Broken primary windings of toroidal transformers usually need to be repaired. Repairing broken wires can be roughly divided into the following steps:
1.Power off and safe operation:Before carrying out any repair work, it is important to ensure that the power supply to the transformer is disconnected and that proper safety measures are in place to prevent electric shock accidents.
2.Check and confirm the location of the broken wire:Double-check the primary windings of the transformer to find the exact location of the disconnection. Sometimes, wire breaks can occur on the outside of the winding, in which case it is easier to repair;But if it's internal, you may need to remove more windings to find where the wire is broken.
3.Removal of insulation and preparation of wires:If a break point is found, the insulation coating must be removed. Using appropriate tools, such as wire strippers or sandpaper, carefully remove insulation from both ends of the broken wire in preparation for twisting or welding.
4.Welding or twisting:Reconnect both ends of the disconnected wire. If the broken wire is in a weldable position and you have enough welding skills, you can directly weld the ends together. Otherwise, the connection can be made using an appropriately sized terminal block or by twisting and wrapping it with insulating tape.
5.Rewinding the coil:If the wire break occurs inside the **ring and there is no way to fix it, it may be necessary to completely rewind the primary winding.
6.Test Connectivity:After the repair is completed, use a multimeter to test the connectivity of the winding and confirm that the repair is successful.
7.Re-insulation:Make sure that the repair area of the broken part is recoated with insulating paint or wrapped with insulating tape to prevent short circuit or leakage.
8.Final Inspection and Testing:After the broken wire has been repaired, a full functional and performance test should be performed to ensure that the transformer is back to normal working order.
Note, if you are unable to repair it yourself or are not familiar enough with the repair of electrical equipment, please contact a professional to repair it. Incorrect repair can lead to safety incidents, including electrical fires or electric shocks.