HOMOLOGATION - HY-LINE...HOMOLOGATION The customer receives samples for testing and approval. PRODUCTION DEVELOPMENT This brochure is a short introduction to Sirio POWER COMPONENTS

HOMOLOGATIONThe customer receives samples

for testing and approval.

PRODUCTION

DEVELOPMENT

This brochure is a short introduction to Sirio POWER COMPONENTS. The new family was created after more than 30 years of experience in the development and production of high frequency electromagnetic components. In order to offer customers a complete service, Sirio has steered many efforts towards the study of the whole building process of power components, from the development stage to the supply of the final product.

CUSTOM SPECIFICATIONThe development of a customized power transformer begins by considering the customer specification.

SIMULATIONSAfter a rough calculation, the R&D team defines few possible solutions. As one of the most important features of a power transformer is the efficiency, power losses are typically the distin-guishing element at the moment of the choice of the final solution.

Thanks to a dedicated software for electromagnetic simulation using the finite element method, it is possible to study the behaviour of the transformer while running on the application circuit, in order to know:

• power losses

• dynamic fields distribution

• dynamic currents distribution

OPTIMIZATIONThe highest Quality/Price ratio can be easily reached when the best technical solution and Sirio production’s facilities and technolo-gies are properly combined.

PROTOTYPINGPrototypes can be built in Sirio Laboratory. They are electrically measured and tested, even in customer’s application too. By considering standard raw materials, the lead time for prototypes is extremely short.

AUTOMATIC WINDING PROCESSThe automatic winding machine is unique to Sirio, as it was developed according to our specifications. A second machine was added in 2012 and today we’re installing the third one.

AUTOMATIC MECHANICAL OPERATIONSBesides the cores assembling, power transformers construction requires some finishing operations. As always, Sirio’s approach has been oriented to automation, investing in tools and machines, in order to offer customers some standard, steady-quality and cheap solutions.

VACUUM CASTING TECHNOLOGYThe vacuum casting process allows to reach high level of isolation in very thin layers of isolation. That is the typical situation in high frequency industrial applications, where high reliability, isolation and safety are required and, on the other hand, very short distances are needed to improve the coupling. More than 40 years of experience in vacuum casting has made this technology one of Sirio’s strong points. The whole casting process is controlled by a dedicated computer.

AUTOMATIC FINAL INSPECTIONAll Sirio products are automatically tested and the production process is continuously checked: from the raw materials incoming to the machines’ setting, from the winding process to the core assembling phase, from the casting process to the final inspection stage.

FEATURESThe Power Components family follows the MILESTONES of all Sirio components:

HIGH RELIABILITYindustrial applications need long life components: every part is important for the good functioning of the whole machine

ISOLATION AND SAFETYtransformers are designed to guarantee the galvanic separation between the mains and the worker

AUTOMATIC PRODUCTIONautomation allows stable construction and reduces the production costs

STANDARD RAW MATERIALSstandardization is useful to reap economies of scale and to reduce the lead time

CUSTOMIZATIONthe transformer’s construction has to be flexible to customer needs.

APPLICATION FIELDSAfter few years from its launch, the Sirio Power Transformer family has become very successful in several APPLICATION FIELDS, e.g. :

• U.P.S. • SOLAR ENERGY

• WELDING • POWER SUPPLIES

• GALVANIC TREATMENTS • INDUCTION HEATING

• BATTERY CHARGERS • WATER CLEANING

From theoretical point of view, TRANSFORMER DIMENSIONS are related mainly to two parameters: the switching frequency and the rated power. An easy formula says that the transformer volume is approximately proportional to the Power/Frequency ratio,

but that is just a quick way to make a first choice and to understand the approximate dimensions. By looking at the whole project, other factors are obviously involved in the final design definition, like topology, working voltage and isolation voltage, currents through the windings, expected power losses and overtemperature, cooling system, duty cycle and so on. Sirio offers a standard range of bobbins and boxes for Power Components, developed by Sirio in order to evenly cover the power range from 1 kW to 20 kW. The following chart is an overview about the Power/Frequency ratio. It was extrapolated form our running projects and, as already said, it can be considered just for reference, as each converter needs an optimized transformer.

MODELS

Multiple EE55 series

2xEE55 - Mechanical Drawing Example

Multiple EE65 series

2xEE65 - Mechanical Drawing


Example

Example

Multiple E80 series




Example

Example

Example

Beside our standard models, optimized for automatic manufacturing process, we can also produce transformers of several other sizes and shapes, customized for your specific applications.

OTHER MODELS

INDUCTORSOptimization of an inductor could be challenging too, in order to keep low losses and compact dimensions while raising the current and frequency ratings.

In power electronics, inductors are usually employed as DC output stage chokes, but also applications like Power Factor Correction filters and resonance tanks for Soft Switching converters are today more and more common: all different applications requiring different design approaches. Hence, we have to put the same care used for power transformers.

The technology involved in producing inductors is the same as well. Again, automatic operations and standard raw materials make possible a just-in-time production of a custom component at the same cost of a catalogue product.

For high frequency applications, the most common core materials are:

• Soft Ferrite

• Amorphous and Nanocrystalline Laminations

• Powder (so-called distributed airgap materials)

Here below some examples of power inductors are shown.

Power transformers are relatively heavy components, therefore we always recommend our customers to design the most suitable mechanical fixing.

Several materials are available on the market, such as thermo-conductive rubber foils which help to avoid mechanical stresses on the cores and to improve, at the same time, the core losses dissipation.

The figure shows one of the most typical solutions, based on a metal bracket and two rubber foils on upper and bottom surface.

CUSTOMER SPECIFICATION SHEETSThe R&D Department is available to receive customer’s specification and to offer the development service, in order to propose the most suitable solution.

Customer specification sheet for SMPS POWER TRANSFORMERSField of applicationSMPS circuit topology (forward, half bridge, full bridge…)Secondary rectifier circuit (center tapped, Graetz bridge,...)Input voltage [V] Min: Max:Output voltage [V]Output current [A]Switching frequency [kHz]Output current ripple [A]Turns ratio Np/NsSwitching time [μs] Min: Max:No load secondary voltage [V]Output filter inductance [μH]Output filter capacitance [μF]Rated output power [kW]Primary current [Arms]Max primary over current [A]Primary inductance [mH]Primary leakage inductance [μH]Secondary current [Arms]Working voltage between primary and secondary [Vrms]Test voltages between primary and secondary [Vrms]Test voltages windings and core [Vrms]Operating temperature [°C]Cooling systemAir flow [m3/s]Size limitations LxWxH [mm]Standards to comply withQuantityTarget price

Customer Specification Sheet for INDUCTORSInductor purpose (output choke, PFC filter, resonance inductor, etc.)Inductance value at nominal rated current [μH]Tolerance on inductance [%]Rated current [Arms]Current ripple peak-to-peak [A]Working voltage [Vrms]Working frequency [kHz]Rated power [VA]Operating temperature [°C]Open construction or box versionSize limitations [mm]Standards to comply withQuantityTarget price

Schematic:

C21-

REV

.04

SIRIO ELETTRONICA s.r.l.Via Selve, 2 35037 TEOLO (Padova)ITALY

Phone: 0039 049 9901090Fax: 0039 049 9901868

E-mail:[email protected]

Code IP[Arms] n RC

[Ω]Rs[Ω] E% Φ [°] D [mm] Up

[kVrms] Drawing

TA 150800 15 max (1) : 1000 7 21 0,2 1 5 4200 1508FA

TA 150815 50 (1) : 1000 4 14 0,1 1 6 4200 1508FC

TA 150810 50 (1) : 1000 50 36 1,0 2 6 4200 1508FB

TA 150830 15 max 1 : 1000 7 21 0,2 1 0,8 4200 1508SA

TA 150811 50 1 : 1000 50 36 1,0 2 2,0 5000 1508SB

PURPOSEThese current transformers are suitable to measure alternate currents at 50-60 Hz, up to 50 Arms. They are typically used in energy metering applications, where high accuracy and small dimensions are required at the same time.

FEATURESFor this kind of component the choice of the magnetic material of the core is the most critical issue, as it makes possible to have high accuracy and a low output to input phase displacement in extremely compact dimensions.

These are critical features in case of equipments for alternate currents measurement, for example to measure rms and peak values, to detect waveforms, to perform harmonic analysis. By connecting a burden resistance to the secondary side, you can read a proportional voltage signal, isolated from the mains, however many different amplification techniques and signal processing are possible, depending on the application.

Typical working temperature is from -25 to +85°C.

Sirio offers current transformers for measurement applications in two different versions: with passing-through hole and with the primary turn inside, to achieve at the same time safety insulation and easy assembly process.

SYMBOLS:• IP rated primary current

• n turns ratio

• RC rated burden resistance

• RS rated secondary winding resistance

• E% accuracy

• Φ phase displacement

• D inner hole diameter/primary wire diameter

• Up insulation voltage test

CURRENT TRANSFORMERS FOR MEASUREMENT APPLICATIONS

TA 1508--

SIRIO ELETTRONICA s.r.l.Via Selve, 2 - 35037 TEOLO (PD) - ITALYPhone: 0039 049 9901090Fax: 0039 049 9901868E-mail: [email protected]

Certificate nr. 50 100 3372

TA03 – Rev.0

values in mm

Code n Vt[μVs]

IMAX[mA]

tr[μs]

RC[Ω]

Ck[pF]

Uis[Vrms]

Up[Vrms] Drawing

TI 108010 1 : 1 250 250 1,5 40 7 500 3100 108A

TI 108020 1 : 1 : 1 250 250 1,5 40 7 500 3100 108C

TI 108030 2 : 1 350 250 3,5 40 8 500 3100 108A

TI 108040 2 : 1 : 1 350 250 3,5 40 8 500 3100 108B

TI 108050 3 : 1 300 250 2,5 40 8 500 3100 108A

TI 108060 3 : 1 : 1 300 250 2,5 40 8 500 3100 108C

TI 110153 1 : 1 : 1 600 100 1,2 100 8 500 4000 110D

TI 110154 3 : 1 : 1 600 100 1,2 100 7 500 4000 110D

TI 110155 1 : 1 500 100 1,0 100 7 500 4000 110E

TI 110233 1 : 1 : 1 300 250 1,2 40 7 500 4000 110D

TI 110234 3 : 1 : 1 300 250 1,0 40 7 500 4000 110D

TI 110239 1 : 1 350 250 2,0 40 5 500 10000 110F

PURPOSEPulse transformers are used in high frequency power converters, when an electrical pulse has to be transferred from the control stage to the power stage, by keeping the galvanic isolation between the circuits, according to the safety standards related to each different application fields. The electrical signal is applied to the primary side and transferred to the secondary side, to fire electronic switches. The 108 and 110 families are based on different sizes of EE cores.

FEATURESThe peculiarity of this kind of components is the low coupling capacity between the windings, that is particularly important to avoid undesired firings of electronic switches; on the other hand, the leakage inductance is relatively high. They are mainly used in the multiple shot firing technique.

Standard versions are designed with one or two secondary windings.

The automatic winding process enhances their quality/price ratio.

LOW COUPLING CAPACITY GATE DRIVE TRANSFORMERS

TI 108 - 110

TI02 – Rev.0



SYMBOLS:• n turns ratio

• Vt secondary transfer area (voltage*time integral), that can be trasferred with unipolar pulse

• tr rise time, needed to trasfer the pulse when the rated load resistance is connected to the secondary side

• IMAX maximum secondary current, available with a rise time equal to tr (rated load resistance connected to the output)


• LP primary winding inductance

• Ls primary leakage inductance

• Ck coupling capacity between windings

• RP primary winding resistance

• RS secondary winding resistance

• IP rated primary effective current (thermal current)

• Uis rated working voltage

• Up isolation voltage

values in mm

Code IP[Arms]

IS[Arms] n RC

[Ω] UOUT [Vrms] Outputs D [mm] Drawing

TA 150120 400 0,400 n1-4 = 1000 20 8,0 Faston 1-4 26 150A

TA 150130200400600

0,4000,4000,400

n1-2 = 500n1-3 = 1000n1-4 = 1500

202020

8,08,08,0

Faston 1-2Faston 1-3Faston 1-4

26 150C

TA 150140 400 0,200 n1-4 = 2000 20 4,0 Faston 1-4 26 150A

TA 150150200300400

0,2000,2000,200

n1-2 = 1000n1-3 = 1500n1-4 = 2000

202020

4,04,04,0


26 150C

TA 150160 600 0,600 n1-4 = 1000 10 6,0 Faston 1-4 26 150A

TA 150170 600 0,200 n1-4 = 3000 20 4,0 Faston 1-4 26 150A

TA 151008 200 0,200 n1-4 = 1000 10 2,0 Faston 1-4 18 151A

TA 151100 100 0,200 n1-4 = 500 20 4,0 Faston 1-4 18 151A

TA 1511102550

100

0,2000,2000,200

n1-2 = 125n1-3 = 250n1-4 = 500

202020

4,04,04,0


18 151C

TA 151133 100 0,100 n1-4 = 1000 20 2,0 Faston 1-4 18 151A

PURPOSECurrent transformers are used to measure and detect alternate currents, by keeping the galvanic isolation between the primary cable (the network) and the control stage. They tipically have a high number of secondary turns, so that the secondary current is relatively low. By connecting a burden resistance to the secondary side, you can read a proportional voltage signal, isolated from the mains. As the secondary current is low, the low power burden resistance can be connected to the PCB.

FEATURESThese current transformers are based on toroidal Silicon Iron core. The family code 150 and 151 identifies the size of the box and, in particular, of the central hole for passing through cable (or copper bar). Both sizes can be equipped with 2 or 4 fastons.

SYMBOLS:• n secondary turns

• IP rated primary current

• IS rated secondary current


• UOUT rated output voltage

• D inner hole diameter for the passing through cable

MAINS FREQUENCY CURRENT TRANSFORMERSFROM 100 TO 600 A

TA 150 - 151

TA02 – Rev.1



values in mm

Code IP[Arms]

IS[Arms] n RC

[Ω] UOUT [Vrms] Outputs D [mm] Drawing

TA 152023 25 0,050 500 40 2,0 Pins 1-2 13 152B

TA 152025 25 0,050 500 40 2,0 Faston 1-2 13 152A

TA 152027 50 0,050 1000 80 4,0 Pins 1-2 13 152B

TA 152050 50 0,050 1000 80 4,0 Faston 1-2 13 152A

TA 153001 70 0,140 500 25 3,5 Faston 1-2 9 153A

TA 153002 70 0,070 1000 50 3,5 Faston 1-2 9 153A

TA 153003 70 0,035 2000 100 3,5 Faston 1-2 9 153A

TA 153004 100 0,040 2500 100 4,0 Faston 1-2 9 153A

TA 153006 70 0,140 500 25 3,5 Pins 1-2 9 153B

TA 153007 70 0,070 1000 50 3,5 Pins 1-2 9 153B

TA 153008 70 0,035 2000 100 3,5 Pins 1-2 9 153B

TA 153009 100 0,040 2500 100 4,0 Pins 1-2 9 153B

PURPOSECurrent transformers are used to measure and detect alternate currents, by keeping the galvanic isolation between the primary cable (the network) and the control stage. They tipically have a high number of secondary turns, so that the secondary current is relatively low. By connecting a burden resistance to the secondary side, you can read a proportional voltage signal, isolated from the mains. As the secondary current is low, the low power burden resistance can be connected to the PCB.

FEATURESThese current transformers are based on toroidal Silicon Iron core. The family code 152 and 153 identifies the size of the box and, in particular, the central hole dimension for the cable. Both sizes are equipped with faston or pin connection.

SYMBOLS:• n secondary turns

• IP rated primary current

• IS rated secondary current


• UOUT rated output voltage

• D inner hole diameter for the passing through cable

MAINS FREQUENCY CURRENT TRANSFORMERSUP TO 100 A

TA 152 - 153

TA01 – Rev.0



values in mm

Documents

HOMOLOGATION - HY-LINE...HOMOLOGATION The customer receives samples for testing and approval. PRODUCTION DEVELOPMENT This brochure is a short introduction to Sirio POWER COMPONENTS