Guru
Joined: 04/10/2019
Location: AustraliaPosts: 665
| Posted: 12:00pm 11 Jun 2024 |
You seem to go from one extreme to another with your choice for choke copper cross section.
10mm sq is obviously too low and 50 sq mm sounds rather generous to me (good for 200A continuous, conservatively)
Why not compromise, use 35mm sq and try to up your inductance?
You can fit more turns by using parallel strands of enameled copper wire. Try 42 -49 strands of 1 mm diameter, thicker wire gets harder to wind onto a stack of those Sendust ring cores.
I like to twist 7 strands initially to make individual 7 strand enameled wire cables.
Then wind 6 or 7 of these the calculated number of turns around the core and connect all in parallel.
There is an online calculator to find out how many 7 strand cables will fit in your core hole - this lets you know how many tuns will fit.
Try not to squeeze in too many turns or the last one will be difficult to pull through.