Rewinding a MOT to make a high current supply.
Ok, I've done a little more research on this, and it seems that MOTs are just pieces of junk basically. Manufacturers design them to go far into saturation because they don't care how much electrical power is wasted, as long as the transformer is cheap to make. The air gap is probably there just so it's easier to cool with a fan. Now I need to bring this thing out of saturation. There are about 90 turns on this primary, which I want to be the secondary at 30 V. So I would have to wind a new primary with 360 turns of thin wire. That's a lot of work, and a lot of wire. Is it worth it? The other option would be to add turns to the existing primary. This seems more reasonable, but just how much would I need to use to bring it out of saturation?
So, I'm a physicist (in training) and I know the theory behind transformers, but actual transformers are still pretty mysterious to me. I've found quite a few Instructables and other sites related to MOTs, specifically related to making high current power supplies with them. The problem I'm having is that even when the secondary is open, and indeed when the secondary has been completely removed (and the shunts removed), the primary draws upwards of 10A when connected to mains. To me, this is unacceptable. Transformers should draw significant power only when current is drawn from the secondary. I'm trying to figure out why (specifically) it does this. I've got a variac and the transformer only begins drawing more than about 2 amps once the variac is set to about 90V. This seems like non-ideal behavior to me, but what I know about saturation tells me that the amount of steel the core has is more than enough to stave off saturation at open secondary, but I could be wrong. The only thing I can think of is that the primary coil has about a 1cm air gap on either side of the core. Since the efficiency is related to the magnetic flux, and I'm guessing the area of the air gap is roughly 1/5 of the area of the core, this could cause significant inefficiency.
Here's what I want:
I want to make a ~30V (possibly with multiple taps) high current supply out of this MOT that draws less than 1 amp when the secondary is open. I tried connecting the mains to the secondary before I removed that and I got about 5 volts on the primary, but I need more than that, and the windings were so saturated with resin I had to just remove the entire secondary. I'm thinking about winding a new primary (using the old primary as the new secondary) with something like 18 gauge wire that would give me 30V. Would this work? What I really need to know is why the existing primary is drawing 10 amps. That's just ridiculous. If I can solve that then the problem is easy.
Update: There is a difference between resistive and reactive current, and I know that reactive current actually draws net zero power because it's 90 degrees out of phase with the source voltage. Capacitive and inductive loads do this apparently. Is this the reason for the massive current draw? If so, I might be able to minimize the current draw from the mains line by putting a matched capacitor in parallel with the primary. But this wouldn't stop the transformer from heating up.