How to Repair a Broken Electric Coil

A close up on an electric coil.
  • 3 hours
  • Advanced
  • 25
What You'll Need
Copper wire
Hot melt glue
Electrical tape
Working gloves

Most electrical systems including power transformers, electrical circuits, and electrical connection terminals use electrical coils. Electrical coils are usually wrapped with insulating tape or coated with varnish to provide insulation. To secure them in place, electric coils are often held together by electrical tapes and placed in secured housing. Although most types of electrical coils are very durable and can last for a long time, they need repairs and rewinding from time to time. If you have a broken electrical coil at home, you need not spend a lot of money on its replacement. Just repair the electrical coil to save some money. To repair your electrical coil, here is what you should do.

Step 1 - Determine the Problem

Before doing repairs on the electrical coil, you need to properly diagnose the problem first. To do this, open the housing of the electrical coil and check the coils for signs of wear and tear, dust, grime, and corrosion on the coil or on the housing. If the electrical coil is physically damaged, you have to replace it. On the other hand, if the electrical coil is physically intact, it may still work well after a repair so get your tools ready to rewind the coil.

Step 2 - Remove the Housing to Reveal the Electric Coil

To get to the electric coil, you need to remove the coil housing. To do this, remove the screws that are holding the housing together then open the housing using the tip of your screwdriver.

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Step 3 - Note the Position and Configuration of the Coils

Once the housing is open, note the position and the configuration of the coil by taking photographs or take a video of the deconstruction process so that it will be easier for you to recreate the original winding patterns of the coil. Note the rewinding electrical coil is a very precise job so you need to know the exact position and configuration of the coil.

Step 4 - Remove the Wire from the Tabs

Carefully remove the wire completely from the tabs on the brush pads. Count the number of winds in each coil as you remove the wire. Be careful not to bend the taps too much when removing the wires to avoid damaging them. After removing the wire, cut the coils of the wind at the top of the armature.

Step 5 - Check the Insulation

Before rewinding the wire, check the insulation. Repair burned or damaged insulation using insulating tape.

Step 6 - Rewind the Coil

Using the same gauge and type of magnet wire that was on the original electric coil, rewind the electrical coil carefully back to its original position. On your first wind, leave the end of the wire loose on the tab. When winding the wire, make sure that you follow the exact winding patterns and number of winds as the original. To complete the job, connect the end of the last winding to the loose end of the first wind.

Step 7 - Reassemble the Coil Housing

After rewinding the coil, reassemble the housing and replace the screws that you removed earlier.

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