How To: High Current Microwave Oven Transformer





Introduction: How To: High Current Microwave Oven Transformer

 Hey! in this instructable i will be detailing the steps involved in modifying a microwave oven transformer for high current lower voltage use which shall be achieved by removing the transformers original secondary windings and replacing it with thicker ones of your own. Now the thing to take into mind before you do this is what kind of power you want out of it.
Examples, if you use thicker wire and less of it you will get higher current but lower voltage, if you use thick wire (not as thick) and a few more turns of it you will get high current and slightly higher voltage. or if you keep the original windings you will get one to two thousand volts at one to two amps.

Now to jump right in here's what you will need!
1) A microwave oven transformer
2) An angle grinder or if you don't one and your very keen.. a hacksaw.
3) 1-5 Gauge insulated copper wire.
4) A grounded 3 pin wall plug

Onto the next step!

Step 1: Removing the Secondary Windings

 Now for the fun part! (not really it kind of sucks)

Step 1) Take you microwave oven transformer and secure it tightly into a vice or onto a solid bench with clamps. Then plug in your angle grinder or pick up your hacksaw (with proper safety gear of course)

Step 2) Cut away the secondary windings, the large amount of thinner wire. and use whatever means necessary to just remove all of the secondary windings. 

Step 3) there will be a small length of usually red wire in the middle below where the primary was this is the filament windings, remove these as well. then there is the magnetic shunts, you can also remove these, just tapping them out with a flat head screw driver will work. once all this is removed leaving only the primary left,continue to the next page!

also pictured below is what you should have, but in the pictures I have not yet removed the shunts. (the primary connections are on the opposite side.)

Step 2: Adding in New Secondary and the Final Product. (VIDEO)

Now the last part! this was easy wasn't it..?

Step 1) Now that you have removed the secondary windings, shunts and filament windings and its as tidy as possible, you can take your new secondary wire (whatever gauge your using) and wind as many turns as possible on your transformer as you can fit, the more turns the more volts. and the thicker the wire the more current you will get. to wind the new secondary, just wrap your new wire round the core of the transformer where the old secondary was.

Step 2) Now you can attach whatever you want to your new secondary's two output leads, whether it be some big heavy duty alligator clamps or connecting it up for use as a spot welder or stick welder 

Step 3) Get your 3 pin grounded wall plug and connect the ground to the base of your transformer, and the hot wire and the neutral wire to your transformers primary inputs.

Step 4) Plug it in, turn it on and you have yourself a power supply that theoretically should be able to supply up too a kilowatt of raw output power! 

And of course a video. 2-3 turns approx 3v AC and around 500 amps of steel melting power...

Heres a snapshot of one rewound MOT i put a bit more effort into. I wound it into a power supply that has 5 voltage taps which once rectified the voltage on each is 0v (GND), 12v, 24v, 30v and 50v DC! all of the voltages besides the 50v can put out 30 amps+ and the 50v limited to around 20 amps.



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    I use 1/4" heavy wall soft copper tubing for the secondary when I make high current transformers out of old microwave transformers. You can buy high temp fiberglass insulation tubing on eBay to slip over the copper tubing to insulate it from the iron core. Using copper tubing allows you to pump coolant through the secondary allowing for continuous use. The coolant also helps cool the core as well as an added bonus. When making spot welders you can run the copper tubing all the way to your electrodes as the wiring as well with T fittings up near the electrode ends with nipples to connect the coolant lines. Then just add a 120mm radiator (of the liquid cooled PC variety) with a 120mm fan and a small pump from eBay as well for a nice compact liquid cooled unit. I found without active cooling the intentionally inefficient (AKA cheap) microwave oven transformers over heat in short order when used for high current applications. They are designed to run a capacitive load through a half wave voltage doubler and they are also designed to be manufactured as cheap as possible without burning down too many homes in the Make sure to remove the shunts as well as they also add to the inductive losses. They are there to balance out the inductance of the half wave doubler circuit in their designed task of driving magnetrons.

    you can wire a second MOT in series with the first, fully short the secondary on the second MOT, and you should run a lot cooler on any setup you use. I get 45 minutes using mine without risk of meltdown/smoke. Not sure EXACTLY why it works, found it while reading about transformers in material from the early 1900's. I think it is a sort of inductive resistor, which allows for the absorption of extra power on the circuit when your primary is not running, so you have a resistor that reacts to your use of power. That is at least how i think it works, the writer had a few theories of his own.

    can this power a tesla coil

    Sorry people lied to you, yes you can use this to power a tesla coil, instead of wrapping the secondary coil with thick gauge and few turns, you use thin gauge and many turns. This will create high voltage and low amps. It'll take quite awhile to wrap since you'll probably want to wrap it a few hundred to over a thousand times.

    More data: You get voltage drop if you have too many winds. If your input voltage doesn't meet the ohms of reactance then you will have wasted your time winding. In short, yes you can power a tesla coil. Just reverse the primary/secondary. But there are a few pitfalls to winding your own transformer.

    I'm not certain from your brief description that you are describing anything like a Tesla coil, which would not have the laminations, but would have LC-coupled tuned coils. You seem to be describing a rather conventional high frequency laminated transformer, and one that might be of high loss design, for the laminations might not be matched to your input frequency. I'm not an LC sort of engineer, but I don't see what you briefly described as resembling a Tesla Coil in any way.

    this was years ago and i ment the MOT

    No... Tesla coils require a high voltage input (not nearly as high voltage as the output of the TC mind, but we're still talking thousands of volts; most use about 10 - 15 kV). This voltage of the output of this transformer is probably about 2V (yes, two) the current is massive, that's the interesting bit.

    So to summarise, no. Try looking into neon sign transformers. Though to be honest, with respect, a tesla coil may be a little beyond your (safe) reach, given your question.

    no that is not true, there're also Tesla Coils that work on only 12VDC!

    can i use that in dc motor?