Slide Choke
Updated: July 29,2006
Check out my slide choke on this page: www.Tesla-Coil.com/Reactor.htm
and : www.tesla-coil.com/Ballasting.htm
Date: Sun, 30 Apr 2006 15:04:34 -0600
From: Tesla list <tesla@pupman.com>
To: tesla@pupman.com
Subject: Slide choke
Original poster: "MIKE HARDY" <MHARDY@EXECPC.COM>
A while ago I successfully built a slide choke using a 500 Ft spool of #10 thhn
house wire, and coated mild steel tig rods, cut to 12". I have acquired some "I"
laminations that are 1 3/4 inches wide, and 18" long. I have enough to make 2 ,
1 3/4 square cores. I have about 750 ft. of #8 PVC wire. Is the length/width
ratio of the coil a major factor? In other words, can I wind an 18" long coil
with the wire I have, and just use the laminations as is? I'll be using this
with 240v, up to 50 A Initially, and maybe 90A later.
Date: Sun, 30 Apr 2006 16:17:44 -0600
From: Tesla list <tesla@pupman.com>
To: tesla@pupman.com
Subject: Re: Slide choke
Original poster: "D.C. Cox"
<resonance@jvlnet.com>
Mike:
You will probably be able to use this successfully up to 30-35 Amperes. Even
with our reactors, due to choke intermittant saturation, running at 30 Amps were
must use at least #10 AWG 150 degree C. magnet wire and a small 200 cfm blower
fan blasting air into the windings( we spacewind each layer with some 1/4 x 1/4
inch cut fiberglass rods to allow the fan airflow thru the coil). We use Nomex
insulation layer to layer to provide some thermal separation between layers. At
12 AWG, the wire starts to overheat substantially. At your proposed range of 50
Amps you will probably have to go down to #6 AWG 150 degree C. magnet wire.
Another idea might be to make up some flat endplates/endcaps for a 4 inch dia.
PVC tube. These endplates would be 1/4 inch thick, circular, and have a dia of
perhaps 10 inches. Then the wire would be spooled off the Home Depot 500 ft
spool onto your newly created coilform.
With some tinkering I think you could come up with a nice design that would use
a fixed, non-moveable core, and perhaps 300-500 turn range of #10 AWG Home Depot
house wiring. Starting with 500 turns keep removing wire until you hit the
30-35 Ampere range. This would be a nice series reactor for use with pole pigs
powering a .05 to .07 uF range cap bank and running at 7.5 kVA approx range.
This sounds like an interesting idea. I plan to also experiment with it using
some tapped Supercil 10 silicon steel cores this summer when I get back to WI
after May 15th. If you have some time off during the week, perhaps you could
come up to our shop and we will do some work together on this idea.
Regards,
Dr. Resonance
Date: Thu, 18 May 2006 12:18:59 -0600
From: Tesla list <tesla@pupman.com>
To: tesla@pupman.com
Subject: Slide choke - second request for advise !!
Original poster: "MIKE HARDY" <MHARDY@EXECPC.COM>
----- Original Message -----
From: "Tesla list" <tesla@pupman.com>
To: <tesla@pupman.com>
Sent: Sunday, April 30, 2006 4:04 PM
Subject: Slide choke
> Original poster: "MIKE HARDY" <MHARDY@EXECPC.COM>
>
I apologise for re-posting this question, but never received an answer to my
real question. (On a side note, DC's invite to investigate this experimentally
is very intriuging, lets talk off-list about this further). So please read
all of this, including the additional question below. THANKS !!
> A while ago I successfully built a slide choke
using a 500 Ft spool
> of #10 thhn house wire, and coated mild steel
tig rods, cut to 12". I
> have aquired some "I" laminations that are 1 3/4
inches wide, and 18"
> long. I have enough to make 2 , 1 3/4 square
cores. I have about 750
> ft. of #8 PVC wire. Is the length/width ratio of
the coil a major
> factor? In other words, can I wind an 18" long
coil with the wire I
> have, and just use the laminations as is, or
should I wind shorter,
and fatter? I'll be using this with 240v, up to 50 A Initially, and maybe 90A
later. My second question, is weather I can weld the lamination stack together
at the edges? I see this done with MOT's all the time.
Date: Thu, 18 May 2006 15:05:27 -0600
From: Tesla list <tesla@pupman.com>
To: tesla@pupman.com
Subject: Re: Slide choke - second request for advise !!
Original poster: "Mike" <mike.marcum@zoomtown.com>
I guess it depends on what your goals are. If weight/cost is not a consideration
and your going for max efficiency (mostly L with little R) then the core would
be close to cube shaped with 1:1 turns ratio.
Most are longish for economic/weight reasons. If you don't mind losing a few
more watts of heat and having a bit more of a voltage drop, use what you have.
As far as welding laminations, that also makes little difference.
Maybe a few watts in eddy currents there out of 12kW+ (most of the flux is in
the center and not the corners/outer edges of the cross-section), as long as the
bead is thin.
Mike
----- Original Message ----- From: "Tesla list" <tesla@pupman.com>
To: <tesla@pupman.com>
Sent: Thursday, May 18, 2006 2:18 PM
Subject: Slide choke - second request for advise !!
>Original poster: "MIKE HARDY" <MHARDY@EXECPC.COM>
>
>
>----- Original Message -----
>From: "Tesla list" <tesla@pupman.com>
>To: <tesla@pupman.com>
>Sent: Sunday, April 30, 2006 4:04 PM
>Subject: Slide choke
>
> > Original poster: "MIKE HARDY" <MHARDY@EXECPC.COM>
> >
>I apologise for re-posting this question, but
never received an answer to
>my real question. (On a side note, DC's invite to
investigate this experimentally
>is very intriuging, lets talk off-list about this
further). So please read all of
>this, including the additional question below.
THANKS !!
>
> > A while ago I successfully built a slide choke
using a 500 Ft spool
> > of #10 thhn house wire, and coated mild steel
tig rods, cut to 12". I
> > have aquired some "I" laminations that are 1
3/4 inches wide, and 18"
> > long. I have enough to make 2 , 1 3/4 square
cores. I have about 750
> > ft. of #8 PVC wire. Is the length/width ratio
of the coil a major
> > factor? In other words, can I wind an 18" long
coil with the wire I
> > have, and just use the laminations as is, or
should I wind shorter,
>and fatter? I'll be using this with 240v, up to
50 A Initially, and maybe 90A later.
>My second question, is weather I can weld the
lamination stack
> together at the edges? I see this done with
MOT's all the time.
> >
Date: Fri, 19 May 2006 10:35:30 -0600
From: Tesla list <tesla@pupman.com>
To: tesla@pupman.com
Subject: Re: Slide choke - second request for advise !!
Original poster: "MIKE HARDY" <MHARDY@EXECPC.COM>
Thanks mike. I'll go ahead and wind it long and narrow. The real problem with
the laminations is that the stack tends to bulgein the middle. This is where
They need the weld bead. You said the middle is where theflux is most severe,
but I think you mean the inside of the core. So is a bead on the outside of the
center of the core ok?Original poster: "Mike"
mike.marcum@xxxxxxxxxxxx
I guess it depends on what your goals are. If weight/cost is not a consideration
and your going for max efficiency (mostly L with little R) then the core would
be close to cube shaped with 1:1 turns ratio. Most are
longish for economic/weight reasons. If you don't mind losing a few more watts
of heat and having a bit more of a voltage drop, use what you have. As far as
welding laminations, that also makes little difference. Maybe a few
watts in eddy currents there out of 12kW+ (most of the flux is in the center and
not the corners/outer edges of the cross-section), as long as the bead is thin.
----- Original Message -----
From: "Tesla list" <tesla@pupman.com>
To: <tesla@pupman.com>
Sent: Thursday, May 18, 2006 1:18 PM
Subject: Slide choke - second request for advise !!
> Original poster: "MIKE HARDY" <MHARDY@EXECPC.COM>
>
>
> ----- Original Message -----
> From: "Tesla list" <tesla@pupman.com>
> To: <tesla@pupman.com>
> Sent: Sunday, April 30, 2006 4:04 PM
> Subject: Slide choke
>
>
> > Original poster: "MIKE HARDY" <MHARDY@EXECPC.COM>
> >
>
> I apologise for re-posting this question, but
never received an answer to
> my real question. (On a side note, DC's invite
to investigate this experimentally
> is very intriuging, lets talk off-list about
this further). So please read all of
> this, including the additional question below.
THANKS !!
>
> > A while ago I successfully built a slide
choke using a 500 Ft spool of #10 thhn house wire, and coated mild steel tig >
>rods, cut to 12". I have aquired some "I" laminations that are 1 3/4 inches
wide, and 18"
long. I have enough to make > >2 , 1 3/4 square cores. I have about 750 ft. of
#8 PVC wire. Is the length/width ratio of the coil a major factor? In other >
>words, can I wind an 18" long coil with the wire I have, and just use the
laminations as is, or should I wind shorter,
> >and fatter? I'll be using this with 240v, up
to 50 A Initially, and maybe 90A later. My second question, is
weather I > > >can weld the lamination stack together at the edges? I see
this done with MOT's all the time.
> >
Date: Fri, 19 May 2006 15:28:30 -0600
From: Tesla list <tesla@pupman.com>
To: tesla@pupman.com
Subject: Re: Slide choke - second request for advise !!
Original poster: "Mike" <mike.marcum@zoomtown.com>
yup, that's fine.
Mike
----- Original Message ----- From: "Tesla list" <tesla@pupman.com>
To: <tesla@pupman.com>
Sent: Friday, May 19, 2006 12:35 PM
Subject: Re: Slide choke - second request for advise !!
>Original poster: "MIKE HARDY" <MHARDY@EXECPC.COM>
>
>Thanks mike. I'll go ahead and wind it long and
narrow. The real problem
>with the laminations is that the stack tends to
bulgein the middle. This is
>where They need the weld bead. You said the
middle is where theflux is most
>severe, but I think you mean the inside of the
core. So is a bead on the
>outside of the center of the core ok?Original
poster: "Mike"
>mike.marcum@xxxxxxxxxxxx
>
>I guess it depends on what your goals are. If
weight/cost is not a
>consideration and your going for max efficiency
(mostly L with little R)
>then the core would be close to cube shaped with
1:1 turns ratio. Most are
>longish for economic/weight reasons. If you don't
mind losing a few more
>watts of heat and having a bit more of a voltage
drop, use what you have. As
>far as welding laminations, that also makes
little difference. Maybe a few
>watts in eddy currents there out of 12kW+ (most
of the flux is in the center
>and not the corners/outer edges of the
cross-section), as long as the bead
>is thin.
>----- Original Message -----
>From: "Tesla list" <tesla@pupman.com>
>To: <tesla@pupman.com>
>Sent: Thursday, May 18, 2006 1:18 PM
>Subject: Slide choke - second request for advise
!!
>
>
> > Original poster: "MIKE HARDY" <MHARDY@EXECPC.COM>
> >
> >
> > ----- Original Message -----
> > From: "Tesla list" <tesla@pupman.com>
> > To: <tesla@pupman.com>
> > Sent: Sunday, April 30, 2006 4:04 PM
> > Subject: Slide choke
> >
> >
> > > Original poster: "MIKE HARDY" <MHARDY@EXECPC.COM>
> > >
> >
> > I apologise for re-posting this question, but
never received an answer > to
> > my real question. (On a side note, DC's invite
to investigate this experimentally
> > is very intriuging, lets talk off-list about
this further). So
> please > read
> > all of this, including the additional question
below. THANKS !!
> >
> > > A while ago I successfully built a slide
choke using a 500 Ft spool
> > > of #10 thhn house wire, and coated mild
steel tig rods, cut to 12". I
> > > have aquired some "I" laminations that are
1 3/4 inches wide, and 18"
> > > long. I have enough to make 2 , 1 3/4
square cores. I have about 750
> > > ft. of #8 PVC wire. Is the length/width
ratio of the coil a major
> > > factor? In other words, can I wind an 18"
long coil with the wire I
> > > have, and just use the laminations as is,
or should I wind shorter,
> > and fatter? I'll be using this with 240v, up
to 50 A Initially, and maybe 90A later.
> > My second question, is weather I can weld the
lamination stack
> > together at the edges? I see this done with
MOT's all the time.