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12/9/2018

Construction of a homemade toroidal transformer

Construction of a homemade toroidal transformer

Step by step manual of how to make a high power toroidal transformer.

When we carry 30% of the necessary turns, we make a test by connecting the Series Circuit at the ends of the wire. This to show that the primary winding is not yet ready and that the missing turns are indispensable.

By placing the series we see how the bulb lights up fully. This shows that the magnetic field has not yet been formed and that this circuit is still short. It has not become a true solenoid. When we have finished winding the calculated turns for the Primary Winding, we reconnect the Serial Circuit and see how it turns off the series. Sometimes it shuts off before completing the calculated laps. This is an advantage because the transformer will consume less energy. When it does not turn off the Serial Circuit, it indicates that laps of wire were missing and that the calculations were poorly made or that the core is of poor quality (few gauss).

12/9/2018

Construction of a homemade toroidal transformer

If completing the wire turns does not turn off the series and the calculations are well done, it may be that the calculations have been made wrong or the core is not made of iron-silicon. When the core is of poor quality or is not of the mentioned material, we must continue winding wire until the point in which the Series Circuit turns off completely. In this case we will have to return to Reformulate or Recalculate the turns that must conform the secondary winding. The procedure is the next:

Turns given in the primary winding, divided by the public network voltage, equal to the number of turns per volt.

Example:

144 turns / 120 volts = 1.2 turns per volt. Now we multiply 1.2 by the average voltage that is 60V and we will have 72 which is the number of turns of double wire that the secondary winding will have.

Upon satisfactory completion of the primary winding, we must weld cables on both ends of the wire ends and coat them with heat shrink spaghetti.

12/9/2018

Construction of a homemade toroidal transformer

Winding of the secondary winding

When we have our primary winding perfectly made and tested and we are going to wind the secondary winding, we must isolate it very well, we do this with a Prespan paper coating and with masking tape. If you can not get the Prespán paper , you can make the covering with cardboard and masking tape. Use the same technique as the one used on the nucleus.

NOTE : The transformers built at industrial level; When the primary winding is coiled, they are submerged in dielectric varnish. This is done so that the wire is completely rigid and does not vibrate for any reason. If you want, you can do it. The transformers that we have built so far have not been applied the varnish and have worked perfectly.

Then you must place the Pole to Earth . This is optional. It consists of placing a thin sheet of copper plate around the primary winding. A piece of wire is welded to the copper tape and then covered with cardboard or Prespan paper .

12/9/2018

Construction of a homemade toroidal transformer

This sheet will surround the transformer and is fixed with tape. This copper shield serves to avoid possible escapes of magnetism that may interfere with the circuits, especially if there are preamplifiers or small signal circuits.

Now we proceed to wind the secondary winding. Usually a secondary winding becomes dual or symmetric. It means that it has a Central TAP or central point; which divides the output voltage into two voltages, at half the total voltage.

12/9/2018

Construction of a homemade toroidal transformer

For this we must wind the double wire. So, first roll the meters calculated in the launcher. They are two equal wires that are then rolled in the toroid in an orderly and very tight manner.

TAP Central transformer

Upon completion of the secondary winding, it must be measured and verified that the output voltage is as required. If it is correct, we proceed to cut the excess wire. Then join the tip of the beginning of one of the wires, with the final tip of the other wire; for this, form the central TAP. Be careful not to join the ends of the same wire. For this, verify with the multimeter in continuity scale.

The multimeter marks continuity when measuring the tips of the same cable. So the two points that do not mark continuity, are the correct ones to join.