Predicting Temperature Rise of

Ferrite Cored Transformers

George Orenchak
TSC Ferrite International
Temperature Rise is

the difference between a

components initial and final temperatures
expressed in degrees Celsius
Acceptable Temperature Rise of
a Transformer is Dependent on
the materials used in the construction of
the transformer
reliability issues associated with other
component parts that are in close proximity
to the transformer
safety agency regulations
Permissible Temperature Rise
of a Transformer
is a constraint to the component size of a
transformer.
Temperature Rise of a
Transformer is Attributed to

the total power loss of the transformer

dissipated in the form of heat.

This total power loss consists of core loss

and of winding losses.
Core Losses Consist of

Hysteresis loss which become more

significant & dominate at higher flux densities
Eddy current loss which become more
significant & dominate at higher frequencies
Residual loss which is additional loss
unaccounted to hysteresis & eddy currents
 Chart #2
Core loss vs Flux Density TSC 5099
@100kHz, 100C
1,000

900

800
Core Loss in mW/cc

700

600

500

400

300

200

100

0
500 1,000 1,500 2,000 2,500 3,000
Flux Density in Gauss
Flux Density

B = E*108 / (4.44 f N Ae)

 Chart #1
Core loss vs Frequency
@1000 Gauss 100C TSC 5099
1,000

900

800
Core Loss in mW/cc

700

600

500

400

300

200

100

0
50 100 150 200 250 300 350 400 450 500
Frequency in kHz
Calculating Core Loss
Pc = k fx By
Pc = Core Loss in mW/cc
k = Constant for a Specific Material Grade
f = Frequency in kHz
B = Flux Density in k Gauss
x = Frequency Exponent
y = Flux Density Exponent
Creation of Core Loss
Formulas
@ some fixed flux density
x=ln(Pc@1stf / Pc@2ndf ) / ln(1stf / 2ndf )
@ some fixed frequency
y=ln(Pc@1stB/Pc@2ndB ) / ln(1stB/2ndB )
k=Pc@B&f / (By*fx)
 Chart #3 TSC 5099
Core loss vs Temperature
@100kHz, 1000gauss TSC 7070
200

180 TSC 8040

160
TSC 5000
Core Loss in mW/cc

140

120
TSF-50ALL
100

80

60

40

20

0
0 20 40 60 80 100 120 140
Temperature in Celsius
Excitation Wave Forms

Providing the frequency & total flux

density excursions remain the same the
core loss of symmetrical sinusoidal, square
wave & unidirectional square wave voltage
excitations are equivalent.
Core Loss for Non-Square
Pulse Voltage Wave Form
Excitations

Calculate apparent frequency (the inverse of

the time period to complete one cycle of
flux swing)
Use this apparent frequency to obtain core
loss from graphs or formulas then multiply
this result by the duty cycle to estimate core
loss
Winding Coil Losses
Copper loss (I2R)
Skin effect loss
Proximity effect loss
Eddy current loss in the windings
Loss from fringing flux intersecting windings
Edge effect loss
Extraneous conductor losses
Calculate Resistance of Each
Winding
Rp or Rs = MLT * Rcu * N
Rp = Primary Winding Resistence
Rs = Secondary Winding Resistance
Rcu = Copper Resistance (/cm)
N = Turn Count
(I2R) Copper Losses

Pcu = I2R
Pcu = Copper Loss in Watts
I = Current in Amps
R = Resistance in Ohms
Summarize Transformer Losses

P = Pcu + Pc
P = Total Transformer Losses
Pcu = Summation of All of the Primary &
Secondary Winding Losses
Pc = Core Loss
Temperature Rise Assumptions

Lump the winding losses & core loss

together and assume the thermal energy is
dissipated uniformly throughout the surface
area of the assembly at all ambient
temperatures
Temperature Rise Estimate

T = (P / At)0.833
T = Temperature Rise in C
P = Total Transformer Losses in mW/cc
(Power dissipated in the form of heat)
At = Surface Area of Transformer in cm2
Creation of the Exponent in the
Temperature Rise Formula

x=ln(P@1stT/P@2ndT)/ln(1stT/2ndT)
 Temperature Rise Proof

TSF-5099-41-16-12-0000
Ve=11.5cm3, At=27cm2 @100mW/cc
Pc = 100mW/cm3*11.5cm3 = 1.15W
P = 1.15W*2 = 2.3W = 2300mW
T = (2300mW/27cm2)0.833 = 40.5 C
 Temperature Rise vs. Transformer Power Loss
Measured on a TSF-7099-41-16-12-0000

80

70
Temperature Rise in Celsius

60

50

40

30

20

10

0
0 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000
Transformer Total Power Loss in mW
Conclusion

Temperature rise in transformers result from

core loss & winding losses. Core loss,
winding loss and temperature rise can be
estimated with calculations by making a few
reasonable assumptions.
Conclusion

New ferrite materials that exhibit consistent

core loss over wide ranges of temperature
will simplify ferrite material selection and
prove to be a valuable asset in the
transformer industry