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Old 19th January 2007, 03:26 PM   #11
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8AWG wire and a iron rod 1" in diameter sound good? I am going to get the iron off mcmaster carr. They have cast gray iron and ductile iron, what sould i use.
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Old 21st January 2007, 10:47 AM   #12
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Iron rod as a core is a really bad idea...

I'd go for an air-core at that kind of capacity. 30seconds with Google turned up this page:
http://www.dpg.devry.edu/~akim/new/inductor.htm

- and 2mins of playing with numbers produced this:

Inductance 0.1 mH
DC Resistance 0.02 Ohms
Wire Gauge 8 AWG
Wire Diameter 128.5 mils (1 mil = .001 in)
Coil Length 1 in
Coil Inner Diameter 3 in
Coil Outer Diameter 4.03 in
Average Turn Diameter 3.37 in
Wire Length 27.36 feet
Copper Weight 1.37 pounds
Turns 31
Levels 3.98
Turns/Level 7.78

Good enough? Bear in mind that at 40A, this coil would dissipate (40*40*0.02) = 32W. You might want to make the thing even larger diameter for better heat dissipation. And to have a think about what you really want to achieve with such a beast!
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Old 21st January 2007, 11:18 AM   #13
AndrewT is offline AndrewT  Scotland
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Hi,
if an air cored coil is OK, then here is some data:

wire diam...........3mm........4mm
bobbin diam.......43.5mm....55mm
bobbin width.....20.7mm.....26.2mm
coil height.........18.6mm....23.6mm
o/a diam...........80.8mm....102.1mm
copper weight...530gms...1070gms
resistance..........0r02.........0r013
turn/layer...........6.9............6.5
layers................6.2............5.9
total turns..........42.9.........38.6
resistive power...32W........21W
@ 40Amps

using the formula L=7.87M^2N^2/(3M+9B+10C)
where C=coil height
B=coil width
M=mean coil diameter
lowest resistance and highest Q when 3M=9B=10C (a squarish coil)
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Old 21st January 2007, 12:01 PM   #14
infinia is offline infinia  United States
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Hi
I looked at that AC filter in the link, and wouldn't recommend it at all. I not sure what exactly you want to filter using that design. What you probably really want is a common mode filter and a diffential filter together ie 2 stages with 3 inductors total. A common mode inductor is 2 windings on the same core. That filter in the link is just a differential design, with extra Y caps to ground, not really effective for common mode without a series impedance. IMO- Common mode is really where the problems are needing the most attention.
If given a choice what to build between the 2 stages I would build a common mode inductor with 2 loosely coupled windings and use it in place of L1 and L2 in the design link. You could use a split bobbin along with E powdered iron for the core material. Magnetics Inc. is what we've used for this.

edit> see link for filter topology http://www.cor.com/Series/PowerLine/SK/
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Old 21st January 2007, 09:13 PM   #15
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So one of these http://www.cor.com/Series/PowerLine/SK/ after an isolation transformer would work better than the design on this site:
http://www.geocities.com/jonrisch/surge.htm

I don't know if an aired cored inductor would work. Hard to wind too, need a winding machine to do i nice job but 8awg is too big for most winders.

What should i do? I would like really clean power.
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Old 21st January 2007, 10:37 PM   #16
infinia is offline infinia  United States
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Read this app note for common mode chokes from Magnetics Inc.
http://www.mag-inc.com/pdf/FC-S2.pdf

As I said before, you want to use an E type core with a split bobbin. Mag Inc won't carry bobbins usually, but their distributors will.
Or else just simply buy the Corcom part. It's UL approved so you are covered.
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Old 21st January 2007, 11:10 PM   #17
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Thats sounds hard and complicated. Is it just going to like a EI transformer with no secondary wire.

How did i know this would not be as winding some wire around some iron.

I would go runing and jumping threw the park like a crazy man if i ever found a good source of iron...
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Old 22nd January 2007, 01:25 AM   #18
infinia is offline infinia  United States
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Software - I have not used this. I normally use a notepad and calc.
http://www.mag-inc.com/software/cmf.asp

More Iron and shapes than you can shake a stick at
http://www.mag-inc.com/ferrites/ferr...wer_shapes.asp
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Old 22nd January 2007, 04:48 AM   #19
radtech is offline radtech  United States
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What are you building that takes 30-40A at 120V, and is your fire insurance paid up?
Why not go to 240, that would halve your current and quarter your I2R losses (for instance, that 32W heating up your choke would be reduced to 8W).
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Old 23rd January 2007, 01:06 AM   #20
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Wow, they have lots of laminations, i can't use ferrite in output transformers right?

I am stepping down 240V to 120V, i achieve isolation & load both legs of the power coming in. Then i plan to filter the 120V.
Triamping with tube mono blocks uses lots of electricity, not to mention, CD, DVD, Switch, elecrostat bias, digital equalizer, tube preamp, active crossover, projector, massive 60 chip DAC, turntable, cable box, tuner. It all seams to add up to a blown 20A fuse and a oh no so i figure i mite as well overbuild.
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