Author Topic: Royer oscillator (ZVS) driven Jacob's ladder, E80 core transformer  (Read 10606 times)

Offline mark_tec_wiz

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Re: Royer oscillator (ZVS) driven Jacob's ladder, E80 core transformer
« Reply #20 on: March 01, 2020, 10:20:21 AM »
Thanks Dave can you post a close up picture of the transformer you wound.   
Could you sketch the segmented bobbin.   I will print one or two for you too if you want to build another one.   

I designed and still manufacturer a user interface - Control for a coil winding machine manufacturer and I can get you more tape I’f you need it.

Is there any links that you can post on winding hv transformers?




Offline mark_tec_wiz

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Re: Royer oscillator (ZVS) driven Jacob's ladder, E80 core transformer
« Reply #21 on: March 01, 2020, 05:05:20 PM »
I found this wire in surplus.

Part Number      Wire Size                                  Ohms     Per 1000 ft   Ft. per Lb.   Lbs. per 1000 ft    Equivalent Gauge / Circular Mils.
(WHS) LW-12/36   12 Strands 36 AWG                  34.56        1006            0.993                                 25 AWG
(WHS) LW-18/30    18 Strands 30 AWG (0.058" O.D.)  6.1        171.82            5.82   18                                  AWG / 1800
(WHS) LW-20/30   20 Strands 30 AWG (0.059 O.D.)    4.85       154.79            6.46   17.5                                AWG / 200

Is the 12/36 to small and the 18/30 to big?  Both wires come with and without poly nylon weave. 
What do you sugest

Mark

Offline davekni

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Re: Royer oscillator (ZVS) driven Jacob's ladder, E80 core transformer
« Reply #22 on: March 02, 2020, 05:24:36 AM »
Here's the best image I have of my transformer.  Definitely not a work of art, but functional:


Here's a couple threads showing segmented bobbins, including a comment that machining is better than 3D printing.  I think that depends on the type of 3D printer, but is likely an accurate comment for obtaining the highest possible voltage in a compact transformer.
https://highvoltageforum.net/index.php?topic=390.msg4534#msg4534
https://highvoltageforum.net/index.php?topic=678.msg4556#msg4556

Thank you for the printing offer.  If my kludged taped winding fails, I'll check with you.  What type of 3D printer do you have?  Is it a plastic extrusion machine as most home ones are?  That might require some careful build-path design to avoid any voids or thin spots that would cause corona and eventually arcing.
BTW, what tape do you use for coil winding?  The single-sided tape is still available.  What I can no longer find is the kind with adhesive on both sides.

The wire size depends on the voltage and current you are after.  How fine litz stranding is needed depends on operating frequency.  The upper size limit is what fits on a bobbin for an E80 core half.  The 12x36AWG might be good for 15kV.  If you know current, first-order power dissipation comes from I^2*R, with R coming from wire length and size.
David Knierim

Offline Mads Barnkob

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Re: Royer oscillator (ZVS) driven Jacob's ladder, E80 core transformer
« Reply #23 on: March 02, 2020, 08:52:02 PM »
Also can you post a source for the E80 cores and spacers.

I got some various E cores for sale if you can use them? E80 and E65 afaik
http://www.kaizerpowerelectronics.dk - Tesla coils, high voltage, pulse power, audio and general electronics

Offline ritaismyconscience

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Re: Royer oscillator (ZVS) driven Jacob's ladder, E80 core transformer
« Reply #24 on: April 05, 2020, 06:21:52 AM »
Can  you tell me the max current through the IGBTs when there's an arc? I'm planning on building this using H30R1103 IGBTs and I want it to be reliable.

Offline davekni

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Re: Royer oscillator (ZVS) driven Jacob's ladder, E80 core transformer
« Reply #25 on: April 05, 2020, 06:53:57 PM »
I have a separate over-current shutdown circuit in series with incoming power, set 35A.  Maximum current is just when the arc reaches the top and is breaking up.  That sometimes trips my 35A shutdown limit.  Short-circuit and open are both low-current for the ZVS oscillator.  Short-circuit causes the ZVS to oscillate with the transformer leakage inductance.  Open-circuit oscillates with the transformer's normal inductance.  The H30R1103 IGBTs look reasonable for this, although I haven't personally used any IGBTs intended for soft-switching only.
David Knierim

High Voltage Forum

Re: Royer oscillator (ZVS) driven Jacob's ladder, E80 core transformer
« Reply #25 on: April 05, 2020, 06:53:57 PM »

 


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