Everything started when I set up my new workshop. I always wanted to have an isolation transformer so I decided to make one. I also had some microwave transformer and the case laying around.
Step 1: Why and parts need
What is an isolation transformer?
An isolation transformer is used to protect people from electrical shocks. (http://en.wikipedia.org/wiki/Isolation_transformer)
!!!DANGER!!! Using an isolation transformer
can be very dangerous, because no safety switch is working! Using it is anyoneís own risk!!!
· 2 identical high-quality microwave transformer (high-quality because no name microwaves normally use an aluminum coil.)
· 2 wall plugs
· 7A fuse and fuse holder
· 4A fuse and fuse holder
· 4A thermal fuse
· LCD Volt and ampere meter (ebay: http://www.ebay.com/itm/Digital-AC-80-300V-100A-Blue-LCD-Volt-Amp-Combo-Panel-Meter-Current-Transformer-/310897651039?pt=LH_DefaultDomain_0&hash=item4862f1ad5f)
· 3 switches
· C13 Plug (from broken pc power supply)
· Bridge rectifier
· 10µF 25V capacitor
· 1K resistor (1K works every time J)
· 3mm diffuse LED (color of your choice)
· 3mm LED holder
· Some screws
· Safety plug (to connect an antistatic necklace)
· Zip ties
· Zip tie sockets
· Wire ends
· Shrink tube
· Soldering iron
· Wig welder
· Hot glue gun
Step 2: Take apart Transformer
Take the first transformer and cut the weld with the hacksaw on both side away. Then knob with the hammer to the side of the weld. The bottom should break away and it should look like image 2. Open the vice and bust the coil to the bust. Now take a piece of wood and put it in the middle of the iron core. Now take the hammer (the one on the picture is to small :-) ) and knob on the piece of wood. The coils should go out and you will get the pieces on picture 4 (and a small red coil who is missing on the picture). You will only need the primary coil (the one with the thick wire). Do the same with the second transformer.
Step 3: Reassembly
Now take one of the iron core and mound the red coil in (I forgot it on the pictures). After that take one of the primary coil and put it over the red one. Put the second primary coil over it and fill it with the metal sheet. It should close nice with the iron core. Take the bottom and lay it to the top of the iron core. Press it with two clams together.
Step 4: Weld it together
Stick some insulating tape to the coil to protect it when welding. Weld the bottom to the iron core. Remove the tape.
Step 5: Install transformer and power
I made the case at school so I have no pictures of the manufacturing :-) . Put the transformer in the case and mark the holes of the transformer to the case. Take the transformer out and drill the holes with the dremel. Now put the transformer back in and screw it to the case. Next you have to make a hole for the C13 Plug with the dremel. Install it. Solder wires to the plug.
Step 6: Fuse, switch and PE
Next you have to install the main switch. Mark the holes to the case, drill the holes and install the switch. Solder the wires coming from the plug and two new ones to the switch. Connect one of the new wires to the fuse F1 like in the schematic. After connecting the fuse F1, put the fuse F2 and the thermal fuse 3 in there holes. Also the switches S2 and S3 have to be mounded in there holes. I also connected a safety plug to add a antistatic necklace. Wire them as it is in the schematic.
Step 7: Wire transformer and fuse
Now take the wire from the switch and the one coming from F1 and connect them to the "Primary" coil of the transformer. Add wires to the "secondary" coil and wire fuse F2 with one of these wires. Wire the second side of F2 with one side of F3.
Step 8: Install LED
To power the led I decided to make a small circuit. The circuit takes the 6v AC from the secondary coil and rectify it. I also had this capacitor so I added it to stabilize the power a little bit, so the led isnít flashing. The resistor protects the led from getting over current. Drill a hole through the board and the case and secure the circuit with a screw to the case. Donít forgot a space holder. Connect the transformer and the led to the circuit. Drill a hole over the main switch and mound the led with the led holder.
Step 9: Install LCD
To install the LCD you have to make a cutout with he size of the panel and put it in. Next you have to connect the wire from the transformer and the fuse to the voltage input of the LCD. Connect the current transformer to the current input of the LCD.
Step 10: Wall plugs
Make a hole for the wall plug and mound them in. Now take wires and connect them to the LCDs voltage input, put the current transformer over one of the wires and connect the other side to the wall plug.
Step 11: Tie
Tie the wires together and secure them with Zip tie sockets to the case.
Step 12: Close and measure
Close the case and power it on. Now take a multimeter and measure the voltage between the two connections of the wall plug and the case. There should not be more than a few volts. Now measure the voltage between the two connections of the wall plug. There should be your mains voltage.
Step 13: Use it!!
I use mine when Iím testing and repairing TVís, receivers, radios, power supplyísÖ. But be sure: Microwave transforms arenít made for continuous operation, so donít make everything over it.
Step 14: Future Development
I wrote that Microwave transforms arenít made for continuous operation, so I maybe will install a pt100, a fan and a relay to control the temperature that on a specific temperature the fan turns on and on a higher temperature the relay turns the transformer ofÖ
Thanks for reading my instructable please leave a comment if you have a question.