Ferro Manual 09

8/17/2019 Ferro Manual 09

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FERRO 1

OPTIMIZED PROGRAM SERVICE, LLC.

Electro-Magnetic Design Using Advanced Computer Techniques

[email protected]

[email protected]

440-238-0700

FERRO

PROGRAM DESCRIPTION AND OPERATING INSTRUCTIONS

I. INTRODUCTION

FERRO is a comprehensive program for developing designs for constant voltage

ferroresonant transformers for power supplies, battery chargers, line-stabilizers and powerconditioning applications. FERRO designs both standard two-coil and three-coil (harmonically

compensated) type transformers. Many of the features used in other OPS programs are included

in FERRO, such as automatic core and conductor selection.

II. INPUT REQUIREMENTS

For entry of design information, See Page 3.

DISCLAIMER

This program and its documentation have been subjected to normal field testingprocedures. Optimized Program Service, llc. makes no warranty, expressed or implied, as to the

documentation and the performance of the program. Users are expected to make the final evaluation

as to the value and correctness of the results obtained for their specific applications.


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FERRO 2

TABLE OF CONTENTS PAGE

MAIN MENU 3

GENERAL DESIGN DATA (2 COIL) 4

GENERAL DESIGN DATA – COOLING DUCTS 5

GENERAL DESIGN DATA – CORE 6 – 8

PRIMARY – WINDING DATA 9 – 10

RESONANT WINDING DATA 11

SECONDARY 1 – WINDING DATA 12

COMPENSATION WINDING DATA 13

CONSTRUCTION 14

PROGRAM EXECUTION 15

GENERAL DESIGN DATA (3 COIL) 16

LAMINATION SIZE TABLE 17

PRIMARY HIGH TAP – WINDING DATA 18

THREE-COIL FERRO CORE/COIL STRUCTURE 19

CORE STRUCTURE LAYOUT/VIEW PIECES 20


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FERRO 3

MAIN MENU

IF NEW DESIGN IS BEING STARTED OR EXISTING DATA IS BEING RUN:

••••Select “BEGIN/REVIEW DESIGN IN ENGLISH UNITS”

INDUCTOR proceeds to General Design Data, Page 4, using English values.

••••Select “RETRIEVE DESIGN DATA” to retrieve an existing design file.

••••Select “GENERATE DESIGN PRINT OUT FROM EXISTING DATA”

to obtain a design.

••••Select “MODIFY ” to modify design input data.

••••Select “TERMINATE” to exit the program.


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FERRO 4

GENERAL DESIGN DATA (2-COIL)

FREQUENCY: Frequency of input voltage in hertz.

CONFIGURATION: Select 2-Coil or 3-Coil FERRO.

NO. OF SECONDARY WINDINGS: Enter number of secondary (output) windings.Eight (8) are permitted.

***** NOTE: See Page 15 for 3-coil FERRO.


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FERRO 5

GENERAL DESIGN DATA – COOLING DUCTSCOOLING DUCTS: Spaces in coils that permit air to flow parallel to the coil axis.

INTERNAL DUCTS: EXTERNAL DUCT:

Ducts are placed Duct is placed betweenwithin winding only winding and core

BOTH: Ducts both within winding and between winding and core.

INTERNAL DUCTS THICKNESS: Radial thickness of duct opening.

EFFECTIVENESS: Percent of duct free from obstruction , such as leads.

EXTERNAL DUCTS# OF LOCATION: Enter number of required duct locations.LOCATIONS: Enter number of winding UNDER which duct is to be located.

(2 indicates duct under second winding, etc.)

THICKNESS: Radial thickness of duct opening.

EFFECTIVENESS: Percent of duct free fromobstruction.

TYPE

END: Ducts on ends of coils outside core window. END DUCTS FULL DUCTS

FULL: Duct around coil.


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FERRO 6

GENERAL DESIGN DATA - CORE

LAM. TYPESCRAPLESS: Standard scrapless EI laminations (User must enter all core dimensions.)

FR: Ferroresonant lamination shapes. (See Page 17)

STRIP: Strip lamination (all core dimensions must be entered.)

IRON GRADE: M Grade of steel.

Y/T RATIO: Ratio of yolk or ends of lamination to tongue width. L/T RATIO: Ratio of lamination outside return legs to tongue width.

THICKNESS: Thickness of individual lamination in inches.

STACK FACTOR: Proportion of lamination stack that is actually iron.

**NOTE: If Iron Grade is selected as SPECIAL: MU FACTOR: Permeability factor used in inductance calculation. (Entered as relative number

such as 1.1 for M6, 1.3 for M19 and M22, or 1.4 for M27).

TW (watts/lb.): Average core loss of the magnetic structure in watts/pound.

POWER FACTOR: Enter power factor, usually -.97 for M6 and -.9 for non oriented grades.

DESCRIPTION: Material grade description.

WEDGE: Space (in inches) allowed on each side of core stack to insert wedges forsecuring coils to core.

SPACE: Space (in inches) on each side of the tongue for mechanical clearance.

WNDG FORM THK: Thickness (in inches) of insulation between core and the first layer of wire.


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FERRO 7

GENERAL DESIGN DATA – CORE (PAGE 1-CONTINUED)

PRI. MAX B: Flux density of iron under primary winding at highest input voltage (in kilogausses).

SEC. MAX B: Flux density of iron under secondary winding to be attained during regulation(in kilogausses).

**NOTE:A Zero (0) entry for either “PRI. MAX B” or “SEC. MAX B” will result in values to be selected by

FERRO from the following table:

IRON GRADE PRI. MAX B SEC. MAX B

M6 19.00 20.80

M19 18.01 19.85

M22 17.40 19.25

M27 17.00 18.80

NET END ALLOW: Net difference between coil lengths and available window length (in inches).This will be subtracted from each window.

SEC. POSITION: Position of the window length, minus shunt stack, allocated to the secondarycoil. If zero (0) entered FERRO will use .67 (2/3 of the available window

length would be allotted to the secondary coil and 1/3 to the primary coil.)

SHUNT AREA RATIO: Ratio of total shunt area to core cross-sectional area.


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FERRO 8

GENERAL DESIGN DATA – CORE (PAGE 2-CONTINUED)

CORE DIMENSIONS:

PROGRAM TO DETERMINE

ALL: FERRO will select complete core from core Table (See Page 17)

STACK: FERRO will use values entered for T, H and W and will determine STACK(S).NONE: FERRO will use values entered by user for T, S, H, and W.

T: Lamination center-leg in inches.

S: Stack of lamination entered in inches.H: Narrow dimension of lamination window entered in inches.

W: Wide dimension of lamination window entered in inches.

WINDOW LENGTH:

CALC: If program to calculate window length.

ENTER: If user to enter Wp, Ws (For 2-Coil) (See Page 16 For 3-Coil).Wp: Window length of primary coil.

Ws: Window length of secondary coil.

CORE NAME: Enter any name or part number to identify core.

SHUNT ID: Description of shunt for printout purposes (max. 8 characters).


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FERRO 9

PRIMARY – WINDING DATA

NO. OF PRI: Possible entries are

ONE SINE-WAVE INPUT: One primary with sine wave input.

TWO SINE WAVE INPUTS: Two identical primaries with sine wave input.ONE SQ-WAVE INPUT: One primary with square wave input.

SQ. WAVE/SINE-WAVE: One primary with square wave input and one primary with sine waveinput.

SEPARATE HI-TAP: (See Page 18).

LO VOLTS: Lowest value of input voltage on primary at which regulation is to be maintained.

NOM VOLTS: Nominal voltage on primary winding.

HI VOLTS: Highest value of input voltage on primary at which regulation is to be maintained.

TEST (KV): Dielectric test voltage in kilovolts.

****NOTE: For worst-case evaluation, enter nominal voltage as low-line voltage. For low-linevoltage, enter slightly less to insure regulation.


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FERRO 10

PRIMARY WINDING DATA (PAGE 2 - CONTINUED)

WIRE TYPE: Select Copper (CU) or Aluminum (AL). WIRE SHAPE- RD : Round wire - enter as AWG wire size.

SQ : Square wire - enter as AWG wire size.

RG : Rectangular wire - enter as thickness and width. FOIL : Foil or Strip - enter as thickness and width.

****NOTE: A Zero (0) entry for thickness will prompt FERRO to select wire sizes for all windings.The shape will be determined by the shape specified in the wire shape selection entry for all subsequent

wire. NO. HIGH, NO. WIDE and LINEAR SPACE FACTOR must be entered for all wires even

when FERRO is selecting wires.

SKEW : Portion of a turn width subtracted from the winding space because of skew in thewinding. A value of (1) means 1 turn width subtracted.

AWG SIZE: Standard American wire gage sizes for round and square wires.

NO. HIGH: Number of wire strands high in a multi-stranded wireNO. WIDE: Number of wire strands wide in a multi-stranded wire.

LINEAR SPACE FACTOR: Proportion of space occupied by wire that is actually wire.

DUCT LOCATION -

NONE: No ductsDIVIDE WINDING: Select where duct is to appear (half indicates a duct halfway in the

winding.)

WINDING MARGIN: Distance from each end of the coil from where winding is to begin.

LAYER INSULATION: Thickness of insulation in inches between layers of wire.

SECTION INS. THK: Insulation thickness in inches over the winding.


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FERRO 11

RESONANT WINDING DATA

RES. WNDG. VOLTAGE: Desired RMS voltage of resonant winding.

HARMONIC FACTOR: Factor to modify calculation of capacitor current for the harmonics present.(Usually 1.5 to 1.6)

Resonant Current = 2π FCV x Harmonic Factor where:F = Fundamental frequency

C = Capacitor in farads

V = Resonant winding voltage

****NOTE:For 3 coil (harmonically compensated) transformers, the sum of the voltages of the resonant winding

plus any load winding connected in series with it should total 516V if 660 volt AC capacitors are being

used. The voltage to enter for the resonant winding is

516 – (Vs1 + Vs2….etc.) Enter harmonic factor as 1.05.

TEST KV: Dielectric test voltage (entered in kilovolts).

****NOTE: (See Page 10) PRIMARY WINDING DATA (PAGE 2 – CONTINUED) for remainingdescriptions.

If FERRO is selecting Wire Size; user must enter No. High, No. Wide and Linear Space Factor.


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FERRO 12

SECONDARY 1 – WINDING DATA

RECTIFIER TYPE-

NONE: No rectifier; resistive load.HW: Half-wave rectifier (one diode).

FW: Full-wave center-tapped (two diodes).BR: Full-wave bridge rectifier (four diodes).

****NOTE: For entries HW, FW and BR FERRO assumes a capacitive filter of sufficiently large size.

WINDING VOLTAGE: Enter output voltage of winding. (If rectified, enter DC voltage; if notRectified, enter RMS voltage).

WINDING CURRENT: Enter output current of winding. (DC if rectified; RMS if not rectified.)

DIEL. TEST (KV): Dielectric test voltage in kilovolts.

****NOTE: (See Page 10) PRIMARY WINDING DATA (PAGE 2- CONTINUED) for remaining

descriptions.

If FERRO is selecting Wire Size, user must enter No. High, No. Wide and Linear Space Factor.


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FERRO 13

COMPENSATION WINDING DATA

COMP. WINDING PROPORTION: HC winding turns as a proportion of sum of resonant windingturns and any secondary windings connected in series with it across the capacitor. Entry is limited to value

between .4 and .7. An entry of ZERO (0) uses a default value of .667. This question is asked only for

Harmonically Compensated Designs.

****NOTE: (See Page 10) PRIMARY WINDING DATA (PAGE 2 – CONTINUED) for remainingdescriptions.



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FERRO 14

CONSTRUCTION

WINDING ORDER: Data for windings has been entered in the order of P1, P2, S1 and S2 etc.Enter a number for each winding indicating the order it is to be wound.

EXAMPLE:1 Primary, 1 Resonant, and 2 Secondaries:

P1, RES1, S1, S2

1, 2, 3, 4 Primary Coil – has primary (1).

Secondary Coil – Resonant (2) is wound first, followed by the 2 secondaries. (3, 4).

1, 4, 2, 3 Primary Coil – has primary (1).

Secondary Coil – The 2 secondaries are wound first, with the resonant wound on the

outside of coil (4th

position) (4, 2, 3).

****NOTE: Any Secondary winding that is to be connected in series with the resonant winding acrossthe capacitor should have it’s winding order entry preceded by a negative ( - ) sign.

% BUILD: Percentage of window height (H) actually occupied by wires, insulation, tubethickness and space. (If Zero (0) entered FERRO will assume 85%).

AMBIENT TEMP: Temperature of surrounding air in which the transformer is to operate. (In degreescentigrade.)

TEMP. RISE: Allowable temperature rise measured by change in resistance of the hottestwinding. (In degrees centigrade.)

% DUTY CYCLE: Percent duty cycle (repetitive).

CONSTRUCTION-

OPEN: Open core-coil.

FORCED AIR: Select forced air if desired (for ducted designs only).

AIR FLOW RATE (FT/MIN): Speed of air flowing past the coils in linear feet per minute

DESIGN IDENTIFIER: Design part number or name for identification purposes.


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FERRO 15

PROGRAM EXECUTION

• Select “EXECUTE” to run the design.

• Select “MODIFY” to modify input data.

• Select “EXECUTE/AIRGAP” to have program calculate air gap. (See page 19)(Only accessible after running a design.)

Navigational Buttons:

New Design- returns to Main Menu page.

Quick Print – allows user to copy and paste current design into Notepad where it

can be saved as a .txt file and printed.

Make Print File – allows user to have any of the following copied into aNotepad file:

Input Questions and entries.

Material cost.

Design details.

Save Design File – creates input data file for current design.

Terminate – exits program.


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FERRO 16

GENERAL DESIGN DATA (3-COIL)

****NOTE: See Page 6, GENERAL DESIGN DATA– CORE for remaining descriptions.

WINDOW LENGTHS-

Wc: Window length of harmonic compensation coil.

2ND

SHUNT RATIO: Second shunt area compared to cross-section of main core (3 coil FERRO) .


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FERRO 17

TABLE 1FERRORESONANT TRANSFORMER LAMINATIONS

(STORED IN FERRO FOR AUTOMATIC CORE SELECTION)

TONGUE WINDOW WINDOW LEG/T

YOKE/TCORE HEIGHT WIDTH RATIO RATIO

(T) (H) (W)

EI-750FR .750 .625 2.50 .583 .583

EI-7 .875 .625 2.75 .571 .571

EI-1000FR 1.000 .750 3.00 .562 .562

EI-8 1.125 .625 3.50 .555 .555

EI-1250FR 1.250 .906 3.687 .550 .550

EI-5731FR 1.375 1.063 4.000 .636 .636

EI-1625FR 1.625 1.125 4.375 .5766.5766

EI-2125FR 2.125 1.312 5.562 .5588.5588

EI-2625FR 2.625 1.562 6.750 .5592.5592

EI-3250FR 3.250 1.875 8.125 .5577.5577

EI-4000FR 4.000 2.250 9.688 .5782.5782

EI-5000FR 5.000 2.688 11.875 .575 .575

EI-6250FR 6.250 3.188 14.438 .570

.570

****NOTE: FERRO will use the above laminations for automatic core selection.However, FERRO is in no way restricted to the above laminations when user enters coredimensions.


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FERRO 18

PRIMARY HIGH TAP – WINDING DATA

HIGH TAP VOLTAGE: This question is meant for winding voltages above nominalinput, where a change in wire size would be appropriate. Examples are shown in Figures1 and 2.

TEST KV: Dielectric test voltage (entered in kilovolts).

****NOTE: See Page 10, PRIMARY WINDING DATA (PAGE 2 – CONTINUED) for remainingdescriptions.



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FERRO 19

THREE-COIL (HARMONICALLY NEUTRALIZED) FERRO

CORE/COIL STRUCTURE

FERRO will automatically calculate the MAIN CORE AIR GAP by selecting MAIN COREAIR-GAP button.

EXAMPLE:

ACROSS CORE (1) Main gap will be calculated to fit across core. (See sketch

above.)CENTER-GAP (0) Main gap will be calculated for center-leg only. (See Page19)

(User has option of "splitting" into multiple sections.)

The following page shows the printout of the gap calculation result and provides thecore structure layout for SHEARED STRIP pieces.

FUNDAMENTAL HARMONIC = 0.8053

THIRD HARMONIC = 0.0462

FIFTH HARMONIC = 0.0145

TOTAL AIR GAP = 0.5520

DESIRED NUMBER OF GAPS ? Enter total number of gaps.


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CORE STRUCTURE LAYOUT

VIEW PIECES

Ferro Manual 09

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