2005B Magnetics Ferrite Catalog Uncut
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Ferrite Cores About Magnetics Magnetics ® offers the confidence of over fifty years of expertise in the research, design, manufacture and support of high quality magnetic materials and components. A major supplier of the highest performance materials in the industry including; MPP, High Flux, Kool Mµ®, power ferrites, high permeability ferrites and strip wound cores, Magnetics products set the standard for providing consistent and reliable electrical properties for a comprehensive range of core materials and geometries. Magnetics is the best choice for a variety of applications ranging from simple chokes and transformers used in telephone equipment to sophisticated devices for aerospace electronics. Magnetics backs its products with unsurpassed technical expertise and customer service. Magnetics’ Application Engineering staff offers the experience necessary to assist the designer from the initial design phase through prototype approval. The knowledgable Sales staff is available to help with all of your customer service needs. This support, combined with a global presence via a worldwide distribution network, including a Hong Kong distribution center, makes Magnetics a premier supplier to the international electronics industry. CONTACT MAGNETICS P.O. Box 11422 Pittsburgh, PA 15238-0422 Phone: 412-696-1300 or 1-800-245-3984 Fax: 412-696-0333 email: magnetics@spang.com web: www.mag-inc.com PART NUMBER INDEX Arranged by Part Number........................................ iii Arranged by Part Type.............................................iv Order Information....................................................v Section 1 INTRODUCTION What are Ferrites?................................................1.1 Application Areas..................................................1.2 Part Number Identification..............................1.4-1.7 Gapped Core Tolerance Data..........................1.8-1.11 Section 2 MEASUREMENT INFORMATION Section 3 MATERIALS Introduction.........................................................3.1 Material Characteristics..................................3.2-3.9 Core Loss Information........................................ 3.10 B vs. H Curves.................................................. 3.11 Ferrite Blocks....................................................3.12 Section 4 POWER DESIGN Introduction.........................................................4.1 General Core Selection.................................. 4.2-4.3 Transformer Core Selection.............................4.4-4.9 Inductor Core Selection................................4.9-4.14 Core Selector Charts................................. 4.15-4.18 DC Bias Data.................................................... 4.19 Section 5 LOW LEVEL DESIGN Introduction.........................................................5.1 Pot Core Design Advantages...................................5.2 Pot Core Design Notes................................... 5.3-5.5 Assembly Notes............................................ 5.6-5.7 Wire Tables..................................................5.8-5.9 Plastics Information.................................. 5.10-5.11 Section 6 POT CORES Introduction........................................................ 6.1 Pot Core Data..............................................6.2-6.5 Pot Core Hardware.....................................6.6-6.16 Section 7 RS/DS CORES Introduction..........................................................7.1 RS/DS Core Data..........................................7.2-7.7 RS/DS Core Hardware................................ 7.8-7.12 Section 8 RM CORES Introduction..........................................................8.1 RM Core Data...............................................8.2-8.9 RM Core Hardware................................... 8.10-8.14 Index Index Section 9 EP CORES Introduction.........................................................9.1 EP Core Data................................................9.2-9.3 EP Core Hardware.........................................9.4-9.9 Section 10 PQ CORES Introduction.......................................................10.1 PQ Core Data...........................................10.2-10.3 PQ Core Hardware....................................10.4-10.6 Section 11 E, I, U CORES Introduction.......................................................11.1 E, I, U Core Data......................................11.2-11.9 E, I, U Core Hardware..........................11.10-11.17 Planar E, I Core Data............................11.18-11.21 Planar E, I Core Hardware.....................11.21-11.23 EEM, EFD Core Data.............................11.24-11.25 EEM, EFD Core Hardware......................11.26-11.30 Section 12 EC, ETD, EER, ER CORES Introduction.......................................................12.1 EC, ETD, EER, ER Core Data........................12.2-12.3 EC, ETD, EER, ER Core Hardware...............12.4-12.14 Section 13 TOROIDS Introduction..............................................13.1-13.3 Toroid Core Data....................................13.4-13.12 Toroid Hardware..................................13.13-13.15 Section 14 GENERAL INFORMATION Definitions............................................... 14.2-14.3 References........................................................ 14.4 Other Products from Magnetics.............................14.5 ii Part Number Index ARRANGED BY PART NUMBER PART NO. TYPE PAGE PART NO. TYPE PAGE PART NO. TYPE PAGE PART NO. TYPE PAGE PART NO. TYPE PAGE RS DS RM RS DS TC 7.2 7.2 8.4 7.2 7.2 13.6 * 43214 43220 43230 43434 43515 43517 PQ PQ PQ ETD EC EC 10.2 10.2 10.2 12.4 11.6 12.2 * 44308 * 44310 44317 44416 44444 44529 EC-IC EC-IC EC TC ETD PC 11.20 11.20 11.8 13.8 12.4 6.4 TC EC UC EC-IC UC-IC IC 13.6 11.4 11.4 11.4 11.4 11.4 43520 43521 43524 43535 43610 43615 EC EER EC PQ TC TC 11.6 12.2 11.6 10.2 13.8 13.8 44715 44721 44916 44920 44924 44925 TC EC TC TC EC TC 13.8 11.8 13.8 13.8 11.8 13.8 44932 44949 45021 45032 45224 45528 TC ETD EC ETD EC EC 13.8 12.4 11.8 12.4 12.2 11.8 40200 40301 40302 40401 40402 40502 TC TC PC TC TC TC 13.4 13.4 6.2 13.4 13.4 13.4 41408 S-41408 * 41425 * 41434 41435 41450 PC RS EC EC TC TC 6.2 7.2 11.18 11.18 13.6 13.6 S-42311 D-42311 42316 S-42318 D-42318 42507 40503 40506 40507 40601 40603 40704 TC PC PC TC TC PC 13.4 6.2 6.2 13.4 13.4 6.2 * 41500 * 41505 41506 41510 41515 41605 RM RM TC RM EFD TC 8.2 8.2 13.6 8.2 11.24 13.6 42508 42510 42512 42515 42515 42516 40705 40707 * 40903 40904 40905 40906 TC EP PC EC PC ER 13.4 9.2 6.2 11.2 6.2 12.2 41707 * 41709 41717 * 41805 41808 41809 EC EC EP EC EC TC 42520 11.2 42523 11.24 42530 9.2 42530 11.18 11.2 * 42610 42614 13.6 EC EFD EC UC PQ PQ 11.4 * 43618 43622 11.24 11.4 S-43622 11.4 D-43622 43723 10.2 43806 10.2 EC-IC PC RS DS RM TC 11.18 6.4 7.4 7.4 8.4 13.8 TC TC TC EP UC-IC PC 13.4 13.4 13.4 9.2 11.2 6.2 41810 41811 41812 41912 42016 42020 42616 S-42616 D-42616 42620 42625 * 42809 PC RS DS PQ PQ RM 6.4 7.2 7.2 10.2 10.2 8.4 * 43808 43813 43825 43939 * 44008 44011 EC-IC TC TC ETD EC-IC EC 45530 11.20 45724 13.8 13.8 * 45810 45959 12.4 46016 11.20 46113 11.6 EC EC EC-IC ETD EC TC 11.8 11.8 11.20 12.4 11.8 13.8 41110 41203 41205 41206 41208 * 41209 RM EC EC TC EC EC 8.2 11.2 11.2 13.4 11.2 11.2 42106 * 42107 42109 * 42110 42120 42206 TC EC TC EC EP TC 13.6 11.18 13.6 11.14 9.2 13.6 42810 42819 42908 42915 43007 43009 EC RM TC TC EC EC 11.4 8.4 13.6 13.6 11.4 11.4 44016 44020 44022 44040 44119 44119 EC EC-IC EC PQ EC UC 11.6 11.6 11.6 10.2 12.1 11.6 46326 * 46409 * 46410 47035 47054 47228 TC EC EC-IC EC ETD EC 13.8 11.20 11.20 12.1 12.4 11.8 41303 41305 41306 * 41309 41313 41406 41407 TC TC TC EEM EP TC TC 42207 13.4 42211 13.4 42212 13.4 42213 11.24 9.2 * 42216 42220 13.6 13.6 * 42309 TC EC TC PC EC UC RM 43013 13.6 43019 11.2 13.6 S-43019 6.4 D-43019 43113 11.18 43205 11.2 8.4 * 43208 EC PC RS DS TC TC EC-IC 44121 11.6 44125 6.4 44130 7.4 44216 7.4 44229 13.8 13.8 S-44229 11.18 D-44229 UC UC UC EER PC RS DS 11.6 11.6 11.8 12.4 6.4 7.4 7.4 47313 47325 48020 48613 49925 49925 49928 * 49938 TC TC EC TC IC UC EC EC 13.8 13.8 11.8 13.8 11.8 11.8 11.8 11.20 40907 41003 41005 41010 41106 41107 EC 11.2 PC 6.4 RM6-R 8.2 RM6-S 8.4 PQ 10.2 PQ 10.2 PLANAR CORES are available in a number of parts as indicated with an * in the index. Note that most cores can be pressed as planar types upon request. Check with the factory for cores that may already have an assigned planar part number or for any other parts for which you may have an interest. iii MAGNETICS EP CORES PC (POT) CORES PART NO. 40302 40506 40507 40704 * 40903 40905 41107 41408 41811 42213 42616 43019 43622 44229 44529 PAGE 6.2 6.2 6.2 6.2 6.2 6.2 6.2 6.2 6.4 6.4 6.4 6.4 6.4 6.4 6.4 PART NO. TYPE 40707 41010 41313 41717 42120 EP7 EP10 EP13 EP17 EP20 OTHER E CORES CONTINUED PAGE 9.2 9.2 9.2 9.2 9.2 PQ CORES PART NO. TYPE PAGE PART NO. TYPE 43520 43524 44011 44016 44020 44022 44924 45021 45528 45530 46016 47228 48020 49928 Metric E40 DIN 42/15 DIN 42/20 Metric E50 DIN 55/21 DIN 55/25 Metric E60 EEM, EFD CORES PAGE PAGE PART NO. TYPE 11.6 11.6 11.6 11.6 11.6 11.6 11.8 11.8 11.8 11.8 11.8 11.8 11.8 11.8 * 41309 EEM12.7 11.24 41515 EFD15 11.24 * 41709 11.24 42523 EFD25 11.24 42016 PQ20/16 10.2 42020 PQ20/20 10.2 * 42610 PQ26/10 10.2 42614 PQ26/14 10.2 Metric E80 42620 PQ26/20 10.2 E-100 42625 PQ26/25 10.2 * 43214 PQ32/14 10.2 U CORES RS (ROUND-SLAB) CORES 43220 PQ32/20 10.2 PART NO. TYPE PAGE 43230 PQ32/30 10.2 PAGE PART NO. 41106 (U&I) 11.2 43535 PQ35/35 10.2 42220 11.2 41408 7.2 44040 PQ40/40 10.2 42512 11.4 42311 7.2 LAMINATION SIZE E CORES 42515 (U&I) 11.4 42318 7.2 42516 11.4 42616 7.2 PART NO. TYPE PAGE 42530 11.4 43019 7.4 41203 E2829 11.2 44119 11.6 43622 7.4 41707 E3233 11.2 44121 11.6 44229 7.4 41808 EI187 11.2 44125 11.6 DS (DOUBLE-SLAB) CORES 42510 E2425 11.4 44130 11.8 43009 E2627 11.4 49925 (U&I) 11.8 PAGE PART NO. 43515 EI375 11.6 42311 7.2 44317 EI21 11.8 PLANAR E CORES 42318 7.2 44721 EI625 11.8 PART NO. TYPE PAGE 42616 7.2 45724 EI75 11.8 43019 7.4 41425 11.18 43622 7.4 41434 (E&I) 11.18 OTHER E CORES 44229 7.4 41805 (E&I) 11.18 PART NO. TYPE PAGE 42107 11.18 RM CORES 40904 11.2 42216 (E&I) 11.18 PART NO. TYPE PAGE 41205 11.2 43208 (E&I) 11.18 41110 RM4 8.2 41208 11.2 43618 (E&I) 11.18 * 41500 RM 8.2 41209 11.2 43808 (E&I) 11.18 * 41505 RM 8.2 41810 11.2 44008 (E&I) 11.20 41510 RM5 8.2 42211 11.2 44308 (E&I) 11.20 41812 RM6-R 8.2 42515 (E&I) 11.4 44310 (E&I) 11.20 41912 RM6-S 8.2 42520 11.4 45810 (E&I) 11.20 * 42309 RM 8.4 42530 11.4 46409 (E) 11.20 42316 RM8 8.4 42810 11.4 46410 (E&I) 11.20 * 42809 RM 8.4 43007 11.4 49938 11.20 42819 RM10 8.4 43013 11.6 43723 RM12 8.4 EC CORES PART NO. TYPE 43517 44119 45224 47035 EC35 EC41 EC52 EC70 PAGE 12.2 12.1 12.2 12.1 ETD, EER CORES PART NO. TYPE 43434 43521 43939 44216 44444 44949 45032 45959 47054 PAGE ETD34 EER35L ETD39 EER42 ETD44 ETD49 12.4 12.2 12.4 12.4 12.4 12.4 12.4 ETD59 12.4 12.4 ER CORES PART NO. TYPE 40906 PAGE (ER9.5) 12.6 TC (TOROID) CORES PART NO. TYPE 40200 40301 40401 40402 40502 40503 40601 40603 40705 40907 41003 41005 41206 41303 *PLANAR CORES Contact Sales Department for newest parts. For sizes not listed here, contact the Magnetics Sales Department. PAGE 13.4 13.4 13.4 13.4 13.4 13.4 13.4 13.4 13.4 13.4 13.4 13.4 13.4 13.4 TC (TOROID) CORES CONTINUED PART NO. TYPE 41305 41306 41406 41407 41435 41450 41506 41605 41809 42106 42109 42206 42207 42212 42507 42508 42908 42915 43113 43205 43610 43615 43806 43813 43825 44416 44715 44916 44920 44925 44932 46113 46326 47313 47325 48613 PAGE 13.4 13.4 13.6 13.6 13.6 13.6 13.6 13.6 13.6 13.6 13.6 13.6 13.6 13.6 13.6 13.6 13.6 13.6 13.8 13.8 13.8 13.8 13.8 13.8 13.8 13.8 13.8 13.8 13.8 13.8 13.8 13.8 13.8 13.8 13.8 13.8 mag-inc.com Part Number Index ARRANGED BY PART TYPE iv Order Information WARRANTY ORDERING All standard parts are guaranteed to be free from defects in material and workmanship, and are warranted to meet the Magnetics published specification. No other warranty, expressed or implied, is made by Magnetics. All special parts manufactured to a customer’s specification are guaranteed only to the extent agreed upon, in writing, between Magnetics and the user. When ordering, please use Magnetics part numbers, or specify material, size, and A L value. Magnetics customer service representatives and applications engineers are available to help you. Magnetics will repair or replace units under the following conditions: 1. The buyer must notify Magnetics, Pittsburgh, PA 15238 in writing, within 30 days of the receipt of material, that he requests authorization to return the parts. A description of the complaint must be included. 2. Transportation charges must be prepaid. 3. Magnetics determines to its satisfaction that the parts are defective, and the defect is not due to misuse, accident or improper application. Magnetics liability shall in no event exceed the cost of repair or replacement of its parts, if, within 90 days from date of shipment, they have been proven to be defective in workmanship or material at the time of shipment. No allowance will be made for repairs or replacements made by others without written authorization from Magnetics. Under no conditions shall Magnetics have any liability whatever for the loss of anticipated profits, interruption of operations, or for special, incidental or consequential damages. v MAGNETICS PACKING UNIT A packing unit is the quantity in a standard full package for a particular part. Special consideration, such as expedited deliveries, is given when ordering stocked standard sized packing units. Contact the factory for details. UL RECOGNITION Magnetics is a UL-recognized molder in the QMMY2 fabricated parts program. Many bobbins shown in this catalog are covered. Contact Magnetics for details on specific parts. WHAT ARE FERRITES? Ferrites are dense, homogeneous ceramic structures made by mixing iron oxide (Fe 2 O 3 ) with oxides or carbonates of one or more metals such as manganese, zinc, nickel, or magnesium. They are pressed, then fired in a kiln up to 2000˚ F, and machined as needed to meet various operational requirements. ADVANTAGES OF FERRITES Section 1 Introduction Ferrites have a paramount advantage over other types of magnetic materials: high electrical resistivity and resultant low eddy current losses over a wide frequency range. Additional characteristics such as high permeability and time/temperature stability have expanded ferrite uses into quality filter circuits, high frequency transformers, wide band transformers, adjustable inductors, delay lines, and other high frequency electronic circuitry. As the high frequency performance of other circuit components continues to be improved, ferrites are routinely designed into magnetic circuits for both low level and power applications. For the most favorable combination of low cost, high Q, high stability, and lowest volume, ferrites are the best core material choice for frequencies from 10 KHz to 50 MHz. Ferrites offer an unmatched flexibility in magnetic and mechanical parameters. FERRITE ADVANTAGES • • • • • • • • LOW COST LARGE SELECTION OF MATERIALS SHAPE VERSATILITY ECONOMICAL ASSEMBLY TEMPERATURE AND TIME STABILITY HIGH RESISTIVITY WIDE FREQUENCY RANGE (10KHz TO 50 MHz) HIGH Q/SMALL PACKAGE MAGNETICS® FERRITES Magnetics’ ferrite cores are manufactured for a wide variety of applications. Magnetics has developed and produces the leading MnZn ferrite materials for power transformers, power inductors, wideband transformers, common mode chokes, and many other applications. In addition to offering the leading materials, other advantages of ferrites from Magnetics include: the full range of standard planar E and I cores; rapid prototyping capability for new development; the widest range of toroid sizes in power and high permeability materials; standard gapping to precise inductance or mechanical dimension; wide range of coil former and assembly hardware available; and superior toroid coatings available in several options. 1.1 Introduction Properties TYPICAL MECHANICAL AND THERMAL PROPERTIES OF FERRITE MATERIALS MECHANICAL DATA UNITS THERMAL DATA Bulk Density 4.85 gm/cm 3 Coefficient of Linear Expansion 10.5X10 -6 ˚C -1 Tensile Strength 5.0, 7.0X10 3 kgf.mm -2 , lbs.in -2 Specific Heat (25˚) 1100, .26 J.kg -1 ˚C -1 , cal.g -1 .˚C -1 Compressive Strength 45, 63X10 3 kgf.mm -2 , lbs.in -2 Thermal Conductivity (25-85˚C) 3500-4300 µW.mm -1 .˚C -1 Youngs Modulus 12.4X10 3 , 1.8X10 7 kgf.mm -2 , lbs.in -2 35-43 mW.cm -1 .˚C -1 Hardness (Knoop) 650 Typical .0083-.010 cal.s-1 .cm-1 .˚C-1 Resistivity 10 2 -10 3 ohm-cm Above properties are averages measured on a range of commercially available MnZn ferrite materials. 1.2 UNITS MAGNETICS FERRITE APPLICATION AREAS APPLICATIONS Common Mode Chokes Differential Inductors Power Transformers DESIRED PROPERTIES Very high µ. Low losses and high temperature stability. High µ and low losses at high flux densities and temperatures. High saturation. PREFERRED MATERIALS J, W, H F, P, R F, P, R AVAILABLE SHAPES Toroids Pot cores, EP cores, E-cores, RM cores, Planar cores Ungapped pot cores, E, U & I cores, toroids, EP cores, RS cores, PQ cores, Planar cores Power Inductors Low losses at high flux densities and temperatures. High saturation. F, P, R Pot cores, E cores, PQ cores, RM cores, Planar cores Converter and Inverter Transformers Low losses, high saturation. F, P, R Pulse Transformers High µ, low loss, high Vt product. J, W, H Toroids, E, U, & I cores, pot cores, RS cores, Planar cores Toroids Broadband Transformers Low loss, high µ. J, W, H Pot cores, toroids, E, U & I cores, RM, EP cores Narrow Band Transformers Moderate Q, high µ, high stability. F Pot cores, toroids Telecom Inductors Low losses and high temperature stability. F, P, R Pot cores, EP cores, E cores, RM cores, Planar cores Noise Filters Very high µ. J, W, H Toroids Machining and Prototyping High µ, low losses, high saturation. J, R Ferrite blocks for machined parts mag-inc.com Introduction Applications 1.3 Part Number Identification 1.4 Ungapped Cores and Toroids 1. TYPICAL PART NUMBER S P 4 30 19 UG XX COATING/SHAPE CODE (SEE NOTE 2) FERRITE CORE MATERIAL USED FOR ALL FERRITE TYPES APPROXIMATE DIAMETER IN MM APPROXIMATE HEIGHT IN MM GEOMETRY CODE (SEE NOTE 3) SPECIAL SPECIFICATION CODE (SEE NOTE 4) 2. COATING/SHAPE CODE For some cores, a designation letter precedes the material code. COATING/SHAPE CODE CODE MEANING EXAMPLE C D F H N P R S V X Y Z O Planar E-core with clip recesses DS core with solid centerpost Planar E-core option: no clip recesses DS core with a center hole RM core with solid centerpost EP core RM core with a center hole RS core Nylon toroid coating Black coating (contact factory) Parylene toroid coating Polyester/Epoxy toroid coating No meaning (e.g.OP-41808-EC is the same as P-41808-EC) CR45810EC DF42311UG FR45810EC HP41408UG NP41510UG PJ41313UG RG41510UG SD41408UG VJ42206TC XW41003TC YA40603TC ZJ42915TC MAGNETICS 3. GEOMETRY CODE For standard ungapped cores, a two letter code indicates the geometry. GEOMETRY CODE CODE GEOMETRY EXAMPLE UNIT OF MEASURE EC All E-cores, including ETD, EC, EER, EEM, EFD, planar and lamination size. I-Core Toroid U-Core POT, RS, DS, RM, PQ, EP OP44317EC Piece OJ42516IC ZJ42915TC OJ41106UC DF42311UG Piece Piece Piece Set IC TC UC UG 4. SPECIAL SPECIFICATION CODE A variety of features over and above the standard specifications are available. For details, see the section on page 1.6, “Special Specification Codes.” 5. UNIT OF MEASURE POT, RS, DS, RM, PQ, and EP cores are ordered in sets. One set is a pair of two pieces. One set usually is ordered for each transformer, inductor, or device to be built. E-, U-, and I-Cores are ordered in individual pieces. Two pieces usually are ordered for each transformer, inductor, or device to be built. Toroids are ordered in individual pieces. HARDWARE Accessory hardware is offered for nearly all of the cores shown in this catalog. Available items are shown together with the appropriate cores. Magnetics is a UL-recognized molder in the QMMY2 fabricated parts program. Many bobbins shown in this catalog are covered. Contact the factory for details on specific parts. Part Number Identification Ungapped Cores and Toroids The part number and material are shown with the drawing for each bobbin. Every bobbin is provided in the material defined by the part number, whether the bobbin is covered in the UL QMMY2 program or not. mag-inc.com 1.5 Part Number Identification Gapped Cores 1. TYPICAL PART NUMBER OP44317 SAME AS FOR UNGAPPED CORES AND TOROIDS(PAGE 1.3) GAP CODE (SEE NOTE 2) SPECIAL SPECIFICATION CODE 2. GAP CODE The letter indicates the type of gap and a three-digit number defines the value. GAP CODE CODE A_ _ _ X_ _ _ F_ _ _ G_ _ _ M_ _ _ MEANING A L is inductance factor, mH/1000 Turns, or nH/T 2 (see page 14.2 for definitions, page 2.1 for measurement setup.) See the chart on pages 1.81.11 for tolerances. The standard gap codes do not apply to U-Cores, toroids, I-Cores, or some E-I combinations. 3. UNIT OF MEASURE See Note 5 on page 1.5. For parts ordered in pieces (E-Cores), the depth of grind is given for each piece. For parts ordered in sets, the depth of grind is given as a total for the set, and may be UG/G or G/G (see the chart on page 1.8 to determine which is standard.) MAGNETICS EXAMPLE A L (if < 1000) A L if 1000 or greater (add 1000 to code) A L if < 100, non-integer (divide code by10) Depth of grind in mils (1000 ths of an inch) Depth of grind, mm (divide code by 10) When ordering E-cores gapped to an A L value it is critical to understand whether the standard is UG/G or G/G. See Note 1 on page 1.9. 1.6 A450 XX DF42311A275 (A L = 275) OP44721X250 (A L = 1250) OR42510F807 (A L = 80.7) OF44317G079 (Gap = 0.079”) OF43019M015 (Gap = 1.5mm) 4. SPECIAL REQUIREMENTS Many non-standard features are available, including gap values and tolerances that are different from those shown on the tables in this catalog. The next section on this page, “Special Specification Codes” explains how part numbers are defined for non-standard requirements. For assistance with any special requirements, Magnetics customer service representatives and applications engineers are available to help you. SPECIAL SPECIFICATION CODES For special customer requirements, a detailed product specification is written. This special specification is referenced to a unique two-character part number suffix. The resulting part number is reserved for the exclusive use of the originating customer and any sub-contractors that the originating customer designates. Special specifications can be written to meet a wide variety of requirements, including: • • • • • • • • CUSTOM PACKAGING CUSTOM MARKING NON-STANDARD TOLERANCES NON-STANDARD UNITS OF MEASURE CUSTOM ELECTRICAL PERFORMANCE MODIFIED HEIGHTS SPECIAL TESTING MANY OTHER NEEDS For five common requirements, a standard letter code is used in the suffix location: SPECIAL SPECIFICATION CODE CODE NS CC EI MEANING Not stamped; the standard part marking is omitted. Color coded; see page 13.1 for the color index. E-core gapped to an A L value when mated with the standard I-core. EXAMPLE DF42311UGNS ZP42915TCCC CR42216A160EI A L = 160±3% with CR42216IC mag-inc.com Part Number Identification Special Specification Codes 1.7 Gapped Cores Depth of Grind Tolerance Ranges Either the A L or the depth of grind (not both) is controlled during production of gapped cores. Part numbering for gapped cores is explained on page 1.6. Codes A, X and F define A L values. Codes G and M define depths of grind. “Ungapped to gap combination” means an asymmetrical gap; the entire gap is taken from one piece, and the other piece is ungapped. “Gap to gap combination” means the gap is symmetrical; half of the total gap is ground into each piece. In most applications, defining the gap with the AL results in inductors with the least variation. Electrical measurement is inherently more precise, and compensation is made for variability in material permeability and core geometry. For deep gaps, however, better consistency often results when the depth of grind is specified. In such cases, variation in the finished inductor is dominated by the variation in the windings, especially if the number of turns is low. INCHES MILLIMETERS GAP TOLERANCE For shapes: POT, RS, DS, RM, PQ, and EP Cores. 0.001”–0.038” 0.039”–0.076” ±0.0005” ±0.001” Ungapped to gap combination. Ungapped to gap combination GAP TOLERANCE 0.1mm–0.9mm 1.0mm–1.9mm ±0.03mm ±0.04mm 2.0mm–2.9mm ±0.07mm 3.0mm–3.8mm 3.9mm–5.0mm ±0.07mm ±0.12mm (Except if the gap is more than 10% of the minimum bobbin depth for the set*. Then gap-to-gap combination.) 0.077”–0.114” ±0.002” Gap to gap combination (Except if the gap is less than 10% of the minimum bobbin depth for the set*. Then ungapped-to-gap combination.) 0.115”–0.152” 0.153”–0.228” ±0.002” ±0.004” Gap to gap combination. Gap to gap combination. *The bobbin depth for the set is the 2D dimension, or 2 times the D dimension. INCHES GAP TOLERANCE 0.001”–0.038” 0.039”–0.076” 0.077”–0.152” 0.153”–0.228” ±0.0005” ±0.001” ±0.002” ±0.004” MILLIMETERS For E-Cores: Lamination Size, EFD, EEM, EC, ETD, ER, EER, Planar E, and other E-Cores. E-cores are sold as pieces, not sets. To make an ungapped/gapped set, use one piece of each. For example, use OR41808G050 with OR41808EC for an asymmetrical gap of 0.050” ± 001”. For the same gap, but symmetric, use two pieces of OR41808G025. For more information about gapped cores and using them, please see pages 4.13-4.19. For tolerance requirements other than those shown below, please contact the factory. 1.8 MAGNETICS GAP TOLERANCE 0.1mm–0.9mm 1.0mm–1.9mm 2.0mm–3.8mm 3.9mm–5.0mm ±0.03mm ±0.04mm ±0.07mm ±0.12mm 1. UNIT OF MEASURE When specifying and ordering E-Cores gapped to an A L , it is important to note which cores are produced in gap-to-gap combination, because two gapped pieces are assembled to achieve the A L . Alternatively, for E-Cores provided ungapped-to-gap, an ungapped piece must be used with the gapped part to achieve the A L . POT, RS, DS, RM, PQ, and EP cores are sold as sets whether the combination is G/G or UG/G. 3. CORRELATION Magnetics tests gapped A L values with full bobbins, usually 100 turns, or 250 turns for deep gaps. The drive level is low (5 Gauss) and the frequency is set low enough to avoid resonance effects. Measured inductance in an application may vary significantly from the theoretical value due to low turns, low bobbin fill, leakage effects, resonance effects, or elevated drive levels. 2. SIGNIFICANT FIGURES A L testing and limits are calculated to three significant digits, based on the nominal value. For example, A L = 99±3% is interpreted as 96.0 Minimum, 99.0 Nominal, and 102.0 Maximum. It is important for the user to verify the correlation between the test of the core and the specific test being applied to the inductor or transformer. Planar E Cores, planar RM, and planar PQ cores are especially susceptible to correlation discrepancies. PC (POT) CORES FOUND IN SECTION 6 GAP TO GAP ±3% 40704 40905 41107 41408 41811 42213 42616 43019 43622 44229 44529 25-35 25-48 25-75 71-113 96-174 113-204 139-249 170-304 222-399 169-389 172-549 RS (ROUND-SLAB) CORES FOUND IN SECTION 7 UNGAPPED TO GAP COMBINATION ±3% ±5% ±7% ±10% 36-62 49-87 76-135 114-210 175-326 205-482 250-695 305-1015 400-1494 390-1965 550-1999 63-95 88-135 136-220 211-307 ≤ 523 ≤ 779 ≤ 1125 ≤ 1642 ≤ 1999 ≤ 1999 Gapped Cores Gapping for AL 96-125 136-180 221-285 308-417 ≤ 712 ≤ 1060 ≤ 1543 ≤ 1999 126-175 181-240 286-399 418-574 ≤ 988 ≤ 1459 ≤ 1999 GAP TO GAP ±3% 41408 42311 42318 42616 43019 43622 44229 25-39 25-39 25-39 25-62 40-62 40-62 UNGAPPED TO GAP COMBINATION ±3% ±5% ±7% ±10% 25-177 40-347 40-452 40-622 63-918 63-1286 63-1732 ≤ 283 ≤ 708 ≤ 731 ≤ 998 ≤ 1485 ≤ 1999 ≤ 1999 ≤ 385 ≤ 963 ≤ 994 ≤ 1369 ≤ 1999 ≤ 530 ≤ 1325 ≤ 1378 ≤ 1884 Charts show type of combination and the guaranteed tolerance for corresponding A L ranges. For special tolerances, or for A L = 2000 or higher, contact the factory. Ranges indicated are the tolerances for standard gapped cores. For ± 5%, ± 7%, and ± 10%, the maximum AL for each tolerance is shown. Standard cores are manufactured to the smallest allowed tolerance. mag-inc.com 1.9 Gapped Cores Gapping for AL DS (DOUBLE-SLAB) CORES FOUND IN SECTION 7 UNGAPPED TO GAP COMBINATION ±3% ±5% ±7% ±10% GAP TO GAP ±3% 42311 42318 42616 43019 43622 44229 109-195 78-135 117-205 149-264 170-300 179-315 196-386 136-441 206-580 265-873 301-1111 316-1543 ≤ 625 ≤ 706 ≤ 930 ≤ 1412 ≤ 1797 ≤ 1999 ≤ 850 ≤ 961 ≤ 1276 ≤ 1922 ≤ 1999 ≤ 1170 ≤ 1332 ≤ 1756 ≤ 1999 RM CORES FOUND IN SECTION 8 ±3% 25-50 56-99 69-120 69-120 84-150 126-200 145-250 51-55 100-162 121-238 121-238 151-395 201-625 251-977 ≤ 75 ≤ 258 ≤ 381 ≤ 381 ≤ 633 ≤ 1002 ≤ 1580 ≤ 170 ≤ 352 ≤ 519 ≤ 519 ≤ 862 ≤ 1374 ≤ 1999 ≤ 250 ≤ 484 ≤ 714 ≤ 714 ≤ 1195 ≤ 1892 EP CORES FOUND IN SECTION 9 GAP TO GAP ±3% 40707 41010 41313 41717 42120 25-63 25-55 25-75 25-100 25-180 GAP TO GAP ±3% 42016 42020 42610 42614 42620 42625 43214 43220 43230 43535 44040 60-184 50-139 200-396 103-334 95-296 77-234 127-416 128-409 84-241 89-255 83-230 UNGAPPED TO GAP COMBINATION ±3% ±5% ±7% ±10% 64-75 56-75 76-110 101-175 181-450 ≤ 125 ≤ 125 ≤ 175 ≤ 275 ≤ 630 ≤ 275 ≤ 400 ≤ 850 ≤ 160 ≤ 160 ≤ 315 ≤ 630 ≤ 1250 GAP TO GAP ±3% 41203 41707 41808 42510 43009 43515 44317 44721 45724 16-27 22-37 27-42 37-61 55-91 54-87 81-136 107-180 129-218 Charts show type of combination and the guaranteed tolerance for corresponding A L ranges. For special tolerances, or for A L = 2000 or higher, contact the factory. Ranges indicated are the tolerances for standard gapped cores. For ± 5%, ± 7%, and ± 10%, the maximum AL for each tolerance is shown. Standard cores are manufactured to the smallest allowed tolerance. ≤ 755 ≤ 754 ≤ 1258 ≤ 1044 ≤ 1436 ≤ 1423 ≤ 885 ≤ 1369 ≤ 1305 ≤ 1575 ≤ 1625 ≤ 1027 ≤ 1026 ≤ 1728 ≤ 1421 ≤ 1955 ≤ 1936 ≤ 1207 ≤ 1878 ≤ 1775 ≤ 1999 ≤ 1999 ≤ 1425 ≤ 1422 ≤ 1999 ≤ 1972 ≤ 1999 ≤ 1999 ≤ 1661 ≤ 1999 ≤ 1999 UNGAPPED TO GAP COMBINATION ±3% ±5% ±7% ±10% 28-55 38-89 43-121 62-200 92-222 88-429 137-762 181-1188 219-1732 ≤ 86 ≤ 140 ≤ 192 ≤ 318 ≤ 353 ≤ 687 ≤ 1222 ≤ 1920 ≤ 1999 ≤ 117 ≤ 190 ≤ 258 ≤ 432 ≤ 475 ≤ 934 ≤ 1676 ≤ 1999 ≤ 160 ≤ 259 ≤ 355 ≤ 595 ≤ 653 ≤ 1284 ≤ 1999 EFD, EEM CORES FOUND IN SECTION 11 ±3% MAGNETICS 185-467 140-467 397-777 335-645 297-888 235-880 417-548 410-846 242-808 256-980 231-1006 LAMINATION SIZE E-CORES FOUND IN SECTION 11 GAP TO GAP 1.10 UNGAPPED TO GAP COMBINATION ±3% ±5% ±7% ±10% UNGAPPED TO GAP COMBINATION ±3% ±5% ±7% ±10% GAP TO GAP 41110 41510 41812 41912 42316 42819 43723 PQ CORES FOUND IN SECTION 10 41309 41515 41709 42110 42523 17-28 19-30 21-34 15-25 41-66 UNGAPPED TO GAP COMBINATION ±3% ±5% ±7% ±10% 29-64 31-81 35-107 26-92 67-296 ≤ 100 ≤ 127 ≤ 169 ≤ 145 ≤ 475 ≤ 135 ≤ 172 ≤ 230 ≤ 195 ≤ 646 ≤ 184 ≤ 236 ≤ 313 ≤ 268 ≤ 888 PLANAR E-CORES* FOUND IN SECTION 11 GAP TO GAP ±3% 41425 41434 41805 42107 42216 43208 43618 43808 44008 44308 44310 45810 46409 46410 49938 19-37 17-31 18-32 35-66 78-141 118-216 119-222 173-315 106-189 201-367 169-305 266-481 413-768 379-701 336-594 EC CORES FOUND IN SECTION 12 UNGAPPED TO GAP COMBINATION ±3% ±5% ±7% ±10% 38-76 32-77 33-205 67-188 142-405 217-643 223-673 316-956 190-507 368-1130 306-1130 482-1496 769-1999 702-1999 595-1999 ≤ 122 ≤ 123 ≤ 329 ≤ 304 ≤ 656 ≤ 1040 ≤ 1088 ≤ 1547 ≤ 821 ≤ 1828 ≤ 1828 ≤ 1999 ≤ 166 ≤ 167 ≤ 448 ≤ 414 ≤ 892 ≤ 1427 ≤ 1491 ≤ 1999 ≤ 1116 ≤ 1999 ≤ 1999 ≤ 228 ≤ 230 ≤ 617 ≤ 569 ≤ 1239 ≤ 1964 ≤ 1999 ≤ 1548 41205 41208 41810 42211 42515 42520 42530 42810 43007 43013 43520 43524 44011 44016 44020 44022 44924 45021 45528 45530 46016 47228 48020 28-47 19-30 44-74 26-42 28-43 107-190 45-72 84-146 42-67 71-121 65-111 41-62 59-95 52-83 78-126 94-156 100-165 99-167 113-186 129-215 102-129 120-199 99-158 UNGAPPED TO GAP COMBINATION ±3% ±5% ±7% ±10% 48-107 31-78 75-235 43-148 44-210 191-397 73-409 147-490 68-307 122-552 112-461 63-439 96-642 84-545 127-916 157-1187 166-1276 168-1127 187-1736 216-1999 130-1231 200-1823 159-1922 ≤ 170 ≤ 123 ≤ 376 ≤ 236 ≤ 333 ≤ 643 ≤ 655 ≤ 786 ≤ 491 ≤ 885 ≤ 738 ≤ 698 ≤ 1029 ≤ 872 ≤ 1480 ≤ 1903 ≤ 1999 ≤ 1807 ≤ 1999 ≤ 229 ≤ 166 ≤ 512 ≤ 320 ≤ 452 ≤ 874 ≤ 891 ≤ 1069 ≤ 668 ≤ 1204 ≤ 1003 ≤ 949 ≤ 1400 ≤ 1185 ≤ 1999 ≤ 1999 ≤ 1989 ≤ 1999 ≤ 1999 ≤ 1999 43517 44119 45224 47035 49-79 61-98 76-123 83-135 ≤ 316 ≤ 228 ≤ 704 ≤ 440 ≤ 616 ≤ 1202 ≤ 1225 ≤ 1483 ≤ 919 ≤ 1669 ≤ 1380 ≤ 1305 ≤ 1940 ≤ 1629 UNGAPPED TO GAP COMBINATION ±3% ±5% ±7% ±10% 80-438 99-627 124-911 136-1403 ≤ 702 ≤ 1004 ≤ 1471 ≤ 1999 ≤ 954 ≤ 1365 ≤ 1999 ≤ 1312 ≤ 1891 ETD, EER CORES FOUND IN SECTION 12 ±3% OTHER E-CORES FOUND IN SECTION 11 ±3% ±3% GAP TO GAP * These tolerances also apply to Planar E-I combinations. GAP TO GAP GAP TO GAP 40906 43434 43521 43939 44216 44444 44949 45032 45959 47054 15-30 55-88 54-86 95-156 71-117 73-117 81-130 62-99 51-118 83-126 UNGAPPED TO GAP COMBINATION ±3% ±5% ±7% ±10% 31-52 89-500 87-566 157-641 118-876 118-881 131-1075 100-807 119-1822 127-1681 53-80 ≤ 806 ≤ 913 ≤ 1028 ≤ 1415 ≤ 1423 ≤ 1736 ≤ 1304 ≤ 1999 ≤ 1999 81-105 ≤ 1095 ≤ 1241 ≤ 1398 ≤ 1925 ≤ 1935 ≤ 1999 ≤ 1773 106-142 ≤ 1507 ≤ 1707 ≤ 1935 ≤ 1999 ≤ 1999 Gapped Cores Gapping for AL ≤ 1999 Charts show type of combination and the guaranteed tolerance for corresponding A L ranges. For special tolerances, or for A L = 2000 or higher, contact the factory. Ranges indicated are the tolerances for standard gapped cores. For ± 5%, ± 7%, and ± 10%, the maximum AL for each tolerance is shown. Standard cores are manufactured to the smallest allowed tolerance. ≤ 1999 mag-inc.com 1.11 Introduction 1.12 Notes MAGNETICS EQUIPMENT The test data included in this catalog was primarily obtained using bridges such as a HewlettPackard 419A impedance analyzer. The HP 4192A was used for permeability and loss factor data from 10kHz to 1MHz. A Wayne-Kerr 3245 inductance analyzer was used for DC bias to 100kHz. Also, for Permeability vs. Temperature, Permeability vs. Frequency, and Disaccommodation, an HP 4192A was coupled with a computer controlled temperature cabinet and an HP 9836 computer. Core loss up to and including 100kHz is measured using a 11401 Tektronix oscilloscope connected to an HP Vectra computer. This is a fully automated system. Other measurements include core loss using a Tektronix 7854 digital oscilloscope and an HP 9836 computer to measure losses at 500kHz to 1MHz. This test setup is also used to obtain B-H loops in the 1kHz to 100kHz ranges. Section 2 Measurement Information High level readings such as Permeability vs. Flux Density were measured on a General Radio 1632A incremental bridge. Q measurements were made on a Boonton 260A Q-meter. MEASUREMENT For initial permeability and inductance measurements, excitation levels are kept at values insuring flux densities below 10 gauss. Temperature measurements normally are obtained between -30° and 70°C but additional temperatures to - 65° and 260°C are used to indicate trends and changes in materials properties outside the normal guaranteed range. Inductance measurements for disaccommodation are made at 10 and 100 minutes after the test core has been demagnetized. Disaccommodation Factor is calculated mathematically. Test bobbins are carefully layer wound with magnet wire or litz wire whose size is chosen so that the calculated number of turns completely fills the bobbin. Before core halves are assembled, the mating surfaces should be clean and free from dust. After aligning the two core halves, pressure indicated in the table below should be applied. Magnetics clamping hardware will handle these pressures. STANDARD POT CORES 40704 40905 41107 41408 41811 4 5 7 7 12 lbs. lbs. lbs. lbs. lbs. RS CORES 41408 42311, 42318 42616 43019 43629 44229 42213 42616 43019 43622 44229 RM CORES 15 20 20 30 35 lbs. lbs. lbs. lbs. lbs. 41110 41510, 41912 41812 42316 42819 PQ CORES 7 15 20 20 30 35 lbs. lbs. lbs. lbs. lbs. lbs. 42016, 42020 42620, 42020 43220, 42330 43535 44040 5 7 7 15 20 lbs. lbs. lbs. lbs. lbs. 6 7 7 13 15 lbs. lbs. lbs. lbs. lbs. EP CORES 15 20 30 30 35 lbs. lbs. lbs. lbs. lbs. 40707 41010 41313 41717 42020 2.1 Measurement 2.2 VOLTAGE BREAKDOWN MEASUREMENT CALIBRATION Core finishes (toroids) are tested for voltage breakdown by inserting the core between two weighted wire mesh pads. Force is adjusted to produce a uniform pressure of 10psi, simulating winding pressure. The test condition to guarantee minimum breakdown (see 13.2) is a 60 Hertz r.m.s. voltage equal to 1.25 times the minimum. All measurement equipment is periodically checked against our NSB traceable standards. These standards include an EDC 2902 DC voltage standard, an EDC 3200 AC/DC current calibrator, a Fluke 5200A AC calibrator, and various resistance, capacitive, and Q standards. PHYSICAL MEASUREMENTS CONVERSION TABLE MULTIPLY NUMBER OF oersteds oersteds gausses gausses in 2 circular mils mWatts/cm 3 BY 79.5 0.795 10 -4 0.10 6.452 5.07 x 10 -6 0.094 MAGNETICS TO OBTAIN NUMBER OF ampere-turns/m ampere-turns/cm teslas (webers/m 2 ) milliTeslas cm 2 cm 2 watts/lb. Specific “+” or “-“ tolerances on part dimensions indicated as “normal” in this catalog can be provided if needed. If a dimension is listed as “typical”, it is the same as nominal except it covers a plurality. RESEARCH AND DEVELOPMENT Magnetics Technology has a continuing program aimed at improving existing products and introducing new materials and geometries. Technology efforts and concentrated programming have made Magnetics a leader in many other magnetic materials, in addition to having a steady growth in ferrites. Technology also provides technical data which may not be regularly available. MATERIALS Magnetics has developed and produces leading MnZn ferrite materials for a variety of applications. POWER MATERIALS Three low loss materials are engineered for optimum frequency and temperature performance in power applications. Magnetics’ R, P and F materials provide superior saturation, high temperature performance, low losses and product consistency. SHAPES: E cores, Planar E cores, ETD, EC, U cores, I cores, PQ, Planar PQ, RM, Toroids (2mm to 86mm), Pot cores, RS (round-slab), DS (double slab), EP, Special Shapes. APPLICATIONS: Telecomm Power Supplies, Computer Power Supplies, Commercial Power Supplies, Consumer Power Supplies, Automotive, DC-DC Converters, Telecomm Data Interfaces, Impedance Matching Transformers, Handheld Devices, High power control (gate drive), Computer Servers, Distributed Power (DC-DC), EMI Filters, Aerospace, Medical. Section 3 Materials HIGH PERMEABILITY MATERIALS Three high permeablility materials (5000µ J material, 10000µ W material and 15000µ H material) are engineered for optimum frequency and impedance performance in signal, choke and filter applications. These Magnetics’ materials provide superior loss factor, frequency response, temperature performance, and product consistency. SHAPES: Toroids (2 mm to 86 mm), E cores, U cores, RM, Pot cores, RS (round-slab), DS (double slab), EP, Special Shapes. APPLICATIONS: Common Mode Chokes, EMI Filters, Other Filters, Current Sensors, Telecomm Data Interfaces, Impedance matching interfaces, Handheld devices, Spike Suppression, Gate Drive Transformers. SPECIAL MATERIALS A number of special materials are engineered for specific performance results, including frequency response, temperature factor, Curie temperature, permeability across temperature for GFCI and telecomm performance, and loss factor. Magnetics’ special materials provide outstanding performance, customization options and superior product consistency. SHAPES: E cores, Planar E cores, ETD, EC, U cores, I cores, PQ, Planar PQ, RM, Toroids (2mm to 86mm), Pot cores, RS (round-slab), DS (double slab), EP, Special Shapes. APPLICATIONS: EMI Filters, Current sensors, Chokes, Tuned Filters, Data interfaces, Special temperature requirements, Other Special Requirements. Contact Magnetics’ Application Engineering for additional information. 3.1 Materials Characteristics EMI/RFI FILTERS & BROADBAND TRANSFORMERS INDUCTORS & POWER TRANSFORMERS Initial Permeability Maximum Usable Frequency (50% roll-off) Relative Loss Factor *Curie Temperature * Relative Temp. Factor -30˚C to +20˚C +20˚C to 70˚C * Flux Density @ 1,194 A/m (15 Oe) * Remanence P F J W H µi — 2,300 ± 25% 2,500 ± 25% 3,000 ± 20% 5,000 ± 20% 10,000 ± 30% 15,000 ± 30% f tan d µiac Tc /˚C MHz <1.5 <1.2 <1.3 <1 <0.25 <0.15 10-6 ˚C 10-6/˚C >230 >230 <8 (100kHz) >250 <20 (100kHz) >140 <7 (10kHz) >125 <15 (10kHz) >120 5,000 500 1,100 110 0.18 14 5,000 500 1,100 110 0.18 14 4,900 490 1,200 120 0.2 16 6 4.8 130 85 70 85 140 100 70 90 375 300 250 300 5 4.8 120 90 95 130 125 90 125 165 300 250 275 350 2 4.8 90 160 240 4,300 430 1,000 100 0.1 8 <3 1 4.8 4,300 430 800 80 0.04 3 <3 0.15 4.8 4,200 420 800 80 0.04 3 <2.5 0.1 4.9 Bm G mT Br G mT 0e A/m 10-6 * Coercivity Hc Disaccommodation Factor * Resistivity * Density Power Loss (PL) Sine Wave, in mW/cm3 (typical) DF r d 25kHz 200mT (2,000G) 100kHz 100mT (1,000G) 500kHz 50mT (500G) 700kHz 50mT (500G) Available In: R Ω-m g/cm3 @25˚C @60˚C @100˚C @120˚C @25˚C @60˚C @100˚C @120˚C @25˚C @60˚C @100˚C @120˚C @25˚C @60˚C @100˚C @120˚C 100 180 225 Pot Cores X X X X X X X X X X RS Cores DS Cores X X X X X X X X X X RM Cores X X X X X EP Cores E, U Cores X X X X X X X X EC, ETD Cores PQ Cores X X X Toroids X X X X X X Blocks X Note: These characteristics are typical for a 42206 size (0.870” O.D.) toroid. Specific core data will usually differ from these numbers due to the influence of geometry and size. Characteristics with a * are typical. 3.2 MAGNETICS GRAPH 1 - FREQUENCY RESPONSE CURVES Frequency Response Curves 80 100 ency (kHz) 200 300 400 600 1000 GRAPH 2 - FREQUENCY RESPONSE CURVES Materials Material Curves 2000 FREQUENCY (kHz) FREQUENCY (kHz) mag-inc.com 3.3 R Material Saturation Flux Density - gausses 5,000 (at 15 oersted, 25˚C) (500 mT) Coercive Force - oersted . . . . . . . . . . . . . . . . . 0.18 (14A/m) Curie Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 230˚C µi 2,300 ±25% NOTE: The core loss curves are developed from empirical data. For best results and highest accuracy, use them. The formula on page 3.10 yields a fair approximation and can be useful in computer programs. PERMEABILITY vs. TEMPERATURE CORE LOSS vs. DENSITY CORE LOSS vs. FLUX DENSITY Mat_R_Coreloss_vs_Temp.eps 10 00 kH z @ 100º C hese curves are determined from ac data. For unidirectional pplications, use 1/2 of the actual ∆B to determine loss. 50 0k Hz TEMPERATURE ˚C 25 0k Hz CORE LOSS vs. TEMPERATURE 25 kH z 50 kH z 10 0k Hz Mat_R_Perm_vs_Fluxden.eps TEMPERATURE ˚C 80 100 150 200 300 400 600 1000 2000 FLUX DENSITY GAUSS FLUX DENSITY GAUSS PERMEABILITY vs. FLUX DENSITY FLUX DENSITY vs. TEMPERATURE FLUX DENSITY GAUSS FLUX DENSITY vs. TEMPERATURE 00 00 H = 15oe 00 00 20 40 60 80 100 120 140 TEMPERATURE ˚C TEMPERATURE (ºC) 3.4 FLUX DENSITY GAUSS MAGNETICS See Page 3.11 for B-H Data P Material Saturation Flux Density - gausses 5,000 (at 15 oersted, 25˚C) (500 mT) Coercive Force - oersted. . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 (14A/m) Curie Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230˚C Mat_P_Core_vs_Flux NOTE: The core loss curves are developed from empirical data. For best results and highest accuracy, use them. The formula on page 3.10 yields a fair approximation and can be useful in computer programs. CORE LOSS vs. FLUX DENSITY CORE LOSS vs. FLUX DENSITY 10 00 kH z Mat_P_Core_vs_Temp.eps 25 0k Hz 50 0k Hz etermined from ac data. pplications, use 1/2 of etermine loss PERMEABILITY vs. TEMPERATURE µi 2,500 ±25% 10 0k Hz TEMPERATURE ˚C 50 kH z CORE LOSS vs. TEMPERATURE Mat_P_Fluxden_vs_Te 25 kH z Mat_P_Perm_vs_Fluxden.eps 150 200 300 400 1000 2000 TEMPERATURE ˚C FLUX DENSITY GAUSS FLUX DENSITY GAUSS PERMEABILITY vs. FLUX DENSITY FLUX DENSITY vs. TEMPERATURE FLUX DENSITY vs. TEMPERATURE H = 15 oe 60 80 100 120 130 TEMPERATURE ˚C TEMPERATURE (ºC) FLUX DENSITY GAUSS See Page 3.11 for B-H Data mag-inc.com 3.5 F Material Saturation Flux Density - gausses 4,900 (at 15 oersted, 25˚C) (490 mT) Coercive Force - oersted . . . . . . . . . . . . . . . . . . 0.20 (16A/m) Curie Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250˚C µi 3,000 ±20% NOTE: The core loss curves are developed from empirical data. For best results and highest accuracy, use them. The formula on page 3.10 yields a fair approximation and can be useful in computer programs. CORE LOSS vs. FLUX DENSITY CORE LOSS vs. FLUX DENSITY PERMEABILITY vs. TEMPERATURE Mat_F_CoreLoss_vs_Temp.eps @ 25º C These curves are determined from ac data. For unidirectional applications, use 1/2 of the actual ∆B to determine loss. 50 0k H z 10 00 kH z µ 250 k Hz TEMPERATURE ˚C kH z CORE LOSS vs. TEMPERATURE 1kH z 5kH z 10k Hz 25k Hz 50k Hz 100 Mat_F_Perm_vs_Fluxden.eps 0 80 100 150 200 300 400 600 1000 2000 TEMPERATURE ˚C FLUX DENSITY GAUSS PERMEABILITY vs. FLUX DENSITY FLUX DENSITY GAUSS FLUX DENSITY vs. TEMPERATURE FLUX DENSITY vs TEMPERATURE µ H = 15 oe 20 40 60 80 TEMPERATURE (ºC) 3.6 100 120 FLUX DENSITY GAUSS See Page 3.11 for B-H Data MAGNETICS TEMPERATURE ˚C J Material Saturation Flux Density - gausses 4,300 (at 15 oersted, 25˚C) (430 mT) Coercive Force - oersted. . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 (8A/m) Curie Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140˚C Disaccomadation Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . <3.0 x 10-6 Mat_J_Coreloss_vs NOTE: The core loss curves are developed from empirical data. For best results and highest accuracy, use them. The formula on page 3.10 yields a fair approximation and can be useful in computer programs. PERMEABILITY vs. TEMPERATURE vs. FLUX DENSITY µi 5,000 ±20% Mat_J_Coreloss_vs_Temp.eps CORE LOSS vs. FLUX DENSITY Hz from ac data. , use 1/2 of the z TEMPERATURE ˚C z CORE LOSS vs. TEMPERATURE Mat_J_Perm_vs_Fluxden.eps Hz z Mat_J_Fluxden TEMPERATURE ˚C 300 400 600 1000 2000 X DENSITY GAUSS FLUX DENSITY GAUSS PERMEABILITY vs. FLUX DENSITY FLUX DENSITY vs. TEMPERATURE UX DENSITY vs. TEMPERATURE H = 15oe 40 60 80 TEMPERATURE (ºC) 100 120 TEMPERATURE ˚C FLUX DENSITY GAUSS See Page 3.11 for B-H Data mag-inc.com 3.7 W Material Saturation Flux Density - gausses 4,300 (at 15 oersted, 25˚C) (430 mT) Coercive Force - oersted. . . . . . . . . . . . . . . . . . . . 0.04 (3A/m) Curie Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125˚C Disaccomadation factor. . . . . . . . . . . . . . . . . . . . . . . <3 x 10-6 µi 10,000 ±30% at 10kHz PERMEABILITY vs. TEMPERATURE OSS vs. FLUX DENSITY Mat_ NOTE: The core loss curves are developed from empirical data. For best results and highest accuracy, use them. The formula on page 3.10 yields a fair approximation and can be useful in computer programs. Mat_W_Coreloss_vs_Temp.eps CORE LOSS vs. FLUX DENSITY mined from ac data. cations, use 1/2 of the loss. 100 kH z TEMPERATURE ˚C 50k Hz CORE LOSS vs. TEMPERATURE 1kH z 10k Hz 20k Hz Mat_W_Perm_vs_Fluxden.eps TEMPERATURE ˚C 0 300 400 600 LUX DENSITY GAUSS 1000 2000 PERMEABILITY vs. FLUX DENSITY FLUX DENSITY GAUSS FLUX DENSITY vs. TEMPERATURE FLUX DENSITY vs. TEMPERATURE H = 15 oe 20 40 60 80 TEMPERATURE (ºC) 3.8 100 120 FLUX DENSITY GAUSS See Page 3.11 for B-H Data MAGNETICS TEMPERATURE ˚C NOTE: The core loss curves are developed from empirical data. For best results and highest accuracy, use them. The formula on page 3.10 yields a fair approximation and can be useful in computer programs. µi 15,000 ±30% at 10 kHz CORE LOSS vs. FLUX DENSITY PERMEABILITY vs. TEMPERATURE re determined from ac data. nal applications, use 1/2 of the etermine loss. CORE LOSS vs. FLUX DENSITY Mat_H_Coreloss_vs 10 0k Hz Mat_H_Coreloss_vs_Temp.eps H Material Saturation Flux Density - gausses 4,200 (at 15 oersted, 25˚C) (420 mT) Coercive Force - oersted. . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 (3A/m) Curie Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120˚C Disaccomadation Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . <2.5 x 10-6 Typical 50 k Hz TEMPERATURE ˚C 20 kH z CORE LOSS vs. TEMPERATURE Mat_H_Fluxden_vs_Te 1k Hz 10 kH z Mat_H_Perm_vs_Fluxden.eps 150 200 300 400 600 FLUX DENSITY GAUSS 1000 2000 TEMPERATURE ˚C FLUX DENSITY GAUSS PERMEABILITY vs. FLUX DENSITY DENSITY vs. TEMPERATURE FLUX DENSITY vs. TEMPERATURE = 15oe 60 80 100 120 TEMPERATURE ˚C FLUX DENSITY GAUSS See Page 3.11 for B-H Data mag-inc.com 3.9 Materials Core Loss Equation Included on pages Pages 3.4-3.9 are material characteristics for the various Magnetics power and inductor materials. For computer programming purposes, the core loss curves can be represented by the equation below. The factors indicated in the chart are split into discrete frequency ranges, so that the equation offers a close approximation to the core loss curves on the above pages. CORE LOSS EQUATION: P = af c B d L P is in mW/cm 3 B is in kG f is in kHz FACTORS APPLIED TO THE ABOVE FORMULA a c d R Material f<100 kHz 100 kHz ≤f<500 kHz f≥500 kHz 0.074 0.036 0.014 1.43 1.64 1.84 2.85 2.68 2.28 P Material f<100 kHz 100 kHz≤f<500 kHz f≥500 kHz 0.158 0.0434 7.36*10-7 1.36 1.63 3.47 2.86 2.62 2.54 F Material f<10 kHz 10 kHz≤f<100 kHz 100 kHz≤f<500 kHz f≥500 kHz 0.790 0.0717 0.0573 0.0126 1.06 1.72 1.66 1.88 2.85 2.66 2.68 2.29 J Material f≤20 kHz f>20 kHz 0.245 0.00458 1.39 2.42 2.50 2.50 W Material f≤20 kHz f>20 kHz 0.300 0.00382 1.26 2.32 2.60 2.62 H Material f≤20 kHz f>20 kHz 0.148 0.135 1.50 1.62 2.25 2.15 3.10 MAGNETICS Mat_BHCurves_F.eps Materials B vs. H Curves (dc) 25º C Bm–.500T @15 oe Mat_BHCurves_J.eps 100º C Bm–.375T @15 oe 1.0 1.5 2.0 Mat_BHCurves_W&H.eps 2.5 H-oersted 25º C Bm=.430T @15 oe 100º C Bm=.250T @15 oe .4 H-oersted .6 .8 1.0 CONVERSION TABLE MULTIPLY NUMBER OF BY TO OBTAIN Oersteds Oersteds Gausses Gausses Teslas 79.5 0.795 0.100 10 -4 10 4 A/m A/cm milli Teslas Teslas Gausses mag-inc.com 3.11 Materials Ferrite Blocks Mat_BlockFeature.e FEATURES OF MAGENTICS FERRITE BLOCKS • • • • • B LOW POROSITY EXTREME HARDNESS UNIFORM PHYSICAL PROPERTIES HIGH DENSITY EASE OF MACHINING C Ferrites can be pressed in block form and then machined into intricate shapes. Where large sizes are required, it is possible to assemble them from two or more smaller machined or pressed sections; the variety of sizes and shapes becomes limitless. A Without sacrificing magnetic properties, many manufacturing operations can be performed on ferrites, providing strict dimensional or mechanical tolerances: Surface grinding Cutting, slicing, slotting ID and OD machining Hole drilling Special machining Assembly of smaller parts Radius .050" Typical MATERIAL SELECTION J material offers high permeability, see page 3.7. R material is suitable for power applications, see page 3.4. STANDARD BLOCKS and HOW TO ORDER PART NUMBER J42500FB J46213FB R42500FB R46213FB 3.12 Dimensions (inches) A B 1.00 2.50 2.45 1.95 2.50 1.00 2.45 1.95 MAGNETICS C 0.50 0.50 0.50 0.50 Wt. (gms) 98.3 188 98.3 188 Vol. (cm 3 ) 20.5 39.2 20.5 39.2 Ferrite is an ideal core material for transformers, inverters and inductors in the frequency range 20 kHz to 3 MHz, due to the combination of low core cost and low core losses. Ferrite is an excellent material for high frequency (20 kHz to 3 MHz) inverter power supplies. Ferrites may be used in the saturating mode for low power, low frequency operation (<50 watts and 10 kHz). For high power operation a two transformer design, using a tape wound core as the saturating core and a ferrite core as the output transformer, offers maximum performance. The two transformer design offers high efficiency excellent frequency stability, and low switching losses. Section 4 Power Design Ferrite cores may also be used in fly-back transformer designs, which offer low core cost, low circuit cost and high voltage capability. Powder cores (MPP, High Flux, Kool Mµ®) offer soft saturation, higher Bmax and better temperature stability and may be the best choice in some flyback applications or inductors. High frequency power supplies, both inverters and converters, offer lower cost, and lower weight and volume than conventional 60 hertz and 400 hertz power sources. Many cores in this section are standard types commonly used in the industry. If a suitable size for your application is not listed, Magnetics will be happy to review your needs, and, if necessary, quote tooling where quantities warrant. Cores are available gapped to avoid saturation under dc bias conditions. J and W materials are available with lapped surfaces. Bobbins for many cores are available from Magnetics. VDE requirements have been taken into account in bobbin designs for EC, PQ and metric E Cores. Many bobbins are also available commercially. 4.1 General Core Selection Materials and Geometries CORE MATERIALS EP CORES F, P, and R materials, offering the lowest core losses and highest saturation flux density, are most suitable for high power/high temperature operation. P material core losses decrease with temperature up to 70˚C; R material losses decrease up to 100˚C. EP Cores are round center-post cubical shapes which enclose the coil completely except for the printed circuit board terminals. The particular shape minimizes the effect of air gaps formed at mating surfaces in the magnetic path and provides a larger volume ratio to total space used. Shielding is excellent. J and W materials offer high impedance for broad transformers, and are also suitable for low-level power transformers. µi (20 gauss) µp (2000 gauss) Saturation Flux Density (Bm Gauss) Core Loss (mw/cm3) (Typical) @100 kHz, 1000 Gauss FERRITE POWER MATERIALS SUMMARY F P R 25˚C 3,000 2,500 2,300 100˚C 4,600 6,500 6,500 25˚C 4,900 5,000 5,000 J 5,000 5,500 4,300 W+ 10,000 12,000 4,300 100˚C 3,700 3,900 3,700 2,500 2,500 25˚C 60˚C 100˚C 100 180 225 125 80* 125 140 100 70 *@80˚C +@10kHz CORE GEOMETRIES POT CORES Pot Cores, when assembled, nearly surround the wound bobbin. This aids in shielding the coil from pickup of EMI from outside sources. The pot core dimensions all follow IEC standards so that there is interchangeability between manufacturers. Both plain and printed circuit bobbins are available, as are mounting and assembly hardware. Because of its design, the pot core is a more expensive core than other shapes of a comparable size. Pot cores for high power applications are not readily available. DOUBLE SLAB AND RM CORES Slab-sided solid center post cores resemble pot cores, but have a section cut off on either side of the skirt. Large openings allow large size wires to be accommodated and assist in removing heat from the assembly. RM cores are also similar to pot cores, but are designed to minimize board space, providing at least a 40% savings in mounting area. Printed circuit or plain bobbins are available. Simple one piece clamps allow simple assembly. Low profile is possible. The solid center post generates less core loss and this minimizes heat buildup. 4.2 PQ CORES PQ cores are designed especially for switched mode power supplies. The design provides an optimized ratio of volume to winding area and surface area. As a result, both maximum inductance and winding area are possible with a minimum core size. The cores thus provide maximum power output with a minimum assembled transformer weight and volume, in addition to taking up a minimum amount of area on the printed circuit board. Assembly with printed circuit bobbins and one piece clamps is simplified. This efficient design provides a more uniform cross-sectional area; thus cores tend to operate with fewer hot spots than with other designs. E CORES E cores are less expensive than pot cores, and have the advantages of simple bobbin winding plus easy assembly. Gang winding is possible for the bobbins used with these cores. E cores do not, however, offer self-shielding. Lamination size E shapes are available to fit commercially available bobbins previously designed to fit the strip stampings of standard lamination sizes. Metric and DIN sizes are also available. E cores can be pressed to different thickness, providing a selection of cross-sectional areas. Bobbins for these different cross sectional areas are often available commercially. E cores can be mounted in different directions, and if desired, provide a lowprofile. Printed circuit bobbins are available for low-profile mounting. E cores are popular shapes due to their lower cost, ease of assembly and winding, and the ready availability of a variety of hardware. PLANAR E CORES Planar E cores are offered in all of the IEC standard sizes, as well as a number of other sizes. Magnetics R material is perfectly suited to planar designs due to its low AC core losses and minimum losses at 100°C. Planar designs typically have low turns counts and favorable thermal dissipation compared with conventional ferrite transformers, and as a consequence the optimum designs for space and efficiency result in higher flux densities. In those designs, the performance advantage of R material is especially significant. The leg length and window height (B and D dimensions) are adjustable for specific applications without new tooling. This permits the designer to adjust the final core specification to exactly accommodate the planar conductor stack height, with no wasted space. Clips and clip slots are avail- MAGNETICS able in many cases, which is especially useful for prototyping. I-cores are also offered standard, permitting further flexibility in design. E-I planar combinations are useful to allow practical face bonding in high volume assembly, and for making gapped inductor cores where fringing losses must be carefully considered due to the planar construction. TOROIDS EC, ETD AND EER CORES SUMMARY These shapes are a cross between E cores and pot cores. Like E cores, they provide a wide opening on each side. This gives adequate space for the large size wires required for low output voltage switched mode power supplies. It also allows for a flow of air which keeps the assembly cooler. The center post is round, like that of the pot core. One of the advantages of the round center post is that the winding has a shorter path length around it (11% shorter) than the wire around a square center post with an equal area. This reduces the losses of the windings by 11% and enables the core to handle a higher output power. The round center post also eliminates the sharp bend in the wire that occurs with winding on a square center post. Ferrite geometries offer a wide selection in shapes and sizes. When choosing a core for power applications, parameters shown in Table 1 should be evaluated. Toroids are economical to manufacture; hence, they are least costly of all comparable core shapes. Since no bobbin is required, accessory and assembly costs are nil. Winding is done on toroidal winding machines. Shielding is relatively good. TABLE 1: FERRITE CORE COMPARATIVE GEOMETRY CONSIDERATIONS See Catalog Section Core Cost Bobbin Cost Winding Cost Winding Flexibility Assembly Mounting Flexibility** Heat Dissipation Shielding POT CORES 6 High Low Low Good Simple Good Poor Excellent DOUBLE SLAB, RM CORES 7-8 High Low Low Good Simple Good Good Good EP CORES 9 Medium High Low Good Simple Good Poor Excellent PQ CORES 10 High High Low Good Simple Fair Good Fair E CORES 11 Low Low Low Excellent Simple Good Excellent Poor EC, ETD, EER CORES 12 Medium Medium Low Excellent Medium Fair Good Poor TOROIDS 13 Very Low None High Fair None Poor Good Good General Core Selection Materials and Geometries ** Hardware is required for clamping core halves together and mounting assembled core on a circuit board or chassis. mag-inc.com 4.3 Transformer Core Selection General Formulas TRANSFORMER CORE SIZE SELECTION The power handling capacity on a transformer core can be determined by its WaAc product, where Wa is the available core window area, and Ac is the effective core cross-sectional area. Substituting for EAw in (4), we obtain: 8 WaAc= P oC x 10 4eB fK Assuming the following operational conditions: C= 4.05 x 10 -3 cm 2 /Amp (square wave) and 2.53 x 10 -3 cm 2 /Amp (sine wave) for toroids C= 5.07 x 10 -3 cm 2 /Amp (square wave) and 3.55 x 10 -3 cm 2 /Amp (sine wave) for pot cores and E-U-I cores. e= 90% for transformers e= 80% for inverters (including circuit losses) K= 0.30 for pot cores and E-U-I cores (primary side only) K= 0.20 for toroids (primary side only) FIGURE 1 The WaAc/power-output relationship is obtained by starting with Faraday’s Law: (1) E=4B Ac Nf x 10 -8 (square wave) (1a) E=4.44 BAc Nf x 10 -8 (sine wave) With larger wire sizes, and/or higher voltages, these K factors may not be obtainable. To minimize both wire losses and core size, the window area must be full. NOTE: For Wire Tables and turns/bobbin data, refer to pgs 5.8. Where: E=applied voltage (rms) B=flux density in gauss Ac=core area in cm 2 N=number of turns f=frequency in Hz Aw=wire area in cm 2 Wa=window area in cm 2 : Core window for toroids Bobbin window for other cores C=current capacity in cm 2 /amp K=winding factor I=current (rms) P i=input power P o=output power e=transformer efficiency Solving (1) for NAc 8 NAc= E x 10 4Bf The winding factor K= NAw thus N= KWa and NAc= KWaAc Aw Aw Wa Combining (2) and (3) and solving for WaAc: 8 WaAc= E Aw x 10 , where WaAc=cm 4 4B fK In addition: C=Aw/l or Aw=IC e= P o/ P i Thus: E Aw=EIC= P i C= P o C/e 4.4 MAGNETICS P i=El We obtain the basic relationship between output power and the WaAc product: ’ 8 WaAc = k P 0 x 10 , Where k ’ = C 4eK Bf For square wave operation k’ = .00633 for toroids, k’ = .00528 for pot cores, k’ = .00528 for E-U-I cores A core selection chart (Table 3) using WaAc can be found on page 4.7. In addition a A core selection procedure which varies by topology can also be found on page 4.8. This procedure is based on the book “Switching Power Supply Design” by A.I. Pressman. While the formula above allows WaAc to be adjusted based on selected core geometry, the Pressman approach uses topology as the key consideration and allows the designer to specify current density. (2) (3) (4) GENERAL INFORMATION An ideal transformer is one that offers minimum core loss while requiring the least amount of space. The core loss of a given core is directly effected by the flux density and the frequency. Frequency is the most important characteristic concerning a transformer. Faraday’s Law illustrates that as frequency increases, the flux density decreases proportionately. Core losses decrease more when the flux density drops than when frequency rises. For example, if a transformer were run at 250 kHz and 2 kG on R material at 100°C, the core losses would be approximately 400 mW/cm 3 . If the frequency were doubled and all other parameters untouched, by virtue of Faraday’s law, the flux density would become 1kG and the resulting core losses would be approximately 300mW/cm 3 . Typical ferrite power transformers are core loss limited in the range of 50200mW/cm 3 . Planar designs can be run more aggressively, up to 600 mW/cm 3 , due to better power dissipation and less copper in the windings. CIRCUIT TYPES CORE IN PUSH-PULL CIRCUIT Some general comments on the different circuits are: The push-pull circuit is efficient because it makes bi-directional use of a transformer core, providing an output with low ripple. However, circuitry is more complex, and the transformer core saturation can cause transistor failure if power transistors have unequal switching characteristics. Feed forward circuits are low in cost, using only one transistor. Ripple is low because relatively steady state current flows in the transformer whether the transistor is ON or OFF. The flyback circuit is simple and inexpensive. In addition, EMI problems are less. However, the transformer is larger and ripple is higher. TABLE 2 CIRCUIT TYPE SUMMARY CIRCUIT Push-pull Feed forward Flyback ADVANTAGES Medium to high power Efficient core use Ripple and noise low Medium power Low cost Ripple and noise low Lowest cost Few components For ferrite transformers, at 20 kHz, it is common practice to apply equation (4) using a flux density (B) level of ±2 kG maximum. This is illustrated by the shaded area of the Hysteresis Loop in Figure 2B. This B level is chosen because the limiting factor in selecting a core at this frequency is core loss. At 20 kHz, if the transformer is designed for a flux density close to saturation (as done for lower frequency designs), the core will develop an excessive temperature rise. Therefore, the lower operating flux density of 2 kG will usually limit the core losses, thus allowing a modest temperature rise in the core. Above 20 kHz, core losses increase. To operate the SPS at higher frequencies, it is necessary to operate the core flux levels lower than ±2 kg. Figure 3 shows the reduction in flux levels for MAGNETICS “P” ferrite material necessary to maintain constant 100mW/cm3 core losses at various frequencies, with a maximum temperature rise of 25˚C. FIGURE 3 DISADVANTAGES More components Core use inefficient Ripple and noise high Regulation poor Output power limited (< 100 watts) PUSH-PULL CIRCUIT A typical push-pull circuit is shown in Figure 2A. The input signal is the output of an IC network, or clock, which switches the transistors alternately ON and OFF. High frequency square waves on the transistor output are subsequently rectified, producing dc. FEED FORWARD CIRCUIT FIGURE 4A – TYPICAL FEED FORWARD SPS CIRCUIT FIGURE 2A – TYPICAL PUSH-PULL SPS CIRCUIT FIGURE 2B – HYSTERESIS LOOP OF MAGNETIC In the feed forward circuit shown in Figure 4A, the transformer operates in the first quadrant of the Hysteresis Loop. (Fig 4B). Unipolar pulses applied to the semiconductor device cause the transformer core to be driven from its B R value toward saturation. When the pulses are reduced to zero, the core returns to its B R value. In order to maintain a high efficiency, the primary inductance is kept high to reduce magnetizing current and lower wire losses. This means the core should have a zero or minimal air gap. mag-inc.com Transformer Core Selection Specific Circuit Examples 4.5 Transformer Core Selection Specific Circuit Examples FIGURE 4B HYSTERESIS LOOP OF MAGNETIC CORE IN FEED FORWARD CIRCUIT FIGURE 6A TYPICAL FLYBACK REGULATOR CIRCUIT FIGURE 6B HYSTERESIS LOOP OF MAGNETIC CORE IN FLYBACK CIRCUIT For ferrites used in this circuit, ∆B (or B max-B R ) is typically 2400 gauss or B (as applied to Equation 4) is ±1200 gauss as shown in Figure 4B. In the push-pull circuit, it was recommended that the peak flux density in the core should not exceed B = ±2000 gauss in order to keep core losses small. Because of the constraints of the Hysteresis Loop, the core in the feed forward circuit should not exceed a peak value of B = ±1200 gauss. Core selection for a feed forward circuit is similar to the push-pull circuit except that B for Equation 4 is now limited to ±1200 gauss. If the transformer operating temperature is above 75˚, the value of B will be further reduced. Figure 5 shows the variation of ∆B with temperature. Therefore the recommended ∆B value of 2400 (B= ±1200) gauss has to be reduced, the amount depending on the final projected temperature rise of the device. FIGURE 5 In most designs, the air gap is large; therefore, BR is small as noted on the Hysteresis Loop in Figure 6B and can be considered zero. The maximum flux density available is approximately 3600. This means ∆B is 3600 or B = ±1800 gauss. Core selection for this circuit can be done using Equation 4. The B value in Equation 4 is ±1800 gauss at 20 kHz and is used until a higher frequency (Figure 3) dictates a lower B required. GENERAL FORMULA – CORE SELECTION FOR DIFFERENT TOPOLOGIES The following formula has been gained from derivations in Chapter 7 of A.I. Pressman’s book “Switching Power Supply Design” (see Reference No. 13, pg 14.4.) The value of ∆B remains virtually unchanged over a large frequency range above 20 kHz. However, at some frequency, the adjusted value of B, as shown in Figure 3, will become less than the B determined by the above temperature considerations (Figure 5). Above this frequency, the B used to select a core will be the value obtained form Figure 3. FLYBACK CIRCUIT A typical schematic is shown in Figure 6A. Unipolar pulses cause dc to flow through the core winding, moving the flux in the core from BR towards saturation (Fig. 6B). When the pulses go to zero the flux travels back to BR as in the feed forward design. However, the difference between the feed forward and the flyback circuit is that the flyback requires the transformer to act as an energy storage device as well as to perform the usual transformer functions. Therefore, to be an effective energy storage unit, the core must not saturate and is usually a gapped structure. 4.6 MAGNETICS P D WaAc = o cma K t B max f WaAc Po Dcma B max f Kt = = = = = = Product of window area and core area (cm 4 ) Power Out (watts) Current Density (cir. mils/amp) Flux Density (gauss) Frequency (hertz) Topology constant (for a space factor of 0.4): Push-Pull = .001 Forward converter = .0005 Full-bridge = .0014 Half-bridge = .0014 Flyback = .00033 (single winding) Flyback = .00025 (multiple winding) For individual cores, WaAc is listed in this catalog under “Magnetic Data.” Choice of Bmax at various frequencies, Dcma and alternative transformer temperature rise calculation schemes are also discussed in Chapter 7 of the Pressman book. TABLE 3 – FERRITE CORE SELECTION BY AREA PRODUCT DISTRIBUTION WaAc* (cm4) PC RS,DS,HS RM, EP See Section 0.001 0.002 6 7 40704 40905 8/9 0.004 0.007 0.010 41107 41110(RM) 41010(EP) 0.020 41408 41408 (RS,DS) 0.040 0.070 0.100 0.200 RM SOLID PQ EE LAM EE,EEM,EFD EE,EI PLANAR UU, UI ETD, EER EC TC 8 11 12 12 13 40601 40603 10 40707 (EP) 11 41309 (EE) 40705 41203 41510(RM) 41510 41313(EP) 41205 41717(EP) 42610 41808 42316(RM) 42316 42016 41810 42614 42510 42020 42620 43214 44308(EI) 46410(EI) 10.00 44022 45021 45528 46016 45530 20.00 48020 40.00 100 49928 43622 43622 (RS,DS,HS) 2.00 44229 44229 44529 (RS,DS,HS) 4.00 7.00 43723(RM) 42625 42520 43220 43515 43723 43230 44317 43535 44721 44040 45724 41003 41106(UU) 40907 41005 41303 42216(EE) 43520 43524 44011 44020 44924 1.00 42819 41106 (UI) 41206 41305 41306 41605 43618(EI) 43208(EI) 0.700 42819(RM) 42120(EP) 41208 41209 41515 41707 41709 42110 42211 42810 43009 42523 42515 43007 43013 0.400 11 40904 40906 41812(RM) 41812 41811 42311 (RS,DS,HS) 42213 42318 (HS) 42616 42318 (RS,DS) 42616 (RS,DS,HS) 43019 (RS,DS,HS) 43019 11 42515 (UI) 41809 42206 43618(EE) 43208(EE) 44308(EE) 45810(EI) 42207 42220(UU) 43517 42512(UU) 42515(UU) 42530(UU) 44119 42507 43434 43521(EER) 44119(UU) 45224 43939 44121(UU) 44216(EER) 43615 44444 45032 44125(UU) 44949 44416 44130(UU) 45810(EE) 46409(EE) 46410(EE) 47035 47228 47054 49938(EE) 42908 43610 43813 44916 44925 46113 47313 47325 48613 49925(UU) 49925(UI) *Bobbin window and core area product. For bobbins other than those in this catalog, WaAc may need to be recalculated. mag-inc.com Transformer Core Selection Area Product Distribution (WaAc*) 4.7 Transformer Core Selection Typical Power Handling TABLE 4 – FERRITE CORE SELECTION LISTED BY TYPICAL POWER HANDLING CAPABILITIES (WATTS) (F, P AND R MATERIALS) (FOR PUSH-PULL SQUARE WAVE OPERATIONS, SEE NOTES BELOW) WATTAGE @F= @F= @F= 20KHZ 50KHZ 100KHZ See Section 2 3 4 @F= POT-RS-RM DS 250KHZ CORES CORES 6/7/8 7 7 41408-PC EP CORES 9 41313 5 8 11 21 41717 12 13 15 18 19 18 20 22 28 30 27 30 32 43 48 53 59 62 84 94 26 28 30 33 40 42 48 60 42 45 49 53 61 70 75 100 58 65 70 80 95 100 110 150 113 127 137 156 185 195 215 293 70 105 110 120 130 140 150 190 200 220 230 260 280 110 160 190 195 205 215 240 300 310 350 350 400 430 170 235 250 270 290 340 380 470 500 530 550 600 650 332 460 480 525 570 663 741 917 975 1,034 1,073 1,170 1,268 300 340 360 410 550 450 550 580 650 800 700 850 870 1,000 1,300 1,365 1,658 1,697 1,950 2,535 650 1,000 1,600 3,120 700 850 900 1,000 1,000 1,400 1,600 2,000 2,800 11,700 1,100 1,300 1,500 1,600 1,700 2,500 2,600 3,000 4,200 19,000 1,800 1,900 2,000 2,500 2,700 3,200 3,700 4,600 6,500 26,500 3,510 3,705 3,900 4,875 5,265 6,240 7,215 8,970 12,675 51,500 4.8 MAGNETICS 41811-PC 42311-RS 42809-RM 42316-RM 42213-PC 42318-RS 42311 PQ CORES 10 41808 42016 42318 42616 E-CORES 11 41707 41810, 42211 42510 42020 LOW-PROFILE PLANAR EC-ETD CORES U CORES 11 12 41709 42107 42110 42610-PQ 42216-EC 42106 41809 42810, 42520 42515 42819-RM 42616-PC 42206 42109 42207 42620 43019 43019-RS 43007 42625 43019-PC 43723-RM 43220 43618-EC 44008-EC 43208-EC 43013 42530, 43009 43515 (E375) 43622 41306 41605 42614-PQ 43618-E, I 43208-E, I 44008-E, I 42120 TC TOROIDS 13 41206 41303 43205 4,221,242,507 43517 (EC35) 44308-E, I 43434 (ETD34) 42908 44011 (E40) 43622-PC 43230 44119 (EC41) 43521 43524, 43520 44317 (E21) 44308-EC 43806 42915, 43113 43939 (ETD39) 44229 43610 44721 (E625) 45032 44020 (42/15) 44216 45021 (E50) 44924 44022 (42/20) 45224 (EC52) 43535 43813 43615 44229-PC 44529-PC 45810-EC 44444 (ETD44) 46410-E, I 43825 44949 (ETD49) 44416 44040 45724 (E75) 45528 (55/21) 46016 (E60) 45530 (55/25) 45810-EC 46409-EC 46410-EC 44715 44916 44920 44925 47035 (EC70) 45959 (ETD59) 46113 47228 44932 47313 48020 47054 49938-EC 48613 49925 (U) Above is for push-pull converter. De-rate by a factor of 3 or 4 for flyback. De-rate by a factor of 2 for feed-forward converter. NOTE: Assuming Core Loss to be Approximately 100mW/cm3, B Levels Used in this Chart are:@ 20kHz-2000 gauss @ 50kHz-1300 gauss @ 100kHz-900 gauss @ 250kHz-700 gauss. SEE PAGE 4.7 — Area Product Distribution TEMPERATURE CONSIDERATIONS TRANSFORMER EQUATIONS The power handling ability of a ferrite transformer is limited by either the saturation of the core material or, more commonly, the temperature rise. Core material saturation is the limiting factor when the operating frequency is below 20kHz. Above this frequency temperature rise becomes the limitation. Once a core is chosen, the calculation of primary and secondary turns and wire size is readily accomplished. Temperature rise is important for overall circuit reliability. Staying below a given temperature insures that wire insulation is valid, that nearby active components do not go beyond their rated temperature, and overall temperature requirements are met. Temperature rise is also very important for the core material point of view. As core temperature rises, core losses can rise and the maximum saturation flux density decreases. Thermal runaway can occur causing the core to heat up to its Curie temperature resulting in a loss of all magnetic properties and catastrophic failure. Newer ferrite power materials, like P and R material, attempt to mitigate this problem by being tailored to have decreasing losses to temperature of 70˚C and 100˚C respectively. CORE LOSS—One of the two major factors effecting temperature rise is core loss. In a transformer, core loss is a function of the voltage applied across the primary winding. In an inductor core, it is a function of the varying current applied through the inductor. In either case the operating flux density level, or B level, needs to be determined to estimate the core loss. With the frequency and B level known, core loss can be estimated from the material core loss curves. A material loss density of 100mw/cm3 is a common operating point generating about a 40˚C temperature rise. Operating at levels of 200 or 300 mw/cm3 can also be achieved, although forced air or heat sinks may need to be used. WINDING CONSIDERATIONS—Copper loss is the second major contributor to temperature rise. Wire tables can be used as a guide to estimate an approximate wire size but final wire size is dependent on how hot the designer allows the wire to get. Magnet wire is commonly used and high frequency copper loss needs to be considered. Skin effects causes current to flow primarily on the surface of the wire. To combat this, multiple strands of magnet wire, which have a greater surface area compared to a single heavier gauge, are used. Stranded wire is also easier to wind particularly on toroids. Other wire alternatives, which increase surface areas, are foil and litz wire. Foil winding allows a very high current density. Foil should not be used in a core structure with significant air gap since excessive eddy currents would be present in the foil. Litz wire is very fine wire bundled together. It is similar to stranded wire except the wire is woven to allow each strand to alternate between the outside and the inside of the bundle over a given length. 8 Np = V p x 10 4BAf Ns = Vs Np Vp l p = P in = P out P in eE in l s = P out E out KWa = N p Awp = N s Aws Where Awp = primary wire area Aws = secondary wire area Assume K = 0.40 for toroids; 0.60 for pot cores and E-U-I cores Assume Np Awp = 1.1 N s Aws to allow for losses and feedback winding P out efficiency e = P out = E in P out + wire losses + core losses 2 Voltage Regulations (%) = R s + (N s /N p ) R p x 100 R load INDUCTOR CORE SELECTION EMI FILTERS Switch Mode Power Supplies (SMPS) normally generate excessive high frequency noise which can affect electronic equipment like computers, instruments and motor controls connected to these same power lines. An EMI Noise Filter inserted between the power line and the SMPS eliminates this type of interference (Figure 8). A differential noise filter and a common mode noise can be in series, or in many cases, the common mode filter is used alone. FIGURE 8 CORE GEOMETRY—The core shape also affects temperature and those that dissipate heat well are desirable. E core shapes dissipate heat well. Toroids, along with power shapes like the PQ, are satisfactory. Older telecommunication shapes, such as pot cores or RM cores, do a poor job of dissipating heat but do offer shielding advantages. Newer shapes, such as planar cores, offer a large flat surface ideal for attachment of a heat sink. mag-inc.com Transformer Core Selection Considerations 4.9 Inductor Core Selection Inductor Design INDUCTOR CORE SELECTION CONT... FIGURE 10 COMMON MODE FILTER In a CMN filter, each winding of the inductor is connected in series with one of the input power lines. The connections and phasing of the inductor windings are such that flux created by one winding cancels the flux of the second winding. The insertion impedance of the inductor to the input power line is thus zero, except for small losses in the leakage reactance and the dc resistance of the windings. Because of the opposing fluxes, the input current needed to power the SMPS therefore will pass through the filter without any appreciable power loss. Common mode noise is defined as unwanted high frequency current that appears in one or both input power lines and returns to the noise source through the ground of the inductor. This current sees the full impedance of either one or both windings of the CMN inductor because it is not canceled by a return current. Common mode noise voltages are thus attenuated in the windings of the inductor, keeping the input power lines free from the unwanted noise. CHOOSING THE INDUCTOR MATERIAL Figure 11 shows total impedance vs. frequency for two different materials. J material has a high total impedance over the range of 1 to 20MHz. It is most widely used for common mode filter chokes. Under 1MHz, W material has 20-50% more impedance than J. It is often used in place of J when low frequency noise if the major problem. For filter requirements specified at frequencies above and below 2MHz, either J or W is preferred. A SMPS normally operates above 20kHz. Unwanted noises generated in these supplies are at frequencies higher than 20kHz, often between 100kHz and 50MHz. The most appropriate and cost effective ferrite for the inductor is one offering the highest impedance in the frequency band of the unwanted noise. Identifying this material is difficult when viewing common parameters such as permeability and loss factor. Figure 9 shows a graph of impedance Z t vs. frequency for a ferrite toroid, J42206TC wound with 10 turns. FIGURE 11 FIGURE 9 CORE SHAPE The wound unit reaches its highest impedance between 1 and 10MHz. The series inductive reactance X s and series resistance R s (functions of the permeability and loss factor of the material) together generate the total impedance Z t . Figure 10 shows permeability and loss factor of the ferrite material in Figure 9 as a function of frequency. The falling off of permeability above 750kHz causes the inductive reactance to fall. Loss factor, increasing with frequency, cause the resistance to dominate the source of impedance at high frequencies. Additional detailed brochures and inductors design software for this application are available from Magnetics. 4.10 MAGNETICS Toroids are most popular for a CMN filter as they are inexpensive and have low leakage flux. A toroid must be wound by hand (or individually on a toroid winding machine). Normally a non-metallic divider is placed between the two windings, and the wound unit is epoxied to a printed circuit header for attaching to a pc board. An E core with its accessories is more expensive than a toroid, but assembly into a finished unit is less costly. Winding E core bobbins is relatively inexpensive. Bobbins with dividers for separating the two windings are available for pc board mounting. E cores have more leakage inductance, useful for differential filtering in a common mode filter. E cores can be gapped to increase the leakage inductance, providing a unit that will absorb both the common mode and differential unwanted noise. FIG. 13: CORE SELECTION AT 400 amps/cm2 CORE SELECTION The following is a design procedure for a toroidal, single-layer common mode inductor, see Figure 12. To minimize winding capacitance and prevent core saturation due to asymmetrical windings, a single layer design is often used. This procedure assumes a minimum of thirty degrees of free spacing between the two opposing windings. The basic parameters needed for common mode inductor design are current (I), impedance (Zs), and frequency (f). The current determines the wire size. A conservative current density of 400 amps/cm2 does not significantly heat up the wire. A more aggressive 800 amps/cm2 may cause the wire to run hot. Selection graphs for both levels are presented. The impedance of the inductor is normally specified as a minimum at a given frequency. This frequency is usually low enough to allow the assumption that the inductive reactance, Xs, provides the impedance, see Figure 9. Subsequently, the inductance, Ls can be calculated from: Ls = Xs 2πf (1) With the inductance and current known, Figures 13 and 14 can be used to select a core size based on the LI product, where L is the inductance in mH and I is the current in amps. The wire size (AWG) is then calculated using the following equation based on the current density (Cd) of 400 or 800 amps/cm2: ( ) AWG = -4.31x In 1.889I Cd (2) The number of turns is determined from the core’s A L value as follows: 1 L x 10 6 /2 N= S (3) AL ( FIG. 14: CORE SELECTION AT 800 amps/cm2 ) DESIGN EXAMPLE An impedance of 100Ω is required at 10kHz with a current of 3 amps. Calculating the inductance from equation 1, Ls = 1.59 mH. With an LI product of 4.77 at 800 amps/cm2, Figure 14 yields the core size for chosen material. In this example, W material is selected to give high impedance up to 1MHz, see Figure 11. Figure 14 yields the core W41809TC. Page 13.6 lists the core sizes and A L values. Using an AL of 12,200 mH/1,000 turns, equation 3 yields N = 12 turns per side. Using 800 amps/cm2, equation 2 yields AWG = 21. Inductor Core Selection Inductor Design FIGURE 12: COMMON MODE INDUCTOR WINDING ARRANGEMENT mag-inc.com 4.11 Inductor Core Selection Inductor Design HALL EFFECT DEVICES Edwin H. Hall observed the “Hall Effect” phenomenon at John Hopkins University in 1897. He monitored the current flowing from top to bottom in a thin rectangular strip of gold foil by measuring the voltages at the geometric center of the left edge and the right edge of the strip. When no magnetic field was present, the voltages were identical. When a magnetic field was present perpendicular to the strip, there was a small voltage difference of a predictable polarity and magnitude. The creation of the transverse electric field, which is perpendicular to both the magnetic field and the current flow, is called the Hall Effect or Hall Voltage. In metals the effect is small, but in semiconductors, considerable Hall voltages can be developed. Designers should consider using Hall sensors in many applications where mechanical or optical sensors have traditionally been used. To monitor ac or dc current flow in a wire, the wire is wrapped around a slotted ferromagnetic core, creating an electromagnet. The strength of the resulting magnetic field is used by the Hall sensor, inserted in the air gap, to measure the magnitude and direction of current flowing in the wire. CORE SELECTION In all cases, the effective permeability of a gapped core will be a function of the size of the air gap and the initial permeability of the core material. Once the gap becomes greater than a few thousandths of an inch, the effective permeability is determined essentially by the air gap. ANALYTICAL METHOD 1. Determine the flux operating extremes based on either the ∆V/∆B of the circuit (volts/gauss), or the maximum flux sensitivity (gauss) of the sensor (as provided by the sensor data sheet). 2. Choose a core based on the maximum or minimum dimension requirements to allow windings, and based on the core cross-section dimensions. The cross-section dimensions should be at least twice the gap length to ensure a relatively homogeneous flux distribution bridging the gap. 3. Calculate the maximum required µ e for the core: bl µe = e .4πNI where B = le = N = I = (1) flux density (gauss) path length (cm) turns current (amps peak) 4. Calculate the minimum required gap length (inches): 1 1 (0.3937) lg = le µ — µ e i ( 4.12 MAGNETICS ) (2) where l g =gap length (inches) l e = path length (cm) µ e = effective permeability µ i = initial permeability 5. If the minimum required gap is greater than the sensor thickness, ensure that the cross-section dimensions (length and width) are at least twice the gap length. If not, choose a larger core and recalculate the new gap length. GRAPHICAL METHOD 1. Calculate NI/B (amp turns per gauss), knowing the flux operating extremes of ∆V/∆B or the maximum B sensitivity of the sensor. 2. Using Figure 15, follow the NI/B value from the vertical axis to the diagonal line to choose a ferrite core size. Drop down from the diagonal line to the horizontal axis to determine the gap length. The core sizes indicated on the selector chart take into account gap length versus cross-section dimensions in order to maintain an even flux distribution across the gap under maximum current. TOROID GAPPING Ferrite cores are a ferromagnetic ceramic material. As such, they exhibit a very high hardness characteristic, they are very brittle, and they do not conduct heat very efficiently. Machining a slot into one side of a ferrite toroid can be a difficult process. Special techniques must be used to prevent chipping, cracking, or breaking of the cores. Diamond bonded-tool machining is the preferred method of cutting ferrite. The bonded diamond particle size should be approximately 100 to 170 mesh (150 to 90 µm). The peripheral speed of the cutting wheel should be 5,000 to 6,000 feet/minute (1,500 to 1,800 meters/minute). The depth of the cut may be as deep as 1” (25 mm), but in order to minimize residual stress, the cut should be limited to a maximum of 0.250” (6 mm) per pass, the smaller the better. During all cutting, the wheel and core should be flooded with ample amounts of coolant water to provide a lubricant as well as remove heat buildup that would cause thermal stress cracking of the core. GAPPED TOROID SELECTOR CHART FIG. 15: HALL EFFECT DEVICE, CORE SELECTOR CHART The value calculated for (∆i) is somewhat arbitrary and can be adjusted to obtain a practical value for the inductance.The minimum capacitance is given by C = ∆i /8f min ∆e o (6) Finally, the maximum ESR of the capacitor is ESR max = ∆e o /∆ i (7) INDUCTOR DESIGN INDUCTOR CORE SIZE SELECTION (USING CORE SELECTOR CHARTS) DESCRIPTION A typical regulator circuit consists of three parts: transistor switch, diode clamp, and an LC filter. An unregulated dc voltage is applied to the transistor switch which usually operates at a frequency of 1 to 50 kilohertz. When the switch is ON, the input voltage, Ein, is applied to the LC filter, thus causing current through the inductor to increase; excess energy is stored in the inductor and capacitor to maintain output power during the OFF time of the switch. Regulation is obtained by adjusting the ON time, ton, of the transistor switch, using a feedback system from the output. The result is regulated dc output, expressed as: E out = E in t on f (1) COMPONENT SELECTION The switching system consists of a transistor and a feedback from the output of the regulator. Transistor selection involves two factors – (1) voltage ratings should be greater than the maximum input voltage, and (2) the frequency cut-off characteristics must be high compared to the actual switching frequency to insure efficient operation. The feedback circuits usually include operational amplifiers and comparators. Requirements for the diode clamp are identical to those of the transistor. The design of the LC filter stage is easily achieved. Given (1) maximum and minimum input voltage, (2) required output, (3) maximum allowable ripple voltage, (4) maximum and minimum load currents, and (5) the desired switching frequency, the values for the inductance and capacitance can be obtained. First, off-time (toff) of the transistor is calculated. t off = (1 - E out /E in max) /f When E in decreases to its minimum value, (2) f min = (1 - E out /E in min) /t off (3) With these values, the required L and C can be calculated. Allowing the peak to peak ripple current (∆i) through the inductor to be given by ∆i = 2 l o min the inductance is calculated using L = E out t off / ∆i (4) (5) Ferrite E cores and pot cores offer the advantages of decreased cost and low core losses at high frequencies. For switching regulators, F or P materials are recommended because of their temperature and dc bias characteristics. By adding air gaps to these ferrite shapes, the cores can be used efficiently while avoiding saturation. These core selection procedures simplify the design of inductors for switching regulator applications. One can determine the smallest core size, assuming a winding factor of 50% and wire current carrying capacity of 500 circular mils per ampere. Only two parameters of the two design applications must be known: (a) Inductance required with dc bias (b) dc current 1. Compute the product of LI 2 where: L= inductance required with dc bias (millihenries) I= maximum dc output current - I o max + ∆ i 2. Locate the LI 2 value on the Ferrite Core Selector charts on pgs 4.15–4.18. Follow this coordinate in the intersection with the first core size curve. Read the maximum nominal inductance, A L , on the Y-axis. This represents the smallest core size and maximum A L at which saturation will be avoided. 3. Any core size line that intersects the LI 2 coordinate represents a workable core for the inductor of the core’s A L value is less than the maximum value obtained on the chart. Inductor Core Selection Inductor Design 4. Required inductance L, core size, and core nominal inductance (A L) are known. Calculate the number of turns using N = 10 3 √ L AL where L is in millihenries 5. Choose the wire size from the wire table on pg 5.8 using 500 circular mils per amp. mag-inc.com 4.13 Inductor Core Selection Inductor Design EXAMPLE Choose a core for a switching regulator with the following requirements: Eo =5 volts ∆e o =0.50 volts I o max =6 amps I o min =1 amp E in min =25 volts E in max =35 volts f =20 KHz 1. Calculate the off-time and minimum switching, f min , of the transistor switch using equations 2 and 3. t off = (1 – 5/35)/20,000 = 4.3 x 10 -5 seconds and f min = (1 – 5/25)/4.3 x 10 -5 seconds = 18,700 Hz. 2. Let the maximum ripple current, ∆i, through the inductor be ∆i = 2(1) = 2 amperes by equation 4. 3. Calculate L using equation 5. L = 5(4.3 x 10 -5 )/2 = 0.107 millihenries 4. Calculate C and ESR max using equations 6 and 7. C = 2/8 (18,700) (0.50) = 26.7 µ farads and ESR max = 0.50/2 = .25 ohms 5. The product of LI 2 = (0.107) (8) 2 = 6.9 millijoules 6. Due to the many shapes available in ferrites, there can be several choices for the selection. Any core size that the LI 2 coordinate intersects can be used if the maximum A L is not exceeded. Following the LI 2 coordinate, the choices are: (a) 45224 EC 52 core, A L315 (b) 44229 solid center post core, A L315 (c) 43622 pot core, A L400 (d) 43230 PQ core, A L250 4.14 MAGNETICS 7. Given the A L, the number of turns needed for the required inductance is: AL Turns 250 21 315 19 400 17 8. Use #14 wire Note: MAGNETICS® Molypermalloy and Kool Mu® powder cores have a distributed air gap structure, making them ideal for switching regulator applications. Their dc bias characteristics allow them to be used at high drive levels without saturating. Information is available in Magnetics Powder Core Catalog and Brochure SR-IA, “Inductor Design in Switching Regulators.” FOR REFERENCES, SEE PAGE 14.4 PC (POT) CORES A — 40903 B — 40704 C — 40905 D — 41107 E — 41408 F — 41811 G — 42213 H — 42616 J — 43019 K — 43622 L — 44229 M — 44529 RS (ROUND-SLAB) & DS (DOUBLE-SLAB) CORES Core Selection designed to accommodate a variety of toroidal core Selector Charts These vertical mount accessories aresizes on to printed circuit board or other assemblies. (Check factory for new parts not shown here) A — 41408 (RS) B — 42311 (DS, RS) 42318 (DS, RS) C — 42616 (DS) D — 43019 (DS, RS) E — 43622 (DS) F — 44229 (DS) RM AND EP CORES A — 40707 (EP7) 41010 (EP10) 41110 (RM4) B — 41313 (EP13) C — 41510 (RM5) D — 41717 (EP17) E — 41812 (RM6) F — 42316 (RM8) G — 42120 (EP20) H — 42809 (RM10 PLANAR) 42819 (RM10) J — N43723 (RM12) mag-inc.com 4.15 Core Selection Selector Charts PQ CORES A — 42016 42020 B — 42614 C — 42610 42620 42625 43214 D — 43220 43230 E — 43535 44040 LAMINATION SIZE E CORES A — 41203 (EE) B — 41707 (EE) C — 41808 (EE) D — 42510 (EE) E — 43009 (EE) 43515 (EE) F — 44317 (EE) G — 44721 (EE) H — 45724 (EE) E CORES 4.16 MAGNETICS A — 40904 (EE) B — 41208 (EE) 41209 (EE) C — 41205 (EE) 42211 (EE) D — 42515 (EE) E — 41810 (EE) 43007 (EE) F — 43524 (EE) G — 42530 (EE) 43520 (EE) H — 42520 (EE) J — 42810 (EE) 43013 (EE) E, EI CORES A — 42110 (EE) B — 41709 (EE) C — 41805 (EE, EI) D — 42216 (EE, EI) E — 44008 (EE, EI) F — 43208 (EE, EI) 43618 (EE, EI) E, EI CORES A — 44016 (EE) B — 44011 (EE) C — 44020 (EE) D — 44308 (EE, EI) E — 44022 (EE) 44924 (EE) 45021 (EE) 46016 (EE) F — 45528 (EE) 45530 (EE) 47228 (EE) 48020 (EE) G — 46410 (EE) H — 49938 (EE, EI) Core Selection Selector Charts EC CORES A — 43517 B — 44119 C — 45224 D — 47035 mag-inc.com 4.17 Core Selection dc_bias_etd_eer.eps Selector Charts ETD AND EER CORES A B C D E F dc_bias_eem_efd_er.eps EEM, EFD, AND ER CORES 4.18 G MAGNETICS A — 43434 (ETD34) B — 43521 (EER35L) C — 43939 (ETD39) D — 44216 (EER42) 44444 (ETD44) E — 44949 (ETD49) F — 47054 G — 45959 (ETD59) A — 41309 (EEM12.7) 40906 (ER 9.5) B — 42110 41515 (EFD15) C — 41709 D — 42523 (EFD25) Gapped Applications DC Bias Data Gap_dc_bias.eps Effective Permeability DC BIAS DATA — FOR GAPPED APPLICATIONS NI = 0.80 x H x le Where NI = maximum allowable ampere-turns H = DC Bias level le = core path length (cm) µe The above curves represent the locus of points up to which effective permeability remains constant. They show the maximum allowable DC bias, in ampere-turns, without a reduction in inductance. Beyond this level, inductance drops rapidly. Example: How many ampere-turns can be supported by an R42213A315 pot core without a reduction in inductance value? le = 3.12 cm µ e = 125 H Maximum allowable H = 25 Oersted (from the graph above) NI (maximum) = 0.80 x H x l e = 62.4 ampere-turns OR (Using top scale, maximum allowable H = 20 A-T/cm.) NI (maximum) = A-T/cm x l e = 20 x 3.12 = 62.4 A-T AL • le 4π A e 1 1 lg = + µe µi le A e = effective cross sectional area (cm 2 ) A L = inductance/1,000 turns (mH) µ i = initial permeability l g = gap length (cm) µe = 4.19 mag-inc.com Notes 4.20 MAGNETICS The information contained in this section is primarily concerned with the design of linear inductors for high frequency LC tuned circuits using ferrite pot cores. Magnetics has arranged the data in this section for ease in (1) determining the optimum core for these LC circuits and (2) ordering the items necessary for any particular Pot Core assembly. Featured are magnetic data, temperature characteristics, core dimensions, accessories, and other important design criteria. Standard Q curves are available on special request, contact Magnetics Application Engineering. Section 5 Pot Cores Low Level Applications The data presented in this section are compiled mainly for selecting cores for high Q resonant LC circuits. However, much of this information can also be used to design pot cores into many other applications, including high frequency transformers, chokes, and other magnetic circuit elements. POT CORE ASSEMBLY A ferrite pot core assembly includes the following items: 1. TWO MATCHED POT CORE HALVES 2. BOBBIN ON WHICH THE COILS ARE WOUND 3. TUNING ASSEMBLY 4. A CLAMP FOR HOLDING THE CORE HALVES TOGETHER The pot core shape provides a convenient means of adjusting the ferrite structure to meet the specific requirements of the inductor. Both high circuit Q and good temperature stability of inductance can be obtained with these cores. The self-shielded pot core isolates the winding from stray magnetic fields or effects from other surrounding circuit elements. The effective permeability (µ e ) is adjusted by grinding a small air gap in the center post of the pot core. For transformers and some inductors, no ground air gap is introduced, and the effective permeability is maximized. The effective permeability of the pot core will always be less than the material initial permeability (µ i ) because of the small air gap at the mating surfaces of the pot core halves. For other inductors where stability of inductance, Q, and temperature coefficient must be closely specified, a controlled air gap is carefully ground into the center post of one or both of the pot core halves. When fitted together, the total air gap then will determine the effective permeability and control the magnetic characteristics of the pot core. Finer adjustment of the effective permeability (gapped pot core inductance) can be accomplished by moving a ferrite cylinder or rod into the air gap through a hole in the center post. Magnetics ferrites are available in various initial permeabilities (µ i ) which for filter applications cover frequency ranges into the megahertz region. Magnetics produces a wide variety of pot core sizes which include fourteen (14) international standard sizes*. These range from 5 x 6 mm to 45 x 29 mm, these dimensions representing OD and height of a pair. Each pot core half is tested and matched with another half to produce a core with an inductance tolerance of ± 3% for most centerpost ground parts. *IEC Publication No. 133 (1961). 5.1 Pot Core Design Advantages of Pot Core Assemblies ADVANTAGES OF POT CORE ASSEMBLIES SPECIAL ADVANTAGES OF MAGNETICS POT CORE ASSEMBLIES • SELF-SHIELDING Because the wound coil is enclosed within the ferrite core, self-shielding prevents stray magnetic fields from entering or leaving the structure. • UNIQUE ONE PIECE CLAMP Provides simple assembly of the two core halves. Easy bending action allows insertion of the core assembly into the clamp, and spring tension holds the assembly rigidly and permanently in place. Rivet, screw, or circuit board tab mounting is available. • COMPACTNESS Self-shielding permits more compact arrangement of circuit components, especially on printed circuit boards. • MECHANICAL CONVENIENCE Ferrite pot cores are easy to assemble, mount, and wire to the circuit. • LOW COST As compared to other core materials, ferrites are easier to make in unusual configurations (such as pot cores), resulting in a lower cost component. In addition, winding a pot core is usually quick and inexpensive because coils can be pre-wound on bobbins. When other costs of assembly, mounting, wiring, and adjustment are added, the total cost is often less than with other core materials or shapes. • ADJUSTABILITY Final adjustment is accomplished by moving a threaded core in and out of the centerpost, and adjustment in the field is relatively easy as compared to any other type of construction. • IMPROVED TEMPERATURE STABILITY AND Q Air gaps inserted between the mating surfaces of the centerposts provide good temperature stability and high Q. • WIDE CORE SELECTION Many combinations of materials, physical sizes, and inductances offer the design engineer a large number of choices in core selection. • LOW LOSSES AND LOW DISTORTION Since ferrites have high resistivities, eddy current losses are extremely low over the applicable frequency range and can be neglected. Hysteresis losses can be kept low with proper selection of material, core size, and excitation level. 5.2 MAGNETICS • CHOICE OF LINEAR OR FLAT TEMPERATURE CHARACTERISTICS Provides a close match to corresponding capacitors. • CONSISTENCY AND UNIFORMITY Modern equipment with closely controlled manufacturing processes produce ferrite pot cores that are magnetically uniform, not only within one lot but from lot to lot. The selection of a pot core for use in LC resonant circuits and high frequency inductors requires a careful analysis of the design, including the following: • OPERATING FREQUENCY. • INDUCTANCE OF THE WOUND POT CORE ASSEMBLY. • TEMPERATURE COEFFICIENT OF THE INDUCTOR. • Q OF THE INDUCTOR OVER THE FREQUENCY RANGE. • DIMENSIONAL LIMITATIONS OF THE COIL ASSEMBLY. • MAXIMUM CURRENT FLOWING THROUGH THE COIL. • LONG TERM STABILITY. The important characteristics which strongly influence the above requirements are: 1 1. Relative loss factor - µ i Q. This factor reflects the relative losses in the core and varies with different ferrite materials and changes in operating frequency. When selecting the proper material, it is best to choose the 1 one giving the lowest over the range of operating frequencies. In this µiQ 1 way, the highest circuit Q can be expected. In a situation where the µ Q i curves may cross over or coincide at various frequencies, each ferrite material should be considered in view of all circuit parameters of importance, including size, temperature coefficient, and disaccommodation, as well as Q. With this analysis, little doubt is left concerning the optimum selection of a proper core material. 2. Inductance factor (A L ). The selection of this parameter is based on a logarithmic progressive series of values obtained by dividing a logarithmic decade into 5 equal parts (International Standardization Organization R5 series of preferred numbers). Since the (A L ) values for the various core sizes are standard, they may be graphed or charted for ease of determining the required turns (N) to give the value of inductance needed. Pot cores with various (A L ) values are obtained by grinding closely-controlled air gaps in the centerposts of the cores. Small gaps are processed by gapping one core half. For larger gaps, both halves are gapped. 3. Temperature Coefficient (TC e ). The temperature coefficient of the pot core is important in LC tuned circuits and filters when attempting to stabilize the resonant frequency over a wide range of temperatures. This temperature coefficient (TC e ) is determined by the properties of the ferrite material and the amount of air gap introduced. Ferrite materials have been designed to produce gapped pot core temperature coefficients that balance the opposite temperature characteristics of polystyrene capacitors, or match similar flat temperature coefficients of silvered mica capacitors. Therefore, careful selection of both capacitors and pot cores with regard to temperature coefficient will insure the optimum temperature stability. 4. Quality Factor (Q)*. The quality factor is a measure of the effects of the various losses on circuit performance. From the designer’s point of view, these losses should include core losses, copper losses, and winding capacitive losses. Therefore, Q will be affected greatly by the number and placement of the turns on the bobbin, and the type and size of wire used. At higher frequencies, litz wire would reduce the eddy current losses in the windings and produce a higher Q than solid wire. Q data include the effects of winding and capacitive losses, which, if removed, would produce significantly higher calculated Q values. Consequently, the Q curves represent more realistically the actual Q values that would be obtained from circuit designs. 5. Dimensional Limitations. Many circuit designs contain dimensional and weight limitations which restrict the size of the inductor and the mounting techniques used. Sometimes, minimum weight or volume is sacrificed to obtain better circuit performance. 6. Current Carrying Capacity. Inductive circuits containing ferrite pot cores are normally operated at extremely low levels of AC excitation to insure the best possible performance. However, the current flowing in the coil may be much higher than anticipated due to superimposed DC currents, or unexpected surges of AC. Therefore, the selection of the wire size used in an inductor design is influenced by both of these factors. Wire data is presented in this catalog as a guide in considering these operating conditions. - Refer to Tables 5 and 6, page 5.10. Pot Core Design Important Considerations 7. Long Term Stability (DF e ). In critical inductive designs, especially resonant circuits, the designer must be concerned with long term drift in resonant frequency. This stability drift (or decrease in inductance), known as disaccommodation, can be calculated for each pot core size and inductance factor (A L ). It occurs at a logarithmic rate, and the long term change of inductance may be calculated from the formula: ∆L = DFe x log t 2 L t1 ∆L where L is the decrease in inductance between the times t 1 and t 2 , DF e is the Effective Disaccommodation Coefficient of the core selected, and t 1 is the elapsed time between manufacture of the core (stamped on shipping container) and its assembly into the circuit, while t 2 is the time from manufacture of the core to the end of the expected life of the device. Disaccommodation starts immediately after the core is manufactured as it cools through its Curie Temperature. At any later time as the core is demagnetized, or thermally or mechanically shocked, the inductance may increase to its original value and disaccommodation begins again. Therefore, consideration must be given to increases in inductance due to magnetic, thermal or physical shock, as well as decreases in inductance due to time. If no extreme conditioning is expected during the equipment life, changes in inductance will be small, because most of the change occurs during the first few months after manufacture of the core. *Q curves referred to here are available on special request. Contact Magnetics Applications Engineering. mag-inc.com 5.3 Pot Core Design Important Considerations LIMITS ON EXCITATION Inductors designed using pot cores are usually identified as linear magnetic components because they are operated within the range of negligible change of effective permeability with excitation. To calculate suggested maximum AC excitation levels, use the following formula: E rms x 10 8 B = 4.44 A Nf e where B N f Ae = = = = 4.44 for sine wave 4.0 for square wave 200 gausses, the suggested conservative limit. turns on pot core operating frequency in hertz. effective area of the pot core in cm 2 . Because superimposed DC current also affects linearity of inductance in pot cores, consideration for DC currents must also be given. The equation shown above must be modified to include effect of DC bias. The combined equation now becomes: B (combined) = E rms x 10 8 4.44 A e Nf + Nl dc A L 10A e where B = 200 gausses, the suggested conservative limit. I dc = bias current in amperes. See pages 4.15 - 4.19 for DC bias data on Magnetics power ferrites. 5.4 MAGNETICS Pot Core Design Notes mag-inc.com 5.5 Pot Core Design Assembly Notes Magnetics ferrite pot cores can be assembled with or without clamping hardware or tuning devices. Mounting clamps are available for the 40905, 41107, 41408, 41811, 42213, 42616, 43019, 43622, and 44229 pot core sizes. These clamps normally eliminate the need to cement the pot core halves together. The mating surfaces of the pot core must be cleaned to remove moisture, grease, dust, or other foreign particles, before clamping or cementing. If the cementing method is chosen, a small amount of cement is placed on the mating surface of the pot core skirt, being careful to keep the centerpost free of all cement. The pot core halves are brought together and rotated together under slight pressure to distribute the cement evenly around the skirt. The halves are separated and the wound bobbin is set in place. A small amount of cement is now placed on the exposed flange of the bobbin to bond it in the pot core assembly and thus insure no movement. The other core half is replaced, the centerpost holes and wire aperture aligned, and the unit clamped together in a pressure jig. Permanent bonding is accomplished by curing the cement at elevated temperatures according to the manufacturer’s recommendations. After curing, storage for a minimum of 24 hours, and heat cycling between room temperature and 70°C may be required before final testing or tuning is completed. The tuning adjusters can be inserted into the pot core immediately after the cemented core halves have been cured and the assembly can then be heat cycled. Some adjusters require insertion of the base into the centerpost hole prior to assembly of the pot core into the clamp when a clamp is used for mounting pg 5.8. The adjuster is usually made in two parts - the plastic base with a threaded hole, and a ferrite cylinder imbedded in a plastic screw. The base is pressed into the centerpost of the pot core, and the plastic screw is turned into the base until the ferrite cylinder enters the air gap. Tuning is completed when the inductance of the pot core assembly reaches the proper value. If this initial adjustment is expected to be the final one, cementing is recommended to prevent accidental detuning. If precise inductance values are expected, final tuning should not be completed earlier than 24 hours after the pot core assembly has been cured or clamped. “TB-P” bases, which are polypropylene, may be etched in order to roughen the adhering surface and improve the bonding that is achieved. Plastic screw drivers are available upon request for use in final tuning. Tuning assemblies are available for most standard size pot cores. Contact Magnetics Application Engineering for details. 5.6 MAGNETICS FIGURE 1 PRINTED CIRCUIT BOBBINS AND MOUNTING HARDWARE Many sizes in the standard pot cores can be supplied with printed circuit board bobbins. The grid pattern (Figure 1) illustrates the location of 6 pin type bobbins. The soldering pins are arranged to fit a grid of 0.1 “, and they will also fit printed circuit boards with 2.50 mm grids. The pin length is sufficient for a board thickness up to .187”. Terminal pin details are illustrated in Figure 2. The board holes should be .046” + .003” in diameter (#56 drill). The bobbin should be cemented to the lower pot core half. For some core types, printed circuit board mounting clamps are also available. A cross section of a completed core assembly using clamps is shown in Figure 3. When clamps are not available, the pot core halves must be cemented together. Printed circuit board hardware for EP, RM and RS cores is described in the sections covering these core types. FIGURE 2 PRINTED CIRCUIT BOBBINS SOLDERING INSTRUCTIONS 1. A solder pot should be used to solder the leads to the terminals. Preferred solder is 63/37 tin/lead eutectic. The solder temperature should be between 275°-300°C. Lower or higher temperatures will both damage the bobbin. Modern soldering techniques commonly use temperatures in excess of the softening points of all thermoplastic bobbin materials. Extreme care is required to prevent loosening of the terminals during soldering. Pot Core Design Assembly Notes 2. Insulation should be removed from the ends of the wire before soldering. This is especially important when litz wire is used. The preferred method is by burning. 3. Dip wound terminals into liquid soldering flux. A rosin based flux in alcohol solution should be used. Allow flux to air dry. FIGURE 3 4. The bobbin should be immersed only far enough to cover the terminals. 5. The part should be immersed in the solder for 2-4 seconds, depending on the size of the wire used. mag-inc.com 5.7 Wire Tables 5.8 Wire Tables TABLE 5 - MAGNET WIRE WIRE SIZE AWG 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 WIRE AREA (MAX.)* HEAVY Circular Mils 11,470 9,158 7,310 5,852 4,679 3,758 3,003 2,421 1,936 1,560 1,246 1,005 807 650 524 424 342 272 219 180 144 117 96.0 77.4 60.8 49.0 39.7 32.5 26.0 20.2 16.0 13.0 10.2 8.40 7.30 5.30 cm 2 10 3 58.13 46.42 37.05 29.66 23.72 19.05 15.22 12.27 9.812 7.907 6.315 5.094 4.090 3.294 2.656 2.149 1.733 1.379 1.110 0.9123 0.7298 0.5930 0.4866 0.3923 0.3082 0.2484 0.2012 0.1647 0.1318 0.1024 0.0811 0.0659 0.0517 0.0426 0.037 0.0269 per in 2 89 112 140 176 220 260 330 410 510 635 800 1,000 1,200 1,500 1,900 2,400 3,000 3,600 4,700 5,600 7,000 8,500 10,500 13,000 16,000 20,000 25,000 32,000 37,000 50,000 65,000 80,000 100,000 125,000 150,000 185,000 TURNS** per cm 2 13.8 17.4 21.7 27.3 34.1 40.3 51.2 63.6 79.1 98.4 124 155 186 232 294 372 465 558 728 868 1,085 1,317 1,628 2,015 2,480 3,100 3,876 4,961 5,736 7,752 10,077 12,403 15,504 19,380 23,256 28,682 RESISTANCE CURRENT CAPACITY (MA) Ohms/1000’ @750 Cir. Mil/amp @500 Cir. Mil/amp .9987 1.261 1.588 2.001 2.524 3.181 4.020 5.054 6.386 8.046 10.13 12.77 16.20 20.30 25.67 32.37 41.0 51.4 65.3 81.2 104 131 162 206 261 331 415 512 648 847 1,080 1,320 1,660 2,140 2,590 3,348 13,840 10,968 8,705 6,912 5,479 4,347 3,441 2,736 2,165 1,719 1,365 1,083 853 681 539 427 338 259 212 171 133 106 85 67 53 42 33 27 21 16 13 11 8.5 6.5 5.5 4.1 20,768 16,452 13,058 10,368 8,220 6,520 5,160 4,100 3,250 2,580 2,050 1,630 1,280 1,020 808 641 506 403 318 255 200 158 128 101 79 63 50 41 32 25 19 16 13 10 8 6.2 TABLE 6 - LITZ WIRE LITZ Wire Size 5/44 6/44 7/44 12/44 20/44 30/44 40/44 50/44 60/44 per in 2 TURNS*** 28,000 25,000 22,000 13,000 7,400 4,000 3,000 2,300 1,900 LITZ per cm 2 Wire Size 4,341 3,876 3,410 2,016 1,147 620 465 356 294 72/44 80/44 90/44 100/44 120/44 150/44 180/44 360/44 TURNS*** per in 2 1,500 1,400 1,200 1,100 900 700 500 250 per cm 2 232 217 186 170 140 108 77 38 *Areas are for maximum wire area plus maximum insulation buildup. ** Based on a typical machine layer wound coil. *** Based on a typical layer wound coil. mag-inc.com Wire Tables Wire Tables 5.9 Arc Resistance (Sec) Oxygen Index (%O 2 ) UL Card No. Max solder temperature (˚C) D150 D257 D495 UL94 67 V-O 30 E69578 250 117 V-O 33 E69578, E69939, E81777 270 HB 16 E66288R 23 8.5 1.2 H 1.7 210 670 3.1 0.004 Rynite 1.67 0.05 22 FR-530 32 1.5 1.6 H 1.4 224 650 3.8 0.011 10 15 10 15 Delrin 29 1.4 1.6 A 2.3 1.63 550 3.8 Delrin 900 1.42 0.25 19.5 1.42 0.25 10 4.5 Zytel 101 1.14 1.2 12 4.2 10.4 130 500 3.7 0.005 10 13 10 14 0.41 1.0 B 4.0 232 480 3.9 0.02 11.9 1.9 B 2.2 241 437 3.6 0.009 2.0 249 530 3.7 33 15.0 2.0 3.4 232 475 3.8 LNP 1.46 0.6 31 RF1008 42 16.0 2.60 260 Technyl 1.38 0.75 19.6 A20-V25 29.7 Zytel FR-50 1.56 0.6 22.8 Zytel 1.38 70G33L RTP 205FR 23 1.3 10 15 18 1.66 0.6 21 Crastin 1.45 S660FR 7.5 9.0 16 0.015 0.8 B 179 560 3.1 HB HB 28 E66288 175 E41938 250 103 V-O E41938 250 135 HB E41938 255 V-O E84658 248 HB E45195 260 10 14 10 14 V-O 32 E44716 0.002 10 16 V-0 30 E69578(M) 240 130 V-O 48 E54705(M) 330 180 V-O 40 E20305 400 2.5 250 11.7 3.9 220 Flammability Vol. Resistivity @73˚F, 50% RH (ohm-cm) D696 D648 D149 D150 Dielectric Strength (v/mil) Dissipation Factor (@1kHz) Deflection Temperature 264 psi (˚C) Dielectric Constant (@1kHz) D792 D570 D638 D638 D790 D790 D256 Rynite FR-515 1.53 0.07 15.5 Coefficient of expansion (10 -5 in/in˚C) Temperature Class* Izod Impact, Notched (ft.-lb/in) Flexural Modulus (10 5 psi) Flexural Strength (10 3 psi) Tensile Modulus (10 3 psi) Tensile Strength (10 3 psi) Water Absorption, 24h 73˚F (%) Specific Gravity Plastics Information ASTM Test E4008 1.70 0.02 21.7 20.1 17.7 2.0 Rogers RX630 1.75 0.07 12 2328 22 1.2 B 1.9 232 500 4.5 0.019 10 13 10 13 Rogers 1.75 0.07 12 RX660B 2328 22 1.2 B 1.9 232 500 4.5 0.019 10 13 180 V-O 40 E123472 400 Vyncolite 1.75 0.07 12 X-611 2328 22 1.2 B 1.9 232 500 4.5 0.019 10 13 180 V-0 40 E63312(M) 400 17.5 23 0.6 B 1.9 229 400 4.6 0.026 2x10 13 180 @1MHz @1MHz 10 11 80 10 12 V-O 42.1 E46372 V-O E41429 V-1 E59481(S) Fiberite 1.79 4017F 9.5 PM9630 1.82 27 T3733J 1.41 0.40 8 11 5.10 MAGNETICS 4.5 1.5 249 305 42 170 300 *A-105˚C, B-130˚C, H-180˚C TYPE NAME Rynite FR-515 Thermoplastic Polyester (PET) Rynite FR-530 Thermoplastic Polyester (PET) Delrin, Delrin 900 Acetal Resin LNP RF1008 6/6 Nylon, 40 % glass-filled Zytel 70633L 6/6 Nylon, 33% glass-filled RTP 205FR 6/6 Nylon, 30% glass-filled Zytel 101 6/6 Nylon, 30% glass-filled Technyl A20-V25 6/6 Nylon, 25% glass-filled Zytel FR-50 6/6 Nylon, 25% glass-filled Crastin S660FR PBT E-4008 Thermoplastic LCP THERMOSET PHENOLIC MATERIALS Rogers RX360 Fiberlite 4017F Rogers RX660B PM9630 Vyncolyte X-611 T373J This document reports typical data as compiled from various suppliers’ literature. Magnetics assumes no responsibility for the use of the information presented herein and hereby disclaims all liability in regard to use. Modern soldering techniques commonly use temperatures in excess of the softening points of all thermoplastic bobbin materials. These typically run from 400˚C - 600˚C. Extreme care is required to prevent loosening of the terminals during soldering. Crastin-DuPont, Wilmington, DE Delrin-DuPont, Wilmington, DE Rynite-DuPont, Wilmington, DE Zytel DuPont, Wilmington, DE Rogers RX630-Rogers Corporation, Manchester, CT Rogers RX660B-Rogers Corporation, Manchester, CT PM9360-Sumitomo Chemical Company. Ltd., Tokyo, Japan E-4008-Sumitomo Chemical Company. Ltd., Tokyo, Japan Fiberite-ICI Inc., Winona, MN LNP-LNP engineering Plastics, Exton,PA RTP-RTP Company, Winona, MN Technyl-Nytech, Lyon, France T373J-Chang Chun Plastics Co. Ltd., Taipei, Taiwan Vyncolite RX611-31-Vynckier S.A., Belgium Plastics Information THERMOPLASTIC MATERIALS Magnetics is a UL-recognized molder in the QMMY2 fabricated parts program. Many bobbins shown in this catalog are covered. Contact Magnetics for details on specific parts. mag-inc.com 5.11 Notes 5.12 MAGNETICS POT CORES The pot core shape is a convenient means of adjusting the ferrite structure to meet the specific requirements of an application. Both high circuit Q and good temperature stability of inductance can be obtained with these cores. Pot cores, when assembled, nearly surround the wound bobbin. This self-shielded geometry isolates the winding from stray magnetic fields or effects from other surrounding circuit elements. Section 6 Pot Cores Both plain and printed circuit bobbins are available, as are mounting and assembly hardware. Typical applications for pot cores include; differential inductors, power transformers, power inductors, converter and inverter transformers, filters, both broadband and narrow transformers and telecom inductors. Magnetics produces a wide variety of sizes, which include fourteen (14) international standard sizes. Standard pot cores are ungapped, but any practical gap is also available (see page1.8-1.11) HOW TO ORDER O P 4 14 08 UG XX STANDARD POT CORE FERRITE CORE MATERIAL USED FOR ALL FERRITE TYPES APPROXIMATE DIAMETER IN MM APPROXIMATE HEIGHT IN MM GEOMETRY CODE/GAP CODE (SEE PAGE 1.6) SPECIAL SPECIFICATION CODE 6.1 Pot Core Data (ungapped) Any practical gap available. See pages 1.8-1.11 MECHANICAL DIMENSIONS PART FIG. A B C D G H 1.910 ± .100 - .445 min .889 min 2.92 min 1.45 max .813 ± .100 - .075 ± .004 - .0175 min .035 min .115 min .057 max .032 ± .004 - 4.06 ± .100 - 1.340 min 2.690 min 3.680 min 2.200 max 1.30 ± .100 - .160 ± .004 - .053 min .106 min .145 min .087 max .051 ± 004 - 3.250 ± .100 - 1.090 min 2.180 min 4.490 min 2.490 max 1.50 ± .100 .991 ± .050 .128 ± .004 - .043 min .086 min .177 min .098 max .059 ± .004 .039 ± .002 4.160 ± .100 4.720 nom 1.400 min 2.790 min 5.740 min 3.000 max 1.520 min 1.09 ± .050 .164 ± .004 .186 nom .055 min .110 min .226 min .118 max .060 min .043 ± .002 1.524 ± .000,-.120 3.05 ± .120 6.6 nom .749 min 1.50 min 7.49 min 3.88 max 1.78 min 2.01 ± .05 .060 ± .000,-.005 .120 ± .005 .260 nom .0295 min .059 min .295 min .153 max .070 min .079 ± .05 6.600 nom 1.800 min 3.61 min 7.490 min 3.880 max 1.780 min 2.010 ± .050 .260 nom .071 min .142 min .295 min .153 max .070 min .079 ± .002 6.500 ± .100 6.80 2.21 4.42 9.0 4.700 22 2.1 ± 0.1 .256 ± .006 .297 nom .087 min .174 min .354 min .185 max .070 min .081 ± .002 8.4 ± .100 9.500 nom 2.80 min 5.6 min 11.600 min 6.0 max 2.70 min 3.00 +.010, -.000 .376 nom .110 min .220 min .457 min .120 min .122 ± .003 0_40302UG 1 mm 3.940 ± .080 .953 ± .050 in .155 ± .003 .0375 ± .002 0_40506UG 1 mm 4.570 ± .127 2.03 ± .050 in .180 ± .005 .080 ± .002 0_40507UG 2 mm 5.720 ± .080 1.620 ± .050 in .225 ± .003 .064 ± .002 0_40704UG 3 mm 7.240 ± .150 2.080 ± .050 in .285 ± .006 0_40903UG 3 mm 9.14 ± .15 in .360 ± .006 .082 ± .002 2B 0_40905UG 3 mm 9.140 ± .150 2.690+.000,-.120 5.26 ± .120 in .360 ± .006 .106+.000, -.005 .207 ± .005 0_41107UG 4 mm 11.100 ± .200 3.250 ± .050 in .437 ± .008 .128 ± .003 0_41408UG 4 mm 14.3+.000,-.500 4.2 ± .050 in .553 ± .010 .167 +.000, -.005 .334+.000, -.011 2D E F .236 max To order, add material code to part number. FIGURE 1 6.2 MAGNETICS FIGURE 2 STAN DAR D BO BBIN PRIN TED CIRC UIT MOU BOB NTIN BIN G CL AMP SUR FACE MOU NT H TUN EADE ING R ASSE MBL Y** AL (mH/1000T) HIGH PERMEABILITY MATERIALS POWER MATERIALS R P Nom F* J MAGNETIC DATA W le (mm) - 4.29 350 WEIGHT WaAc Ae (mm2) A MIN (mm2) Ve (mm3)CORE (grams per set) 2.1 1.5 9.0 0.076 - 36.0 0.210 - 0.200 - 69.0 0.500 - 38.0 0.1843 - AVAILABLE HARDWARE Note: +/- 35% for Ind. specs Nom 500 606 - 8.88 4.1 3.6 Note: +40%/-30% for Ind. specs Nom 775 930 - 7.75 4.4 3.9 34.0 Pot Cores Pot Core Data (ungapped) Note: +40%/-30% for Ind. specs 9.9 Min 620 Min 865 Min 760 675 940 825 1,200 1,670 1,365 Min 1,150 1,250 1,667 Min 1,540 1,680 2,800 1,580 2,200 2,045 2,925 3,805 3,000 7.0 5.9 Note: +40%/-30% for F 6.24 6.1 - 12.5 10.1 8.0 126.0 1.000 0.003 15.5 16.2 13.2 251 1.800 0.00815 19.8 25.1 19.8 495 3.200 0.024 4,150 4,220 5,750 6,300 * F material nominal ± 25% except where noted ** See page 5.6 for tuning assembly information FIGURE 3 FIGURE 4 mag-inc.com 6.3 Pot Core Data (ungapped) Any practical gap available. See pages 1.8-1.11 MECHANICAL DIMENSIONS PART FIG. A B 2B C D 2D E F G H 0_41811UG 4 mm 18.0 ± .4 5.33 ± .05 10.6 ± .1 13.4 ± .3 3.7 ± .1 7.4 ± .2 15.15 ± .25 7.45 ± .15 3.8 ± 0.6 3.100 ± .1 0_42213UG 4 mm 21.600 ± .380 6.7 ± .1 13.4 ± .2 15.0 nom 4.59 min 9.200 min 17.900 min 9.400 max 2.990 min 4.550 ± .100 .264 ± .004 .528 ± .008 .590 nom .181 min .362 min .705 min .370 max .118 min .179 ± .004 0_42616UG 4 mm 25.5 ± .5 8.05 ± .1 16.1 ± .2 18.0 ± .4 5.5 + .2, -0 11.0 + 4, -0 21.6 ± .4 11.3 ± .2 3.8 ± .6 5.5 ± .1 0_43019UG 4 mm 30.0 ± .5 9.45 ± .05 18.9 ± .1 20.5 ± .5 6.5 ± .1 13 ± .2 25.4 ± .4 13.3 ± .2 4.3 ± .6 5.5 ± .1 0_43622UG 4 mm 35.6 ± .6 10.95 ± .05 21.9 ± .1 26.2 ± .6 7.4 ± .1 14.8 ± .2 30.4 ± .5 15.9 ± .3 4.9 ± .6 5.55 ± .15 0_44229UG 4 mm 42.400 ± .710 14.800 ± .200 29.600 ± .410 32.000 nom 10.200 min 20.400 min 35.600 min 17.700 max 4.490 min 5.5600 ± .100 1.164 ± .016 1.260 nom .219 ± .004 29.200 ± .200 32.990 ± .510 9.400 min 18.800 min 36.500 min 20.700 max 4.490 min 5.560 ± .130 1.150 ± .008 1.299 ± .020 .370 min .740 min .219 ± .005 in .851 ± .015 in 1.669 ± .028 .582 ± .008 0_44529UG 4 mm 45.000 ± .900 14.600 ± .100 in 1.772 ± .035 .575 ± .004 .402 min .804 min 1.402 min 1.438 min .697 max .814 max .177 min .177 min To order, add material code to part number. FIGURE 4 6.4 MAGNETICS STAN DAR D BO BBIN PRIN TED CIRC UIT MOU BOB NTIN BIN G CL A M SUR P FACE MOU NT H TUN EADE ING R ASSE MBL Y** AL (mH/1000T) POWER MATERIALS R P F* Min 2,300 2,500 4,000 Min 3,030 3,300 4,900 Min 3,910 4,250 6,350 Min 5,010 5,450 8,100 HIGH PERMEABILITY MATERIALS J W 5,625 6,825 8,775 10,200 Min 6,530 7,100 10,200 13,125 Min 6,900 7,500 12,000 15,000 Min 9,660 10,500 14,300 18,750 MAGNETIC DATA le (mm) WEIGHT Ae (mm2) A MIN (mm2) Ve (mm3) CORE (grams per set) WaAc 25.8 43.3 36.0 1120 7.3 0.073 31.2 63.9 50.9 2000 13.0 0.187 37.6 93.9 77.4 35.30 20.0 0.392 45.2 137.0 116.0 6190 34.0 0.737 53.2 202.0 172.0 10700 57.0 1.53 68.5 266.0 213.0 18200 104.0 3.69 67.2 360.0 299.0 24200 149.6 3.85 AVAILABLE HARDWARE 8,400 11,200 Pot Cores Pot Core Data (ungapped) 14,000 18,750 24,500 28,000 35,000 * F material nominal ± 25% ** See page 5.6 for tuning assembly information mag-inc.com 6.5 Pot Core Hardware Bobbins A MAX B MAX C MIN D MAX E NOM NOMINAL WINDING AVERAGE AREA PER SECTION LENGTH OF TURN FT in2 cm2 F NOM 3.657 0.144 5.740 0.226 7.416 0.292 7.416 0.292 8.915 0.351 8.915 0.351 11.53 0.454 11.53 0.454 11.53 0.454 2.540 0.100 2.743 0.108 3.530 0.139 3.530 0.139 4.318 0.170 4.318 0.170 5.511 0.217 5.511 0.217 5.511 0.217 2.260 0.089 3.048 0.120 3.962 0.156 3.962 0.156 4.775 0.188 4.775 0.188 6.070 0.239 6.070 0.239 6.070 0.239 2.667 0.105 3.657 0.144 5.181 0.204 5.181 0.204 5.994 0.236 5.994 0.236 7.289 0.287 7.289 0.287 7.289 0.287 2.006 0.079 2.082 0.082 2.540 0.100 2.540 0.100 3.327 0.131 1.447 0.057 4.521 0.178 2.032 0.080 2.032 0.080 0.355 0.014 - MECHANICAL DIMENSIONS PART FIG. CORE SIZE 00B050601 1 40506 mm in 00B070401 2 40704 mm in 00B090501 3 40905 mm in 00B090501FR 3 40905 mm in 00B110701 3 41107 mm in 00B110702 3 41107 mm 2 Section in 00B140801 3 41408 mm in 00B140802 3 41408 mm 2 Section in 00B140802FR 3 41408 mm 2 Section in FIGURE 1 6.6 MAGNETICS MATERIAL 0.00150 0.0097 0.0322 0.00380 0.0250 0.0479 Thermoplastic polyester (PET) Glass-filled nylon 0.00470 0.0300 0.0633 Delrin 0.00470 0.0300 0.0633 Crastin S660FR 0.00785 0.0500 0.0751 Delrin 0.00342 0.0220 0.0751 Delrin 0.01530 0.0980 0.0953 Delrin 0.00688 0.0440 0.0953 Delrin 0.00688 0.0440 0.0953 Crastin S660FR FIGURE 2 MECHANICAL DIMENSIONS PART 00B181101 00B181101FR 00B181102 2 Section 00B181102FR 00B181103 3 Section 00B221301 00B221301FR 00B221302 2 Section 00B221302FR 2 Section 00B221303 3 Section FIG. CORE SIZE 3 41811 mm in 3 41811 mm in 3 41811 mm in 3 41811 mm in 3 41811 mm in 3 42213 mm in 3 42213 mm in 3 42213 mm in 3 42213 mm in 3 42213 mm in A MAX B MAX C MIN D MAX E NOM 14.909 0.587 14.909 0.587 14.909 0.587 14.909 0.587 14.909 0.587 17.830 0.702 17.830 0.702 17.830 0.702 17.830 0.702 17.830 0.702 7.137 0.281 7.137 0.281 7.137 0.281 7.137 0.281 7.137 0.281 9.118 0.359 9.118 0.359 9.118 0.359 9.118 0.359 9.118 0.359 7.670 0.302 7.670 0.302 7.670 0.302 7.670 0.302 7.670 0.302 9.474 0.373 9.474 0.373 9.474 0.373 9.474 0.373 9.474 0.373 8.89 0.350 8.89 0.350 8.89 0.350 8.89 0.350 8.89 0.350 10.693 0.421 10.693 0.421 10.693 0.421 10.693 0.421 10.693 0.421 6.096 0.240 6.096 0.240 2.819 0.111 2.819 0.111 1.727 0.068 8.128 0.320 8.128 0.320 3.835 0.151 3.835 0.151 2.413 0.095 NOMINAL WINDING AVERAGE AREA PER SECTION LENGTH OF TURN FT in2 cm2 F NOM - MATERIAL 0.02645 0.1700 0.120 Delrin 0.02645 0.1700 0.120 Crastin S660FR 0.01315 0.0840 0.120 Delrin 0.01315 0.0840 0.120 Crastin S660FR 0.00755 0.0490 0.120 Delrin 0.04530 0.2920 0.145 Delrin 0.04530 0.2920 0.145 Crastin S660FR 0.02140 0.1380 0.145 Delrin 0.02140 0.1380 0.145 Crastin S660FR 0.01350 0.0870 0.145 Delrin Pot Core Hardware Bobbins FIGURE 3 mag-inc.com 6.7 Pot Core Hardware Bobbins (con’t) MECHANICAL DIMENSIONS PART FIG. CORE SIZE 00B261601 3 42616 mm in 00B261601FR 3 42616 mm in 00B261602 3 42616 mm 2 Section in 00B261603 3 42616 mm 3 Section in 00B261603FR 3 42616 mm 3 Section in A MAX B MAX C MIN D MAX E NOM 21.132 0.832 21.132 0.832 21.132 0.832 21.132 0.832 21.132 0.832 10.922 0.430 10.922 0.430 10.922 0.430 10.922 0.430 10.922 0.430 11.557 0.455 11.557 0.455 11.557 0.455 11.557 0.455 11.557 0.455 12.776 0.503 12.776 0.503 12.776 0.503 12.776 0.503 12.776 0.503 9.931 0.391 9.931 0.391 4.749 0.187 3.022 0.119 3.022 0.119 FIGURE 3 FIGURE 4 6.8 MAGNETICS NOMINAL WINDING AVERAGE AREA PER SECTION LENGTH OF TURN FT in2 cm2 F NOM - MATERIAL 0.06530 0.4210 0.173 Delrin 0.06530 0.4210 0.173 Crastin S660FR 0.03140 0.2020 0.173 Delrin 0.01990 0.1280 0.173 Delrin 0.01990 0.1280 0.173 Crastin S660FR A MAX B MAX C MIN D MAX NOMINAL WINDING AVERAGE AREA PER SECTION LENGTH OF TURN FT in2 cm2 E NOM F NOM 24.917 0.981 24.917 0.981 24.917 0.981 29.768 1.172 29.768 1.172 29.768 1.172 35.407 1.394 35.407 1.394 36.068 1.420 36.068 1.420 12.928 0.509 12.928 0.509 12.928 0.509 14.478 0.570 14.478 0.570 14.478 0.570 20.015 0.788 20.015 0.788 22.86 0.900 22.86 0.900 13.563 0.534 13.563 0.534 13.563 0.534 16.230 0.639 16.230 0.639 16.230 0.639 17.983 0.708 17.983 0.708 20.878 0.822 20.878 0.822 15.036 0.592 15.036 0.592 15.036 0.592 18.059 0.711 18.059 0.711 18.059 0.711 19.710 0.776 19.710 0.776 18.592 0.732 18.592 0.732 11.684 0.460 5.562 0.219 3.505 0.138 12.979 0.511 6.146 0.242 3.860 0.152 17.805 0.701 8.407 0.331 16.256 0.640 7.620 0.300 MECHANICAL DIMENSIONS PART 00B301901 00B301902 2 Section 00B301903 3 Section 00B362201 00B362202 2 Section 00B362203 3 Section 00B422901 00B422902 2 Section 00B452901 00B452902 2 Section FIG. 3 43019 mm in 3 43019 mm in 3 43019 mm in 3 43622 mm in 3 43622 mm in 3 43622 mm in 4 44229 mm in 4 44229 mm in 5 44529 mm in 5 44529 mm in - MATERIAL 0.08400 0.5420 0.204 Delrin 0.03940 0.2540 0.204 Delrin 0.02460 0.1590 0.204 Delrin 0.11700 0.7550 0.244 Delrin 0.05540 0.3570 0.244 Delrin 0.03480 0.2250 0.244 Delrin 0.21500 1.3900 0.282 Delrin 0.09700 0.6300 0.282 Delrin 0.16700 1.0700 0.308 Glass-filled nylon 0.07800 0.5000 0.308 Glass-filled nylon Pot Core Hardware Bobbins (con’t) FIGURE 5 mag-inc.com 6.9 Pot Core Hardware Printed Circuit Bobbins MECHANICAL DIMENSIONS PART FIG. CORE SIZE PCB140811 1A 41408 mm in PCB140821 1A 41408 mm in PCB140812 1A 41408 mm 2 Section in PCB140822 1A 41408 mm 2 Section in PCB1408S1 2A 41408 mm in PCB181111 2B 41811 mm in PCB181121 2B 41811 mm in PCB181112 2B 41811 mm 2 Section in PCB181122 2B 41811 mm 2 Section in PCB221311 2B 42213 mm in PCB221321 2B 42213 mm in PCB221312 2B 42213 mm 2 Section in FIGURE 1 6.10 MAGNETICS A MAX B MAX C MAX D NOM E MAX F MAX G NOM H X1 NOM X2 NOM 11.506 0.453 11.506 0.453 11.506 0.453 11.506 0.453 11.506 0.453 14.808 0.583 14.808 0.583 14.808 0.583 14.808 0.583 17.805 0.701 17.805 0.701 17.805 0.701 7.112 0.280 7.112 0.280 7.112 0.280 7.112 0.280 7.112 0.280 8.813 0.347 8.813 0.347 8.813 0.347 8.813 0.347 10.693 0.421 10.693 0.421 10.693 0.421 5.410 0.213 5.410 0.213 5.410 0.213 5.410 0.213 5.410 0.213 7.035 0.277 7.035 0.277 7.035 0.277 7.035 0.277 8.991 0.354 8.991 0.354 8.991 0.354 4.445 0.175 4.445 0.175 2.032 0.080 2.032 0.080 4.445 0.175 6.045 0.238 6.045 0.238 2.794 0.110 2.794 0.110 7.797 0.307 7.797 0.307 3.683 0.145 18.999 0.748 18.999 0.748 18.999 0.748 18.999 0.748 18.999 0.748 23.799 0.937 23.799 0.937 23.799 0.937 23.799 0.937 27.203 1.071 27.203 1.071 27.203 1.071 5.892 0.232 5.892 0.232 5.892 0.232 5.892 0.232 10.668 0.420 10.210 0.402 10.210 0.402 10.210 0.402 10.210 0.402 10.210 0.402 10.210 0.402 10.210 0.402 16.205 0.638 16.205 0.638 16.205 0.638 16.205 0.638 16.205 0.638 21.539 0.848 21.539 0.848 21.539 0.848 21.539 0.848 25.146 0.990 25.146 0.990 25.146 0.990 - 4.749 0.187 4.749 0.187 4.749 0.187 4.749 0.187 4.749 0.187 4.749 0.187 7.137 0.281 7.137 0.281 7.137 0.281 7.137 0.281 7.137 0.281 7.137 0.281 - FIGURE 2 FIGURE A FIGURE B MECHANICAL DIMENSIONS PART FIG.CORE SIZE PCB140811 1A 41408 mm in PCB140821 1A 41408 mm in PCB140812 1A 41408 mm 2 Section in PCB140822 1A 41408 mm 2 Section in PCB1408S1 2A 41408 mm in PCB181111 2B 41811 mm in PCB181121 2B 41811 mm in PCB181112 2B 41811 mm 2 Section in PCB181122 2B 41811 mm 2 Section in PCB221311 2B 42213 mm in PCB221321 2B 42213 mm in PCB221312 2B 42213 mm 2 Section in YY12 NOM Y2 NOM 1.549 0.061 1.549 0.061 1.549 0.061 1.549 0.061 1.549 0.061 1.447 0.057 1.447 0.057 1.447 0.057 1.447 0.057 0.584 0.023 0.584 0.023 0.584 0.023 3.937 0.155 3.937 0.155 3.937 0.155 3.937 0.155 3.937 0.155 3.835 0.151 3.835 0.151 3.835 0.151 3.835 0.151 2.971 0.117 2.971 0.117 2.971 0.117 FIGURE 3 NOMINAL WINDING AREA PER SECTION in2 cm2 AVERAGE LENGTH OF TURN FT BOBBIN MATERIAL PIN MATERIAL 0.013 0.084 0.095 Glass-filled nylon Tin coated brass 0.013 0.084 0.095 Glass-filled nylon Tin coated brass 0.006 0.039 0.095 Glass-filled nylon Tin coated brass 0.006 0.039 0.095 Glass-filled nylon Tin coated brass 0.013 0.084 0.095 Glass-filled nylon Tin coated brass 0.024 0.151 0.121 Glass-filled nylon Tin coated brass 0.024 0.151 0.121 Glass-filled nylon Tin coated brass 0.010 0.064 0.121 Glass-filled nylon Tin coated brass 0.010 0.064 0.121 Glass-filled nylon Tin coated brass 0.043 0.280 0.144 Glass-filled nylon Tin coated brass 0.043 0.280 0.144 Glass-filled nylon Tin coated brass 0.020 0.130 0.144 Glass-filled nylon Tin coated brass Pot Core Hardware Printed Circuit Bobbins NOTES: If short pin (X 1 ) is desired, part number is -11 or -12. If long pin (X 2 ) is desired, part number is -21 or -22. Y-Pin length available under board for soldering, using spring clip mounting (on 1/16” board). mag-inc.com 6.11 Pot Core Hardware Printed Circuit Bobbins (con’t) MECHANICAL DIMENSIONS PART PCB221322 2 Section PCB221313 3 Section PCB221323 3 Section PCB261611 PCB261621 PCB261612 2 Section PCB261622 2 Section PCB261613 3 Section PCB261623 3 Section PCB301911 PCB301921 PCB362211 FIG. CORE SIZE A MAX B MAX C MAX D NOM E MAX F MAX G NOM H X1 NOM X2 NOM 2B 42213 mm in 2B 42213 mm in 2B 42213 mm in 2B 42616 mm in 2B 42616 mm in 2B 42616 mm in 2B 42616 mm in 2B 42616 mm in 2B 42616 mm in 2B 43019 mm in 2A 43019 mm in 3 43622 mm in 17.805 0.701 17.805 0.701 17.805 0.701 20.904 0.823 20.904 0.823 20.904 0.823 20.904 0.823 20.904 0.823 20.904 0.823 24.942 0.982 24.942 0.982 29.845 1.175 10.693 0.421 10.693 0.421 10.693 0.421 12.801 0.504 12.801 0.504 12.801 0.504 12.801 0.504 12.801 0.504 12.801 0.504 14.884 0.586 14.884 0.586 18.034 0.710 8.991 0.354 8.991 0.354 8.991 0.354 10.795 0.425 10.795 0.425 10.795 0.425 10.795 0.425 10.795 0.425 10.795 0.425 12.877 0.507 12.877 0.507 16.179 0.637 3.683 0.145 2.311 0.091 2.311 0.091 9.601 0.378 9.601 0.378 4.572 0.180 4.572 0.180 2.895 0.114 2.895 0.114 11.684 0.460 11.684 0.460 12.852 0.506 27.203 1.071 27.203 1.071 27.203 1.071 30.683 1.208 30.683 1.208 30.683 1.208 30.683 1.208 30.683 1.208 30.683 1.208 38.150 1.502 38.150 1.502 14.478 0.570 10.210 0.402 10.210 0.402 10.210 0.402 10.210 0.402 10.210 0.402 10.210 0.402 10.210 0.402 10.210 0.402 10.210 0.402 10.210 0.402 10.210 0.402 5.588 0.220 25.146 0.990 25.146 0.990 25.146 0.990 28.727 1.131 28.727 1.131 28.727 1.131 28.727 1.131 28.727 1.131 28.727 1.131 35.915 1.414 35.915 1.414 29.210 1.150 40.64 1.600 4.749 0.187 4.749 0.187 4.749 0.187 4.749 0.187 4.749 0.187 - 7.137 0.281 7.137 0.281 7.137 0.281 7.137 0.281 7.137 0.281 7.137 0.281 - FIGURE 2 6.12 MAGNETICS FIGURE A FIGURE B Pot Core Hardware Printed Circuit Bobbins (con’t) MECHANICAL DIMENSIONS PART PCB221322 2 Section PCB221313 3 Section PCB221323 3 Section PCB261611 PCB261621 PCB261612 2 Section PCB261622 2 Section PCB261613 3 Section PCB261623 3 Section PCB301911 PCB301921 2 Section PCB362211 FIG.CORE SIZE 2B 42213 mm in 2B 42213 mm in 2B 42213 mm in 2B 42616 mm in 2B 42616 mm in 2B 42616 mm in 2B 42616 mm in 2B 42616 mm in 2B 42616 mm in 2B 43019 mm in 2B 43019 mm in 3 43622 mm in Y12 NOM 0.584 0.023 0.584 0.023 0.584 0.023 1.066 0.042 1.066 0.042 1.066 0.042 1.066 0.042 1.066 0.042 1.066 0.042 0.431 0.017 0.431 0.017 - FIGURE 3 Y2 NOM 2.971 0.117 2.971 0.117 2.971 0.117 3.454 0.136 3.454 0.136 3.454 0.136 3.454 0.136 3.454 0.136 3.454 0.136 2.819 0.111 2.819 0.111 - NOMINAL WINDING AREA PER SECTION in2 cm2 AVERAGE LENGTH OF TURN FT BOBBIN MATERIAL PIN MATERIAL 0.020 0.130 0.144 Glass-filled nylon Tin coated brass 0.013 0.080 0.144 Glass-filled nylon Tin coated brass 0.013 0.080 0.144 Glass-filled nylon Tin coated brass 0.060 0.390 0.174 Glass-filled nylon Tin coated brass 0.060 0.390 0.174 Glass-filled nylon Tin coated brass 0.028 0.190 0.174 Glass-filled nylon Tin coated brass 0.028 0.190 0.174 Glass-filled nylon Tin coated brass 0.018 0.120 0.174 Glass-filled nylon Tin coated brass 0.018 0.120 0.174 Glass-filled nylon Tin coated brass 0.090 0.580 1.970 Glass-filled nylon Tin coated brass 0.090 0.580 1.970 Glass-filled nylon Tin coated brass 0.117 0.755 0.244 Glass-filled nylon Phosphor Bronze Tin coated NOTES: If short pin (X 1 ) is desired, part number is -11 or -12. If long pin (X 2 ) is desired, part number is -21 or -22. Y-Pin length available under board for soldering, using spring clip mounting (on 1/16” board). 6.13 mag-inc.com Pot Core Hardware FIG. CORE SIZE 00C090511 1 40905 mm in 00C110711 1 41107 mm in 00C140811 2 41408 mm in 00C1408RS 3 41408 mm in 00C181111 3 41811 mm 2 in 00C221314 4 42213 mm in 0PC221314 5 42213 mm in 00C261614 4 42616 mm in 0PC261614 7 42616 mm in 00C301917 4 43019 mm in 00C362217 6 43622 mm in 00C422917 6 44229 mm in A NOM B NOM C NOM D±.020"* F NOM TAB DIMENSIONS LENGTH WIDTH 5.689 0.224 6.985 0.275 9.652 0.380 8.89 0.35 11.684 0.460 14.859 0.585 14.859 0.585 16.637 0.655 16.637 0.655 20.320 0.800 23.241 0.915 56.388 1.233 9.499 0.374 11.480 0.452 14.478 0.570 13.97 0.55 18.542 0.730 22.250 0.876 22.250 0.876 26.289 1.035 26.289 1.035 30.734 1.210 36.322 1.430 50.800 1.700 8.001 0.315 9.194 0.362 13.208 0.520 8.001 0.315 16.764 0.660 20.828 0.820 20.828 0.820 21.082 0.830 21.082 0.830 28.575 1.125 21.590 0.850 43.180 1.000 10.008 0.394 12.497 0.492 13.208 0.520 16.510 0.650 27.940 1.100 21.488 0.846 32.817 1.292 24.638 0.970 38.608 1.520 44.450 1.750 25.400 2.000 33.020 1.300 3.581 0.141 38.405 1.512 5.080 0.200 44.196 1.740 50.038 1.970 6.604 2.220 4.394 0.173 5.003 0.197 3.962 0.156 3.962 0.156 - * The C090511, C110711, C140811and C1408RS have a D dimension tolerance of ± .010" ** Mounting Clamps are made to allow for tuning adjusters. If these adjusters are not used a polypropylene washer must be inserted to take up extra space. The part number and dimension of available washers are detailed above. 6.14 MAGNETICS 1.016 0.040 1.193 0.047 2.159 0.085 2.032 0.080 - Phosphor Bronze Phosphor Bronze Spring Steel Stainless Steel Spring Steel Spring Steel Spring Steel Spring Steel Spring Steel Spring Steel Spring Steel Spring Steel .009" .010" 0.011" .020" .014" #4-40 - .014" WAS DIM HER ENSI ONS WAS THIC HER KNE SS PART WAS HER ** MECHANICAL DIMENSIONS MAT ERIA L MAT THIC ERIAL KN MAC ESS IMP HINE SC RESS IONSREW Mounting Clamps - - - - 00W140815 .540 ± .008" .015" 00W140815 .540 ± .008" .015" 00W181118 .700 ± .008" .020" 00W221324 .840 ± .008" .025" 00W221324 .840 ± .008" .025" .014" #4-40 - - - .014" #4-40 - - - .017" #6-32 - - - #6-32 - - - #6-32 - - - FIGURE 1 Pot Core Hardware Mounting Clamps FIGURE 2 FIGURE 5 FIGURE 4 FIGURE 3 FIGURE 6 FIGURE 7 6.15 mag-inc.com Pot Core Hardware 6.16 Surface Mount Headers MECHANICAL DIMENSIONS PART CORE FIG. SIZE BOBBIN MATERIAL PIN MATERIAL A MAX B MAX C TYP D TYP SMH11078A 1 41107 mm 16.967 12.751 in 0.668 0.502 8.992 0.354 3.988 0.157 0.483 0.019 15.240 11.354 2.134 0.600 0.465 0.084 0.991 0.039 1.270 0.050 Thermoset plastic Tin coated phosphor bronze SMH1408TA 2 41408 mm 19.990 15.748 in 0.787 0.620 11.989 0.472 - 0.483 0.019 18.263 14.351 2.134 0.719 0.565 0.084 0.991 0.039 1.270 0.050 Thermoset plastic Tin coated phosphor bronze SMH1811LA 3 41811 mm 24.181 19.761 in 0.952 0.778 14.732 0.580 - 0.483 0.019 22.454 18.339 2.134 0.884 0.722 0.084 0.991 0.039 1.270 0.050 Thermoset plastic Tin coated phosphor bronze FIGURE 1 MAGNETICS E NOM F MAX G MIN K MAX L NOM M MIN FIGURE 2 FIGURE 3 RS/DS CORES Slab cores are modified pot cores with the sides removed. The slabs can be paired with one round half of a standard pot core (RS combination) or two slabs can be paired together for a double slab (DS combination). Available in seven sizes, the RS geometry offers all the advantages of pot cores for filter applications, plus many additional features for power applications. Section 7 RS/DS Cores DS cores, available in six sizes, accommodate large size wire and assist in removing heat from the assembly. Both plain and printed circuit bobbins are available for both types of cores. Typical applications for RS/DS combinations include; low and medium power transformers, switched-mode power supplies, and converter and inverter transformers. HOW TO ORDER S P 4 30 19 UG XX SHAPE CODE* FERRITE CORE MATERIAL USED FOR ALL FERRITE TYPES APPROXIMATE DIAMETER IN MM APPROXIMATE HEIGHT IN MM GEOMETRY CODE/GAP CODE (SEE PAGE 1.5 - 1.6) SPECIAL SPECIFICATION CODE *SHAPE CODES D – DS Core with solid centerpost H – DS Core with center hole S – RS Core 7.1 RS/DS Cores RS/DS Core Data (ungapped) Any practical gap available. See page 1.8 - 1.11 MECHANICAL DIMENSIONS PART FIG. COMBINATION H_41408UG 1 DS mm with center hole in S_41408UG 1 RS mm in D_42311UG 3 DS mm in H_42311UG 4 DS mm with center hole in S_42311UG 2 RS mm in D_42318UG 3 DS mm in H_42318UG 4 DS mm with center hole in S_42318UG 2 RS mm in D_42616UG 3 DS mm in H_42616UG 4 DS mm with center hole in S_42616UG 1 RS mm in A 14 ± .250 .553 ± .010 14 ± .250 .553 ± .010 22.86 ± .460 .900 ± .018 22.86 ± .460 .900 ± .018 22.9 ± .460 .900 ± .018 22.860 ± .460 .900 ± .018 22.860 ± .460 .900 ± .018 22.900 ± .460 .900 ± .018 25.500 ± .510 1.004 ± .020 25.500 ± .510 1.004 ± .020 25.500 ± .510 1.004 ± .020 B 4.24 .167 4.24 .167 5.54 .218 5.54 .218 5.54 .218 9.00 .355 9.00 .355 9.00 .355 8.05 .317 8.05 .317 8.05 .317 + + + + ± ± ± ± ± ± ± ± ± ± ± ± ± ± ± ± ± ± .000, .000, .000, .000, .130 .005 .130 .005 .130 .005 .180 .007 .180 .007 .180 .007 .100 .004 .100 .004 .100 .004 -.130 -.005 -.130 -.005 2B C 8.48 + .000, -.280 .334 + .000, -.011 8.48 + .000, -.280 .334 + .000, -.011 11.080 ± .260 .436 ± .010 11.080 ± .260 .436 ± .010 11.08 ± .250 .436 ± .010 18.00 ± .360 .710 ± .014 18.00 ± .360 .710 ± .014 18.00 ± .360 .710 ± .014 16.10 ± .200 .634 ± .008 16.10 ± .200 .634 ± .008 16.10 ± .200 .634 ± .008 9.4 ± .150 .370 ± .006 9.4 ± .150 .370 ± .006 15.24 ± .250 .600 ± .010 15.24 ± .250 .600 ± .010 15.2 ± .250 .600 ± .010 15.24 ± .250 .600 ± .010 15.24 ± .250 .600 ± .010 15.20 ± .250 .600 ± .010 17.09 nom .673 nom 17.09 nom .673 nom 17.09 nom .673 nom To order, add material code to part number. FIGURE 1 7.2 MAGNETICS FIGURE 2 MECHANICAL DIMENSIONS D MIN 2.800 0.110 2.800 0.110 3.630 0.143 3.630 0.143 3.630 0.143 6.930 0.273 6.930 0.273 6.930 0.273 5.510 0.217 5.510 .217 5.510 .217 2D MIN 5.580 0.220 5.580 0.220 7.260 0.286 7.260 0.286 7.260 0.286 13.860 0.546 13.860 0.546 13.870 0.546 11.020 0.434 11.020 0.434 11.020 .434 FIGURE 3 E MIN F MAX G MIN 11.600 0.457 11.600 0.457 17.930 0.706 17.930 0.706 17.940 0.706 17.93 0.706 17.93 0.706 17.94 0.706 21.21 0.835 21.21 0.835 21.21 .835 5.990 0.236 5.990 0.236 9.900 0.390 9.900 0.390 9.900 0.390 9.900 0.390 9.900 0.390 9.900 0.390 11.480 0.452 11.480 0.452 11.480 .452 7.600 0.300 7.600 0.300 13.210 0.520 13.210 0.520 13.200 0.520 13.200 0.520 13.200 0.520 13.200 0.520 15.500 0.610 15.500 0.610 15.500 .610 H 3.10 .122 3.10 .122 5.08 .200 5.08 .200 5.56 .219 ± ± ± ± .076 .003 .076 .003 ± .10 ± .004 RS/DS Cores RS/DS Core Data (ungapped) ± .100 ± .004 ± .100 ± .004 FIGURE 4 mag-inc.com 7.3 RS/DS Cores RS/DS Core Data (ungapped) Any practical gap available. See page 1.8 - 1.11 MECHANICAL DIMENSIONS PART FIG. COMBINATION D_43019UG 3 H_43019UG 4 S_43019UG 1 D_43622UG 3 H_43622UG 4 S_43622UG 1 *D_44229UG 3 H_44229UG 4 S_44229UG 1 mm in DS mm with center hole in RS mm in DS mm in DS mm with center hole in RS mm in DS mm in DS mm with center hole in RS mm in DS A B 30.00 ± .051 1.181 ± .020 30.00 ± .510 1.181 ± .020 30.00 ± .510 1.181 ± .020 35.61 ± .510 1.402 ± .020 35.61 ± .510 1.402 ± .020 35.61 ± .510 1.402 ± .020 42.4 ± .710 1.669 ± .028 42.4 ± .710 1.669 ± .028 42.4 ± .710 1.669 ± .028 9.4 ± .100 .370 ± .004 9.4 ± .100 .370 ± .004 9.400 ± .100 .370 ± .004 10.87 ± .130 .428 ± .005 10.87 ± .130 .428 ± .005 10.87 ± .130 .428 ± .005 14.8 ± .200 .582 ± .008 14.8 ± .200 .582 ± .008 14.8 ± .200 .582 ± .008 2B 18.800 ± .200 .740 ± .008 18.800 ± .200 .740 ± .008 18.70 ± .200 .740 ± .008 21.7 ± .250 .856 ± .010 21.7 ± .250 .856 ± .010 21.7 ± .250 .856 ± .010 29.6 ± .400 1.164 ± .016 29.6 ± .400 1.164 ± .016 29.6 ± .400 1.164 ± .016 To order, add material code to part number. *This core has a .198” x .043 wire slot (not shown in figure) FIGURE 1 7.4 MAGNETICS FIGURE 2 C 20.32 ± .250 .800 ± .010 20.32 ± .250 .800 ± .010 20.32 ± .250 .800 ± .010 23.85 nom .939 nom 23.85 nom .939 nom 23.85 nom .939 nom 28.40 nom 1.118 nom 28.40 nom 1.118 nom 28.40 nom 1.118 nom MECHANICAL DIMENSIONS D MIN 6.500 .256 6.500 .256 6.500 .256 7.29 .287 7.29 .287 7.29 .287 10.21 .402 10.21 .402 10.21 .402 2D MIN 13.000 .512 13.000 .512 13.000 .512 14.580 .574 14.580 .574 14.580 .574 20.420 .804 20.420 .804 20.420 .804 FIGURE 3 E MIN 25.000 .984 25.000 .984 25.000 .984 29.85 1.177 29.85 1.177 29.85 1.177 35.61 1.402 35.61 1.402 35.61 1.402 F MAX G MIN 13.510 .532 13.510 .532 13.500 .532 16.100 .634 16.100 .634 16.100 .634 17.700 .697 17.700 .697 17.700 .697 15.490 .610 15.490 .610 15.500 .610 20.300 .800 20.300 .800 20.300 .800 25.000 .985 25.000 .985 25.000 .985 H 5.56 .219 5.56 .219 5.56 .219 - ± .10 ± .004 ± .10 ± .004 RS/DS Cores RS/DS Core Data (ungapped) ± .10 ± .004 FIGURE 4 mag-inc.com 7.5 RS/DS Cores RS/DS Core Data (ungapped) Any practical gap available. See page 1.8 - 1.11 POWER MATERIALS PART H_41408UG S_41408UG D_42311UG H_42311UG S_42311UG D_42318UG H_42318UG S_42318UG D_42616UG H_42616UG S_42616UG D_43019UG H_43019UG S_43019UG D_43622UG H_43622UG S_43622UG D_44229UG H_44229UG S_44229UG 7.6 AL (mH/1000T) COMBINATION R HIGH PERMEABILITY MATERIALS P F* 1,150 1,250 1,990 3,080 4,930 - 1,320 1,435 2,274 3,375 5,350 - 2,580 2,810 4,460 6,300 11,245 16,800 2,400 2,595 4,170 5,890 9,815 - 2,950 3,210 5,200 6,300 11,250 - 2,180 2,370 3,800 4,760 7,000 10,500 1,950 2,115 3,350 4,000 7,000 - 2,300 2,500 4,000 4,800 8,400 - 2,870 3,120 5,000 6,070 9,100 - - 2,880 4,600 6,080 9,100 - Min 3,270 3,550 5,300 6,700 11,000 - Min DS with center hole Min RS Min DS Min DS with center hole Min RS Min DS Min DS with center hole Min RS Min 3,330 3,620 5,800 7,120 10,500 - 3,170 3,450 5,525 7,130 10,500 - 4,150 4,520 6,700 8,360 13,000 - 4,020 4,370 7,000 8,700 12,600 - - 4,050 6,520 8,700 12,600 - 5,230 5,685 8,600 11,200 18,600 - 4,830 5,250 8,400 9,220 13,300 - - 5,000 8,100 9,220 13,300 - 5,440 5,910 10,200 12,200 - - DS with center hole Min RS Min DS Min DS with center hole Min RS Min DS Min DS with center hole Min RS Min DS Min DS with center hole Min J W H RS DS To order, add material code to part number. * F material nominal ±25% MAGNETICS le (mm) Ae (mm2) A MIN (mm2) Ve (mm3) CORE WEIGHT WaAc (grams per set) 20.6 21.0 019.2 433.0 - - 20.2 23.0 19.2 460.0 2.85 0.019 26.8 51.2 37.8 1,370.0 10.00 0.081 27.0 48.2 37.8 1,300.0 - - 26.5 58.0 37.8 1,540.0 11.65 0.092 39.9 58.0 40.7 2,310.0 13.0 0.213 40.1 53.4 40.7 2,130.0 - - 38.6 60.0 40.7 2,320.0 17.40 0.221 38.9 77.0 62.7 3,000.0 15.00 0.283 39.0 72.1 62.7 2,810.0 - - 38.3 82.6 62.7 3,180.0 20.00 .392 46.2 117.0 96.0 5,410.0 22.00 0.601 46.1 111.0 96.0 5,110.0 - - 45.6 123.0 96.0 5,610.0 30.95 0.632 52.8 149.0 125.0 7,870.0 37.00 1.15 53.1 146.0 125.0 7,750.0 - - 53.0 174.0 125.0 9,220.0 57.00 1.53 71.7 209.0 178.0 14,990.0 78.00 2.91 71.7 203.0 178.0 14,560.0 - - 70.1 234.5 178.0 16,400.0 104.00 3.69 MOU NTIN G CL AMP PRIN TED CIRC UIT BOB BIN STAN DAR D BO BBIN MAGNETIC DATA AVAILABLE HARDWARE mag-inc.com RS/DS Cores RS/DS Core Data (ungapped) 7.7 RS/DS Core Hardware Bobbins MECHANICAL DIMENSIONS PART 00B261601 CORE FIG. SIZE A MAX B MAX C MIN D MIN E NOM 42616 1 mm 21.132 10.922 11.557 12.776 9.931 0.832 0.430 0.455 0.503 0.391 10.922 11.557 12.776 9.931 0.832 0.430 0.455 0.503 0.391 21.132 10.922 11.557 12.776 4.749 0.832 0.430 0.455 0.503 0.187 21.132 10.922 11.557 12.776 3.022 0.832 0.430 0.455 0.503 0.119 10.922 11.557 12.776 3.022 0.832 0.430 0.455 0.503 0.119 24.917 12.928 13.563 15.036 11.684 0.981 0.509 0.534 0.592 0.460 24.917 12.928 13.563 15.036 5.562 0.981 0.509 0.534 0.592 0.219 24.917 12.928 13.563 15.036 3.505 0.981 0.509 0.534 0.592 0.138 29.768 14.478 16.230 18.059 12.979 1.1721 0.570 0.639 0.711 0.511 29.768 14.478 16.230 18.059 6.146 1.172 0.570 0.639 0.711 0.242 29.768 14.478 16.230 18.059 3.860 1.172 0.570 0.639 0.711 0.152 35.407 20.015 17.983 19.710 17.805 1.394 0.788 0.708 0.776 0.701 35.407 20.01 17.983 19.710 8.407 1.394 0.788 0.708 0.776 0.331 in 00B261601FR 42616 1 mm 21.132 in 2 Section 00B261602 42616 1 mm in 3 Section 00B261603 42616 1 mm in 3 Section 00B261603FR 42616 1 mm 21.132 in 3 Section 00B301901 43019 1 mm in 00B301902 43019 1 mm in 2 Section 00B301903 43019 1 mm in 3 Section 00B362201 43622 1 mm in 00B362202 43622 1 mm in 2 Section 00B362203 43622 1 mm in 3 Section 00B422901 44229 2 mm in 00B422902 44229 2 mm 2 Section 7.8 MAGNETICS in NOMINAL WINDING AREA PER SECTION in2 cm2 AVERAGE LENGTH OF TURN FT MATERIAL 0.06530 0.4210 0.173 Delrin 0.06530 0.4210 0.173 Crastin S660FR 0.03140 0.2020 0.173 Delrin 0.01990 0.1280 0.173 Delrin 0.01990 0.1280 0.173 Crastin S660FR 0.0840 0.542 0.204 Delrin 0.0394 0.254 0.204 Delrin 0.02460 0.159 0.204 Delrin 0.11700 0.755 0.244 Delrin 500 0.05540 0.357 0.244 Delrin 500 0.34800 0.225 0.244 Delrin 500 0.21500 1.3900 0.282 Delrin 0.09700 0.6300 0.282 Delrin RS/DS Core Hardware Bobbins BOBBIN FIGURE 1 BOBBIN FIGURE 2 mag-inc.com 7.9 RS/DS Core Hardware Printed Circuit Bobbins MECHANICAL DIMENSIONS PART PCB4140861 CORE SIZE FIG. 41408 A MAX 1 mm in PCB2311T1 42311 2 mm in PCB2318T1 42318 2 mm in PCB2616TA 42616 3 mm in PCB3019T1 43019 2 mm in PCB3622L1 43622 4 mm in PCB4229L1 44229 5 mm in B MAX C MAX D MIN E NOM F MAX 12.776 ref 11.532 7.290 6.071 4.064 16.586 ref 5.486 4.775 0.503 ref 0.454 0.287 0.239 0.160 .653 ref 0.216 0.188 19.812 17.780 11.430 10.033 5.156 23.241 6.858 5.588 0.780 0.700 0.450 0.395 0.203 0.915 0.270 0.220 23.114 17.78 11.404 10.033 11.887 22.86 13.665 5.537 0.910 0.700 0.449 0.395 0.468 0.900 0.538 0.218 25.527 28.194 12.878 11.557 8.890 21.133 10.922 5.588 1.005 1.110 0.507 0.455 0.350 0.832 0.430 0.220 28.194 24.765 14.935 13.563 10.744 30.099 12.776 4.775 1.110 0.975 0.588 0.534 0.423 1.185 0.503 0.188 35.687 38.862 19.558 16.231 12.446 29.769 14.478 4.953 1.405 1.530 0.770 0.639 0.490 1.172 0.570 0.195 43.307 43.688 19.710 17.831 17.907 35.484 20.320 4.826 1.705 1.720 0.776 0.702 0.705 1.397 0.800 0.190 FIGURE 1 41408 FIGURE 2 42311 & 42318 7.10 PCB2311T1 and PCB2318T1 have no standoff at X MAGNETICS 43019 G MAX H NOM NOMINAL WINDING AREA PER SECTION in2 cm2 AVERAGE LENGTH OF TURN FT BOBBIN MATERIAL PIN MATERIAL PIN DIMENSIONS BOARD CLEARANCE (in.)* Length Width Height 0.013 0.086 0.095 Glass-filled nylon Tin coated Phosphor bronze .042" x .015" .565 .850 .375 0.025 0.159 0.143 Glass-filled nylon Tin coated Phosphor bronze .042" x .015" .925 1.030 .450 0.057 0.368 0.143 Glass-filled Nylon Tin coated Phosphor bronze .042" x .015" .925 1.030 .735 0.057 0.368 0.174 Rynite FR530 Tin-lead plated brass .045" x .015" 1.030 1.500 .740 0.080 0.514 0.206 Glass-filled nylon Tin coated Phosphor bronze .042" x .015" 1.215 1.330 .775 0.120 0.774 0.246 Rynite FR530 Tin-lead plated brass .060" x .020" 1.425 1.950 .975 0.217 1.390 0.284 Rynite FR530 Tin-lead plated brass .060" x .020" 1.715 2.150 1.275 *reference figure 6 for board clearance FIGURE 3 42616 FIGURE 4 FIGURE 6 RS/DS Core Hardware Printed Circuit Bobbins 43622 FIGURE 5 44229 magnetics.com 7.11 RS/DS Core Hardware 7.12 Mounting Clamps MECHANICAL DIMENSIONS PART 00C1408RS CORE SIZE 41408 FIG. 1 mm in 00C362217 43622 2 mm in 00C422917 44229 2 mm in A NOM B NOM C NOM 8.89 13.97 8.001 - - 0.35 0.55 0.315 - - 23.241 36.322 21.590 44.450 50.038 0.915 1.430 0.850 1.750 1.970 31.064 43.180 25.40 50.80 56.388 1.223 1.700 1.00 2.000 2.220 D ± .020" F NOM Clamps are not available for the PCB2311T1 ot PCB2318T1. Cores may be cemented or bolted (with non-magnetic materials) to mounting surface. FIGURE 1 MAGNETICS FIGURE 2 MATERIAL Stainless Steel MACHINE SCREW IMPRESSIONS - Spring Steel #6-32 Spring Steel #6-32 RM CORES RM Cores are square-designed cores that offer all the magnetic and mechanical advantages of pot cores, plus the added feature of maximizing magnetic performance while minimizing PC board space. Easy to assemble and adaptable to automation, completed units provide at least 40% savings in mounting area compared to a similar size pot core assembly. Section 8 RM Cores RM cores are available in seven standard sizes. Three of the sizes are also available as low profile cores. Printed circuit bobbins or plain bobbins are available. Typical applications include differential inductors, power inductors, filter inductors, telecom inductors and broadband transformers. HOW TO ORDER R P 4 15 10 UG XX SHAPE CODE* FERRITE CORE MATERIAL USED FOR ALL FERRITE TYPES APPROXIMATE DIAMETER IN MM APPROXIMATE HEIGHT IN MM GEOMETRY CODE/GAP CODE (SEE PAGE 1.5) SPECIAL SPECIFICATION CODE *SHAPE CODES N – RM Core with solid centerpost R – RM Core with center hole 8.1 RM Cores RM Core Data (ungapped) Any practical gap available. See page 1.8 - 1.11 MECHANICAL DIMENSIONS PART CORE TYPE R_41110UG RM4 FIG. A MAX 1 mm in R_41500UG RM5/low profile 2 mm in R_41505UG RM5/low profile 2 mm in R_41510UG RM5 2 mm in N_41510UG RM5 2 mm in No center hole R_41812UG RM6-R 3 mm in N_41812UG RM6-R 3 mm in no center hole R_41912UG RM6-S 4 mm in B 2B C 5.20 ± .050 10.400 4.45 nom 3.61 ± .100 0.465 .205 ± .002 .410 ± .004 0.175 nom .142 ± .004 14.9 2.160 ± .050 4.320 ± .100 6.6 nom .760 ± .100 0.587 .085 ± .002 .170 ± .004 0.260 nom .030 ± .004 14.9 2.490 ± .050 4.980 ± .100 6.6 nom .585 ± .100 0.587 .098 ± .002 .196 ± .004 0.260 nom .023 ± .004 14.9 5.200 ± .050 10.400 ± .100 6.6 nom 3.250 ± .100 0.587 .205 ± .002 .410 ± .004 0.260 nom .128 ± .004 14.9 5.200 ± .050 10.400 ± .100 6.6 nom 3.250 ± .100 0.587 .205 ± .002 .410 ± .004 0.260 nom .128 ± .004 18.3 6.200 ± .050 12.400 ± .100 7.400 nom 4.100 ± .100 0.720 .244 ± .002 .488 ± .004 0.292 nom .161 ± .004 18.3 6.200 ± .050 12.400 ± .100 7.400 nom 4.100 ± .100 0.720 .244 ± .002 .488 ± .004 0.292 nom .161 ± .004 18.3 6.200 ± .050 12.400 ± .100 8.200 nom 4.100 ± .100 0.720 .244 ± .002 .488 ± .004 0.323 nom .161 ± .004 To order, add material code to part number. FIGURE 1 8.2 MAGNETICS D 11.8 FIGURE 2 MECHANICAL DIMENSIONS 2D E F G H J 7.21 ± .200 8.15 ± .200 3.800 ± .10 5.79 ref 2.05 ± .05 9.600 ± .200 .284 ± .008 .321 ± .008 .150 ± .004 0.228 ref 0.081 ± .002 .378 ± .008 1.520 ± .200 10.400 ± .200 4.800 ± .100 6.71 nom 2.050 ± .050 12.050 ± .250 .060 ± .008 0.409 ± .008 .189 ± .004 0.264 nom .081 ± .002 .474 ± .010 1.170 ± .200 10.400 ± .200 4.800 ± .100 6.71 nom 2.050 ± .050 12.050 ± .250 .046 ± .008 0.409 ± .008 .189 ± .004 0.264 nom .081 ± .002 .474 ± .010 6.520 ± .200 10.400 ± .200 4.800 ± .100 6.71 nom 2.050 ± .050 12.050 ± .250 .256 ± .008 0.409 ± .008 .189 ± .004 0.264 nom .081 ± .002 .474 ± .010 6.520 ± .200 10.400 ± .200 4.800 ± .100 6.71 nom - 12.050 ± .250 .256 ± .008 0.409 ± .008 .189 ± .004 0.264 nom - .474 ± .010 8.200 ± .200 12.650 ± .250 6.250 ± .150 5.850 nom 3.050 ± .050 14.400 ± .300 0.323 ± .008 .498 ± .010 .246 ± .006 0.250 nom .120 ± .002 .567 ± .012 8.200 ± .200 12.650 ± .250 6.250 ± .150 5.850 nom - 14.400 ± .300 0.323 ± .008 .498 ± .010 .246 ± .006 0.230 nom - .567 ± .012 8.200 ± .200 12.650 ± .250 6.250 ± .150 9.000 nom 3.050 ± .050 14.400 ± .300 0.323 ± .008 .498 ± .010 .246 ± .006 0.355 nom .120 ± .002 .567 ± .012 FIGURE 3 RM Cores RM Core Data (ungapped) FIGURE 4 mag-inc.com 8.3 RM Cores RM Core Data (ungapped) Any practical gap available. See page 1.8 - 1.11 MECHANICAL DIMENSIONS PART CORE TYPE N_41912UG RM6-S FIG. A MAX 4 mm in no center hole N_42309UG RM8/low profile 2 mm in no center hole R_42316UG RM8 2 mm in N_42316UG RM8 2 mm B 2B C D 18.30 6.200 ± .050 12.400 ± .100 8.200 nom 4.100 ± .100 0.720 .244 ± .002 .488 ± .004 .323 nom .161 ± .004 23.20 7.87 ± .050 15.74 ± .100 10.800 1.270 ± .130 0.913 .155 ± .002 .310 ± .004 0.425 .050 ± .005 23.20 8.200 ± .050 16.400 ± .100 10.800 5.530 ± .130 0.913 .323 ± .002 .646 ± .004 0.425 .218 ± .005 23.2 8.2 ± .05 16.4 ± .1 11.0+0 -.5 5.5 ± .1 28.50 4.750 ± .050 9.500 ± .100 13.200 ± .250 1.900 ± .150 1.122 .187 ± .002 .374 ± .004 .520 ± .010 .074 ± .006 28.50 9.300 ± .050 18.600 ± .100 13.200 ± .250 6.400 ± .150 1.122 .366 ± .002 .732 ± .004 .520 ± .010 .250 ± .006 28.50 9.300 ± .050 18.600 ± .100 13.200 ± .250 6.400 ± .150 1.122 .366 ± .002 .732 ± .004 .520 ± .010 .250 ± .006 37.40 11.700 ± .050 23.500 ± .100 16 nom 8.55 ± .150 1.472 .462 ± .002 .924 ± .004 .626 nom .337 ± .006 no center hole N_42809UG RM10/low profile 2 mm in no center hole R_42819UG RM10 2 mm in N_42819UG RM10 2 mm in no center hole N_43723UG RM12 4 mm in To order, add material code to part number. FIGURE 2 8.4 MAGNETICS FIGURE 4 MECHANICAL DIMENSIONS E F G 8.200 ± .200 12.650 ± .250 6.250 ± .150 9.000 nom - 14.400 ± .300 0.323 ± .008 .498 ± .010 .246 ± .006 0.355 nom - .567 ± .012 2.54 ± .250 17.350 ± .350 8.400 ± .150 11.700 nom - 19.300 ± .400 .100 ± .010 .683 ± .014 .331 ± .006 0.460 nom - .760 ±.016 11.050 ± .250 17.350 ± .350 8.400 ± .150 11.700 nom 4.500 ± .100 19.300 ± .400 .435 ± .010 .683 ± .014 .331 ± .006 0.415 nom 0.177 ± .004 .760 ±.016 11.0 17.0 +.6 - 0 8.55+0 - .3 - - 19.7+0 - .8 3.800 ± .300 21.650 ± .450 10.700 ± .200 11.400 nom - 24.15 ± .550 .148 ± .012 .852 ± .018 .421 ± .008 0.450 nom - .951 ± .022 12.700 ± .300 21.650 ± .450 10.700 ± .200 11.400 nom 5.563 ± .100 24.15 ± .550 .500 ± .012 .852 ± .018 .421 ± .008 0.450 nom 0.219 ± .005 .951 ± .022 12.700 ± .300 21.650 ± .450 10.700 ± .200 11.400 nom - 24.15 ± .550 .500 ± .012 .852 ± .018 .421 ± .008 0.450 nom - .951 ± .022 17.100 ± .300 25.500 ± .500 12.55 ± .250 15.200 nom - 29.25 ± .550 .673 ± .012 1.004 ± .020 .494 ± .010 0.600 nom - 1.152 ± .022 2D H J mag-inc.com RM Cores RM Core Data (ungapped) 8.5 RM Cores RM Core Data (ungapped) Any practical gap available. See page 1.8 - 1.11 AL (mH/1000T) HIGH PERMEABILITY MATERIALS POWER MATERIALS PART CORE TYPE R_41110UG RM4 FIG. R P F* J W 1 Min 690 750 1,200 1,480 2,100 Min 1,950 2,030 3,380 5,250 - Min 2,290 2,390 3,980 6,180 - Min 1,290 1,400 2,100 3,100 4,200 Min 1,290 1,400 2,100 3,100 4,200 Min 1,640 1,750 2,800 4,480 5,400 Min 1,790 1,950 3,080 5,030 6,020 Min 1,490 1,620 2,600 4,040 5,400 R_41500UG RM5/low profile 2 R_41505UG RM5/low profile 2 R_41510UG RM5 2 N_41510UG RM5 2 R_41812UG RM6-R 3 N_41812UG RM6-R 3 no center hole R_41912UG RM6-S 4 To order, add material code to part number. * F material nominal ±25% FIGURE 1 8.6 MAGNETICS FIGURE 2 Ie (mm) Ae (mm2) A MIN (mm2) Ve (mm3) CORE WEIGHT WaAc 10.8 7.9 222.0 1.600 0.0080 11.8 18.3 15.0 217.0 1.052 - 12.0 21.9 14.8 262.0 1.271 - 21.40 21.0 13.9 449.0 3.000 0.2030 22.40 22.8 18.1 510.0 3.300 0.0219 25.60 32.0 22.6 819.0 5.100 0.0507 27.10 38.0 31.0 1,030.0 5.400 0.0507 27.00 31.0 22.6 837.0 4.800 0.0507 FIGURE 3 AVAILABLE HARDWARE (grams per set) 20.60 MOU NTIN G CL AMP PRIN TED CIRC UIT BOB BIN MAGNETIC DATA RM Cores RM Core Data (ungapped) FIGURE 4 mag-inc.com 8.7 RM Cores RM Core Data (ungapped) Any practical gap available. See page 1.8 - 1.11 AL (mH/1000T) POWER MATERIALS PART CORE TYPE N_41912UG RM6-S FIG. HIGH PERMEABILITY MATERIALS R P F* J W Min 1,660 1,800 2,880 4,500 6,020 Min 3,490 3,790 6,400 10,300 14,700 Min 1,760 1,920 3,500 5,220 7,420 Min 2,025 2,200 3,700 6,000 8,540 Min 4,710 5,120 8,520 11,600 17,400 Min 2,700 2,950 5,210 6,690 10,000 Min 3,035 3,300 5,500 7,490 11,200 Min 3,450 3,750 6,000 8,850 15,820 4 no center hole N_42309UG RM8/low profile 5 no center hole R_42316UG RM8 N_42316UG RM8 5 5 no center hole N_42809UG RM10/low profile 2 no center hole R_42819UG RM10 N_42819UG RM10 2 2 no center hole N_43723UG RM12 4 To order, add material code to part number. * F material nominal ±25% FIGURE 2 8.8 MAGNETICS FIGURE 4 Ie (mm) Ae (mm2) A MIN (mm2) Ve (mm3) CORE WEIGHT WaAc (grams per set) 28.60 36.6 31.0 1,050 5.1 0.0507 20.8 60.5 55.5 1,260 6.111 - 35.50 52.0 36.9 1,850 10.4 0.1520 38.4 63.0 55.4 2,440 13.0 0.1520 26.1 90.1 82.9 2,360 11.446 - 41.70 8.3 61.8 3,460 20.0 0.4410 44.00 98.0 90.0 4,310 23.0 0.4410 56.60 146.0 125.0 8,340 42.0 1.0240 MOU NTIN G CL AMP PRIN TED CIRC UIT BOB BIN MAGNETIC DATA AVAILABLE HARDWARE RM Cores RM Core Data (ungapped) FIGURE 5 mag-inc.com 8.9 RM Core Hardware Printed Circuit Bobbins MECHANICAL DIMENSIONS PART PCB11104A CORE SIZE 41110 FIG. 1 mm in PCB115104A 41510 2 mm in PCB115104B 41510 2 mm in 2 section PCB151061 41510 3 mm in PCB151081 41510 4 mm in PCB181241 41812/41912 5 mm in FIGURE 1 FIGURE 3 8.10 MAGNETICS A MAX B MAX C MIN D NOM 7.899 4.902 3.937 5.740 0.311 0.193 0.155 10.109 5.944 0.398 E MAX F NOM G NOM H NOM 6.807 4.496 5.740 5.258 0.226 0.268 0.177 0.226 0.207 4.978 5.080 6.096 5.004 - - 0.234 0.196 0.200 0.240 0.197 - - 10.109 5.944 4.978 5.080 6.096 5.004 - - 0.398 0.234 0.196 0.200 0.240 0.197 - - 10.109 6.045 4.978 4.928 6.147 4.572 - - 0.398 0.238 0.196 0.194 0.242 0.180 - - 10.109 6.045 4.978 4.928 6.147 4.572 - - 0.398 0.238 0.196 0.194 0.242 0.180 - - 12.294 7.391 6.502 6.706 7.899 4.496 0.762 - 0.484 0.291 0.256 0.264 0.311 0.177 0.030 - FIGURE 2 NOMINAL WINDING AREA PER SECTION in2 cm2 AVERAGE LENGTH OF TURN FT BOBBIN MATERIAL PIN MATERIAL PIN DIAMETER 0.012 0.077 0.065 Glass-filled nylon Tin coated Phosphor bronze 0.021" 0.015 0.096 0.082 Thermoset Phenolic Tin coated Phosphor bronze .022" 0.015 0.096 0.082 Thermoset Phenolic Tin coated Phosphor bronze 0.022" 0.015 0.096 0.082 Thermoset Phenolic Tin coated Phosphor Bronze 0.021" 0.015 0.096 0.082 Thermoset Phenolic Tin coated Phosphor Bronze 0.019" 0.025 0.160 0.098 Thermoset Phenolic Tin coated Phosphor Bronze .020" square/round FIGURE 4 FIGURE 5 RM Core Hardware Printed Circuit Bobbins PIN LAYOUTS 41110 41510 41812 41912 mag-inc.com 8.11 RM Core Hardware Printed Circuit Bobbins MECHANICAL DIMENSIONS PART CORE SIZE FIG. PCB181261 41812/41912 6 mm in PCB231651 42316 7 mm in PCB231652 42316 2 section PCB231681 42316 7 mm in 7 mm in PCB231682 42316 2 section PCB2819L1 42819 7 mm in 8 mm in PCB3723L1 43723 9 mm in FIGURE 6 FIGURE 7 8.12 MAGNETICS A MAX B MAX C MIN D NOM F NOM G NOM 12.294 7.391 6.502 6.706 E MAX 7.899 4.496 0.762 - 0.484 0.291 0.256 0.264 0.311 0.177 0.028 - 16.891 9.957 8.687 9.042 10.592 5.486 - - 0.665 0.392 0.342 0.356 0.417 0.216 - - 16.891 9.957 8.687 4.242 10.592 5.486 - - 0.665 0.392 0.342 0.167 0.417 0.216 - - 16.891 9.957 8.687 9.042 10.592 5.486 - - 0.665 0.392 0.342 0.356 0.417 0.216 - - 16.891 9.957 8.687 4.242 10.592 5.486 - - 0.665 0.392 0.342 0.167 0.417 0.216 - - 21.006 12.243 11.100 10.592 12.192 5.207 1.295 - 0.827 0.492 0.437 0.417 0.480 0.205 0.051 - 24.790 14.503 13.005 14.681 16.459 6.096 1.219 - 0.976 0.571 0.512 0.578 0.648 0.240 min 0.048 - FIGURE 8 H NOM NOMINAL WINDING AREA PER SECTION cm2 in2 AVERAGE LENGTH OF TURN FT BOBBIN MATERIAL PIN MATERIAL PIN DIAMETER 0.025 0.160 0.098 Thermoset Phenolic Tin coated Phosphor Bronze .020" square/round 0.046 0.300 0.138 Thermoset Phenolic Tin coated Phosphor Bronze .026" 0.022 0.142 0.138 Thermoset Phenolic Tin coated Phosphor Bronze .026" 0.046 0.300 0.138 Thermoset Phenolic Tin coated Phosphor Bronze .026" 0.022 0.142 0.138 Thermoset Phenolic Tin coated Phosphor Bronze .026" 0.070 0.452 0.172 Thermoset Phenolic Tin coated Phosphor Bronze .024" 0.113 0.730 0.200 Thermoset Phenolic Tin coated Phosphor Bronze .033" FIGURE 9 42316 42819 RM Core Hardware Printed Circuit Bobbins 43723 mag-inc.com 8.13 RM Core Hardware 8.14 RM Mounting Clamps MATERIAL MECHANICAL DIMENSIONS PART CORE SIZE FIG. A NOM 00C111012 41110/41510 1 mm in 00C181211 41812/41912 1 mm in 00C231615 42316 1 mm in 00C281916 42819 1 mm in B NOM 2.083 .686 x .305 8.382 4.343 0.082 .027 x .012 0.330 0.171 2.591 .711 x .381 9.855 4.343 0.102 .028 x .015 0.388 0.171 4.496 .711 x .356 13.589 4.597 0.177 .028 x .014 0.535 0.181 4.496 .711 x .406 15.545 5.055 0.177 .028 x .016 0.612 0.199 Two mounting clamps are required per core set. FIGURE 1 MAGNETICS MATERIAL THICKNESS Spring Steel 0.012" Spring Steel 0.015" Spring Steel 0.014" Spring Steel 0.016" EP CORES EP cores are round center-post cubical shapes which enclose the coil completely except for the printed circuit board terminals. This particular shape minimizes the effect of air gaps formed at mating surfaces in the magnetic path and provides a larger volume ratio to total space used. EP cores provide excellent shielding. Typical applications for EP cores include differential and telecom inductors and power transformers. Section 9 EP Cores HOW TO ORDER P W 4 10 10 UG XX SHAPE CODE* FERRITE CORE MATERIAL USED FOR ALL FERRITE TYPES APPROXIMATE DIAMETER IN MM APPROXIMATE HEIGHT IN MM GEOMETRY CODE/GAP CODE (SEE PAGE 1.5) SPECIAL SPECIFICATION CODE *SHAPE CODES: P – EP core 9.1 EP Cores EP Core Data (ungapped) Any practical gap is available. See page 1.8-1.11 MECHANICAL DIMENSIONS PART P_40707UG CORE TYPE FIG. EP7 A MAX 1 mm in P_41010UG EP10 2 mm in P_41313UG EP13 3 mm in P_41717UG EP17 1 mm in P_42120UG EP20 2 mm B 2B C 9.20 ± .200 3.700 ± .050 7.400 ± .100 6.35 ± .150 .362 ± .008 .146 ± .002 .292 ± .004 .250 ± .006 11.500 ± .300 5.150 ± .100 10.300 ± .008 7.60 ± .200 .453 ± .012 .202 ± .004 .404 ± .008 .301 ± .008 12.500 ± .280 6.450 ± .076 12.900 ± .150 8.800 ± .200 4.92 ± .011 .253 ± .003 .506 ± .006 .346 ± .008 17.980 ± .510 8.40 ± .100 16.80 ± .200 11.00 ± .250 .708 ± .020 .331 ± .004 .662 ± .008 .433 ± .010 24.0 ± .5 10.7 ± .1 21.4 ± .2 15 ± .35 To order, add material code to part number. A L (mH/1,000T) POWER MATERIALS PART P_40707UG P_41010UG P_41313UG P_41717UG P_42120UG R P F* J W Min 810 880 1,240 1,930 3,600 Min 780 850 1,200 1,850 3,360 Min 1,150 1,250 2,000 2,800 5,000 Min 1,790 1,950 3,100 4,400 8,000 Min 3,170 3,450 5,000 7,200 13,500 CORE TYPE FIG. EP7 EP10 EP13 EP17 EP20 HIGH PERMEABILITY MATERIALS 1 2 3 1 2 * F material nominal ±25% FIGURE 1 9.2 MAGNETICS FIGURE 2 FIGURE 3 EP Cores EP Core Data (ungapped) MECHANICAL DIMENSIONS D MIN 2D MIN E MIN F MAX 2.500 5.000 7.200 3.400 1.70 ± .100 0.098 0.196 0.283 0.134 .067 ± .004 3.600 7.200 9.2 3.450 1.850 ± .100 0.142 0.284 0.362 0.136 .073 ± .004 4.500 8.990 9.72 4.520 2.36 ± .130 0.177 0.354 0.383 0.178 .093 ± .005 5.55 11.10 11.6 5.88 3.30 ± .200 0.22 0.440 0.457 0.230 .128 ± .007 7.05 14.1 16.1 9.05 4.5 ± .2 E AC RF U S MAGNETIC DATA CORE WEIGHT le (mm) Ae (mm2) A MIN (mm2) Ve (mm3) (grams per set) WaAc (cm 4 ) 15.70 10.3 7.8 162 1.4 0.0039 19.2 11.3 78.0 217 2.8 0.0100 24.2 19.5 14.0 472 5.1 0.0300 29.50 33.7 25.5 999 11.6 0.0810 41.1 78.7 60.8 3,230 27.6 0.2480 K BIN OB B T UN O M BIN OB B IT CU R I C D TE IN R P AVAILABLE HARDWARE G IN NT U MO P AM CL mag-inc.com 9.3 EP Core Hardware 9.4 Printed Circuit Bobbins MECHANICAL DIMENSIONS PART PCB07076B CORE SIZE FIG. 40707 A REF 1 mm in PCB10108A 41010 2 mm in PCB1313TA 41313 3 mm in PCB17178A 41717 4 mm in PCB2120TA 42120 5 mm in MAGNETICS B REF C MAX D MIN E NOM F NOM G NOM H REF J MAX K REF L REF 9.144 7.391 7.112 3.429 3.505 4.496 3.734 4.572 4.724 2.515 5.055 0.360 0.291 0.280 0.135 0.138 0.175 0.147 0.180 0.186 0.099 0.199 10.998 10.998 8.992 3.556 5.588 4.902 3.404 5.385 7.112 2.489 7.493 0.433 0.433 0.354 0.140 0.220 0.193 0.134 0.212 0.280 0.098 0.295 13.157 13.411 9.703 4.572 7.772 5.791 5.334 6.147 8.941 2.489 10.084 0.518 0.528 0.382 0.180 0.306 0.228 0.210 0.242 0.352 0.098 0.397 18.999 18.999 11.455 5.994 9.474 7.112 4.699 7.493 11.100 - 0.748 0.748 0.451 0.236 0.373 0.280 0.185 0.295 0.437 24.689 21.514 16.078 9.093 12.344 10.211 5.004 8.306 13.894 - 0.972 0.847 0.633 0.358 0.486 0.327 0.547 0.402 0.197 FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 - NOMINAL WINDING AVERAGE BOBBIN MATERIAL AREA PER SECTION LENGTH OF TURN FT in2 cm2 0.007 0.018 0.021 0.029 0.051 0.044 0.114 0.138 0.188 0.332 0.059 0.070 0.078 0.094 0.134 Phenolic Phenolic Phenolic Phenolic PIN MATERIAL Tin coated Phosphor Bronze Tin coated Phosphor Bronze Tin coated Phosphor Bronze Tin coated Phosphor Bronze Thermoset Phenolic Tin coated Phosphor Bronze PIN DIAMETER 0.016" square .026" 0.020" square 0.026" 0.026" BOARD CLEARANCE (in.)* Length Width Height with clamp 0.4850 0.3850 0.4100 no clamp 0.375 0.300 0.390 with clamp 0.5500 0.5100 0.4700 no clamp 0.470 0.440 0.450 with clamp 0.6250 0.6250 0.5450 no clamp 0.535 0.545 0.515 with clamp 0.8400 0.8000 0.6400 no clamp 0.760 0.760 0.625 with clamp 1.0800 1.0000 0.8150 no clamp .995 .875 .755 *reference figure 6 for board clearance FIGURE 5 FIGURE 6 EP Core Hardware Printed Circuit Bobbins PIN LAYOUTS mag-inc.com 9.5 EP Core Hardware Surface Mount Bobbins MECHANICAL DIMENSIONS PART SMB07076A CORE SIZE FIG. A REF B REF 40707 9.195 8.585 0.362 1 mm in SMB10108A 41010 2 mm in SMB1313TA 41313 3 mm in FIGURE 1 FIGURE 3 9.6 MAGNETICS C MAX D MIN E NOM F NOM H REF J MAX K REF L REF 7.112 3.404 3.607 4.496 3.505 4.902 10.592 12.700 0.338 0.280 0.134 0.142 0.177 0.138 0.193 0.417 0.500 11.506 10.490 9.093 3.505 5.791 4.801 4.496 7.112 12.497 14.605 0.453 0.413 0.358 0.138 0.228 0.189 0.177 0.280 0.492 0.575 12.802 13.005 9.601 4.496 7.595 5.791 5.258 8.788 15.392 16.993 0.504 0.512 0.378 0.177 0.299 0.228 0.207 0.346 0.606 0.669 FIGURE 2 NOMINAL WINDING AREA PER SECTION in2 cm2 AVERAGE LENGTH OF TURN FT BOBBIN MATERIAL PIN THICKNESS 0.007 0.044 0.059 L.C.P. 0.012" 0.019 0.120 0.070 L.C.P. 0.012" 0.021 0.138 0.078 L.C.P. 0.012" mag-inc.com EP Core Hardware Surface Mount Bobbins 9.7 EP Core Hardware Mounting Clamps MECHANICAL DIMENSIONS (NOMINAL) PART 0AC070716 A B C D E F mm 9.601 12.167 4.978 3.988 2.083 5.893 0.406 - in 0.378 0.4790 0.196 0.157 0.082 0.232 0.016 - mm 10.389 7.188 4.978 - - - - - in 0.409 0.2830 0.196 - - - - - mm 16.510 12.141 6.401 4.953 2.591 9.525 2.489 1.016 in 0.650 0.4780 0.252 0.195 0.102 0.375 0.098 0.040 mm 13.005 8.590 6.502 - - - - - in 0.512 0.3382 0.256 - - - - - mm 16.510 13.0048 7.518 3.988 2.591 11.684 2.997 1.219 in 0.650 0.5120 0.296 0.157 0.102 0.460 0.118 0.048 mm 14.072 12.649 7.518 - - - - - in 0.554 0.4980 0.296 - - - - - mm 19.990 18.593 8.992 5.004 5.004 15.596 5.004 0.991 in 0.787 0.7320 0.354 0.197 0.197 0.614 0.197 0.039 mm 19.177 16.586 8.992 - - - - - in 0.755 0.6530 0.354 - - - - - mm 22.276 24.613 11.989 3.505 4.572 17.602 2.540 0.991 in 0.877 0.9690 0.472 0.180 0.693 0.100 0.039 mm 24.994 21.488 11.989 - - - - - in 0.984 0.8460 0.472 - - - - CORE SIZE FIG. 40707 2 YOKE 0BC070712 40707 1 CLAMP 00C10102A YOKE/ 41010 41010 3 1 CLAMP 0AC131316 41313 4 YOKE 0BC131314 41313 1 CLAMP 00C17172A YOKE/ 41717 41717 5 1 CLAMP 0AC212016 42120 6 YOKE 0BC212016 42120 1 CLAMP Yoke and Clamp are required for assembly. Part numbers OOC10102A & 00C17172A are for yoke/clamp set. 9.8 MAGNETICS 0.138 - G H MATERIAL MATERIAL THICKNESS Nickel Silver 0.016" Nickel Silver 0.012" Phosphor Bronze 0.015" Phosphor Bronze 0.012" Nickel Silver 0.016" Nickel Silver 0.014" Phosphor Bronze 0.016" Phosphor Bronze 0.012" Nickel Silver 0.016" Nickel Silver 0.016" FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 FIGURE 5 FIGURE 6 mag-inc.com EP Core Hardware Mounting Clamps 9.9 Notes 9.10 MAGNETICS PQ CORES PQ cores are designed specifically for switched mode power supplies. This design provides an optimized ratio of volume to winding area and surface area. As a result, both maximum inductance and winding area are possible with a minimum core size. The cores provide maximum power output with minimum assembled transformer weight and volume, in addition to taking up a minimum amount of area on the printed circuit board. Assembly with printed circuit bobbins and one piece clamps is simplified. This efficient design provides a more uniform cross-sectional area; thus cores tend to operate with fewer hot spots than with other designs. Section 10 PQ Cores Typical applications include power transformers and power inductors. HOW TO ORDER O P 4 20 16 UG XX STANDARD CORE FERRITE CORE MATERIAL USED FOR ALL FERRITE TYPES APPROXIMATE DIAMETER IN MM APPROXIMATE HEIGHT IN MM GEOMETRY CODE/GAP CODE (SEE PAGE 1.5) SPECIAL SPECIFICATION CODE 10.1 PQ Cores PQ Core Data (ungapped) Any practical gap is available. See page 1.8-1.11 MECHANICAL DIMENSIONS PART CORE TYPE FIG. 0_42016UG PQ 20/16 A 1 mm 21.3 ± .400 in 0.837 ± .016 B 2B C D MIN 2D MIN E MIN F MAX G MIN 8.100 ± .100 16.200 ± .200 14.00 ± .400 5.000 10.000 17.600 9.000 12 .319 ± .004 .638 ± .008 .551 ± .016 0.197 0.394 0.693 0.356 0.472 0_42020UG PQ 20/20 1 mm 21.3 ± .4 10.1 ± .1 20.2 ± .2 14. ± .4 7.0 14.0 17.6 9.0 12 0_42610UG 1 mm 27.2 ± .450 5.100 ± .100 10.200 ± .200 19.00 ± .450 1.200 2.390 22.05 12.200 15.50 .200 ± .004 .400 ± .008 .748 ± .018 0.047 0.094 0.868 0.480 0.610 5.94 ± .100 11.90 ± .200 19.00 ± .450 3.400 6.700 22.05 12.200 15.50 .234 ± .004 .468 ± .008 .748 ± .018 0.132 0.264 0.868 0.480 0.610 10.100 ± .130 20.200 ± .250 19.00 ± .450 5.600 11.200 22.05 12.200 15.50 .397 ± .005 .794 ± .010 .748 ± .018 0.220 0.440 0.868 0.480 0.610 in 1.073 ± .018 0_42614UG 1 mm 27.200 ± .450 in 1.073 ± .018 0_42620UG PQ 26/20 1 mm 27.300 ± .460 in 1.073 ± .018 0_42625UG PQ 26/25 1 mm 27.3 ± .46 12.35 ± .125 24.7 ± .25 19.0 ± .45 7.9 15.8 22.04 12.2 15.5 0_43214UG 1 mm 33.00 ± .500 5.940 ± .100 11.900 ± .200 22.00 ± .500 3.4 6.700 27 13.750 19 .234 ± .004 .468 ± .008 .866 ± .020 0.132 0.264 1.063 0.540 0.748 10.300 ± .130 20.500 ± .250 22.0 ± .500 5.6 11.200 27 13.750 19 .405 ± .005 .810 ± .010 .866 ± .020 0.22 0.440 1.063 0.540 0.748 in 1.300 ± .020 0_43220UG PQ 32/20 1 mm 33.00 ± .500 in 1.300 ± .020 0_43230UG PQ 32/30 1 mm 33.0 ± .5 15.15 ± .125 30.3 ± .25 22.0 ± .5 10.5 21.0 27.0 13.75 19.0 0_43535UG PQ 35/35 1 mm 36.1 ± .6 17.4 ± .13 34.7 ± .25 26.0 ± .5 12.2 24.7 31.5 14.65 23.5 0_44040UG PQ 40/40 1 mm 41.5 ± .9 19.9 ± .15 39.8 ± .3 28.0 ± .6 14.35 29.1 36.4 15.2 28 To order, add material code to part number. FIGURE 1 10.2 MAGNETICS R P F* HIGH PERMEABILITY MATERIALS PRIN TED CIRC UIT B OBB IN MOU NTIN G CL AMP POWER MATERIALS MAGNETIC DATA CORE WEIGHT le (mm) Ae (mm2) A MIN (mm2) Ve (mm3) (grams per set) WaAc (cm4) J W Min 2,690 2,930 4,690 4,100 7,630 37.6 61.9 59.1 2,330.0 13.000 0.1570 Min 2,210 2,410 3,860 3,380 6,320 45.7 62.6 59.1 2,850.0 15.000 0.2380 Min 5,800 6,310 — — — 29.40 105.0 93.8 3,090.0 15.000 0.0960 Min 4,210 4,585 7,335 6,420 12,000 33.30 86.4 70.9 2,880.0 14.000 0.1720 Min 4,170 4,540 7,270 6,350 11,800 45.00 121.0 109.0 5,470.0 31.000 0.3950 Min 3,450 3,750 6,010 5,250 9,800 54.3 120.0 108.0 6,530.0 36.000 0.5930 Min 5,150 5,600 8,960 8,000 14,000 34.40 109.0 092.0 3,750.0 21.000 0.3000 Min 4,980 5,410 8,660 7,580 14,100 55.9 169.0 142.0 9,440.0 42.000 0.8010 Min 3,500 3,810 6,100 5,360 9,940 74.7 167.0 142.0 12,500.0 55.000 1.6000 Min 3,610 3,930 6,300 5,510 10,300 86.1 190.0 162.0 16,300.0 73.000 3.1200 Min 3,200 3,480 5,580 4,880 9,100 102.0 201.0 175.0 20,500.0 95.000 5.0000 AVAILABLE HARDWARE PQ Cores PQ Core Data (ungapped) *F material nominal ±25% 10.3 mag-inc.com PQ Core Hardware Printed Circuit Bobbins MECHANICAL DIMENSIONS (NOMINAL UNLESS NOTED) PART PCB2016FB CORE SIZE FIG. 42016 1 mm in PCB2020FB 42020 1 mm in PCB2620LA 42620 2 mm in PCB2625LA 42625 2 mm in PCB3220LA 43220 2 mm in PCB3230LA 43230 2 mm in PCB3535LA 43535 2 mm in PCB404012 44040 3 mm in A B C MAX 22.885 22.936 9.881 0.901 0.903 22.885 D F G H J 10.871 7.976 4.496 20.320 3.810 2.540 17.221 16.332 0.389 0.428 0.290 0.800 0.150 0.100 0.678 22.936 13.843 10.871 11.938 7.366 20.320 3.810 2.540 17.221 20.295 0.901 0.903 0.545 0.428 0.470 0.290 0.800 0.150 0.100 0.678 26.492 29.312 10.998 14.199 8.992 7.366 25.400 3.810 7.620 21.590 21.641 1.043 1.154 0.433 0.559 0.290 1.000 0.150 0.300 0.850 26.492 29.312 15.748 14.199 13.589 7.366 25.400 3.810 7.620 21.590 26.238 1.043 1.154 0.620 0.559 0.535 0.290 1.000 0.150 0.300 0.850 32.004 33.985 10.998 15.900 8.788 6.350 30.480 5.080 7.620 26.594 22.835 1.260 1.338 0.433 0.626 0.250 1.200 0.200 0.300 1.047 32.004 33.985 20.701 15.900 18.593 6.350 30.480 5.080 7.620 26.594 32.639 1.260 1.338 0.815 0.626 0.250 1.200 0.200 0.300 1.047 35.001 38.989 24.460 16.789 22.301 6.350 35.560 5.080 10.160 31.090 37.160 1.378 1.535 0.963 0.661 0.250 1.400 0.200 0.400 1.224 40.005 42.012 28.804 17.399 26.797 6.350 38.100 5.080 15.240 35.992 42.164 1.575 1.654 1.134 0.685 0.25 1.5 0.200 0.600 1.417 FIGURE 1 MAGNETICS 0.314 0.354 0.346 0.732 0.878 1.055 FIGURE 2 FIGURE 3 10.4 E K L 0.643 0.799 0.852 1.033 0.899 1.285 1.463 1.660 NOMINAL WINDING AVERAGE BOBBIN MATERIAL AREA PER SECTION LENGTH OF TURN FT in2 cm2 0.040 0.060 0.050 0.078 0.073 0.154 0.247 0.386 0.256 0.384 0.332 0.502 0.470 0.994 1.590 2.490 0.144 0.144 0.184 0.184 0.220 0.220 0.247 0.275 Rynite Rynite Rynite Rynite Rynite Rynite Rynite Rynite PIN MATERIAL Tin plated Brass Tin plated Brass Tin plated Brass Tin plated Brass Tin plated Brass Tin plated Brass Tin plated Brass Tin plated Brass PIN DIAMETER .024" .024" .036" .036" .036" .036" .036" .036" BOARD CLEARANCE (in.)* Length Width Heighth no clamp 0.915 0.915 0.700 with clamp 0.930 0.915 0.830 no clamp 0.915 0.915 0.850 with clamp 0.930 0.915 0.985 no clamp 1.100 1.170 0.910 with clamp 1.115 1.170 1.000 no clamp 1.100 1.170 1.015 with clamp 1.115 1.170 1.180 no clamp 1.340 1.350 0.950 with clamp 1.355 1.350 1.030 no clamp 1.340 1.350 1.335 with clamp 1.355 1.350 1.415 no clamp 1.470 1.550 1.515 with clamp 1.470 1.550 1.585 no clamp 1.700 1.675 1.725 with clamp 1.700 1.675 1.775 *reference figure 4 for board clearance FIGURE 4 PQ Core Hardware Printed Circuit Bobbins PIN LAYOUTS 10.5 mag-inc.com PQ Core Hardware Mounting Clamps MECHANICAL DIMENSIONS PART CORE SIZE FIG. 00C201612 42016 1 mm in 00C202012 42020 1 mm in 00C262012 42620 1 mm in 00C262512 42625 1 mm in 00C322017 43220 1 mm in 00C323017 43230 1 mm in 00C353517 43535 1 mm in 00C404017 44040 1 mm in FIGURE 1 10.6 MAGNETICS A±.020 B±.003 C±.010 D REF E NOM F NOM MATERIAL MATERIAL THICKNESS 29.007 7.899 17.501 14.986 6.401 1.499 Nickel Silver 0.012" 1.142 0.3110 0.689 0.590 0.252 0.059 32.995 7.899 21.488 14.986 6.401 1.499 Nickel Silver 0.012" 1.299 0.3110 0.846 0.590 0.252 0.059 32.995 10.490 21.488 21.006 8.992 1.499 Nickel Silver 0.012" 1.299 0.4130 0.846 0.827 0.354 0.059 37.490 10.490 26.111 21.006 8.992 1.499 Nickel Silver 0.012" 1.476 0.4130 1.028 0.827 0.354 0.059 36.500 12.2936 21.996 27.000 10.592 1.702 Nickel Silver 0.017" 1.437 0.4840 0.866 1.063 0.417 0.067 46.507 12.294 31.801 27.000 10.592 1.702 Nickel Silver 0.017" 1.831 0.4840 1.252 1.063 0.417 0.067 50.495 12.700 36.195 29.997 11.303 1.702 Nickel Silver 0.017" 1.988 0.5000 1.425 1.181 0.445 0.067 55.499 13.487 41.199 35.001 11.786 1.702 Nickel Silver 0.017" 2.185 0.5310 1.622 1.378 0.464 0.067 E, I, U CORES E cores are less expensive than pot cores, and have the advantage of simple bobbin winding plus easy assembly. E cores do not, however, offer self-shielding. Lamination size E cores are available to fit commercially offered bobbins previously designed to fit the strip stampings of standard lamination sizes. Metric and DIN sizes are also available. E cores can be pressed to different thicknesses, providing a selection of cross-sectional areas. Bobbins for these different cross sections are often available commercially. E cores can be mounted in different directions and, if desired, provide a low profile. Printed circuit bobbins are available for low profile mounting. Typical applications for E cores include differential, power and telecom inductors, as well as, broadband, power, converter and inverter transformers. Section 11 E, I, U Cores U cores, which offer a larger window/cross-sectional area, provide more power handling capability than E cores of the same size. Typical applications are similar to E cores. HOW TO ORDER C R 4 14 34 EC XX SHAPE CODE FERRITE CORE MATERIAL USED FOR ALL FERRITE TYPES APPROXIMATE DIAMETER IN MM APPROXIMATE HEIGHT IN MM GEOMETRY CODE/GAP CODE (SEE PAGE 1.5) SPECIAL SPECIFICATION CODE SHAPE CODE 0 – Standard C – Planar E core with clip recesses F – Planar E core option: no clip recesses GEOMETRY CODE EC – All E cores including ETD, EC, ER, EER, EEM, EFD, planar and lamination sizes IC – I cores UC – U cores GAP CODE – see page 1.5 Note – Standard gap codes do not apply to U cores, I cores and some EI combinations. Cores are sold per piece (for sets multiply by 2). Gapped pieces are normally packed separately from ungapped pieces. If desired in sets, this must be specified. 11.1 E, I, U Cores E, I, U Core Data (ungapped) Any practical gap available. See pages 1.8-1.11 MECHANICAL DIMENSIONS PART CORE TYPE FIG. A B C D MIN 8.86 ± .38 .349 ± .015 10.8 ± .20 .427 ± .008 10.8 ± .20 0.427 ± .008 12.700 ± .25 .500 ± .010 12.700 ± .25 .500 ± .010 12.300 ± .25 .485 ± .010 12.400 ± .30 .488 ± .012 16.800 ± .38 .660 ± .015 19.1 ± .4 4.06 ± .25 0.160 ± .010 1.83 ± .12 0.072 ± .005 4.19 ± .12 .165 ± .005 5.690 ± .18 .224 ± .007 5.690 ± .18 .224 ± .007 7.750 ± .25 .305 ± .010 7.390 ± .10 .291 ± .004 7.110 ± .18 0.280 ± .007 8.1 ± .13 1.91 ± .12 0.075 ± .005 6.3 ± .12 .248 ± .005 6.3 ± .12 .248 ± .005 3.180 ± .12 0.125 ± .005 6.350 ± .12 .250 ± .005 4.320 ± .12 .170 ± .005 4.850 ± .15 .191 ± .006 3.560± .12 .140 ± .005 4.7 ± .13 2.03 0.08 2.11 0.083 3.960 0.156 3.960 0.156 5.460 0.215 4.800 0.189 3.940 0.155 5.54 0_41810EC Lam EI187 1 mm 19.300 ± .30 Double stack in .760 ± .012 0_42211EC E core 1 mm 22.000 ± .41 in 0.866 ± .016 0_42220UC U core 4 mm 22.100 ± .38 in 0.869 ± .015 8.100 ± .18 .3188 ± .007 11.200 ± .13 0.442 ± .005 20.600 ± .38 .810 ± .015 9.530 ± .12 .375 ± .005 5.740 ± .25 .226 ± .010 6.270 ± .18 .247 ± .007 5.590 0.220 7.490 0.295 13.980 0.550 0_40904EC E core 0_41106IC I core 0_41106UC U core 0_41203EC Lam E2829 0_41205EC Lam E2829 Double stack 0_41208EC E core 0_41209EC EE12.5 0_41707EC Lam E3233 0_41808EC Lam EI187 2 mm in 3 mm in 4 mm in 1 mm in 1 mm in 1 mm in 1 mm in 2 mm in 1 mm E MIN F L M S T 4.85 0.191 7.19 .283 ref 9.190 0.362 9.270 0.365 7.850 0.309 9.140 0.360 10.400 0.411 13.92 1.91 ± .12 .075 ± .005 3.180 ± .08 .125 ± .003 3.180 ± .08 1.25 ± .003 2.670 ± .08 .105 ± .003 2.390 ± .10 .094 ± .004 3.560 ± .12 0.140 ± .005 4.57 min 1.91 ± .25 .075 ± .010 1.83 ± .12 .072 ± .005 1.570 0.062 nom 1.570 .062 ref 2.160 ± .13 0.085 ± .005 1.510 ± .10 .0595 ± .004 2.790 0.110 nom 2.39 1.57 ± .25 .062 ± .010 3.050 0.120 min 3.180 ± .12 .125 ± .005 2.670 .105 ref 3.490 ± .15 0.1375±.006 3.630 0.143 min 4.82 ref - - 14.000 0.552 17.100 0.673 9.500 ± .38 .375 ± .015 4.760 ± .08 .1875 ± .003 4.290 ± .20 .169 ± .008 - 2.380 .09375 ref 2.300 .0905 nom 6.270 ± .18 .247 ± .007 4.890 .1925± .005 6.550 .258 nom - - - To order, add material code to part number. FIGURE 1 11.2 MAGNETICS FIGURE 2 STAN DA SUR RD BOB FACE B MOU IN PRIN NT B TED OB CI MOU NTIN RCUIT B BIN O G CL AMP BBIN AL (mH/1000T) HIGH PERMEABILITY MATERIALS POWER MATERIALS R COMB. P F* J W H MAGNETIC DATA le (mm) 15.4 E-E Min 370 405 650 780 - Min 710 770 1,150 1,580 - 840 1,010 1,330 - 480 770 1,025 - 1,200 1,950 2,475 3,705 685 1,100 1,200 1,820 710 1,150 1,240 1,900 825 1,300 1,425 2,240 940 1,500 1,875 3,220 1,875 3,000 3,750 7,420 1,000 1,610 1,890 3,500 730 1,360 1.5 0.0100 29.2 12.0 12.0 350.0 1.8 0.0250 27.70 10.1 10.0 279.0 1.300 0.0170 27.70 20.2 20.0 558.0 2.600 0.0330 32.10 14.5 11.5 464.0 2.500 0.0280 30.6 14.4 11.6 440.0 4.200 0.0390 30.4 16.6 12.6 505.0 3.000 0.0310 39.9 22.6 22.1 900.0 4.400 0.0760 40.1 45.5 45.4 1820.0 8.500 0.1560 51.10 28.3 24.6 1450.0 8.200 0.2120 95.80 39.7 39.7 4130.0 19.000 0.9100 5,250 U-U Min 670 283.0 - E-E Min 920 11.5 - E-E Min 1,725 11.5 - E-E Min 865 24.6 - E-E Min 760 0.0020 - E-E Min 660 0.5 - E-E Min 630 78.0 - E-E Min 1,100 3.6 - E-E Min 440 5.1 - U-U Min 770 4 WEIGHT Ae (mm2) A MIN (mm2) Ve (mm3) CORE (grams per set) WaAc (cm ) AVAILABLE HARDWARE - U-I E, I, U Cores E, I, U Core Data (ungapped) 1,580 2,400 - * F material nominal ± 25% FIGURE 3 FIGURE 4 11.3 mag-inc.com E, I, U Cores E, I, U Core Data (ungapped) Any practical gap available. See pages 1.8-1.11 MECHANICAL DIMENSIONS PART CORE TYPE FIG. A B C D MIN E MIN F L M S T 0_42510EC Lam E2425 1 mm 25.4 ± .6 9.65 ± .2 6.35 ± .25 6.4 18.8 6.35 ± .25 3.02 6.1 min - - 0_42512UC 12.900 ±.38 .510 ± .015 15.900 ± .25 .625 ± .010 3.180 ± .12 .125 ± .005 15.900 .625 ref 6.350 ± .12 .250 ± .005 9.530 ± .18 .375 ± .007 15.900 ±.25 .625 ± .010 15.900 .625 ref 10.500 ±.12 .415 ± .005 15.01 ± .2 12.700 ± .38 .500 ± .015 6.350 ± .25 .250 ± .010 7.370 ± .25 .290 ± .010 6.350 ± .12 .250 ± .005 6.350 ± .12 .250 ± .005 12.700± .25 .500 ± .010 12.700 ± .25 .500 ± .010 12.700±.25 .500 ± .010 11.200 ± .38 0.440 ± .015 7.3 + 0, -.5 6.350 0.250 12.600 0.495 9.270 0.365 6.250 0.246 12.600 0.495 9.270 0.365 5.440 0.214 9.7 12.800 .504 ref 18.800 0.740 12.700 .500 ref 18.800 0.741 18.800 0.742 12.700 .500 ref 18.500 0.730 19.5 6.350 ± .12 .250 ± .005 6.100 ± .12 .240 ± .005 6.350 ± .12 .250 ± .005 7.700 ± .25 .303 ± .010 7.2 + 0, -.5 6.300 .248 ± .005 3.120 ± .12 .123 ± .005 6.350 ± .12 .250 ± .005 3.020 .119 nom 3.120 ± .12 .123 ± .005 6.350 ± .12 .250 ± .005 4.340 ± .25 .171 ± .010 5.01 ref 6.400 ± .25 .252 ± .010 6.220 .245 min 6.400 ± .25 .252 ± .010 5.800 .2285 ref 6.46 - - 0_43009EC Lam E2627 1 mm 30.480± .38 13.4 ± .25 9.400 ± .12 in 1.200 ± .015 .5275 ± .010 .370 ± .005 8.830 0.3475 21.410 0.843 9.400 ± .13 4.290 .370 ± .005 0.169 nom 6.000 0.236 min - - U core 0_42515EC Lam EL2425 0_42515IC I core 0_42515UC U core 0_42516IC I core 0_42520EC Lam E2425 Double stack 0_42530EC EL2425 Double stack 0_42530UC U core 0_42810EC E core 0_43007EC DIN 30/7 4 mm in 1 mm in 3 mm in 4 mm in 3 mm in 1 mm in 1 mm in 4 mm in 1 mm in 1 mm 25.400 ± .51 1.000 ± .020 25.400± .38 1.000 ± .015 26.400± .38 1.040 ± .015 25.400 ± .51 1.000 ± .020 25.400 ± .51 1.000 ± .020 25.150 ±.38 .990 ± .015 25.400 ± .38 1.000 ± .015 25.400 ± .51 1.000 ± .020 28.000± .63 1.102 ± .025 30.8 ± 1.4 To order, add material code to part number. FIGURE 1 11.4 MAGNETICS FIGURE 3 STAN DA SUR RD BOB FACE B MOU IN PRIN NT B TED OB CI MOU NTIN RCUIT B BIN O G CL AMP BBIN AL (mH/1000T) HIGH PERMEABILITY MATERIALS POWER MATERIALS COMB. R P F* J W H MAGNETIC DATA le (mm) 49.0 E-E Min 1325 1440 2300 2775 4635 Min 1430 1550 2480 3300 - 940 1500 1800 3080 1435 2290 2750 4690 1000 1600 1880 2730 1110 1770 2180 - 2880 4600 5500 10360 1880 3000 3600 6160 1710 2740 3650 - 3430 5500 6000 12600 1680 2700 2850 5740 2360 3780 4420 8500 29.000 0.6700 73.5 40.1 39.7 2950.0 15.000 0.4210 48.10 40.1 39.7 1930.0 10.000 0.2100 83.40 40.4 40.4 3370.0 17.000 0.6300 64.3 40.4 40.4 2600.0 13.000 0.3200 48.0 78.4 76.8 3760 19.000 0.4000 73.50 80.2 79.4 5900.0 30.000 0.8420 83.40 80.8 80.8 6740.0 34.000 1.2700 47.70 96.7 86.0 4610.0 23.000 0.3470 67.0 60.0 49.0 4000 20.000 0.5000 62.40 83.6 80.7 5220.0 26.000 0.7400 - E-E Min 2170 4170 - E-E Min 1545 80.0 - E-E Min 3155 80.0 - U-U Min 1570 68.9 - E-E Min 1730 0.1620 - E-E Min 2650 9.500 - U-I Min 1020 1930 - U-U Min 830 37.0 - E-I Min 1320 39.5 - E-E Min 865 4 WEIGHT Ae (mm2) A MIN (mm2) Ve (mm3) CORE (grams per set) WaAc (cm ) AVAILABLE HARDWARE - U-U E, I, U Cores E, I, U Core Data (ungapped) - * F material nominal ± 25% FIGURE 4 FIGURE 5 11.5 mag-inc.com E, I, U Cores E, I, U Core Data (ungapped) Any practical gap available. See pages 1.8-1.11 MECHANICAL DIMENSIONS PART CORE TYPE FIG. A B C D MIN E MIN F L M S T 0_43013EC Metric E30A 1 mm 30.000± .51 13.160 ± .15 10.690±.30 in 1.181 ±.020 .518 ± .006 .421 ± .012 0_43515EC Lam EI375 2 mm 34.3 ± .6 14.1 ± .15 9.3 ± .25 8.000 0.315 9.67 19.700 0.776 25.5 10.690± .30 5.000 ± .15 4.650 ± .12 .421 ± .012 .197 ± .006 .183 ± .005 9.32 ± .2 4.45 7.87 - - 0_43520EC 15.600 0.615 18.740 0.738 10.000 0.394 15.000 0.587 14.8 25.100 0.990 25.300 0.998 27.600 1.087 30.400 1.195 29.5 9.530 ± .25 .375 ± .010 9.350 ± .20 .368 ± .008 10.690 ± .30 0.421 ± .012 11.900 ± .25 .468 ± .010 12.2 + 0, -.5 4.750 ± .25 .187 ± .010 4.450 ± .08 .175 ± .003 5.990 ± .25 .236 ± .010 5.940 ± .13 .234 ± .005 6.75 ref 7.950 .313 nom 7.870 .310 min 8.860 .341 nom 9.540 ± .25 .3755 ± .010 8.65 ref - - 3 mm 42.800 ± .64 5.920 ± .12 15.400 ± .25 in 1.687 ± .025 .233 ± .005 .608 ± .010 0_44022EC DIN 42/20 1 mm 43.0 + 0, -1.7 21.0 ± .2 20.000 +0,-8 14.8 - - - - 29.5 12.2 + 0, -.5 6.75 ref 8.65 ref - - 0_44119UC U core 0_44121UC U core 0_44125UC U core 19.100 ±.64 .750 ± .025 19.100 ±.64 .750 ± .025 19.100 ±.64 .750 ± .025 3.180 .125 nom 3.180 .125 nom 3.180 .125 nom 35.300 1.39 ref 35.300 1.39 ref 35.300 1.39 ref 0_43524EC 0_44011EC 0_44016EC 0_44020EC 0_44020IC 1 mm in EL375 1 mm in Metric E40 1 mm in E core 1 mm in DIN 42/15 1 mm E core 34.900 ±.38 1.375 ± .015 34.540 ± .38 1.360 ± .015 40.010 ±.51 1.575 ± .020 42.800 ± .64 1.687 ± .025 43.0 + 0, -1.7 20.620± .25 .812 ± .010 23.800 ± .18 .9375 ± .007 17.000 ±.30 .669 ± .012 21.100 ± .18 .830 ± .007 21.0 ± .2 9.530 ± .18 .375 ± .007 9.350 ± .18 .368 ± .007 10.690±.30 .421 ± .012 9.000 ± .25 .354 ± .010 15.2 + 0, -.6 I core 5 mm in 5 mm in 5 mm in 41.960 ±.41 1.652 ± .016 41.960 ±.41 1.652 ± .016 41.960 ± .41 1.652 ± .016 20.900 ±.12 .826 ± .005 20.600 ±.12 .812 ± .005 25.400 ± 1. 2 1.000 ± .005 11.700± .25 .460 ± .010 11.700 ± .25 .460 ± .010 11.700± .25 .460 ± .010 13.400 0.528 10.900 0.429 15.700 0.617 - - - To order, add material code to part number. FIGURE 1 11.6 MAGNETICS FIGURE 2 STAN DA SUR RD BOB FACE B MOU IN PRIN NT B TED OB CI MOU NTIN RCUIT B BIN O G CL AMP BBIN AL (mH/1000T) HIGH PERMEABILITY MATERIALS POWER MATERIALS R COMB. P F* J W H MAGNETIC DATA le (mm) 57.80 E-E Min 3070 3340 5340 6200 12000 Min 2000 2180 3500 4360 7990 1590 2555 3180 6440 1435 2300 2984 4230 3260 5200 5470 11550 2180 3495 4235 7905 3750 6000 7275 13580 5100 8150 9500 15500 4510 7600 7960 18200 1330 2130 2830 4000 1535 2465 3290 4600 1310 2105 2800 3920 33.000 0.8560 94.30 90.6 90.5 8540.0 42.000 1.6800 107.00 85.8 83.1 9180.0 46.000 1.6600 76.70 127.0 114.0 9780.0 49.000 1.3900 98.40 107.0 106.0 10500.0 52.000 2.0800 97.0 178.0 175.0 17300 87.000 3.5500 68.0 183.0 183.0 12400.0 60.000 1.7800 97 233 233 22700 114.000 4.5900 121.20 91.1 80.5 11000.0 54.000 2.8600 113.40 98.8 98.8 11100.0 55.000 3.0900 132.80 98.8 98.8 13000.0 64.000 4.4400 - U-U Min 1200 5590 - U-U Min 1410 80.7 - U-U Min 1220 80.7 - E-E Min 4150 69.30 - E-I Min 4690 0.6500 - E-E Min 3450 32.000 - E-E Min 2000 6330.0 - E-E Min 3000 107.0 - E-E Min 1320 109.0 - E-E Min 1460 4 WEIGHT Ae (mm2) A MIN (mm2) Ve (mm3) CORE (grams per set) WaAc (cm ) AVAILABLE HARDWARE - E-E E, I, U Cores E, I, U Core Data (ungapped) - * F material nominal ± 25% FIGURE 3 FIGURE 5 11.7 mag-inc.com E, I, U Cores E, I, U Core Data (ungapped) Any practical gap available. See pages 1.8-1.11 MECHANICAL DIMENSIONS PART CORE TYPE FIG. A B C D MIN E MIN F L M - - 5 mm 41.960 ± .41 30.500±.30 11.700 ± .25 20.800 in 1.652 ± .016 1.200 ± .012 .460 ± .010 0.817 0_44317EC Lam EI21 2 mm 40.6 ± .65 16.6 ± .20 12.4 ± .3 10.4 19.100 ± .64 .750 ± .025 28.6 12.45 ± .25 6.05 7.87 0_44721EC Lam EI625 2 mm 46.9 ± .8 19.6 ± .2 15.6 ± .25 12.1 32.4 ± .65 15.6 ± .25 7.54 0_44924EC 23.8 ±.25 .936 ± .010 21.300 ± .30 .839 ± .012 27.5 ± .3 15.620 ± .43 .615 ± .017 14.600 ±.38 .575 ± .015 21 + 0, -.8 15.100 0.594 12.500 0.492 18.500 31.600 1.246 34.500 1.359 37.500 9.140 ± .12 .366 ± .005 7.370 ± .25 .290 ± .010 9.35 ref 0_44130UC U core S 3.180 35.300 .125 nom 1.39 ref 7.87 - - 7.870 .310 min 10.1 ± .30 .3975 ± .012 10.15 ref - - 0_45530EC DIN 55/25 1 mm 54.900 ± .64 27.600± .38 24.610 ± .38 18.500 37.500 in 2.16 ± .025 1.085 ± .015 0.969 ± .015 0.730 1.476 0_45724EC Lam EI75 2 mm 56.1 ± 1.0 23.6 ± .25 18.8 ± .25 14.6 ± .13 38.1 15.620 ± .38 8.380 ± .38 10.700±.38 .660 ± .015 .330 ± .015 .420 ± .015 18.8 ± .25 9.02 9.4 - - 0_46016EC Metric E60 2 mm in 0_47228EC F11 1 mm in 0_48020EC Metric E80 1 mm 15.620 ± .38 .615 ± .015 19.000 ± .38 .750 ± .015 19.8 ± .4 7.700 ± .25 .303 ± .010 9.530 ± .38 .375 ± .015 9.9 14.490 ± .25 .5705 ± .010 16.900 .665 min 19.45 min - - - - - - - - - - 1 mm in 0_45021EC Metric E50 1 mm in 0_45528EC DIN 55/21 1 mm EL10 49.070 ± .64 1.932 ± .025 49.500 ± .64 1.95 ± .025 56.2 + 0, -.21 22.300 ± .30 .878 ± .012 27.900±.33 1.100 ± .013 38.1±.30 15.620 ±.38 .615 ± .015 19.000 ± .33 .750 ± .013 19.8 ± .4 0_49925IC I100/25/25 3 mm 101.6 ±1.5 25.4 ±.4 25.4 ±.6 0_49925UC U/100/57/25 4 mm 101.6 ± 1.5 57.1 ± .4 25.4 ± .6 0_49928EC E-100 59.990 ± .78 2.362 ± .031 72.400 ± .76 2.85 ± .030 80.0 ± 1.6 13.800 0.543 17.800 0.700 27.9 44.000 1.732 52.600 2.072 59.1 - - 30.95 50.7 15.620 ± .25 .615 ± .010 14.600 ± .38 .575 ± .015 17.2 + 0, -.5 - 25.4 ± .8 27.500 ± .51 13.700 ± .38 22.700 ± .51 2 mm 100.300 ±2.03 59.400 ±.51 27.500 ± .51 46.900±.38 72.000 in 3.948 ± .080 2.340 ± .020 1.082 ± .02 1.845±.015 2.834 min 1.082 ± .020 .541 ± .015 .892 ± .020 To order, add material code to part number. FIGURE 1 11.8 T MAGNETICS FIGURE 2 STAN DA SUR RD BOB FACE B MOU IN PRIN NT B TED OB CI MOU NTIN RCUIT B BIN O G CL AMP BBIN AL (mH/1000T) HIGH PERMEABILITY MATERIALS POWER MATERIALS COMB. R P F* J W H MAGNETIC DATA le (mm) 152.80 U-U Min 1050 1140 1830 2440 3420 3180 5900 7350 13720 4370 8300 10600 19810 4380 7010 8180 - 5000 8000 8010 - 5130 8220 9375 - 6130 9800 11190 - 6600 10400 10610 18000 4680 6590 7445 - 4860 7780 8885 - 3810 6000 6940 - 4650 7440 - - 3650 5900 - - 5080 8120 - - 234.0 226.0 20800 103 2.7700 104.00 257.0 244.0 26700 132 3.9600 92.90 225.0 213.0 20900 108 4.0000 124 353 345 44000 212 9.9100 123.00 417.0 413.0 51400 255 11.8000 107.00 337.0 337.0 36000 179 6.3400 110.00 248.0 240.0 27200 135 7.1600 137.00 368.0 363.0 50300 264 14.8000 184 392 392 72300 357 30.8000 245.0 645.0 645.0 158000 308.00 645.0 645.0 199000 975 168.0000 274.00 738.0 692.0 202000 - 156.0000 324 102.0000 - E-E Min 4670 88.9 - U-U Min 3400 1.4800 - U-I Min 4280 57 - E-E Min 3505 11500 - E-E Min 4470 142.0 - E-E Min 4300 149.0 - E-E Min 6070 77.0 - E-E Min 5640 5.8800 - E-E Min 4720 75 - E-E Min 4600 15100 - E-E Min 4030 98.8 - E-E Min 4020 98.8 - E-E Min 2925 4 WEIGHT Ae (mm2) A MIN (mm2) Ve (mm3) CORE (grams per set) WaAc (cm ) AVAILABLE HARDWARE E, I, U Cores E, I, U Core Data (ungapped) - * F material nominal ± 25% FIGURE 3 FIGURE 4 FIGURE 5 11.9 mag-inc.com E, I, U Hardware Bobbins MECHANICAL DIMENSIONS PART CORE SIZE FIG. 00B120301 41203EC 1 mm in 00B120801 41208EC 3 mm in 00B180801 41808EC 1 mm in 00B18100A 41810EC 4 mm in 00B251001 42510EC 1 mm in 00B251501 42515EC 5 mm in 00B300901 43009EC 2 mm in 00B351501 43515EC 1 mm in 00B402001 44020EC 6 mm in 00B431701 44317EC 1 mm in 00B472101 44721EC 1 mm in 00B552801 45528EC 6 mm in 00B572401 45724EC 1 mm in 00B722801 47228EC 7 mm in 00B802001 48020EC 7 mm in * UL 94 HB rated ** UL 94 V-O rated 11.10 MAGNETICS A MAX B MAX C MAX D MAX E MIN F NOM 9.2964 0.366 7.8232 0.308 13.843 0.545 13.716 0.540 18.4912 0.728 15.0876 0.594 21.336 0.840 24.8412 0.978 29.845 1.175 28.0162 1.103 31.1912 1.228 36.576 1.440 37.846 1.49 51.0794 2.011 57.5818 2.267 9.525 0.375 18.415 0.725 15.0876 0.594 24.892 0.980 35.052 1.380 42.037 1.655 51.0794 2.011 57.5818 2.267 7.874 0.310 10.668 0.420 11.049 0.435 10.922 0.43 12.3444 0.486 22.098 0.870 17.526 0.690 18.923 0.745 16.129 0.635 min 20.4724 0.806 23.5712 0.928 21.209 0.835 min 28.575 1.125 19.7612 0.778 min 20.5486 0.809 min 4.5212 0.178 4.50 0.177 min 6.477 0.255 9.7028 0.382 min 8.4074 0.331 6.35 0.250 min 11.4808 0.452 11.9888 0.472 12.319 0.485 min 14.605 0.575 18.415 0.725 17.399 0.685 min 21.59 0.850 19.7612 0.778 min 20.5486 0.809 min 3.302 0.13 9.58 0.377 nom 4.953 0.195 9.1694 0.361 nom 6.6294 0.261 20.574 0.810 nom 9.6012 0.378 9.906 0.390 26.162 1.030 nom 12.827 0.505 16.129 0.635 36.576 1.440 19.1262 0.753 34.4678 1.357 55.118 2.17 6.6294 0.261 2.870 0.113 min 9.525 0.375 4.953 0.195 min 10.3124 0.406 6.35 0.250 min 15.6464 0.616 17.145 0.675 29.21 1.150 18.9484 0.746 21.3868 0.842 33.528 1.320 26.543 1.045 30.4038 1.197 51.054 2.01 NOMINAL WINDING AVERAGE MATERIAL AREA PER SECTION LENGTH OF TURN FT in2 cm2 0.02400 0.1580 0.089 Nylon* 0.02900 0.19 0.09 0.05300 0.3420 0.131 Glass filled Nylon** Nylon* 0.04900 0.316 0.164 0.07900 0.510 0.184 0.111 0.716 0.149 0.13000 0.8390 0.226 Glass filled Nylon Nylon* 0.17500 1.130 0.236 Nylon* 0.321 2.07 0.32 0.19500 1.260 0.277 Glass filled Nylon* Nylon* 0.21800 1.410 0.320 Nylon* 0.438 2.830 0.400 0.332 2.14 0.388 Glass filled Nylon Nylon* 0.632 4.08 0.49 Zytel 50 1.25 8.06 0.542 Zytel 50 Glass filled Nylon* Nylon* E, I, U Hardware Bobbins FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 FIGURE 6 FIGURE 5 FIGURE 7 11.11 mag-inc.com E, I, U Hardware Printed Circuit Bobbins MECHANICAL DIMENSIONS PART CORE SIZE FIG. PCB180881 41808EC 1 mm in PCB180882 41808EC 1 mm 2 Section in PCB2510T1 42510EC 2 mm in PCB2510T2 42510EC 2 mm 2 Section in PCB2520TA 42520EC 5 mm in PCB3007T1 43007EC 6 mm in PCB3009LA 43009EC 4 mm in PCB3515L1 43515EC 3 mm in PCB3515L2 43515EC 3 mm 2 Section in FIGURE 1 11.12 MAGNETICS A MAX B MAX C MAX D MAX E MIN F MAX 13.843 0.545 13.843 0.545 18.669 0.735 18.669 0.735 26.289 1.035 24.003 0.945 21.387 0.842 25.146 0.990 25.146 0.990 16.129 0.635 16.129 0.635 20.371 0.802 20.371 0.802 21.209 0.835 32.080 1.263 26.035 1.025 25.527 1.005 25.527 1.005 17.399 0.685 17.399 0.685 20.955 0.825 20.955 0.825 13.335 0.525 min 7.442 0.293 min 30.734 1.210 27.483 1.082 27.483 1.082 7.315 0.288 7.315 0.288 8.890 0.350 8.890 0.350 6.680 0.263 min 7.442 0.293 min 12.192 0.480 12.014 0.473 12.014 0.473 4.953 0.195 4.953 0.195 6.629 0.261 6.629 0.261 18.542 .730 nom 18.796 0.740 nom 9.652 0.380 9.677 0.381 9.677 0.381 19.177 0.755 19.177 0.755 26.289 1.035 26.289 1.035 27.940 1.100 nom 18.796 0.740 nom 33.909 1.335 37.465 1.475 37.465 1.475 FIGURE 2 G MIN 4.191 0.165 4.191 0.165 4.191 0.165 4.191 0.165 12.369 .487 max 19.050 0.750 max 5.080 0.200 4.191 0.165 4.191 0.165 H NOM 3.810 0.150 3.810 0.150 3.810 0.150 3.810 0.150 10.668 0.420 17.272 0.680 5.080 0.200 3.810 0.150 3.810 0.150 FIGURE 3 J NOM K MAX 5.080 0.200 5.080 0.200 5.080 0.200 5.080 0.200 15.748 0.620 25.400 1.000 5.080 0.200 5.080 0.200 11.049 0.435 11.049 0.435 12.319 0.485 12.319 0.485 3.429 .135 nom 3.048 0.120 17.145 0.675 18.593 0.732 18.593 0.732 E, I, U Hardware Printed Circuit Bobbins MECHANICAL DIMENSIONS PART CORE SIZE FIG. PCB180881 41808EC 1 mm in PCB180882 41808EC 1 mm 2 Section in PCB2510T1 42510EC 2 mm in PCB2510T2 42510EC 2 mm 2 Section in PCB2520TA 42520EC 5 mm in PCB3007T1 43007EC 6 mm in PCB3009LA 43009EC 4 mm in PCB3515L1 43515EC 3 mm in PCB3515L2 43515EC 3 mm 2 Section in L NOM M NOM 9.322 0.367 9.322 0.367 10.262 0.404 10.262 0.404 5.080 0.200 14.732 0.580 16.510 0.650 16.510 0.650 13.081 0.515 13.081 0.515 15.621 0.615 15.621 0.615 22.860 0.900 21.895 0.862 21.895 0.862 NOMINAL WINDING AVERAGE AREA PER SECTION LENGTH OF TURN FT in2 cm2 BOBBIN MATERIAL PIN MATERIAL PIN DIAMETER 0.049 0.316 0.133 Glass filled Nylon* Phosphor Bronze .025" square 0.049 0.316 0.133 Glass filled Nylon* Phosphor Bronze .025" square 0.063 0.406 0.178 Glass filled Nylon* Phosphor Bronze .025" square 0.063 0.406 0.178 Glass filled Nylon* Phosphor Bronze .025" square 0.098 0.630 0.225 PET Polyester .025" square 0.129 0.833 0.180 Thermoset Phenolic .030" 0.111 0.714 0.218 DAP** Alloy 510 tin plated .036" square 0.147 0.948 0.241 Glass filled Nylon* Phosphor Bronze .025" square 0.147 0.948 0.241 Glass filled Nylon Phosphor Bronze .025" square * UL 94 HB rated ** UL 94 V-O rated FIGURE 4 FIGURE 5 FIGURE 6 11.13 mag-inc.com E, I, U Hardware Printed Circuit Bobbins (con’t) MECHANICAL DIMENSIONS PART CORE SIZE FIG. PCB4020L1 44020EC 7 mm in PCB4022L1 44022EC 8 mm in PCB4317L1 44317EC 3 mm in PCB4317L2 44317EC 3 mm 2 Section in PCB4721L1 44721EC 3 mm in PCB4721L2 44721EC 3 mm 2 Section in PCB5528WA 45528EC 9 mm in PCB5530FA 45530EC 10 mm in PCB5724L1† 45724EC 3 mm in A MAX B MAX C MAX D MAX E MIN F MAX G MIN H NOM J NOM K MAX 46.609 1.835 46.609 1.835 28.067 1.105 28.067 1.105 31.369 1.235 31.369 1.235 54.991 2.165 37.160 1.463 37.719 1.485 37.313 1.469 42.393 1.669 28.829 1.135 28.829 1.135 32.131 1.265 32.131 1.265 51.181 2.015 40.157 1.581 39.243 1.545 15.748 0.620 min 20.447 .805 min 29.210 1.15 29.210 1.15 32.893 1.295 32.893 1.295 21.133 0.832 min 27.737 min 1.092 38.227 1.505 12.167 .479 min 12.167 .479 min 15.265 0.601 15.265 0.601 18.415 0.725 18.415 0.725 17.120 0.674 min 17.551 min 0.691 21.514 0.847 28.524 1.123 nom 28.448 1.120 nom 12.827 0.505 12.827 0.505 16.129 0.635 16.129 0.635 37.033 1.458 nom 37.008 1.457 nom 19.279 0.759 38.735 1.525 nom 42.428 1.670 nom 41.402 1.63 41.402 1.63 44.577 1.755 44.577 1.755 50.292 1.98 nom 49.403 1.945 nom 44.577 1.755 29.718 1.170 nom 29.718 1.170 nom 4.318 0.17 4.318 0.17 4.445 0.175 4.445 0.175 36.068 1.42 nom 35.611 1.402 4.394 0.173 27.686 1.090 27.432 1.080 5.080 0.200 5.080 0.200 5.080 0.200 5.080 0.200 35.560 1.400 33.401 1.315 5.080 0.200 7.620 0.300 7.620 0.300 6.350 0.250 6.350 0.250 7.620 0.300 7.620 0.300 45.720 1.800 40.005 1.575 7.620 0.300 5.080 0.200nom 20.320 0.800 20.32 0.800 23.49 0.925 23.495 0.925 4.064 0.160 4.496 0.177 28.321 1.115 † This bobbin has no standoff FIGURE 3 11.14 MAGNETICS FIGURE 7 FIGURE 8 E, I, U Hardware Printed Circuit Bobbins (con’t) MECHANICAL DIMENSIONS PART CORE SIZE FIG. PCB4020L1 44020EC 7 mm in PCB4022L1 44022EC 8 mm in PCB4317L1 44317EC 3 mm in PCB4317L2 44317EC 3 mm 2 Section in PCB4721L1 44721EC 3 mm in PCB4721L2 44721EC 3 mm 2 Section in PCB5528WA 45528EC 9 mm in PCB5530FA 45530EC 10 mm in PCB5724L1† 45724EC 3 mm in L NOM M NOM 3.810 0.150 4.572 0.180 18.110 0.713 18.110 0.713 21.082 0.830 21.082 0.830 52.070 2.050 37.008 1.457 26.162 1.030 24.130 0.950 24.130 0.950 27.940 1.100 27.940 1.100 33.020 1.300 NOMINAL WINDING AVERAGE AREA PER SECTION LENGTH OF TURN FT in2 cm2 BOBBIN MATERIAL PIN MATERIAL PIN DIAMETER 0.300 1.940 0.300 Rynite FR-530** .036" square 0.300 1.940 0.335 Rynite FR-530** .036" square 0.156 1.010 0.281 Rynite Phosphor Bronze .025" square 0.156 1.010 0.281 Rynite Phosphor Bronze .025" square 0.185 1.193 0.325 Glass filled Nylon* Phosphor Bronze .025 " square 0.185 1.193 0.325 Glass filled Nylon* Phosphor Bronze .025 " square 0.468 3.020 0.352 Glass filled Nylon** .036" square 0.448 2.890 0.439 Glass filled Nylon** .035" 0.293 1.890 0.386 Glass filled Nylon* .035" square † This bobbin has no standoff * UL 94 HB rated ** UL 94 V-O rated. FIGURE 9 FIGURE 10 11.15 mag-inc.com E, I, U Hardware Surface Mount Bobbins MECHANICAL DIMENSIONS PART CORE SIZE FIG. SMB1203LA 41203EC 1 mm in 11.16 FIGURE 1 MAGNETICS A MAX B MAX C MAX D MAX E MIN F MAX G MIN H NOM J NOM 9.119 0.359 10.490 0.413 14.072 0.554 4.496 0.177 3.302 0.130 17.221 0.678 - 2.540 0.100 3.810 0.150 K MAX L NOM NOMINAL WINDING AREA PER SECTION in2 cm2 7.925 0.312 6.909 0.272 0.025 MECHANICAL DIMENSIONS PART CORE SIZE FIG. SMB1203LA 41203EC 1 mm in 0.162 AVERAGE LENGTH OF TURN FT 0.087 BOBBIN MATERIAL LCP** PIN MATERIAL PIN DIAMETER Phosphor Bronze .020” square ** UL 94 V-O rated E, I, U Hardware Surface Mount Bobbins 11.17 mag-inc.com Planar E, I Cores Planar Core Data (ungapped) Any practical gap available. See pages 1.8-1.11 MECHANICAL DIMENSIONS PART CORE TYPE FIG. 0_41425EC C_41434EC* E14 C_41434IC I14 C_41805EC* E18 C_41805IC I18 0_42107EC C_42216EC* E22 C_42216IC I22 F_43208EC E32 F_43208IC I32 0_43618EC 0_43618IC F_43808EC E38 A B C 6 mm in 1 mm in 3 mm in 1 mm 14 ± .30 0.551 ± .012 14 ± .30 .555 ± .012 14 ± .30 .551 ± .012 18 ± .35 2.5 ± .10 .098 ± .004 3.5 ± .10 0.138 ± .004 1.8 ± .05 .071 ± .002 4 ± .1 5 ± .15 .197 ± .006 5 ± .15 .197 ± .006 5 ± .15 .197 ± .006 10 ± .20 3 mm in 6 mm in 1 mm in 3 mm in 1 mm in 2 mm in 7 mm in 8 mm in 1 mm in 18 ± .41 .709 ± .016 21.8 ± .43 .858 ± .017 21.8 ± .400 .850 ± .010 21.8 ± .400 .850 ± .010 31.75 ± .640 1.250 ± .020 31.75 ± .64 1.250 ± .020 35.56 ± .51 1.400 ± .020 36.58 ± .51 1.440 ± .020 38.1 ± .76 1.500 ± .030 2.39 ± .10 .094 ± .004 3.91 ± .08 .154 ± .003 5.72 ± .12 .225 ± .005 2.95 ± .10 .116 ± .004 6.35 ± .130 .250 ± .008 3.18 ± .13 .125 ± .005 6.35 ± .12 .250 ± .005 3.81 ± .25 .150 ± .010 8.26 ± .13 .325 ± .005 10 ± .20 .394 ± .008 7.8 ± .51 .307 ± .020 15.8 ± .30 .625 ± .010 15.9 ± .25 .625 ± .010 20.32 ± .41 .800 ± .016 20.32 ± .41 .800 ± .016 17.8 ± .38 .700 ± .015 18.29 ± .38 .720 ± .015 25.4 ± .51 1.000 ± .020 D MIN E MIN F L M 0.9 0.035 1.91 0.075 10.5 0.414 10.5 0.414 3 ± .10 .118 ± .004 3 ± .10 .118 ± .004 1.5 .059 ref 1.5 .059 ref 4 .1575 ref 4 .1575 ref 2 ± .1 13.7 4 ± .1 2.0 ref 5.0 ref 1.52 0.06 3.05 0.12 16.5 0.649 16.1 0.632 5 ± .20 .197 ± .008 5.08 ± .12 .200 ± .005 2.5 ± .12 .0985 ± .005 2.54 ref .100 ± .005 5.89 ± .25 .232 ± .010 5.7 ref .225 ± .012 2.98 0.12 24.9 0.98 6.35 ± .130 .250 ± .005 3.18 .125 ref 9.27 .365 min 2.41 0.095 27.2 1.070 7.62 ± .18 .300 ± .007 3.81 ± .12 .150 ± .005 10.16 ± .25 .400 ± .010 4.32 0.170 30.2 1.190 7.62 ± .15 .300 ± .008 3.81 .150 ref 11.43 .450 ref To order, add material code to part number. * All E-cores available with clamp recesses are also available without. NOTE: Clamps are available for the EI combination of parts 41434, 41805 and 42216 only. FIGURE 1 11.18 MAGNETICS FIGURE 2 FIGURE 3 MOU NTIN G CL AMP AL (mH/1000T) HIGH PERMEABILITY MATERIALS POWER MATERIALS COMB. R P F* J W E-E MAGNETIC DATA WEIGHT BOBBIN WINDOW WaAc (cm4) AVAILABLE le (mm) Ae (mm2) A MIN (mm2)Ve (mm3) CORE (grams per set) AREA (cm2) HARDWARE 16.7 Min 1240 1350 2150 2650 1000 1080 1730 2140 3420 E-I Min 1330 1450 2320 2880 2520 2740 4380 5470 3000 3260 5210 6450 2190 2380 3810 4350 3590 3905 6250 8640 4467 4858 7776 10750 5025 5465 8744 10930 5930 6446 10313 12892 5170 5640 9020 - 5870 6400 10250 12760 5900 6430 10300 - 24.2 40.1 39.9 972 4.9 0.16 0.064 20.3 39.5 35.9 830 4.1 0.08 0.032 25.7 37.1 36.0 960.0 4.2 0.15 0.056 32.3 76.0 73.n 26.1 80.4 72.5 2100 10.4 0.15 0.12 41.4 130.0 130.0 5380 26 0.51 0.66 35.1 130.0 130.0 4560 22 0.25 0.33 42.4 135.0 135.0 5750.0 28 0.412 0.556 37.4 135.0 135.0 5060.0 25 0.206 0.278 52.4 194.0 194.0 10200 50.9 0.813 1.56 21600 E-E Min 0.009 - E-I Min 0.064 - E-E Min 1.2 - E-I Min 245.0 - E-E Min 0.019 13300 E-I Min 0.128 8260 E-E Min 1.5 - E-E Min 0.0090 - E-I Min 0.064 - E-E Min 244 244.0 303.9 4260 E-E Min 14.7 14.7 14.66 30.4 14.7 1.2 20.7 1.47 16.7 14.7 14.7 14.66 14.7 14.7 Planar E, I Cores Planar Core Data (ungapped) - * F material nominal ± 25% FIGURE 6 FIGURE 7 FIGURE 8 11.19 mag-inc.com Planar E, I Cores Planar Core Data (ungapped) Any practical gap available. See pages 1.8-1.11 MECHANICAL DIMENSIONS PART F_43808IC CORE TYPE FIG. A B C 38.1 ± .76 1.500 ± .030 40.64 ± .51 1.600 ± .020 40.64 ± .51 1.600 ± .020 43.2 ± .9 3.81 ± .13 .150 ± .005 8.51 ± .25 .335 ± .010 4.45 ± .25 .175 ± .010 8.51 ± .25 25.4 ± .51 1.000 ± .020 10.7 ± .25 .421 ± .010 10.7 ± .25 .421 ± .010 27.9 ± .6 0_44308EC 2 mm in 7 mm in 8 mm in 7 mm 0_44308IC 8 mm 43.2 ± .9 4.1 ± .13 27.9 ± .6 1 mm in 2 mm in 4 mm in 5 mm in 7 mm in 4 mm in 5 mm in 7 mm in 9.53 ± .12 0.375 ± .005 4.06 ± .12 .160 ± .005 10.54 ± .20 .415 ± .008 4.04 ± .12 .159 ± .005 9.65 ± .12 .380 ± .005 10.2 ± .10 .402 ± .004 5.08 ± .12 .200 ± .005 20.3 ± .25 .800 ± .010 27.9 ± .38 1.100 ± .015 27.9 ± .38 1.100 ± .015 38.1 ± .78 1.500 ± .031 38.1 ± .78 1.500 ± .031 50.8 ± .64 2.000 ± .025 50.8 ± .81 2.000 ± .032 50.8 ± .81 2.000 ± .032 37.5 ± .56 1.476 ± .022 I38 0_44008EC 0_44008IC F_44310EC E43 F_44310IC I43 C_45810EC* E58 C_45810IC I58 0_46409EC C_46410EC* E64 C_46410IC I64 0_49938EC E102 43.18 ± .51 1.700 ± .020 43.18 ± .51 1.700 ± .020 58.42 ± 1.17 2.300 ± .046 58.42 ± 1.17 2.300 ± .046 64 ± .76 2.520 ± .030 64 ± .76 2.520 ± .030 64 ± .76 2.520 ± .030 102 ± 1.52 4.016 ± .060 D MIN E MIN F L M 3.56 0.140 29.8 1.175 10.16 ± .12 .400 ± .005 5.08 ± .12 .200 ± .005 10.16 .400 nom 4.19 34.7 8.1 ± .2 4.06 ref 13.46 ref 5.33 0.21 34.4 1.355 8.13 ± .25 .320 ± .010 4.06 ± .25 .160 ± .010 13.46 ± .25 .530 ± .010 6.35 0.25 50.39 1.984 8.1 ± .20 .319 ± .008 3.66 .144 ref 21.5 ± .25 .8465 ± .010 4.45 0.175 5.03 0.198 52.8 2.08 53.16 2.093 10.16 ± .18 .400 ± .007 10.16 ± .18 .400 ± .007 5.08 ± .12 .200 ± .005 5.08 ± .12 .200 ± .005 21.8 ± .25 .860 ± .010 21.8 ± .25 .860 ± .010 12.9 0.507 85 3.346 14 ± .25 .551 ± .010 8 ± .25 .315 ± .010 35.9 ± .51 1.415 ± .020 To order, add material code to part number. * All E-cores available with clip recesses are also available without. NOTE: Clips are available for the EI combination of parts 41434, 41805 and 42216 only. FIGURE 1 11.20 MAGNETICS FIGURE 2 FIGURE 4 MOU NTIN G CL AMP AL (mH/1000T) HIGH PERMEABILITY MATERIALS POWER MATERIALS COMB. R P F* J W E-I Min 7100 7730 12400 - 3150 3430 5488 6860 3690 4013 6421 8026 6420 6982 11172 13966 7600 8261 13200 16400 6000 6530 10450 13000 7350 8000 12800 15900 6030 6550 10500 12100 7210 7840 12500 14500 11500 12500 20000 22000 11100 12100 19400 21200 12800 13900 22200 24100 6330 6880 11000 - 5220.0 26 0.66 0.667 43.8 99.5 95.1 4360.0 21 0.33 0.328 57.5 227.0 227.0 13100.0 64 0.96 2.18 50.4 229.0 229.0 11500 54 0.48 1.09 61.5 227.0 227.0 14000.0 70.6 1.18 2.68 50.6 227.0 227.0 11500.0 58 0.588 1.34 81.2 301.0 279.0 24600.0 125 2.5 7.53 68.3 303.0 279.0 20700.0 105 1.25 3.79 77.4 516.0 516.0 40000.0 200 1.78 9.18 80.2 516.0 516.0 41400.0 195 2.02 10.4 69.9 516.0 516.0 36100.0 170 1.01 5.21 148.0 540.0 525.0 79800.0 400 8.5 46 42200 E-E Min 95.1 37200 E-I Min 101.0 38500 E-E Min 51.9 - E-E Min 0.78 - E-I Min 0.406 27900 E-E Min 42.5 22800 E-I Min 8460 - E-E Min 194.0 - E-I Min 194.0 - E-E Min 43.7 - E-I Min WEIGHT BOBBIN WINDOW WaAc (cm4) AVAILABLE le (mm) Ae (mm2) A MIN (mm2)Ve (mm3) CORE (grams per set) AREA (cm2) HARDWARE - E-E Min MAGNETIC DATA Planar E, I Cores Planar Core Data (ungapped) - * F material nominal ± 25% FIGURE 5 FIGURE 7 FIGURE 8 11.21 mag-inc.com Planar Hardware Clamps MECHANICAL DIMENSIONS PART CORE SIZE FIG. 00C143420 41434EC/IC 1 mm in 00C180520 41805EC/IC 1 mm in 00C221620 42216EC/IC 3 mm in 11.22 A 14 .551 ± .020 18.01 0.709 ± .008 22.2 0.874 ± .008 FIGURE 1 MAGNETICS B 5.4 .2126 ± .004 6.61 .260 ± .004 8.74 .3425 ± .004 C 2.21 0.087 2.2098 0.087 2.4892 0.098 D 13.59 .535 ± .015 17.6 .693 ± .020 21.4122 0.843 E 0.3048 0.012 0.4064 0.016 0.4064 0.016 FIGURE 2 MATERIAL Stainless Steel Stainless Steel Stainless Steel MECHANICAL DIMENSIONS PART CORE SIZE FIG. 00C581001 45810EC/EC 2 mm in 00C581002 45810EC/IC 2 mm in 00C641001 46410EC/EC 2 mm in 00C641002 46410EC/IC 2 mm in A 18.24 .718 ± .006 11.61 .457 ± .006 17.58 .692 ± .006 11.86 .467 ± .006 B 4.57 .180 ref 4.57 .180 ref 4.57 .180 ref C D 4.5 .177 ± .004 4.5 0.177 4.5 .177 ± .004 4.5 .177 ± .004 19.87 .782 ± .006 13.23 .521 ± .006 9.2 .756 ± .006 13.72 .540 ± .006 E 0.381 .015 ± .001 0.381 .015 ± .001 0.381 .015 ± .001 0.381 .015 ± .001 MATERIAL Stainless Spring Steel Stainless Spring Steel Stainless Spring Steel Stainless Spring Steel FIGURE 3 Planar Hardware Clamps 11.23 mag-inc.com EEM/EFD Cores EEM/EFD Core Data (ungapped) Any practical gap available. See pages 1.8-1.11 MECHANICAL DIMENSIONS PART CORE TYPE FIG. 0_41309EC EEM 12.7 0_41515EC EFD 15 0_41709EC 0_42523EC EFD 25 A D MIN E MIN 2 mm 12.8 ± .25 6.86 ± .15 3.3 ± .15 in .502 ± .010 .270 ± .006 .130 ± .006 3 mm 15.5 ± .4 7.5 ± .15 4.65 ± .15 4.42 0.174 5.25 9.22 0.363 10.65 6 ± .10 1.85 ± .10 1.68 ± .08 1.7 ± .15 .236 ± .004 .073 ± .004 .066 ± .003 .067 ± .006 5.3 ± .15 2.4 ± .10 1 mm in 4 mm in 6.73 0.265 9.1 0.358 12.3 0.485 18.1 0.712 7.11 ± .18 .280 ± .007 11.4 ± .20 .448 ± .008 17.8 ± .30 .700 ± .012 25 ± .66 .984 ± .026 To order, add material code to part number. 11.24 MAGNETICS B 9.4 ± .12 .370 ± .005 12.5 ± .15 .492 ± .006 C 4.32 ± .25 .170 ± .010 9.1 ± .20 .358 ± .008 F K 2.54 ± .18 .100 ± .007 5.2 ± .15 .205 ± .006 L 2.54 ± .18 0.100 ± .007 3.15 ± .20 .124 ± .008 M 2.79 ± .18 .110 ± .007 3.65 ± .20 .144 ± .008 SUR FACE MOU PRIN NT B TED C IRCU OBBIN MOU IT BO NTIN BB G CL AMP IN EEM/EFD Core Data (ungapped) AL (mH/1000T) HIGH PERMEABILITY MATERIALS POWER MATERIALS R Nom Min Nom Min Nom Min Nom Min 600 670 740 1570 P 650 730 800 1710 F* 1000 1170 1280 2730 J 1080 1450 1600 3380 W MAGNETIC DATA 4 WEIGHT BOBBIN WINDOW le (mm) Ae (mm2) AMIN(mm2) Ve (mm3) CORE (grams per set) AREA (cm2) WaAc (cm ) AVAILABLE HARDWARE 28.5 11.7 11.1 330.0 1.6 0.124 0.015 34.0 15.0 12.2 510.0 2.8 0.167 0.025 41.5 20.1 18.1 834.0 4.1 0.27 0.054 57.0 58.0 55.0 3300.0 16.2 0.402 0.233 2150 5820 * F material nominal ± 25% FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 11.25 mag-inc.com EEM/EFD Hardware Printed Circuit Bobbins MECHANICAL DIMENSIONS PART CORE SIZE FIG. PCB15158A 41515EC 1 mm in PCB2523TA 42523EC 2 mm in 11.26 A NOM B NOM C MIN D MIN E MAX F NOM G MAX H NOM J TYP 14.986 0.590 24.9936 0.984 16.3068 0.642 25.8572 1.018 2.4892 0.098 5.3848 0.212 5.4356 0.214 11.6078 0.457 10.5918 0.417 18.1102 0.713 8.509 0.335 13.208 0.520 10.5918 0.417 18.0086 0.709 9.1948 0.358 16.6878 0.657 3.7592 0.148 5.0038 0.197 FIGURE 1 MAGNETICS MECHANICAL DIMENSIONS PART CORE SIZE FIG. PCB15158A 41515EC 1 mm in PCB2523TA 42523EC 2 mm in K NOM L±.012” 13.7414 0.541 22.5044 0.886 3.5052 0.138 3.5052 0.138 NOMINAL WINDING AREA PER SECTION in2 cm2 AVERAGE LENGTH OF TURN FT BOBBIN MATERIAL PIN MATERIAL PIN DIAMETER 0.026 0.169 0.118 Phenolic* CP Wire .024” 0.065 0.412 0.196 Phenolic* CP Wire .024” * UL 94 V-O rated FIGURE 2 EEM/EFD Hardware Printed Circuit Bobbins 11.27 mag-inc.com EEM/EFD Hardware Surface Mount Bobbins MECHANICAL DIMENSIONS PART CORE SIZE FIG. SMB1515TA 41515EC 1 mm in A NOM B NOM C MIN D MIN E MAX F NOM G MAX H NOM J TYP 14.986 0.590 14.986 0.590 2.4892 0.098 5.3848 0.212 10.6934 0.421 7.493 0.295 10.4902 0.413 8.89 0.350 2.4892 0.098 FIGURE 1 11.28 MAGNETICS MECHANICAL DIMENSIONS PART CORE SIZE FIG. SMB1515TA 41515EC 1 mm in K NOM 21.59 0.850 NOMINAL WINDING AREA PER SECTION in2 cm2 0.027 0.175 AVERAGE LENGTH OF TURN FT BOBBIN MATERIAL PIN MATERIAL PIN DIAMETER 0.12 L.C.P.* Nickel Bronze .016" * UL 94 V-O rated EEM/EFD Hardware Surface Mount Bobbins 11.29 mag-inc.com EEM/EFD Hardware Clamps MECHANICAL DIMENSIONS PART CORE SIZE FIG. A 00C15151A* 41515EC 1 mm in 00C25231A* 42523EC 2 mm in 4.4958 0.177 8.001 0.315 B C D MATERIAL 5.207 0.205 5.3848 0.212 18.796 0.740 29.0068 1.142 0.254 0.010 0.3048 0.012 Stainless Steel *Two clamps required per core set 11.30 FIGURE 1 MAGNETICS FIGURE 2 Stainless Steel Section 12 EC,ETD,EER and ER Cores EC, ETD, EER AND ER CORES EC, ETD and EER cores are a cross between E cores and pot cores. Like E cores they provide a wide opening on each side. This gives adequate space for the large size wire required for low output voltage switched mode power supplies. It also allows for a flow of air which keeps the assembly cooler. The center posts of these cores are round, like that of the pot core. One of the advantages of the round center post is that the winding has a shorter path length (11% shorter) than the wire around a square center post with an equal area. This reduces the losses of the windings by 11% and enables the core to handle a higher output power. The round center post also eliminates the sharp bend in the wire that occurs with winding on a square center post. The most common application is switched mode power supplies. HOW TO ORDER O R 4 34 34 EC XX STANDARD CORE FERRITE CORE MATERIAL TYPE USED FOR ALL FERRITE TYPES APPROXIMATE DIAMETER IN MM APPROXIMATE HEIGHT IN MM GEOMETRY CODE/GAP CODE SPECIAL SPECIFICATION CODE GEOMETRY CODE EC – All E cores including ETD, EC, ER, EER, EEM, EFD, planar and lamination sizes. 12.1 mag-inc.com EC, ETD, EER, ER Cores EC, ETD, EER and ER Core Data (ungapped) Any practical gap available. See pages 1.8-1.11 MECHANICAL DIMENSIONS PART CORE TYPE A FIG. 0_40906EC ER 9.5 3 mm 9.5 + 0, -.3 B 2.45 ± .05 C D MIN 5 + 0, -.2 1.6 E F G S T 7.5 + .25, -0 3.50 + 0, -.2 7.21 ± .10 - - - - - 0_43434EC ETD 34 2 mm 35.0 +.0,-1.6 17.3 ± .20 11.1 + 0, -.6 11.8 27 max 0_43517EC 9.5 ± .30 22.75 ± .55 9.5 ± .30 - 2.75 ± .25 28.5 ± .8 0_43521EC EER 35L 2 mm 35 ± .65 20.70 ± .20 11.30 ± .35 14.40 in 1.378 ± .020 .815 ± .008 .445 ± .010 0.567 0_43939EC ETD 39 2 mm 40.0 + 0, - 1.8 19.8 ± .20 12.8 + 0, -.6 14.2 26.15 ± .55 11.30 ± .25 1.028 ± .020 .445 ± .010 29.3 +1.6,-0 12.8 + 0, -.6 - - - 0_44119EC EC 35 1 mm 34.5 ± .8 EC41 1 mm 40.6 ± 1.0 0_44216EC EER 42 2 mm in 0_44444EC ETD 44 2 mm in 0_44949EC ETD 49 2 mm 0_45032EC 0_45224EC EC52 42.10 ± .81 1.659 ± .032 45 + .0, -.2 1.732 ± .040 49.8 + 0, -2.2 59.80 ± 1.30 2.354 ± .051 70 ± 1.52 2.756 ± .060 68.58 ± 1.52 2.700 ± .060 To order, add material code to part number. MAGNETICS 11.9 19.5 ± .15 11.6 ± .3 13.5 27 + .8, -.7 11.6 ± .3 - 3.25 ± .25 33.6 ± 1.0 21.60 ± .20 .850 ± .008 22.30 ± .20 .878 ± .008 24.7 ± .20 14.70 ± .30 .579 ± .012 15.2 + .0, -.6 .583 ± .015 16.7 + 0, -.6 15.60 0.614 16.10 0.635 17.7 31 ± .58 1.220 ± .023 32.5 + 1.6,-0 1.311 ± .032 36.1 + 0, -1.8 - - - 2 mm 49.80 ± .76 15.90 ± .25 13.20 ± .38 9.50 in 1.960 ± .030 .625 ± .010 .520 ± .015 0.373 1 mm 52.2 ± 1.3 24.2 ± .15 13.4 ± .35 11.9 0_45959EC ETD 59 2 mm in 0_47035EC EC70 1 mm in 0_47054EC 2 mm in 12.2 17.3 ± .15 11.1 + 0, -.6 31 ± .20 1.220 ± .008 34.50 ± .15 1.358 ± .006 54 ± .38 2.125 ± .015 21.65 ± .45 .852 ± .018 16.38 ± .38 .645 ± .015 20 ± .38 .787 ± .015 22.10 0.87 22.30 0.879 41.80 1.647 FIGURE 1 14.70 ± .30 .579 ± .012 15.2 + 0, -.6 .583 ± .015 16.7 + 0, -.6 39.10 ± .51 14.50 ± .25 1.540 ± .020 .570 ± .010 33 ± .9 13.4 ± .35 - 3.75 ± .25 44 ±1.3 44.70 ± 1.09 1.760 ± .043 44.50 ± 1.14 1.752 ± .045 54.10 ± 1.27 2.130 ± .050 - 4.75 ± .250 .187 ± .010 - 59.6 ± .15 2.346 ± .060 - 21.65 ± .45 .852 ± .018 16.38 ± .38 .645 ± .015 20 ± .38 .787 ± .015 FIGURE 2 HIGH PERMEABILITY MATERIALS POWER MATERIALS R Min Min Min Min Min Min Min Min Min Min Min Min Min Min 730 2030 1660 2020 2230 2210 2880 2750 3070 3010 2900 4310 3310 2440 P 790 2200 1800 2220 2420 2400 3130 3000 3330 3270 3150 4680 3600 2650 * F material nominal ± 25% F* 1270 3600 3000 3550 4050 3700 5000 4950 5400 5230 5040 7500 5760 4240 J 1550 7160 9320 - W MAGNETIC DATA le (mm) WEIGHT WaAc (cm4) Ae (mm2) A MIN (mm2) Ve (mm3) CORE (grams per set) 14.2 8.47 7.6 120 0.6 .0026 78.6 97.1 91.6 7640 40 1.2100 77.4 84.3 71.0 6530 36 0.833 90.8 107.0 100.0 9710 49 1.91 92.2 125.0 123.0 11500 60 2.21 89.3 121.0 106.0 10800 52 1.67 98.7 175.0 166.0 17300 106 3.55 103 173 172.0 17800 94 3.75 114.0 211 209 24000 124 5.83 84.7 161.0 156.0 13640 66 2.75 105.0 180.0 141.0 18800 111 3.87 139.0 368.0 368.0 51200 248 13.7 141.0 281.0 211.0 39600 253 13.4 231.0 339.0 314.0 78600 396 34 STAN DAR D BO PRIN BBI TED CIRC N MOU U IT BO NTI SUR NG CLAM BBIN FACE P MOU NT B OBB IN AL (mH/1000T) EC, ETD, EER, ER Cores EC, ETD, EER and ER Core Data (ungapped) AVAILABLE HARDWARE 2520 FIGURE 3 12.3 mag-inc.com EC, ETD, EER, ER Hardware Bobbins MECHANICAL DIMENSIONS PART CORE SIZE FIG. 00B351701 43517EC 1 mm in 00B411901 44119EC 1 mm in 12.4 FIGURE 1 MAGNETICS A MAX B MAX C MAX D MAX E NOM 21.9456 0.864 26.035 1.025 23.5712 0.928 26.7462 1.053 9.8806 0.389 12.065 0.475 11.6586 0.459 14.097 0.555 21.7932 0.858 24.6126 0.969 NOMINAL WINDING AVG. LENGTH AREA PER SECTION OF TURN FT MATERIAL in2 cm2 0.173 1.12 0.172 0.225 1.45 0.205 Glass filled Nylon* Glass filled Nylon* MECHANICAL DIMENSIONS PART CORE TYPE FIG. 00B522401 45224EC 1 mm in 00B703501 47035EC 1 mm in A MAX 31.75 1.250 42.799 1.685 B MAX 30.734 1.210 44.323 1.745 C MAX D MAX E NOM 13.766 0.542 16.916 0.666 15.595 0.614 19.481 0.767 28.346 1.116 41.605 1.638 NOMINAL WINDING AVG. LENGTH AREA PER SECTION OF TURN FT MATERIAL in2 cm2 0.352 2.27 0.242 0.748 4.82 .319 Glass filled Nylon* Glass filled Nylon* * UL 94 HB rated EC, ETD, EER, ER Hardware Bobbins 12.5 mag-inc.com EC, ETD, EER, ER Hardware Printed Circuit Bobbins MECHANICAL DIMENSIONS PART CORE SIZE FIG.† PCB3434FA 43434EC 5 mm in PCB351701 43517EC 1 mm in PCH351701 43517EC 3 mm in PCB3521LA 43521EC 10 mm in PCB3939SA 43939EC 6 mm in PCB411901 44119EC 1 mm in PCH411901 44119EC 3 mm in A MAX B MAX C MAX D NOM E NOM F MAX G NOM H NOM 40.513 1.595 34.1122 1.343 34.163 1.345 29.21 nom 1.15 nom 44.2976 1.744 38.6334 1.521 38.6588 1.522 21.488 nom .846 nom 28.8036 1.134 29.0068 1.142 26.162 nom 1.03 nom 26.1874 nom 1.031 nom 28.6258 1.127 28.9052 1.138 13.8938 0.547 31.6484 1.246 26.6954 1.051 14.1732 0.558 15.2908 0.602 36.5506 1.439 31.1912 1.228 11.01 min .437 min 2.032 0.080 2.032 0.08 11.6586 min 0.459 min 12.7 min 0.500 min 2.032 0.080 2.032 0.080 25.5016 1.004 10.0076 0.394 10.0076 0.394 25.4 1.00 30.2006 1.189 12.0904 0.476 12.0904 0.476 26.01 ref 1.024 ref 23.749 0.935 23.622 0.930 39.8272 ref 1.568 ref 32.791 ref 1.291 ref 26.9494 1.061 26.8224 1.056 5.08 0.200 21.4884 0.846 21.4884 0.846 4.826 0.190 5.588 0.220 24.511 0.965 24.511 0.965 35.20 min 1.386 min 21.6408 0.852 21.6408 0.852 29.21 min 1.15 min 40.1066 min 1.579 min 25.654 1.010 25.654 1.010 † Figures 7-12 found on pages 12.8-12.9 12.6 FIGURE 1 FIGURE 3 FIGURE 2 MAGNETICS I NOM 12.192 0.480 12.192 0.480 14.097 0.555 14.097 0.555 EC, ETD, EER, ER Hardware Printed Circuit Bobbins MECHANICAL DIMENSIONS J NOM K MAX M NOM 11.30 min .445 min 7.62 0.300 7.62 0.300 12.7 0.500 13.0048 min 0.512 min 7.62 0.300 7.62 0.300 25.2984 0.996 30.48 1.200 30.48 1.200 25.5016 1.004 28.9052 1.138 33.02 1.300 33.02 1.300 5.0038 0.197 5.08 0.200 5.0038 0.197 - NOMINAL WINDING AVG. LENGTH BOBBIN PIN PIN AREA PER SECTION OF TURN FT MATERIAL MATERIAL DIAMETER in2 cm2 BOARD CLEARANCE (in)† L W H 0.19000 1.23 0.200 Phenolic* 1.675 1.575 1.350 0.150 0.970 0.164 - - - 0.15 0.97 0.164 - - - 0.230 1.48 0.20 - - - 0.270 1.740 0.220 Glass Filled Nylon** Glass Filled Nylon** Rynite FR530** Phenolic* 1.900 1.800 1.475 0.21 1.35 0.197 - - - 0.21 1.35 0.197 - - - CP Wire .031" Glass Filled Nylon** Glass Filled Nylon** * UL 94 V-1 rated **UL 94 V-O rated † Reference figure 12 for board clearance FIGURE 4 FIGURE 5 FIGURE 6 12.7 mag-inc.com EC, ETD, EER, ER Hardware Printed Circuit Bobbins (con’t) MECHANICAL DIMENSIONS PART PCB4216FA PCB4444WA PCB4949WA PCB522401 PCH522401 PCB5959AA PCB703501 PCH703501 CORE SIZE FIG.† A MAX B MAX C MAX D NOM E NOM F MAX G NOM H NOM I NOM 44216EC 11 mm in 44444EC 7 mm in 44949EC 8 mm in 45224EC 2 mm in 45224EC 4 mm in 45959EC 9 mm in 47035EC 2 mm in 47035EC 4 mm in 30.988 1.220 51.308 2.02 53.797 2.118 44.526 1.753 44.551 1.754 66.04 2.600 57.937 2.281 57.937 2.281 27.305 nom 1.075 nom 29.997 nom 1.181 nom 33.0962 nom 1.303 nom 44.018 1.733 44.094 1.736 41.376 nom 1.629 nom 56.794 2.236 56.896 2.24 17.983 0.708 17.805 0.701 19.507 0.768 41.630 1.639 36.499 1.437 24.866 0.979 51.816 2.040 47.117 1.855 15.392 min 0.606 min 15.189 min 0.598 min 16.484 min 0.649 min 2.032 0.080 2.032 0.08 22.352 min 0.88 min 4.4958 0.177 4.4958 0.177 24.993 0.984 35.712 1.406 40.386 1.590 13.944 0.549 13.944 0.549 50.8 2 17.145 0.675 17.145 0.675 45.593 1.795 39.700 ref 1.563 ref 40.690 ref 1.602 ref 30.708 1.209 30.708 1.209 48.514 ref 1.91 ref 44.2722 1.743 44.2722 1.743 5.08 0.200 5.08 0.200 5.08 0.2 28.2956 1.114 28.2956 1.114 4.191 0.165 41.4528 1.632 41.4528 1.632 39.878 1.570 45.135 min 1.777 min 49.504 min 1.949 min 31.445 1.238 31.445 1.238 61.341 min 2.415 min 42.443 1.671 42.545 1.675 16.205 0.638 16.205 0.638 19.507 0.768 19.507 0.768 † Figures 1-6 found on pages 12.6-12.7 12.8 FIGURE 7 FIGURE 9 MAGNETICS FIGURE 8 FIGURE 10 EC, ETD, EER, ER Hardware Printed Circuit Bobbins (con’t) MECHANICAL DIMENSIONS J NOM K MAX M NOM 15.6972 0.618 15.3924 min 0.606 min 16.891 min 0.665 min 7.62 0.300 7.62 0.300 22.352 min 0.88 min 10.16 0.400 10.16 0.400 30.48 ref 1.20 ref 32.512 1.280 35.5092 1.398 38.1 1.500 38.1 1.500 43.18 1.700 50.8 2.000 50.8 2.000 5.0038 0.197 5.0038 0.197 5.0038 0.197 5.08 0.200 - NOMINAL WINDING AVG. LENGTH BOBBIN PIN PIN AREA PER SECTION OF TURN FT MATERIAL MATERIAL DIAMETER in2 cm2 L W H 0.488 3.15 0.30 - - - 0.33 2.13 0.25 Rynite FR530** Phenolic* 2.075 2.000 1.580 0.420 2.71 0.28 Phenolic* 2.275 2.175 1.680 0.33 2.13 0.239 - - - 0.33 2.13 0.239 - - - 0.58 3.72 0.35 2.845 2.635 1.940 0.74 4.77 0.312 - - - 0.74 4.77 0.312 Glass Filled Nylon** Glass Filled Nylon** Rynite FR530L** Glass Filled Nylon** Glass Filled Nylon** - - - CP Wire .039" BOARD CLEARANCE (in)† * UL 94 V-1 rated **UL 94 V-O rated. † Reference figure 12 for board clearance FIGURE 11 FIGURE 12 TERMINAL ASSEMBLY General Purpose Terminal PNEC01000 NOTE: Terminals are not normally inserted but shipped separately in strip form. See above Terminal Assembly. Printed Circuit Terminal PNEC02000 12.9 mag-inc.com EC, ETD, EER, ER Hardware Mounting Clamps MECHANICAL DIMENSIONS PART ITEM CORE SIZE FIG. 00C09061A Clamp 40906EC 00C343416 43434EC 0AC351717 Clamp (2 required per set) U Bolt 0BC351740 Plate 43517EC 0CC351700 43939EC 0AC411919 Nut (2 required) Clamp (2 required per set) U Bolt 0BC411940 Plate 44119EC 0CC411900 Nut (2 required) 00C393916 12.10 FIGURE 1 MAGNETICS A B C 7 mm in 4 mm in 3 mm in 2 mm in - - 10.007 0.394 22.8854 0.901 32.385 1.275 39.37 1.55 - 5.384 .212 10.8458 0.427 42.164 1.66 9.525 0.375 - 3.988 .157 39.624 1.56 2.1082 0.083 31.5976 1.244 - 13.97 .055 12.7 0.500 3.8862 0.153 - 4.445 0.175 - mm in 1 mm in 2 mm in - - 25.3238 0.997 38.100 1.500 46.736 1.840 - 12.5476 0.494 46.99 1.850 11.1252 0.438 - 44.704 1.76 2.3622 0.093 37.211 1.465 - 12.7 0.500 4.7752 0.188 - 4.699 0.185 - FIGURE 2 D E FIGURE 3 MECHANICAL DIMENSIONS PART ITEM CORE SIZE FIG. 00C09061A Clamp 40906EC 00C343416 43434EC 0AC351717 Clamp (2 required per set) U Bolt 0BC351740 Plate 43517EC 0CC351700 43939EC 0AC411919 Nut (2 required) Clamp (2 required per set) U Bolt 0BC411940 Plate 44119EC 0CC411900 Nut (2 required) 00C393916 FIGURE 4 F G H THREAD MATERIAL 7 mm in 4 mm in 3 mm in 2 mm in - - 2.6416 0.104 - 2.6416 0.104 - 1.016 0.040 - - - mm in 1 mm in 2 mm in - - 3.048 0.120 - 3.048 0.120 - 1.016 0.040 - #3-48-2A Stainless Steel Brass Aluminum - #4-40-2A Stainless Steel Brass Aluminum - FIGURE 7 EC, ETD, EER, ER Hardware Mounting Clamps 12.11 mag-inc.com EC, ETD, EER, ER Hardware Mounting Clamps (con’t) MECHANICAL DIMENSIONS PART ITEM 00C444416 44949EC 0AC522423 Clamp (2 required per set) Clamp (2 required per set) U Bolt 0BC522440 Plate 45224EC 0CC522400 45959EC 0AC703531 Nut (2 required) Clamp (2 required per set) U Bolt 0BC703540 Plate 47035EC 00C522400 Nut 00C494916 00C595916 CORE SIZE FIG. 44444EC A B C 4 mm in 4 mm in 3 mm in 2 mm in - - 28.6766 1.129 30.8864 1.216 48.895 1.925 59.69 2.350 - 14.9098 0.587 16.383 0.645 57.15 2.25 12.70 0.500 - 49.657 1.955 54.61 2.15 2.921 0.115 48.1076 1.894 - 15.24 0.600 5.9182 0.233 - 5.715 0.225 - 5 mm in 3 mm in 4 mm in - - 12.9032 0.508 65.405 2.575 76.962 3.03 - 22.098 0.87 78.74 3.100 15.875 0.625 - 65.405 2.575 2.921 0.115 64.6938 2.547 - 15.24 0.600 6.2738 0.247 - 5.715 0.225 - FIGURE 2 12.12 MAGNETICS D E FIGURE 3 MECHANICAL DIMENSIONS PART ITEM 00C444416 44444EC 0AC522423 Clamp (2 required per set) Clamp (2 required per set) U Bolt 0BC522440 Plate 45224EC 0CC522400 45959EC 0AC703531 Nut (2 required) Clamp (2 required per set) U Bolt 0BC703540 Plate 47035EC 00C522400 Nut 00C494916 00C595916 FIGURE 4 CORE SIZE FIG. 44949EC F G H THREAD 4 mm in 4 mm in 3 mm in 2 mm in - - 3.6576 0.144 - 3.6576 0.144 - 1.016 0.040 - - Stainless Steel - Stainless Steel 5 mm in 3 mm in 4 mm in - - 5.715 0.225 - 3.6576 0.144 - 1.016 0.04 - #6-32-2A - MATERIAL Brass Aluminum #6-32-2A Stainless Steel Brass - Aluminum - - FIGURE 5 EC, ETD, EER, ER Hardware Mounting Clamps (con’t) 12.13 mag-inc.com EC, ETD, EER, ER Hardware Surface Mount Bobbin NOMINAL WINDING AVERAGE AREA PER SECTION LENGTH OF TURN FT in2 cm2 A NOM B NOM C MAX D MIN E NOM F MAX G MAX H NOM J TYP K NOM MECHANICAL DIMENSIONS PART CORE SIZE FIG. SMB09068A 40906EC 12.14 1 mm 8.509 8.102 4.55 in .335 .319 .179 FIGURE 1 MAGNETICS 3.505 2.159 7.391 2.997 4.292 2.006 11.557 .138 .085 .291 .118 1.69 .079 .455 .0047 .030 .06 TOROIDS Ferrite toroids offer high magnetic efficiency as there is no air gap, and the cross sectional area is uniform. Available in many sizes (O.D.s from 0.100" to 3.375") and materials (permeabilities ranging from 750 to 15,000), this section lists common sizes. For additional sizes contact Magnetics Sales. Typical applications for high permeability toroids (J, W, and H materials) include common mode chokes, broadband transformers, pulse transformers and current transformers. R, P and F material toroids are excellent choices for high frequency transformers. Special sizes in J material are available for Ground Fault Interrupter applications. HOW TO ORDER OJ Section 13 Toroids 4 22 06 TC XX COATING CODE (SEE PG 13.2) FERRITE CORE MATERIAL TYPE USED FOR ALL FERRITE TYPES APPROXIMATE DIAMETER IN MM APPROXIMATE HEIGHT IN MM TOROID CORE SPECIAL SPECIFICATION CODE *COATING CODES 0 – Bare core V – Nylon coating Y – Parylene C® Z – Polyester/Epoxy coating *SPECIAL SPECIFICATION CODES CC – Color Coded *See page 13.2 – 13.3 for discussion of coating and other special requirements. 13.1 Toroids COATINGS In order to increase winding ease and improve voltage breakdown, toroids are available coated. There are three categories of coatings available; Parylene, Nylon and Polyester/Epoxy. Parylene C® is a vacuum-deposited material which has a uniform coating (including edges) with a thickness of .0005" to .002", a smooth winding surface, and good moisture resistance to organic solvents and acid bases. The electrical characteristics are superior to other coatings. To specify Parylene use "Y" as the coating code when ordering. Parylene C® is available for cores with O.D.s up to .500". The continuous maximum rating is 130° C. Note that minimum inductance is 5% lower than listed for Parylene coated cores. Nylon coating (V designation) provides good adhesion, a smooth winding surface and excellent resistance to moisture and organic solvents. Typically, Nylon coating is .004” to .008” thick. Available in the 12.7 mm to 29 mm size range, Nylon is a good finish for continuous operation from -65° C to +155° C. Nylon coating offers a minimum voltage breakdown of 1000 volts (wire to wire). Polyester/Epoxy coating (Z designation) meets the same general visual requirements, standard dimensional and voltage breakdown guarantees as Nylon. Polyester/Epoxy is rated to 200° C continuous operation. Coating thickness with Polyester/Epoxy is typically less than with Nylon, although the guaranteed limits are the same. The size range for Polyester/Epoxy is from 9.5 mm to 86 mm. Parylene C® offers a minimum voltage breakdown of 600 volts wire to wire. NOTE: H material (15,000µ) is not available in Nylon coating. 13.2 MAGNETICS HIGH VOLTAGE COLOR CODING Voltage breakdown, higher than the standard guarantees, can be provided. Dimensional tolerances are relaxed to allow for the added coating. Contact Magnetics Application Engineering for specifications. Toroids (as well as other cores) can be marked with a color code to help differentiate different materials. When ordering add "CC" as the special specification code. MATERIAL ASSIGNED COLOR CODES R Blue P Green F White J Red W Yellow H Purple Toroids SPECIAL SPECIFICATION CODES 13.3 mag-inc.com Toroids Toroid Core Data AL (mH/1000T) MECHANICAL DIMENSIONS PART 40200TC 40301TC 40502TC 40503TC 40401TC 40402TC 40601TC 40603TC 40705TC 40907TC 41003TC 41005TC 41206TC 41303TC 41305TC 41306TC mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in A (OD) B (ID) C (HGT.) 2.54 0.100 3.51 0.138 3.94 0.155 3.94 0.155 4.83 0.190 4.83 0.190 5.84 0.230 5.84 0.230 7.62 0.300 9.53 0.375 9.53 0.375 9.53 0.375 12.7 0.500 12.7 0.500 12.7 0.500 12.7 0.500 1.27 0.050 1.83 0.072 2.24 0.088 2.24 0.088 2.29 0.090 2.29 0.090 3.05 0.120 3.05 0.120 3.18 0.125 5.59 0.220 4.75 0.187 4.75 0.187 5.16 0.203 8.14 0.312 8.14 0.312 8.14 0.312 1.27 0.050 1.27 0.050 1.27 0.050 2.54 0.100 1.27 0.050 2.54 0.100 1.52 0.060 3.18 0.125 4.78 0.188 7.11 0.280 3.18 0.125 4.78 0.188 6.35 0.250 3.15 0.125 5.08 0.200 6.35 0.250 POWER MATERIALS R 2300µ ± 25% P 2500µ ± 25% HIGH PERMEABILITY MATERIALS F 3000µ ± 20% J 5000µ ± 20% 454 525 875 1,750 2,625 380 410 495 825 1,650 2,475 340 368 440 735 1,470 2,205 670 716 885 1,475 2,950 4,425 440 474 570 950 1,900 2,850 870 948 1,140 1,900 3,800 5,700 450 488 585 980 1,960 2,940 940 1,020 1,225 2,040 4,080 6,120 1,920 2,088 2,505 4,175 8,350 12,500 1,730 1,884 2,260 3,765 7,530 11,300 1,000 1,095 1,314 2,196 4,392 6,590 1,510 1,650 1,980 3,308 6,616 9,920 2,600 2,820 3,384 5,640 11,280 16,900 680 745 894 1,488 2,976 4,460 1,090 1,190 1,430 2,380 4,760 7,140 1,360 1,485 1,782 2,968 5,936 8,900 ∆ AL values based on testing at 5 gauss in a de-gaussed state. For the cores listed here, dimensional tolerances for bare and coated cores are on pages 13.10-13.12. Page 3.12 also lists guidelines for dimensional tolerances of all toroids. Other core heights are available upon special request. MAGNETICS H 15,000µ ± 30% 400 To order, add coating and material code. 13.4 W 10,000µ ± 30% Toroids MAGNETIC DATA Ae (mm2) Ve (mm3) WINDOW CORE WEIGHT WaAc (cm4) (g) AREA (cm2) AVA IL. C OAT INGS Toroid Core Data PART le (mm) 40200TC 5.53 .77 4.3 0.013 .03 Y 40301TC 7.65 1.03 7.87 0.026 .04 Y 40502TC 9.2 1.05 9.7 0.039 .05 Y 40503TC 9.2 2.10 19.4 0.039 .10 Y 40401TC 10.21 1.54 15.7 0.041 .09 Y 40402TC 10.21 3.08 31.4 0.041 .17 Y 40601TC 13.0 2.0 26.7 0.073 .14 Y 40603TC 13.0 4.3 56.0 0.073 .30 Y 40705TC 15 9.9 149.0 0.079 .90 Y 40907TC 22.7 13.7 310.0 0.245 1.6 41003TC 20.7 7.3 151.0 0.177 .82 41005TC 20.7 10.9 227.0 0.177 1.2 0.019 Y, Z 41206TC 24.6 22.1 554.0 0.209 3.3 0.046 Y, Z 41303TC 31.7 7.1 224.0 0.493 1.2 0.035 Y, Z 41305TC 31.7 11.4 361.0 0.493 1.9 0.058 V, Y, Z 41306TC 31.7 14.2 451.2 0.493 2.4 0.072 V, Y, Z 0.033 Y, Z Y, Z 13.5 mag-inc.com Toroids Toroid Core Data (con’t) AL (mH/1000T) MECHANICAL DIMENSIONS PART 41406TC 41407TC 41506TC 41435TC 41450TC 41605TC 41809TC 42106TC 42109TC 42206TC 42207TC 42212TC 42507TC 42508TC 42908TC 42915TC mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in HIGH PERMEABILITY MATERIALS POWER MATERIALS A (OD) B (ID) C (HGT.) 12.7 0.500 12.7 0.500 13.2 0.520 13.6 0.535 14.0 0.551 15.9 0.625 18.4 0.726 20.6 0.810 20.6 0.810 22.1 0.870 22.1 0.870 22.1 0.870 25.34 1.000 25.34 1.000 29.0 1.142 29.0 1.142 7.14 0.281 7.14 0.281 7.37 0.290 7.01 0.276 8.99 0.354 8.89 0.350 9.75 0.384 12.7 0.500 12.7 0.500 13.7 0.540 13.7 0.540 13.7 0.540 15.45 0.610 15.45 0.610 19.0 0.748 19.0 0.748 6.35 0.250 4.78 0.188 3.96 0.156 3.51 0.138 5.00 0.197 4.70 0.185 10.3 0.404 6.35 0.250 8.89 0.350 6.35 0.250 7.90 0.312 12.44 0.500 7.66 0.312 10.0 0.394 7.50 0.295 15.2 0.600 R P F J 15,000µ ± 30% 2,166 3,612 7,224 10,800 1,356 1,630 2,715 5,430 8,140 1,020 1,111 1,334 2,295 4,590 6,880 1,040 1,130 1,350 2,260 4,520 6,780 990 1,080 1,290 2,160 4,320 6,480 1,260 1,375 1,650 2,760 5,520 8,280 2,810 3,050 3,660 6,115 12,200 18,300 1,380 1,500 1,680 2,800 5,600 8,400 1,930 2,100 2,520 4,200 8,400 12,600 1,380 1,510 1,812 3,020 6,040 9,060 1,720 1,875 2,250 3,700 7,400 11,100 2,770 3,020 3,624 6,040 12,080 18,100 1,800 1,958 2,348 3,913 7,825 11,700 2,220 2,420 2,900 4,830 9,660 14,490 1,450 1,585 1,902 3,170 6,340 9,510 2,960 3,222 3,868 6,447 12,894 19,300 1,660 1,805 1,240 3000µ ± 20% ∆ AL values based on testing at 5 gauss in a de-gaussed state. For the cores listed here, dimensional tolerances for bare and coated cores are on pages 13.10-13.12. Page 13.12 also lists guidelines for dimensional tolerances of all toroids. Other core heights are available upon special request. MAGNETICS H 10,000µ ± 30% 2500µ ± 25% To order, add coating and material code. 13.6 W 5000µ ± 20% 2300µ ± 25% Toroids MAGNETIC DATA le (mm) Ae (mm2) Ve (mm3) WINDOW CORE WEIGHT WaAc (cm4) (g) AREA (cm2) AVA IL. C OAT INGS Toroid Core Data (con’t) 41406TC 29.5 16.9 498.0 0.400 2.7 0.064 V, Y, Z 41407TC 29.5 12.6 373.0 0.400 1.9 0.050 V, Y, Z 41506TC 30.6 10.9 332.0 0.426 1.9 0.046 V, Z 41435TC 30.1 10.8 326.0 0.386 1.8 0.042 V, Z 41450TC 35.0 12.0 421.0 0.636 2.2 0.076 V, Z 41605TC 36.8 15.3 562.0 0.620 2.8 0.094 V, Z 41809TC 41.4 40.3 1670.0 0.746 9.9 0.301 V, Z 42106TC 50.0 23.1 1150.0 1.27 5.4 0.293 V, Z 42109TC 50.0 32.6 1630.0 1.27 8.1 0.414 V, Z 42206TC 54.1 26.2 1417.0 1.48 6.4 0.370 V, Z 42207TC 54.2 32.5 1763.0 1.48 8.5 0.466 V, Z 42212TC 54.2 51.3 2776 1.48 13.5 0.756 V, Z 42507TC 61.5 37.1 2284 1.89 11.6 0.707 V, Z 42508TC 61.5 48.45 2981.0 1.89 14.9 0.898 V, Z 42908TC 73.2 37 2704.0 2.84 12.9 1.02 V, Z 42915TC 73.2 74.9 5481.0 2.84 27.6 2.10 Z 13.7 mag-inc.com Toroids Toroid Core Data (con’t) AL (mH/1000T) MECHANICAL DIMENSIONS SIZE 43113TC 43205TC 43610TC 43615TC 43806TC 43813TC 43825TC 44416TC 44715TC 44916TC 44920TC 44925TC 44932TC 46113TC 46326TC 47313TC 47325TC 48613TC mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in HIGH PERMEABILITY MATERIALS POWER MATERIALS A (OD) B (ID) C (HGT.) 30.83 1.220 32.0 1.260 36.0 1.417 36.0 1.417 38.1 1.500 38.1 1.500 38.1 1.500 44.5 1.750 46.9 1.846 49.1 1.932 49.1 1.932 49.1 1.932 49.1 1.932 61.0 2.400 63.0 2.480 73.7 2.900 3.66 2.900 85.7 3.375 19.06 0.748 15.0 0.591 23.0 0.906 23.0 0.906 19.0 0.750 19.0 0.750 19.0 0.750 19.0 0.750 27.0 1.063 33.8 1.332 31.8 1.252 31.8 1.252 33.8 1.332 35.6 1.400 38.0 1.496 38.9 1.530 38.860 1.530 55.5 2.187 12.74 0.512 4.50 0.177 10.0 0.394 14.6 0.590 6.11 0.250 12.45 0.500 25.4 1.000 15.9 0.625 15.0 0.591 15.6 0.625 15.9 0.625 19.0 0.750 31.8 1.250 12.7 0.500 24.5 0.984 12.5 0.500 25.40 1.000 12.7 0.500 R P F J 6,200 12,400 - 1,930 3,220 6,440 - 2,210 2,726 4,543 9,085 - 3,100 3,366 4,040 6,736 13,400 - 2,020 2,200 2,640 4,400 8,800 - 3,850 4,185 5,020 8,365 16,700 - 8,060 8,762 10,040 16,730 33,400 - 5,360 5,830 7,000 11,600 23,200 - 3,700 4,030 4,840 8,075 16,100 - 2,710 2,950 3,540 5,900 11,800 - 2,790 3,032 3,640 6,065 12,130 - 3,420 3,718 4,460 7,435 14,870 - 5,430 5,900 7,080 11,800 23,600 - 3,140 3,491 4,107 6,845 13,690 - 5,770 6,270 7,530 12,500 25,100 - 3,700 4,024 4,880 8,140 16,280 - 7,400 8,050 9,760 16,280 32,560 - 2,510 2,726 3,310 5,520 11,040 - 3000µ ± 20% 2,850 3,100 3,720 1,480 1,610 2,030 To order, add coating and material code. 13.8 ∆ AL values based on testing at 5 gauss in a de-gaussed state. For the cores listed here, dimensional tolerances for bare and coated cores are on pages 13.10-13.12. Page 13.12 also lists guidelines for dimensional tolerances of all toroids. Other core heights are available upon special request. MAGNETICS H 15,000µ ± 30% 2500µ ± 25% 5000µ ± 20% W 10,000µ ± 30% 2300µ ± 25% Toroids MAGNETIC DATA WINDOW CORE WEIGHT WaAc (cm4) (g) AREA (cm2) AVA IL. C OAT INGS Toroid Core Data (con’t) le (mm) Ae (mm2) Ve (mm3) 43113TC 75.4 73.6 5547 2.83 29.3 2.11 Z 43205TC 67.2 34.5 2320.0 1.77 12.9 0.611 Z 43610TC 89.7 62.6 5616 4.15 29.4 2.61 Z 43615TC 89.6 93.3 8366 4.15 44.0 3.93 Z 43806TC 82.9 56.1 4644 2.85 26.4 1.62 Z 43813TC 83.0 114.2 9462 2.85 51.7 3.27 Z 43825TC 83.0 231.0 19200.0 2.85 103.4 6.58 Z 44416TC 88.7 187.0 16600.0 2.85 80.8 5.33 Z 44715TC 110.0 142.0 15700.0 5.72 84 8.12 Z 44916TC 127 118 15010 8.99 75.3 10.4 Z 44920TC 123.0 119.0 14700.0 7.94 74.6 9.45 Z 44925TC 123.0 146.0 18000.0 7.94 91.0 11.6 Z 44932TC 127.0 236.0 30000.0 8.99 150.6 21.2 Z 46113TC 145.0 156.0 22500.0 9.93 117.3 15.5 Z 46326TC 152.0 300 45598 11.3 231 34.4 Z 47313TC 165.0 210 34771 11.9 177 25.2 Z 47325TC 165.0 424.0 71000.0 11.9 354 50.4 Z 48613TC 215.0 187.0 40200.0 24.2 203 45.2 Z 13.9 mag-inc.com Toroids Bare Core Limiting Dimensions R, P, F MATERIALS PART 40200TC 40301TC 40502TC 40503TC 40401TC 40402TC 40601TC 40603TC 40705TC 40907TC 41003TC 41005TC 41206TC 41303TC 41305TC 41306TC 41406TC 41407TC 41506TC 41435TC 41450TC 41605TC 41809TC 42106TC 42109TC 13.10 mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in W AND H MATERIALS O.D. MAX I.D. MIN HGT. MAX O.D. MAX I.D. MIN HGT. MAX 2.75 0.108 3.71 0.146 4.14 0.163 4.14 0.163 5.03 0.198 5.03 0.198 6.13 0.241 6.13 0.241 7.88 0.310 9.78 0.385 9.78 0.385 9.78 0.385 12.96 0.510 12.96 0.510 12.96 0.510 12.96 0.510 12.96 0.510 12.96 0.510 13.47 0.530 13.85 0.545 14.25 0.561 16.26 0.640 18.83 0.741 20.96 0.825 20.96 0.825 1.06 0.042 1.62 0.064 2.03 0.080 2.03 0.080 2.08 0.082 2.08 0.082 2.76 0.109 2.76 0.109 2.92 0.115 5.33 0.210 4.49 0.177 4.49 0.177 4.90 0.193 7.67 0.302 7.67 0.302 7.67 0.302 6.88 0.271 6.88 0.271 7.11 0.280 6.75 0.266 8.73 0.344 8.50 0.335 9.37 0.369 12.31 0.485 12.31 0.485 1.45 0.057 1.45 0.057 1.45 0.057 2.80 0.110 1.45 0.057 2.80 0.110 1.71 0.067 3.43 0.135 4.91 0.193 7.29 0.287 3.31 0.130 4.91 0.193 6.53 0.257 3.31 0.130 5.26 0.207 6.53 0.257 6.53 0.257 4.91 0.193 4.09 0.161 3.64 0.143 5.14 0.202 4.83 0.190 10.52 0.414 6.53 0.257 9.15 0.360 2.75 0.108 3.71 0.146 4.14 0.163 4.14 0.163 5.03 0.198 5.03 0.198 6.13 0.241 6.13 0.241 8.01 0.315 9.91 0.390 9.91 0.390 9.91 0.390 13.09 0.515 13.09 0.515 13.09 0.515 13.09 0.515 13.09 0.515 13.09 0.515 13.59 0.535 13.97 0.550 14.38 0.566 16.46 0.648 19.03 0.749 21.16 0.833 21.16 0.833 1.06 0.042 1.62 0.064 2.03 0.080 2.03 0.080 2.08 0.082 2.08 0.082 2.76 0.109 2.76 0.109 2.79 0.110 5.20 0.205 4.36 0.172 4.36 0.172 4.77 0.188 7.54 0.297 7.54 0.297 7.54 0.297 6.75 0.266 6.75 0.266 6.98 0.275 6.62 0.261 8.61 0.339 8.30 0.327 9.16 0.361 12.11 0.477 12.11 0.477 1.45 0.057 1.45 0.057 1.45 .057 2.80 0.110 1.45 0.057 2.80 0.110 1.71 0.067 3.43 0.135 5.03 0.198 7.40 0.291 3.43 0.135 5.03 0.198 6.63 0.261 3.43 0.135 5.36 0.211 6.63 0.261 6.63 0.261 5.03 0.198 4.22 0.166 3.76 0.148 5.26 0.207 4.96 0.195 10.65 0.419 6.63 0.261 9.28 0.365 MAGNETICS R, P, F MATERIALS PART 42206TC mm in 42207TC mm in 42212TC mm in 42507TC mm in 42508TC mm in 42908TC mm in 42915TC mm in 43113TC mm in 43205TC mm in 43610TC mm in 43615TC mm in 43806TC mm in 43813TC mm in 43825TC mm in 44416TC mm in 44715TC mm in 44916TC mm in 44920TC mm in 44925TC mm in 44932TC mm in 46113TC mm in 46326TC mm in 47313TC mm in 47325TC mm in 48613TC mm in W AND H MATERIALS O.D. MAX I.D. MIN HGT. MAX O.D. MAX I.D. MIN 22.48 0.885 22.48 0.885 22.48 0.885 25.91 1.020 25.91 1.020 29.52 1.162 29.52 1.162 31.50 1.240 32.52 1.280 36.50 1.437 36.50 1.437 38.87 1.530 38.87 1.530 38.87 1.530 45.22 1.780 47.65 1.876 49.84 1.962 49.84 1.962 49.84 1.962 49.84 1.962 61.85 2.435 63.89 2.515 74.68 2.940 74.68 2.940 87.00 3.425 13.33 0.525 13.33 0.525 13.33 0.525 14.98 0.590 14.98 0.590 18.49 0.728 18.49 0.728 18.49 0.728 14.50 0.571 22.50 0.886 22.50 0.886 18.28 0.720 18.28 0.720 18.28 0.720 18.28 0.720 26.23 1.033 33.07 1.302 31.03 1.222 31.03 1.222 33.07 1.302 34.67 1.365 37.10 1.461 37.84 1.490 37.84 1.490 54.28 2.137 6.53 0.257 8.18 0.322 12.96 0.510 8.18 0.322 10.27 0.404 7.68 0.302 15.63 0.615 13.26 0.522 4.63 0.182 10.27 0.404 15.24 0.600 6.53 0.257 12.96 0.510 25.91 1.020 16.26 0.640 15.27 0.601 16.26 0.640 16.26 0.640 19.44 0.765 32.26 1.270 12.96 0.510 25.38 0.999 12.96 0.510 25.91 1.020 12.96 0.510 22.69 0.893 22.69 0.893 22.69 0.893 26.17 1.030 26.17 1.030 29.77 1.172 29.77 1.172 31.75 1.250 32.77 1.290 36.76 1.447 36.76 1.447 39.25 1.545 39.25 1.545 39.25 1.545 45.60 1.795 48.04 1.891 50.22 1.977 50.22 1.977 50.22 1.977 50.22 1.977 62.31 2.453 64.34 2.533 75.19 2.960 95.19 2.96 87.63 3.450 13.13 0.517 13.13 0.517 13.13 0.517 14.73 0.580 14.73 0.580 18.23 0.718 18.23 0.718 18.23 0.718 14.24 0.561 22.25 0.876 22.25 0.876 17.90 0.705 17.90 0.705 17.90 0.705 17.90 0.705 25.85 1.018 32.69 1.287 30.65 1.207 30.65 1.207 32.69 1.287 34.21 1.347 36.65 1.443 37.33 1.470 37.33 1.470 53.64 2.112 HGT. MAX 6.63 0.261 8.31 0.327 13.09 0.515 8.31 0.327 10.39 0.409 7.78 0.306 15.83 0.623 13.39 0.527 4.70 0.185 10.39 0.409 15.37 0.605 6.63 0.261 13.09 0.5155 26.17 1.030 16.46 0.648 15.40 0.606 16.46 0.648 16.46 0.648 19.64 0.773 32.52 1.280 13.09 0.515 25.58 1.007 13.29 0.523 26.54 1.045 13.29 0.523 R, P, F MATERIALS PART 40907TC 41003TC 41005TC 41206TC 41303TC 41305TC 41306TC 41406TC 41407TC 41506TC 41435TC 41450TC 41605TC 41809TC 42106TC 42109TC 42206TC 42207TC 42212TC 42507TC 42508TC mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in W AND H MATERIALS R, P, F MATERIALS O.D. MAX I.D. MIN HGT. MAX O.D. MAX I.D. MIN HGT. MAX PART 10.16 0.400 10.16 0.400 10.16 0.400 13.34 0.525 13.34 0.525 13.34 0.525 13.34 0.525 13.34 0.525 13.34 0.525 13.84 0.545 14.23 0.560 14.64 0.576 16.64 0.655 19.21 0.756 21.34 0.840 21.34 0.840 22.86 0.900 22.86 0.900 22.86 0.900 26.29 1.035 26.29 1.035 4.95 0.195 4.11 0.162 4.11 0.162 4.52 0.178 7.29 0.287 7.29 0.287 7.29 0.287 6.50 0.256 6.50 0.256 6.73 0.265 6.37 0.251 8.35 0.329 8.12 0.320 8.99 0.354 11.93 0.470 11.93 0.470 12.95 0.510 12.95 0.510 12.95 0.510 14.60 0.575 14.60 0.575 7.68 0.302 3.69 0.145 5.29 0.208 6.91 0.272 3.69 0.145 5.64 0.222 6.91 0.272 6.91 0.272 5.29 0.208 4.47 0.176 4.02 0.158 5.52 0.217 5.21 0.205 10.90 0.429 6.91 0.272 9.53 0.375 6.91 0.272 8.56 0.337 13.34 0.525 8.56 0.337 10.65 0.419 10.29 0.405 10.29 0.405 10.29 0.405 13.47 0.530 13.47 0.530 13.47 0.530 13.47 0.530 13.47 0.530 13.47 0.530 13.97 0.550 14.36 0.565 14.76 0.581 16.84 0.663 19.41 0.764 21.54 0.848 21.54 0.848 23.07 0.908 23.07 0.908 23.07 0.908 26.55 1.045 26.55 1.045 4.82 0.190 3.98 0.157 3.98 0.157 4.39 0.173 7.16 0.282 7.16 0.282 7.16 0.282 6.37 0.251 6.37 0.251 6.60 0.260 6.24 0.246 8.23 .0324 7.92 0.312 8.78 0.346 11.73 0.462 11.73 0.462 12.75 0.502 12.75 0.502 12.75 0.502 14.35 0.565 14.35 0.565 7.78 0.306 3.81 0.150 5.41 0.213 7.01 0.276 3.81 0.150 5.75 0.226 7.01 0.276 7.01 0.276 5.41 0.213 4.60 0.181 4.14 0.163 5.64 .0222 5.34 0.210 11.03 0.434 7.01 0.276 9.66 0.380 7.01 0.276 8.69 0.342 13.47 0.530 8.69 0.342 10.77 0.424 42908TC 42915TC 43113TC 43205TC 43610TC 43615TC 43806TC 43813TC 43825TC 44416TC 44715TC 44916TC 44920TC 44925TC 44932TC 46113TC 46326TC 47313TC 47325TC 48613TC mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in W AND H MATERIALS O.D. MAX I.D. MIN HGT. MAX O.D. MAX I.D. MIN HGT. MAX 29.90 1.177 29.90 1.177 31.88 1.255 32.90 1.295 36.89 1.452 36.89 1.452 39.25 1.545 39.25 1.545 39.25 1.545 45.60 1.795 48.04 1.891 50.22 1.977 50.22 1.977 50.22 1.977 50.22 1.977 62.23 2.450 64.27 2.530 75.06 2.955 75.06 2.955 87.38 3.440 18.11 0.713 18.11 0.713 18.11 0.713 14.12 0.556 22.12 0.871 22.12 0.871 17.90 0.705 17.90 0.705 17.90 0.705 17.90 0.705 25.85 1.018 32.69 1.287 30.65 1.207 30.65 1.207 32.69 1.287 34.29 1.350 36.72 1.446 37.46 1.475 37.46 1.475 53.89 2.122 8.06 0.317 16.01 0.630 13.64 0.537 5.01 0.197 10.65 0.419 15.63 0.615 6.91 0.272 13.34 0.525 26.29 1.035 16.64 0.655 15.65 0.616 16.64 0.655 16.64 0.655 19.82 0.780 32.64 1.285 13.34 0.525 25.76 1.014 13.34 0.525 26.289 1.035 13.34 0.525 30.15 1.187 30.15 1.187 32.14 1.265 33.15 1.305 37.14 1.462 37.14 1.462 39.63 1.560 39.63 1.560 39.63 1.560 45.98 1.810 48.42 1.906 50.60 1.992 50.60 1.992 50.60 1.992 50.60 1.992 62.69 2.468 64.72 2.548 75.57 2.975 75.565 2.975 88.02 3.465 17.85 0.703 17.85 0.703 17.85 0.703 13.86 0.546 21.86 0.861 21.86 0.861 17.52 0.690 17.52 0.690 17.52 0.690 17.52 0.690 25.47 1.003 32.30 1.272 30.27 1.192 30.27 1.192 32.30 1.272 33.83 1.332 36.27 1.428 36.95 1.455 36.957 1.455 53.26 2.097 8.16 0.321 16.21 0.638 13.77 0.542 5.08 0.200 10.77 0.424 15.75 0.620 7.01 0.276 13.47 0.530 26.55 1.045 16.85 0.663 15.78 0.621 16.85 0.663 16.85 0.663 20.02 0.788 32.90 1.295 13.47 0.530 25.96 1.0225 13.67 0.538 26.924 1.060 13.67 0.538 Toroids V and Z Coated Limiting Dimensions 13.11 mag-inc.com Toroids Y Coated Limiting Dimensions and Dimensional Tolerance Guidelines R, P, F MATERIALS PART 40200TC 40301TC 40502TC 40503TC 40401TC 40402TC 40601TC 40603TC 40705TC mm in mm in mm in mm in mm in mm in mm in mm in mm in R, P, F MATERIALS W AND H MATERIALS O.D. MAX I.D. MIN HGT. MAX O.D. MAX I.D. MIN HGT. MAX PART 2.82 0.111 3.79 0.149 4.22 0.166 4.22 0.166 5.11 0.201 5.11 0.201 6.20 0.244 6.20 0.244 7.95 0.313 0.99 0.039 1.54 0.061 1.95 0.077 1.95 0.077 2.00 0.079 2.00 0.079 2.69 0.106 2.69 0.106 2.84 0.112 1.53 0.060 1.53 0.060 1.53 0.060 2.87 0.113 1.53 0.060 2.87 0.113 1.78 0.070 3.51 0.138 4.98 0.196 2.82 0.111 3.79 0.149 4.22 0.166 4.22 0.166 5.11 0.201 5.11 0.201 6.20 0.244 6.20 0.244 8.08 0.318 0.99 0.039 1.54 0.061 1.95 0.077 1.95 0.077 2.00 0.079 2.00 0.079 2.69 0.106 2.69 0.106 2.71 0.107 0.53 0.060 1.53 0.060 1.53 0.060 2.87 0.113 1.53 0.060 2.87 0.113 1.78 0.070 3.51 0.138 5.11 0.201 40907TC 41003TC 41005TC 41206TC 41303TC 41305TC 41306TC 41406TC 41407TC mm in mm in mm in mm in mm in mm in mm in mm in mm in O.D. MAX I.D. MIN HGT. MAX O.D. MAX I.D. MIN HGT. MAX 9.86 0.388 9.86 0.388 9.86 0.388 13.03 0.513 13.03 0.513 13.03 0.513 13.03 0.513 13.03 0.513 13.03 0.513 5.25 0.207 4.42 0.174 4.42 0.174 4.82 0.190 7.59 0.299 7.59 0.299 7.59 0.299 6.80 0.268 6.80 0.268 7.37 0.290 3.38 0.133 4.98 0.196 6.61 0.260 3.38 0.133 5.34 0.210 6.61 0.260 6.61 0.260 4.98 0.196 9.99 0.393 9.99 0.393 9.99 0.393 13.16 0.518 13.16 0.518 13.16 0.518 13.16 0.518 13.16 0.518 13.16 0.518 5.13 0.202 4.29 0.169 4.29 0.169 4.69 0.185 7.46 0.294 7.46 0.294 7.46 0.294 6.68 0.263 6.68 0.263 7.47 0.294 3.51 0.138 5.11 0.201 6.71 0.264 3.51 0.138 5.44 0.214 6.71 0.264 6.71 0.264 5.11 0.201 DIMENSIONAL TOLERANCE GUIDELINES OD AND ID TOLERANCES (1) (2) HEIGHT TOLERANCES R, P, F W&H MATERIALS MATERIALS R, P, F MATERIALS W&H MATERIALS Up to .099" ±.005" ±.005" Up to .099" ±.003" ±.007" .100" – .199” ±.008" ±.008" .100" – .199” ±.005" ±.010" .200" – .299" ±.011" ±.011" .200" – .299" ±.007" ±.011" .300" – .599" ±.010" ±.015" .300" – .599" ±.010" ±.015" .600" – .999" ±.015" ±.023" .600" – .999" ±.015" ±.023" 1.000" – 1.499" ±.020" ±.030" 1.000" – 1.499" ±.020" ±.030" 1.500" – 1.999" ±.030" ±.045" 1.500" – 1.999" ±.030" ±.045" 2.000” – 2.499” ±.035" ±.053" 2.500" – 2.999" ±.040" ±.060" (1) For W and H material cores 2.8” and larger in OD, add 50% to height tolerance 3.000" – 3.500" ±.050" ±.075" CORE OD’S CORE HEIGHTS (2) For cores <.300” OD, use W & H column COATING SIZE LIMITS Parylene (Y) 41406 and smaller (Minimum inductance 5% lower than listed). Grey (Z) 40907 and larger. FOR COATED CORES Allow .003” for Y finish. Allow .015” for V and Z finish. Allow .030” for voltages above 1000 up to 4000. 13.12 MAGNETICS W AND H MATERIALS DIMENSIONS (IN.) PART TVB22066A (6 pins) TVB2908TA (10 pins) TVB3610FA (14 pins) FIG FOR CORE O.D A NOM B NOM C REF D NOM E REF F TYP G TYP H NOM J REF K REF 1 0.500”-0.870” 0.748 0.425 0.472 0.138 0.189 0.236 0.295 0.216 0.216 0.079 2 0.810”-1.25” 1.063 0.748 0.630 0.197 0.276 0.590 0.197 0.295 0.320 0.138 3 1.142”-1.500” 1.409 0.819 0.433 0.197 0.276 0.630 G1 0.248 G2 0.197 0.299 0.384 0.177 These vertical mount accessories are designed to accommodate a variety of toroidal core sizes on to printed circuit board or other assemblies. (Contact Magnetics Application Engineering for new parts not shown here) FIGURE 1 For use with P/N’s 41206TC – 42212TC Toroid Hardware Toroid Mounts FIGURE 2 For use with P/N’s 42507TC – 43113TC FIGURE 3 For use with P/N’s 42908TC – 43825TC All parts Material: Phenolic UL 94 VO rated Pin Material: CP Wire Pin Diameter: .039” 13.13 mag-inc.com Toroid Hardware Toroid Mounts (con’t) DIMENSIONS (IN.) (NOM.) PART FIG A B C E F G H J FOR CORE O.D. TVH22064A 1 0.750 0.425 - 0.385 0.250 0.600 0.125 0.150 0.5" – 1.00" TVH25074A 2 1.000 0.600 0.600 0.510 0.400 0.800 0.200 0.200 0.81" – 1.14" TVH38134A 2 1.100 0.800 0.800 0.710 0.600 0.900 0.200 0.200 1.25" – 1.50" TVH49164A 2 1.400 0.900 1.270 0.810 0.700 1.20 0.200 0.200 1.5" – 2.5" TVH61134A 2 1.700 1.100 1.400 1.010 0.900 1.500 0.200 0.200 1.9" - 2.8" FIGURE 2 FIGURE 1 Material: Nylon UL 94 VO rated Pin Material: CP Wire Pin Diameter: .040” 13.14 MAGNETICS Material: Nylon UL 94 VO rated Pin Material: CP Wire Pin Diameter: .050” DIMENSIONS (IN.) PART FIG A MAX B MAX C NOM D TYP E NOM F MAX G MIN H NOM J MIN K MAX L NOM M MIN FOR CORE O.D. SMC03016A 1 0.431 0.303 0.200 0.100 0.010 0.232 0.161 0.264 0.197 0.228 0.028 0.189 <0.155 SMC06018A 2 0.636 0.409 0.300 0.100 0.012 0.409 0.301 0.449 0.301 0.240 0.024 0.205 <0.250 SMH05025A 3 0.240 0.161 0.157 0.079 0.010. 0.250 - - - 0.043 0.024 - <0.200 SMH07058A 4 0.398 0.378 0.295 0.098 0.010 0.494 - - - 0.063 0.024 - <0.310 SURFACE MOUNT HEADERS Several surface mount headers are available. See page 6.16 for sizes and dimensions. FIGURE 1 Material: L.C.P. UL 94 VO rated Pin Material: Phosphor Bronze FIGURE 3 Material: Phenolic UL 94 VO rated Pin Material: Phosphor Bronze FIGURE 2 Toroid Hardware Toroid Cups and Headers Material: Phenolic UL 94 VO rated Pin Material: Phosphor Bronze FIGURE 4 Material: L.C.P. UL 94 VO rated Pin Material: Phosphor Bronze 13.15 mag-inc.com Toroids Notes 13.16 MAGNETICS Section 14 General Information 14.1 Definitions SYMBOL UNITS µ — DEFINITION Permeability—The ratio of magnetic flux density in gausses to magnetic field strength in oersteds. µ=B H µi — Initial Permeability—The value of the permeability at very low magnetic field strengths. µi = lim B HÞO H µe — AL millihenries per 1,000 turns or nanohenries/turn2 TC /˚C Effective Permeability—If a magnetic circuit is not homogeneous (i.e., contains an air gap), the effective permeability is the permeability of a hypothetical homogeneous (ungapped) structure of the same shape, dimensions, and reluctance, that would give the inductance equivalent to the gapped structure. Inductance factor—In a wound core, the inductance per unit turn when L is in henries. More often, when L is expressed in millihenries, AL is the inductance as measured using a thousand turn coil. When calculating for other turns, use: L (mH) = ALn2/1,0002. Temperature Coefficient—The relative change in permeability per ˚C when measured at two different temperatures. TC = µ2 – µ1 µ2 (T2–T1) TF /˚C Temperature Factor—The temperature coefficient of a material per unit of permeability. TF = TC µi TC e DA /˚C Effective Temperature Coefficient—The actual temperature coefficient of a magnetic structure whose material permeability has been reduced to µe by gapping. TCe = TF x µe — Disaccommodation—The relative decrease in permeability of a magnetic material with time after magnetic conditioning (demagnetization). t2 t1 = time from demagnetization to 1st measurement DA = ∆µ µ1 log t1 t2 = time from demagnetization to 2nd measurement For each decade of time, when t2 = 10t1 DF 14.2 MAGNETICS — DA = ∆µ µi Disaccommodation Factor—The disaccommodation of a material per unit of permeability. DA DF = µi UNITS DEFINITION DFe — Effective Disaccommodation Coefficient—The actual disaccommodation of a magnetic circuit whose material permeability has been reduced to µe by gapping. DFe = DF x µe Q — Q Factor—The efficiency of an inductor, that is the ratio of series inductive reactance to loss resistance. Q = qLS RS tand — Definitions SYMBOL Loss angle—Deviation from ideal phase angle (90˚) due to losses. tand = RS = 1 qLS Q tand µi — Relative loss factor—Losses per unit of permeability. Figure of merit of a material. tand = 1 µi µiQ Ch /gausses Hysteresis coefficient—The coefficient in the Legg** equation which separates the hysteresis losses from the eddy current and residual losses. RS = C hB + C ef + C r µifLS This coefficient can be evaluated by noting the variation of series resistance with B. Ch µi2 /gausses Relative Hysteresis Factor. This hysteresis coefficient normalized to unit permeability so that it is strictly a material property. Ch(e) /gausses B Bmax H Hc gausses gausses Teslas oersteds oersteds L amp-turns/m henries Effective Hysteresis Coefficient—The actual hysteresis loss in a magnetic structure whose permeability has been reduced to µe by gapping. Ch(e) = Ch x µe2 µi2 2 Flux density—The magnetic flux in maxwells per cm of cross sectional area. The flux density at high field strengths (normally 25 oersteds). 104 gausses = 1 Tesla Field strength—The externally applied magnetizing field in oersteds. Coercive force—The reverse magnetic field needed to reduce a magnetically saturated structure from remanence to zero magnetic induction. 1oersted = 79.5 amp-turns/m Inductance—The magnetic flux linkages in maxwells-turns per ampere of magnetizing current. L= –N df di le cm Ae cm2 Ve Tc cm3 ˚C Effective magnetic path length—In a structure containing a non-uniform cross section, the effective magnetic path length is that length of a similar structure with uniform cross section which is equivalent to the first for purposes of magnetic calculations. Effective cross-sectional area—In a structure containing a non-uniform cross section, the effective magnetic cross section is the area of a structure with uniform cross section which is equivalent to the first for purposes of magnetic calculations. Effective magnetic volume. Curie Temperature—Temperature at which a ferromagnetic material loses its ferromagnetism and becomes paramagnetic (µe approaches 1). **V.E. Legg, Magnetic Measurements at Low Flux Densities Using the Alternating Current Bridge, Bell System Technical Journal, 15, 39 (1936) 14.3 mag-inc.com References 1.* Handbook of Modern Ferromagnetic Materials Alex Goldman Klywer Academic Publishers, Norwell, MA 02061 2.* Magnetic Core Selection for Transformers & Inductors, Colonel Wm. T. McLyman Marcel Dekker, 270 Madison Avenue, New York, NY 10016-0602 3.* Transformer and Inductor Design Handbook (second edition) Colonel Wm. T. McLyman 270 Madison Avenue, New York, NY 10016-0602 4.* Fundamentals of Power Electronics Robert Erickson Chapman and Hall, New York, NY 10003 5.* Introduction to Power Electronics Daniel Hart Prentice-Hall, Upper Saddle River, NJ 07458 6.* Resonant Power Converters Marian Kazimierczok John Wiley & Sons, Inc., New York, NY 10158 7.* Power Switching Coverters Simon Ang Marcel Dekker, 270 Madison Avenue, New York, NY 10016 8.* Designing Magnetic Components for High Frequency DC-DC Converters Colonel W.T. McLyman Kg Magnetics, Idyllwild, CA 92549 9.* Elements of Power Electronics Philip Krein Oxford University Press, Cary, NC 27513 10.* Modern DC-DC Switchmode Power Converter Circuits (reprint) Severns & Bloom, e/j Bloom associates inc. 11.* Switchmode Power Conversion K. Kit Sum Marcel Dekker, 270 Madison Avenue, New York, NY 10016-0602 12.* Applications of Magnetism, J.K. Watson, (self-published). 13.* Switching Power Supply Design (second edition) A.I. Pressman McGraw-Hill Publishing Co., 1221 Avenue of Americas, New York, NY 10020 14.* EMI Filter Design R. Ozenbaugh Marcel Dekker, 270 Madison Avenue, New York, NY 10016-0602 15.* Handbook of Switch Mode Power Supply Design K. Billings McGraw-Hill Publishing Co., 1221 Avenue of Americas, New York, NY 10020 16.* Handbook of Transformer Applications (second edition) W. Flanagan McGraw-Hill Publishing Co., 1221 Avenue of Americas, New York, NY 10020 17.* Practical Switching Power Supply Design, Marty Brown Academic Press Inc., San Diego, CA 92101 14.4 MAGNETICS 18. Modern Ferrite Technology Alex Goldman Van Nostrand Reinhold, 115 Fifth Avenue, New York, NY 10003 19. Power Line Filter Design for Switch-Mode Power Supplies Mark J. Nave EMC Services, P.O. Box 2504, Huntsville, AL, Telephone 205-461-0241 20.* Solid-State Power Conversion Handbook R. Tarter John Wiley & Sons Inc., 605 Third Avenue, New York, NY 10158 21.* Power Electronics: Converters, Applications & Design (second edition) N. Mohan et. al. John Wiley & Sons Inc., 605 Third Avenue, New York, NY 10158 22.* Power Supply Cookbook Marty Brown Butterworth - Heinemann, 313 Washington Street, Newton, MA 02158 23.* Designing Magnetic Components for High Frequency DC-DC Converters Colonel Wm. T. McLyman KG Magnetics Inc., P.O. Box 3703, 26504 Crestview Dr., Idyllwild, CA 92549, Telephone 909-659-4548 24.* Pulse Width Modulated DC-DC Converters Keng Wu Chapman and Hall, New York, NY 10003 25.* Power Electronics-Principles & Applications Joseph Vithayathil McGraw Hill Inc., 1221 Avenue of Americas, New York, NY 10020 26. MMPA Publications of Soft Ferrites PC 110 Pot Core Standard UEI 310 U, E and I Core Standard FTC 410 Toroid Standard Soft Ferrites, A User’s Guide Available from: Magnetic Materials Producers Association, 8 South Michigan Avenue, Suite 1000, Chicago, IL 60603, Telephone 312-456-5590, Fax 312-580-0165 *Available from: e/j Bloom associates inc., 115 Duran Drive, San Rafael, CA 94903-2317 Phone (415) 492-8443 Fax (415) 492-1239 email ejbloom@compuserve.com http://www.ejbloom.com ADDITIONAL MAGNETICS FERRITE LITERATURE CG-01 - A Critical Comparison of Ferrites with other Magnetic Materials FC-S1 - Ferrite Material Selection Guide FC-S2 - EMI-RFI Filter, Common Mode Filter - Material Selection FC-S3 - Qcurves for Ferrite Cores FC-S4 - Step Gap E-Core Swing Chokes FC-S7 - Curve Fit Equations for Ferrite Materials FC-S8 - Designing with Ferrite Planar Cores CG-2 - Material Selection Charts for Frequency, Temperature, Geometry, Stability PS-01 - Cores for SMPS CG-03 - Cores for Flybacks HED-01 - Cores for Hall Effect Devices POWDER CORES Powder cores are excellent as low loss inductors for switched-mode power supplies, switching regulators and noise filters. Most core types can be shipped immediately from stock. Molypermalloy powder cores (MPP) are available in ten permeabilities ranging from 14 through 550, and have guaranteed inductance limits of ±8%. Insulation on the cores is a high dielectric strength finish not affected by normal potting compounds and waxes. Thirty sizes include I.D.s from 0.070” (1.78 mm) to 1.938” (49.2 mm) and O.D.s from 0.140” (3.56 mm) to 3.063” (77.8 mm). Standard cores include either temperature stabilized (as wide as -65° C at 125° C for stable operation) or standard stabilization. High Flux powder cores have a much higher energy storage capacity than MPP cores and are available in six permeabilities from 26µ through 160µ. High Flux cores a re available in sizes identical to MPP cores. Kool Mµ® powder cores have a higher energy storage capacity than MPP cores and are available in five permeabilities from 26µ through 125µ. Kool Mµ toroids are available in sizes identical to MPP cores, and this material is also available in a number of E-core sizes. Permeability for Kool Mµ E-cores is from 26 to 90 and sizes are tooled ranging from the EF 12.6 to the Metric E80 size. MPP THINZ® are extremely low height (<1 mm) self-shielded power inductor cores, allowing finished inductor heights in the 1.5 mm to 2mm range. THINZ come in 5 sizes with O.D.s ranging from 0.120” through 0.310” and four permeabilities: 125µ, 160µ, 200µ and 250µ. Miniature Tape Wound Bobbin Cores are manufactured from Permalloy 80 and Orthonol ultra-thin tape (0.000125” to 0.001” thick). They are available in widths from 0.031” to 0.250” (wider on special request). Wound on non-magnetic stainless steel bobbins, core diameters are available down to 0.050”, with flux capacities as low as several maxwells. Magnetics’ sophisticated pulse test equipment reproduces most test programs and can measure accurately in the millivolt-microsecond region. Applications include: magnetometers, flux gates, oscillators, inverters and magnetic amplifiers. For further information view the Bobbin Core Design Manual at www.maginc.com. RAPID PROTOTYPING SERVICE Magnetics' world-class materials offer unique and powerful advantages to almost any application. An even greater competitive edge can be gained through innovations in new core shapes and custom geometries, and Magnetics is poised to help. Our Rapid Prototyping Service can quickly make a wide variety of core shapes in ferrite, MPP, High Flux, or Kool Mu®. The time between receipt of your drawing and delivery of the parts to you is usually less than 10 days. This quick turnaround time results in a shorter design period, which gets your product to market faster. Plus, our application engineers may be able to provide design assistance that could lead to a lower piece price. To learn more about how our Rapid Prototyping Service can help you shorten your design cycle, contact a Magnetics Application Engineer. Other Products Other Products from Magnetics For further information view Powder Cores Design Manual at www.mag-inc.com. STRIP WOUND CORES Tape wound cores are made from high permeability alloys of nickel-iron, grain oriented silicon-iron. The alloys are known as Orthonol®, Alloy 48, Square Permalloy 80, Supermalloy and Magnesil® . Cores are available in more than 50 standard sizes. For a wide range of frequency applications, materials are produced in thicknesses from 1/2 mil(0.013 mm) through 14 mils (0.356 mm). Cases are robust nylon boxes, rated for 200° C continuous operation and 2000 voltage minimum breakdown. Applications include: magnetic amplifiers, reactors, regulators, static magnetic devices and current transformers. For further information view the Tape Wound Core Design Manual at www.mag-inc.com. 14.5 mag-inc.com General Information Notes 14.6 MAGNETICS www.mag-inc.com Visit MAGNETICS’ website for a wealth of easy to access information on soft magnetic cores and materials… All product specifications for MAGNETICS’ ferrite cores, powder cores and strip wound cores can be found quickly by using the menu driven product locator. MAGNETICS’ Digital Library contains all of the company’s technical bulletins, white papers and design manuals, which can be viewed on-screen or downloaded. The Software section of the website provides access to the MAGNETICS’ software design aids for designing Common Mode Filters, Current Transformers, Inductors and MagAmps. Contact information for MAGNETICS’ global distribution network, including access to STOCKCHECK, an easy way to check distributor inventory via the web. CONTACT MAGNETICS P.O. Box 11422 Pittsburgh, PA 15238-0422 Phone: 412-696-1300 or 1-800-245-3984 Fax: 412-696-0333 email: magnetics@spang.com web: www.mag-inc.com ©2005 MAGNETICS P.O. Box 11422 Pittsburgh, PA 15238-0422 Phone: 1.800.245.3984 Fax: 412.696.0333 www.mag-inc.com magnetics@spang.com
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