EE42 Transformer Rewinding - 12V To 380V 600W
2 videos • 53 views • by Creative For You Hi friends, in this video, I'm going to rewind an EER-42×15 Transformer for a 600W Inverter, 380V output, 12V Input The winding calculations EER42x15 core transformer in a push-pull configuration for a 500W, 12V to 380V output at 40 kHz. Core Information: * Core Type: EER42 * Material: PC44 OL Ferrite Core * Operating Frequency: 40 kHz Target Specifications: * Input Voltage (Vp): 12V * Output Voltage (Vs): 360V - 380V * Output Power (Pout): 500W - 600W Winding Configuration: * Primary: 2.5-0-2.5 turns (centre-tapped) * Secondary: 90 turns * Maximum Flux Density (Bm): * Using Vp = 2 * f * Np_{half} * Ae * Bm, and assuming Ae \approx 1.67 \times 10^{-4} m^2: * 12V = 2 * 40000 Hz * 3 * 1.67 \times 10^{-4} m^2 * Bm * Bm \approx 0.299 T (Check PC44 datasheet for core loss and saturation at this Bm and frequency). * Primary Current (I_pri): * Assuming 85% efficiency, Input Power (Pin) ≈ 588W. * DC input current (Iin) ≈ 49A. * RMS current per half of primary (I_{pri\_rms}) ≈ 34.6A. * Wire Requirement (1mm wire): Requires approximately 6-7 parallel strands per half to handle this current safely. * Secondary Current (I_sec): * Isec \approx 1.39 A RMS. * Wire Requirement (1mm wire): Single strand is sufficient. * Number of Turns: * Primary: 3 turns on each side of the centre tap. * Secondary: 90 turns. * Winding Length (Estimates with MLT = 8 cm): * Primary (per strand): ≈ 0.48 meters. Total 1mm wire ≈ 2.88 - 3.36 meters. * Secondary: ≈ 7.2 meters. Important Considerations: * Datasheet Dependency: All calculations rely on the EER42/15 PC44 OL datasheet for accurate Ae, core loss data, and saturation flux density. * Current Handling: To manage the high current, the primary winding needs a substantial number of parallel strands of 1mm wire. * Winding Space: Ensure the bobbin accommodates the thick primary and secondary winding. * Thermal Management: Heat generated by core and copper losses must be effectively dissipated. * Efficiency: The actual efficiency will impact current calculations and thermal design. * Skin Effect: Consider using Litz wire for the primary if practical, with multiple strands at 40 kHz. In essence, achieving 500W output with this core and winding configuration is possible but demands careful attention to wire selection, thermal design, and accurate core parameters from the datasheet. The high primary current is the most significant challenge. EE42 Transformer Rewinding - 12V To 380V 600W #EE42 #Transformer #rewinding #inverter