Table Of ContentOPTIMIZED PROGRAM SERVICE, LLC.
Electro-Magnetic Design Using Advanced Computer Techniques
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FERRO
PROGRAM DESCRIPTION AND OPERATING INSTRUCTIONS
I. INTRODUCTION
FERRO is a comprehensive program for developing designs for constant voltage
ferroresonant transformers for power supplies, battery chargers, line-stabilizers and power
conditioning applications. FERRO designs both standard two-coil and three-coil (harmonically
compensated) type transformers. Many of the features used in other OPS programs are included
in FERRO, such as automatic core and conductor selection.
II. INPUT REQUIREMENTS
For entry of design information, See Page 3.
DISCLAIMER
This program and its documentation have been subjected to normal field testing
procedures. Optimized Program Service, llc. makes no warranty, expressed or implied, as to the
documentation and the performance of the program. Users are expected to make the final evaluation
as to the value and correctness of the results obtained for their specific applications.
FERRO 1
TABLE OF CONTENTS PAGE
MAIN MENU 3
GENERAL DESIGN DATA (2 COIL) 4
GENERAL DESIGN DATA – COOLING DUCTS 5
GENERAL DESIGN DATA – CORE 6 – 8
PRIMARY – WINDING DATA 9 – 10
RESONANT WINDING DATA 11
SECONDARY 1 – WINDING DATA 12
COMPENSATION WINDING DATA 13
CONSTRUCTION 14
PROGRAM EXECUTION 15
GENERAL DESIGN DATA (3 COIL) 16
LAMINATION SIZE TABLE 17
PRIMARY HIGH TAP – WINDING DATA 18
THREE-COIL FERRO CORE/COIL STRUCTURE 19
CORE STRUCTURE LAYOUT/VIEW PIECES 20
FERRO 2
MAIN MENU
IF NEW DESIGN IS BEING STARTED OR EXISTING DATA IS BEING RUN:
••••Select “BEGIN/REVIEW DESIGN IN ENGLISH UNITS”
INDUCTOR proceeds to General Design Data, Page 4, using English values.
••••Select “RETRIEVE DESIGN DATA” to retrieve an existing design file.
••••Select “GENERATE DESIGN PRINT OUT FROM EXISTING DATA”
to obtain a design.
••••Select “MODIFY ” to modify design input data.
••••Select “TERMINATE” to exit the program.
FERRO 3
GENERAL DESIGN DATA (2-COIL)
FREQUENCY: Frequency of input voltage in hertz.
CONFIGURATION: Select 2-Coil or 3-Coil FERRO.
NO. OF SECONDARY WINDINGS: Enter number of secondary (output) windings.
Eight (8) are permitted.
***** NOTE: See Page 15 for 3-coil FERRO.
FERRO 4
GENERAL DESIGN DATA – COOLING DUCTS
COOLING DUCTS: Spaces in coils that permit air to flow parallel to the coil axis.
INTERNAL DUCTS: E X T E RNAL DUCT:
Ducts are placed D u c t i s p l a c e d b e t w een
within winding only winding and core
BOTH: Ducts both within winding and between winding and core.
INTERNAL DUCTS
THICKNESS: Radial thickness of duct opening.
EFFECTIVENESS: Percent of duct free from obstruction , such as leads.
EXTERNAL DUCTS
# OF LOCATION: Enter number of required duct locations.
LOCATIONS: Enter number of winding UNDER which duct is to be located.
(2 indicates duct under second winding, etc.)
THICKNESS: Radial thickness of duct opening.
EFFECTIVENESS: Percent of duct free from
obstruction.
TYPE
END: Ducts on ends of coils outside core window. END DUCTS FULL DUCTS
FULL: Duct around coil.
FERRO 5
GENERAL DESIGN DATA - CORE
LAM. TYPE
SCRAPLESS: Standard scrapless EI laminations (User must enter all core dimensions.)
FR: Ferroresonant lamination shapes. (See Page 17)
STRIP: Strip lamination (all core dimensions must be entered.)
IRON GRADE: M Grade of steel.
Y/T RATIO: Ratio of yolk or ends of lamination to tongue width.
L/T RATIO: Ratio of lamination outside return legs to tongue width.
THICKNESS: Thickness of individual lamination in inches.
STACK FACTOR: Proportion of lamination stack that is actually iron.
**NOTE: If Iron Grade is selected as SPECIAL:
MU FACTOR: Permeability factor used in inductance calculation. (Entered as relative number
such as 1.1 for M6, 1.3 for M19 and M22, or 1.4 for M27).
TW (watts/lb.): Average core loss of the magnetic structure in watts/pound.
POWER FACTOR: Enter power factor, usually -.97 for M6 and -.9 for non oriented grades.
DESCRIPTION: Material grade description.
WEDGE: Space (in inches) allowed on each side of core stack to insert wedges for
securing coils to core.
SPACE: Space (in inches) on each side of the tongue for mechanical clearance.
WNDG FORM THK: Thickness (in inches) of insulation between core and the first layer of wire.
FERRO 6
GENERAL DESIGN DATA – CORE (PAGE 1-CONTINUED)
PRI. MAX B: Flux density of iron under primary winding at highest input voltage (in kilogausses).
SEC. MAX B: Flux density of iron under secondary winding to be attained during regulation
(in kilogausses).
**NOTE:
A Zero (0) entry for either “PRI. MAX B” or “SEC. MAX B” will result in values to be selected by
FERRO from the following table:
IRON GRADE PRI. MAX B SEC. MAX B
M6 19.00 20.80
M19 18.01 19.85
M22 17.40 19.25
M27 17.00 18.80
NET END ALLOW: Net difference between coil lengths and available window length (in inches).
This will be subtracted from each window.
SEC. POSITION: Position of the window length, minus shunt stack, allocated to the secondary
coil. If zero (0) entered FERRO will use .67 (2/3 of the available window
length would be allotted to the secondary coil and 1/3 to the primary coil.)
SHUNT AREA RATIO: Ratio of total shunt area to core cross-sectional area.
FERRO 7
GENERAL DESIGN DATA – CORE (PAGE 2-CONTINUED)
CORE DIMENSIONS:
PROGRAM TO DETERMINE
ALL: FERRO will select complete core from core Table (See Page 17)
STACK: FERRO will use values entered for T, H and W and will determine STACK(S).
NONE: FERRO will use values entered by user for T, S, H, and W.
T: Lamination center-leg in inches.
S: Stack of lamination entered in inches.
H: Narrow dimension of lamination window entered in inches.
W: Wide dimension of lamination window entered in inches.
WINDOW LENGTH:
CALC: If program to calculate window length.
ENTER: If user to enter Wp, Ws (For 2-Coil) (See Page 16 For 3-Coil).
Wp: Window length of primary coil.
Ws: Window length of secondary coil.
CORE NAME: Enter any name or part number to identify core.
SHUNT ID: Description of shunt for printout purposes (max. 8 characters).
FERRO 8
PRIMARY – WINDING DATA
NO. OF PRI: Possible entries are
ONE SINE-WAVE INPUT: One primary with sine wave input.
TWO SINE WAVE INPUTS: Two identical primaries with sine wave input.
ONE SQ-WAVE INPUT: One primary with square wave input.
SQ. WAVE/SINE-WAVE: One primary with square wave input and one primary with sine wave
input.
SEPARATE HI-TAP: (See Page 18).
LO VOLTS: Lowest value of input voltage on primary at which regulation is to be maintained.
NOM VOLTS: Nominal voltage on primary winding.
HI VOLTS: Highest value of input voltage on primary at which regulation is to be maintained.
TEST (KV): Dielectric test voltage in kilovolts.
****NOTE: For worst-case evaluation, enter nominal voltage as low-line voltage. For low-line
voltage, enter slightly less to insure regulation.
FERRO 9
PRIMARY WINDING DATA (PAGE 2 - CONTINUED)
WIRE TYPE: Select Copper (CU) or Aluminum (AL).
WIRE SHAPE- RD : Round wire - enter as AWG wire size.
SQ : Square wire - enter as AWG wire size.
RG : Rectangular wire - enter as thickness and width.
FOIL : Foil or Strip - enter as thickness and width.
****NOTE: A Zero (0) entry for thickness will prompt FERRO to select wire sizes for all windings.
The shape will be determined by the shape specified in the wire shape selection entry for all subsequent
wire. NO. HIGH, NO. WIDE and LINEAR SPACE FACTOR must be entered for all wires even
when FERRO is selecting wires.
SKEW : Portion of a turn width subtracted from the winding space because of skew in the
winding. A value of (1) means 1 turn width subtracted.
AWG SIZE: Standard American wire gage sizes for round and square wires.
NO. HIGH: Number of wire strands high in a multi-stranded wire
NO. WIDE: Number of wire strands wide in a multi-stranded wire.
LINEAR SPACE FACTOR: Proportion of space occupied by wire that is actually wire.
DUCT LOCATION -
NONE: No ducts
DIVIDE WINDING: Select where duct is to appear (half indicates a duct halfway in the
winding.)
WINDING MARGIN: Distance from each end of the coil from where winding is to begin.
LAYER INSULATION: Thickness of insulation in inches between layers of wire.
SECTION INS. THK: Insulation thickness in inches over the winding.
FERRO 10
