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The power put into the arc if you are in tune, i.e. if your frequency is your secondary resonant frequency, is (neglecting all losses)
P = Ip^2 * k^2 * Lp/Ls * Rarc,
where Rarc is the arc loading resistance. From model calculations, which may be way off, I'd guess that to be around 500k for a 1.5kW CW arc. If I add some more guesses about your coil, i.e. Lp = 20uH primary and Ls = 100mH secondary and a k of 0.54, the necessary primary current would turn out to about 7 A (RMS). That shouldn't heat up your primary too much. Do you know your primary current? Adding primary turns would help, since the power transferred would go as turns^2 but the heat loss in the primary grows only linearly with the number of turns.
Unfortunately I do not have a way of measuring the Ip, wish I did though. If I had a CT I could scope it out but my scope is an old analogue one which cannot take measurements (other than counting the grid manually and estimating).
I had considered increasing the primary turns but thought that it would increase the impedance of the primary and thus limit current draw, in turn reducing input power. Are you saying that the increase in energy transfer would negate the loss in input power resulting in greater output power (due to lower overall loss)?
I have to figure out a better way to wind the primary, or use different wire. This stuff I have is so springy that the primary wants to uncoil itself completely. I have about thirty plastic zipties holding the primary together. I want to try soft multistrand cable like welding cables use, but don't need the 2ga (or thicker) they use in welding cables. I know Po210 suggested "audio power wire", is this stuff similar or very springy?
You're right about the primary impedance. Ideally the primary turns should be chosen so, that your drivers max voltage and current capabilities are reached at the same time. If you can't increase the driver voltage beyond your current settings, using more primary turns will reduce input power. The lower resistive loss in the primary probably won't compensate for that.
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SSTC Primary Heating
