| For high power inductor applications in low pass or bandpass filters, antenna tuners, etc.; we need to select an iron powder core that will | |||||||||||||||||||||||||||||||||||||||
| deal with the power without failure. Failure in these applications is typically due to heating caused by core losses, which are greater at | |||||||||||||||||||||||||||||||||||||||
| lower frequency. Losses in the wire used to wind the inductors, which are greater at higher frequency, can also be an issue, | |||||||||||||||||||||||||||||||||||||||
| and are treated at the bottom of the page. | |||||||||||||||||||||||||||||||||||||||
| To compute the core loss, you need the AC flux loss formula for your material type, which can sometimes be found on the web. As it happens, | |||||||||||||||||||||||||||||||||||||||
| #2 material and #6 material are the most commonly used, and their loss curves are very similar. We can use #6 material as a proxy for both. | |||||||||||||||||||||||||||||||||||||||
| #17 material is lower loss than #6, but exactly how much lower isn't know even by the manufacturer, Micrometals. | |||||||||||||||||||||||||||||||||||||||
| Always remember that #0 material, phenolic material, has no core loss - and thus can and should be used if it is possible to fit enough wire | |||||||||||||||||||||||||||||||||||||||
| onto the core to deliver the inductance required. | |||||||||||||||||||||||||||||||||||||||
| To compute the core loss, and the temperature rise resulting therefrom, use the following formulae or find your data in the sample charts below. | |||||||||||||||||||||||||||||||||||||||
| You can download this spreadsheet at http://www.k6if.com/coreLossCalcs.xls. Temperture rise is linearly related to voltage, | |||||||||||||||||||||||||||||||||||||||
| so you can use these data tables and multiply or divide from the reference 375 volts if you please. | |||||||||||||||||||||||||||||||||||||||
| Temperature rise greater than 50 degrees C will result in permanent damage to the core, and should be avoided (assuming 25 C ambient temp.). | |||||||||||||||||||||||||||||||||||||||
| Bmax (max flux density in gauss) | = (Voltage * 10 ^ 2) / (4.44 * Cross Sectional Area in cm^3 * Turns * Frequency in mHz) | ||||||||||||||||||||||||||||||||||||||
| Core Loss for #6 material in mw | = 8.34 * 10 ^ -10 * Frequency in Hz ^ 1.15 * Bmax ^ 2.17 * Core Volume in cm^3 | ||||||||||||||||||||||||||||||||||||||
| Temperature Rise in degrees C | = (Core Loss / Surface Area) ^ 0.833 | ||||||||||||||||||||||||||||||||||||||
| In a 50 ohm system: | |||||||||||||||||||||||||||||||||||||||
| At 3:1 SWR max RMS volts is | 450 | and max RMS amps is | 9 | 1.4:1 @ 100 watts is 81 volts RMS | |||||||||||||||||||||||||||||||||||
| At 2:1 SWR max RMS volts is | 375 | and max RMS amps is | 7.5 | ||||||||||||||||||||||||||||||||||||
| Core Power Loss in Watts | Core Power Loss in Watts | Core Power Loss in Watts | Core Power Loss in Watts | Core Power Loss in Watts | |||||||||||||||||||||||||||||||||||
| T130-6 Data | T157-6 Data | T184-6 Data | T200-6 Data | T94-6 Data | |||||||||||||||||||||||||||||||||||
| Voltage = | 375 | X-Sectional Area (cm^2) = | 0.698 | Voltage = | 375 | X-Sectional Area (cm^2) = | 1.06 | Voltage = | 375 | X-Sectional Area (cm^2) = | 1.88 | Voltage = | 375 | X-Sectional Area (cm^2) = | 1.27 | Voltage = | 100 | X-Sectional Area (cm^2) = | 0.362 | ||||||||||||||||||||
| Volume (cm^3) = | 5.78 | Volume (cm^3) = | 10.7 | Volume (cm^3) = | 21 | Volume (cm^3) = | 16.4 | Volume (cm^3) = | 2.16 | ||||||||||||||||||||||||||||||
| Frequency (mHz) | Frequency (mHz) | Frequency (mHz) | Frequency (mHz) | Frequency (mHz) | |||||||||||||||||||||||||||||||||||
| Turns | 28 | 21 | 14 | 7 | 3.5 | 1.8 | Turns | 28 | 21 | 14 | 7 | 3.5 | 1.8 | Turns | 28 | 21 | 14 | 7 | 3.5 | 1.8 | Turns | 28 | 21 | 14 | 7 | 3.5 | 1.8 | Turns | 28 | 21 | 14 | 7 | 3.5 | 1.8 | |||||
| 1 | 926 | 1242 | 1878 | 3809 | 7723 | 15219 | 1 | 692 | 929 | 1404 | 2847 | 5774 | 11378 | 1 | 392 | 526 | 795 | 1612 | 3268 | 6440 | 1 | 717 | 961 | 1454 | 2948 | 5979 | 11782 | 1 | 82 | 110 | 166 | 336 | 681 | 1343 | |||||
| 2 | 206 | 276 | 417 | 846 | 1716 | 3382 | 2 | 154 | 206 | 312 | 633 | 1283 | 2528 | 2 | 87 | 117 | 177 | 358 | 726 | 1431 | 2 | 159 | 214 | 323 | 655 | 1329 | 2618 | 2 | 18 | 24 | 37 | 75 | 151 | 298 | |||||
| 3 | 85 | 114 | 173 | 351 | 712 | 1403 | 3 | 64 | 86 | 129 | 262 | 532 | 1049 | 3 | 36 | 48 | 73 | 149 | 301 | 594 | 3 | 66 | 89 | 134 | 272 | 551 | 1086 | 3 | 8 | 10 | 15 | 31 | 63 | 124 | |||||
| 4 | 46 | 61 | 93 | 188 | 381 | 751 | 4 | 34 | 46 | 69 | 141 | 285 | 562 | 4 | 19 | 26 | 39 | 80 | 161 | 318 | 4 | 35 | 47 | 72 | 146 | 295 | 582 | 4 | 4 | 5 | 8 | 17 | 34 | 66 | |||||
| 5 | 28 | 38 | 57 | 116 | 235 | 463 | 5 | 21 | 28 | 43 | 87 | 176 | 346 | 5 | 12 | 16 | 24 | 49 | 99 | 196 | 5 | 22 | 29 | 44 | 90 | 182 | 358 | 5 | 2 | 3 | 5 | 10 | 21 | 41 | |||||
| 6 | 19 | 25 | 38 | 78 | 158 | 312 | 6 | 14 | 19 | 29 | 58 | 118 | 233 | 6 | 8 | 11 | 16 | 33 | 67 | 132 | 6 | 15 | 20 | 30 | 60 | 122 | 241 | 6 | 2 | 2 | 3 | 7 | 14 | 28 | |||||
| 7 | 14 | 18 | 28 | 56 | 113 | 223 | 7 | 10 | 14 | 21 | 42 | 85 | 167 | 7 | 6 | 8 | 12 | 24 | 48 | 94 | 7 | 11 | 14 | 21 | 43 | 88 | 173 | 7 | 1 | 2 | 2 | 5 | 10 | 20 | |||||
| 8 | 10 | 14 | 21 | 42 | 85 | 167 | 8 | 8 | 10 | 15 | 31 | 63 | 125 | 8 | 4 | 6 | 9 | 18 | 36 | 71 | 8 | 8 | 11 | 16 | 32 | 66 | 129 | 8 | 1 | 1 | 2 | 4 | 7 | 15 | |||||
| 9 | 8 | 11 | 16 | 32 | 66 | 129 | 9 | 6 | 8 | 12 | 24 | 49 | 97 | 9 | 3 | 4 | 7 | 14 | 28 | 55 | 9 | 6 | 8 | 12 | 25 | 51 | 100 | 9 | 1 | 1 | 1 | 3 | 6 | 11 | |||||
| 10 | 6 | 8 | 13 | 26 | 52 | 103 | 10 | 5 | 6 | 9 | 19 | 39 | 77 | 10 | 3 | 4 | 5 | 11 | 22 | 44 | 10 | 5 | 7 | 10 | 20 | 40 | 80 | 10 | 1 | 1 | 1 | 2 | 5 | 9 | |||||
| 11 | 5 | 7 | 10 | 21 | 42 | 84 | 11 | 4 | 5 | 8 | 16 | 32 | 63 | 11 | 2 | 3 | 4 | 9 | 18 | 35 | 11 | 4 | 5 | 8 | 16 | 33 | 65 | 11 | 1 | 1 | 2 | 4 | 7 | ||||||
| 12 | |||||||||||||||||||||||||||||||||||||||