I am not an expert in transformer design, but I echo Joe's recommendation that you get your transformer tested. Here are some tests I found on the Internet:
1. Winding resistance test.
2. Transformer ratio test.
3. Measurement of insulation resistance.
4. Dielectric tests of the transformer.
The transformer winding resistances can be measured by
current voltage method. In this method of measurement of winding resistance, the test current is injected into the winding and corresponding voltage drop across the winding is measured. By applying simple
Ohm’s law i.e. Rx = V ⁄ I, one can easily determine the value of resistance.
The procedure of the transformer ratio test is simple. Just apply power to the primary winding, with keeping secondary winding open. We measure the induced voltages at primary and secondary terminals of the transformer to find out actual voltage ratio of the transformer.
Insulation resistance measurement steps:
- Disconnect all the primary and secondary terminals of the transformer
- Megger one of the leads to primary and one of the leads to secondary to measure insulation resistance in between the primary and secondary windings
- Megger leads to primary and transformer earth point to measure insulation resistance in between the primary windings and earth
- Megger leads to secondary and transformer earth point to measure insulation resistance in between the secondary windings and earth
Dielectric test can be done by the Separate Source Voltage Withstand Test:
- The terminals of the primary winding are connected together.
- The terminals of the secondary winding are connected together and also the frame of the transformer are connected to earth.
- Then a 60 cycle 120 Volt source is applied for 60 seconds across the terminals of the primary winding and earth.
- The test is successful if no break down in the dielectric of the insulation occurs during test.
Thoughts?