12/9/2018 Construction of a homemade toroidal transformer

Construction of a homemade toroidal transformer

PROJECTS , SOURCES PROJECTS

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

one two 3

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).

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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.

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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 .

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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.

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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.

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