stillsdesign.

com 9716

Wiltan
Ambassador Buildings
Pontnewynydd Industrial Estate
Pontypool Torfaen NP4 6YW
T. +44 (0)1495 750 711
F. +44 (0)1495 753 730

A Transformer Designers Guide

EDITION 1

sales@wiltan.co.uk
www.wiltan.co.uk

Telmag is a brand of Wiltan

Wound Cores

This project has been part funded by

the European Regional Development Fund

Page

Contents

1. Introduction

2. Wiltan Assurance of Quality

3. C Cores

General C Core Information

British Range C Cores Imperial Dimensions
British Range C Cores Metric Dimensions
Cee Clamp Cast Alloy Clamping Frames
54 Series Pressed Steel Clamping Frames
Cee Frame Pressed Steel Clamping Frames
Rectangular Tubes
Co-relation Table British C Cores and Accessories
C Cores Equivalent to Lamination Patterns
Continental C cores ranges SM, SU and SE to DIN 41309
Co-relation Table British C Cores Continental References
Co-relation Table Continental C Cores - Wiltan References
American Range of C Cores
Standard Electrical Guarantees C Cores

4. E Cores

British Range E cores Imperial Dimensions

British Range E cores Metric Dimensions
Continental E Core Range S3U to DIN 41309
Co-relation Table British E Cores Continental References
Circular E Type Cores
Rectangular Tubes for British Range E Cores
Standard Electrical Guarantees E Cores

5. Toroidal Cores

General information on Strip Width, Tolerances and Finishes

Calculation of Core Weights and Standard sizes to DEF.5193
Standard Performance Guarantees
TS Non-Impregnated Toroidal Cores Performance Guarantees and
Mechanical Parameters

6. Single & Three Phase Power Distribution Cores

Application of C Cores in Small Power Transformers

Current Transformer Design Guide
Useful Magnetic Formulae

8. Performance Curves

23
24
25
26
27
28
29
29
31
32
33
33
34
35

General Information
36
Standard Core Circle Diameters and Examples of Cut Single Phase Cores 37
Magnetic Characteristics & Guarantees
38

7. Engineering Section

5
6
7
8
9
10
11
12
13
14
15-17
18
19
20
21

Interpretation of Loss and Magnetising VA Curves

C Core Curves 0.3, 0.1 and 0.05mm Material
Hanna Design Curves
Incremental Permeability, C Cores
E Core Curves 0.3 and 0.1mm Material
Relative Permeability 0.3mm Material for Toroidal Cores
Toroidal Cores 0.3mm Material 50Hz, Resolved Component Curves
Toroidal Cores Losses 0.3mm Material 50Hz and above
TS Toroidal Cores 0.3mm Material, Resolved Component Curves
DC Hysteresis Curves 0.3, 0.1 and 0.05mm Material
Cruciform Section Core Curves

39
40-43
44-45
46
47
48
49-57
58
59
60-61
62
63
64
65
66-68
69

Wound Cores

Introduction

Wound Cores for Transformers and Chokes

Wiltan specialises in the manufacture of all types of wound cores in cold rolled
grain oriented silicon steel to British, American and Continental specifications.
Cold rolled grain oriented silicon steel (G.O.S.S.) is a 3% silicon iron, cold
reduced to develop a high degree of grain orientation which gives numerous
advantages when compared with laminated cores: 1)
2)
3)
4)
5)

Up to 30% more flux for the same magnetising force.

Increased rating for a given size of transformer.
Better regulation.
Reduction in size and weight.
Reduced assembly time, storage and handling costs.

Normally, Wiltan cores are produced in three material thicknesses: 0.3mm for frequencies up to 200Hz; 0.1mm for frequencies between
200Hz and 2KHz; and 0.05mm for higher frequencies and pulse
applications.
Processing of Wiltan cores is carefully controlled at all stages of
production by the inspection organisation and cores are tested to the
appropriate specification prior to despatch.

Accessories

Wiltan supplies a wide range of accessories for the British standard range of C
Cores, which include Rectangular Tubes, Clamping Frames, Banding Strip
and Seals.

Technical

Curves The curves given in this publication are those in common use. It is
clearly impracticable to attempt to produce curves for applications which are
peculiar to individual users.
Incremental permeability curves shown on page 59 apply with little error for
0.3mm, 0.1mm and 0.05mm cores up to 1500Hz. Cores in 0.3mm material are
suitable for use in smoothing chokes at frequencies up to 1500Hz.
Ratings The core VA ratings shown are intended for guidance only when
determining the size of any transformer since clearly many other factors must be
considered, e.g.
a) Temperature rise.
b) Voltage regulation.
c) The number of separate windings.
d) The voltage of the individual windings.
e) The test voltage of the individual windings.
f ) The frequency of the supply.
g) Any special requirements, e.g. low exciting current, low electrostatic
capacity or ability to operate satisfactorily at a frequency lower than the
nominal frequency.
The ratings given are based on a maximum temperature rise of 60C and
individual windings of 250 volts at 50Hz.

Preferred Strip Widths

Throughout this publication we quote, wherever possible, preferred sizes of strip

width in an attempt to give reductions on delivery times. However, cores can be
supplied in strip widths outside the preferred sizes but a surcharge may
be made.

Design Procedure

Simplified procedures for the design of a current transformer and a small power
transformer are described in the Engineering Section.

Cut Core Assembly Procedure

To ensure the correct assembly of cut cores and to keep the magnetising current
to a minimum level, we suggest that: 1. Care be taken that the cut core faces are not damaged during handling.
2. To avoid mis-matching, use the core halves as packed and assemble with
the colour coding dots on the same side of the core.
3. The cut faces may be cleaned with a suitable solvent or by gently rubbing
on a clean sheet of paper.
4. Extra care should be taken when inserting the cut core halves into the
winding former to prevent any foreign matter or winding former scrapings
being trapped between the cut core faces.

Note: The Companys policy is one of continuous development and

improvement of its products and therefore the right is reserved to supply
products which may differ slightly from those described and illustrated in
this publication.

Wound Cores

Wiltan
assurance
of quality

The assurance of quality is essential to the successful outcome of

continuous component production. To this end, Wiltan gives emphasis to
quality in both design and test. The Inspection system follows Ministry of
Defence guidelines.
Due to the complexity and variations in customers requirements, the
inspection organisation is continually evaluated and updated to meet
new situations.
The general lines upon which the inspection system is based are outlined
as follows:1. Selection of magnetic steels by electrical and mechanical qualities to
ensure suitability for the particular strip wound core to be manufactured.
2. Electrical test and a check for correct dimensions following the heat
treatment cycle to ensure that the cores have been wound correctly and that
the heat treatment conditions have been satisfactory.
3. It is normal practice to inspect cores on a 100% basis after final
processing. This ensures that the dimensions are correct and the electrical
specification limits have been adhered to.
4. The Inspection Department organisation monitors the packing methods of
strip wound cores in order to ensure that the product arrives at the user in
good condition.
The members of the Inspection Department are trained in such a manner as to
be able to adapt to changing needs for the assurance of quality in strip wound
core manufacture.
The ideal conditions are when the requirement for a strip wound core can be
designed to meet some Internationally agreed specification, such as IEC, BS or
DIN. However, as frequently happens, this is not always possible. Design and
Inspection organisations at Wiltan are willing to give every assistance when such
situations arise.

C cores

Wound Cores

C cores

Standard C Cores

To cater for the demands of the electronic and electrical industries in the
manufacture of transformers, chokes, reactors and magnetic amplifiers, Wiltan
manufacture a wide range of strip wound C Cores.
Cut C Cores are produced in three standard ranges British, Continental and
American all of which can be supplied to various electrical specifications. The
cores covered by these standard ranges can be supplied with short
despatch times.

Non-Standard C Cores

C Cores can be manufactured outside the physical dimensions of the standard

ranges for special applications. It is however, advantageous to utilise the
standard ranges whenever practicable to obtain price and delivery advantage.

Preferred Strip Widths

The preferred strip widths from which Wiltan produces cores are: METRIC

mm
6.0
10.0
12.5
13.0
15.0
16.0
19.0

mm
20.0
22.0
25.0
28.0
30.0
32.0
35.0

mm
38.0
40.0
42.0
44.5
45.0
46.0
48.0

mm
50.0
55.0
56.0
60.0
62.0
63.5
65.0

mm
70.0
75.0
80.0
82.5
85.0
90.0
95.0

Above 100mm in steps of 5mm up to 200 mm.

The preferred strip widths cater for all cores in the standard ranges listed. Cores
can be supplied in strip widths outside the preferred sizes but a surcharge may
be made.

Electrical Guarantees

All cores, unless otherwise stated, are individually tested to the standard
guarantee specifications shown under the tables covering the standard range
of cores.
Special test conditions, when required, can be applied and guaranteed to suit
customers individual requirements.

BRITISH RANGE 0.3, 0.1 & 0.05mm C CORES TO DEF 5193

Imperial Dimensions

WILTAN C CORES, BRITISH RANGE

NOTE: This range of cores is equivalent to the German DIN.41309

SG Series and the French UTE C93 325 FA Series.

CORE REF.
DIMENSION IN INCHES
Length
Nett Cross
Nominal

Max of Flux
Section
Weight
A
B
D
E
F
G
B.S. HWR
Corner Path (Lm)
Area cm2
Kgs
5347
Tol.
Tol.
Tol.
Tol. Min. Min. Radius cms
0.3 mm 0.1mm 0.3mm 0.1mm

1
1
1
9
Q 1.1
3/4 3/4
11/16
/4
/4
/4
/16
6.42
-
0.372
- 0.018
1
2.1
4/5 15/16 + 5/64 15/16 + 3/32 5/16 +1/32 5/16 + 1/32 5/16 11/16
/32
7.87
-
0.582
- 0.035
3
3
3
7
3.1
5/6 11/8
15/8
/8
/8
/8
/8
9.64
-
0.862
- 0.063
3
3
7
4.1
7/6 13/16
17/8
/8
/8
/16 11/8
11.23
0.89
0.862
0.076 0.074
1
Q 5.1 10/8
/2
0.96
0.93
0.093 0.090
1
5.2 10/12 11/8 +5/64 21/8 +3/32 3/4 +1/32 5/16 +1/32 1/2
11/2
/16
12.82
1.44
1.40
0.140
0.136
5.3 10/16
1
1.92
1.86
0.187 0.181
5.4 10/24
11/2
2.88
2.79
0.280
0.271
1
Q 6.1 30/8
/2
1.15
1.12
0.145 0.140
1
6.2 30/12 13/8 +5/64 23/4 +1/8 3/4 +1/32 3/8 +1/32 5/8 2
/16
16.57
1.72
1.67
0.217 0.210
6.3 30/16
1
2.30
2.23
0.290 0.281
6.4 30/20
11/4
2.87
2.78
0.362 0.350
3
Q 7.1 40/12
/4
1.72
1.67
0.239 0.231
1
7.2 40/16 11/2 +5/64 3 +1/8 1 +1/32 3/8 +1/32 3/4 21/4
/8
18.20
2.30
2.23
0.318 0.300
7.3 40/20
11/4
2.87
2.78
0.398 0.385
7.4 40/24
11/2
3.45
3.35
0.477 0.462
7
Q 8.1 50/14
/8
2.68
2.60
0.431 0.417
1
8.2 50/18 17/8 +5/64 31/2 +1/8 11/8 +1/32 1/2 +1/32 7/8 21/2
/8
21.10
3.45
3.35
0.553 0.535
8.3 50/24
11/2
4.60
4.46
0.738 0.715
8.4 50/32
2
6.13
5.95
0.985 0.954
3
Q 9.1 70/12
/4
2.87
2.78
0.566 0.548
1
9.2 70/18 23/8 +5/64 41/4 +1/8 11/8 +1/32 5/8 +1/32 11/8 3
/8
25.90
4.54
4.40
0.850 0.893
9.3 70/24
11/2
5.75
5.57
1.134 1.098
9.4 70/32
2
7.66
7.42
1.511 1.463
Q 10.1 90/16
1 +1/32
4.60
4.45
1.074 1.040
1
10.2 90/24 27/8 +5/64 5 +1/8 11/2 +1/32 3/4 +1/32 13/8 31/2
/8
30.72
6.90
6.68
1.613 1.562
10.3 90/32
2 +1/32
9.23
8.94
2.150 2.082
10.4 90/44
23/4 +1/16
12.65
12.25
2.956 2.862
Q 11.1 110/20
11/4 +1/32
7.68
7.44
2.324 2.250
1
11.2 110/32 33/4 +5/64 61/2 +3/16 2 +1/32 1 +1/32 13/4 41/2
/8
39.86
12.26
11.87
3.719 3.601
110/64
4 +1/16
24.60
23.82
7.438 7.203

Approx V.A.
Ratings for
2 Loops
0.3 mm 0.1mm
50Hz
400Hz
-
-
-
-
17
85
26
130
32
160
40
200
38
190
53
260
70
350
84
420
63
315
80
400
95
475
120
600
120
575
150
720
210
1000
270
1300
210
450
320
1420
390
1750
490
2200
420
1800
630
2700
810
3500
1050
4500
1000
4200
1600
6700
2700 10000

The ratings quoted have been determined under conditions described in the introduction

RELAXED TOLERANCES (ins) FOR COMMERCIAL GRADE

CORES REFERRING TO SPECIFICATIONS OS-210 ONLY
A + 332
B + 532
+ 316
+ 14
D + 132
+ 116

HWR 10 to 110 Range

HWR 10 Range
HWR 30 to 90 Range
HWR 110 Range
WHEN D 2
WHEN D > 2

E + 132
HWR 10 to 50 Range
- 164
+ 132
HWR 70 to 110 Range
- 132
F & G MINIMUM

CALCULATION OF WEIGHT OF C CORES

Weight in kilos = [ A+B+F+G (8-2p) (R +E )] x E x D x p
2
Where A,B,D,E,F & G are dimensions in inches
p = 0.125 x Stacking Factor
& Stacking Factor 0.3mm Material = 0.95
0.1mm Material = 0.92
0.05mm Material = 0.88

Wound Cores

BRITISH RANGE 0.3, 0.1 & 0.05mm C CORES TO DEF 5193

Metric Dimensions

WILTAN C CORES, BRITISH RANGE

NOTE: This range of cores is equivalent to the German DIN.41309
SG Series and the French UTE C93 325 FA Series.

CORE REF.
DIMENSION IN mm
Length
Nett Cross
Nominal

of Flux
Section
Weight
A
B
D
E
F
G
R
B.S. HWR
Path
Area cm2
Kgs
5347 max. max. min. max. min. max. min. min. max. (Lm) 0.3mm 0.1mm 0.3mm 0.1mm
cms

Q 1.1
3/4 21.03 29.37 6.35
7.14 6.35 7.14 6.35 14.29
6.42
- 0.372
-
0.018
2.1
4/5 25.80 35.72 7.94
8.73 7.94 8.73 7.94 17.46 0.79
7.87
- 0.582
-
0.063
3.1
5/6 30.56 43.66 9.52 10.32 9.52 10.32 9.52 22.22
9.64
- 0.862
-
0.063
4.1
7/6 32.15 50.01 9.52 10.32 9.52 10.32 11.11 28.58 11.23
0.89 0.862
0.076
0.074
Q 5.1 10/8 12.70 13.49


0.96
0.93
0.093
0.090
5.2 10/12 30.56 56.36 19.05 19.84 7.94 8.73 12.70 38.10 1.59 12.82
1.44
1.40
0.140
0.136
5.3 10/16 25.40 26.19


1.92
1.86
0.187
0.181
5.4 10/24 38.10 38.89



2.88
2.79
0.280
0.271
Q 6.1 30/8 12.70 13.49


1.15
1.12
0.145
0.140
6.2 30/12 36.91 73.02 19.05 19.84 9.52 10.32 15.88 50.80 1.59 16.57
1.72
1.67
0.217
0.210
6.3 30/16 25.40 26.19


2.30
2.23
0.290
0.281
6.4 30/20 31.75 32.54
2.87
2.78
0.362
0.350
Q 7.1 40/12 19.05 19.84
1.72
1.67
0.239
0.231
7.2 40/16 40.08 79.38 25.40 26.19 9.52 10.32 19.05 57.15 3.18 18.20
2.30
2.23
0.318
0.300
7.3 40/20 31.75 32.54
2.87
2.78
0.398
0.385
7.4 40/24 38.10 38.89
3.45
3.35
0.477
0.462
Q 8.1 50/14 22.22 23.02
2.68
2.60
0.431
0.417
8.2 50/18 49.61 92.08 28.58 29.37 12.70 13.49 22.22 63.50 3.18 21.10
3.45
3.35
0.553
0.535
8.3 50/24 38.10 38.89
4.60
4.46
0.738
0.715
8.4 50/32 50.80 51.59
6.13
5.95
0.985
0.954
Q 9.1 70/12 19.05 19.84
2.87
2.78
0.566
0.548
9.2 70/18 62.31 111.12 28.58 29.37 15.88 16.67 28.58 76.20 3.18 25.90
4.54
4.40
0.850
0.893
9.3 70/24 38.10 38.89
5.75
5.57
1.134
1.098
9.4 70/32 50.80 51.59
7.66
7.42
1.511
1.463
Q 10.1 90/16 25.40 26.19
4.60
4.45
1.074
1.040
10.2 90/24 75.01 130.18 38.10 38.89 19.05 19.84 34.92 88.90 3.18 30.72
6.90
6.68
1.613
1.562
10.3 90/32 50.80 51.59
9.23
8.94
2.150
2.082
10.4 90/44 69.85 71.44
12.65 12.25
2.956
2.862
Q11.1 110/20 31.75 32.54
7.68
7.44
2.324
2.250
11.2 110/32 97.23 169.86 50.80 51.59 25.40 26.19 44.45 114.30 3.18 39.86
12.26 11.87
3.719
3.601
110/64 101.60 103.18
24.60 23.82
7.438
7.203

Approx V.A.
Ratings for
2 Loops
0.3mm 0.1mm
50Hz 400Hz
-
-
-
-
17
85
26
130
32
160
40
200
38
190
53
260
70
350
84
420
63
315
80
400
95
475
120
600
120
575
150
720
210
1000
270
1300
210
450
320
1420
390
1750
490
2200
420
1800
630
2700
810
3500
1050
4500
1000
4200
1600
6700
2700 10000

The ratings quoted have been determined under conditions described in the introduction

RELAXED TOLERANCES (ins) FOR COMMERCIAL GRADE

CORES REFERRING TO SPECIFICATIONS OS-210 ONLY
A + 2.4
B + 4.0
+ 4.8
+ 6.4
D + 0.8
+ 1.6

HWR 10 to 110 Range

HWR 10 Range
HWR 30 to 90 Range
HWR 110 Range
WHEN D 50.8
WHEN D > 50.8

E + 0.8 HWR 10 to 50 Range

- 0.4
+ 0.8 HWR 70 to 110 Range
- 0.8
F & G MINIMUM

CALCULATION OF WEIGHT OF C CORES

Weight in kilos = [A+B+F+G (8-2p) (R +E )] x E x D x p
2
Where A,B,D,E,F & G are dimensions in mm
p = 7.65 x 10-6 Stacking Factor
Stacking Factor 0.3mm Material = 0.95
0.1mm Material = 0.92
0.05mm Material = 0.88

CEE CLAMP CAST ALLOY OPEN TYPE ASSEMBLY TO SUIT

BRITISH RANGE OF C CORES
A
(MAX)

C
(MAX)

A
D

B
(MAX)

PATTERN H
PATTERN J
MAX. PLAN
FIXING
FIXING SCREW

CENTRES
SIZE

Height
Height
DIMENSIONS

Clamp
Max.
Clamp
Max.
(mm)
(mm)
Metric

Ref.
C
Ref.
C

(mm)
(mm)
A
B
D
E
TDH 1008
66.5
TDJ 1008
53.8

1012
72.9 1012
60.2
71.5
66.7
49.2
46.0
M4

1016
79.2 1016
66.5

1024
91.9 1024
79.2
TDH 3008
73.2
TDJ 3008
60.45
3012
79.5 3012
66.8
84.2
81.8
61.9
58.7
M4

3016
85.9 3016
73.1

3020
92.2 3020
79.5
TDH 4012
87.9
TDJ 4012
75.2

4016
94.2 4016
81.5
90.5
88.9
66.7
65.1
M5

4020
100.5 4020
87.9

4024
106.9 4024
94.2
TDH 5014
97.2
TDJ 5014
84.6

5018
103.6 5018
90.9
109.6
101.6
80.9
73.0
M5

5024
113.0 5024
100.3

5032
125.7 5032
113.0
TDH 7012
107.4 7012
94.7

7018
117.1 7018
104.4
138.1
122.3
101.6
87.3
M6

7024
126.5 7024
113.8

7032
139.2 7032
126.5
TDH 9016*
126.7 9016
114.0

9024*
139.4 9024
126.7
161.9
139.7
123.8
103.2
5/16" BSF

9032*
152.1 9032
139.4

9044*
172.7 9044
160.0
TDH 11020*
158.7
TDJ 11020
146.0

1032*
177.8 11032
165.1
212.7
185.8
165.1
133.4
5/16" BSF

11064*
229.1 11064
216.4
* TDH AND TDJ PATTERN RANGES 90 AND 110 ARE THREE FRAME ASSEMBLIES

NOTE: Height and Plan dimensions as quoted in A.S.R.E Specification 12429R

Wound Cores

54 SERIES PRESSED STEEL CLAMPING FRAME

ASSEMBLY TO SUIT BRITISH RANGE C CORES

C Core
Range


10 Range


30 Range


40 Range


50 Range


70 Range

10

A
Clamping
Height
Frame
Type
Reference
ins
54/2751
Shrouded
2 9/16
54/2701
Open Short
2 9/16
54/2731
Open Tall
3 1/32
54/2755
Shrouded
3 1/16
54/2705
Open Short
3 1/8
54/2735
Open Tall
3 9/16
54/2759
Shrouded
3 5/16
54/2709
Open Short
3 3/8
54/2739
Open Tall
3 13/16
54/2763
Shrouded
4 1/8
54/2713
Open Short
4 1/4
54/2743
Open Tall
4 5/8
54/2767
Shrouded
5 1/8
54/2717
Open Short
5 1/4
54/2747
Open Tall
5 5/8

B
Max. Width
Dimensions
ins
2 11/16
2 3/16
2 3/16
3 5/16
3 5/16
3 5/16
3 9/16
3 9/16
3 9/16
4 1/16
4 1/16
4 1/16
4 13/16
4 13/16
4 13/16

C
Fixing
Centre
ins
2 5/8
2 5/8
2 5/8
2 3/4
2 3/4
2 3/4
2 7/8
2 7/8
2 7/8
3 3/8
3 3/8
3 3/8
3 5/8
3 5/8
3 5/8

Clamping
Screw
Size
4 BA
4 BA
4 BA
4 BA
4 BA
4 BA
2 BA
2 BA
2 BA
2 BA
2 BA
2 BA
1
/4 BSF
1
/4 BSF
1
/4 BSF

CEE FRAME PRESSED STEEL OPEN TYPE

ASSEMBLY TO SUIT BRITISH RANGE C CORES

G
H

Core
Frame DIMENSIONS IN

Ref.
Ref.
A
B
C
D
E
HWR 10/8
1 116 2 58
2 916 1 12
2

10/12
1 516 2 58
2 916 1 34
2

10/16 CF 10
1 916 2 58
2 916 2
2

10/24
2 116 2 58
2 916 2 12
2
HWR 30/8
1 116 3 516 3 18
1 12
2 58

30/12

1 516 3 516 3 18
1 34
2 58
CF 30

30/16
1 916 3 516 3 18
2
2 58

30/20
11116 31516 3 18
2 14
2 58
HWR 40/12
1 38
3 12
3 38
2
2 34

40/16

1 58
3 12
3 38
2 14
2 34
CF 40

40/20
1 78
3 12
3 38
2 12
2 34

40/24
2 18
3 12
3 38
2 34
2 34
HWR 50/14
1 12
4
4 14
2 18
3 18

50/18

1 34
4
4 14 2 38
3 18
CF 50

50/24
2 18
4
4 14
2 34
3 18

50/32
2 58
4
4 14 3 14
3 18
HWR 70/12
1 916 41316 5 14
2 14
3 34

70/18

11516 41316 5 14
2 58
3 34
CF 70

70/24
21516 41316 5 14
3
3 34

70/32
21316 41316 5 14
3 12
3 34
HWR 90/16
2
51732 6 14
3 18
4 12

90/24

2
51732 6 14
3 58
4 12
CF 90

90/32
3
51732 6 14
4 18
4 12

90/44
3
51732 6 14
4 18
4 12

INCHES
F
G
2
2 964
2
2 964
2
2 964
2
2 964
2 12 2 34
2 12 2 34
2 12 2 34
2 12 2 34
2 34 2 1516
2 34 2 1516
2 34 2 1516
2 34 2 1516
3 12 3 516
3 12 3 516
3 12 3 516
3 12 3 516
4 38 31516
4 38 31516
4 38 31516
4 38 31516
5 14 4 916
5 14 4 916
5 14 4 916
5 14 4 916

H
1
2
1
2
1
2
1
2
1
2
1
2
1
2
1
2
5
8
5
8
5
8
5
8
5
8
5
8
5
8
5
8
3
4
3
4
3
4
3
4
1 116
1 116
1 116
1 116

I
32
5
32
5
32
5
32
5
32
5
32
5
32
5
32
7
32
7
32
7
32
7
32
7
32
7
32
7
32
7
32
9
32
9
32
9
32
9
32
3
8
3
8
3
8
3
8
5

J
4
1
4
1
4
1
4
1
4
1
4
1
4
1
4
3
8
3
8
3
8
3
8
3
8
3
8
3
8
3
8
7
16
7
16
7
16
7
16
5
8
5
8
5
8
5
8
1

11

Wound Cores

RECTANGULAR TUBES TO SUIT BRITISH RANGE C CORES

D +0
-0.031"

C +- 0.010"
A +0.010"
-0

B +0.010"
-0

CORE REF.

SPEC.
CORE REF.
TUBE REF. DIMENSIONS IN INCHES
BS. 5347
DEF. 5193

IEC.329
A
B
C
D
5
5
1
1
16
16
32
2
Q. 1.1
HWR 3/4
* 50/8888
3
3
1
5

2.1
4/6
* 50/8889
8
8
32
8
7
7
1
13

3.1
5/6
* 50/8890
16
16
32
16
7
7
1

4.1
7/6
* 50/8891
16
16
32
1 116
3
1

5.3
10/16
* 50/8892
1 116
8
16
1 716
9
3
1
Q. 5.1
HWR 10/8
50/8975
16
4
16
1 716
13
3
1

5.2
10/12
50/8976
16
4
16
1 716
3
1

5.3
10/16
50/8977
1 116
4
16
1 716
3
1

5.4
10/24
50/8978
1 916
4
16
1 716
9
7
1
Q. 6.1
HWR 30/8
50/8979
16
8
16
1 1516
13
7
1

6.2
30/12
50/8980
16
8
16
1 1516
7
1

6.3
30/16
50/8981
1 116
8
16
1 1516
7
1

6.4
30/20
50/8982
1 516
8
16
1 1516
13
7
1
Q. 7.1
HWR 40/12
50/8983
16
8
16
2 18
1
7
1

7.2
40/16
50/8984
16
8
16
2 18
7
1

7.3
40/20
50/8985
1 516
8
16
2 18
7
1

7.4
40/24
50/8986
1 916
8
16
2 18
15
1
Q. 8.1
HWR 50/14
50/8987
16
1 18
16
2 38
1

8.2
50/18
50/8988
1 316
1 18
16
2 38
9
1
1

8.3
50/24
50/8989
1 16
1 8
16
2 38
1

8.4
50/32
50/8990
2 116
1 18
16
2 38
13
1
Q. 9.1
HWR 70/14
50/8991
16
1 38
16
2 78
1

9.2
70/18
50/8992
1 316
1 38
16
2 78
1

9.3
70/24
50/8993
1 916
1 38
16
2 78
1
3
1

9.4
70/32
50/8994
2 16
1 8
16
2 78
3
Q. 10.1
HWR 90/16
50/8995
1 116
1 58
32
3 38
3

10.2
90/24
50/8996
1 916
1 58
32
3 38
3

10.3
90/32
50/8997
2 18
1 58
32
3 38
3

10.4
90/44
50/8998
2 78
1 58
32
3 38
5
1
1
Q. 10.1
HWR 110/20
50/8999
1 16
2 8
8
4 38
1

11.2
110/32
50/8848
2 18
2 18
8
4 38
1

110/64
50/8851
4 18
2 18
8
4 38

NOTE:* Single Loop only. All other sizes, Double Loop.

TUBES ARE MANUFACTURED IN SPBP TO BS.6128 (RATED 120 OPERATING).

12

CORRELATION OF BRITISH RANGE C CORES AND ACCESSORIES

BS Spec. 5347
UK
UK 54 Series Pressed Steel Clamp Frames Rectangular

&
Spec.
Inter-Services
Ceeclamps Ceeframes
Tubes
IEC Spec. 329
Def.
Core Ref.
Pattern
Reference Shrouded Open Short Open Tall
Reference

5193
0.3mm
0.1mm

Strip
Strip
Q.
1.1
HWR 3/4
Z371030
*50/8888

2.1
4/5
Z371031
*50/8889

3.1
5/6
Z371032
*50/8890

4.1
7/6
Z371033
*50/8891

5.3
10/16
Z371001 Z371020
*50/8892
Q.
5.1
HWR 10/8
Z371038 Z371018 TDH 1008
CF 10
54/2751
54/2701
54/2731
50/8975

5.2
10/12
Z371000 Z371019 TDH 1012
CF 10
54/2751
54/2701
54/2731
50/8976

5.3
10/16
Z371001 Z371020 TDH 1016
CF 10
54/2751
54/2701
54/2731
50/8977

5.4
10/24
Z371002 Z371034 TDH 1024
CF 10
54/2751
54/2701
54/2731
50/8978
Q. 6.1
HWR 30/8
Z371039 Z371021 TDH 3008
CF 30
54/2755
54/2705
54/2735
50/8979

6.2
30/12
Z371003 Z371022 TDH 3012
CF 30
54/2755
54/2705
54/2735
50/8980

6.3
30/16
Z371004 Z371023 TDH 3016
CF 30
54/2755
54/2705
54/2735
50/8981

6.4
30/20
Z371005 Z371035 TDH 3020
CF 30
54/2755
54/2705
54/2735
50/8982
Q. 7.1
HWR 40/12
Z371040 Z371024 TDH 4012
CF 40
54/2759
54/2709
54/2739
50/8983

7.2
40/16
Z371006 Z371025 TDH 4016
CF 40
54/2759
54/2709
54/2739
50/8984

7.3
40/20
Z371007 Z371026 TDH 4020
CF 40
54/2759
54/2709
54/2739
50/8985

7.4
40/24
Z371008 Z371036 TDH 4024
CF 40
54/2759
54/2709
54/2739
50/8986
Q. 8.1
HWR 50/14
Z371041 Z371027 TDH 5014
CF 50
54/2763
54/2713
54/2743
50/8987

8.2
50/18
Z371009 Z371028 TDH 5018
CF 50
54/2763
54/2713
54/2743
50/8988

8.3
50/24
Z371010 Z371029 TDH 5024
CF 50
54/2763
54/2713
54/2743
50/8989

8.4
50/32
Z371011 Z371037 TDH 5032
CF 50
54/2763
54/2713
54/2743
50/8990
Q. 9.1
HWR 70/12
Z371042
TDH 7012
CF 70
54/2767
54/2717
54/2747
50/8991

9.2
70/18
Z371012
TDH 7018
CF 70
54/2767
54/2717
54/2747
50/8992

9.3
70/24
Z371013
TDH 7024
CF 70
54/2767
54/2717
54/2747
50/8993

9.4
70/32
Z371014
TDH 7032
CF 70
54/2767
54/2717
54/2747
50/8994
Q. 10.1
HWR 90/16
Z371043
TDH 9016
CF 90
50/8995

10.2
90/24
Z371015
TDH 9024
CF 90
50/8996

10.3
90/32
Z371016
TDH 9032
CF 90
50/8997

10.4
90/44
Z371017
TDH 9044
CF 90
50/8998
Q. 11.1
HWR 110/20 Z371044
TDH 11020
50/8999

11.2
HWR 110/32 Z371045
TDH 11032
50/8848

HWR 110/64
TDH 11064
50/8851

NOTE: * Single Loop only. All other sizes, Double Loop.

13

Wound Cores

PATTERNS 0.3 mm MATERIAL

WILTAN C CORES EQUIVALENT TO LAMINATION PATTERNS

Lamination
C Core
C Core

Pattern
Equivalent
Window

Number
Number
Dimensions

Minimum

Inches

22 or 202
LC. 2
5 14 x 1 116

28 or 628
LC. 19
3 18 x 1 1764

29
LC. 3
1 58 x 1 12

41 or 641
LC. 24
4 78 x 1 34

60 or 660
LC. 25
2 78 x 1

78
LC. 5
2 x 58

87
LC. 6
4 58 x 1 12

117
LC. 8
5 58 x 1 12

122
LC. 10
8 18 x 34

136 or 636
LC. 21
2 78 x 1

137 or 637
LC. 22
5 18 x 1 58

217
LC. 16
5 38 x 1 34

220 or 248
LC. 17
2 34 x 78

235 or 635
LC. 20
3 78 x 1 58

E 9
LC. 1
4 58 x 1 12

E135
LC. 12
6 78 x 2 14

E638
LC. 23
3 516 x 1 116

E825
LC. 26
4 14 x 1 38

Build
Up
+ 0
- 1/32
Inches
3
4
5
8
1
2
1 14
5
8
5
8
1
1 14
1 12
3
4
7
8
1 34
7
8
3
4
1 12
2 14
1 116
1 38

Overall
C Core
Dimensions
Maximum
Inches
6 1516 x 2 58
4 716 x 2 1732
2 2332 x 1 1732
7 916 x 2 516
4 316 x 2 516
3 38 x 1 2932
6 78 x 3 1932
8 516 x 4 116
11 38 x 4 2732
4 12 x 2 1732
7 716 x 3 716
9 116 x 5 516
4 58 x 2 1116
5 12 x 3 532
7 1316 x 4 1732
11 916 x 6 2532
5 916 x 3 1364
7 316 x 4 532

Strip
Width
Inches
Up to 4
Up to 3
Up to 1
Up to 4
Up to 2
Up to 2
Up to 3
Up to 4
Up to 3
Up to 2
Up to 4
Up to 4
Up to 3
Up to 2
Up to 3
Up to 6
Up to 4
Up to 4

2
2

1
1

2
2

1
1

2 C Cores are required per laminated stack.

These C Cores have been designed to suit Bobbins common to Laminations and they offer savings in
handling and assembly time, improved electrical performance, and a greater rating for a given size of transformer.
Increments in the C Core strip or ribbon width of 1/8" up to 2", and 1/4" from 2" to 4 1/2", allow for a wide variation
in the preferred core stack heights.
Many of the cores listed are available from stock, or on short delivery.
NOTE: Clamping Frames are not always interchangeable when using C Cores in place of Laminations.

14

WILTAN C CORES TYPE SM

SM RANGE 0.3, 0.1 & 0.05mm C CORES TO DIN 41309

SM Dimensions in mm
Core
A
B
C
E
F
G
R
Ref Max. Max.
Tol.
Min.
Tol. Min. Max.

Length of
Flux Path
(Lm) cms.

30a
7.0

28.6 14.3 3.5 - 0.5 21.0
- 0.5 7.0 1.0
6.6
30b
11.0

Nett Cross Nominal Approx V.A.

Section
Weight
Ratings for
Kgs 2 Loops 50 Hz.
Area cm 2
0.3mm
0.18
0.29

0.3mm
0,009
0.015

0.3mm
1.0
2.0

42

43.6

21.8 6.0

- 0.8

31.0 15.2 - 0.7

9.5

1.5

9.8

0.72

0.054

5.0

55

56.3

28.4 8.5

- 0.8

38.5 20.8 - 0.8 11.0

1.5

12.4

1.46

0.138

21.0

65

65.6

33.2 9.9

- 0.9

45.0 27.0 - 0.8 13.0

1.5

14.6

2.24

0.250

45.0

74
74.6 37.7 11.4 - 0.9 51.0 32.5 - 1.0 14.5 1.5
16.5
3.14
0.396
84.0
85a
32.5
4.01
0.561
115.0

85.6 43.2 14.4 - 1.0 56.0
- 1.0 14.0 2.0
18.3
85b
45.5
5.66
0.792
159.0
102a
35.5
5.21
0.885
200.0

103.0 51.9 16.9 - 1.0 68.0
- 1.0 17.5 2.0
22.2
102b
52.2
7.78
1.321
300.0

NOTE: The Ratings quoted relate to conditions specified in DIN. 41300.

CALCULATION OF WEIGHT OF C CORES

CALCULATION OF NETT CROSS SECTION

AREA & WEIGHT
FOR 0.1mm & 0.05mm C CORES

Weight in Kilos = [A+B+E+G - (8-2p) (R + C

2)] x C x F x p

To Calculate Nett Cross Section & Weight for 0.1mm

Multiply 0.3mm figures by 0.968

Where A,B,C,E,F,G & R are dimensions in mm.

p = 7.65 x 10 -6 x Stacking Factor
STACKING FACTOR 0.3mm Material = 0.95
0.1mm Material = 0.92
0.05mm Material = 0.88

To Calculate Nett Cross Section & Weight for 0.05mm

Multiply 0.3mm figures by 0.926

15

Wound Cores

WILTAN C CORES TYPE SU

SU RANGE 0.3, 0.1 & 0.05mm C CORES
TO DIN 41309

Su DIMENSIONS IN mm
Length of Nett Cross Nominal
Approx. V.A
Core
A
B
C
E
F
G
R
Flux Path
Section
Weight
Ratings for
Kgs.
2 loops, 50Hz.

Ref. Max. Max.
Tol. Min.
Tol.
Min.
Max. (Lm) cms. Area cm2

0.3mm
0.3mm
0.3mm
a
5.4
0.22
0.010
-
15
28.7 15.0 4.9
- 0.5 18.5
-0.4
5
1.5
6.1
b
8.4
0.35
0.015
-
a
8.5
0.58
0.042
24
42.7 24.0 7.9
- 0.6 26.5
-0.5
8
1.5
9.2
b 13.5
0.95
0.066
a 10.1
0.82
0.072
3
30
52.7 30.0 9.9
-0.8 32.5
-0.6
10
1.5
11.4
b 16.1
1.34
0.117
6
a 13.4
1.44
0.163
12
39
67.9 39.1 12.9 -0.8 41.5
-0.9
13
1.5
14.8
b 20.4
2.24
0.254
20
a 16.5
2.19
0.303
30
48
82.9 48.0 15.8 -0.9 50.5
-1.0
16
1.5
18.1
b 25.5
3.47
0.480
48
a 20.6
3.50
0.605
82
60
103.6 60.1 19.8 -0.9 63.0
-1.1
20
2.0
22.6
b 30.6
5.30
0.916
122
a 26.1
5.63
1.22
200
75
128.6 75.0 24.7 -1.0 78.0
-1.1
25
2.0
28.2
b 41.1
9.01
1.95
306
a 30.9
8.0
2.08
387
90
155.8 90.0 29.6 -1.1 95.0
-1.4
30
3.0
34.0
b 50.9
13.4
3.49
630
a 35.4
10.3
3.09
620
102
175.4 102.4 33.7 -1.2 106.0
-1.4
34
3.0
38.4
b 56.4
17.0
5.00
960
a 39.2
12.9
4.23
920
114
195.6 114.4 37.6 -1.3 118.0
-1.7
38
3.0
42.8
b 63.2
21.2
6.96
1440
a 45.2
17.4
6.58
1580
132
225.4 132.1 43.4 -1.4 136.0
-1.7
44
3.0
49.5
b 71.2
27.1
10.50
2370
a 51.2
22.5
9.70
2370
150
255.6 150.2 49.4 -1.5 154.0
-1.7
50
3.0
56.2
b 76.2
33.9
14.58
3380
a 57.0
28.1
13.53
3620
168
286.0 168.3 55.3 -1.6 172.0
-2.0
56
3.0
63.0
b 91.0
45.5
21.88
5400
a 62.0
33.0
17.07
4560
180 b 307.2 181.3 59.7 -1.8 184.0 77.0
-2.0
60
3.0
67.6
41.3
21.35
6500
c 92.0
49.5
25.60
6400
a 71.7
44.6
26.90
7800
210 b 357.2 211.2 69.9 -2.0 214.0 101.7
-2.2
70
3.0
78.7
63.9
38.50
10500
c 131.7
83.2
50.10
12900

NOTE: The ratings quoted relate to conditions specified in DIN. 41300

CALCULATION OF WEIGHT OF C CORES

CALCULATION OF NETT CROSS SECTION

AREA & WEIGHT
FOR 0.1mm & 0.05mm C CORES

Weight in Kilos = [A+B+E+G - (8-2p) (R + C

2 )] x C x F x p

To Calculate Nett Cross Section & Weight for 0.1mm

Multiply 0.3mm figures by 0.968

Where A,B,C,E,F,G & R are dimensions in mm.

p = 7.65 x 10 -6 x Stacking Factor
STACKING FACTOR 0.3mm Material = 0.95
0.1mm Material = 0.92
0.05mm Material = 0.88

16

To Calculate Nett Cross Section & Weight for 0.05mm

Multiply 0.3mm figures by 0.926

WILTAN C CORES TYPE SE

SE RANGE 0.3, 0.1 & 0.05mm C CORES
TO DIN 41309

SE
DIMENSIONS IN mm
Length of
Core
Flux Path
Ref.
A
B
C
E
F
G
R
(Lm) cms.

Max. Max. Tol. Min. Tol. Min. Max.

Nett Cross
Section
Area cm2
0.3mm

Nominal
Weight
Kgs
0.3mm

Approx. VA
Ratings for
2 Loops, 50Hz
0.3mm

60
52.2 30.0
9.9
-0.8 32.0 20.5
-0.8 10.5
1.5
11.4
1.8
0.15
66
57.2 33.5 10.9
-0.8 35.0 22.5
-0.8 11.5
1.5
12.5
2.19
0.20
78
68.2 39.5 12.9
-0.8 42.0 27.0
-0.9 13.5
2.0
14.9
3.16
0.343
a
29.0
3.66
0.428
84
73.4 42.6 13.9
-0.8 45.0
-1.0 14.5
2.0
16.0
b
43.0
5.51
0.641
a
24.0
2.44
0.333
92
77.6 46.2 11.4
-0.8 54.0
-1.0 23.0
2.0
18.7
b
33.0
3.39
0.461
a
33.0
4.35
0.662
106
88.6 53.2 14.4
-0.8 59.0
-1.0 24.0
2.0
20.9
b
46.0
6.12
0.930
a
37.2
5.64
1.12
130 108.8 65.3 17.4
-0.9 73.0
-1.2 30.0
2.0
25.9
b
47.2
7.21
1.43
a
41.2
7.18
1.63
150 b 123.8 75.2 19.8
-0.9 83.0 51.2
-1.2 35.0
2.0
29.7
8.98
2.04
c
61.2
10.80
2.45
a
56.0
11.0
2.92
170 b 145.8 85.0 22.1
-1.0 100.0 66.0
-1.5 40.0
3.0
34.7
12.9
3.42
c
76.0
14.9
3.96
a
57.0
13.8
4.58
195 b 186.8 98.2 27.3
-1.1 130.0 70.0
-1.5 42.5
3.0
42.9
17.0
5.58
c
85.0
20.8
6.83
a
63.0
18.0
6.87
231 b 216.0 116.1 32.1
-1.3 149.0 79.0
-1.5 50.5
3.0
49.9
22.7
8.67
c
98.0
28.2
10.77

387
484
590
720
860
1130
1308
1490
1890
2250
2390
3000
3710
4400

NOTE: The ratings quoted relate to conditions specified in DIN. 41300

CALCULATION OF WEIGHT OF C CORES

CALCULATION OF NETT CROSS SECTION

AREA & WEIGHT
FOR 0.1mm & 0.05mm C CORES

Weight in Kilos = [A+B+E+G - (8-2p) (R + C

2 )] x C x F x p

To Calculate Nett Cross Section & Weight for 0.1mm

Multiply 0.3mm figures by 0.968

Where A,B,C,E,F,G & R are dimensions in mm.

p = 7.65 x 10 -6 x Stacking Factor
STACKING FACTOR 0.3mm Material = 0.95
0.1mm Material = 0.92
0.05mm Material = 0.88

To Calculate Nett Cross Section & Weight for 0.05mm

Multiply 0.3mm figures by 0.926

17

Wound Cores

Correlation Reference nos.

British Range of C Cores - Continental References

BS Spec. 5347
UK Spec. DEF 5193
German Spec.

&
&
DIN. 41309
IEC Spec. 329
Wiltan Ref.

18

French Spec.
UTE
C93325
FA10/30
FL10/30

Q1.1*
HWR 3/4*
SG 27/6*
D 06*
2.1*
4/5*
33/7*
F 08*
3.1*
5/6*
41/9*
H 10*
4.1
7/6
48/19
J 10
5.1
10/8
54/13
Q 13
5.2
10/12
54/19
Q 19
5.3
10/16
54/25
Q 25
5.4
10/24
54/38
Q 38
6.1
30/8
70/13
T 13
6.2
30/12
70/19
T 19
6.3
30/16
70/25
T 25
6.4
30/20
70/32
T 32
7.1
40/12
76/19
U 19
7.2
40/16
76/25
U 25
7.3
40/20
76/32
U 32
7.4
40/24
76/38
U 38
8.1
50/14
89/22
V 22
8.2
50/18
89/29
V 29
8.3
50/24
89/38
V 38
8.4
50/32
89/51
V 51
9.1
70/12 108/19
X 19
9.2
70/18 108/29
X 29
9.3
70/24 108/38
X 38
9.4
70/32 108/51
X 51
10.1
90/16 127/25
Z 25
10.2
90/24 127/38
Z 38
10.3
90/32 127/51
Z 51
10.4
90/44 127/70
Z 70
11.1
110/20 165/32
AD 32
11.2
110/32 165/51
AD 51

110/64

Correlation Reference nos.

British Range of C Cores - Continental References

French Spec.
I EC Spec.329
German Spec.
UTE C93325
Wiltan

DIN.41309
FA10/30
Ref.

FL10/30

R 1.1
SE 130A
RA 36
SE 130A
R 1.2
SE 130B
RA 46
SE 130B
R 2.1
SE 150A
RB 40
SE 150A
R 2.2
SE 150B
RB 50
SE 150B
R 2.3
SE 150C
RB 60
SE 150C
R 3.1
SE 170A
RC 55
SE 170A
R 3.2
SE 170B
RC 65
SE 170B
R 3.3
SE 170C
RC 75
SE 170C
R 4.1
SE 195A RD 56
SE 195A
R 4.2
SE 195B RD 69
SE 195B
R 4.3
SE 195C
RD 84
SE 195C
R 5.1
SE 231A
RE 62
SE 231A
R 5.2
SE 231B
RE 78
SE 231B
R 5.3
SE 231C
RE 97
SE 231C
P 1.1
BA 3
P 1.1
P 2.1
BB 3
P 2.1
P 3.1
BB 6
P 3.1
P 4.1
BD 3
P 4.1
P 4.2
BD 6
P 4.2
P 5.1
BH 6
P 5.1

French Ref.

AJ. 32
AJ. 51
AP. 32
AP. 51
AS. 51
AS. 70
AS. 100
HB. 32
HB. 51
HF. 38
HG. 38
HJ. 51
HK. 51

Wiltan Ref.
C 3272
C 3168
C 3430
C 3431
C 3432
C 3433
C 3434
C 3435
C 3436
C 3437
C 3438
C 3439
C 3440

19

Wound Cores

AMERICAN RANGE C CORES

Due to the large number of cores in this range, it is not practicable to publish
dimensions in the normal manner.
To assist the Designer in selection, we list below preferred window dimensions
along with maximum strip width appropriate to a given window. More detailed
information will be given on application.

DIMENSIONS
DIMENSIONS
Window Dimensions (Ins)
Strip Width
Window Dimension (Ins)

Tolerance 164"
Maximum
Tolerance 164"

Ins.
1 x 12
12 x 14
1
2
1 18 x 12
58 x 14
78 x 14
1 516 x 12

1 38 x 12
13
5
16 x 16
1 12 x 12
78 x 516
1 916 x 12
3

1 x 516
4
1 1116 x 12

1 1 16 x 516

2 14 x 516
1 14 x 58

1 516 x 58

1 x 38
1 12 x 58

1 1 8 x 38
1 916 x 58

1 3 16 x 38
1
1 1116 x 58

1 14 x 38
1 34 x 58
1 1516 x 58

1 7 16 x 38

1 34 x 58

1 316 x 716
1 1516 x 58

1 38 x 716
2 716 x 58

1 9 16 x 716
1 14
2 12 x 58
11
7

1 16 x 16

20

Strip Width
Maximum
Ins.

112

STANDARD ELECTRICAL GUARANTEES

0.3, 0.1mm C CORES

Wiltan Spec. Material
Guarantee Total Iron Loss
BS Spec
No.
Thickness Frequency Induction Not Greater Than
5347
mm
Hz.
Tesla
Watts/Kg


T
OS 210
0.3
50
1.7
2.2



Y
OS-110
0.3
50
1.7
2.0



R
OS-111
0.3
50
1.7
1.8

Total R.M.S.
Mag. VA/Kg
Not Greater Than

-
OS-15
0.1
400
1.5
22.0



-
OS-10
0.1
400
1.0
9.9 for Lm

less than 10 cms

8.8 for LM

equal or more

than 10 cms.

(28.6 + 1019
--------- ) 2 + 222
Lm

135
13.5 +
Lm

Remarks
Supplied to commercial tolerances
and only when available

84
9.9 + Lm
42
5.95 +Lm

89.5 ) 2 + 8.82
(13.2 + -------Lm

C CORES IN 0.05mm Material:

SPECIFICATION OS 112
To give customers a guidance as to the performance levels of cores manufactured to this specification, we detail below test
conditions for this particular range of cores.
All cores tested at a Bmax of 0.5 Tesla and a frequency of 2000Hz.
For cores with a magnetic path length equal to or greater than 10cms: Total iron losses not greater than 19.8 Watts/Kg.
Total R.M.S. magnetising VA/Kg. = (28.6 + 89.5)2 + 19.82
Lm
For cores with a magnetic path length less than 10cms: Total iron losses not greater than 24.8 Watts/Kg.
Total R.M.S. magnetising VA/Kg. = (28.6 + 89.5)2 + 24.82
Lm
NOTE: In all the above formulae, Lm is the mean length of magnetic path of core in cms.

21

Wound Cores

NOTES

22

E cores

23

Wound Cores

British Range 0.3 & 0.1mm E cores

Imperial dimensions
Wiltan E Type Cores

E
R

G
B

CORE REF.
DIMENSIONS IN INCHES

Nominal Nett
Nominal
Max. Cross Section
Weight
Approx.V.A.
IEC HWE
A
B
D
E
F
G
Corner
Area cm2
Kgs.
Rating
329
Tol
Tol
Tol
Tol
Min Min Radius
50Hz
400Hz

0.3mm 0.1mm 0.3mm 0.1mm 0.3mm 0.1mm
.010 916

13 2 14 + 18 1 78 + 18 12 + 132 38
+.020
'' 2 14
'' 34 '' 12 58

14 2 34

1 18 132

1.15

1.11

0.17

0.16

40

1 14 132

2.29

2.22

0.39

0.37

16

80

3Q1

3Q2

''

2 12

''

1 '' 12

'' 34

1 12 116

3.06

2.97

0.60

0.58

30

150

3 12

''

''

1 '' 58

'' 1316 1 34 116

3.77

3.66

0.85

0.82

45

250

3Q3

3 58

''

3 14

''

1 18 '' 58

'' 78

2 116

4.24

4.11

1.04

1.01

60

350

3Q4

4 14

''

3 34

''

1 14 '' 34

''

2 14 18

5.67

5.50

1.59

1.54

100

600

3Q5

4 78

''

4 14

''

1 14 '' 78

''

1 18

2 12 18

6.65

6.45

2.10

2.04

150

800

3Q6

5 34

''

''

1 14 ''

''

1 38

3 18

7.60

7.37

2.86

2.77

250

1350

3Q7

3Q8

6 34

''

''

1 14 ''

1 14

''

1 12

3 12 18

9.50

9.22

4.17

4.04

400

2000

''

6 34

+ 532

1 12 ''

1 12

''

1 34

3 34 18

13.70

13.29

6.80

6.60

700

3500

3Q9

8 58

''

7 12

''

1 58 ''

1 58

''

1 78

4 14 18

16.10

15.62

8.81

8.55

1000

5000

3Q10 10

9 78

''

8 12

''

1 78 ''

1 78

''

2 18

4 34 18

21.40

20.76 13.30

12.90

1700

8500

3Q11 11 11 18

''

9 14

''

2 18 +116 2 18

''

2 38

5 18

27.60

26.77 18.80

18.24

2500

12500

3Q12 12 12 58

'' 10 14

''

2 38 ''

''

2 34

5 12 18

34.40

33.37 26.40

25.61

4000

20000

2 38

The ratings quoted have been determined under conditions described in the introduction

24

British Range 0.3 & 0.1mm E cores

Metric dimensions
Wiltan E Type Cores

E
R

G
B

CORE REF.
DIMENSIONS INmm



A
B
D
E
F
IEC
329 HWE max max
min max min max min

G
min

Nominal Nett
Cross Section
Area cm2

max 0.3mm 0.1mm

Nominal
Weight
Kgs

Approx. V.A.
Ratings

0.3mm 0.1mm

0.3mm 0.1mm

- 13

60.40 50.80 12.70 13.50 9.30 10.00 14.30 28.60 0.80

1.15

1.11

0.17

0.16

- 14

73.00 60.30 19.00 19.80 12.50 13.20 15.90 31.70 0.80

2.22

2.29

0.37

0.39

16

40
80

3Q1

79.50 67.50 25.40 26.20 12.70 13.50 19.00 38.10 1.60

3.06

2.97

0.60

0.58

30

150

3Q2

92.00 79.60 25.40 26.20 15.60 16.60 20.60 44.40 1.60

3.77

3.66

0.85

0.82

45

250

3Q3

95.20 86.20 28.60 29.40 15.60 16.60 22.20 50.80 1.60

4.24

4.11

1.04

1.01

60

350

3Q4

111.10 99.00 31.70 32.50 18.80 19.60 25.40 57.20 3.20

5.67

5.50

1.59

1.54

100

600

3Q5

127.00 111.80 31.70 32.50 22.00 23.00 28.60 63.50 3.20

6.65

6.45

2.10

2.04

150

800

3Q6

148.40 130.80 31.70 32.50 25.10 26.10 34.90 76.20 3.20

7.60

7.37

2.86

2.77

250

1350

3Q7

174.20 156.60 31.70 32.50 31.50 32.50 38.10 88.90 3.20

9.50

9.22

4.17

4.04

400

2000

3Q8

206.00 175.90 38.10 38.90 37.80 39.00 44.40 95.30 3.20 13.70 13.29

6.80

6.60

700

3500

3Q9

222.20 195.30 41.30 42.10 41.00 42.20 47.60 108.00 3.20 16.10 15.62

8.81

8.55

1000

5000

3Q10 10

254.70 221.50 47.60 48.40 47.40 48.90 54.00 120.70 3.20 21.40 20.76

13.30 12.90

1700

8500

3Q11 11

286.80 241.30 54.00 55.60 53.70 55.20 60.30 127.00 3.20 27.60 26.77

18.80 18.24

2500 12500

3Q12 12

326.10 268.20 60.30 61.90 60.10 61.80 69.90 140.00 3.20 34.40 33.37

26.40 25.61

4000 20000

The ratings quoted have been determined under conditions described in the introduction

25

Wound Cores

S3U Range 0.3mm E Cores

to Din 41309
C
G

Wiltan E Cores Type S3U

E
A

S3U
DIMENSIONS INmm
CORE
Ref.
A
B
C
E
F

Max
Max Tol
Min Tol

G
Min

R
Max

Nett
Nominal Approx. V.A.
Cross
Weight Ratings 50Hz
Sectional
Area cm2
Kgs

a
10.1
0.86
0.115
30
53.7 50.9
9.9
-0.8
32.5
-0.6
10
1.5
b
16.1
1.41
0.189

7
15

a
13.4
1.51
0.262
39
70.9 66.0
12.9
-0.8
41.5
-0.9
13
1.5
b
20.4
2.36
0.409

20
25

a
16.6
2.32
0.492
48
83.9 80.8
15.8
-0.9
50.5
-1.0
16
1.5
b
25.6
3.67
0.779

30
40

a
20.6
60
104.6 100.9
19.8
-0.9
63.0
-1.1
20
2.0
b
30.6

3.69
5.58

0.959
1.470

60
100

a
26.1
75
129.7 125.7
24.7
-1.0
78.0
-1.1
25
2.0
b
41.1

5.93
9.48

1.82
2.93

140
180

a
30.9
90
156.8 150.6
29.6
-1.1
95.0
-1.4
30
3.0
b
50.9

8.41
14.11

3.33
5.59

270
450

a
35.4
102
176.4 171.1
33.7
-1.2
106.0
-1.4
34
3.0
b
56.4

11.05
17.88

4.94
8.00

450
700

a
39.2
114
196.2 191.0
37.6
-1.3
118.0
-1.7
38
3.0
b
63.2

13.54
22.20

6.78
11.10

650
1000

a
45.2
132
226.4 220.5
43.4
-1.4
136.0
-1.7
44
3.0
b
71.2

18.27
29.19

10.50
16.80

1000
1800

a
51.2
150
255.6 249.6
49.4
-1.5
154.0
-1.7
50
3.0
b
76.2

23.71
35.69

15.50
23.40

2000
3000

a
57.0
168
286.0 279.6
55.3
-1.6
172.0
-2.0
56
3.0
b
91.0

29.54
47.79

21.70
35.10

3000
4000

a
180b
307.2 301.0
59.7
-1.8
184.0
c

62.0
77.0
-2.0
60
3.0
92.0

34.74
43.43
52.11

27.40
34.20
41.10

3500
4500
5000

a
210b
357.2 350.8
69.6
-2.0
214.0
c

71.7
101.7
-2.2
70
3.0
131.7

46.98
67.26
87.54

43.10
61.70
80.40

6000
8000
10000

The ratings quoted have been determined under conditions described in the introduction
The above can also be supplied in 0.1mm material.

26

Correlation Reference Nos.

British Range of E Cores Continental References

BSSpec. 5347
German
& IEC Spec. 329
Specification

Din. 41309

French
Specification
UTE C93-325
FA 10/30
FA 10/30

Telmag
Reference

3R 1.1 S3U 150A

S3U 150A
3R 1.2 S3U 150B
S3U 150B
3R 2.1 S3U 168A
S3U 168A
3R 2.2 S3U 168B
S3U 168B
3R 3.1 S3U 180A
S3U 180A
3R 3.2 S3U 180B
S3U 180B
3R 3.3 S3U 180C
S3U 180C
3R 4.1 S3U 210A
S3U 210A
3R 4.2 S3U 210B
S3U 210B
3R 4.3 S3U 210C
S3U 210C
3P 1.1
EA 8 E 175
3P 1.2
EA 13 E 176
3P 1.3
EA 16 E 177
3P 2.1
EB 10 E 178
3P 2.2
EB 13 E 163
3P 2.3
EB 16 E 164
3P 2.4
EB 19 E 179
3P 2.5
EB 22 E 180
3P 3.1
EC 13 E 181
3P 3.2
EC 16 E 182
3P 3.3
EC 19 E 183
3Q 1
EC 25 E 1
3Q 2
ED 25 E 2
3Q 3
EF 29 E 3
3Q 4
EH 32 E 4
3Q 5
EK 32 E 5
3Q 6
EM 32 E 6
3Q 7
EP 32 E 7
3Q 8
ER 38 E 8
3Q 9
ET 41 E 9
3Q 10
EV 48 E 10
3Q 11
EX 54 E 11
3Q 12
EZ 60 E 12
3Q 00 - E 13
3Q 0 - E 14

27

Wound Cores

Wiltan Circular E Type Core

Standard Range of Sizes

Wiltan Circular E Type Cores are now produced in the range of sizes shown in
the table below. The Wiltan Technical Advisory Service is available to design
engineers regarding the application of Circular E Type Cores to particular
requirements which they have in view.

60

1/8 " R

120

1/8 " R

WINDING AREA

E NOM
2E + .020"
- .010"
B MIN
A +.093"
-0

D +.031"
-0

Wiltan
USA
Dimensions in Inches
Complete
Nett Cross Effective Window Area
Part
Part
Weight Kg. Section
No.
No.
Area cm2

A
B
D
E
2E
0.3
0.1
0.3
0.1
F
G
K
M
N In2
38
316
38
18
1732 14
18
18 .097
CE 500 5192
178 1 12
.082
.020
12
14
12
12
732
932 .38
.249
.036
1
12
CE 501 5283
3
2 12
34
14
12
12
732
932 .38
CE 502 5091
3
2 12
.372
.054
1
12
14
12
12
732
932 .38
.499
.071
1
12
CE 503 5188
3
2 12 1
932
916
58
14
38 .59
CE 504 5213
3 58 3 116 916
.381
.045
1 14
58
932
916
58
14
38 .59
.503
.059
1 14
58
CE 505 5284
3 58 3 116 34
932
916
58
14
38 .59
CE 506 5145
3 58 3 116 78
.594
.070
1 14
58
34
516
58 .631 .612 .070 .067
1116 1 38
38 .71
CE 507 5198
4
3 38
1116 516
78
516
58 .726 .703 .081 .079
1116 1 38 1116 516
38 .71
CE 508 5282
4
3 38
78
14
12 .594 .576 .065 .062
1116 1 38
38 .71
1116 516
CE 509 5137
4
3 12
34
38
34 .739 .717 .082 .081
34
38
716 .87
CE 510 5285
4 12 3 34
1 916 34
78
38
34 .898 .871 .096 .093
34
38
716 .87
CE 511 5090
4 12 3 34
1 916 34
38
34 1.306 1.270 .141 .136
34
38
716 .87
CE 512 5236
4 12 3 34 1 932
1 916 34
38
34 1.025 .993 .110 .107
34
38
716 .87
1 916 34
CE 513 5286
4 12 3 34 1
38
34 1.152 1.116 .124 .119
34
38
716 .87
CE 514 5101
4 12 3 34 1 18
1 916 34
38
34 1.284 1.243 .138 .133
34
34
716 .87
CE 515 5125
4 12 3 34 1 14
1 916 34
716
78 1.488 1.442 .129 .126
78
12 1.18
CE 516 5142
5 14 4 38 1
1 34 1516 516
716
78 2.232 2.164 .194 .188
78
12 1.18
1 34
1516 516
CE 517 5156
5 14 4 38 1 12
716
78 2.413 2.341 .209 .203
78
12 1.18
CE 518 5157
5 14 4 38 1 58
1 34
1516 516
78
716
78 1.374 1.334 .112 .109
1516 1 78
12 1.32
CE 519 5287
5 12 4 58
1516 716
716
78 1.569 1.524 .129 .126
1516 1 78 1516 716
12 1.32
CE 520 5288
5 12 4 58 1
716
78 1.769 1.715 .144 .140
1516 1 78 1516 716
12 1.32
CE 521 5289
5 12 4 58 1 18
716
78 1.964 1.905 .160 .155
1516 1 78 1516 716
12 1.32
CE 522 5290
5 12 4 58 1 14
58
12
916 1.70
CE 523 5154
7
5 34 1 12
1 14 4.087 3.960 .276 .267 1 116 218 1 116
58
12
916 1.70
CE 524 5291
7
5 34 1 14
1 14 3.402 3.298 .229 .222 1 116 218 1 116

28

Rectangular Tubes to Suit British Range E Cores

D +0
-0.031"

C +- 0.010"
A +0.010"
-0

B +0.010"
-0

Core Ref.Spec.
BS 5347
IEC. 329
3Q00
3Q0
3Q1
3Q2
3Q3
3Q4
3Q5
3Q6
3Q7
3Q8
3Q9
3Q10
3Q11
3Q12

HWE
DIMENSIONSININCHES
Core
Ref.
A
B
13 716 916
1316
14 916
1 916
1 116
1 116
2 1116
3 1116
1 316
4 1316
1 516
5 1516
1 516
6
1 116
1 516
7
1 516
1 516

8
1 916
1 916

9
1 1116
1 1116

10
1 1516
1 1516

11
2 14
2 14

12
2 12
2 12

D
1 116
1 316
1 716
1 1116
1 1516
2 18
2 38
2 78
3 38
3 58
4 18
4 58
4 78
5 38

132
132
116
116
116
116
116
116
116
116
332
332
18
18

Standard electrical Guarantees 0.03mm & 0.1mm E Cores

Telmag Spec
Material
Frequency
Guarantee

No.
mm
Hz
Induction Tesla



OS-17
0.3
50
1.7

OS-12

0.1

400

1.2

Total Iron Loss

Not Greater Than
Watts/kg

Total R.M.S.
magnetising VA/Kg
Not Greater Than

2.7

(9.7 + 2.63 x A)2 + 2.72

W

17.6

(17.6 + 8.2 x A)2 + 17.62

W

Where A is nett cross section per limb (cm2) W is nett weight of core (kilograms).

29

Wound Cores

NOTES

30

Toroidal
cores

31

Wound Cores

Toroidal
cores

WILTAN Toroidal Cores are supplied in numerous sizes and grades of material.
Cores can be manufactured in material thicknesses 0.3mm, 0.1mm and
0.05mm.
The various forms of toroids are as follows: a) Uncut, not impregnated
b) Uncut, treated for added rigidity
c) Cut and impregnated

Range of Diameters

Imperial
Smallest Inside 12"
Largest Outside 54"

Metric
12.5mm
1372mm

Preferred Strip Widths

Refer to preferred strip width quoted on Page 6.

Limits of Tolerance
d + 132" up to 6" d+ 0.8mm up to 152mm
Over 9" by agreement
D +132" up to 9" D+ 0.8mm up to 240mm

Over 6" by agreement

T

-0
for cores less
+ 132" than 9" O/D

for cores over

T - 01
+ 16" 9" O/D

-0
+ 0.8mm

for cores less

than 240mm O/D

-0
for cores over
T + 1.59mm 240mm O/D

The various forms of finishes are as follows: a) Uncut, non-impregnated.

b) Uncut, lightly impregnated with varnish.
c) Uncut, fully impregnated with resin.
d) Cut and fully impregnated with resin.
e) Multi cut fully impregnated with resin.
f) Supplied with plastic end cheeks, polypropylene (Max Temp 90C), Crastine
(Max Temp 130C).
g) Insulated vacuum wrapped with polypropylene (Max Temp 90C).
h) Epoxy resin coated (Max Temp 170C).
Note
It should be noted that with an epoxy coated Toroidal Core, the coating thickness
is normally:
0.025" + 0.005 (0.64mm + 0.12mm)

32

Calculation of Core Weights

Nominal Finished Weight per Core = KT (D + d) (D d) Kilos
Where D = Outside diameter

d = Inside diameter

T = Stripwidth
Where Dimensions are in inches

K = p/4 x 126 x SF
Where Dimensions are in millimetres

K = p/4 x 7.65 x SF x 10-6
SF for 0.3mm material is 0.95

0.1mm material is 0.92

0.05mm material is 0.88
As already stated, Toroidal Cores may be manufactured in a great variety of
sizes. As an indication of the smaller dimensional cores that are available on
request, we detail below the cores as listed in Defence Specification 5193.

Style
H.W.T.
4/4
4/8
6/3
6/5
7/3
7/5
7/7
8/4
8/6
8/8
10/4
10/6
10/8
12/4
12/6
12/8
14/5
14/7
14/9
16/5
16/7
16/9
18/5
18/7
18/9

Dimensions in Inches
d
D
T
1
13
1
2
16
4
1
1
2
1
2
3
3
4
1 18
16
3
5
4
1 18
16
7
3
8
1 516
16
7
5
8
1 516
16
7
7
8
1 516
16
1
4
1
1 12
3
1
1 12
8
1
1
1 12
2
1
1 78
4
1 14
3
1 14
1 78
8
1
1 78
2
1 14
1
1 12
2 14
4
3
1 12
2 14
8
1
2 14
2
1 12
5
1 34
2 58
16
7
2 58
16
1 34
9
1 34
2 58
16
5
16
2
3
7
16
2
3
9
2
3
16
5
2 14
3 38
16
7
3 38
16
2 14
9
2 14
3 38
16

Mean Perimeter
Cms
5.25
6.00
7.50
7.50
8.75
8.75
8.75
10.00
10.00
10.00
12.50
12.50
12.50
15.00
15.00
15.00
17.43
17.43
17.43
20.00
20.00
20.00
22.42
22.42
22.42

Gross Cross
Section cms
.252
.807
.227
.348
.264
.440
.616
.403
.605
.807
.504
.756
1.010
.605
.907
1.210
.882
1.230
1.580
1.010
1.410
1.810
1.130
1.590
2.040

Toroidal Cores
Performance Guarantees:Non-impregnated Toroidal Cores are normally offered with the following
standard guarantees

Material

Test
Frequency

Flux
Density

0.3mm GRADE M4
50 Hz
1.0

0.3mm GRADE M5
50 Hz
1.0

0.1m
400 Hz
1.5


0.05mm
400 Hz
1.2

Tesla
Tesla
Tesla
Tesla

Limit:
19.0
20.0
26.5
17.5
17.5
12.5

A/M
A/M
VA/Kg
Watts/Kg
VA/Kg
Watts/Kg

Magnetic degradation occurs when Toroidal Cores are impregnated with

varnish or epoxy coated and, as a guide, the increased losses expected are as
shown below:

Lightly impregnated in varnish

Fully impregnated in epoxy resin
Epoxy coated

+ 15%
+ 20%
+ 40%

33

Wound Cores

WILTAN TS NON-IMPREGNATED TOROIDAL CORES

Wiltans TS non-impregnated Toroidal cores are made from Hib

0.3mm grain oriented silicon steel and demonstrate extremely good
magnetic properties at low and high flux densities.
The cores are particularly suited to current and voltage transformer applications
requiring high accuracy and can sometimes replace cores made from more
costly materials. In such cases, an immediate saving is apparent.

Performance Guarantees

Curves showing the power, quadrature and total magnetising components of

TS Cores are shown in the Engineering Section of this publication and, for
comparison, similar curves for cores made from the best normally available grain
oriented silicon steel.
TS Cores are normally tested and guaranteed at 2 points on the
magnetisation curve: T

1. 0.3 Tesla 6.5 A/M

2. 1.0 Tesla 16.0 A/M
Other points of guarantee can be agreed to customers preferred test conditions.

Mechanical Parameters

To achieve the guarantee performance figures shown above, TS cores must

comply with the following dimensional parameters.
D

a) Inside diameter must be greater than 30mm

b) The ratio of Inside Diameter must be greater than 1.
Strip Width
TS Cores which are required outside these mechanical parameters should be
referred to Wiltan for evaluation.

34

Single &
three-phase
power
distribution
cores

35

Wound Cores

Wiltan single and three-phase strip wound distribution transformer cores are
operating in many thousands of transformers in the UK and overseas.

Advantages

Single &
three-phase
power
distribution
cores

The cores are strip wound in grain oriented silicon iron and offer the following
advantages when compared with stack laminated cores: 1. Reduction in iron losses lower stand-by losses.
2. Reduced assembly time
3. Ease of storage and handling.

Range

No standard range of design exists owing to the diversity of design requirements

but we detail in this Section a range of standard core limb sections suitable for
use with Bobbins ranging from 2.5/8" to 7.1/8" inside diameter. These sections
can be produced with any desired window so that great flexibility in design is
possible and advantage should be taken of these standard sections whenever
practicable because tooling already exists and shorter delivery times can
therefore be offered.
Cores of this type can be produced in the cut or uncut form, single or threephase, up to one tonne.

Cross Section

Distribution transformer cores can be supplied with the following cross sections:
a) Cruciform Section: - This gives a simulated circle to accommodate ease of
winding with heavy strip copper. (Figs 1&1a)
b) Half Cruciform Section: - In shell type construction, a full cruciform section
is obtained on the centre limb when 2 loops are used. (Fig 2)
c) Rectangular Section: - (Fig 3)

Fig. 1

Fig. 1a

36

Standard core circle Diameters for single & three-phase

power distribution cores

Fig. 2

Core
Section

Ref

Nominal Core
Circle Diam.
No. of
(ins.)
Steps

Fig. 3

Nett Cross
% of
Section of Iron
Core
(cm2)
Circle Area

2 12 SD
2 34 SD

2 12
2 34

3
3

25.55
30.97

85
85

3
SD
3 14 SD
3 12 SD

3
3 14
3 12

4
4
4

38.39
44.90
51.75

88
88
87

3 34
4
4 14
4 12
4 34
5

5
5
5
5
5
5

61.10
69.68
78.71
88.39
97.43
108.97

90
90
90
90
89
90

5 14
5 12
5 34
6
6 14
6 12
6 34
7

7
7
7
7
7
7
7
7

123.36
135.43
148.33
160.27
174.85
189.00
203.17
219.00

93
93
93
93
93
93
93
93

4 SD
SD
1
4 SD
1
2 SD
3
4 SD
SD

3
4
4
4
4
5

5 14
5 12
5 34
6
6 14
6 12
6 34
7

SD
SD
SD
SD
SD
SD
SD
SD

EXAMPLES OF CUT SINGLE PHASE CRUCIFORM CORES

Core Reference
Approx. k Va Rating
Window Size
Overall Size
Mean Length of Flux Path
Core Section Reference
Minimum Inside Dimensions
of Bobbin
Nett Cross Section of Iron
Estimated Finished
Weight (Min.)

Maximum Total Loss,

At guarantee level of
1.5 Tesla, 50 Hz.

D 5000

D 15000

D 25000

5
7 34" x 3 34"
12 2132" x 8 2132"
77.47 cms
2 34 SD

15
11" x 4 38"
17" x 10 38"
101.16 cms
3 14 SD

25
1158" x 4 38"
181116" x 11716"
108.9 cms
3 34 SD

2 78"
30.97 cms.

3 38"
44.91 cms.

3 78"
61.1 cms.

18.371 kgs.

34.70 kgs.

50.576 kgs

25.9 watts

48.9 watts

71.3 watts

37

Wound Cores

Magnetic Characteristics and Guarantees

All cores are individually inspected for physical and electrical characteristics
and conform to the following guarantees: Single Phase
Uncut Cores
Test Level 1.5 Tesla, 50 Hz.
Total Iron Loss not greater than 1.41 Watts/kg.
Total R.M.S. Magnetising VA not greater than 3.1 VA/Kg.
Cut Cores
Test Level 1.5 Tesla, 50 Hz.
Total Iron Loss not greater than 1.41 Watts/Kg.
Total R.M.S. Magnetising VA not greater than 3.1 + 179 VA/kg.
Lm

Three Phase
Uncut Cores
Test Level 1.5 Tesla, 50 Hz.
Total Iron Loss not greater than 1.6 Watts/Kg.
Total R.M.S. Magnetising VA not greater than 3.9 VA/Kg.
Cut Cores
Test Level 1.5 Tesla, 50 Hz.
Total Iron Loss not greater than 1.6 Watts/Kg.
Total R.M.S. Magnetising VA not greater than 3.9 + 2.05 x AREA Va/kg.

Weight
Where AREA is the nett cross sectional area in cms2 and WEIGHT is in kilos.

Information Required

When enquiring or ordering power distribution transformer cores, the

following information is required: Window Dimensions
Strip Width or core section reference
Build Up
Electrical Specification, if differing from standard guarantees

38

Engineering
section

39

Wound Cores

Application of C cores in small power transformers

Engineering
section

To assist the Designer in the selection of core pattern, the following table gives a
list of Transformers, each utilising two C Core loops in shell configuration. The
working peak flux density is taken at 1.7 Tesla throughout, and the current
density chosen to produce a temperature rise of 60c above an ambient of 35c,
with non-impregnated windings. The winding space is adequate for two 240V
interleaved windings of round wire insulated to withstand 2,000V test.
At the smaller end of the range, Transformer design is usually limited by
consideration of the voltage drop on load (regulation), and so the output values
shown may not be attained. These figures may also be reduced by requirements
of lower temperature rise, more insulation, or lower flux density to accommodate
frequency and voltage fluctuations, etc. On the other hand, the output may be
increased by a choice of higher flux density, better cooling due to winding
impregnation, or better class of insulation.
An outline procedure is therefore given, showing how these designs may
be modified.

The following symbols are used:

Vp
Ip
Vs
Is
Rp
Rs
N
Pcu
Pfe

Bm
E

Afe
p

-
-
-
-
-
-
-
-
-
-
-
-
-
-
-

Primary voltage (volts)

Primary current (amps)
Secondary voltage (volts)
Secondary current (amps)
Primary winding resistance (ohms)
Secondary winding resistance (ohms)
No. of turns
Power losses in copper (watts)
Power losses in core (watts)
Current density (amps per mm2)
Peak flux density (Tesla)
Regulation (percent)
Efficiency (percent)
Nett cross sectional area of core (cm2)
Specific resistivity (ohms mm2/mm)

Procedure

a) S
 elect design which shows power capacity more than sufficient for required
Transformer. (See Table on page 43)
b) C
 onsider the working flux density. If there is an overvoltage requirement or
limitation on idling current, reduce the flux density (Bm) to a suitable value
(refer to characteristic curves) and correct the power capacity figure prorata.
Otherwise, for intermittent operation, or less demanding applications,
consider raising Bm to 1.8 Tesla or higher.
c) If 60 temperature rise is too high, current density must be reduced. A
reduction of 20% will keep the temperature rise to below 40 C, and in most
cases allow the use of Class A insulating materials. Correct the rated power,
also the regulation and copper losses, for the new current density.
d) If extra insulation or higher voltage is needed, or if multiple tappings are
specified, the rated power figure must be reduced to allow space for this.
 heck that the voltage regulation is acceptable. If necessary, reduce the
e) C
rated output in the proportion required to bring the regulation to the
required value.

40

f) Read estimated efficiency and calculate the primary current:

Ip

VA (output) x 100

Vp

where Ip
Vp

=
=

primary current
primary voltage

Select primary wire size, using Ip and value of current density given in table
(corrected if necessary).
Acu
=

Ip

g) Read volts per turn Vt from table, correcting for new flux density if necessary:
Vt (corrected) =
Vt x Bm

1.7

Determine the number of primary turns:
Np
=

Vp
Vt

h) From wire tables, the required primary winding space can be found and the
primary resistance calculated.
i) Similar calculations for the secondary are made, making approximate
corrections for the voltage drop, thus: No. of secondary turns
Ns
=
Vs x
100

Vt
100 - E

Where E
Vs

=
=

Regulation %
Secondary voltage on load

j) Having selected wire size appropriate to secondary current at density , the

resistance of the secondary winding can be estimated with the help of wire
tables, or calculated by the formula: R
=

Where L
=

p x L ohms
S

p
=




S
=

Specific resistivity of copper

(0.0175 ohms mm2/mm at 20C
or 0.021 ohms-mm2/mm at 50 C)

total length of winding wire in metres.

Cross sectional area of wire in mm2

k) Knowing primary and secondary resistances, the copper losses and

regulation can be verified.
This procedure assumes a resistive load but can be used for transformers
supplying reactive loads, providing consideration is given to leakage reactance.
This can be minimized by the careful disposition of the windings together with a
choice of lower operating flux density.
Reducing the flux density to 1.6 or 1.5 Tesla will also ease problems with inrush
currents, stray magnetic fields and acoustic noise.

41

Wound Cores

Example

Required 60VA Transformer 240V input, 50Hz.

48V output, 1.25A resistive load

% Regulation 10% max.

Efficiency 85% min.
a)
b)
c)
d)

Try pair of HWR 30/16 cores

Assume Bm = 1.7 Tesla
Class E insulation, therefore, 60c rise is permissible.
For 10% regulation, output of 70VA at 18% regulation

Suggested in table on page 43 must be reduced to 70 x 10 = 38.9VA

8

As this is now insufficient.

a) Try pair of HWR 30/20 cores

Output will be 85 x 10 = 57VA

15

Current density will reduce to 3.5 x 57 = 2.35

85

b) By raising Bmax to 1.8 Tesla output may be increased to 57 x 1.8 = 60VA

1.7
c) Iron losses will rise to 2.5 Watts/Kg. As seen from characteristic curves
giving total iron loss of 1.83 Watts. Copper losses, however will fall to
57 x 10.3 = 6.9 watts, so temperature rise will be less than 60o C.
85
d) No extra insulation is needed, so winding space is adequate.
e) Regulation is now estimated 10%.
f) Efficiency will now be

60
= 87%
60 + 1.83 + 6.9

Therefore, Primary VA = 60 x 100 = 69VA

87

p = 69 = 0.29 Amps
240

at = 2.35 amps/mm2, wire area will be 0.123 mm2, say, 0.4mm dia.

g) Volts per turn at 1.8 Tesla are .216 x 1.8 = 0.229 volts

1.7

Therefore, No. of turns Np = 240 = 1,048 turns.

0.229

Mean length of turn = 12.3 + 21 = 16.65 cms.

2

Total length of wire -= 1,048 x 16.65 x 10-2 = 175 metres.

From wire tables, resistance Rp = 24 Ohms.

h) No. of turns on Secondary Ns = 48 x 100 = 233 turns

0.229 90
i)

Secondary wire size will be 1.25 = 0.532 mm2, say 0.8mm dia.
2.35
Length of wire = 16.65 x 233 = 38.5 Metres.
From wire tables, Resistance Rs = 1.32 Ohms.

j) Total copper losses

Iron loss

42

Therefore, efficiency

=
=
=

p2 Rp + s2 Rs
2.01 + 2.06 = 4.07 watts
1.83 watts

60
x 100 = 91%.
60 + 1.83 + 4.07

Transformer design data HWR range C

cores @ 17,000 Gauss, 50Hz

Core Output Current

Ref.
Rating Density Mag.
HWR
VA
A/mm2
VA

Iron
Loss
Watts
Pfe

Copper
Loss
Watts
Pcu

Volts
%
&
Per Regulation Efficiency
Turn
E
n
Vt

Mean length
of Turn (cm)
Inner

Outer

10/8
10/12
10/16
10/24

17
26
32
40

5.0
4.8
4.4
4.0

3.0
4.5
6.0
9.0

0.4
0.6
0.8
1.2

7.2
7.5
7.1
7.16

0.072
0.11
0.145
0.218

38
27
24
20

69
76
80
82

7.9
9.1
10.4
13.0

14.5
15.8
17.1
19.7

30/8
30/12
30/16
30/20

38
53
70
85

4.4
4.0
3.8
3.5

4.2
6.4
8.5
10.6

0.6
0.9
1.25
1.55

9.2
11.4
11.3
10.3

0.088
0.13
0.174
0.216

26
20
18
15

79
81
83
86

8.6
9.8
11.0
12.3

17.1
18.4
19.7
21.0

40/12
40/16
40/20
40/24

63
80
95
120

3.6
3.4
3.0
2.9

7.0
9.0
11.5
13.5

1.08
1.35
1.7
2.05

13.0
13.2
12.0
11.5

0.13
0,175
0.216
0.26

18
14
12
11

82
84
87
89

9.8
11.0
12.3
13.6

20.4
21.7
23.0
24.3

50/14
50/18
50/24
50/32

120
150
210
270

3.1
3.0
2.8
2.6

11.5
15.5
20
27

1.85
2.4
3.2
4.2

18.0
17.0
15.0
16.0

0.202
0.26
0.348
0.464

12
11
10
9

86
88
91
93

11.7
13.0
14.9
17.4

24.3
25.6
27.5
30.0

70/12
70/18
70/24
70/32

210
320
390
490

2.8
2.5
2.3
2.2

15
22
29
39

2.45
3.65
4.9
6.5

26.0
24.5
22.0
22.0

0.216
0.326
0.382
0.58

9
7
6
5

88
92
94
94

12.3
14.2
16.1
18.7

29.0
30.9
32.8
35.3

90/16
90/24
90/32
90/44

420
630
810
1050

2.6
2.4
2.2
2.0

27
40
54
74

4.65
7.0
9.4
12.7

40.0
39.4
36.4
34..0

0.346
0.52
0.695
0.955

6
5
4
4

91
93
94
95

15.4
18.0
20.9
24.7

35.8
38.2
41.1
44.9

110/20 1000
110/32 1600
110/64 2700

2.0
1.8
1.5

55
88
176

10.1
16.2
22.2

50.8
48.0
44.0

0.58
0.93
1.28

4
3
3

94
93
95

19.9
24.1
34.5

45.6
49.7
60.0

43

Wound Cores

Current Transformer Design Guide

An effective design of a Ring Type C.T. may be produced first time, using the
following procedure, without any previous experience.

Principles

In operation, the C.T. will induce current in its secondary winding and burden
which serves to completely oppose the magnetising effect of the primary current,
except for that small proportion required to magnetise the core. This core
magnetising component will then be the only source of error if the secondary
current is to be used as a measure of the primary current.
Making two assumptions, ie, that the C.T. has no leakings reactance and that its
burden is purely resistive, the vector diagram for a one-to-one ratio CT will look
like this.

1
r

Bm
m

=
Where N2

V2
=

Rb
=

I
=

2 =

m
=

r
=

w
=

e
=

V2 = 2 R 2
2

No of secondary Turns
Secondary Voltage
Burden Resistance
Primary Current
Secondary Current
Excitation Current
Reactive component of m
Watt loss of component m
Ratio Error

From this diagram the primary current 1 differs from the secondary 2 in
magnitude and phase angle. The angle error is Sin 1 r/ 1 and the
1
magnitude of 1 = [ (2 N2 + w)2 + r 2] 2
In practice, the angle is so small as to allow the approximations 1 = 2N2 +w
and = r/1 radians, i.e. the current error is due to the watt loss component of
the excitation current and the phase error is proportional to the reactive
component r. The ratio error can be corrected by an amendment to the turns
ratio, the secondary winding being reduced by several turns or fractions of a
turn. Because of the non-linearity in the excitation characteristics, such
corrections do not maintain accuracy as the current changes, and a choice must
be made which gives good balance over the whole range of current. Cores can
be supplied with drilled holes, enabling fractions of a turn to be wound.
The phase angle error, on the other hand, cannot be corrected, being a function
of the reactive component of the excitation characteristics which vary widely over
the current range and must take priority in the design of the transformer and
choice of core.
The procedure is best described by considering an example, as follows: 1.

Transformer Specification
Ratio 150/1
50Hz. Burden 2.5 Va at Power Factor = 1.0
Accuracy BS.3938, Class 0.5
Insulation level 11 Kv.

Maximum Permissible Error

From 10% to Ratio error
20% of rated current Phase displacement

From 20% to Ratio error
100% of rated current Phase displacement

From 100% to Ratio error

120% of rated current Phase displacement

1%
60 minutes
0.75%
45 minutes
0.5%
30 minutes

2. Internal Diameter
The I.D. of the core is fixed by physical consideration of the primary
conductor and insulation, plus allowance for the secondary winding and core
insulation. The main insulation is invariably placed on the primary conductor

44

so that a 20mm dia.conductor insulated for 11Kv will have an overall diameter
of about 40mm. The secondary winding and core insulation for a nominal 660
volts lead to the choice of core I.D. of 60mm. Assuming a maximum O.D. of
110mm, the mean path length will then be

p (60 + 110) = 267mm.
2

3. Flux Density
The requirements of phase displacement and angle error limit the working flux
density of the core. An estimate of the flux density can be made by
considering one working condition, preferably one likely to be most stringent.
So considering the phase displacement at the 20% full load condition: 1 = 30 amps

= 45

From phase diagram, Sin = r

1
.
. . r = 1 Sin = 30 x .013

= 0.4A

Hr = r = .4
Lm .267

= 1.5 A/M

By inspection of resolved component curves for TS grade core material on
page 65 Hr = 1.5 when Bm = 60mT.
If the flux density at 20% F. L condition is chosen at 60mT, it will rise to
300mT at full load, and other points pro-rata which can now be checked for
error. If for any condition the phase displacement is excessive, a lower flux
density must be chosen.
Condition
(% Full Load)
Primary Current 1 (amps)
Bmax (mT)
HR (from curves) A/m
R (HR x 0.267)
(Sin 1 r/1)
Hw (from curves) A/m
Iw (Hw x 0.267)
E (Iw/1 x 100)
%
1 Turn Compensation %
Compensated Error e1 %

120%
180
360
4.5
1.2
2.3'
5.2
1.39
0.77
- 0.67
0.1

100%
150
300
4.0
1.068
2.4'
4.5
1.20
0.80
- 0.67
0.13

20%
30
60
1.5
0.4
45'
1.05
0.28
0.94
- 0.67
0.27

10%
15
30
0.95
0.307
58.5'
0.6
0.16
1.07
- 0.67
0.4

4. Compensation
Assuming the phase angle displacements are within allowable limits, the
ratio error is calculated for each condition as shown above, and a turns
ratio correction is chosen which will make them acceptable. In this case, 1
turn correction is made by reducing the secondary winding to 149 turns.
5. Cross Sectional Area
Having chosen the working flux density at full load, the required cross
sectional area is calculated thus: Voltage across Burden at full load = 2.5 volts
Allowing secondary winding resistance 0.1 ohms
then additional voltage for internal burden = 0.1 Volts
Total secondary E.M.F. = 2.6 volts
For 149 turn secondary
Volts/Turns = 2.6 = 0.0175 Volts

149
At rated condition Bm = 0.3 Tesla
By transformer equation V = 0.222 x Bm x Afe
.
T
. . Nett C.S.A. Afe
=
.0175
= 2.63 cm2


.0222 x 0.3
Allowing 0.95 space factor, Gross C.S.A. = 2.77 cm2

6. Final Dimensions

Before fixing the final dimensions, take account of possible core degradation
during winding. If protected by a case, this will be small, but it is prudent to
allow 20% extra area for a core taped, wound and impregnated.

In this example, a strip width of 20mm

final core dimension of
I/D
O/D
Length -

with a build up of 17mm gives a

60mm
94mm
20mm

45

Wound Cores

USEFUL MAGNETIC FORMULAE

Area of Cores with Rectangular Cross Section Afe

Afe = Emin x Dmin x K

Mean Magnetic Path Length (Lm) for C Cores

L

m = Amax + Bmax + Fmin + Gmin -1.72 (R +

E max)

Core Weight (Mfe)

Mfe = Afe x Lm x 7.65 x 10-6

Where

Afe

Lm

Mfe

A

B

D

E

F

G

R

K

=
=
=
=
=
=
=
=
=
=
=
=
=
=

Cross Sectional Area (mm2)

Mean Magnetic Path Length (mm)
Core Weight (Kg)
Overall Core Width (mm)
Overall Core Length (mm)
Strip Width (mm)
Build Up (mm)
Core Window Width (mm)
Core Window Length (mm)
Inner Radius (mm)
Stacking Factor
0.95 for 0.3mm strip
0.92 for 0.1mm strip
0.88 for 0.05mm strip

B
..................................(1)
H
I x N ................................(2)
Lm
o r .................................(3)
Induction in Tesla (Webers per sq. metre)
Magnetising force in Amps/Metre
Permeability
Permeability of Free Space (4p x 10 7)
Relative Permeability
Current in Amps
Number of turns
Magnetic Path Lengths in Metres

Permeability




H



Where
B

H



o

r



N

Lm

=
=
=
=
=
=
=
=
=
=

Modules of Complex Permeability

B max
Hpeak

= B max for sinusoidal waveform

Hrms x2

Effective Permeability p

p =

Bmax
Hrms

Transformer Equation

Where

V
V
F
Bm
N
Afe
f

=
=
=
=
=
=
=

4 x F x Bm x N x Afe x f
Rms Voltage
Form Factor for Voltage Wave
Maximum Induction in Tesla
Number of Turns
Cross-section of Iron in Metres2
Frequency in Hertz

For 50hz sine wave, this reduces to

V
= 222 x Bm x Afe x N

Inductance

Inductance in Henries = 4p x N2 x Afe x r


107 x Lm
Where

46

N
Afe
r
Lm

= Number of turns
= Cross-sectional Area of Iron M2
= Relative Permeability
= Magnetic Path Length in Metres

Performance
curves

47

Wound Cores

Performance
curves

Interpretation of Loss and Magnetising VA Curves

The magnetising VA of a core is the product of the applied voltage and the total
magnetising current and may be shown as a vector in phase with the current and
lagging relative to the voltage. This lagging VA may be resolved into two
components, the watts (in phase with the volts) and reactive VA (in quadrature).
The reactive VA for the gap is the product of the voltage and the current required
to produce the necessary ampere-turns to magnetise the gap and may also be
shown by a vector in quadrature to the voltage. To calculate the total
magnetising VA it is necessary to add arithmetically the reactive VA for the core
and for the gap and add this sum vectorially to the watts.
This is true at any frequency, but at 50Hz., the magnetising VA is so nearly in
quadrature that the reactive VA for the gap may be added arithmetically with
negligible error. At frequencies of 400Hz. or higher this is not so and for this
reason reactive and total VA curves are included in this handbook.

VOLTS

VA (CORE)

VA (GAP)
AND
GAP)

WATTS
(CORE)

REACTIVE VA
(CORE)

48

REACTIVE VA
(GAP)

Bmax (Tesla)

0.1

1.0

2.0

Gap Allowance (VA/kg)for

cores of 1 metre path length

VA/kg

0.1

Total V.A./core =

1.0

Material VA/kg + Gap Allowance VA/kg

Flux Path Length m

Magnetising VA/kg
for core material

OS 110
OS 111

x Core Wt.

10

Magnetising characteristics for C cores in 0.3mm G.O.S.S. tested at 50 hz.

49

50

0.1

1.0

1.5

2.0

10

VA per Kg

20

0.01

30

60

120

Magnetising VA/kg

50

Where B= Flux density in Tesla

= Frequency in Hertz
Lm = Mean magnetic path in cms

0.58 x B x
L
m

Note : Add allowance for gap.

0.1

300

400 Hz

1.0

0.3mm C Cores
Magnetising Characteristics
at Various Frequencies

10

Wound Cores

0.3mm C CORES - magnetising characteristics at various frequencies

Peak Flux Density (Tesla)

Peak Flux Density Bm (Tesla)

0.1

1.0

1.5

2.0

10

20

30

0.01

50

120

Iron Losses Watts/Kg

60

0.1

300

400 Hz

1.0

10

0.3mm C cores - losses at various frequencies

51

52

0.01

0.10

1.0

1.5

2.0

200 Hz

400 Hz

0.1

1 KHz

C Cores in 0.1 mm G.O.S.S

Watt Losses at
various frequencies

1.0

5 KHz

Core Loss (Watts per Kg)

2 KHz

10 KHz

10.0

100

Wound Cores

C cores in 0.1mm G.O.S.S. Watt losses at various frequencies

Peak Flux Density Bm (Tesla)

Peak Flux Density Bm (Tesla)

0.01

0.1

1.0

1.5

2.0

200 Hz

OS.10 - 0.23 x B
L
m

OS.15 - 1.12 x B
L
m

x f

x f

Add allowance for gap

400 Hz

0.01

1 KHz

Where B= Flux density in Tesla

f = Frequency in Hertz
Lm = Mean magnetic path in cms

Note:

Magnetising VA (reactive)per kilogram at

various frequencies.

C Cores in 0.1 mm G.O.S.S

Magnetising VA/kg

2 KHz

1.0

5 KHz

10 KHz

10.0

100

Magnetising VA/KG at various Frequencies for C cores in 0.1mm G.O.S.S.

53

54

0.01

0.1

1.0

1.5

0.001

10.00

0.01

Hz

0.1

0H

18

0H

40
Hz

1K
2

1.0

Hz

3K

Hz

5K

Wattloss/kg for 0.05mm (0.002")Strip Cores

60

10

z
KH

20

z
KH

10.0

z
KH
40
50

KH

100.0

Wound Cores

Total iron loss characteristics for cut C cores in 0.05mm (0.002") material

Flux Density in Tesla

BMax Tesla

0.1

1.0

1.5

2.0

0.001

10.0

VA per Kg

0.01

Where B= Flux density in Tesla

= Frequency in Hertz
Lm = Mean magnetic path in cms

1.04 x B
L
m

Note : Add allowance for gap

Hz

18

Hz

1.0

40

Hz
1K

Hz
2K

3K

Hz

Hz

Max Volt amp (reactive)per kg for 0.05mm (0.002)strip cores

0.1

60

5K

10

Hz

10.0

K
20

z
KH

K
40

Hz

50

Hz

z
KH

100.0

Total reactive magnetising characteristics for cut C cores in 0.05mm (0.002") material

55

56

0.1

0.5

1.0

1.5

2.0

10

20

0.25 Microsecs.

0.5 Microsecs.

1 Microsec.

2 Microsecs.

Pulse Width

Peak Pulse Magnetisation Force - A/cm

Pulse Magnetisation Curves

at different pulse widths

C Cores in 0.05 mm G.O.S.S

thus

B
H

b)
Flux density is that attained at the
instant of Max.H.

Note:
a)
These curves include the reluctance

of core gaps.

Wound Cores

C cores in 0.05mm G.O.S.S. pulse magnetisation curves at different pulse widths

Pulse Flux Density (Tesla)

Pulse Flux Density (Tesla)

0.1

0.2

0.5

1.0

1.5

2.0

0.001

0.002

Core losses under

Pulse Conditions

0.01

0.25 Microsecs.

0.02
Losses - Joules per Kg. per cycle

0.005

C Cores in 0.05 mm G.O.S.S

0.05

0.5 Microsecs.

1 Microsec.

2 Microsecs.

Pulse Width

C cores in 0.05mm G.O.S.S. losses under pulse conditions

57

Wound Cores

HANNA Design curves - Material 30m5 (M097-30N)

L 2
V
Calculated from DCMagnetisation and Incremental Permeability

Henry

Frequency = 50 Hz

Amp2
Cm3
0.0014

.0020
a = 0.0012
Lm

B = 250 mT
B = 500 mT
0.0010

.0015

0.0008
0.0016

.0010
B = 100 mT
B = 10 mT

0.0006

B
I
L
V
a
Lm

0.0004

.0005

=
=
=
=
=

Incremental Induction in Tesla

D.C. Current in Amps
A.C. Inductance in Henries
Core Volume in Cm3
Total Air Gap Length in Cm

= Iron Path Length in Cm

= Number of Turns

0.0002
a values Apply to Regions between
Dotted Curves
Lm

10
NI
Lm

58

Amp turns per cm.

At/Cm

15

Total Permeability of Core &Gap

100

1,000

5,000

1.0

10
11
12

16
17
18

15

13
14

Incremental Permeability valid for

cores in 0.3, 0.1 and 0.05mm material
at frequencies up to 1500 Hz.

C Cores

10

Total DC Magnetising Force (A/cm)

7
G = .001
8
9
10
G = .002
11
12
13
G = .003
14
15
16
G = .005
17
18

B = 200
B = 20
B=2

B = 200
B = 20
B=2

B = 200
B = 20
B = 2

B = 200
B = 20
B=2

B = 200
B = 20
B=2

B = 200
B = 20
B=2

100

B = A.C. Flux Density in mT

G = Effective Total Gap

Core Flux Path Length

4
G = .0005
5
6

1
G = 0
2
3

Key

Incremental Permeability for G.O.S.S. C cores

59

60

0.2

0.5

1.0

2.0

Losses at 50 Hz. 3 phase

0.1

VA/Kg

Watts/kg

Core Loss (Watts &VA per kg)

Flux Density (Tesla)

2
Cross Sectional Area(Cm )
Core Weight (kg)

=
=
=

Where B
A
W

0.915 B x A
W

VAcurve neglects gap. Add allowance

Gap VA/kg

Note:

0.3mm E-cores

10

Wound Cores

0.3mm G.O.S.S. E - cores - losses at 50 Hz., 3

Bmax (Tesla)

Bmax (Tesla)

0.1

0.2

1.0

2.0

0.1

Losses at 400 Hz. 3 phase

0.2

0.5

Core Loss (Watts &VA per kg)

Watts/kg

Flux Density (Tesla)

2
Cross sectional Area (Cm )
Core Weight (kg)

=
=
=

Where B
A
W

5.733 B x A
W

VAcurve neglects gap. Add allowances

Gap VA/kg

Note:

0.1mm E - cores

VA/Kg

10

20

50

0.1mm G.O.S.S. E - cores - losses at 400 Hz., 3

61

62

10

2 x 10

3 x 10

35M6

30M5

27M4

0.5

B
H

where

B
H

10
4p

B Tesla

1.0

=
Peak flux density in Tesla
= Peak Magnetisation
Force in Amps/Metre

Modulus of Complex Permeability

Relative Permeability 50 Hz

Toroidal Cores
in 0.3 G.O.S.S.

1.5

2.0

Wound Cores

Toroidal cores in 0.3mm G.O.S.S. relative permeability @ 50 Hz

Relative Permeability

RMS Magnetising Force H. eff (A/M)

0.01

10

20

50

100

0.02

Note:

0.05

B Max (Tesla)

0.1

0.2

Watt Loss Component Hw

Total Magnetising Force Ho

Tested with sinusoidal magnetising current

at 50 Hz. Flux measured with integrating
type fluxmeter.

Resolved Component Magnetising Curves

0.5

1.0

2.0

Reactive Component Hr

Toroidal cores in 27M4 (Mo89 - 27N) material

63

64

0.01

0.1

1.0

1.5

2.0

0.01

0.1
Iron Losses Watts/Kilogram

1.0

50 Hz
100 Hz

10

200 Hz

400 Hz

10,000 Hz

5000 Hz

2000 Hz

1000 Hz

100

Wound Cores

Toroidal Core losses for 27m4 ( M089-27n)- Material at various frequencies

Bmax Tesla

Magnetising Force H eff (A/M)

0.01

10

20

50

100

0.02

0.05

0.2

Watt Loss Component Hw

B Max (Tesla)

0.1

Total Magnetising Force Ho

Note:
Tested with sinusoidal magnetising

current at 50 Hz. Flux measured

with integrating type fluxmeter.

Resolved Component Magnetising Curves

0.5

1.0

Reactive Component Hr

2.0

Toroidal cores in 30 MIH (Miii -30P)

65

66

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

-0.2

0.2

0.4

0.6

0.8

1.0

Magnetising Force H(AT/Cm)

Uncut ring cores in 27M4

Material tested at 50 Hz

Hysteresis Curves

Note change of scale

Wound Cores

DC Hysteresis curves

Flux Density (Tesla)

Flux Density (Tesla)

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

-0.2

0.2

0.4

0.6

0.8

1.0

1
3

Magnetising Force H(AT/Cm)

Uncut Ring Cores in

0.1 mm material

DC Hysteresis Curves

Note change of scale

DC Hysteresis curves

67

68

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

0.2

Uncut Ring Cores in 0.05mm material

0.4

0.6

0.8

1.0

1.0
3.0

Magnetising Force H(AT/Cm)

2.0

Note change of scale

4.0

Wound Cores

DC Hysteresis curves

Flux Density (Tesla)

Flux Density (Tesla)

0.1

1.0

2.0

Watts/Kg

Where

VA/Kg

VA/Kg

VA or Watts per Kg

0.1

56 x B
Lm

B = Flux density in Tesla

Lm = Mean Magnetic path in cms

Note:
Add gap allowance

Watt losses and Magnetising VA at 50 Hertz

Cruciform Cores 27M4 & 30 M5 material

30M5

27M4

10

Cruciform cores in 27M4 (m089-27N) and 30M5 (M097-30N)

69

Wound Cores

NOTES

70

NOTES

71

Wound Cores

NOTES

72

stillsdesign.com 9716

Wiltan
Ambassador Buildings
Pontnewynydd Industrial Estate
Pontypool Torfaen NP4 6YW
T. +44 (0)1495 750 711
F. +44 (0)1495 753 730

A Transformer Designers Guide

EDITION 1

sales@wiltan.co.uk
www.wiltan.co.uk

Telmag is a brand of Wiltan

Wound Cores

This project has been part funded by

the European Regional Development Fund