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Tesla Coil secondary repair (worklog)

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Move Thread LAN_403
Kizmo
Thu Oct 04 2007, 06:12PM Print
Kizmo Registered Member #599 Joined: Thu Mar 22 2007, 07:40PM
Location: Northern Finland, Rovaniemi
Posts: 624
 		So here it is, my attempt to repair quite badly burned secondary.

It had several types of failure:
- Shorted turns (overlapped turns, turn-turn arcing)
- turn-turn arcing (bad coupling, holes in varnish)
- racing arcs (bad coupling)


--4.10.2007--
All of these failures are at the bottom end of secondary so rest of winding is fine.
I started the job by unwinding few hundred turns away to see better what happened. (later i unwound some more):
http://xs220.xs.to/xs220/07404/alkutilanne.jpg


Then i ground all burns and carbon tracks away with pneumatic tool:
http://xs220.xs.to/xs220/07404/jyrsitaan.jpg
http://xs220.xs.to/xs220/07404/siistitty.jpg

Few turns of 'old' winding needed to be exposed
http://xs220.xs.to/xs220/07404/paljastetaan_kaamia.jpg

..And then i sanded the surface:
http://xs220.xs.to/xs220/07404/hiottu.jpg

And then filled all holes with polyester filler and sanded it again:
http://xs220.xs.to/xs220/07404/hiottu_ja_paklattu.jpg

And finally i coated it with thick layer of polyurethane varnish
http://xs220.xs.to/xs220/07404/hiottu_paklattu_ja_lakattu.jpg

More to come, tomorrow i will start rewinding.

I have no idea if this works but it think i have nothing to loose (except some time and materials)
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Dr. Dark Current
Thu Oct 04 2007, 07:06PM
Dr. Dark Current Registered Member #152 Joined: Sun Feb 12 2006, 03:36PM
Location: Czech Rep.
Posts: 3384
 		I don't know if you want to keep the old winding but if so I would wind the lower part of the secondary with a thicker wire so you don't risk burning it again (usually the highest currents in a TC secondary are present near its base).
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Kizmo
Thu Oct 04 2007, 07:15PM
Kizmo Registered Member #599 Joined: Thu Mar 22 2007, 07:40PM
Location: Northern Finland, Rovaniemi
Posts: 624
 		Whole idea is just to replace damaged part of winding. Beefier wire is actually good idea, i will go for that.
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Danielle
Thu Oct 04 2007, 08:42PM
Danielle Registered Member #632 Joined: Mon Apr 09 2007, 01:09AM
Location:
Posts: 267
 		remember that, puting thicker wire will raise the fres of the secondary.
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Kizmo
Thu Oct 04 2007, 09:12PM
Kizmo Registered Member #599 Joined: Thu Mar 22 2007, 07:40PM
Location: Northern Finland, Rovaniemi
Posts: 624
 		I know

It will need retuning anyways because of new primary coil
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Steve Conner
Thu Oct 04 2007, 10:25PM
Steve Conner Registered Member #30 Joined: Fri Feb 03 2006, 10:52AM
Location: Glasgow, Scotland
Posts: 6706
 		Using two gauges of wire worked for me. The bottom 2" of my DRSSTC resonator is now something like 1mm PVC covered stranded wire, and the rest is the 0.315mm magnet wire that I started with. Lord knows what those are in AWG.
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Ken M.
Fri Oct 05 2007, 12:52PM
Ken M. Registered Member #618 Joined: Sat Mar 31 2007, 04:15AM
Location: Us-Great Lakes
Posts: 628
 		Well steve, if my caliper is correct your coil is using something like 34-38 AWG wire.
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Steve Ward
Fri Oct 05 2007, 11:23PM
Steve Ward Registered Member #146 Joined: Sun Feb 12 2006, 04:21AM
Location: Austin Tx
Posts: 1055
 		.315mm is .012" or about 29-30awg magnet wire.
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Ken M.
Sat Oct 06 2007, 12:25PM
Ken M. Registered Member #618 Joined: Sat Mar 31 2007, 04:15AM
Location: Us-Great Lakes
Posts: 628
 		=\ Oh well, it was an eye guess, I was still close in the fact that its a 30 gaugish wire.
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Kizmo
Sat Oct 20 2007, 06:19PM
Kizmo Registered Member #599 Joined: Thu Mar 22 2007, 07:40PM
Location: Northern Finland, Rovaniemi
Posts: 624
 		Finally i got time for this project

Rewinding is done and first layer of polyester varnish is applied and it seems fine for now.
Link2

New winding is done with .75mm wire. I connected new and old winding together by soldering, then i sanded the joint as smooth as possible and wrapped some high voltage insulation tape around it.

Hopefully in few days we will see if this repair works.
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