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OPTIMIZED PROGRAM SERVICE, LLC.

Electro-Magnetic Design Using Advanced Computer Techniques


info@opsprograms.com
opseast@msn.com
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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.

FERRO

TABLE OF CONTENTS

PAGE

MAIN MENU

GENERAL DESIGN DATA (2 COIL)

GENERAL DESIGN DATA COOLING DUCTS

GENERAL DESIGN DATA CORE

68

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

FERRO

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.

FERRO

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.

FERRO

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:
FULL:

FERRO

Ducts on ends of coils outside core window.


Duct around coil.

END DUCTS

FULL DUCTS

GENERAL DESIGN DATA - CORE

LAM. TYPE
SCRAPLESS:
FR:
STRIP:

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


Ferroresonant lamination shapes. (See Page 17)
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:

Enter power factor, usually -.97 for M6 and -.9 for non oriented grades.
Material grade description.

WEDGE:

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.

SPACE:

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

FERRO

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
M6
M19
M22
M27

PRI. MAX B
19.00
18.01
17.40
17.00

SEC. MAX B
20.80
19.85
19.25
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 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.

FERRO

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:

S:
H:

W:

Lamination center-leg in inches.


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

Ws:

Window length of primary coil.


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).

FERRO

PRIMARY WINDING DATA

NO. OF PRI: Possible entries are


ONE SINE-WAVE INPUT:
TWO SINE WAVE INPUTS:
ONE SQ-WAVE INPUT:
SQ. WAVE/SINE-WAVE:
SEPARATE HI-TAP:
LO VOLTS:

One primary with sine wave input.


Two identical primaries with sine wave input.
One primary with square wave input.
One primary with square wave input and one primary with sine wave
input.
(See Page 18).

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-line
voltage, enter slightly less to insure regulation.

FERRO

PRIMARY WINDING DATA (PAGE 2 - CONTINUED)

WIRE TYPE: Select Copper (CU) or Aluminum (AL).


WIRE SHAPE- RD : Round wire - enter as AWG wire size.
Square wire - enter as AWG wire size.
SQ :

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.

FERRO

10

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 1.05.

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.

FERRO

11

SECONDARY 1 WINDING DATA

RECTIFIER TYPENONE: 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.

FERRO

12

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.

FERRO

13

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 across
the capacitor should have its 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).

CONSTRUCTIONOPEN:
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.

FERRO

14

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.

FERRO

15

GENERAL DESIGN DATA (3-COIL)

****NOTE: See Page 6, GENERAL DESIGN DATA CORE for remaining descriptions.
WINDOW LENGTHSWc: Window length of harmonic compensation coil.
2ND SHUNT RATIO: Second shunt area compared to cross-section of main core (3 coil FERRO) .

FERRO

16

TABLE 1
FERRORESONANT TRANSFORMER LAMINATIONS
(STORED IN FERRO FOR AUTOMATIC CORE SELECTION)

TONGUE

WINDOW

WINDOW

LEG/T

HEIGHT
(H)

WIDTH
(W)

RATIO

RATIO

(T)

YOKE/T
CORE

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
.5766

1.625

1.125

4.375

.5766

EI-2125FR
.5588

2.125

1.312

5.562

.5588

EI-2625FR
.5592

2.625

1.562

6.750

.5592

EI-3250FR
.5577

3.250

1.875

8.125

.5577

EI-4000FR
.5782

4.000

2.250

9.688

.5782

EI-5000FR

5.000

2.688

11.875

.575

EI-6250FR
.570

6.250

3.188

14.438

.570

.575

****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.

FERRO

17

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.

FERRO

18

THREE-COIL (HARMONICALLY NEUTRALIZED) FERRO


CORE/COIL STRUCTURE

FERRO will automatically calculate the MAIN CORE AIR GAP by selecting MAIN CORE
AIR-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 Page

19)
(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

= 0.8053
= 0.0462
= 0.0145
= 0.5520

DESIRED NUMBER OF GAPS ? Enter total number of gaps.

FERRO

19

CORE STRUCTURE LAYOUT

VIEW PIECES

FERRO

20

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