HIGH FREQQUENCY TRANSFORMER DESIGN PROGRAM MANUAL V12.0

Transcription

1 HITRIN OPTIMIZED PROGRAM SERVICE, LLC Electro-Magnetic Design Using Advanced Computer Techniques HIGH FREQQUENCY TRANSFORMER DESIGN PROGRAM MANUAL V

2 HITRIN HIGH FREQUENCY TRANSFORMER PROGRAM PROGRAM DESCRIPTION AND OPERATING INSTRUCTIONS I. INTRODUCTION HITRIN is a powerful computer-aided design program, which is a companion program to TRANS intended for high frequency applications up to 2.8 MHz. It is capable of processing a large volume of information, performing all necessary calculations and producing design solutions in less time than it would take an individual designer to prepare the same information. It is intended to be used by experienced transformer designers as an extension to their engineering capabilities and relies on their background for judgment and subjective analysis of the results obtained. The computational power of HITRIN enables the designer to examine many alternatives and quickly provides the effects of each decision made during the design process. HITRIN is an interactive program that allows the user to establish and maintain custom data files containing proprietary material, cost and labor information. This gives the user greater control over a wide range of design considerations. It enables the designer to research more efficient and most cost effective design solutions, resulting in improved product quality, improved productivity and lower costs. II. FEATURES CUSTOM DATABASE HITRIN operates using a database of materials supplied by the individual user. This feature allows the designer to further control the material types and sizes to be considered. With conductor selection options, the program is limited to selecting components readily available from the user s own inventory of materials. The database contains core information for the standard ferrite shapes including Toroid, E-cores, Pot cores, PQ cores, EC Cores, PM Cores, RM cores, UU and UI cores. The program also considers LITZ wire conductors. THERMAL MODELING HITRIN uses sophisticated thermal network modeling techniques to determine temperature rise. The thermal model is developed using a comprehensive nodal circuit analysis routine that considers the effects of the mechanical structure as well as the thermal characteristics of the materials used in the design. This provides more accurate results in the temperature calculations. ELECTRICAL ANALYSIS Extended analysis of a fixed design is further enhanced in HITRIN. Subroutines now include Temperature, Frequency, Duty Cycle, Impedance, Load Performance, Set Turns, Input Volts and Loss Summary. Enhancements are continuously being made to expand capabilities and to improve HITRIN. 2

3 III. USE HITRIN will design a broad range of single or three-phase transformers with or without rectified outputs. Standard industry winding schemes can be accommodated. Cooling methods available are air, forced-air and oil-filled. HITRIN is used to design such as High Frequency Power Transformer, Switch Mode Power Supply Transformer, High Voltage High Frequency Pulsed Transformer, High Current Transformer III. INPUT REQUIREMENTS For entry of design information see Page 6. DISCLAIMER This program and its documentation have been subjected to normal field testing procedures. Optimized Program Service, Inc. 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 application. 3

4 TABLE OF CONTENTS PAGE MAIN MENU 6 GENERAL DESIGN DATA 7 8 GENERAL DESIGN DATA COOLING DUCTS 9 GENERAL DESIGN DATA THREE-PHASE CORE (PAGE 1) GENERAL DESIGN DATA THREE-PHASE CORE (PAGE 2) PRIMARY WINDING DATA (PAGE 1) 20 PRIMARY WINDING DATA (PAGE 2) 22 PRIMARY HIGH TAP 24 SECONDARY 1 WINDING DATA (PAGE 1) 25 CONSTRUCTION (PAGE 1) CONSTRUCTION (PAGE 2) THERMAL CONSIDERATIONS 30 SPECIAL THERMAL ROUTINES OIL FILLED ROUND TANK 33 OIL FILLED RECTANGULAR 34 EXTENDED PRIMARIES 3 WINDINGS (PAGE 1) 35 EXTENDED PRIMARIES 3 WINDINGS (PAGE 2) 36 EXTENDED PRIMARIES 3 WINDINGS (PAGE 3) 37 EXTENDED PRIMARIES 4 WINDINGS (PAGE 1) 38 EXTENDED PRIMARIES 4 WINDINGS (PAGE 2) 39 EXTENDED PRIMARIES 4 WINDINGS (PAGE 3) 40 EXTENDED PRIMARIES 4 WINDINGS (PAGE 4) 41 SPECIAL ENTRIES 42 4

5 WINDOW CLEARANCE 43 BUSSBAR ALLOWANCE 44 SPECIAL VA CALCULATION 45 AUTO TRANSFORMER 46 BOBBINS 47 NOISE BULGE FACTOR 48 LAYER SHARE 49 SINGLE PHASE RECTIFIER THREE PHASE RECTIFIER 52 TRANSFORMER WITH INVERTER INPUT 53 INTERNAL DUCTS FOR CORE-TYPE 54 APPENDIX A APPLICATION EXAMPLES EXTENDED ANALYSIS ROUTINE

6 MAIN MENU IF NEW DESIGN IS BEING STARTED OR EXISTING DATA IS BEING RUN: Select BEGIN/REVIEW DESIGN IN ENGLISH UNITS HITRIN proceeds to General Design Data, Page 6. Select BEGIN/REVIEW DESIGN IN METRIC UNITS HITRIN proceeds to General Design Data, Page 6. Select RETRIEVE DESIGN FILE to retrieve an existing 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. 6

7 GENERAL DESIGN DATA FREQUENCY : Frequency of input voltage in hertz. 7

8 GENERAL DESIGN DATA (CONTINUED) GAPPED DESIGN : Air gap is to be present in the core leg. YES : Enter total length of the air gap to appear across the core. NO : No air gap is used. INVERTER : Primary voltage is alternating D.C. UNBALANCED DC : Primary voltage or current contain an unbalanced DC component. NO. OF SECONDARIES : Enter number of secondary (output) windings. Twelve (10) are permitted. SIDE BY SIDE : Secondaries are wound side by side. Up to (4) are permitted. SPACE BETWEEN : Space between side by side secondaries. (See figure below). 8

9 COOLING DUCTS No Ducts automatically selected in HITRIN program. Proceed to Core Page. 9

10 THREE-PHASE CORE (PAGE 1) CORE TYPE : Type of Core Structure- C-CORE : Wound cut cores. SCRAPLESS : Tool made laminations. FERRITE: Magnetic core made of FERRITE ENTER CORE - YES : Core dimensions must be entered by user (see next page). NO : Core will be selected by HITRIN for C-Core, Scrapless and Strip only. FLUX DENSITY : Induction in core. Enter in kilo-gausses. 10

11 THREE-PHASE CORE (FERRITE) STORED CORE MATERIALS 11

12 STORED CORE MATERIALS (CONTINUED) 12

13 THREE-PHASE CORE (C CORE) THREE-PHASE CORE (SCRAPLESS) 13

14 ENTER CORE - YES : Core dimensions must be entered on next page. NO : Program selects core from core database file. SPECIAL : User to enter the following: AW : Excitation loss : C-Core and Scrapless - VA/Pound TW : Core loss : C-Core and Scrapless - Watts/Pound, Ferrite mw/cm 3 IRON DENSITY : Core material weight : C-Core and Scrapless - pounds/cubic inch Ferrite Kg/cubic meter DESCRIPTION : Name of core material THICKNESS : Thickness of individual lamination. STACK FACTOR : Proportion of core leg that is actually iron. FLUX DENSITY : Induction in core. Use Kilo-gausses for English units. 14

15 FERRITE CORE: THREE-PHASE CORE (PAGE 2) Core Shape: Rectangular If core has rectangular core section For simple type and core type : Available core would be U Core and UI Core Round If core has round cross section None If POT, PM, PQ, EC, PM core shape. Enter core dimensions: 1) Enter the core dimensions from catalog. (Refer Figures given below.) 2) Select the part number from the listing. Prompt box is provided to preview the dimension before use it. User can able to transfer the value by clicking Shift + Left Click. All the part number and their corresponding dimensions are directly listed from the core catalog provided by manufacturer. User can also edit values after selecting the core part number from listing. Note: If core part number is N/A you must enter the core dimensions Figures : 15

16 1) Rectangular E-Core: Enter the dimensions A, D, E, F, G, H, Core Weight and Effective Area. 2) Rectangular U-Core: Enter the dimensions A, D, E, F, G, H, Core Weight and Effective Area. 3) Rectangular UI-Core: Enter the dimensions A, D, E, F, G, H, Core Weight and Effective Area. 4) Round Core: Enter the dimensions A, D, E, G, H, Core Weight and Effective Area. 16

17 5) POT-Core: Enter the dimensions A, B, C, G, H Core Weight and Effective Area. 6) RM-Core: Enter the dimensions A, B, C, G, H Weight and Effective Area. 7) PQ-Core: Enter the dimensions A, B, C, E, H Core Weight and Effective Area. 8) EC-Core: Enter the dimensions A, C, E, B, D Core Weight and Effective Area. 17

18 9) PM-Core: Enter the dimensions A, B, C, G, H Core Weight and Effective Area. Bobbin: Clearances Enter total clearance over center leg thickness and total clearance over center leg width. Bobbin: Thickness Enter thickness of bobbin. Length Enter length of bobbin over flanges. C-CORE CORE: CORE DIMENSIONS - D : Strip width of wound core. E : Build-up of strip F : Narrow dimension of core window. G : Wide dimension of core window. SCRAPLESS CORE: 18

19 CORE DIMENSIONS - T - Strip width of core center leg. S - Stack of laminations. H - Narrow dimensions of core window. W - Wide dimension of core window. CORE NAME : Core identifier when core is entered. WEDGE : Clearance allowed at each of D dimension SPACE : Clearance allowed at each side of E dimension WNDG FORM THK: Total thickness of winding tube, bobbin, or insulation under the first layer of wire. NET END ALLOW: Net difference between coil length and window G dimension. PRIMARY WINDING DATA (PAGE 1) 19

20 NO. OF PRI : Number of Primary windings. Select 1 for single primary winding Select 2 for two identical primaries Select 3 or 4 for extended primaries (See Pages 37-43). SAME HITAP WIRE - YES : Entire primary is wound with the same wire. NO : Portion of primary above the nominal is wound with a different wire. LO VOLTS : Lowest voltage tap on the primary. NOM VOLTS : Nominal voltage tap on the primary HI VOLTS : Highest voltage tap on the primary. DIEL. TEST (KV) : Test voltage in kilo-volts usually applied for 1 minute. SECONDARY TAPS ONLY : Taps will be prompted for in the secondary windings only. No taps will appear in the primary. PRIMARY WINDING DATA (CONTINUED) 20

21 PRIMARY TAPS - NONE: No Taps. LO NOM HI: Tap below nominal and above nominal in primary only. END LAYER: Up to 6 taps permitted in each winding with all taps exiting at end of layers. RANDOM: Up to 6 taps permitted in each winding with taps exiting the coil wherever they occur. % TAPS : Standard % taps selected from table when button is depressed FOR THREE PHASE - WYE: One end of each three-phase winding is connected to a common point. (neutral) DELTA: Three-phase windings are connected in series for a closed circuit. WYE DELTA 21

22 PRIMARY WINDING DATA (PAGE 2) PRIMARY WIRE: Select Copper (CU), Aluminum (AL), AL-58 or CU-ANNEALED. WIRE FILM: Select Single Film or Heavy Film. PRI. WIRE SHAPE - PICK: Program selects from wire file. DIAM: Round wire can be entered by diameter. 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. HRD: Round half AWG size wire. RDP: Round wire precision wound. MULTI: Wire consisting of more than one size. LITZ: Litz Wire 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 gauge sizes for round and square wires Or size of individual wire strand within the Litz Wire NO HIGH: Number of wire strands high in a multi-stranded wire. NO. WIDE: Number of wire strands wide in a multi-stranded wire. No. of Strands: Total number of individual wire strands Thickness: Overall thickness of actual Litz Wire Width: Overall width of actual Litz Wire WRAP: Thickness of wrap on a conductor. If (0) the program uses designated film thickness. Linear Space Factor : proportion of wire space in layer actually occupied by wire. 22

23 PRIMARY WINDING DATA (CONTINUED) DUCT LOCATION- NONE: No ducts SPECIFY LAYERS: Select number of layers desired between internal ducts in this winding. BULGE FACTOR: Factor applied to winding build when calculating the winding mean turn. Default value is 1.1 WINDING MARGIN: Distance from each end of the coil from where winding is to begin. (For bobbins, enter flange thickness.) LAYER INS. THK: Thickness and number of thickness between layers of wire. SECTION INS. THK: Enter as thickness and number of thicknesses. #? : Number of section/layer insulation. ***NOTE: If program is to select insulation, enter voltage stress in volts/per mil. Value must be greater than 9. For SI units enter as volts/mm. Value must be greater than

24 HIGH TAP WINDING DATA WINDING VOLTAGE : Total voltage of the primary nominal voltage plus the high tap section. NUMBER OF TAPS : Up to 6 permitted. TAP VOLTS : Entered as values between the nominal primary voltage and the value shown in the winding voltage. (Highest voltage of the section) 24

25 SECONDARY WINDING DATA (PAGE 1) RECTIFIER TYPE - NONE : If Output not rectified. (For Three-phase HW, FW, BR, and DWY) (For Single-phase rectified options) POWER FACTOR: Enter as cosine of load power factor angle or as negative (-) if leading WINDING VOLTAGE: For single phase enter as winding RMS voltage. For three phase Enter as line to line voltage. WINDING CURRENT: For single phase enter as winding RMS current for three phase Enter as line current. DIEL. TEST (KV): Enter winding test volts in KV. NUMBER OF TAPS: Up to 6 taps are permitted below the rated secondary voltage. TAP VOLTS: Enter a voltage for each tap specified above. 25

26 CONSTRUCTION (PAGE 1) LAYER SHARE - YES : (See Page ***** for explanation and example.) NO : Layer sharing will not be used. WINDING ORDER : Data for windings has been entered in the order of P1, P2, S1, S2, etc. Enter a number for each winding indicating the order it is to be wound. SHIELDS - YES : Transformer is to have electro-static shields between some windings. NO : No shields are to be used. NUMBER OF SHIELDS : Enter total number of shields. POSITION : Enter number of the winding under which a shield is to be located. Quantity of entries must correspond to the number of shields. 26

27 CONSTRUCTION (CONTINUED) SHIELD SHAPE - WIRE : A layer of wire corresponding to the smallest wire in the windings adjacent to the shield will be used. FOIL : A foil will be used for the shield. Enter the thickness of the foil. SHIELD TYPE - Select Copper or Aluminum. COMPENSATION - YES : Secondary turns will be adjusted to achieve the voltage entered at full load and at operating temperature. NO : Secondary turns will be determined from the primary/secondary voltage ratio and will not be adjusted for voltage drops. % REGULATION : Enter output voltage change from no load to full load, as a percentage of full load output volts. % BUILD : Percentage of the core narrow window dimension actually filled by wire, full ducts, insulation, winding form thickness, and clearance (space). AMBIENT TEMP : Temperature in degrees C of surrounding air in which the transformer is operating. TEMP. RISE : Temperature rise permitted in the hottest winding, above the ambient temperature. % DUTY CYCLE : Percent of on-time where a full rated load is present in a repetitive on-off cycle. Full load continuous is 100%. 27

28 CONSTRUCTION (PAGE 2) CONSTRUCTION - OPEN : Open core-coil FORCED AIR : Open core-coil with blower driven air. ENCAPSULATED : Transformer covered with conformal coating. COMPOUND FILLED : Transformer embedded in material filling an enclosure. SAND RESIN : Transformer embedded in a mixture of sand and resin in an enclosure. OIL FILLED : Liquid filled enclosure using oil as an insulator and as a cooling medium. SPECIAL : Special thermal routines. 28

29 CONSTRUCTION (CONTINUED) STRAY LOSSES - YES : User enters additional stray loss which will be used in temperature calculation. NO : Only conductor I 2 R, conductor eddy current loss, and core loss will be used in temperature calculation. OTHER STRAY LOSSES : User entered additional stray losses. IN WATTS : User enters a total figure in watts. % OF CONDUCTOR LOSS : User enters a percentage of the conductor losses. K FACTOR : For non-sinusoidal loads, user can enter a number, which will be used to multiply eddy current losses and other stray loss and add them to conductor loss for calculation of temperature rise. 29

30 THERMAL CONSIDERATIONS STANDARD THERMAL PARAMETERS - YES : HITRANS uses default values for altitude, surface emissivity, and thermal conductivity. NO : User enters values. AIR FLOW RATE : For forced air designs enter air flow rate in linear feet per minute. MAX. ALTITUDE : Enter altitude in thousands of feet. Default value is 3.3. RELATIVE SURFACE EMISSIVITY : A relative measure of surface emissivity used in the calculation of radiation coefficient. Default is.93 INSUL THERMAL CONDUCTIVITY : Average conductivity of layer and section insulation in watt-inches per inch per degree celsius. Default value is.005. COMP. THERMAL CONDUCTIVITY: Conductivity of material surrounding core-coil. AVERAGE COATING THICKNESS : SPECIAL ENTRIES - YES : A group of special entry options appears. NO : No special entries are used. Average thickness of encapsulating material, compound, or sand-resin embedment. YOUR DESIGN IDENTIFIER : Used to identify the print-out. Enter any combinations of letters and numbers up to 16 characters. 30

31 SPECIAL THERMAL ROUTINES ALT. TEMP. ROUTINE : Temperature routines in addition to those shown on CONSTRUCTION- (PAGE 2). FOR SMALL UNDUCTED TRANSFORMERS - THRM. COUPL. : This routine is intended for small, single phase, shell-type transformers where the % build is so low that coil contact with outer legs of the laminations is partial or non-existent. User is given the choice between partial contact or none. SPHERICAL APPROXIMATION : This routine uses Rueben Lee s formula. Temp Rise.1 x Total Losses (Weight of Copper Iron)

32 SPECIAL THERMAL ROUTINES (CONTINUED) DUCTED TRANSFORMERS - ALT. DUCT : This routine calculates the total cooling surface of air ducts and exposed surfaces for each winding and uses those areas to determine individual winding temperature rises. ALT. DUCT TEST : Calculates winding temperatures in the same way as Alt. Duct for a simulated shorted winding condition circulating rated current and having no core loss present. These rises are then combined with an open circuit temperature rise to give final winding temperature rises. DUCT SPACERS REMOVED - NONE : No spacers removed. ALL : All spacers removed. PARTIALLY : User enters the number of spacers to be used in each winding. RESTRICTED AIR FLOW : This is intended for full ducted coils where insufficient space is left under the core yokes for air flow. DUCT WIDTH FANNED OUT - NO : width of all ducts are equal. YES : width of the ducts increase as the coil build increases. 7< Angle : width of the ducts increase by 7 degrees. 14<Angle : width of the ducts increase by 14 degrees. FANNED OUT NOT FANNED OUT 32

33 OIL-FILLED ROUND TANK With Standard Thermal Parameters YES 1. Without Radiators HITRIN calculates tank dimensions without radiators. 2. HITRIN calculates tank dimensions and radiator area if needed. 3. User enters tank dimensions, radiator area, radiator efficiency, oil viscosity and oil type. With Standard Thermal Parameters NO User enters tank dimensions, oil viscosity and oil type. MIN. SIDE OIL: Space allowed on each end of core coil diagonal. MIN. TOP OIL : Minimum oil level above the core-coil. TANK DIMS. - DIAMETER : Diameter of the round tank HEIGHT : Wetted tank height OIL VISCOSITY : Enter viscosity of oil in centipoise at operating temperature. If zero (0) entered, HITRIN program uses stored data for Type-C oil. OIL TYPE : Type of Cooling Fluid: If C is entered HITRIN uses stored data for type C mineral oil If 561 is entered HITRIN uses stored data for 561 silicone oil. If NONE program use data from viscosity custom data file. ****NOTE : For special fluids both oil viscosity and oil type must be entered. 33

34 OIL-FILLED RECTANGULAR TANK With Standard Thermal Parameters YES HITRIN calculates tank dimensions and radiator area if needed. With Standard Thermal Parameters NO User enters tank dimensions, radiator area, and radiator efficiency, oil Viscosity, and oil type. MIN. SIDE OIL : Clearance over coil sides and coil ends. MIN. TOP OIL : Minimum oil level above the core-coil. TANK DIMS - LENGTH : Includes length of core-coil plus min. side oil on each end. DEPTH : Includes depth of core-coil plus min. side oil on each end. HEIGHT : Wetted tank height includes core-coil height plus min. top oil. RAD. AREA : Area of external radiators. RAD. % EFF. : Percent efficiency of radiators. 34

35 EXTENDED PRIMARIES (3 WINDINGS PAGE 1) THREE DIFFERENT WIRE SIZES P1 P2 P3 NO. OF PRI : Select 3 PRIMARY TAPS : All 4 entries are permitted. LO VOLTS : Lowest voltage below nominal volts. NOM VOLTS : Nominal primary voltage V1. HI VOLTS : Enter nominal primary voltage V1. *** For random and end taps, up to 6 additional are permitted between Lo Volts and Nom Volts. ***See next 2 pages for entered V2 and V3. 35

36 EXTENDED PRIMARIES (3 WINDINGS PAGE 2) WINDING VOLTAGE : Enter V2. Up to 6 additional taps are permitted between V1 and V2. 36

37 EXTENDED PRIMARIES (3 WINDINGS PAGE 3) WINDING VOLTAGE : Enter V3 Up to 6 additional taps are permitted between V2 and V3. 37

38 EXTENDED PRIMARIES (4 WINDINGS PAGE 1) FOUR DIFFERENT WIRE SIZES P1 P2 P3 P4 NO. OF PRI : Select 4 PRIMARY TAPS : Only 2, 3, and 4 are permitted. LO VOLTS : Lowest voltage below nominal volts V1. NOM VOLTS : Nominal primary voltage V1. HI VOLTS : Enter V2. ***For Random and End Taps up to 6 additional taps are permitted between Lo Volts and V1. For V2, V3, and V4 see next 3 pages. 38

39 EXTENDED PRIMARIES (4 WINDINGS PAGE 2) WINDING VOLTAGE : Entered on primary winding data page 1 as Hi Volts V2. For Random and End Taps up to 6 additional taps are permitted between V1 and V2. 39

40 EXTENDED PRIMARIES (4 WINDINGS PAGE 3) WINDING VOLTAGE : Enter as V3. Up to 6 additional taps are permitted in winding P3 between voltages V2 and V3. 40

41 EXTENDED PRIMARIES (4 WINDINGS PAGE 4) WINDING VOLTAGE : Enter as V4. Up to 6 additional taps are permitted between V3 and V4. 41

42 SPECIAL ENTRIES WINDOW CLEARANCE (See Page 38) BUSSBAR ALLOWANCE (See Page 39) SPECIAL VA CALC (See Page 40) AUTOTRANSFORMER VA (See Page 41) DUAL BOBBIN (See Page 42) NOISE BULGE FACTOR (See Page 42) 42

43 WINDOW CLEARANCE YES : Additional window clearance which will be disregarded in the build calculation. 43

44 BUSSBAR ALLOWANCE YES : Additional space allowance for leads, busbars in each winding used in nominal depth calculation. 44

45 SPECIAL VA CALCULATION YES : If number of secondaries is one enter % coil loss to be used in temperature calculation. If number of secondaries is greater than 1, program uses only the current of the first secondary in VA rating calculation. 45

46 AUTO TRANSFORMER YES : If step down auto-transformer program will use the total of the primary and first secondary voltage in the exciting VA and current calculations. 46

47 BOBBINS YES : If space between bobbins is different than flange thickness. NO : If space between bobbins is different than flange thickness, enter the thickness for margin. If SHELL-BOBBIN is selected from GENERAL DESIGN DATA Enter inside dimension of bobbin from page CORE DATA PAGE-2 DIM. OVER S : Dimension over lamination stack DIM. OVER T : Dimension over lamination tongue BOBBIN THK. : Thickness of bobbin BOBBIN LGTH : Bobbin length SECONDARY PROPORTION: From page CORE DATA PAGE-1 Enter proportion of net winding space to be allocated to SECONDARY: Secondary Space Primary Space + Secondary Space 47

48 NOSE BULGE FACTOR 48

49 LAYER SHARE YES : Enter winding order to share layer with the above winding. EXAMPLE: 1 Primary and 4 Secondary windings. P1 S1 S2 S3 S4 Winding order is entered as Second winding wound (S1) shares layer with third winding (S2) and fourth winding (S3) shares layer with fifth winding (S4). Enter 2, 4 49

50 SINGLE PHASE RECTIFIER HW (2) BR (4) HALF WAVE RECTIFIER BRIDGE RECTIFIER FW (3) FULL WAVE RECTIFIER FW(5) FULL WAVE (Center-Tap placed at the end of layer) LOAD TYPE : ( FW or FWE only) RESISTIVE : Output feeds into a pure resistance. INDUCTIVE : Output feeds into an inductive filter. 50

51 SINGLE PHASE RECTIFIER (CONTINUED) CAPACITOR INPUT FILTER: If (HWC; FWC; BRC; and FWEC) HWC (6) HALF WAVE CAPACITIVE FILTER BRC(8) BRIDGE CAPACITIVE FILTER FWC(7) FULL WAVE CAPACITIVE FILTER FWEC(9) FULL WAVE CAPACITIVE FILTER Center-Tap placed at the end of layer) CAP : Filter capacitance in farads DCR : Any external DC resistance in series with Diode. RMSR : RMS resistance of Diode. PEAK R : Peak resistance of Diode. DIODE DROP : Net forward Diode drop in volts. OPEN CIRCUIT VOLTS : Open circuit voltage of the secondary (Only asked when all core dimensions are entered) If zero (0), program will determine value. ****Note: If user enters capacitor value only program will calculate the values for the remaining parameters. A negative entry for Diode drop will instruct program to use entered value for calculation of RMSR and PEAK R. 51

52 THREE PHASE RECTIFIER HW (2) FW(3) BR (8) DW(10) HALF WAVE RECTIFIER FULL WAVE BRIDGE ( STAR ) DOUBLE WYE RECTIFIED (Number of Secondaries must be 2) Double wye rectifier entries must be made as follows: -select number of secondaries as two -enter DC volts, Total DC current WINDING VOLTAGE : Enter DC output volts of rectifier. WINDING CURRENT : Enter DC load current for winding current. NOTE: Capacitive filter entries apply only to single-phase transformers. HITRIN does not handle 3-phase capacitor input filtered rectifiers. 52

53 TRANSFORMER WITH INVERTER INPUT There are two possible configuration of primary winding. NO. OF PRIMARY = 1 Vdc Ip Ip=VOLT AMPERES Vde For primary nominal volts enter DC voltage of primary. NO. OF PRIMARY = 2 S P1 F S P2 F WIND BIFILAR AS ABOVE CENTER-TAP Vdc S F S F Ip CONNECT AS ABOVE IP=VOLT AMPERES x.707(heating value) Vdc For primary nominal volts enter DC voltage of primary. 53

54 INTERNAL DUCTS FOR CORE-TYPE 3 SIDED : Ducts are located on ends of coil and on exposed coil sides. 1 SIDED : Ducts are located on exposed coil sides only. 3 SIDED 1 SIDED ****NOTE : 3 sided and 1 sided ducts are for internal ducts only. 54

55 APPENDIX A APPLICATION EXAMPLES Appendix A contains examples of input data requirements for special design applications of HITRIN. This section will be updated periodically to provide users with instructions for using HITRIN for designing transformers and magnetic components other than those explained in the User's Manual. Program users are encouraged to submit examples to be included in this section, or offer suggestions for other uses of HITRIN. APPENDIX A. Contents: I. Auto Transformers II. Special Use of Power Factor Entry 59 III. Double Bridge Rectified Outputs 60 V. Build Info. for Small Transformers Using Round Wires 61 VI. Rectifier Constants 62 55

56 I. AUTO TRANSFORMERS To design Auto Transformers using HITRIN, the input data must be arranged to simulate a twowinding transformer to obtain the proper current for each voltage section. This is accomplished by calculating an "equivalent" volt-ampere rating in the output section that, combined with the equivalent VA of the input section, will produce the actual VA rating of the transformer with the correct currents. Single-Phase Auto Transformer Single-Phase Auto Transformer A. Output Current Output VA = V 2 x I 2 Output VA eq = (1 - V 2 / V 1 ) x Output VA therefore: V 2 I 3 = VA eq and, I 3 = VA eq /V 2 B. Current of Input Section (V 1 - V 2 ) x I 1 = Input VA eq and I 1 = VA eq /(V 1 - V 2 ) 56

57 C. Design Procedure Step 1 Determine Output VA equivalent. VA eq = (1-Low Voltage/Nominal High Voltage) x Rating actual where: Rating actual = V out x I out Step 2 Determine secondary (output section) Current. (Is) DATA ENTRY HITRIN Is = VA eq /Low Voltage For Primary voltage PRIMARY WINDING DATA PAGE-1 enter LO VOLTS, NOM VOLTS and HI VOLTS. For Secondary Winding Volts(low voltage) and Current SECONDARY WINDING DATA PAGE-1 enter V s and I s. Design Example: 1. VA eq = (1-48/115) x (48 x 5.5) = Is = /48 = 3.2 (Enter as secondary winding current) 3. Vs = 48 (Enter as secondary winding voltage) PRIMARY INPUT DATA Low V=62 Nom V=67 Hi V=72 (110-48=62; =67; =72) ****NOTE: PRIMARY AND SECONDARY ARE CONNECTED IN SERIES**** 57

58 Three-Phase Auto Transformers are designed using the same procedures as single-phase using LINE VOLTAGE and LINE CURRENT values. DATA ENTRY HITRIN Primary Voltage PRIMARY WINDING DATA PAGE-1 enter High Voltage - Low Voltage. Secondary Voltage SECONDARY WINDING DATA PAGE-1 enter Low Voltage. Secondary Current SECONDARY WINDING DATA PAGE-1 enter Is (from Step 2). (Select both Primary and secondary as "WYE" configuration). DESIGN EXAMPLE: OUTPUT RATING: 9 KVA INPUT VOLTAGES: 600/660 OUTPUT VOLTAGE: 480 Therefore: Nominal Voltage is 600V Lowest Voltage is 480V VA eq = (1-480/600) x 9KVA x 1000 = 1800 For Primary: Enter As: Lo Volts=120 Nom Volts=120 Hi Volts=180 For Secondary: Voltages are: = = 180 Voltage is 480 Current is VAeq = 1800 = x voltage 3 x 480 Enter As: Winding Volts = 480 Winding Current = 2.17 ****PRIMARY AND SECONDARY ARE CONNECTED IN SERIES**** 58

59 II. SPECIAL USE OF POWER FACTOR ENTRY For use when the sum of two secondary VA's are greater than the rated Primary VA. Procedure: Case 1 - VA3 larger than VA1 Let: VA1 = VA of larger secondary VA2 = VA of smaller secondary VA3 = VA of primary PF1 = Power factor of secondary 1 PF2 = Power of factor of secondary 2 Where: Entries are: PF1 = (VA3) 2 - (VA2) 2 + (VA1) 2 2 x VA3 x VA1 PF2 = (VA3) 2 - (VA1) 2 + (VA2) 2 2 x VA3 x VA2 ****NOTE: PF2 is always entered as a NEGATIVE number for Case 1. From SECONDARY 1 WINDING DATA PAGE-1 page Rectifier Type = NONE Load Power Factor = PF1 From SECONDARY 2 WINDING DATA PAGE-1 page Rectifier Type =NONE Load Power Factor = -PF2 Case 2 - VA3 less than VA1 PF1 = 1 - {((VA3) 2 - (VA1) 2 - (VA2) 2 )/ (2 x VA1 x VA2)} 2 PF1 is always entered as a negative for Case 2. PF2 is entered as zero (0) 59

60 III. DOUBLE BRIDGE RECTIFIERS OUTPUT Calculate Secondary D.C. current as: = Select largest capacitor value. Input from SECONDARY 1 WINDING DATA PAGE 1 page RECTIFIER TYPE=BR CAP=0.01 DCR=0 RMSR=0 DROP=0 OPEN V=0 WINDING VOLTAGE=24 WINDING CURRENT=

61 IV. BUILD INFORMATION FOR SMALL TRANSFORMER USING ROUND WIRES WIRE WITH TYPE OF LINEAR SPACE FILM THICKNESS USED SELECT ENTRY LAYER WINDING FACTOR IF ZERO IF VALUE ENTERED SKEW MODE INS.? USED WIRES BEING ENTERED RD RD RDP YES NO NO LAYER RANDOM PRECISION ENTERED VALUE ENTERED VALUE ENTERED VALUE (USUALLY 1.0) FROM WIRE FILE ENTERED VALUE ENTERED VALUE (USUALLY.5) HITRIN SELECTS WIRES PICK PICK PICK - PRECISION YES NO NO LAYER RANDOM PRECISION FROM WIRE FILE FROM WIRE FILE 1.0 FROM WIRE FILE FROM WIRE FILE ENTERED VALUE (USUALLY.5) NOTES : 1. WIRE O.D. = BARE NOMINAL O.D. + 2 X FILM THICKNESS = NOMINAL INSULATED O.D. 2. TURNS/LAYER = WINDING SPACE X LINEAR S.F. - SKEW (TRUNCATED TO NEXT LOWER INTEGER) WIRE O.D. 3. LAYERS = TURNS (ROUNDED TO NEXT HIGHER INTEGER) TURNS PER LAYER 4. WINDING BUILDS LAYER WINDING BUILD = (WIRE O.D. + LAYER INSULATION) X LAYERS LAYER INSULATION RANDOM AND PRECISION WINDING BUILD = (.866 X LAYERS +.134) X WIRE O.D. 61

62 VI. RECTIFIER CONSTANTS SINGLE PHASE RECTIFIERS TYPE OF RECTIFIER CONFIGURATION SINGLE PHASE HALF-WAVE SINGLE PHASE FULL-WAVE SINGLE PHASE BRIDGE TYPE OF LOAD RESISTIVE RES. IND. INDUCTIVE SECONDARY RMS VOLTS PER LEG TO CT TO CT SECONDARY RMS LINE CURRENT SECONDARY VOLT-AMPERES PRIMARY VOLT-AMPERES

63 THREE-PHASE RECTIFIERS TYPE OF RECTIFIER CONFIGURATION THREE PHASE HALF-WAVE OR STAR THREE PHASE FULL- WAVE SIX-PHASE STAR THREE-PHASE BRIDGE THREE-PHASE DOUBLE WYE W/INTERPHASE XFMR TYPE OF LOAD INDUCTIVE RESISTIVE INDUCTIVE INDUCTIVE SECONDARY RMS VOLTS PER LEG.855 TO NEUTRAL.428 TO NEUTRAL.74 TO NEUTRAL.855 TO NEUTRAL SECONDARY RMS LINE CURRENT SECONDARY VOLT-AMPERES PRIMARY VOLT-AMPERES

64 EXTENDED ANALYSIS The Extended Analysis Subroutine allows the designer to further evaluate a fixed design for further operational characteristics. It can only be accessed after executing the design program by selecting the EXTENDED ANALYSIS button. A menu page will then appear to allow selection of the choices when needed the program will prompt for additional information. (Duty cycle, load currents, winding turns, etc) 64

65 EXTENDED ANALYSIS (continued) LOAD PERFORMANCE: The program will provide the electrical characteristics (regulation, efficiency, %IR, %IX, %IZ, coil loss, and temperature rise) for loading at 25, 35, 50, 65, 75, 100, 125, and 150 percent. Note: This option can only be run by itself. TEMPERATURE: Electrical characteristics will be re-calculated at the inputted temperature value. FREQUENCY: Electrical characteristics will be re-calculated at the inputted frequency value. DUTY CYCLE: Electrical characteristics will be re-calculated at the inputted duty cycle value. IMPEDANCE: The program will provide the impedance characteristics including %IR, %IX, lead %IX, %IZ, and short-circuit current and inrush current (absolute peak and practical). EXTENDED ANALYSIS (continued) 65

66 LOSS SUMMARY: The program will show all losses for each winding including, I 2 R loss, eddy current loss, and stray loss. CHANGE LOAD: Allows the designer to obtain operating characteristics for different loading or duty cycles (as entered by the user). SET TURNS: Allows the designer to obtain operating characteristics for slight changes in the winding turns (as entered by the user) used primarily for checking turns round-off. INPUT VOLTS: Allows the designer to obtain operating characteristics at different input volts and taps (as entered by the user). 66

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