541 lines
31 KiB
Plaintext
541 lines
31 KiB
Plaintext
_____________________________________________________________________________
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| File Name : XFMRS.ASC | Online Date : 11/22/94 |
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| Contributed by : Bert Pool | Dir Category : ENERGY |
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| From : KeelyNet BBS | DataLine : (214) 324-3501 |
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| KeelyNet * PO BOX 870716 * Mesquite, Texas * USA * 75187 |
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| A FREE Alternative Sciences BBS sponsored by Vanguard Sciences |
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|---------------------------------------------------------------------------|
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Power Transformers, How to Safely Connect and Use Them
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by Bert Pool
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Many of the experimenters on KeelyNet do work with Tesla coils, Lakhovsky
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MWO's, Rife generators, and some even do experiments with high voltage
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capacitive discharge explosion of water. Jerry Decker of KeelyNet asked me to
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write up a paper discussing the methods of connecting and using transformers,
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including the larger "pole pig" transformers. Because these transformers are
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dangerous high voltage, high power devices, I agreed that a paper discussing
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proper connections and safety needed to be written up.
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The purpose of this paper is not to induce you to try any of these things, but
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to point out specific dangers that you need to be aware of if you are
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contemplating lines of research using big transformers.
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Power transformers can be INCREDIBLY dangerous!
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_____________________________________________________________________________
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***********************************************************************
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*** Disclaimer ***
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I've tried to put information in here which is factual and of safety
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interest, but I don't guarantee anything! You are, I assume, an
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intelligent, thinking adult, and your actions are your responsibility, not
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mine. I assume NO liability. If you don't know what you are doing, then
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stay away from high voltage equipment. If you get electrocuted or kill
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somebody, or you burn off a hand, don't come crying to me! I'm trying to
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warn you with this paper; that this stuff is dangerous if you are not
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careful or if you don't know exactly what you are doing. It's rather like
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working with explosives or hand guns: if you know what you are doing, the
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danger is minimal. If you are careless or stupid, then someone, most
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likely yourself, can get badly hurt or killed.
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***********************************************************************
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_____________________________________________________________________________
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I begin this technical paper with a quote:
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***********************************************************************
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"I'm more careful when working on big transformers than just about
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anything else I do, because I know that I probably won't survive making
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a mistake." - Quote by me, in one of my more lucid moments.
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***********************************************************************
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If you are a novice, stay away from distribution transformers!
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Neon transformers will hurt you - distribution transformers will kill you.
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Violently.....
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_____________________________________________________________________________
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Neon Transformers
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Using the smaller neon transformers is relatively safe, compared to the large
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potential and distribution transformers. Most neon transformers range in
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voltage outputs from 7,000 volts to 15,000 volts. Output current can range
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from about 5 milliamps (.005 amperes) to 60 milliamps (.060 amps), and you can
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occasionally find a rare 120 m.a. transformer. Neon transformers can deliver
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a very nasty shock, and can cause painful burns, and under proper
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circumstances can even be lethal.
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_____________________________________________________________________________
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**** Warning *****
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A neon transformer's output CAN be lethal if the current path travels
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through the heart, i.e., if you were to touch a transformer's two
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terminals with both hands (or one terminal and ground). It only takes
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a small current of 20 to 30 milliamps to cause the heart to go into
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ventricular fibrillation - a condition where the heart no longer pumps
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blood rhythmically, but just sits and quivers like a mass of jello.
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Once the heart goes into ventricular fibrillation, a medical defibrillator
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must quickly be applied to the victim's chest to try and re-start the
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heart's natural beats. De-fib units work by passing a pulse of high
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voltage, high current through the thoratic cavity, causing the heart to
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contract into a hard ball. If a victim is lucky, his heart may start
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beating again. Then you worry about whether he will be a vegetable
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because of oxygen deprivation to the brain during the time the paramedics
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were enroute..... CPR can be a life saver in these situations. If you
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are going to work with power transformers I HIGHLY suggest you and your
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assistant(s) need some real CPR training. Contact your local Red Cross
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office for their scheduled classes.
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So, rule #1 - KEEP ONE HAND BEHIND YOUR BACK
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WHEN WORKING ON HIGH VOLTAGE EQUIPMENT.
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_____________________________________________________________________________
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Sounds dumb, right? Well, Nikola Tesla himself rigorously followed this rule,
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and I learned it years ago in school while working on the high voltage section
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of color television receivers (27,000 volts). You are much more likely to
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survive touching a high voltage current with only one hand - the current will
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most likely travel down one side of the body and bypass the heart. And, if you
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are wearing thick rubber-soled shoes you are even less likly to be injured or
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killed!
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_____________________________________________________________________________
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Neon transformers
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Used neon transformers may be found at neon sign shops, salvage yards, etc.
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9,000 to 15,000 volt units usually can be had for $30 to $35. New
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transformers start at about $100. The tar insulation used in neon
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transformers carbonizes with age, and old transformers do not hold up as well
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as new transformers when connected to Tesla coil circuits. You may carefully
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remove the metal case and tar on old neon transformers, and the exposed
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transformers will be much more reliable in Tesla coil circuits. Be very
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careful not to cut or break the very fine wire used in the secondaries if you
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disassemble a neon transformer. This wire can be smaller in diameter than a
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human hair.
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_____________________________________________________________________________
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Connecting neon transformers together
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Neon transformers almost always have an input of 115 volts, and output
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voltages of several thousand volts. The case of the transformer is grounded.
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What is very important to understand is that the secondary winding is a
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center-tapped winding, and the center tap is connected directly to the case
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(and laminated iron core) of the transformer. This means that if you have a
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12,000 volt transformer, you have 12,000 volts between the two high voltage
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insulators, and you also have 6,000 volts measured from the case to either
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high voltage connection!
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You can connect neon transformers in parallel, but you CANNOT connect them in
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series!
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_____________________________________________________________________________
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**** Very important safety warning! *******
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Do NOT connect neon transformers in series! If you try to connect neon
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transformers in series to get a higher combined voltage, you will be
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placing several thousand volts on the cases of the transformers. The
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high voltage will most likely arc to the 115 volt terminals, causing a
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disastrous short. You will also create a very, very dangerous safety
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condition with the cases being energized! Do NOT connect neon
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transformers in series!
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Neon transformers CAN be connected in parallel for more CURRENT. The
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voltage will remain the same. If you have two 12,000 volt transformers
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rated at 30 milliamps and parallel them, the current available is now
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60 milliamps. It is very important to make sure the transformers are
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rated at the same voltage, and preferably the same current. If you
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connect two neon transformers in parallel, and they have different
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voltage ratings, one or both transformers will almost certainly be
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destroyed (especially if connected to a Tesla coil. I know, I've tried
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it.)
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You need to know that neon transformers are self-limiting in the amount
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of current they can supply. You can actually short out the two high
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voltage connections of a neon transformer with a wire and then plug in
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the transformer and nothing violent will happen! Neon transformers
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have a built-in feature which limits the power available to the
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secondary winding. Still, it is not a good idea to short out these
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transformers for extended lengths of time. Some neon transformers can
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have this current limiting feature bypassed to extract more power -
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this is covered in a later section.
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_____________________________________________________________________________
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Connecting transformers in parallel
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How do you connect two neon transformers in parallel for more current?
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First, number the 115 volt input connections on each transformer #1, and #2.
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Next, number the high voltage output connections #3, and #4 on each
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transformer.
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Connect #1 to #1, #2 to #2, #3 to #3, and #4 to #4. Run wires from the two
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high voltage terminals (3 & 4) to a spark gap (a spark gap is simply two wires
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placed about 1/4 inch apart). Connect 115 volts to 1 & 2.
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A beautiful flame-type arc should immediately jump across the spark gap. If
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this does not happen, then the two transformers have been connected "out of
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phase". Should you do this, simply disconnect power, and swap the wires going
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to 1 & 2 on ONE of the transformers (not both!). Re-connect power, and you
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should see the high voltage jump across the spark gap. You may parallel
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additional transformers, connecting them one at a time, and testing to make
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sure you get the polarity of 1 & 2 correct each time. I have connected six
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neon transformers in parallel, and a friend of mine once had twelve
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transformers paralleled for a really big Tesla coil!
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_____________________________________________________________________________
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Bypassing current shunts
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Some larger neon transformers have special laminations which are located in
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the core, between the primary and secondary windings. These laminations are
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at right angles to the core laminations, and these "sideways" laminations may
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be driven out of the transformer core with a hammer and a small block of wood.
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You will find that the amount of current available to the secondary will be
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much greater once you do this. You should be careful to not short out a
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transformer's secondary windings after you have performed this modification,
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since you have removed part of the current limiting feature. One Tesla coil
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builder in Dallas, David Chapa, has a Tesla coil which puts out 48 inch+
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discharges using ONE 15,000 volt, 60 ma neon transformer with this
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modification!
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_____________________________________________________________________________
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**** Neon transformers with current shunts removed are much more
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dangerous than shunt protected transformers - use caution!
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_____________________________________________________________________________
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Potential and distribution transformers
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For our purposes, watts and kva (kilovolt*amps) are the same thing. Whenever
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I say this, engineers will always jump to their feet and start shouting things
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about reactances and inductances and phases and impedances, but the fact is
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that in 99 out of 100 cases, experimenters can either use the term "kilowatts"
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or they can use the term "kva" and the transformer will never know the
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difference. If you are going to use a potential transformer for a Tesla coil,
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or other similar intermittent duty application, you can push the transformer
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to twice or even three times its specification plate power rating safely.
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This means that you can operate a 5 kva transformer at 10 kva for short
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periods of time, with time-outs to allow the core and windings to cool down.
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Be aware that you will NOT get the same performance out of a 5 kva transformer
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pushed to 10 kva as you will from a 10 kva transformer running at its rated 10
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kva! Larger transformers use heavier wire, and peak or instantaneous currents
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will always be larger in the bigger transformers. A Tesla coil using a 10 kva
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transformer, running at 10 kva will always outperform a 5 kva transformer
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pushed to 10 kva. More instantaneous power is always available from the
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larger transformer.
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Main point: you can get a lot more power out of a transformer than the spec
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plate shows.
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Potential transformers usually can be found in old Ham radio transmitters,
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r.f. induction heating units, microwave ovens, radar transmitters, etc.
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Output voltage ratings can run from a few hundred to several thousand volts.
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Current available in the secondary windings is always much higher than in neon
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transformers.
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_____________________________________________________________________________
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***** Lethality Warning! ******
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*** Death, Doom and Destruction! ********
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Potential transformers are MUCH more dangerous to work with than neon
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transformers, since the current is higher and more likely to cause
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serious physical damage. A neon transformer will cause a nasty shock
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and a mild burn. A large potential or distribution transformer can
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burn off an entire arm or leg! Large potential transformers will
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literally cook you; it can make the blood in your body boil and
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explode.
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YOU ABSOLUTELY MUST BE CAREFUL AT ALL TIMES WHEN WORKING WITH POTENTIAL
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AND DISTRIBUTION TRANSFORMERS! NEVER WORK ON POTENTIAL/DISTRIBUTION
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TRANSFORMERS ALONE - ALWAYS HAVE SOMEONE WATCHING YOU IN CASE SOMETHING
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GOES WRONG. USE RUBBER MATS ON THE FLOOR. USE HIGH VOLTAGE RUBBER
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GLOVES. USE COMMON SENSE!
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_____________________________________________________________________________
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Potential transformers are not self-limiting in current. What does this mean
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in real life? If you were to take a large potential transformer, say like out
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of a large radar transmitter, or a distribution transformer (pole pig) and if
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you connect it to your electrical outlet in your lab, it will probably just
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sit there and produce a lot of high voltage as it quietly hums.
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If you measure the current flowing in the transformer's primary, it will be a
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piddly three or four amps. UNTIL you connect it to a load! If you try to
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connect the high voltage to a spark gap, or to a Tesla coil, you will hear a
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violent hum, the lights will dim, and you will instantly blow the circuit
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breakers in your power panel. Guaranteed!
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Think about it for a minute. A standard pole pig is designed to step DOWN
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12,400 volts to 120 and 220 volts, to run your house, and two or three of your
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neighbors' houses. The typical house uses 110 and 220 volts, usually up to a
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couple hundred amps. Combine the power usage of four houses, and the
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transformer has to supply 220 volts at maybe 800 amps. That's a LOT of amps!
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We experimenters usually connect these monster transformers BACKWARDS, putting
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in 120 or 220 volts so we can get out 12,400 volts to run our Tesla coils and
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other nefarious devices. Guess how many amps that transformer is going to
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want to pull from the 220 volt line so that it can deliver that 12,400 volts
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at its rated current? Right! It will want to pull 800 amps. Most of us are
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not going to be able to supply 220 volts at 800 amps - and indeed, we don't
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WANT to! We have to limit the current to something reasonable - maybe 20 or
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50 or 100 amps. We do this by placing a current limiting device in series
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with the primary of the transformer.
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_____________________________________________________________________________
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Limiting current and power
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How do you limit the current in the primary circuit? By placing either a
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resistor or an inductor (coil) or a variable transformer (variac) in series
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with the primary of the transformer, or a combination of these.
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Large potential/distribution transformers are rated at several thousand watts.
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The resistor or inductor or variac that you use with a transformer of this
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type must be capable of handling the maximum rated power you intend to work
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with. If you have a 5,000 watt transformer (5 kva), then you're going to need
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to limit the power available to the transformer to 5 kva or less, and your
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limiting device must be capable of handling this same amount of power!
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You may be asking yourself, where am I going to get a 5,000 watt resistor?
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You can use heating elements out of electric heaters and ovens, and even
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electric water heater elements (which cost aboust $7).
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When using variacs, remember that you cannot use a 500 watt variac to control
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a 5,000 watt transformer, unless you expect to limit the transformer's power
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to 500 watts or less. If you have a 5 kva transformer, and you expect to push
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it near 5 kva, then you will need variacs rated near 5 kva. 220 volt variacs
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would need to be rated at 20 to 30 amps. Remember that variacs too, can be
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pushed beyond their rated output in watts, but only for short lengths of time.
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You are best off here using variacs rated near the power level you expect to
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work at. You will get into trouble using variacs too small or too large! Too
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small, and the windings will fry. Too large and you cannot limit the current
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adequately. For example, it is not a good idea to use 10 kva variacs to
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control the current going to, say, a 1 kva transformer. Why? The internal
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resistance of the variac will be so low that you may not be able to limit
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current to a controllable level.
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Most big Tesla coils use a combination of two variacs in series to control
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power to the potential transformer. One variac is used as a giant current
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limiting inductor, and the other variac is used to vary voltage. You may also
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take a Lincoln arc welder, short the output leads (the low voltage side), and
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connect the 115 or 220 volt side of the welder in series with your variac and
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potential transformer. The potential transformer cannot receive more current
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than can pass through the primary of the welder. You may even use the current
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settings on the welder to pre-select different current settings (the higher
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the current setting, the more power will flow through the primary circuit).
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Let us say that under full load, your welder will pull 25 amps, max on the
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primary (220 volt) side. Placing it in series with your potential transformer
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guarantees that the transformer cannot pull more than 25 amps either!
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I've even used a 3,000 watt clothes dryer in series with a transformer to act
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as a current limiter!
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As I mentioned earlier, most large Tesla coil controllers use two variacs in
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series to control the voltage and current going to a potential transformer.
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You do, however, want to make sure that you don't adjust the current limiting
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variac for too few turns, or the windings will burn. Start out so that your
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current limiting variac has current going through the maximum number of turns.
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Turn your "voltage" adjusting variac up and see what how your potential
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transformer performs. Turn the voltage down, and adjust the current limiting
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variac so that there are a few less turns and increase your voltage again.
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Repeat this procedure until operation is optimal. You want just enough of an
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inductance in the current limiting variac so that magnetic saturation occurs
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at just the desired power level. You may also place high power, low
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resistance heating elements in series with the variac(s) and/or other
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inductive current limiters.
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Appliance repair centers usually have the heating elements in stock. You may
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use the "exposed coil" type of element, and place sliding taps on the coiled
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nichrome wire element and precisely adjust the resistance of the element.
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You may also parallel heating elements to allow more current to flow through
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the circuit. For example, if you place a 1,000 watt heating element in series
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with a potential transformer, you've just guaranteed that no more than 1,000
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watts of power can flow through the primary of the transformer. If you place
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a second 1,000 watt element across (in parallel) with the first heating
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element, you allow a maximum of 2,000 watts of power to flow through the
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primary of the transformer, etc..
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One note on using heating elements to limit current: a heating element has a
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lower resistance when it is cold than when it is hot. You will start out with
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a lot of current, and as the element gets hot, the current will drop. This is
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why heating elements are seldom used by themselves to limit current. Usually
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a very large wattage element is used in series with one or two variacs. Do I
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need to remind you if you run power through a heating element it will get hot?
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(duuuuuhhh?????) Make sure you mount the electric heating elements so that the
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heat produced doesn't burn anything.
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A final way to adjust the current is to use a variac to control voltage, and
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an electrolytic resistor element to limit the current. An electrolytic
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resistor can be made from two stainless steel plates, about one foot square,
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immersed in an insulated container filled with a mixture of water and
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bicarbonate of soda.
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Build your electrolytic resistor by taking a plastic trash can, set it on a
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plexiglass plate or rubber pad, and fill it 2/3 full with warm water. Mix in
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bicarbonate of soda until the mixture saturates (the soda stops dissolving and
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starts to accumulate on the bottom of the tub). Your two stainless steel
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plates are placed in the solution a few inches apart.
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You will control current by raising and lowering the plates into the solution.
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The more of the plate surface which is in the solution, the more current that
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can flow between the two plates.
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This variable resistor is connected in SERIES with your control variacs to
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limit current. Make sure the control rods which raise and lower the plates
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are insulated! You may even use a reversible geared motor with a worm drive
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to operate the control rods. During operation, the water will get hot. Do
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not operate the electrolytic resistor for extended runs, or the water may
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boil.
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_____________________________________________________________________________
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******** WARNING #1 ********
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DO NOT USE SALT WATER AS THE ELECTROLYTIC SOLUTION!!!!! DURING
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ELECTROLYSIS, THE NaCl (SODIUM CHLORIDE) IN THE WATER WILL DECOMPOSE
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AND RELEASE LARGE QUANTITIES OF CHLORINE GAS WHICH IS VERY POISONOUS!
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EVEN SMALL AMOUNTS OF CHLORINE CAN CAUSE SERIOUS BURNS TO THE LUNGS.
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USE BICARBONATE OF SODA, NOT SALT.
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********* WARNING #2 ********
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ELECTROLYSIS WILL ALWAYS RELEASE OXYGEN AND HYDROGEN GAS, WHICH FORM A
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VERY EXPLOSIVE MIXTURE, IF CONFINED. MAKE SURE YOUR ELECTROLYTIC
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RESISTOR IS VERY WELL VENTILATED!
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_____________________________________________________________________________
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A word about capacitors
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Many circuits involving power transformers also involve capacitors.
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Capacitors can store appreciable quantities of electrical power. High voltage
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capacitors can hold enough of a residual charge to cause a violent muscle
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contraction, and large capacitors can even deliver enough charge to kill you.
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Always discharge a capacitor with a discharge tool (a high wattage, 250k ohm
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resistor with well-insulated leads works well) before servicing capacitors.
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Most Tesla coil designs will self-discharge capacitors through the power
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transformer when power is turned off. There is an exception, however! Some
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Tesla coils designs use TWO capacitors in a "balanced driver" configuration.
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The nature of this design is such that the caps can retain a charge even after
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power has been disconnected.
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Rule #2: always discharge capacitors before handling them.
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I'd like to finish this paper by making some final comments on safety:
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1) I always stand on rubber mats to insulate me from ground.
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2) I keep one hand behind me when making adjustments on high voltage
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equipment.
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3) I have an observer on hand who knows CPR.
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4) I keep a cordless phone handy in case of emergency.
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5) I keep a fire extinguisher nearby - remember, pole pigs are filled with
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flammable oil!
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6) I use indicator lights to show when power is on.
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7) I always disconnect power at both the circuit mains and at the on/off
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switch to insure that the circuit is DEAD, so I won't be, before working
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on circuits powered by high voltage transformers.
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And I repeat the quote:
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*****************************************************************
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"I'm more careful when working on big transformers than just about
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anything else I do, because I know that I probably won't survive making
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a mistake."
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*****************************************************************
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Distribution transformers will burn off arms and legs and kill you. It's not
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a pretty way to die. Be super careful!
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Informational note: Interested researchers may obtain invaluable information
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on high voltage equipment, specifically Tesla coil related, from the Tesla
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Coil Builders Of Richmond (VA). Richard Hull is one of the mainstays of this
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excellent group of researchers. Dozens of 2 hour videos are available on the
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proper ways to test, rebuild, and connect transformers and capacitors of all
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sizes, and using them in Tesla coils to produce voltages as high as several
|
|
million volts. Distribution and potential transformers beyond 10 kva are
|
|
sometimes used, and man-made lightning 13 feet long (and more) is produced
|
|
from large Tesla coils and shown. Safe operation is always stressed. Ask for
|
|
a catalog of available video tapes and books.
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|
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The address for this info is:
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Richard Hull
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TCBOR 7103 Hermitage Rd
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Richmond VA 23338
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_____________________________________________________________________________
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Vanguard Note
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A Superb Paper! Very well written, humorous as well as being highly
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|
informative and safety conscious.
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|
The 2.3 million volt Tesla Coil we used in our shows are posted on KeelyNet
|
|
as ZAP1, ZAP2 and ZAP3.GIF. We no longer have this coil since it was
|
|
leased for experimental and show purposes. The system as pictured had a
|
|
single variac, feeding a pole pig, running off 220VAC. The pole pig fed a
|
|
rotating tungsten spark gap which fed the primary. The coil was tuned to
|
|
170kHZ. For safety purposes, a dead man switch (had to be held closed
|
|
manually to keep power flowing) was used and controlled by the operator.
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|
|
|
Since we ran the high voltage over the body, we took the least chances we
|
|
could for shocks. Only one time was anyone ever 'tingled' and that was me
|
|
when I was doing our ZAP show. I leaned over too far toward the audience
|
|
and a bolt that I was shooting off my fingers, arced around to one of the
|
|
lightning rods....I disengaged, but it was quite a shock at around 900,000
|
|
volts.
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|
|
|
Curious events we noticed during our Tesla coil operation...
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|
|
|
A digital watch still ran fine after being accidentally left on during the
|
|
show in which part of the routine was to allow 900,000 VDC to run over the
|
|
body.
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|
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|
During one demonstration with all the theater lights turned off, I was
|
|
watching the streamers shoot off my fingers and saw small golden yellow
|
|
spheres that were about the size of glowing BBs.
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|
They were randomly shooting from the skin into the bright blue plasma
|
|
stream and could not be seen by Ron or Chuck from the necessary safe
|
|
distance to keep from being hit with a bolt.
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|
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|
We did not know what to make of them. The effect ONLY OCCURRED around
|
|
850KVDC or greater. We tried to photograph the spheres, but could never
|
|
get a good clean shot because of the distance.
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|
|
|
The bolts averaged around 3 to 6 feet at 900,000 depending on humidity and
|
|
other conditions. After much puzzlement, we came to the conclusion that
|
|
the spheres must be glowing sodium, since salt had been sprayed on the
|
|
metal plate on which I stood barefoot.
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|
|
To test this hypothesis, we made absolutely sure there was no outside salt
|
|
introduced and the upper body, arms, hands and props were all cleaned with
|
|
pure water.
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|
|
The glowing spheres still appeared. The other idea was that it was cell
|
|
salts containing sulphur since they glowed yellow. It is a known
|
|
phenomenon that high voltage streaming off the body in this manner can
|
|
electrify and carry matter with it. Perhaps it was dead skin cells.
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|
|
|
The funniest thing we saw was one time when Ron Barker stood on the metal
|
|
plate (5 feet off the floor). You had to wet your feet with salt water to
|
|
increase conductivity, then spray your head and hair with distilled water
|
|
to keep it from catching on fire.
|
|
|
|
Ron did not get his head wet enough and so he was waving his hands around
|
|
as Chuck increased the power to about 800,000 VDC. Since high voltage
|
|
streams most easily off of pointed structures, the fingers are the
|
|
'logical' emitter. However, I have shot it off my knuckles, elbows, nose
|
|
and tongue....they wouldn't let me do the experiment I wanted to do....what
|
|
a picture that would make!
|
|
|
|
Anyway, as Ron moved his hands downward, the top of his head was not wet
|
|
enough and we noticed a major series of bolts shoot out of the crown of his
|
|
head. At the time, we imagined we heard a thwump as a chunk of hair got
|
|
blown off, but we got him down and he was all right. Nothing really
|
|
dangerous, just that it was so unexpected. When the plasma is streaming at
|
|
full velocity, it does cause burns and blackened holes in the skin.
|
|
|
|
We really wanted to duplicate Dr. Nelsons picture as in HARDY1.GIF on
|
|
KeelyNet but using a 2 million volt pyramid instead of the 100,000 volts he
|
|
used. If Mary and Dean Hardy are correct in their idea that such an
|
|
arrangement generates a double helix beacon that is detectable by ET's who
|
|
then come to investigate, we should get a mother ship with a 2 million volt
|
|
coil. We never did get a chance to set up that experiment because we were
|
|
so dog tired from working our 40 hour real time jobs, then doing the
|
|
lighting shows, 3 per day (Mon-Fri) and 5 on Sat and Sun. It will
|
|
definitely be something we want to do at the State Fair of Texas when we
|
|
hit the lotto....
|
|
|
|
Don't read this wrong, we aren't all crazy, just that if you don't try new
|
|
things, you will end up saying, "I could have....". As Bert points out, if
|
|
you decide to do any experimenting with high voltage, be extremely careful.
|
|
Good luck...>>> Jerry
|
|
_____________________________________________________________________________
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