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Australian Homemade 7.5KVA Single Phase Medium Voltage Power Transformer

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Published on Mar 20, 2012

This is another homemade power transformer, but this time rather than building the core out of Lycore 150 laminated bar strips, I've gone for a Cold Rolled Grain Orientated Steel C Core. The beauty of the the C core, is that the transformer can be assembled or disassembled in just a few minutes, where as laminated cores have to be interleaved and built up 1 lamination at a time, which can take hours for a large core. Also the Grain Orientated Steel enables me to run the core at a high flux of 1.65 Tesla, where you get more volts per turn. This means less turns, and less winding length giving better regulation, less losses and more power. The core I'm using has a leg cross-sectional area of 33.5cm2, weighs 18.15kg, Leg dimensions are 71.5mm X 52mm and Window is 190.5mm x 63.5mm OBA Part: 190/44/32.

I'm using 2.5mm diameter magnet wire for the primaries and 0.75mm wire for the secondaries, with DMD insulation and Isonel 301 varnish and glass tape. I also had to make up a winding machine, and used a simple 3 digit BCD counter kit from Jaycar Electronics, which counts the number of turns, as I wind. The winding is assisted with a battery powered drill on a current limited power supply, allowing it to be stalled without damage.

The reason why I make the transformers myself, is it is way cheaper! To get anything made like this in Australia costs thousands and thousands of dollars. This project cost just under $1000 dollars.

Just because it's home made doesn't mean it has to be of poor quality either, my transformer easily exceeds BIL and safety isolation insulation test voltages, and exceeds required creep-age distances too. It has to really, or it will fail!

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