English Amorphous Magnetic Parts Amorphous Magnetic Parts Amorphous Magnetic Parts http://www.toshiba-tmat.co.jp/ - 1 - 2K1412 Index 1 Noise Suppressor Devices AMOBEADSTM Noise Suppression Devices AB/LB series Standard Specifications Examples of Applied Circuits and their Characteristics Effects of Noise Suppression by AMOBEADSTM 4 5 6 7 2 Noise Suppressor Devices SPIKE KILLERSTM SPIKE KILLERSTM Wired SPIKE KILLERSTM and AMOBEADSTM Examples of Applied Circuits and Effects of Noise Suppression 8 8 9 3 Saturable Cores for Mag-Amps Saturable Cores for Mag-Amps MT/MS Series Standard Specifications Merits of Mag-Amp Method Full Mag-Amp Metod Examples of Circuit and Characteristics 10 11 12 12 13 High Magnetic Permeability Cores for Pulse Transformer 4 High Magnetic Permeability Cores Characteristics FS Series Standard Specifications Applications 14 14 15 15 Instructions How to Select the Proper Size "AmobeadsTM " Principle of the Noise Suppressing Device Mag-Amp Operating Principle Mag-Amp Design (Forward Converter) Examples of the Design Evaluation of the Mag-Amp Circuit Unit Glossary of Amorphous Magnetic Parts Notices on Handle Maintenance and Discontinue List 16 17 18 19 20 21 22 23 23 - 2 - Amorphous Magnetic Materials and their Applications There is a magnetic metal material with very unique characteristics that does not have a crystalline structure. At Toshiba Materials, we focused on the excellent magnetic characteristic of this amorphous magnetic alloy and started research and development years ago, anticipating future applications and need for such a product. This Amorphous alloy was called "alloy of dreams" at the time when we started our research but in recent years, it has and is finding application in electrical products (desk top computer, copying machine, printer etc.) Amorphous magnetic parts make it possible to reduce energy consumption, and minimize electronic circuit noise for electrical products with a product considered environmentally friendly (RoHS). Amorphous Ribbon Amorphous Alloy Amorphous alloy is a general term for a metal with a non-crystalline structure of atoms. Regular alloys have a uniformly formed metallic crystalline structure, but for amorphous alloys, the atoms are distributed randomly. As a result of this random atomic distribution, the magnetic properties of amorphous alloys are anisotropic. Also, in addition to an increase of electrical resistivity, thin ribbons are made so that the eddy current losses will be small and the magnetic characteristics will be significantly improved. At Toshiba Materials, we manufacture a Cobalt based amorphous alloy by the liquid rapid cooling method. This method of rapid cooling, at a rate of about 1 million degrees per second, prevents the metal from solidifying in an amorphous structure rather than in its normal ordered crystalline structure. Models of Atomic Arrangement Regular Alloy Amorphous Alloy (Crystalline Structure) (Non Crystalline Structure) - 3 - TM 1Noise Suppression Devices AMOBEADS TM An amorphous noise suppression device is unique and completely different from conventional noise filters. Conventional noise prevention products focus on somehow minimizing the noise after it's been created, by typically trying to absorb the noise, and so their effectiveness in noise reduction is directly influenced by frequency of the circuit. Amorphous noise suppressing devices, on the other hand, focus on the source of the noise and work to prevent or minimize the noise before it has a chance to develop. The source of the electronic circuit noise is the rapid change of current or voltage, and the effectiveness of the amorphous cores in eliminating this noise is independent of frequency. An amorphous noise suppression device is a product that takes full advantage of the unique magnetic characteristics of the cobalt based amorphous alloy. Toshiba Materials offers two noise suppression devices, "AMOBEADSTM " and "SPIKE KILLERSTM ". AMOBEADSTM " deliver excellent noise suppression results and are convenient to use by simply being slipped over the leads of the semiconductor device. "AMOBEADSTM " are also available with a lead thru and in a surface mount configuration. "SPIKE KILLERSTM ", which are larger in size than "AMOBEADSTM ", most often are wire wound and are effective in eliminating or minimizing higher noise levels. C Noise Suppression Device R AB RC Snubber Magnetic Snubber Basic Snubber Circuit Diagram B[T] 0.6 Amorphous 0.4 Ferrite 0.2 -80 -40 0 -0.2 40 80 H [A/m] -0.4 -0.6 100 kHz, RT B-H Curvetypical Example for Noise Suppressing Effect (Chopper Converter) With an excellent saturable characteristic, "AMOBEADSTM " suppress the reverse recovery current of the diode and decrease the noise that is occurring. When the current for diode reverses and tries to go into the recovery condition, the "AMOBEADSTM " displays a large inductance and oppose the generation of the recovery current. In this instance, a soft recovery is possible for core material with a smaller coercive force. Output Noise Diode Current A/div With AMOBEADSTM (AB4x2x8W) Without Countermeasure - 8 - - 4 - ABLB Series RoHS compliant products Standard Specifications AMOBEADSTM W series Finished Dimensions [mm] O.D. max I. D. min H.T. max 4.0 1.5 4.5 Type No. AB3X2X3W Core Size [mm]1 O.D. I. D. H.T. 3.0 2.0 3.0 Total Flux2 c[Wb] min 0.9 AL value3 L[H] min 3.0 AB3X2X4.5W 4.0 1.5 6.0 3.0 2.0 4.5 1.3 5.0 AB4X2X4.5W 5.0 1.5 6.0 4.0 2.0 4.5 2.7 9.0 AB4X2X6W 5.0 1.5 7.5 4.0 2.0 6.0 3.6 12.0 AB4X2X8W 5.0 1.5 9.5 4.0 2.0 8.0 4.8 16.0 DY series (low price) Type No. Packing Unit PBT case Blue 2,000 [pcs/box] Recommend for big demand, 10,000pcs/lot ) Finished Dimensions [mm] Total Flux*7 c[Wb] Insulating Cover 4.00.2 4.00.2 4.00.2 5.0+0.2/-0.3 5.950.2 0.9min 0.9min 1.3min 3.6min 0.45min PBT PBT PBT PBT PBT O.D. AB2.8X4.5DY AB3X2X3DY AB3X2X4.5DY AB4X2X6DY AB5X4X3DY Insulating Cover H.T. 5.70.3 4.20.3 5.70.3 7.20.3 4.20.3 Packing Unit [pcs/bag Black Black Gray Black Black 10,000 10,000 10,000 5,000 5,000 Inner diameter can pass through a 1.20.7mm lead. However, Inner diameter of AB5x4x3DY can pass through a 2.5x0.7 mm lead. W series DY sereis AMOBEADSTM with lead Bulk type Finished Dimensions [mm] Type No. *4 *2 B *3 Current Total flux AL Value Insulating Packing Unit Cover [A] c[Wb] L[H] B D E F LB4X2X8F 16.0max 4.20.5 14.01.0 1.250.1 8.0 LB4X2X8U 20.0max 4.00.5 5.01.0 1.250.1 4.8 min 16.0 min B F PBT case 1,000 Black [pcs/box] D E LB4X2X8F Radial taping Type No. P [mm] Po [mm] LB2.8X4.5U 12.7 Do [mm] a [mm] 12.7 4.0 9.0max d [mm] Current4 I [A] 0.8 (5) Total Flux7 Packing c[Wb] Unit 0.9min D0 P0 Finished Dimensions [mm] Lead width length height width x thickness 4 2 Io [A] Total Flux c[Wb] 3 AL value Insulating Cover L[H] AB3X2X3SM 5.00.3 5.00.3 4.00.3 (1.8x0.35) 6.0 0.9 min 3.0 AB4X2X6SM 6.00.3 8.00.3 5.00.3 (1.8x0.52) 9.0 3.6 min 12.0 Packing Unit [pcs/reel] 2,000 LCP case Black 1,000 Recommended Land Pattern (mm) 2.4 H L W 2.0 9.4 AB3X2X3SM 1 Reference Value 2 Minimum Guarantee on Measuring Condition : 50kHz80A/m(sine wave), R.T. 3 Measuring Condition50kHz, 1V, 1turn, R.T. 4 Typical Value, using a cross section of lead 5 Measuring Condition100kHz, 80A/m sine wave), R.T. 6 Tolerance 0.2mm 7 Converted from Inductance Value L1 at 1kHz 100mA(sine wave)R.T. (Wb)0.282 x L1() TM "AMOBEADS " sample kits are available. Please ask sales department. TM TM "AMOBEADS " and "SPIKE KILLER " : Registered trademarks of TOSHIBA MATERIALS Co., Ltd. TM TM "AMOBEADS " and "SPIKE KILLER " : Resistered in U.S.A., France, Germany, U.K., Japan. - 9 - - 5 - 2.4 3.3 14.7 AB4X2X6SM F LB4X2X8U P 3,000 [pcs/box] SMD Type AMOBEADSTM Type No. D E Examples of Applied Circuits and their Characteristics Application of Amorphous Noise Suppression Devices AB M AB AB Chopper Converter Control Circuit for Motor AB AB AB M AB Flyback Converter AB AB Motor Driving Circuit AB 100 Forward Converter AB AB4x2x8W AB4x2x6W AB4x2x4.5W AL value ] 10 AB AB3x2x6W AB3x2x4.5W 1 AB2.8x4.5DY AB3x2x3W Push-pull Converter Characteristics (Typical value) 1k 100k Frequency f [Hz] 1M 100 (t)/(25) Pfe [kW/m3 1000 100 500kH z 300kH z 50 200kH z 100kH z Typical value R.T. Sine Wave 50kH z 1 0.01 10k Frequency Characteristics of Inductance 10000 10 Typical Value R.T. 0.1 0.1 0. 1 0 B | [T] 20 40 60 80 100 120 Temperature [] Flux() Decline Ratio vs. Temperature Coreloss Characteristic [AMOBEADSTM ] - 10 - - 6 - TM Effects of Noise Suppression by AMOBEADS TM Spike Voltage Suppression Without Countermeasure Spike voltage can be reduced and ringing phenomena can also be prevented by AMOBEADS. Also Schottky barrier diode (SBD) can be protected from over voltage. Diode Voltage VD 10V/div Frequency500kHz Output Voltage - Current 5-20 Output Noise Reduction AMOBEADSTM "AB4x2x4.5" Diode Current ID 5A/div AMOBEADSTM "AB4x2x4.5" RC Snubber +Ferrite Beads When the ferrite is replaced by AMOBEADS at the secondary output diode (FRD) of the forward converter circuit, the output noise can be tremendously reduced, not only the noise peak level but also the amplitude range. Output Noise VN 20mv/div Frequency150kHz Output Voltage - Current 15-10 Ferrite Beads 4x2x4 AMOBEADSTM "AB4x2x4.5" Primary Surge Voltage MOS-FET Drain-Source Voltage VDS 200V/div When the ferrite is replaced by AMOBEADS at the secondary output diode (SBD) of the forward converter circuit, the output noise and harmful influence to the primary stage can be reduced. These effects are based on the inclination of the actual BH curves between amorphous and ferrite materials. Frequency250kHz Output Voltage - Current 5-15 Output Noise VN 50mv/div Output Noise B H Actual BH Curve BH characteristics of Ferrite - 11 - - 7 - BH characteristics of Amobeads TM 2Noise Suppression Devices SPIKE KILLER RoHS compliant products Standard Specifications SPIKEK KILLER TM *1 2 Finished Dimensions [mm] Type No. O.D. SS7X4X3W 9.1 SS10X7X4.5W 11.5 SS14X8X4.5W 15.8 I.D. H.T 3.3 5.8 6.8 2 O.D. 4.8 7.5 6.6 10.0 6.6 14.0 I.D. 4.5 7.0 8.0 2 Mean Flux Effective core cross section Path Length 2 Ae[mm ] Lm [mm] Core Size [mm] H.T 3.0 4.5 4.5 3.38 5.06 10.1 18.8 26.7 34.6 3 Total Flux c[Wb]min 3.15 4.73 9.46 Coercive Force 3 Rectangular Ratio 3 22max 90min Hc[A/m] Br/Bm[%] Insulating Cover PET case Black *1 Tolerance 0.2mm *2 Reference value *3 Measuring condition100kHz80A/m (sine wave), R.T. TM "SPIKE KILLER " : Registered trademarks of TOSHIBA MATERIALS Co., Ltd. TM "SPIKE KILLER " : Resistered in U.S.A., France, Germany, U.K., Japan. Type No. TM and AMOBEADS Current*1 Wire Dia. [A] [mm] Core No. N [turn] Flux*2 [uWb] Dimensions[mm] A max B max AB44DY0305 AB4x2x4.5DY 0.5 0.3 5 13.5 7 9 AB44DY0307 AB4x2x4.5DY 0.5 0.3 7 18.9 7 9 SS7x4x3W 0.5 0.3 9 28.3 12 8 AB34DY0402 AB3x2x4.5DY 1.0 0.4 2 2.6 6 9 AB34DY0403 AB3x2x4.5DY 1.0 0.4 3 3.9 6 9 AB44DY0402 AB4x2x4.5DY 1.0 0.4 2 5.4 7 9 AB44DY0403 AB4x2x4.5DY 1.0 0.4 3 8.1 7 9 AB44DY0404 AB4x2x4.5DY 1.0 0.4 4 10.8 7 9 SS07S0507 SS7x4x3W 1.5 0.5 7 22.1 12 8 SS07S0510 SS7x4x3W 1.5 0.5 10 31.5 12 8 SS07S0515 SS7x4x3W 1.5 0.5 15 47.3 12 8 SS10S05105 SS10x7x4.5W 1.5 0.5 5 23.7 14 10 SS10S05107 SS10x7x4.5W 1.5 0.5 7 33.1 14 10 SS10S05110 SS10x7x4.5W 1.5 0.5 10 47.3 14 10 SS10S09110 SS10x7x4.5W 5 0.9 10 47.3 15 11 SS14S09108 SS14x8x4.5W 5 0.9 8 75.7 20 11 SS14S09205 SS14x8x4.5W 10 0.9x2 5 47.3 20 11 SS07S0309 B 3max A 155 TM Wired SPIKE KILLER soldered Type of wire1UEW *1Typical Value, using a cross section of winding wire *2Total Flux of core x turn Example of applied circuit and it' s characterisitic [dB/div] Chopper Converter Testing Condition of Radiant Noise Measurment Input 20[V Output 12[V]2[A] Frequency 90kHz Rectifier FRD Detector Simple Loop Antenna Noise Radiation Without Countermeasure FM radio band Snubber TM AMOBEADS 12 - 12 - - 8 - 24 36 48 60 72 84 Frequency MHz 96 108 120 Examples of Applied Circuits and Effects of Noise Suppression Example CircuitSelf-Exiting Single Flyback(RCC) 100% L R Q1 Cg Rg TM 90% Eficiency + Wired AMOBEADS SR C 80% Diode Clamp CR Snubber 70% 60% 50% SRWired AMOBEADSTM JPN.P. USP No. 3190775 Toshiba Materials Co. Ltd. No. 5745353 Example of Effects Delaytor Diode Clamp 680.022F 40% 0 0.5 1 1.5 2 2.5 Output Currrent 3 Power Supply Efficiency Vin:DC140V, Vo:24V) CR Snubber (101500F Wired AMOBEADSTM AB44DY0307 applied Swirching Waveform Vds 100V/div Id 1A/div Turn-on Waveform Vds 100V/div Id 0.5A/div Output Voltage Noise Vn 20mV/div Wired AMOBEADSTM delay the turn-on time of the MOSFET when they are inserted between the gate of the MOSFET and drive winding on the primary side of the self-exiting single flyback (RCC). The wired AMOBEADSTM reduce both noise, due to surge current and switching loss, by turning on the switching element at the point when the voltage of the transformer becomes low, utilizing the the LC resonance phenomenon induced by inductance L of the primary winding of the transformer and a snubber capacitor C. Note : The diode clamp circuit has a tendency to increase the out put noise. - 13 - - 9 - 3. Saturable Cores for Mag-Amps The Mag-amp method is one of several output voltage regulation methods used in switching power supplies. A saturable core is used in the secondary side of the main transformer to regulate voltage by magnetic pulse width modulation (PWM). The Mag-amp method is especially effective and economically attractive in low voltage/high current circuits and is frequently used in power supplies for information processing equipment, such as desktop PCs and computer servers, in power supplies for office equipment such as photocopy machines and printers, and in power supplies for communication equipment, such as mobile phone stations. Miniaturization, high efficiency, low noise, high reliability, and high precision can be easily realized by adopting the Mag-amp method. Utilizing the unique magnetic characteristics of cobalt-based amorphous alloys, we have realized low loss at high frequencies which cannot be realized using other materials. Our lineup consists of MS series cores, which are well suited for general purpose applications, and MT cores, which have lower loss than the MS series. Mag-Amp DC MT out put AB Core temperature rise T[] Basic Circuit Diagram of Mag-Amp method 50 280kHz,15V 40 30 MS 20 MT 10 0 0.0 0.5 1.0 1.5 Output current Io[A] 2.0 Comparison of Core Temperature Rise in a Power Supply Basic Characteristics Typical Value B[T] 0.6 0.4 100,000 MT 0.2 Core Loss Pfe [kW/m3] MS 10,000 -300 -200 -100 0 100 200 -0.2 300 H[A/m] B=0.2T, RT MS MT 1,000 -0.4 100 -0.6 B-H Curve 500kHz, RT) 100 Frequency [kHz] Core Loss - 10 - 1,000 MT / MS Series RoHS compliant products B Standard Specifications A D C soldered MT Standard Wired Series Type No. MT12S115 MT12S208 MT15S125 MT15S214 MT18S130 MT18S222 MT21S134 MT21S222 Core Type No. MT12X 8X4.5W MT15X10X4.5W MT18X12X4.5W MT21X14X4.5W Type of wire1UEW Wire N Diameter Parallel [mm] Number [turn] Flux*1*2 [Wb] Example of Circuit (150kHz)*3 Vo [V] Finished Dimensions [mm] Io [A] A max B max 6 20 13 10 20 13 12 6 25 15 110 5 10 25 15 30 284 15 6 28 15 2 22 208 12 10 28 15 1.0 1 34 375 24 6 32 15 0.9 2 22 243 15 10 32 15 1.0 1 15 94.7 5 0.9 2 8 50.5 3.3 1.0 1 25 197 0.9 2 14 1.0 1 0.9 Lead Length Length of Non Solder Package C [mm] D [mm] 205 3 max 1,000 [pcs in a box] MT Series Type No. Effective Core Coercive Rectangular cAW Mean flux *6 Total Flux*2 Insulating Cross Section Path Length Force *2 Ratio *2 2 Ae [mm2] *5 H.T. Lm [mm]*5 c[Wb]min Hc[A/m] Br/Bm[%] [Wbmm ] Covers Finished 5 Dimensions*4 [mm] Core Size* [mm] O.D. I.D. H.T. MT10X7X4.5W 11.5 5.8 6.6 10 7 4.5 5.06 26.7 4.73 116 A MT12X8X4.5W 13.8 6. 6.6 12 8 4.5 6.75 31.4 6.31 215 A MT14X8X4.5W 15.8 6.8 6.6 14 8 4.5 34.6 9.46 323 A MT15X10X4.5W 16.8 8.8 6.6 15 10 4.5 39.3 7.88 457 A MT16X10X6W 17.8 8.3 8.1 16 10 6.0 13.5 40.8 649 B MT18X12X4.5W 19.8 10.8 6.6 18 12 4.5 10.1 47.1 834 A MT21X14X4.5W 22.8 12.8 6.6 21 14 4.5 11.8 55.0 1371 A O.D. I.D. 10.1 8.44 12.6 20 max 94 min 9.46 11.0 MS Series Type No. Type No. Finished Dimensions*4 [mm] Core Size*5 [mm] Effective Core Mean Flux Coercive Rectangular *6 2 cAW Insulating Cross Section Path Length Total Flux* Force *2 Ratio *2 Ae [mm2] *5 Lm [mm]*5 c[Wb]min Hc[A/m] Br/Bm[%] [Wbmm2] Covers O.D. I.D. H.T. O.D. I.D. H.T. 9.1 3.3 4.8 7.5 4.5 3.0 3.38 18.8 3.15 23 A MS10X7X4.5W 11.5 5.8 6.6 10 7 4.5 5.06 26.7 4.73 116 A MS12X8X4.5W 13.8 6.8 6.6 12 8 4.5 6.75 31.4 6.31 215 A MS12X8X4.5W-HF 13.8 6.8 6.6 12 8 4.5 6.75 31.4 6.31 215 D MS14X8X4.5W 15.8 6.8 6.6 14 8 4.5 34.6 9.46 323 A MS15X10X4.5W 16.8 8.8 6.6 15 10 4.5 39.3 7.88 457 A MS16X10X6W 17.8 8.3 8.1 16 10 6.0 13.5 40.8 649 B MS18X12X4.5W 19.8 10.8 6.6 18 12 4.5 10.1 47.1 834 A MS21X14X4.5W 22.8 12.8 6.6 21 14 4.5 11.8 55.0 11.0 1371 A MS26X16X4.5W 29.5 13.0 16 4.5 16.9 65.9 15.8 2097 B 13.7 6.4 max 26 MS12X8X3W min 8.0 4.8 12 8 3.0 4.50 31.4 4.20 126 C 16.7 8.4 4.8 15 10 3.0 5.63 39.3 5.25 277 C MS7X4X3W MS15X10X3W max 10.1 8.44 12.6 25 max 9.46 94 min *1 The amount of magnetic flux is equal to () x(c ). *2 Measuring condition : 100kHz, 80A/m (sine wave), R.T. *3 Recommend for designing (note : A design of a transformer in the case may be unable to use this data. Please set up the operating magnetic flux 70% or less of the magnetic flux.) *4 Dimensions of the Finished Insulating Covers ; Tolerance : 0.2mm *5 Reference value *6 Insulating cover is made with UL94V-0 approved material A : Black PET, B : Black PBT, C : Red LCP, D : Halogen-free Those other than standard winded articles can be manufactured. Please ask to sales department. MT sample kits are prepared. Please ask to sales department. - 11 - Merits of the Mag-Amp Method Since the Mag-amp method uses saturable cores to regulate voltage, there is a big advantage that cannot be achieved by semiconductor-based regulation methods. The advantage is especially clear when there are large changes in the current. (Downsizing) Large currents can be handled by small size cores. Also, there is no need for a heat sink and the number of parts as the regulation circuit is small. This results in a smaller mount area compared to semiconductor-based methods. Power Saving Because cobalt-based amorphous alloy is used, the operating loss at high frequencies is small. Also, the power needed for control of the Mag-amp is smaller, enabling power to be saved. Low Noise The noise from the output diode is small because the Mag-amp is connected in series with the output diode. In semiconductor-based methods, since the number of switching elements increases, so also does the noise. Miniaturization High Reliability Since Mag-amps are magnetic parts, the cores are not destroyed by surges in voltage and current. For this reason, they have been used in power supplies requiring reliability such as those for electricity or large computers. High Precision The Mag-amps realize precise output voltage because the secondary side of the main transformer is directly controlled. It is possible to conduct voltage torelance with high precision (1%), from no-load conditions to full-load conditions. As seen above, when the Mag-amp method is used in regulating output voltage of switching power supplies, excellent characteristics can be achieved in size, efficiency, noise, reliability, and precision. Advantages in cost performance are especially realized in low voltage / high current circuits (example: 3.3V5A). Full Mag-Amp Method The simple Mag-amp method is used mainly for voltage control of the post circuit in power supplies, called the cross-regulation (master-slave) method. This cross-regulation method stabilizes the output voltage by feedback of the main circuit to the primary side. Therefore, the post circuit output is affected by the situation of the load in the main circuit (cross regulation error). There is also the problem that power supplies do not operate unless some current (minimum current) is sent through the main circuit. The Full Mag-amp method is a way to solve this problem. The Full Mag-amp method controls each output at the secondary side. Therefore, there is no need for feedback to the primary side, and each output can be controlled from no-load conditions. Also, since each output operates independently, the optimization of the winding ratio for the main transformer and high efficiency can be realized compared to the cross-regulation method. Furthermore, since each output is independent in the Full Mag-amp method, it is only necessary to adjust the circuit where the specification was changed. Therefore, time can be saved in the process of a design change. Mag-Amp Mag-Amp AB +12V 0 A OSC. P.W.M +12V A 0 AB +3.3V 0 10A Mag-Amp Mag-Amp AC AB AB +3.3V 0 10A AB +5V 0 15A AC Mag-Amp AB OSC. P.W.M Full Mag-Amp Method Cross-Regulation (Master-Slave) Method - 6 - - 12 - +5V 1 15A Examples of Circuits and Characteristics Examples of Circuit Mag-Amp Mag-Amp Flyback converter (ON-OFF Type Ringing choke converterRCC) Mag-Amp Push-pull converterCenter tap type Mag-Amp Full bridge converter Mag-Amp Forward Converter (ON-ON Type Half Bridge Converter Characteristics (Typical Value) 140 10000 10000 120 500kHz 300kHz 200kHz 10 1 0.01 100 Magnetic flux density 300kHz 900 MS MT 0.1 Magnetic flux density 10 100 50 500 1000 frequency [kHz] Hc vs. Frequency 1 80.0 1000 100 MTMS 70.0 800 60.0 MTMS 600 500 400 90 50.0 40.0 Typical Value f=100kHz Hm=80A/m 30.0 300 Typical Value f=100kHz Hm=80A/m 200 100 -20 0 20 40 60 Temperature [] 80 Bm vs. Temperature 100 120 -40 -20 0 80 Typical Value f=100kHz Hm=80A/m 70 MT 10.0 0.0 -40 MS 20.0 Br/Bm [%] 700 Hc [A/m] Bm [mT] 0 Typical Value Room Temp. Sine Wave Saturable Core MS Core Loss Saturable Core MT Core Loss 0 Typical Value Room Temp. Hm=200A/m Sine Wave 60 20 100kHz 1 0.01 1 80 40 50kHz Typical Value Room Temp. Sine Wave 0.1 500kHz 200kHz 10 100kHz 100 1000 Hc [A/m ] 100 Core Loss Pfe [kW/m3] Core Loss Pfe [kW/m3] 1000 20 40 60 80 Temperature [] Hc vs. Temperature 100 120 60 -40 -20 0 20 - 13 - 60 80 100 Br/Bm vs. Temperature Examples of a use other than Mag-Amp : Resonancer for Switching Power Supply ( Partial Resonace Element ), CT Magnetic Sensor, Transformer Core for Self-Invertor Oscillator, High Frequency Saturable Core for Current Delay or Timing Control - 7 - 40 Temperature [] 120 4 High Magnetic Permeability Cores for Pulse Transformer After suitable heat treatment has been done, cobalt base amorphous material shows excellent magnetic properties. TOSHIBA MATERIALS has developed new high permeability core 'FS Series' with this material. FS series maintain high initial permeability i especially at the high frequency zone, and are suitable for Pulse Transformers, Noise Filter and Cores for Sensors. High permeability enables electronic parts to be smaller and have higher performance. High Permeability : i at 10kHz is 100,000 it changes inductance module smaller and higher performance. Low Loss : Smaller core loss, higher exchange efficiency, lower self heat of core can be obtained. Constant Permeability : Small permeability change depending on magnetic field. Thin and Small Core : Small miniature core enables to mount in a PC-card. Characteristics (Typical Value) 0.8 1,000,000 Specific Permeability [ 0.6 0.4 0.2 -10 -5 FS Ferrite 100,000 5 -0.2 10 H [A/m] -0.4 10,000 1,000 -0.6 100 1 -0.8 10 100 1000 10000 FS26x16x10W FS32x20x10W ALVaue [H/n2] Ferrite 100 10 100 Frequency [kHz] Core Loss VS. Frequency Impedance [/n2 ] 1 1000 10 FS26x16x10W FS32x20x10W 1 FS12x8x4.5W FS18x12x4.5W FS21x14x4.5W 10 100 1000 10000 Frequency [kHz] Impedance VS. Frequency FS12x8x4.5W FS18x12x4.5W FS21x14x4.5W 10 0.1 10 100 0.1 1 100 1 10 100 1000 10000 Frequency [kHz] AL Value VS. Frequency 100 AL Value [H/n2] Core Loss [kW/m3] 1 10000 Frequency vs. Permeability DC BH Curve 1000 1000 Frequency [kHz] FS32x20x10W FS26x16x10W FS21x14x4.5W FS18x12x4.5W FS12x8x4.5W 10 1 10 100 DC [mA] DC Bias Characteristic - 14 - - 14 - 1000 FS Series RoHS compliant products Standard Specifications Type No. Finished Dimensions [mm] Core Size [mm] 1 O.D.max I.D.min H.T.max O.D. I.D. H.T. 1 1 Effective core Mean flux cross section path length Ae [mm2] Lm [mm] 2 3 4 AL Value Insulating Cover [H/n2] FS12X8X4.5W 14.0 6.6 6.8 12 8 4.5 6.75 31.4 27.0 A FS18X12X4.5W 20.0 10.6 6.8 18 12 4.5 10.1 47.1 27.0 A FS21X14X4.5W 23.0 12.6 6.8 21 14 4.5 11.8 55.0 27.0 A FS26X16X10W 29.5 13.0 13.0 26 16 9.5 35.6 66.0 67.8 B FS32X20X10W 35.5 17.0 13.0 32 20 9.5 42.8 81.7 65.7 B Operating temperature has to be less than 85 (include self rise up) 1 Reference value 2 Tolerance30% 3 Measuring Condition : 10kHz,10mA, 1turn, R.T. 4 Insulating cover made with UL94V-0 Approved Material. A: PET, B: PBT Don't hesitate to ask our sales section about other size items. Applications Magnetic core of pulse transformer Communication instrument (ADSL etc.) Small size, high density assemble Magnetic core for common mode noise filter Switching power supply Communication and measuring instrument Magnetic core for current transformer ADSL modem, or pulse transformer for terminal adapter PC Common mode noize filter for switching power supply FS FS AB Telephone - 15 - - 15 - TM How to Select the Proper Size "AMOBEADS Reference " The proper size "AMOBEADSTM " core is selected by calculating the necessary voltage times the time in seconds (=flux). From its operating theory, there is a need to increase the voltage used in the calculation by that which develops during the reverse recovery period of diode. The multiple of the voltage and time (voltage times second) is equal to the operating flux. Therefore, the magnetization ns necessary to suppress the noise is calculated by the voltage Ec[V] and time for reverse recovery of diode, that is added to "AMOBEADSTM " ns [Wb] Ecxtrr VxSec] A good result is achieved when the voltage Ec added to "AMOBEADSTM " is close to voltage added to diode. Please select the "AMOBEADSTM " that have a larger core magnetization c than the voltage times seconds that was calculated here. However, the actual noise suppression result for "AMOBEADSTM " on real circuit may differ from the calculated value due to the peculiar recovery characteristics of the diode used or the circuit structure. So please confirm the effect by performing examination. "AMOBEADSTM " can be also affected by things like a CR snubber, so please perform evaluation under condition without any effect of a snubber. Since "AMOBEADSTM " have high circuit voltage, sometimes an insufficient result is obtained when the reverse recovery time is long and has minimal magnetization. Under this condition, please consider a wire wound type "SPIKE KILLERTM " Example of "AMOBEADSTM " Selection Forward Converter trr 35nsec 60nsec 3.3V AB3x2x3W AB3x2x4.5W 5V AB3x2x4.5W AB3x2x6W Output Voltage 12V AB3x2x6W AB4x2x4.5W 15V AB4x2x4.5W AB4x2x6W 24V AB4x2x6W SPIKE KILLER 15V AB3x2x6W AB4x2x4.5W 24V AB4x2x4.5W AB4x2x6W Flyback Converter trr 35nsec 60nsec Output Voltage 3.3V AB3x2x3W AB3x2x3W 5V AB3x2x3W AB3x2x4.5W 12V AB3x2x4.5W AB3x2x6W Example of Noise Reduction Without Countermeasure With AMOBEADS (AB4x2x8W) - 20 - - 16 - Reference Principle of the Noise Suppressing Device We will explain the behavior of "AMOBEADSTM " when slipped over the lead of a switching power supply output diode. Period,0(When Diode is On) During period I, which is when the diode is in the "ON" condition and the forward current is running, the "AMOBEADSTM " are in the saturated magnetic condition "I". There will be almost no inductance under this condition. (Inductance is proportional to the slope of the B-H curve.) Period(When Diode is Turn Off) During period , which is when the diode current starts to turn off and the current decreases heading towards zero, the "AMOBEADSTM " magnetization curve will change like "" in a condition of almost no inductance until the current crosses zero. Since there is no inductance during this period , the angle or slope of the diode current during turn off is constant, a unique characteristic of the "AMOBEADSTM ". If materials such as ferrite is used, inductance will occur during this period and the angle or slope of current during the turn off period will change and this will lead to increased of diode loss. Period (Reverse Recovery Period) During period, a reverse recovery current tries to flow in a direction opposite to the normal direction of current flow of the diode and as a result, the magnetization curve of the "AMOBEADSTM " change like "" and the inductance increases rapidly. At this time, the large inductance of the "AMOBEADSTM " intercepts and opposes the recovery current and converts the current into a soft recovery condition. Thus by converting the sharp reverse recovery to a soft recovery condition by decreasing the rate of the current change (di/dt), the "AMOBEADSTM " minimize the rapid change of current (High di/dt) and suppress the noise in the circuit. Period (After Reverse Recovery Ends) During period , when the reverse recovery of the diode ends, the magnetization of the "AMOBEADSTM " will move parallel to the vertical axis of the magnetization curve as shown in period "". Period (When Diode is Turn On) The "AMOBEADSTM " magnetization will change as shown in "" of the magnetization curve and go back to a saturation condition. At this point, the diode will turn on and after a slight delay of the start up of current, the next current pulse will develop and the cycle described above from Periodthru will repeat itself. As the complete cycle repeats itself at the circuit operating frequency, the "AMOBEADSTM " repeatedly suppress circuit noise during period III of the cycle by eliminating the rapid change in the reverse recovery current of the diode, which is the cause of noise. "AMOBEADSTM " use a cobalt based amorphous alloy with a small coercive force under frequency and this results in excellent noise suppression. Reverse Current Forward Current [Wb] trr t high di/dt Reverse Recovery Soft Recovery by AMOBEADSTM H (A/m) Ir=HcxLm/N Current Waveform of Diode - 21 - - 17 - Actual BH Curve Reference Mag-Amp Operating Principle The Mag-Amp method is a switching regulation method for D.C power supply in which the magnetic switch is created through using saturated area and unsaturated area of the saturable core. Voltage regulation at the secondary side of the switching supply is realized by P.W.M. (Pulse Width Modulation). Period(Pulse is on) When the "ON" pulse is from the main transformer, the flux changes as "" on the actual magnetization curve. At this time, the saturable core has very high inductance because the core's magnetization is in an unsaturated area. When voltage is added, it is handled at both ends of the coil and the current does not flow toward the side with the current load. During Period "", the voltage is blocked with the switch OFF, and the pulse width modulation is done. Period (Mag-amp is saturation) After some time at Period , the saturable core becomes saturated "" and the inductance rapidly decreases to a minimum and the current is supplied toward the load side. The switch is ON in Period . Period (Pulse is off) When the pulse from the main transformer is OFF (Period ), the magnetic curve of the saturable core changes as in . It rises over the magnetization axis from the effects of the reverse recovery current and leaked current of the output diode. Period (Reset) While the polarity of the pulse voltage is reversed (Period ), there is voltage control which corresponds with the preset output voltage by the Mag-amp control circuit. The saturable core's magnetization changes (resets) itself as in "". Period Period is operated repeatedly through the operated frequency and the voltage is regulated. The reset area at Period and the area at Period is equal. Therefore, by changing the reset amount at Period , the blocked area at Period can be changed, and it becomes possible to regulate voltage by magnetic P.W.M. Secondary voltage of the transformer BH cuve of the material Actual magnetization curve B Voltage of Mag-Amp E2 T H Current of Mag-Amp E2 xT - 16 - - 18 - Reference Mag-Amp Design (Forward Converter) The standard methodology for designing and selecting the proper size mag-amp is to first determine the product of the secondary voltage of the transformer and the "on duty" time, measured in seconds. The proper size mag-amp can then be selected by determining which mag-amp core can adequately handle the highest product of this secondary voltage and "on duty" time, otherwise known as core flux. All calculations must be made on the condition that this on-pulse product of voltage and time is at its maximum. On-pulse maximum product of time The on-pulse maximum product of time V2 is calculated from the secondary voltage of the transformer (=E2) [V] and the maximum on time duty period (=Don) and operating frequency (=f)[Hz]. For cross-regulation type circuits, the on-duty values for the main circuit at maximum load current are usually used. V2 [Wb]E2xDONf [VxSec] V2 DOFF DON Mag-Amp Vo E2 Io E2 Mag-Amp circuit of the secondary side Transformer voltage of the secondary side Flux needed for mag-amp control The calculation of the Voltage-time product (=Magnetic Flux) mag differs between when the mag-amp is used for voltage regulation only and when the mag-amp is also used to protect against over currents. 1Voltage regulation magV2xKv [Wb] KV= Vh Vo 2Protection of over currents Transformer Voltage The mag-amp is designed with the standard of no load, because the flux deviation is usually largest when there is no load. The coefficient for the incremental increase in voltage at no load (Kv) is used. (Kv=<1) see right figure When the mag-amp is also used to protect against over-currents, the on-pulse maximum voltage-time productv2 must be handled by the mag-amp. Therefore, the following calculation is applied. magV2 [Wb] Transformer System Vh Mag-Amp Control V0 Output Current Output Current vs. Transformer Voltage Selection of core size The core size is selected based on the flux needed to control the mag-amp, mag. The following simplified calculation is used to select core size. Aw magxIo/(KfxJ) /Kt [Wbmm2] Here, C is the total flux of the core and AW is the core winding area. The values for CAw are found in the standard specification chart. Kt is the design safety coefficient; Kf is the coefficient for wire winding, and J is the current density. Calculation of Number of Turn The number of turns () is calculated by the following equation, where N is an integer. N mag / C min / Kt [turn] Calculation of Diameter of the Wire From the equation for current density J [A/mm2], wire diameter[mm], output current Io[A], Io(d/2)2xxJ [A] d = 2x Io/(xJ) [mm] Please always confirm operation on the actual circuit after design. - 17 - - 19 - Reference Examples of the Design Here, we show a design example when regulating a 5V-10A circuit using a forward converter with an operating frequency of 150kHz. On-pulse maximum voltage-time product The E2 on the secondary side of the main transformer and the maximum on duty cycle are assumed to be E2=15[V] and Don=0.4. V2E2xDon[VxSec][Wb] 15x0.4/150000 40 [Wb] When using a Mag-amp to also protect against over currents, magV2. Here, we assume that the mag-amp only regulates voltage and set the incremental increase at the time of no current load as KV=0.6. magV2xKV40x0.624 [Wb] Choice of core size The wire winding coefficient, Kf, is the coefficient that it is possible to wind on the inside of a toroidal core. Usually, Kf=0.4 is used. The current density J is usually set as J=510[A/mm2]. Here, we assume J8[A/mm2]. If the mag-amp's maximum operating temperature is assumed to be 120, we assume that the flux density of the core decreases to 80%. We also allow flux design space to be 70%. CAW magxIo/(KfxJ)/Kt 24x10/(0.4x8)/(0.8x0.7) 133.9 [Wbmm2] From the standard specification table, MT12X8X4.5W is chosen. Number of wire winding Nmag/Cmin/Kt [turn] 24/6.31/(0.8x0.7)6.8 7 [turn] Wire diameter When the wire diameter is over 1.0mm, there is difficulty in the actual wire winding of the toroidal cores. Therefore, when the output current Io is over 5[A], parallel winding is used. Here, since Io10[A], two parallel wires are used. d2x Io/2/(xJ) [mm] 2x 10/2/(x8)0.89 [mm] As a result, 2 parallel 0.9mm wires are wound. Results of design (Operating Frequency 150kHz, 5V-10A, Voltage Regulation) MT12X8X4.5W, 0.9mm, 2 parallel windings, 7[turn] Please always confirm operation on the actual circuit after design. Since the mag-amp is a passive part, it becomes susceptible to effects from the waves of the transformer, and actual operating tests are necessary. Design Example ( Forward Converter, 150kHz operating Over Current Protection (at E2xDON =1.2Vo Voltage Controlat Kv=0.6 Current Voltage 3.3V 5V 12V 15V 24V 6A (1.0mm) MT12S115 MT12S115 MT15S125 MT15S125 MT18S130 15A 10A 0.9mmx2p. 0.9mmx3p. MT12S208 MT12S208 MT15S214 MT18S222 MT18S222 MT12 : 5turn MT15 : 6turn MT18S311 MT18 :14turn MT21 :19turn 6A (1.0mm) MT12S115 MT12S115 MT15S125 MT18S130 MT21S134 15A 10A 0.9mmx2p. 0.9mmx3p. MT12S208 MT15S214 MT18S222 MT21S222 MT21:32turn MT15:7turn MT16:6turn MT21:16turn MT21:20turn MS26:18turn Note) Operating flux is influenced by the main transformer of the circuit, and the value shown in the table is not necessarily applied as it is. - 18 - - 20 - Evaluation of the Mag-Amp Circuit Unit Reference 1At no-Load Generally, the range of the flux becomes large at no, or small current load. There is a possibility that the mag-amp may not be able to control the output voltage because there is a shortage of core flux. This problem occurs because the large range of the flux density causes saturating on the other side and there is not enough ability to control the voltage-time product. In order to set the allowances for design, the wire winding for the Mag-amp is reduced and the operating range is confirmed. However, the core flux necessary at the time of no current load is largely influenced by such factors as the dummy current value. Therefore, when the core flux is large at no current load, such factors as the dummy current value must be adjusted, taking efficiency into account. 2At Full-Load Generally, the mag-amp's flux range becomes small at the full current load. There is the possibility that output voltage cannot be regulated because it is not possible to make the range any smaller. This problem is called the dead angle. The allowances for design at full current load are confirmed by increasing the number of wire windings. Transformer Voltage [ V ] However, the dead angle value is influenced not only by the core characteristics, but also by the reverse recovery current of the output diode and leaked currents. Please select output diodes with fast recovery times. Also, when using SBD (Schottky Barrier Diode), please use one with small current leaks and stable temperature characteristics. Transformer Dead Angle (Vd) No load V0 Mag-Amp controlled Output Current [ A ] Output Current vs. Transformer Voltage 3Temperature Rise The temperature rise from no current load to full current load should be confirmed. Since the upper limit temperature for continuous use of our mag-amp saturable cores is 120, the mag-amp should be designed so that the sum of the surrounding temperature and core temperature rise does not exceed 120. Please measure core temperature rise under the condition of natural air-cooling (Without cooling fan). Generally, the mag-amp is designed calculating the temperature rise at T3040. With forward converters, the temperature rise at no current load is especially high. When this occurs, the wire winding should be increased and the operating flux density reduced. When the temperature rise is too high at full current load, the wire winding should be reduced and the operating magnetic field reduced. 4Output voltage precision It is necessary to confirm the voltage regulation characteristics (specifications) from no current load to full current load conditions. When there is a mismatch between the gain of the mag-amp and the gain of the regulated circuit, the circuit vibrates abnormally. Especially when there are sounds from the mag-amp circuit, there is a high possibility that the regulated circuit is abnormally vibrating. 5Protection from Over currents When protecting for over currents, the range of operating flux for the mag-amp becomes large. Please set the maximum flux range to be 70% of the core flux, similar to when there is no current load. - 19 - - 21 - Reference Glossary of Amorphous Magnetic Parts Technical Terms Saturable Core A magnetic core can be able to saturate. These cores have a high square shape ratio, and it can use magnetic saturation and magnetic being un-saturated. Toroidal Core Magnetic core which has doughnut shape. Cross Section Effective core cross section area :Ae, Ae [m2] = ((OD[m] - ID[m] ) x height HT[m] Packing Factor pf The ratio of the absolute area of magnetic material to its geometrical area . Magnetic Path Length Lm Length of the magnetic circuit. In the case of the toroidal core, magnetic mean path length Lm is adopted. Lm [m] = (OD[m] + ID[m]) x /2 Magnetic Flux Density B Magnetic flux strength of the material, which is perpendicular magnetic flux of the unit area. B[T] = [Wb] / Ae [m2] Magnetic Flux [Wb = Vsec] = B[T] x Ae [m2] Magnetic Field Strength H H[A/m] = I [A] Permeability = B / H. Inductance L is proportional to permeability . Initial Permeability i *1 First inclination of the initial growth of magnetic flux density B see the illustration below Maximum Flux Density Bm In this booklet, Bm is defined as the flux density at the magnetic field Hm. see the illustration below / 2 ) x pf / Lm [m] Residual Magnetic Br is the flux density at the time the magnetic field return to H = 0 see the illustration below Fux Density Br Total Magnetic Flux c Total magnetic flux of the core. In this booklet, total magnetic flux c is defined as the following equation. c [Wb] = 2 x Bm [T] x Ae [m2] Rectangular Ratio Br / Bm The ratio of the Bm and Br. Greater the rectangular ratio, the more superior the magnetic saturability. Br / Bm = Br [T] / Bm [T] Coercive Force Hc Hc is the cross point of the BH curve and X axis. Smaller the Hc, the less the loss and the more superior the Hc.see the illustration below *1 Initial permeability is out of control in the case of saturable cores, because it is unrelated to the Mag-Amp. B magnetic path length Br cross section Bm i -Hc - 22 - 0 Hc Hm H Notices on Handle, Maintenance and Discontinue List Reference Notices of the amorphous magnetic parts on handle Detail information are described on the technical data sheet or the specification for supply. Maximum 120 (include temperature rising by self-heating, under natural air cooling) Operating Temperature (except FS series which is 85) Wire Winding Mounting Soldering Circuit Design Be careful at wire winding or lead insertion. Damage or deformation of the core or insulating cover has a harmful influence. Be careful to the rare short circuit. Make sure not to apply any stresses which will lead to deformation of the core exterior. If the product is to be impregnated, bonded, cleaned or otherwise treated, confirm that such treatment will not adversely affect the magnetic characteristics. When impregnating the core, be sure that the magnetic properties will not be influenced. Prevent radiation and conduction from high temperature components from reaching the core. Be sure to consider vibration and shock when installing these parts. When soldering be sure that the core exterior will not be deformed by heat conducted through the lead wire. Do not subject parts to re-flow or flow soldering. (Except the surface mounting type) Be careful, of imput voltage, rated current, ambient temperature and temperature rise. When revising the circuit, please recheck the core temperature rise. Recheck the maximum temperature or maximum loads. Transport and Storage Do not drop the parts. Protect the parts from water. Discontinued List Discontinued Type No. Substitution (recommend) Discontinued Type No. Substitution (recommend) FS10X4X1 (FS12X8X4.5W) MB15X10X4.5 MS15X10X4.5W MA7X6X4.5X (MS10X7X4.5W) MB18X12X4.5 MS18X12X4.5W MA8X6X4.5X (MS10X7X4.5W) MB21X14X4.5 MS21X14X4.5W MA10X6X4.5X (MS10X7X4.5W) MS8X7X4.5W (MS10X7X4.5W) MA14X8X4.5X MS14X8X4.5W MS9X7X4.5W (MS10X7X4.5W) MA18X12X4.5X MS18X12X4.5W MS10X6X4.5W (MS10X7X4.5W) MA22X14X4.5W (MS26X16X4.5W) MT10X6.5W MT10X7X4.5W MA26X16X4.5W MS26X16X4.5W SA4.5X4X3 AB5x4x3DY MB8X7X4.5 (MS10X7X4.5W) SA5X4X3 AB5x4x3DY MB9X7X4.5 (MS10X7X4.5W) SA7X6X4.5 (SS7X4X3W) MB10X7X4.5 MS10X7X4.5W SA8X6X4.5 (SS10X7X4.5W) MB12X8X4.5 MS12X8X4.5W SA10X6X4.5 (SS10X7X4.5W) MB14X8X4.5 MS14X8X4.5W SA14X8X4.5 SS14X8X4.5W AB3X2X6W AB3X2X3W 2pieces Attention : Same or similar core size items are listed up for substitution. Magnetic or electric characterisitcs are changeable. Please test substitution parts before replacing to ensure performance. Wired parts made by these cores are also discontinued items. - 23 - Copyright 2015, TOSHIBA MATERIALS Co., LTD. All Rights Reserved Printed in Japan 27. 1. AT