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Re: [TCML] How to Fix Damaged Secondary
Hi Carl,
Thanks for describing the procedure. The wire surgery does not seem to be too difficult, and I admire it's precision delicacy and thoroughness. My coil burn is not yet bad enough to require this, but I will do it after I test the coil now that I have cleaned it and re varnished it and possibly reduced the coupling. However, I will definitely take to this measure if my coil burn gets worse.
Thank you for your help Carl,
Amir Mojarradi
-----Original Message-----
From: Carl Noggle <cn@xxxxx>
To: Tesla Coil Mailing List <tesla@xxxxxxxxxx>
Sent: Wed, Oct 26, 2011 5:22 am
Subject: Re: [TCML] How to Fix Damaged Secondary
Hello, Amir,
You probably have a shorted turn. I have fixed several of these. It's
not hard, but requires the drastic delicacy of a brain surgeon. Find
all the turns that have burned insulation and carefully cut them back at
least 1/2 inch each way from the burn, then cut the ends in a staggered
fashion. Be very careful not to nick any insulation. Then take the
first good turn on each side and cut it so that there is overlap between
the ends. Carefully scrape the insulation back 1/4 inch on each. Then
drill a small hole through the form and put both ends through to the
inside of the form. Reach inside the form and pull them tight and twist
them together. Solder them inside the form. This leaves a point, but
it's in a relatively field-free region. Smoothe and dress the wire ends
in the surgery area on the outside, and coat them all with epoxy. Heat
it with a heat gun or hair dryer to remove bubbles, but not too hot.
This leaves a visible injury on the coil, but I have never had one
fail. If it is a shorted turn, fixing it will greatly improve the
performance o your coil. The final step is to turn the coil so the
injury is away from the audience.
This kind of problem is usually due to secondary arcs attaching to the
side of the coil. Avoid this like the plague. The burns will be worse
with higher power, of course.
I wind my coils with monofilament nylon fishing line of about the same
diameter between the turns. This is surprisingly easy.
Good luck.
---Carl
> Hi everyone!
>
>
> I recently finished completion of a fairly large Tesla coil, (specs and video
below), and have been testing it.
>
>
> Maximum Arc Length (so far) 9 feet
> Secondary Diameter: 12"
> Secondary Coil Winding Height: 57"
> Wire Gauge: 18awg
> Number of Turns: 1400
> Toroid Minor Diameter: 12in
> Toroid Major Diameter: 60in
> Power Supply: 14.4kv 10kw Pole Pig
> Ballast: Lincoln Arc Welder (240 Volts @~ 26 amps)
> Primary Capacitance: 0.1289 uf
> Asynchronous Rotary Spark Gap
>
>
>
> Video: http://www.youtube.com/watch?v=KfQYHF6Z62c&feature=related
>
>
>
> When testing at about 5 Kw, I noticed some arcing one individual turn at
exactly one point about 12" on the secondary. Upon examination, there is a small
burn mark at the point on the turn where it was arcing. At this point on the
wire, the varnish is melted and has left the point exposed. I have re-varnished
the entire coil already. Is there anything I can do to "heal" the damaged point
to prevent further arcing? I was originally planning to step up the power to
about 12 Kw, but I might have to hold off, or possibly reduce coupling. Any
suggestions or advice would be much appreciated.
>
>
> Thank you for your kindness,
>
>
> Amir Mojarradi
> _______________________________________________
> Tesla mailing list
> Tesla@xxxxxxxxxx
> http://www.pupman.com/mailman/listinfo/tesla
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