FERRORESONANT PROGRAM MANUAL V12.0

Transcription

1 FERRO OPTIMIZED PROGRAM SERVICE, LLC Electro-Magnetic Design Using Advanced Computer Techniques FERRORESONANT PROGRAM MANUAL V

2 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 power conditioning 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 testing procedures. 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. 1

3 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 2

4 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. 3

5 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. 4

6 GENERAL DESIGN DATA COOLING DUCTS COOLING DUCTS: Spaces in coils that permit air to flow parallel to the coil axis. INTERNAL DUCTS: Ducts are placed within winding only EXTERNAL DUCT: Duct is placed between 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 from obstruction. TYPE END: Ducts on ends of coils outside core window. END DUCTS FULL DUCTS FULL: Duct around coil. 5

7 GENERAL DESIGN DATA - CORE LAM. TYPE SCRAPLESS: 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: Y/T RATIO: L/T RATIO: M Grade of steel. Ratio of yolk or ends of lamination to tongue width. 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: DESCRIPTION: WEDGE: SPACE: Enter power factor, usually -.97 for M6 and -.9 for non oriented grades. Material grade description. Space (in inches) allowed on each side of core stack to insert wedges for securing coils to core. 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. 6

8 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 M M M M NET END ALLOW: SEC. POSITION: Net difference between coil lengths and available window length (in inches). This will be subtracted from each window. Position of the window length, minus shunt stack, allocated to the secondary coil. 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. 7

9 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: SHUNT ID: Enter any name or part number to identify core. Description of shunt for printout purposes (max. 8 characters). 8

10 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 wave input. 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: TEST (KV): ****NOTE: Highest value of input voltage on primary at which regulation is to be maintained. Dielectric test voltage in kilovolts. For worst-case evaluation, enter nominal voltage as low-line voltage. For low-line voltage, enter slightly less to insure regulation. 9

11 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 the winding. 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 wire NO. 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 ducts DIVIDE 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. 10

12 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 = 2 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 TEST KV: Dielectric test voltage (entered 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. 11

13 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 not Rectified, 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. 12

14 COMPENSATION WINDING DATA COMP. WINDING PROPORTION: HC winding turns as a proportion of sum of resonant winding turns 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 remaining descriptions. If FERRO is selecting Wire Size; user must enter No. High, No. Wide and Linear Space Factor. 13

15 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 (4 th position) (4, 2, 3). ****NOTE: Any Secondary winding that is to be connected in series with the resonant winding across the capacitor should have it s winding order entry preceded by a negative ( - ) sign. % BUILD: Percentage of window height (H) actually occupied by wires, insulation, tube thickness and space. (If Zero (0) entered FERRO will assume 85%). AMBIENT TEMP: Temperature of surrounding air in which the transformer is to operate. (In degrees centigrade.) TEMP. RISE: Allowable temperature rise measured by change in resistance of the hottest winding. (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. 14

16 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 a Notepad file: Input Questions and entries. Material cost. Design details. Save Design File creates input data file for current design. Terminate exits program. 15

17 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. 2 ND SHUNT RATIO: Second shunt area compared to cross-section of main core (3 coil FERRO). 16

18 TABLE 1 FERRORESONANT TRANSFORMER LAMINATIONS (STORED IN FERRO FOR AUTOMATIC CORE SELECTION) TONGUE WINDOW WINDOW LEG/T YOKE/T CORE HEIGHT WIDTH RATIO RATIO (T) (H) (W) EI-750FR EI EI-1000FR EI EI-1250FR EI-5731FR EI-1625FR EI-2125FR EI-2625FR EI-3250FR EI-4000FR EI-5000FR EI-6250FR ****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 core dimensions. 17

19 PRIMARY HIGH TAP WINDING DATA HIGH TAP VOLTAGE: This question is meant for winding voltages above nominal input, where a change in wire size would be appropriate. Examples are shown in Figures 1 and 2. TEST KV: Dielectric test voltage (entered 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. 18

20 THREE-COIL (HARMONICALLY NEUTRALIZED) FERRO CORE/COIL STRUCTURE FERRO will automatically calculate the MAIN CORE AIR GAP by selecting MAIN CORE AIR-GAP button. 19) 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 Page (User has option of "splitting" into multiple sections.) The following page shows the printout of the gap calculation result and provides the core structure layout for SHEARED STRIP pieces. FUNDAMENTAL HARMONIC = THIRD HARMONIC = FIFTH HARMONIC = TOTAL AIR GAP = DESIRED NUMBER OF GAPS? Enter total number of gaps. 19

21 CORE STRUCTURE LAYOUT VIEW PIECES 20

22 14532 PEARL ROAD SUITE 201 P.O. BOX STRONGSVILLE, OH PHONE: FAX: