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My 12kW powerjack build - Ozinverter Inspiration!

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influence:
Hi all

Well done as always to ozules for laying the groundwork for the powerjack builds....

I finally received my custom toroidal core.....dimensions: 230mm diameter, 100mm hole, 210mm tall...
Weight has not been measured accurately but is estimated at over 50kg bare...

I will document my journey here to produce a 12kW inverter using the 15kW powerjack MOS and controller boards.

influence:
First step was to clean, grind the edges.

Then I coated it with a potting compound epoxy...

influence:
Then I wrapped it with Kapton tape...and then with mylar film.
I *really* don't want the core to ever be conductive....

influence:
My calculations

Many thanks to oztules "rule" of 2800sqmm/volt as the core basis for 1V/turn

Based on my core, the core cross sectional area is 210 x 65 = 13650mm2

So we take 13650 / 2800 = 4.875V / turn !!!

Gotta love this method of using huge cores to reduce turn requirements...

So going with a ratio of 1:8 (30V : 240V)

I ended up using a ratio of 6 turns of the primary : 48  turns of the secondary.

I decided to use what I had lying around (orange 4+E cabling).

So I set the primary coil gauge to 3 lots of 25mm2 olex 90C cable and
for the secondary 1 lot of 16mm2 olex 90C cable.

Based on the above, I would require:
3 lengths of 25mm2 cable - 3.8m-4.0m each
1 length of 16mm2 cable - 28m long

influence:
So I wind the secondary first....

Boy this was a bugger to wind...lucky I was on carpet tiles....

But seriously sore afterwards!!

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