970-0400 . The wound dimensions and weight of the copper wire can also be displayed. An important new feature of the YEAR 2000 revision is that predicted changes in core temperature versus time and temperature can be graphically displayed for the designs. 7) Analyze a design of an inductor based on user defined parameters.CORE LOSS IRON POWDER CORE INDUCTOR DESIGN SOFTWARE Micrometals Inductor Design Software is a flexible user-friendly tool designed to supplement this catalog in the selection of iron powder cores for a variety of power conversion and line filter applications. 7) DC Winding Resistance. 9) Percent Initial Permeability. A single-layer or full winding can be specified.000 C° mW/sq-cm 0. dc resistance. commonly referred to as PFC chokes. The user can select the preferred core geometry (i.micrometals.37 - MICROMETALS TEL. 1) Micrometals Part Number. 5) Design of Power Line Frequency Inductors for differential-mode filtering using toroidal cores. 6) Design of a Resonant Converter Inductor where the current is sinusoidal with no DC bias. 11) Copper Loss. The software allows the design engineer to quickly work up multiple design solutions based on user specified electrical requirements and be easily printed for hard copies. Copies of the disk can be obtained from the factory or through any of our sales representatives. and frequency. 6) Percent Window Fill. but is otherwise similar to 1. The use of pop-up menus and the ability to scroll backwards through the design solutions greatly enhances this revision. The following are definitions of the units utilized by the design software: Unit AL Price RDC HDC P FE P CU T Rise Description Inductance Rating US Dollars DC Resistance Magnetizing Force Core Loss Copper Loss Temperature Rise Defined nH/N2 Approx. Toroid. 2) Approximate unit price. The graph will display projected core temperature change out 100. The software can also be down loaded from the Micrometals website at www. 8) Display Micrometals Catalog 9) Wire Table The design portion of the software accepts typical inputs such as required inductance. The main menu for the YEAR 2000 revision contains the following selections: 1) DC Biased Inductors Design where the inductor must meet a given inductance at a DC current level with ripple conditions defined by voltage and frequency. 8) DC Magnetizing Force. and 12) Temperature Rise.e. Micrometals will gladly provide sample cores to assist in your evaluation. 10) Core Loss. dc bias current. There are pre-set Design Constants and Limits which can be changed by the user. E-Core or Ferrite/Iron Powder Composite) and select specific core materials or all materials.com.000 hours..Value* ohms oersteds watts watts celsius degrees *Approximate value at 5. 3) Core AL Value.000 dimensionless 1. 5) Wire Size. This feature will allow the design engineer to see if the design is capable of meeting a minimum life expectancy. These parameters and their pre-set values follow: Measurement Units System Wire Gage Standard Ambient Temperature Maximum Temperature Rise Minimum Copper Density Maximum Window Fill Factor Minimum % Perm Under DC Bias Wire Resistivity Adjust Factor Temp Rise Factor Temp Rise Characteristic Exponent Lead Length Allowance Mixed English American AWG 25 °C 40 C° 150 cir-mils/Amp 40 percent 40 percent 1.833 dimensionless 2. material type and core manufacturer. It is much easier to remove heat from a copper loss dominated design than a core loss dominated design. This design utilizes a core that can not safely dissipate the high level of core loss even with the benefit of forced air.36 W for a MICROMETALS The upper curve in Figure 1 illustrates how quickly the projected core loss increases due to the excessive operating temperature. The first example will illustrate what happens in a design that is dominated by core loss and uses an undersized core. the inductor can be several degrees hotter on the inside of the core and in the “shadow of the air flow". These temperatures are much too hot for a core operating under these conditions where eddy current losses are a significant portion of the total loss. Pages 64 and 65 show the “Total Power Dissipation (W) Vs Temperature Rise” for various sized Micrometals cores. It should be obvious the surface area of this design is much too small to safely dissipate the excessive core loss in spite air flow.72 W of copper loss. (714) 970-9400 FAX (714) 970-0400 temperature rise of 95C°in free standing air. All iron powder cores. The peak AC flux density is 670 G at 80 kHz produces a core loss of 4. While the copper loss will decrease at lower power levels. core volume and shape. Caution. the 4. The core selected is part number T106-52 wound with 14 turns of AWG-14 resulting in 1. The parameters are as follows: TEL. a warning flag should go up on a design that is core loss dominated and depends on the use of air flow to reduce the temperature particularly if it uses a variable speed fan. The middle curve in Figure 1 illustrates the smallest physical core size that meets the design requirements and has a temperature rise of less than 40C°.59 W for a 40C°temperature rise. L = 11. These tables are useful to quickly determine if the design is capable of meeting a 40C°or less temperature rise. It is the eddy current portion of the core loss which is affected by high temperature thermal aging.9 W nominal can be 5. It should be noted that the core loss tolerances for Micrometals cores are +/-15%. peak ac flux density.CORE LOSS CORE LOSS INCREASE DUE TO THERMAL AGING The following discussion and examples illustrate the phenomenon of thermal aging and detail the variables and conditions that effect a change in core loss characteristics. Eddy current loss will be the dominant loss at higher frequencies while hysteresis loss will be the dominate loss at lower frequencies. this is generally not the case with core loss.9 W. operating frequency. time. ambient temperature and air flow.64 W resulting in a total loss of 7. Under worst case core loss conditions.38 - . are susceptible to permanent increases in core loss when exposed to elevated temperatures for extended periods of time. Thermal aging is an irreversible increase in core loss as a result of prolonged exposure to elevated temperatures.3 V The maximum ambient temperature is 60°C with forced air cooling supplied by a variable speed fan that provides less air flow at lower power levels. The combined loss is 6.62 W which calculates to a temperature rise of approximately 83C°in free standing air. The contribution of each form of loss to the total is also affected by the operating flux density. regardless of the manufacturer. It is important for the design engineer to understand the conditions under which thermal aging can occur and incorporate this knowledge into their standard design process. The copper winding radiates the heat while the core material has a thermal impedance barrier that must first be overcome. Additionally.5 μH Idc = 18 A E pk = 45 V E dc = 12. The first design example is for a buck inductor operating at 80 kHz. This core is part . The T106 size core can safely dissipate a total of 2. Since the maximum ambient temperature specified for this part is 60°C the inductor can easily reach 140°C without the benefit of forced air. The extent of these changes and realized effect on the wound core are a function of the following variables. Variable speed fans should not be used with core loss dominated designs. 9 18. After 100.35 W is the same as the 60 Hz example.5 W.324 3. the combined loss of 14. The next design examples will illustrate differences using a much larger core size.3 V.000 hours at 125°C. The calculated core loss is about 7. The upper curve in Figure 2 shows how quickly the core loss increases in a design operating at 40 kHz with a peak AC flux density of 283 G.5 9. the latest version of Micrometals design software includes a PFC core loss application. the eddy current losses are now dominant and increase with constant exposure to 125°C. 10 kG on Micrometals part number T300-26D. After 20.5 W. This design will safely operate at 100°C total temperature for more than 100.23 <12.000 MICROMETALS . the core loss has increased to 12. The combined core and copper losses are 2. Assuming the copper loss is 7.7 W resulting in a temperature rise of 33C°at time zero. While the total core loss of 7.7 x 1.000. Another popular application for iron powder cores is power factor correction boost chokes.35 W.5 2.7 1. (714) 970-9400 FAX (714) 970-0400 Solution #1 Part Number AL (nH/N2) Turns AWG# Bpk @ 100 kHz (G) Core Loss (mW/cm3) Core Volume (cm3) Core Loss (mW) Copper Loss (mW) Total Loss (mW) Wound Surface Area (cm2) Maximum Size (in) T (C°) Approx. The first design is operating at 60Hz. For a detailed discussion of proper core loss analysis for PFC boost chokes refer to page 58 of this catalog. This design example is not an extreme case but illustrates how the temperature rise of the inductor continues to increase as a function of time and temperature.000 hours the core loss has increased to 9.35 W and assuming a copper loss of 7. The lower curve in Figure 2 predicts that the core loss does not change even after 100. The peak AC flux density has been reduced to 465 G at 80 kHz decreasing the core loss to 2.0 18.0 W. TEL.461 66. operating at two differing frequencies and peak AC flux densities.35 W.040 66.000 hours at 125°C. This can be a very demanding application where core loss calculation is more complex and often misunderstood.000 Table 1 . the total loss of this design is 14. Almost all of the core loss at this frequency is hysteresis loss and is unaffected at this temperature. Core Cost (per piece) Thermal Life (Hours) E168-52 179 45 14 389 495.7 1.000 hours.000 hours.700 66.7 W results in a 33C° temperature rise.55 >10. Also.137 2.000.5 18.5 W and the temperature rise now reaches 37C°.7 65 $0.7 x 1.220 3.7 x 1.39 - Solution #2 E168-52 179 90 17 195 120.23 ~1.000 Solution #3 E168-2 44 76 16 230 61.7 27 $0.CORE LOSS number T130-8/90 wound with 19 turns of AWG-10 for a copper loss of about 1.7 41 $0. The lower curve of Figure 1 shows part number T10652 used under similar conditions to the first design except now the dc output voltage is 5 V instead of 12.480 5.5 1.7 1. With 14 turns of AWG-12 wire.174 866 10.0 W. This can lead to poor designs that will have reliability problems. the peak AC flux density has decreased to 305 G and core loss to 1. pushing the temperature rise to 42C°.04 W for a temperature rise of 33C°. The graph predicts this design will safely operate at 100°C total temperature well past 100. It is also very important to regulate the supply chain and monitor that subsuppliers are not making any unknown core substitutions.000 hours. Solution #3 illustrates how the Micrometals 10μo (-2 Material) performs.17 watts of core loss with only 0. While it may seem obvious that solution #1 is a poor design. a lower operating temperature (∆T=41C°). Clearly. MICROMETALS TEL. in other words. The Micrometals core will safely operate for 300. This is also true with different manufacturers of core materials.87 watts of copper loss. Again. This results in a temperature rise of 65C°.000 hours whereas the competitor will runaway in less than 30. This results in improved efficiency (saving 4. and a dramatic improvement in thermal life (almost 2 orders of magnitude). As the example above demonstrate. you can see that design Solution #1 is a design that is dominated by 9. the core and copper losses can also be better balance by selecting a lower permeability material. If the higher inductance produced by adding turns in solution #2 is unacceptable in the circuit. Less obvious is the variation of initial core operating temperatures between the Micrometals and competitor cores. but this material type is more expensive than the –52 Material option. the ambient temperature for the Micrometals winding was increased to 60 °C to match the initial core operating temperature of the competitor. In another example. the term “equivalent core” is solely based on dimensional and permeability characteristics. this part will have thermal runaway in less than 2 years. Solution #2 demonstrates that with the same core.40 - . this is a fairly common mistake. In many cases. beware of “equivalent” iron powder cores.CORE LOSS The third design example is a PFC boost choke operating at 100 kHz with the following requirements: Lmin = 250 μH Idc = 7 A Epk In = 120V Edc Out = 400V Referring to Table 1. As demonstrated above.3 watts). The competitors increased initial core temperature is a result of higher core losses. This choke will be the most efficient and reliable. by simply increasing the number of turns with the required smaller wire size. the core and copper losses will become more balanced. Figure 4 illustrates the thermal aging characteristic of Micrometals T90-26 at 75kHz with 633G as well as the same winding on an “equivalent” competitor. the predicted difference in thermal life is dramatic. different materials will thermally age at different rates. Figure 3 indicates that with an ambient of 55°C. (714) 970-9400 FAX (714) 970-0400 . evaluating one manufacturers core and substituting another at a later time can be a critical error. Another important thermal aging consideration is the source of the iron powder cores. both cores are thermally aging at different rates. and 40 C° temperature rise in freestanding air.) For single-layer windings on toroidal cores. is the primary limiting factor in inductor design. the only heat generated results from the resistive winding (copper) losses. DC inductors.DESIGN SOFTWARE The design software described on the previous page is an extremely useful tool for selecting Micrometals iron powder cores for DC applications and compliments the energy storage curves provided here. Under this condition. These ampere-turn constants are included in the full windig table. Energy storage is proportional to the flux density squared divided by the effective premeability of the structure. (DC flux does not have a noticeable effect on core loss. -30. Micrometals Energy Storage Curves are presented for a number of core sizes in each material (except -2 Material due to its low permeability) to assist in the design of such inductors. 2. -40. 2. fall into one of 3 basic categories: 1. -40 and -52 Materials are generally recommended for designs concerned with minimum inductance because they ar the most cost effective. These materials have higher permeability and can produce a 2:1 swing (50% saturation point).57 for additional information. Those specifically designed to have greater inductance. -34 and -35 Materials ( or a gapped E Core.36.41 - MICROMETALS TEL. (page 65) In the case of full windings. the current handling capability of a given wire size is no longer independent of core size. However. and percent saturation (100% -% initial permeability) at the bottom portion of each page. aside from saturation. The -26. energy storage fo an inductor is described: Energy = 1/2 LI2 Microjoules (μJ) Microhenries (μH) Amperes (a) is present. B2 Energy ~ μ effective The introduction of a discreet air gap significantly lowers the effective permeability of core structures made from ferrites and iron alloys. under minimum load conditions (swing). Those specifically designed to maintain a relatively constant inductance from zero to full-rated load. The -8. the current handling capability of a wire size as a function of temperature rise is relatively independent of core size. the cores will produce higher inductance due to the AC magnetization characteristics shown at the top of page 27. 3. (714) 970-9400 FAX (714) 970-0400 . most commonly. 25 C°. The importance of the swing of the inductor must be determined before the appropriate core material can be selected. 1. The -8 . for any particular core size. see pags 54-55) should be considered if the inductor must maintain a relatively constant inductance from minimum to full-rated current. These curves are shown a both in terms of ampere-turns (NI) at the top portion of each page. This will typically represent a ripple current of less than 1%. -18 and -52 Materials should be considered for DC shokes operating above 100kHz due to their lower core loss characteristics at high frequency. a single-layer winding table has been developed giving current ratings for temperature rises of 0 C°. 25 C°. an ampere-turn rating for a given temperature rise does become a constant. Under this condition. The amount of energy stored is a function of inductance and current. -18. this temerature rise is a result of copper loss in the winding. Refer to page 57 for design examples using the Energy Storage Curves. (page 64) For full windings (45% toroid inside diameter remaining) a similar table has been developed. and 40 C° temperature rise (in free-standing air) resulting from winding losses are shown on each graph. Making use of this. In this application the core must support a significant DC current while maintaining an inductance adequate to filter high frequency signals. -45 and -52 materials should be considered if the inductor should “swing” (increase in inductance as current decreases) a moderate amount. When significantly greater AC or ripple flux density . The curves shown on pages 42-51 are based on a peak AC flux density of 10 gauss (1 mT). In the case of DC inductors with very low level AC ripple. This increases the energy storage capabilities of the core by allowing additional energy to be stored in the gap. Specifically. the high frequency core losses must also be taken into account as described on pages 29 . The energy storage limits for 10 C°. Refer to pages 56 . The temperature rise of the wound unit. These materials are able to store high energy with a minimum of staturation. DC energy storage inductors are an ideal application for Micrometals iron powder cores. 3. Those simply requireing a minimum inductance. The -26. 42 - .MICROMETALS TEL. (714) 970-9400 FAX (714) 970-0400 DC APPLICATIONS . . (714) 970-9400 FAX (714) 970-0400 .43 - DC APPLICATIONS MICROMETALS TEL. MICROMETALS TEL. (714) 970-9400 FAX (714) 970-0400 DC APPLICATIONS .44 - . (714) 970-9400 FAX (714) 970-0400 .45 - DC APPLICATIONS MICROMETALS TEL.. (714) 970-9400 FAX (714) 970-0400 -34 Material MICROMETALS .DC APPLICATIONS -34 Material VALUES FOR -34 MATERIAL TEL.46 - . DC APPLICATIONS -35 Material VALUES FOR -35 MATERIAL -35 Material . (714) 970-9400 FAX (714) 970-0400 .47 - MICROMETALS TEL. MICROMETALS TEL.48 - . (714) 970-9400 FAX (714) 970-0400 DC APPLICATIONS . (714) 970-9400 FAX (714) 970-0400 .49 - DC APPLICATIONS MICROMETALS TEL.. (714) 970-9400 FAX (714) 970-0400 DC APPLICATIONS .50 - .MICROMETALS TEL. . (714) 970-9400 FAX (714) 970-0400 .51 - DC APPLICATIONS MICROMETALS TEL. The Energy Storage Table on page 38 indicates that the T94 size toroid is the smallest core able to meet the energy storage requirements at < 40C° temperature rise.5 = 29 turns In the case of the E137 core. refer to the winding table on page 60. This table indicates that #16 wire should be used. -52 and -40 Materials should be considered since the inductor requirements do not limit swing and these materials are the most cost effective. This table shows that #7 wire will fit in a single layer and result in a 25C° temperature rise from the wire. refer to the Single Layer Winding Table on page 60. Therefore.75 amps DC 60 μH max at 0 amps DC (25% saturation max) (< 1% ripple current) Determine importance of the following design considerations: component size. Example #1: Design Priorities cost temperature rise component size Example #2: Design Priorities component size temperature rise cost Select appropriate materials to be considered.0) (. 1/ 2 Calculate the required Energy Storage (1/2 LI2) LI2 = (1/2) (45) (7.5)2 = 1266 μJ Select core size and shape -26 Material will be used in this example.5 = 22 turns N= = 46 turns MICROMETALS Determine In the case of the T106 toroidal core. (714) 970-9400 FAX (714) 970-0400 Therefore. Solution: Part number T94-8/90 with 46 turns #16 . Solution: T106-26 with 29 turns #17 or E137-26 with 22 turns #14 wire size Since a “full” winding was required to keep the temperature rise of the T94 below 40C°. -8.5)2 = 1266 μJ 1/ 2 LI2 = (1/2) (45) (7. -26. -28 and -33 Materials should be considered because of the limited swing requirements. This table also contains the information necessary to calculate the DC resistance of a winding. The -8 Material is the best choice since component size is the primary concern. Refer to the Energy Storage Table on page 40.5% of initial permeability (15. The T106 size toroid will be selected in order to keep the winding “simple” and the temerature rise around 25C°. In the case of the E137. We must also check the % saturation curves (page 38 bottom) to verify that this core will be operating at less than 25% saturation. -18. the “simple” winding limits are close estimates of typical single layer windings. NI = 162 / 7. temperature rise and cost. the curves indicate that 162 ampere-turns will be required to provide 1266 μJ. NI = 162 / 7. The E137 is an attractive choice if bobbin winding is preferred. Use the following formula to calculate turns: N= desired L (nH) (AL) (%μo) 45. TEL. referring to the Full Winding Table on page 61 indicates that up to #13 wire can be used.000 (25.52 - .85) 1/2 1/2 Determine number of turns The curve at the top of page 40 indicates the T106 will require 217 ampere-turns to produce 1266 μJ. The curves at the bottom of page 38 indicate that the T94 will be operating at 84.DC APPLICATIONS DC INDUCTOR DESIGN EXAMPLES EXAMPLE #1 Requirements: 45 μH at 7.75 amps DC (< 1% ripple current) EXAMPLE #2 Requirements: 45 μH at 7.5% saturation) to produce 1266 μJ. 2 μH 10 turns 3.960 μH 172 turns 108 turns T184-52 1.6 μH 39.760 μH 591 μH 67 turns 332 μH 59 turns 195 μH 41 turns 102 μH 31 turns 270 turns T400-52 26.0 μH 8 turns 303 turns * Based on max temperature rise of 40Co due to copper and core loss MICROMETALS TEL.0 μH 32 turns 2.3 μH 36 turns 27 turns 21 turns 5.100 μH 160 turns 157 turns 5.8 μH 59 turns T68-52A 224 μH 72 turns 250 μH 13.5 amps 10 amps 15 amps 1.0 μH 8.0 amps 7.4 μH 15 turns 5.0 μH 6 turns 212 turns DC APPLICATIONS E220-52 11.5 μH 23 turns 204 turns .420 μH 136 turns 976 μH 25.3 μH 15 turns 30 amps 0.8 μH 11 turns 118 turns T131-52 1.1 μH 7.3 μH 24 turns 0.0 μH 260 μH 55 turns 15 amps #12 AWG 20 amps #11 AWG 30 amps FOIL 50 amps FOIL 100 amps FOIL #20 AWG E137-52 1.080 μH 107 μH 213 μH 64 turns 50 turns 11.2 μH 3 turns #28 AWG T50-52 81.4 μH 12 turns 8 turns 20 amps 0.320 μH 345 μH 978 μH 86 turns 127 μH 210 μH 50 turns 69.3 μH 4.080 194 turns 4.DC Inductor Examples Note: This table assumes < 1% ripple current.690 μH 317 turns 14.7 μH 40.1 μH 20 turns 9.0 μH 44 turns 34 truns 26 turns 20 turns 10.0 μH 22 turns 202 turns T250-52 8.2 μH 13 turns 134 turns T157-52 1.700 μH 760 μH 78 turns 311 μH 49 turns 190 μH 39 turns 88.8 μH 18 turns 15.8 μH 5 turns 74 turns T90-52 362 μH 74 turns 46 turns 680 μH 124 μH 188 μH 52 turns 41 turns 3. (714) 970-9400 FAX (714) 970-0400 .0 μH 63.7 μH 3 turns 112 turns E168-52 4.3 μH 14 turns 8.7 μH 11 turns 115 turns T106-52 550 μH 85 truns 1.8 μH 18 turns 9.1 μH 30 turns 21.3 μH 23.0 amps #24 AWG #20 AWG #18 AWG #15 AWG #13 AWG #11 AWG #9 AWG 2. The presence of significant ripple current will result in both greater inductance and higher operating temperature.050 μH 126 turns 590 μH 100 turns 347 μH 78 turns 190 μH 61 turns 494 turns E CORES: FULL BOBBIN WINDINGS 5.4 μH 7 turns 0.7 μH 11 turns 3.0 μH 27 turns 41.6 μH 74.800 μH 1.000 μH 105 μH 34 turns 64.2 μH 16.790 μH 129 turns 3.7 μH 37 turns 22 turns 16 turns 12 turns 8 turns 6 turns TOROIDAL CORES: SINGLE LAYER WINDINGS 5. DC CURRENT WIRE * PART # SIZE 1.53 4.5 amps 348 μH 71 turns 29 turns 10 amps 64.400 μH 114 μH 38 turns 65.660 μH 380 μH 624 μH 81 turns 63 turns 18.0 μH 29 turns 34.0 μH 21.100 μH 1.3 μH 33.9 μH 27 turns 32.5 amps 30.7 μH 2.720 μH 3.0 amps #18 AWG #14 AWG DC CURRENT WIRE * PART # SIZE 2.090 μH 129 turns 81 turns 1.0 μH 16 turns 8.9 μH 69.3 μH 39 turns 40.6 μH 46 turns 28 turns 21 turns 16 turns 94 μH 27. While -40 Material has an initial permeability approximately 20% lower than -26 and -52 Materials. the gapping of iron powder E Cores is relatively non-critical when compared to ferrites and iron alloy lamitations.18. This creates an effective discrete gap of . some variation will exist between particular E Cores sizes. (714) 970-9400 FAX (714) 970-0400 . Similarly. -18. E220 and E305 size E Cores are available with standard center-leg gaps as detailed in the E Core listing on pages 15 . These curves are for reference only.54 - .010 inches. An additional discrete gap in iron powder does not have a dramatic impact on effective permeability as illustrated by the graph to the upper right.DC APPLICATIONS GAPPING IRON POWDER E CORES Gapping iron powder E Cores increases energy storage capabilities beyond that inherent in the distributed air gap structure that is characteristic of the material. Similar results occur for -40 and -52 Materials. when the two materials are gapped the resulting effective permeabilities are much closer to one another. The E168.020 inches per half. and -52 Materials are less expensive than -8. In addition to increasing energy storage. -34. Energy Storage Curves for optimum butt-gapped E Cores in -26 Material are shown at the bottom of the following page. -40 and -52 Materials due to ampereturn temperature rise limitations.020 inches.015 inches per half. MICROMETALS TEL.010 inches is equivalent to a total center-leg gap of . By example. The E220 is available with a center-leg gap of . E168A. and -35 Materials without a gap. -18. A set made up of two of these gapped cores will produce a center-leg gap of . -30. The graphs below and to the right illustrate the typical effect of gapping on the basic magnetic characteristics of -26 Material. Similar or slightly higher energy storage will result with -52 Material while slightly lower energy storage will result for -40 Material with the same windings. The term butt-gap has been used to indicate the physical separation of two standard E Cores (that are butted up against a spacer). A butt-gap of . -30. gapping also significantly reduces the swing of these materials with DC bias resulting in performance similar to -8. Gapping of E Cores is advantageous only in the higher permeability -26.030 inches.020 inches. As a result. The E168 and E168A are available with a center-leg gap of . -34 and -35 Materials this offers an attractive design alternative. -40.010 inches has a butt-gap of . Since -26. This difference is due to the variation in leakage between the geometries. a set of cores with all three legs separated by . The magnetization curves for the E Core geometry vary somewhat from curves for toroidal cores. 55 - DC APPLICATIONS MICROMETALS TEL. (714) 970-9400 FAX (714) 970-0400 .. 56 - . Most DC output chokes operate with a peak AC flux density of less than 1000 gauss (100 mT). (714) 970-9400 FAX (714) 970-0400 . The -26 Material is a commonly used core material for DC output chokes. Since volume is a cubed function and surface area is a squared function. When significantly greater AC flux density is present. -18. The winding tables on pages 64 and 65 contain information on surface area and power dissipation for temperature rises of 10Cº. Fewer ampere-turns are required for the same energy storage than when <1% ripple is present. 25Cº. as switching frequencies increase. The DC energy storage curves provided on pages 42-49 are based on a peak AC flux density of 10 gauss (1 mT) which will typically represent less than 1% ripple current. The various iron powder material are affected by peak AC flux density as shown by the graph at the top of page 27. Energy Storage Curves which take into account both the core loss and permeability characteristics for -26 Material with 10% and 25% ripple are provided on page 57. a core’s capacity to dissipate heat per unit volume varies inversely with size. it becomes necessary to consider its effect on both core loss and permeability (inductance). The -8 Material will gain an additional advantage due to its lower permeability. The interpretation of core loss in DC chokes is covered on pages 29-30.DC APPLICATIONS THE EFFECT OF AC OR RIPPLE ON DC INDUCTORS The effect of AC or ripple flux can be significant in many DC inductor applications. The -26 Material responds to the combined effects of AC and DC magnetization as shown by the graph below. MICROMETALS TEL. with high ripple at high frequency this material will be able to store less energy due to core loss limitations. The core loss curves on pages 31-36 also include Et/N (volt-microsecond per turn) ratings for various core sizes at a number of frequencies for a 15Cº temperature rise due to core loss. The responses of -40 and -52 Materials are very similar. The temperature rise that will result from a given core loss per unit volume (mW/cm3) is dependent on the core’s effective surface area available to dissipate the heat. However. and 40Cº. with a level of 200 gauss (20 mT) being more typical. However. The percent initial permeability increases for all materials as the peak AC flux density is increased from 10 gauss (1 mT) to 1000 gauss (100 mT). Large cores can dissipate less heat per unit volume than small cores for the same temperature rise. the lower core loss characteristics of -8. and -52 Materials also make them good choices. and -52 Materials have the most pronounced response to elevated AC flux density. The -26. -40. . (714) 970-9400 FAX (714) 970-0400 .57 - DC APPLICATIONS MICROMETALS TEL. The loss calculation approach used here is generally applicable to constant switching frequency circuits where the boost inductor current is above “critical”. A convenient formula ˆ ” in CGS units is: for peak AC flux “ B Figure 2 Relative Peak Flux in L1 Core vs. Inc. the line current is also sinusoidal. The operation of this circuit is generally well known. throughout most of the AC line cycle. The peak HF AC flux in the inductor core can be calculated from the switching voltage waveform. for various ratios of Vi/Vo (where Vi = Peak AC Input Voltage) are plotted in figure 2 TEL. (714) 970-9400 FAX (714) 970-0400 Figure 1 Basic Unity Power Factor boost preregulator power circuit The actual control technique and circuit used are largely irrelevant to the calculation of losses in UPF boost preregulators. MICROMETALS . while forcing the short term average input current (=L1 current) to be proportional to the instantaneous AC line voltage. Curves of B line phase angle 0. where the loss exponent “n” is “Pfe” will vary as B typically between 1. The basic AC-DC boost preregulator power circuit is shown in Figure 1.58 - . however. as AC flux in changing continuously in a complex manner even with “fixed” input and output voltages.AC APPLICATIONS POWER FACTOR BOOST PREREGULATOR CORE LOSS CALCULATIONS The following article is a synopsis of an application note written by Bruce Carsten for Micrometals. Calculation of the core losses in the main inductor is problematic. The unabridged original version of the Bruce Carsten application note is available upon request. for core loss exponents of 2. 2.0. The boost preregulator “front end” is increasingly used with AC line inputs to obtain an (essentially) Unity Power Factor. the duty cycle of the main switch Q1 is controlled by logic (not shown) to boost the rectified line input voltage “Vi” to the output voltage “Vo”. AC Input Voltage and Phase At a constant switching frequency. followed by a section on PFC Design Guidelines written by Micrometals. or UPF. constant output voltage and constant conversion frequency are assumed for calculating the (relative) AC core and HF winding current losses in the main inductor (L1).0 are plotted in Figure 3. Since the AC line voltage is (ideally) sinusoidal. including powder iron materials. or continuous. The ratio of average core loss (over an AC line voltage cycle) to the “maximum” loss (at Vi = Vo/2).65 and 3 for most magnetic materials. AC AC line voltage half cycle. ˆ = B 108 E ∆T 2NA Where: E = Peak Inductor Voltage ∆T= Time Increment N = Number of Winding Turns A = Core Area (cm2) ˆ max” occurs when: The maximum flux “ B Vi = Vo/2 Where: Vi = “Instantaneous” Input Voltage Vo= DC Output Voltage The actual switching frequency AC flux varies over the ˆ /B ˆ max vs. the core loss ˆ n. A sinusoidal input voltage.5 and 3. It is recommended that the unit is operated continuously under the worst case conditions for a period of 4 to 8 hours or until the inductor reaches thermal equilibrium. with the largest average/maximum ratio only ranging from 0. The soundness of the thermocouple connection to the core is critical for accurate results. It is also important to remember that it is much easier to remove heat from the copper winding than from the core. The worst case winding losses will occur at the lowest input voltage since this is when the maximum current will flow. the core will be subjected to excessive high frequency core loss resulting in a temperature rise that can possibly lead to thermal failure. the increase in temperature rise due to losses must be kept to a minimum. It is important to recognize that a PFC design dominated by core loss is not acceptable without first completing a thorough design analysis.61 times the peak output voltage. (714) 970-9400 FAX (714) 970-0400 . Since operation at the loss ratio maxima will occur in most UPF boost preregulators. The core loss ratio is not very sensitive to the core loss exponent. Many designs today utilize variable speed fans in order to cool and “quiet down” the power supply. Even at a reduced power load condition.AC APPLICATIONS when the peak input voltage is .725 for n = 2. generally. Close attention should be paid to the “shadow” areas that do not get the benefit of good air flow. Iron Powder core materials do have differing thermal conductivities which will effect their temperature gradient. These areas will be at a higher temperature than those directly in the air flow path. PFC applications mean that higher Peak AC Flux density conditions are often present in the core than traditional output choke applications. The best way to determine the “hot spot” core temperature is to drill a small hole midway into the core and install a thermocouple wire. In fact. being somewhat less for higher loss exponents. Most present day applications for iron powder cores can have ambient temperatures up to 55Cº.61 times the boost or output voltage. a 20/80% or 25/75% split between core to copper loss is preferred. Please refer to the Thermal Conductivity information on page 3.61. Vi/Vo and Loss Exponent “n” It can be seen that the ratio of average/maximum core loss reaches a maxima when the peak AC line/ DC output voltage ratio is near 0. The Micrometals Design Software is also available for a rapid solution to your requirements. If an inappropriate core material or undersized core is selected. The true maximum temperature of the core can then be determined. Only the copper loss (I2R) has been reduced. more than offset any increase in winding losses. It is generally recommended that the loss distribution be no greater than a 50/50% split between core and copper loss. Therefore. the effective AC flux density and resulting core loss of the PFC inductor can remain fairly constant. It is important for a PFC design to be evaluated under the worst case conditions which will be at maximum power and in most designs when the peak input voltage is either at its lowest level or . This reduction in core loss can be very significant and will.59 - MICROMETALS TEL. Figure 3 Ratio of Average to Maximum Core Loss vs. but the worst case core losses will occur when the peak input voltage is . a useful rule-of-thumb is that the “worst case” average core loss will be 70% of the loss calculated for Vi = Vo/2. where the Peak flux is: 108 Vo 8NAf ˆ = B Where: f = Boost Switching Frequency IRON POWDER PFC DESIGN GUIDELINES Extra care must be taken when designing and specifying iron powder cores for PFC applications due to the AC content and complexity of the core loss calculations.672 for n = 3 to 0. Selecting a lower permeability core material will reduce the peak operating flux density and associated core loss. Extreme care should be taken since a reduction in fan speed can result in a higher than expected temperature owing to the reduction of air flow. It is also dependent on operating AC flux density. The balun winding allows the 60 Hz flux density generated by each line to cancel in the core. While the -8. thus avoiding saturation. MICROMETALS TEL. It appears that this increase in permeability is experienced in applications such as light dimmers. Differential-mode chokes usually have a single winding. In certain 60 Hz applications. Energy Storage Curves for 60 Hz filtering applications for -26 and -40 Materials are shown on page 61. For applications where it is unclear if the high frequency signal will experience the same increase in permeability as the 60 Hz signal. This type of noise is more readily filtered when the choke is in close proximity to the noise source. 25Cº and 40 Cº are also listed for 60 Hz applications for a number of different core sizes. the majority of the loss is due to the core losses. and International regulations has increased the need to effectively filter the main power line. it is not clear if this is the case for instantaneous noise signals. an inductance reference table is included on page 63. With physically large cores. The -26 and -40 Materials maintain good permeability versus AC flux density characteristics as illlustrated at the top of page 27. for most common-mode applications. This type of choke must be able to support significant 60 Hz flux density without saturating and at the same time respond to the high frequency noise. but the loss distribution differs.AC APPLICATIONS IRON POWDER FOR 60Hz FILTER INDUCTORS The addition of both U. (see pages 27-33). This means that as the material is magnetized it experiences a very slight change in dimensions. This phenomenon is not unique to iron powder. It wil also be more significant with signals which have been chopped (light dimmers. The distributed air-gap of iron powder in addition to its high saturation flux density of greater than 12. but it does not provide a clear view of how the inductance will vary with current. Otherwise. These curves take into account the increase in permeability illustrated by the curves at the top of page 27. In applications above audible frequencies (>20 kHz) this is of no concern. the higher core loss characteristics of the -26 and -40 Materials at frequencies above 25 KHz will produce a coil with low Q at high frequency. While this may be the case for a contiuous time averaged signal. the increased core size necessary to accommodate the number of turns needed to achieve the required inductance makes this alternative less attractive. it is recommended that the 60 Hz signal be treated as DC current. Differential-mode noise is the interference that is present between the positive and neutral lines and is typically generated by switching devices such as transistors. (714) 970-9400 FAX (714) 970-0400 . This mandated low value of capacitance for common-mode filtering makes a high value of inductance essential for effective filtering.000 gauss (1. This will produce a significantly different result but will be the most conservative approach. The representation of percent permeability versus peak AC flux density at the top of page 27 shows how the permeability (inductance) will change with voltage across the coil. both the common-mode and differential-mode (normal-mode) noise must be controlled. Common-mode noise is interference that is common to both the positive and neutral lines in relation to earth ground and is usually a result of capacitive coupling. Common-mode filtering requires capacitors to earth ground. This characteristic is an additional benefit in helping to suppress the unwanted signals.60 - .S. Common-mode inductors typically require a minimum inductance of 1000 mH and are most often wound in a balun configuration on a 5000 or higher permeability ferrite core. however. The graphs at the top of page 62 are an attempt to illustrate (in relative terms only) how the relative inductance will change with changes in current. Tests performed with a low-level 10 KHz sinewave superimposed over a 60 Hz signal of increasing level did indicate that the high frequency signal experienced an increase in inductance as the 60 Hz signal was increased. Iron powder experiences magnetostriction. This condition will be more noticeable with E Cores than with toroids. A design example can be found at the bottom of page 62. The AC flux density levels have been referenced. For the same temperature rises. SCRs and triacs. while with the physically small cores the majority of the loss is due to the losses in winding. -18 and -52 Materials have lower core losses at 60 Hz. The significant increase in percent permeability for these materials can be a considerable advantage. core buzzing can be noticeable. Further. and core saturation.2 T) make it well-suited for this requirement. all core sizes operate at a similar flux density. though it is possible to put more than one differentialmode choke on a core by connecting the windings in the additive configuration rather than in the balun configuration. Safety regulations limit these capacitors to a relatively low value. Lower permeability materials like iron powder are useful for common-mode applications involving significant line imbalance. motor controllers) than with normal sinewaves. Energy storage inductor design is limited by temperature rise resulting from the combined copper and core loss. In addition. These flux density references can be useful in approximating core loss as well as determining how the inductance will bary with current. Energy stroage limits for temperature rises of 10Cº. In order to accomplish this. . (714) 970-9400 FAX (714) 970-0400 .61 - AC APPLICATIONS MICROMETALS TEL. 5 ÷ 42 = 6.5 = 25% of I max before lower inductance will result. This shows that.62 - MICROMETALS .AC APPLICATIONS Relative Current vs Inductance as a Fuction of AC Flux Density Relative Inductance (%) Relative Inductance (%) 60 Hz INDUCTOR DESIGN Requirements: 500 μH minimum from 1 to 5 amps of 60 Hz Current. Since the “simple” winding results are a rough approximation of typical single-layer windings. the T131-40 indicates 235 ampere-turns. NI = 235 N = 235 / 5 = 47 turns Select wire size. At 6250 μJ. Solution: Part no. or down to 20% of full-rated current (I max). the Single Layer Winding table on page 64 can be used as a guide in selecting the wire size. the T131 will be selected. in the case of -40 Material. Consider minimum current level.6 ÷ 19.0% of I max. the inductor must maintain 500μH minimum from 1 to 5 amperes. the inductor must be designed to operate at greater than 8 kG at I max. TEL. For this example. This requires a core no larger than the E137 core or T131 toroidal core. if the inductor is designed to operate at 10 kG at I max. #19 will fit in a single layer and yield about 20C° temperature rise due to the winding losses. that the inductance will be greater than or equal to L at I max down to 2. T131-40 47 turns #19 . Likewise. if the inductor operates at 8 kG at I max. Determine number of turns. In order to maintain a minimum inductance down to 1 amp (20% of I max). the inductor can only be operated down to 4. The importance of this consideration is illustrated by the graph above. To keep temperature rise down. (714) 970-9400 FAX (714) 970-0400 Calculate Energy Storage Required (1/2 LI2 ) 1/ 2 LI2 = (1/2) (500) (52) = 6250 μJ Select appropriate core size. In this example -40 Material will be used. 60 Hz Inductor Examples Note: If the inductors are operated to at least 15% of full-rated current.100 μH 1.5 amps #15 AWG 10 amps #13 AWG 15 amps #12 AWG 20 amps #11 AWG 30 amps #10 AWG #23 AWG E137-26 5.200 μH 19.920 μH 70 turns 1.1 μH 53.840 μH 83 turns 1.000 μH 2.600 μH 1.600 μH 331 μH 729 μH 64 turns 44 turns 30.3 μH 140 μH 213 μH 32 turns 24 turns 16 turns 22.000 μH 10.0 μH 9 turns 141 turns T157-26 6.100 μH 452 μH 704 μH 53 turns 37 turns 8.3 μH 8 turns 125 turns T131-26 4.3 μH 11 turns 3.420 μH 93 turns 1.7 μH 7 turns 217 turns E168-26 11. 400 μH 258 μH 28 turns 140 μH 21 turns 64.8 μH 47.0 amps 2.730 μH 135 turns 370 μH 590 μH 43 turns 198 μH 34 turns 180 μH 25 turns 56.140 μH 77 turns 46 turns 3.700 μH 65 turns 811 μH 46 turns 507 turns E CORES: FULL BOBBIN WINDINGS 2.4 μH 5.0 μH 12 turns 13.63 25.000 μH 132 turns 82 turns 7. (714) 970-9400 FAX (714) 970-0400 .9 μH 3 turns 63 turns T68-26A 960 μH 74 turns 1.0 μH 10 turns 14.0 amps #24 AWG #20 AWG #18 AWG #15 AWG #13 AWG #11 AWG 2.180 μH 87 turns 5.0 μH 18 turns 3.2 μH 11.240 μH 82 turns 57 turns 46.5 μH 14 turns 20.380 μH 59 turns 615 μH 39 turns 356 μH 30 turns 147 μH 19 turns 80.0 μH 120 μH 180 μH 27 turns 8.6 μH 77.720 μH 132 turns 13.200 μH 197 turns 22.0 μH 14 turns 34.5 amps 10 amps 15 amps 20 amps 2.6 μH 0.8 μH 35.6 μH 11 turns 30 amps #9 AWG 60Hz current WIRE * PART # SIZE #28 AWG T50-26 352 μH 47 turns 28 turns 18 turns 13 turns 15 turns 460 μH 113 μH 308 μH 44 turns 30 truns 22 turns 15 turns 40.3 μH 80.7 μH 19 turns 213 turns .0 μH 25.700 μH 140 turns 34. the inductance will be greater than or equal to te value listed 1.340 μH 2.4 μH 11 turns 350 turns * Based on max temperature rise of 40Co due to copper and core loss MICROMETALS TEL.000 μH 5.290 μH 72 turns 760 μH 56 turns 344 μH 38 turns 435 turns T400-26D 180.600 μH 1.0 amps 544 μH 43 turns 7.600 μH 241 μH 29 turns 132 μH 21 turns 64.5 μH 7 turns 79 turns T90-26 1.5 amps #19 AWG #16 AWG 60Hz current WIRE * PART # SIZE 1.5 amps 136 μH 47 turns 21 turns 16 turns 9 turns 6 turns 5 turns TOROIDAL CORES: SINGLE LAYER WINDINGS (approximate) 5.0 amps 7.0 μH 9 turns 295 turns AC APPLICATIONS E220-26 73.900 μH 272 turns 169 turns T184-26 8.0 μH 15 turns 31.300 μH 47 turns 730 μH 35 turns 320 μH 23 turns 175 μH 17 turns 74.050 μH 4.700 μH 157 turns 2.600 μH 317 turns 88.0 μH 8 turns 120 turns T106-26 2.560 μH 19.4 μH 14 turns 213 turns T300-26D 57.140 μH 87 truns 4.540 μH 118 turns 13.400 μH 108 turns 2. 83 9.5 15.156 .824 1.326 .1 41.21 10.32 2.8 7.936 1.79 3.81 3. (714) 970-9400 FAX (714) 970-0400 T124 T130 T130A T131 T132 T141 T150 T157 T175 MICROMETALS T184 T200 T200B T201 T225 T225B T250 T300 T300D T400 T400D T520 T520D T650 .05 1.74 2.26 1.77 4.060 .27 8.33 5. RISE MAXIMUM AMPS 10C° PER ALLOWABLE 25C° TEMP RISE 40C° PART No.88 2.470 .633 .0521 11 .530 20 .64 3.1 42.97 1.360 .8 3.5 18.4 22.75 3.79 7.85 2.11 4.1 14.6 14.0 22.54 6.2 42.5 12.57 1.38 .44 4.09 4.2 90.23 6.35 10.241 .42 1.16 1.574 .63 2.23 2.350 .76 4.84 1.492 .0 25. T16 T20 T25 T26 T30 T37 T38 T44 T50 T50B T50D T51C T60 T60D T68 T68A T68D T72 T80 T80B T80D T90 T94 T106 T106A T106B Surface cm/turn Area cm2 MLT .223 .58 2.2 79.00 2.WINDING TABLE SINGLE LAYER WINDING TABLE WIRE SIZE (AWG) RESISTIVITY (mΩ/cm) 28 2.28 9.7 22.72 6.28 5.48 3.79 3.33 8.6 NUMBER OF TURNS 9 11 18 15 25 37 31 43 59 59 59 36 67 67 74 74 74 54 103 103 103 115 117 118 118 118 150 165 165 134 147 188 180 204 230 202 270 270 202 305 305 270 422 422 494 494 680 680 789 6 8 14 11 20 29 24 34 47 47 47 28 53 53 59 59 59 43 82 82 82 92 94 95 95 95 120 133 133 107 118 151 145 164 186 163 217 217 163 245 245 217 341 341 399 399 550 550 621 4 5 10 8 15 22 18 26 37 37 37 22 41 41 46 46 46 33 64 64 64 72 74 74 74 74 95 105 105 85 93 119 114 129 147 129 172 172 129 195 195 172 271 271 317 317 437 437 494 2 3 7 5 11 17 13 20 28 28 28 16 32 32 36 36 36 26 51 51 51 57 58 59 59 59 75 83 83 67 74 95 91 103 117 102 137 137 102 155 155 137 216 216 254 254 350 350 396 1 2 5 3 7 12 10 15 22 22 22 12 25 25 28 28 28 19 39 39 39 44 45 46 46 46 59 65 65 52 58 75 71 81 92 81 108 108 81 123 123 108 171 171 201 201 278 278 315 1 4 2 6 11 8 13 19 19 19 10 21 21 24 24 24 17 35 35 35 39 40 40 40 40 52 58 58 46 51 66 63 72 82 72 96 96 72 109 109 96 153 153 179 179 248 248 281 3 1 5 9 7 11 16 16 16 9 19 19 21 21 21 14 30 30 30 34 35 36 36 36 46 51 51 41 45 59 56 64 73 63 86 86 63 97 97 86 136 136 160 160 221 221 250 4 7 5 9 14 14 14 7 16 16 18 18 18 12 27 27 27 30 31 31 31 31 40 45 45 36 40 52 49 56 64 56 76 76 56 86 86 76 121 121 142 142 197 197 223 3 6 4 7 12 12 12 6 14 14 16 16 16 11 23 23 23 26 27 27 27 27 36 40 40 32 35 46 44 50 57 50 67 67 50 78 78 67 108 108 126 126 176 176 199 2 5 3 6 10 10 10 5 12 12 14 14 14 9 20 20 20 23 24 24 24 24 31 35 35 28 31 40 38 44 50 44 60 60 44 68 68 60 96 96 113 113 156 156 177 1 4 2 5 8 8 8 4 10 10 12 12 12 7 17 17 17 20 21 21 21 21 27 31 31 24 27 35 34 39 44 38 53 53 38 60 60 53 85 85 100 100 139 139 158 1 3 2 4 7 7 7 3 8 8 10 10 10 6 15 15 15 17 18 18 18 18 24 27 27 21 23 31 29 34 39 34 46 46 34 53 53 46 75 75 88 88 123 123 139 2 1 3 6 6 6 2 7 7 8 8 8 5 13 13 13 15 15 15 15 15 21 23 23 18 20 27 26 30 34 29 41 41 29 48 48 41 66 66 78 78 109 109 124 2 4 4 4 1 6 6 7 7 7 4 11 11 11 13 13 13 13 13 18 20 20 16 18 24 22 26 30 26 36 36 26 41 41 36 58 58 69 69 97 97 110 4 4 5 5 5 3 9 9 9 11 11 11 11 11 15 17 17 13 15 20 19 23 26 22 31 31 22 36 36 31 52 52 61 61 86 86 98 1 3 3 3 1 1 2 1 10C° .166 16 .77 3.80 .16 11.6 30.88 10.28 1.91 1.45 5.5 11.2 46.15 2.89 6.233 .178 .52 3.01 1.2 23.23 10.427 .198 .7 28.529 .44 4.78 3.246 .330 19 .0 15.95 10.157 .9 21.87 7.634 .79 6.29 2.25 4.7 13.9 14.95 4.2 63.11 1.52 1.7 23.01 2.104 14 .7 17.07 1.533 .41 3.7 25C° .67 5.97 2.013 .249 .53 3.3 18.8 35.07 1.083 .6 9.29 6.68 2.25 2.90 6.9 13.53 3.74 1.3 32.212 .0 46.097 .210 17 .4 7.07 3.53 1.846 1.97 11.529 .55 4.50 9.53 2.80 1.5 .5 18.2 12.70 5.2 33.120 .49 3.27 1.34 24 .95 4.47 7.669 .0651 12 .228 .78 8.4 26.88 8.50 8.21 6.0828 13 .58 2.74 5.042 .722 .373 .298 .90 1.19 3.671 .2 23.736 .62 4.1 .211 .109 .038 .157 .826 .089 .1 9.5 33.2 19.58 2.0 33.05 1.044 .86 7.133 .6 6.565 .41 5.92 4.81 1.264 18 .86 5.58 7.84 14.11 4.132 15 .12 5.69 1.45 1.2 13.0413 10 .7 82.1 89.00 2.67 2.316 .96 1.4 13.43 5.27 2.88 1.75 5.0 31.17 2.127 .70 3.125 .56 9.356 .01 2.7 10.01 1.19 1.95 2.9 120 111 109 143 166 173 223 301 384 496 629 986 TEL.30 1.76 1.5 52.60 12.9 40C° .64 - .8 53.0328 TOTAL POWER DISSIPATION (WATTS) VS TEMP.371 .1 15.3 42.067 .75 3.842 22 .47 1.018 .659 .45 7.350 .26 6.8 16.468 .92 1.64 1.16 7.93 9.47 2.13 26 1.01 3.03 15.10 7.681 .055 .59 2.44 1.071 .83 3.20 .7 25.030 .437 .892 1.04 1.671 .744 .180 .61 10.3 11.8 18.3 15.594 .28 5.84 2. 59 2.80 .50 8.2 18.3 15.28 9.07 1.25 4.211 .79 3.547 .80 1.2 42.89 6.54 3.92 1.96 1.157 .8 21.470 .79 7.2 41.3 15.53 3.58 6.7 25Cº .80 3.13 26 1.01 2.50 8.77 4.88 2.34 24 .437 .042 .156 .574 .6 208 226 384 328 96 250 351 598 637 731 896 784 1460 1460 952 2024 1360 3999 3999 6298 6298 48 160 242 370 390 442 585 507 944 944 585 1332 864 2600 2600 4104 4104 30 96 136 232 248 297 360 310 564 564 396 826 559 1660 1660 2580 2580 21 60 98 161 175 176 232 200 370 370 232 517 350 1072 1072 1725 1725 12 40 55 90 100 119 138 140 240 240 161 342 216 689 689 1100 1100 10 24 45 80 90 90 120 108 189 189 120 272 168 564 564 833 833 8 21 32 56 64 65 90 80 144 144 90 210 132 420 420 704 704 4 18 28 52 56 60 64 70 126 126 80 162 114 342 342 546 546 3 12 18 33 36 44 56 48 95 95 56 144 85 272 272 420 420 3 10 15 30 33 36 36 44 64 64 48 105 60 210 210 341 341 2 8 10 18 18 24 33 27 60 60 33 76 52 162 162 280 280 2 4 8 16 16 21 30 24 39 39 30 68 36 144 144 225 225 1 3 8 14 14 12 18 14 33 33 18 45 30 105 105 176 176 0 3 6 12 12 10 14 12 30 30 14 39 27 78 78 133 133 0 2 3 5 6 10 14 12 18 18 14 33 16 68 68 102 102 41 74 100 150 150 180 190 190 270 278 210 370 280 610 620 850 820 72 120 170 270 270 280 340 320 470 480 370 640 490 1060 1071 1480 1420 96 170 220 360 360 370 450 430 620 630 500 850 650 1400 1400 1970 1890 .3 22.47 3.40 4.00 2.47 1.1 29.4 45.88 10.530 20 .01 1.842 22 .45 5.26 1.44 1.3 42.671 .01 3.097 .88 8.371 .178 .95 4.12 5.01 2.864 1.8 18.326 .93 10.85 2.75 4.7 73.824 .1 5.23 6.210 17 .56 9.43 5.81 1.17 17.47 7.1 13.76 4.133 .4 22.64 3.1 89.018 .28 5.81 5.07 1.26 5.492 .38 8.WINDING TABLE "FULL WINDING" TABLE (45% TOROID ID REMAINING) WIRE SIZE (AWG) RESISTIVITY (mΩ/cm) PART No.223 .42 6.15 2.7 23.67 2.99 7.038 .10 5.5 20.0521 .35 9.030 .54 6.212 .79 3.083 .104 14 13 12 11 10 .88 3.42 3.249 .58 2.4 .8K 8 6 20 15 32 59 43 73 128 56 158 192 110 343 424 440 455 707 853 574 687 1086 1002 1266 1606 1266 2192 1266 2770 2192 5227 7104 5 4 12 9 20 37 27 46 81 35 100 122 69 218 269 279 289 449 542 365 437 690 636 805 1021 805 1393 805 1760 1393 3322 4515 8461 3 2 8 6 13 24 17 30 52 23 65 78 45 141 174 180 187 290 350 236 282 446 411 520 659 520 933 520 1137 900 2146 2916 5465 7057 2 2 5 4 8 15 11 19 33 14 41 50 28 89 110 114 118 184 222 149 179 283 261 329 418 329 571 329 721 571 1361 1850 3467 4477 1 1 4 3 6 12 9 15 26 11 33 40 22 71 88 91 95 147 177 119 143 226 208 263 334 263 456 263 277 456 1089 1480 2773 3581 1 1 3 2 5 9 7 12 21 9 26 32 18 57 70 73 75 117 142 95 114 180 168 210 267 210 365 210 461 365 870 1182 2261 2861 1 1 2 2 4 7 5 9 17 7 21 25 14 45 56 58 60 93 113 78 91 144 132 168 213 168 290 168 367 290 693 942 1765 2280 1 2 1 3 6 4 7 13 6 16 20 11 36 45 46 48 75 90 61 73 115 106 134 170 134 232 134 294 232 554 754 1413 1824 1 1 2 5 3 6 10 4 13 16 9 29 36 37 38 60 72 48 58 92 85 107 136 107 186 107 235 186 443 602 1129 1458 1 1 2 4 2 5 8 3 10 13 7 23 28 29 20 47 57 38 46 73 67 85 108 85 148 85 186 148 352 479 868 1159 1 3 2 3 6 3 8 10 5 18 22 23 24 37 45 30 36 57 53 67 85 67 116 87 147 116 278 378 708 914 1 2 1 3 5 2 6 8 4 14 18 18 19 30 36 24 29 46 42 53 68 53 93 53 117 93 221 301 564 729 1 2 1 2 4 1 5 6 3 11 14 14 15 23 28 19 23 36 33 42 54 42 74 42 92 74 176 240 450 581 1 1 2 3 1 4 5 3 9 11 11 12 19 23 15 18 29 27 34 43 34 59 34 74 59 140 191 350 463 1 10Cº 10 12 19 16 27 42 34 50 73 44 87 100 75 150 170 180 190 260 300 240 260 360 350 400 480 420 610 430 720 650 1170 1530 2420 2980 25Cº 17 21 34 29 47 72 60 87 120 77 150 170 130 260 300 320 330 460 520 410 460 620 600 700 830 730 1050 750 1260 1120 2030 2650 4180 5170 40Cº 23 29 45 39 62 96 79 110 160 100 200 230 170 340 400 420 440 601 690 550 610 820 800 930 1110 970 1400 1000 1670 1490 2690 3510 5550 6850 10Cº .3K 26.0 33.242 .5 22.15 2.52 2.28 5.41 1.5 .2K 17.0 31.86 7.166 16 .2 79.4 18.089 .2 46.717 .65 - MICROMETALS TEL.77 4.178 .75 5.52 3.132 15 .61 9.264 18 .73 2. TEMP RISE DUE TO COPPER LOSS TOTAL POWER DISSIPATION (WATTS) VS.53 3.74 1.48 3.4 113 97.109 .16 7.9 111 109 166 173 301 496 986 25.50 11.58 7.76 1.044 .30 3.360 .532 .529 .936 1.88 15.64 1.246 .0651 .9 32. TEMP.634 .05 3.1 . Surface MLT Area cm/turn cm2 28 2.5 11.64 9.05 1.289 .0328 AMPERE TURNS VS.90 6.92 4.060 .42 1.38 6.21 5.1 42.18 3.26 8.23 2.49 3.2 90.44 4.84 11.55 3.4 36.330 19 .53 3. (714) 970-9400 FAX (714) 970-0400 14.533 .74 2.936 1.2 13.23 14.736 1.8 .33 5.6 34.0828 .19 1.055 .9K E CORES E49 E75 E100 E118 E125 E137 E145 E162 E168 E168A E187 E220 E225 E305 E305A E450 E450H 2.3 23.316 .120 .067 .2 63.8 53.2K 10.48 2.11 1.9 16 T20 T25 T26 T30 T37 T38 T44 T50 T51C T60 T68 T72 T80 T90 T94 T106 T124 T130 T131 T132 T141 T10 T157 T175 T184 T200 T201 T225 T250 T300 T400 T520 T650 .468 .95 4.4 7.06 1.180 .21 .809 1.09 11.671 .1 67.633 .9 40Cº .071 .013 .63 2.58 2.3K 13.75 5.744 .RISE NUMBER OF TURNS 13 16 30 23 48 90 65 112 196 85 241 293 168 525 648 672 696 1080 1301 877 1050 1659 1530 1933 2453 1933 3348 1933 4230 3348 7981 10.233 .669 .5 82.426 .16 1.127 .01 2.53 1.88 1.30 1.356 .29 6.4 15.11 4.45 1.84 2.5 16.65 9.9 66.16 13.16 1.85 9.1 50.95 11.59 6.1 27.21 7.0413 .350 .579 .6 46.48 2.081 .846 1.08 5. 500 2.000 10.250 700 1.225 504 800 360 300 200 150 240 80 110 48 36 18 36 Weight/Box lbs/kg 51/23 44/20 45/20 36/16 51/23 33/15 36/16 52/24 50/23 42/19 39/18 40/18 44/20 31/14 35/16 31/14 34/15 35/16 34/15 33/15 25/11 24/17 34/15 27/12 31/14 38/17 40/18 34/15 41/19 44/20 29/13 39/18 29/13 34/15 30/14 30/14 48/22 31/14 38/17 36/16 37/17 37/17 40/18 MICROMETALS T14A T16 T20 T22 T25 T26 T27 T30 T37 T38 T40 T44 T44C T44D T50 T50B T50C T50D T51C T57 T57A T60 T60D T68 T68A T68D T69 T72 T80 T80B T80D T90 T94 T106 T106A T106B T124 T130 T130A T131 T132 T141 T150 T150A T157 T175 T184 T200 T200B T201 T224C T225 T225B T249 T250 T300 T300D T400 T400B T400D T520 T520D T650 E49 E50 E65 E75 E80 E99 E100 E101 E118 E125 E137 E145 E162 E168 E168A E187 E220 E225 E305 E305A E450 E450H TEL.000 40.000 20.000 4. (714) 970-9400 FAX (714) 970-0400 .000 1.000 3.000 3.600 1. Standard pallets contain 48 boxes with dimensions 38 x 48 x 32 inches.66 - .000 4.000 1.000 4. freight charges can be a significant part of the total cost.000 1.000 10.000 3.000 3.600 3.000 4.000 1.000 3. Part Prefix Qty. Micrometals standard box size is 6 x 9 x 12 inches.000 10.000 6. The following table is provided to assist in planning shipment sizes and estimating freight costs. Weights for other material will vary in accordance with the densities listed on page 1.000 25.000 200.000 30.000 100./Box (pieces) 350 420 240 140 140 120 75 90 90 120 60 45 45 54 30 21 15 12 12 6 2 10.000 40.000 5.000 5.000 560 600 500 600 500 500 400 Weight/Box lbs/kg 41/19 51/23 45/20 43/20 39/18 45/21 41/19 42/19 44/20 43/19 37/17 46/21 42/19 35/16 37/17 41/19 34/15 37/17 43/19 42/19 42/19 36/16 39/18 39/18 53/24 40/18 43/19 48/22 40/18 39/18 42/19 39/18 46/21 52/24 50/23 54/25 37/17 50/23 31/14 59/27 56/25 42/19 Part Prefix Qty. Add approximately 50 pounds for each pallet for large volume shipments.000 20.000 1.000 2.000 1. Weights specified below include box and packaging materials for the -26 Material.600 2.000 4./Box (pieces) 250.PACKAGE SIZE AND WEIGHTS Due to the relatively low price and high density of iron powder cores.000 1.000 10.250 1.000 3.000 1. Note: 35. (714) 970-9400 FAX (714) 970-0400 . tightness of winding. Common-Mode Noise: Electrical interference that is common to both lines in relation to earth ground. ∆B = 2 Bpk. Percent Ripple: The percentage of ripple or AC flux to total flux. this can also be considered Percent AL Value.0 mH for 1000 turns. Temperature Rise (∆T): The increase in surface temperature of a component in free-standing air due to the total power dissipation (both copper and core loss). Energy Storage (1/2LI2): The amount of energy stored in microjoules (10-6 joules) is the product of one-half the inductance (L) in microhenries (10-6 henries) times the current (I) squared in amperes. 1 oersted = 79. Core Loss (watts): The power loss or heat generated by a magnetic material subjected to an alternating magnetic field. This is also known as normal-mode noise. Since the cores are manufactured to the AL value rather than to the listed reference permeability. . Butt-Gap: The gapping of E Cores by equally spacing all three legs of the cores rather than introducing a gap in the center-leg only. The thickness of insulation and tightness of winding will affect results. Example: A 2:1 swing corresponds to an inductor which exhibits 2 times more inductance at very low current than it does at its maximum rated current. Percent Saturation: This is equal to 100% – Percent Initial Permeability. Magnetizing Force (H): The magnetic field strength which produces magnetic flux. Surface Area (cm2): The effective surface area of a typical wound core available to dissipate heat. Cross-Sectional Area (A): The effective cross-sectional area (cm2) of a core available for magnetic flux. Often times this will produce a single-layer winding. The cores are manufactured to the listed AL values. Copper Loss (watts): The power loss (I2R) or heat generated by current (I) flowing in a winding with resistance (R). The permeability listed for each material is for reference only.67 - MICROMETALS TEL. The crosssectional area listed for toroidal cores is based on bare core dimensions with a 5% radius correction. MLT (cm): The mean length per turn of wire for a core. See pages 64 and 65. Twice as much center-leg gap is required to electrically duplicate a given butt-gap. Single-Layer Winding: A winding for a toroidal core which will result in the full utilization of the inside circumference of the core without the overlapping of turns. Swing: A term used to describe how inductance responds to changes in current.0 nH/N2 = 350 μH for 100 turns = 35. Choke: Another term for an inductor which is intended to filter or choke out signals. The type of insulation. the percentage of alternating current to average current.GLOSSARY AL Value (nH/N2): The inductance rating of a core in nanohenries (10-9 henries) per turn squared based on a peak AC flux density of 10 gauss (1 millitesla) at a frequency of 10 kHz. This would also correspond to the core operating at 50% of initial permeability (also 50% saturation) at maximum current.7958 A/cm In cgs units: H= . μ=B/H. Differential-Mode Noise: Electrical interference that is not common to both lines but is present between both lines. or in an inductor. ie: 20% saturation = 80% of initial permeability.833 In SI units: H= NI Where: H = amperes per meter N = Number of turns I = Current (amperes) = Mean Magnetic Path (cm) Mean Magnetic Path Length ( ): The effective magnetic length of a core structure (cm). Full Winding: A winding for toroidal cores which will result in 45% of the core’s inside diameter remaining. See figures on pages 64 and 65. See figures on pages 64 and 65. it is assumed that the peak to peak flux density is twice the value of peak AC flux density.4 π N I Where: H = oersteds (Oe) N = Number of turns I = Current (amperes) = Mean Magnetic Path (cm) Peak AC Flux Density (Bpk): The number of lines of flux per unit of cross-sectional area generated by an alternating magnetic field (from zero or a net DC). Initial Permeability (μo): That value of permeability at a peak AC flux density of 10 gauss (1 millitesla). The following formula has been used to approximate temperature rise: ∆T (C°) = Total Power Dissipation (milliwatts) Surface Area (cm2) . In general: (1 gauss = 10-4 tesla) In cgs units: Bpk = Eavg 108 Where: Bpk = Gauss (G) 4ANf Eavg = Average voltage per half cycle (volts) A = Cross-sectional area (cm2) N = Number of turns F = Frequency (hertz) Peak to Peak Flux Density (∆B): In an alternating magnetic field.58 A/m = . Simple Winding: A winding for toroidal cores which will result in 78% of the core’s inside diameter remaining. A winding for E Cores which will result in a full bobbin. Percent Initial Permeability (%μo): Represents the percent change in permeability from the initial value. and coil winding equipment limitations will all introduce variations. Materials permeabilities range from 35 to 125 with toroid geometries up to 4. -42 and -0. plain cores. -6. cups.0 inches and E-cores up to 4.68 - . . The geometries shown in this catalog are offered in traditional iron powder material and magnetic alloy powder. Radio Frequency Applications TEL. high current applications such as voltage regulated modules (VRM’s).5 inches. disks. -3.ADDITIONAL LITERATURE 200C SeriesTM High Temperature Powder Cores Microcubes Low Profile Linear Wound HC/IC Cores Micrometals 200C SeriesTM of magnetic alloy materials are specifically designed for severe environment applications where cores are exposed to or generate elevated temperatures. -17. balun core. Micrometals series of cores for high density inductors are well-suited for either through-hole or surface mount applications. -12. Permeabilities range from 1 to 35 for applications from 10 khz to 500 MHz. bobbins. These cost competitive core materials are not subject to thermal aging for operating temperatures up to +200°C. point of load power supplies and other DC/DC applications. bobbin sleeves and squared bobbins in the following materials: -1. -10. sleeves. Microcubes are ideal for low inductance. The Q Curve catalog is a design and application supplement containing over 30 pages of Q versus Frequency curves and other useful information. -2. hollow cores. -4. threaded cores. (714) 970-9400 FAX (714) 970-0400 Q Curves Supplement to RF Catalog MICROMETALS Micrometals RF catalog contains iron powder toroids. -7. Phone: +65-338-7317 Fax: +65-338-0914 Israel: Chaim Messer . Ltd. Kreger Co.BFI Optilas Phone: +31-172-446060 Fax: +31-172-443414 Norway: Andreas Olsson .MAM Inc. Ltd. IN.Avnet Kopp Phone: +27-11-444-2333 Fax: +27-11-444-1706 Spain: Salvador Pons .Leo & Company Phone: +852-2604-8222 Fax: +852-2693-2093 India: Sashu Tatikola .69 1 -- MICROMETALS TEL. 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