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There are two baslc naterial groups of Iron Powders cores. The Carbonyl Irons
and the Hydrogen Reduced lrons.
The Carbonyl Irons are especially noted for their excellent stabllity over a wlde
range of flux levels and temperatures. Their perrneability range is from one to
35 mu they can offer excellent rQr factors up to more then 200 MHz. They are
widely used for broadband lnductors, especially in higher power applications.
The Hydrogen Reduced Irons have higher permeabilities up to 90 mu. This group
will have somewhat lower rQr and they are rnainly used for EI{I filters, low
frequency chokes, and lnput and output filters for switched mode power supplies,
Toroidal cores are self shielding and it is not necessary to isolate or shield a
them to Drevent cross talk or feedback, Each Iron Powder core an Ar value listed
in uh/10b turns and can be found elsewhere in this paper. Turns for a desired
lnductance may be calculated by using the given Ar. value and the formula below.
MATERIAL#0 (u=1) Most conmonly used for frequencies above 200 MI{2. Available i.n
toroidal form only, Inductance vs. turns nay vary according to winding technique.
MATERIAL/11 (u=20) A Carbonyl 'Cr rnaterial very similar to material /13 except
that it has higher volune resistivity and better stability. Available in both
toroidal form and shielded coil form.
MATERIAL /i2 (u=10) A carbonyl rEr iron powder naterial having high volume
resistivity and offers high rQ' for the I to 30 MIIz. frequency range. Available
in both toroidal and shielded coil forrns.
MATERIAL//3 (u=35) A carbonyl rHPr rnaterial having excellent stability and good
rQr for the lower ftequencles frorn 50 KHz. to 500 KHz. Available in toroidal and
shielded coil forms.
MATERIAL/16 (u=8) A carbonyl rSFr naterial very similar to /12 material but has
an improved rQr for frequencies 20 MIlz to 50 MHz. Available ln toroidal core form
and shielded coil form.
MATERIAT/110 (u=6) A powdered iron rWr material. Offers good rQr and high
stability for frequencies 40 Mhz to 100 MHz. Available in both toroidal form and
shielded coil form.
MATERIAT//12 (u=3) A Synthetic Oxide material which will provide good rQrand
moderate stability for frequencies 50 Mhz to 100 MHz. Available in toroidal fortn
only.
MATERIAL#15 (u=25) A carbonyl rGS6r material. I{as excellent stability and good
tQ'. A good choice for corrnercial broadcast frequencies where good rQr and
stability are essential. Available in toroidal form on1y.
MATERIAL/117 (u=3) This is a carbonyl material very slnilar to that of the of
the /112 naterial.
'Qt. It has greater temperature stabllity but the cost of sonewhat
looer Available in all shlelded coil forros. In the toroidal forn, only
sizes T-12 through 1-50 are available.
MATERIAL/126 (u=75) A Hydrogen Reduced material, Has highest perneability of
all of the iron powder materials. Used for FII filters and DC chokes, The 1126
material is very sinilar to the older ll4l material but provides an extended
frequency range. Available in all toroidal core sizes.
IF'ON POWDER TOROIDAL COFTES
Ptr5zsl-ea-1 Dl-mensions
Core outer Iruler Height Mean Cross Core outer Imer Height Mm Cross
Size diu. dia. Igth. set, size dim dim Igt!. sect.
\/ (in) (in) (in) (cn) f.r2l (1n) (in) (in) (cn) ("r2)
T- L2 .LZ5 .062 .050 0.75 .010 T-130 1.30 .78 .437 8.29 0.73
I- 16 .160 .078 .060 0,95 .016 T-157 1.57 .95 .570 10.05 1.14
T- 20 .200 .088 .070 1.15 .025 T-184 1.84 .95 .710
t- 25 .250 ,120 .096 1.50 .042 r-200 2.00 1.25 .550 t2,97 1.33
T- 30 .307 .151 .128 1.83 .065 T-2004 2,00 1.000 12,97 2.42
T- 37 .375 ,205 .128 2.32 .0i0 T-225 2.25 1.40 .550 14,56 1,50
T- 44 .440 ,229 ,r59 2.67 ,107 r.-2254 2.25 1.40 1,000 14.56 2.73
T- s0 .500 .300 .190 3.20 ,121 T-300 3.00 L,9Z .500 19.83 1,81
T- 68 .690 .370 .190 4.24 .196 T-300A 3.00 1,92 1.000 19.83 3.58
r- 80 .795 .495 .250 5.15 ,242 1-400 4.00 ? t( ,650 24.93 3.66
T- 94 ,942 .560 .3L2 6.00 .385 T-400A 4,00 2.25 1.000 24.93 7,43
T-106 1.060 .570 .437 6.50 .690 T-500 5,20 3.08 .800 33.16 5.46
cor6 26 Mlx 3 illx 15 Mix 1 Mlx 2 ilix 6 illx 10 Mix 12/1i Mlx 0 ilix
Size Yel-Iih cray Rd-I,lh Blue Red Ye1low Black Grn-Wh Tan
\ / u = 7 5 u = 3 5 u = 2 5 u = 2 0 u = 1 0 u = 8 u = 6 u . 3 , 5 u = 1
I'lhz> to1.0 ,05-,5 ,r-2. .5-5. 1-30 3-50 5-100 20-200 50-300
m - not available. Noter #12 mterial will eventually be superseded by the #U mterial.
Irorr Porvder lforoidaf- Cores
CHARTS
COEFFICIENT
TEMPERATURE
COEFFICIENTCURVS,
TTMPERATURE TEMPERATURE CURW!
COEFFICICNT
//
c
I
s
T
zeom./lc -
, r t*tor'tot , 2 M.ht.l ts pF /
oc -
370pFl:c - -
, 3 Motoriar , 6 t#brrol 35 Fm / "c -----
p$l-c --'- -
, 15trt.rlol190
TEMPENATURI
COEFFICIENT
COCFFICIENT
TEMPETATURE CURVS
l-r
s \
a.-
Moteriol
# g (croy)
# 151na
a wh) -
# t (slue)
# z (nea)
# o (yettow)
# to (slock).
# t7 (Blu"
& iel.)
- ' ( ' " ' ) - ,Tl -l ll l l l
Freq.(MHz) .05 .l .5 l. 3. 5. l0 30 50 100 2N 300
CoPPer Wj-re Tabae
40 1
.003 10 3 8 20. 1 0 0 7. 7
0
T-25 I 1 1 3 4 5 7 1l 15 2t 28 37 48 62 79 101
T-30 1 1 3 4 5 7 11 15 2l 28 37 48 62 78 101r29
"t-37 I 3 5 7 g t2 17 23 31 41 53 67 87 110 140 r77
rQ' CIJR\/ES
200
190 Wire
20 19 1.63
180 22 25 2.64
24 34 4.72
IE 42 1.20
170 28 62 14.40
30 82 25.20
160 3'l 92 31,40
J ' r ' r - ! l _ . .
13 l5 17 19
mo Mlx-3 Mlx - t0
Bhck- 'W
,oor-,.e.!,@-r,16 ,.^. liil;Jil,l-r, r., ptrmCitiry - 6
_--------- "r
"6;s-'sTT.\"
!@-! ,20 ,,-
-"o. uI
-#fe--ii,
'-fii-1" t'l:^*
<6 l3---i!. r
l$
Mtx-2
R l d- ' E
Psrmbilitv- l0 l?0
tao
ts
l&
l@ t@
AC LINE FILTER.S arrd DC CIIOKES (* 26 liaterial)
High rQt inductors are no longer required for energy storage applications, in
fact low rQr actually helps damp high frequency oscillatlons. The 1126I:.on
Powder materiaL is ideally suited for these applications since it conbines low
tQr, good frequency response, and high energy capabilities.
In 60 Hz. line filter applications, the high frequency to be filtered falls into
two categories: (1) Cornnron-modenoise and (2) Differential-node noise. The
conmon-modenoise is in relation to earth ground and is corrnon to both lines'
Dlfferential mode noise is the noise between the two lines.
Iron Powder cores are not recorotended for Conmon-mode noise filters. Ihey are
usually constructed on a high permeability I'ERRITE core wlth a bifilar winding.
This allows the 60 Hz. flux generated by each line to cancel withln the core.
The Iron Powder /126 rnaterial is ideal for Differential-mode filters' since the
core must be able to support a significant arnount of 60H2. flux without
saturating. The AC saturation characterlstlcs of the /126 rnaterial (Fig. B) and
core loss infornation (3ig. C) can be seen below. Notice how the perroeability
lnltial-ly increases wlth AC excitation. This effect allows greater energy
storage in 60 Hz. applications.
r26.Mor.rror
^^,],] LlLl_ i I I I ric,*,i,
AC FLUXtrNSIT
26 MAftXAT
r. kqwrcy ( Hdr)
to I IItJl_lfll","
^
r r o u o - t " lt l l l l I
Perccntpermcobility vs, mognetizing force l
s
1.p6664 (Amp*rd
2
Is
m
Irorr Por^rder lforoida.]- Cores
DC Chokes
- TURNS(NI)
AMPERE
DC ENERGYSTORAGE
(I2U2)
Zzoo
z
''
l@
:
< 5 0
650 uh 220 fi 8?.5 uh 47,Z t*l 20.0 uh 10.2 tfi 5.3 uh 2,6 uh
T-9t+-26 123 turn 75 turns 52 tum 40 turu 27 tms 20 turu 14 turns 10 tms
1660 uh 575 uh 23l lltl 127 uh 55,0 uh 28.0 uh 16,5 dr 10.4 uh
T-1.30-26 173 tms 107 tms 75 tlm 58 tm6 40 tums 30 t|m 23 turns 1.7 tms
3200 uh 1100 uh 438 uh 244 uh 106 uh 55.6 dr 32 uh 16.4 uh
t-L57-26 213 tms 122 turns 93 t|,ff 73 tums 50 tlJm 38 tums 29 turns 22 tllru
5600 rft 1950 rtr 788 uh 439 uh 190 uh 99.6 uh 57.5 uh 29.3 uh
T-184-26* 213 tl'm I22 tums 93 t|ffi 73 turns 50 tm6 38 tlIru 29 tms 22 tuns
8600 uh 2300 uh 938 uh 528 rtr 230 ttll 127 uh 72.5 uh 40 uh
T-225-26 3U tuffi 198 tms 139 t|,ff 110 tums 77 turns 60 tm 46 tms 35 turns
22.4 tu 7850 uh 3120 uh 1750 uh 750 uh 418 uh 250 uh 129 uh
T-300A-26tr 435 tms 272 tms 190 turns 151 tffi 105 tums 82 turns 63 turns 44 tums
51.0 mh 17.5 dr 7120 ft AO0Ouh 1760 uh 951 uh 550 uh 293 uh
I-400A-26* 507 tms 317 tlm 223 tms U6 tl,ff 122 tms 95 t|ffi 73 tms 57 turns
Note: * size not shom on above cwe chart, :l* l{ire slze based on }bx. tenD. rise 4oE0 C.
Irorr Por^rder Toroidaa Cores
AC Line Filters
IO
l||tllltilll,u_ 50,m lm,m 2@,m
Ac INIRGY tIoMG[ - rru? (ui.oi-t,
ACAnps > lAnp 2 Anps 4 Anps 6 AEps 10 Arps 15 tups 20 Anps 30 Anps
Wlfe size > 28 AIIG 24 AWG 21 Ar,rG 19 AllG 15 AI{G 13 ATJG L1 AltG 9 AlrG
Part\/No
130 uh 50,0 uh L5 llll 6.7 ult 2.4 uh 1.1 uh '60 uh .07 uh
L''t -Lo'
41 tms 27 tms 1.5 tms 10 turns 6 turns 4 turns 3 tums I tm
13.6 nh 4650 uh 1810 uh 806 ft 290 uh 129 ubh 72.5 uh 32.2 utr
r-rf,/ -zo
213 tms 139 tms 93 turns 62 tms 37 turns 25 tums 18 tuns 12 tums
Note: rt Size not shom on above cwe chtrt. ,$r t.lire sizg based on lGx. lemp. rise 400 C.
POWER. CONSIDERATIONS (rP md Ferrite)
Iron Powder cores (low perrneability) are superior to the Ferrite material cores
for high power inductors for this reasoni Fewet turns will be required by the
Ferrlte type core for a given inductance. When the sane voltage droP is applied
across a decreased nunber of turns, the flux density will increase accordingly.
To prevent the flux density from increasing when fewer turns are used, the flux
drive will have to be decreased.
Either core material can be used for transformer applications, but both will
require rtrade-offsr. Ferrite cores will require fewer turns and will couple
better, whereas the Iron Powder cores will require more turns and not couple as
well but will tolerate more power and are more stable.
The equation for \.* and a sample calculation are shown below: The sanple
calculation is based on a frequency of. 7 MHz, a peak voltage of 25 volts' a
primary winding of 15 turns, and a cross-sect, area of 0'133 cnz (as per data
sheet). From above guide-lines, Bru* at 7 MHz should be not more than 57 gauss,
Eop = aPPlied Peak RMSvolts
R = E p p' lo2 = 25i loo A:' = cross-sect. area (cmz)
"mox - +u gouss
N- = number of wire turns
4 . 4 4 A cN | 4,44x0.133x15x7
f = frequency (l"tltz)
This hypothetical toroid core will have a flux density of 40 gauss. This is well
wlthin the above guidelines to prevent overheating,
Core saturation is affected by both AC and DC signals, Saturation will decrease
the permeability of the core causing it to have impaired performance or to become
inoperative. The safe operating total flux density for nost Ferrites is
typically 2000 gauss, while the Iron Powdets can tolerate up to 5000 gauss.
Both roire heating and magnetic action within the core will contrlbute to the
tenperature rlse of the coil. This can be calculated with the equation belowi
[lt:YIg'P"t9lI t'iylI
..-l.sss
rise oC =
Temperorure | I
oreo ( cmr )
Surfoce
L J
If the operating temperature (ambient temperature + temperature rise) exceeds
100oC when used internittently, or nore that 75uC if used contlnuously, a larger
size core or/and a heavier gauge wire should be selected.
Irorr Powrder Material-s
SATUMTION
ond FLUXDENSIry
Factors affecting power capability vill vary with operating conditions. Core losses are lowet at low
frequencies md 1ow power 1eve1s, but increase rapidly as either is increased.
Core losses cil crte overheating, which in turn will affect tfie saturation point. Milim flu
density cil be calculated vith the Faraday law md Anperes Law, both of which are shom below:
1m
s e 0
g
5 8 0
c
d 7 0
t
'E oo
g i l
g
{l)
30
m
10
10