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Registered Member #162
Joined: Mon Feb 13 2006, 10:25AM
Location: United Kingdom
Posts: 3141
Tom, under certain circumstances these cores MAY handle 30 kVA, but certainly not with an eht winding which will require lots of insulation, (consider the core as a conductor, not an insulator, check it with a dmm on Ohms range !) in any case, where would you get a 30 kVA source, and the bridge components would cost a LOT of money.
The easiest way to wind an eht transformer is to keep the voltages as low as possible, e.g. for 20 kV make two 10 kV windings, each with one end to earth/ground/core so the output would be 10kV - 0 - 10kV
You will find that even a 10 kV winding at 50 to 200 kHz will need to be under oil, or VERY well potted.
When you do wind the secondaries self-capacitance will be an issue, -wind the coils as a single layers with clearance at the ends, at the end of each layer run the wire back along the winding (insulated from the layer below and the layer above) before winding the next layer, that is, each layer starts at the same end of the secondary. This reduces self-capacitance and insulation problems, I have found.
Registered Member #103
Joined: Thu Feb 09 2006, 08:16PM
Location: Derby, UK
Posts: 845
I'd be tempted to try and do it in a modular fashion, rather than a single winding.
For some inspiration, look at this page and scroll down to the part where he makes his own winding formers out of FR4 fibreglass (with the copper etched away).
If I were doing it i'd probably try to make 4 separate formers, and wind them for say 3.6kV each. Then wind a couple more for primaries, and you can arrange them how you like on the core after potting or vacuum impregnating them, and you can easily modify the transformer just by making more formers and winding them differently. If you don't need AC for your final application you could wind for a lower voltage and use a multiplier.
Insulation will be a right pain to get right, I found that gummy brown paper worked reasonably well between each layer, then you could soak the whole thing afterwards in some kind of melted wax or liquid epoxy and it might wick it in between the layers. I've tried the brown paper but not the soaking.
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what to do with such a mighty core...
but im sure il find my way, anyone have any tips or reccomendations?
