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At my first try i increased air gap to about 0.5 mm just for to make AC current of the input with no load same as the original.The circuit worked well up to 110 A DC output current without air cooling!!After that 30 USD is gone...Original core had no gap.Switching frequency is 100 KHz.Topology 2 transistor forward. Core E65/32/27
May be i should adjust air gap at DC output of 100A to reduce input power for efficiency??
Need Help.
If you are trying to get a substitute for a certain ferrite, look at the following:
Shape availability
For the material mix, the saturation flux and the losses per volume unit at your operating frequency (usually at a temperature of 80~100°C). Compare these against the original.
The Al value is not really that important: for flybacks it is dictated by the airgap, so it depends very little on the actual ferrite material. For forward-derived topologies, it is generally sufficiently high. Slight variations will cause some change in the magnetizing current, but generally nothing serious. I never worry about it.
If you are trying to get a substitute for a certain ferrite, look at the following:
Shape availability
For the material mix, the saturation flux and the losses per volume unit at your operating frequency (usually at a temperature of 80~100°C). Compare these against the original.
Yes Iam tring to get a substitute but for an unknown core.Saturation flux is too what I am really worriying most about.For instance difference is only 30 mT between 3c92 and 3c90.I am keeping try..
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