I DECIDED TO TRY WINDING MY OWN HIGH VOLTAGE TRANSFORMER. I HAD AN OLD 240 VOLT SINGLE PHASE 3.5KVA TRANSFORMER WITH A 120/240 VOLT SECONDARY. I DECIDED TO UNWIND THIS TRANSFORMER AND JUST COUNT THE TURNS, FIGURE VOLTS PER TURN AND REWIND FOR THE 2800 VOLT SECONDARY I WANTED AT 1 AMP.
I HAD TO HEAT AND BEAT THE WOOD WEDGES THAT WERE INSTALLED AROUND THE COIL. THE SCREWS THAT HOLD THE CORE TOGETHER WOULD NOT COME OUT. A HEAT GUN AND A HAMMER WAS THE METHOD, ONE WOULD NOT COME OUT. IT WAS MUCH MORE LABOR INTENSIVE THAN I THOUGHT IT WOULD BE, BUT WHEN YOU LOOK AT THE COST OF A CUSTOM
2800 VOLT TRANSFORMER GOOD FOR 1.5 AMPS, I HOPE IT WILL ALL BE WORTH WHILE!
THE SECONDARY IS WOUND! ALL 14 WINDINGS! NOW THE PRIMARY...
THE PRIMARY IS WOUND! NOW TO PUT ALL THOSE LAMINATIONS BACK IN...
ALMOST DONE...
SUCCESS!! 240 VOLTS INPUT YIELDS 2800 VOLTS OUTPUT. 4100 VOLTS DC! PERFECT! I OWE A NOTE OF THANKS TO LUDENS PRACTICAL TRANSFORMER WINDING PAGE. WITHOUT HIS INFORMATION THIS TRANSFORMER WOULD NOT HAVE BEEN POSSIBLE.
THE PRIMARY IS 150 TURNS IN FOUR LAYERS OF 10AWG WIRE, THE SECONDARY IS 1750 TURNS IN 14 LAYERS OF 20AWG WIRE. I USED NMN FOR INSULATION BETWEEN THE WINDINGS. THIS COST ABOUT $260.00 TO REWIND.
I DID A LOAD TEST, WITH 800MA FOR 15 MINUTES IT WAS STILL AMBIENT. THE VOLTAGE DROPPED 400 VOLTS. IT WAS DEFINATELY WORTH IT!!
