Very High Current Power

The CWS' HCS Series of Very High Current Choke / Very High Power Inductor handles up to 450 Amperes and are designed using multiple copper foils winding to achieve lower DC resistance (DCR), lower AC resistance (skin effect loss), and high inductance. The core materials used are stacked E-shaped Distributed Air Gaps Compacted E-Cores from Micrometal. Both Gapped and UnGapped cores are used to extend the DC bias capability.

The HCS Series of Very High Power Inductor / Very High Current Inductor are capable of handling high DC bias current up to 450 Amps, high energy storage and high voltage swing due to higher mass and higher saturation flux densities of the cores used.

The table below shows the types of cores used in each of the part number. The HCS Series are constructed using Iron Powder, Silicon Iron or Sendust cores and are suitable for swinging chokes, energy storage filter inductor in SMPS with high ripple current, in-line noise filters with large AC voltage swing, unidirectional drive application such as pulse transformer and flyback transformer.

The HCS Series stacked E-Cores are from Micrometals's #26 materials (Iron Powder), Micrometal's Super-MSS (Sendust) and Micrometal's FluxSan (Silicon Iron). The Silicon Iron version is suitable for those application requiring small inductance drop when a high DC current (DC bias) is flowing into the inductor. The Sendust version is suitable for energy storage inductors. The Iron Powder version is suitable for Output Ripple filtering, High Power Output Chokes and High Current Inductor where a good DC bias characteristics is desired. The core loss of the Sendust and Silicon Iron are very similar at frequency below 300 Khz. Silicon Iron version cost a little more than the others. The Silicon Iron cores are not suitable for application over 750 Khz, and has a much higher core loss than the Sendust cores.

The part PDF drawing has the DC Bias Current versus Inductance table. It is not necessary that inductor with higher Inductance versus DC Bias Current is better in all cases. This is because Energy Storage in a filter is defined as 1/2 x [L] x [Sq I], where [L] is the inductance and [Sq I] is the square of the current flowing into the inductor. For energy storage filtering application, having a good DC bias is not always a desired feature. When the current flow into the inductor increases, the amount of energy stored increased to the square of the current [Sq I], and if the inductance [L] does not drop when the current increase, the energy stored maybe too high and could potentially cause a circuit to blow up. For such energy storage filtering application such as Input Filter ( Phi or butterworth or chebyshev filters), or the Boost Inductor, the HCS Series using Sendust is usually the desired choice. However, every application is different and the design engineer must balance the trade offs. <./p>

These very high current inductors need appropriate air flow for cooling down at DC Bias and at full load conditions. There are several different methods for cooling down and here we recommend the most straightforward method by using a fan. The link below show a typical type of Server Rack cooling fan which has 550 CFM for these big inductors. There is a Performance graph for your reference together with many detailed information to look at this type of fan for your applications.

Link of the recommended fan

	Part Number	Inductance	Current Rating (Amps)	Inductance at 120 Amps DC Bias	DCR Max (milli-Ohms)	Dimension: Length x Width x Height mm	Core Material	Inductance at 300 Amps DC Bias	3D Model	Thermal Model								Quantity on hand	Price
	HCS-211M-300A	210uH	300	129 uH	1.2	393.7x118.1x96.5	Iron Powder	60 uH	3D STEP	Thermal Model								1	$1,750.00
	HCS-161M-450A	160uH	450	136 uH	1.2	393.7x118.1x96.5	MegaFlux	92 uH	3D STEP	Thermal Model								0	$1,500.00
	HCS-631M-450A	630uH	450	423 uH	4.5	393.7x118.1x96.5	MegaFlux	249 uH	3D STEP	Thermal Model								0	$1,750.00
	HCS-801M-350A	800uH	350	268 uH	4.5	393.7x118.1x96.5	Powder Core	123 uH	3D STEP	Thermal Model								0	$2,000.00
	HCS-143M-30A	14mH	30	N/A	225	117.0x115.0x95.0	Powder Core	N/A	3D STEP	Thermal Model								1	$1,500.00
	HCS-201M-600A	190uH	600	162uH	2.5	457.2x114.3x101.60	Iron Powder	79uH	3D STEP	Thermal Model								0	$1,750.00
		0																0	$1,750.00
	HCS-850M-280A	85uH	280	56 uH	1.0	292.1x119.38x96.52	Powder Core	N/A	3D STEP	Thermal Model								0	$1,750.00
	CWS-1EE-12720	104uH	300	101 uH	4.0	393.7x127.0x118.84	High Flux	90u uH	3D STEP	Thermal Model								0	$1,350.00
	CWS-1EE-12721	71uH	300	69 uH	4.0	393.7x127.0x127.0	High Flux	61 uH	3D STEP	Thermal Model								1	$1,550.00
	HCS-121M-450A	120uH	450	102 uH	1.2	393.7x118.1x96.5	Powder Core	77 uH	3D STEP	Thermal Model								0	$1,750.00
	HCS-121M-450A-CI	120uH	450	102 uH	1.35	420.0x118.1x96.5	Powder Core	77 uH	3D STEP	Thermal Model								-2	$1,300.00
	HCS-280M-180A	28uH	180	22 uH	0.65	393.7x118.1x96.5	Iron Powder	N/A	3D STEP	Thermal Model								1	$1,750.00
	HCS-BRA-001 REV C	0N/A	N/A	BRACKET	FOR MOUNTING	121.5 x 53.3 x 105.29	Aluminum	N/A	3D STEP	N/A								10	$35.00
	009CS-EN002 REV.B	0N/A	N/A	CASE	FOR ENCAPSULATION	457.2 x 155.96 x 113.79	Aluminum	N/A		N/A								0
	009CS-EN001 REV.B	0N/A	N/A	CASE	FOR ENCAPSULATION	533.4 x 155.96x 113.79	Aluminum	N/A		N/A								0
	HCS-631M-450A-3KV	630uH	450	423 uH	4.5	393.7x118.1x96.5	MegaFlux	249 uH										0	$1,500.00
	CWS-1EE-13097	100uH	1000	82 uH	3.5	609.6 x 304.8 x 254.0	Powder Core											0
	HCS-601M-500AG RB1	600uH	500	400 uH	4.5	495.30 x 114.30 x 101.50	Powder Core	274 uH										0	$1,750.00
	HCS-601M-500AG RB1																	0	$1,750.00 Min:  0 Units:  0
	HCS-601M-500AG REV A																	0	$1,750.00 Min:  0 Units:  0