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DC injection braking and a burned out transformer

I have been fettling a lathe which was fitted with DC injection braking. I was a bit unsure about the condition of the components in an enclosure on the back, but having looked up a bit about motor control circuits and having learned about ladder diagrams, I have satisfied myself that I know what has happened.


At some stage, a transformer (240/130V) has burned out. That leaves two questions: (1) why? and (2) what is the spec of the old one?


The horizontal surfaces of the enclosure and its contents have been covered by a thin brown layer, which I assume is vapourised enamel from the transformer windings, but there is no evidence of any further damage.


Father taught me never to replace a fuse without finding the fault which blew it. Along the same lines, I want to be satisfied that none of the other components has caused a short circuit. However, it appears that it is the primary which has overheated. So my first question is what would happen if the secondary of a transformer is shorted. Would it be fried? Woud the primary be fried? Or would both be fried?


My second difficulty is determining the spec of the transformer. The circuit diagram has "N" and "240" on the primary side, and "Z" and "130" on the secondary side. I assume that this means that the secondary provides 130 V, which after rectification, is fed to the motor. The problem is that there are no markings on the transformer. The manufacturer of the unit ceased trading 10+ years ago, so no help there. The motor plate specifies 6.4/3.7 A. The transformer wires (both sides) are about 4.2 sqmm CSA so good for 3 - 5 A (?). Based on a weight of 4.0 kg and the transformer's dimensions, and comparing them with current models; I am guessing that a 320 VA transformer is required. My second question is whether my above reasoning is sound.


Before anybody else says it, yes, I think that I could get a modern module which will do the job, but isn't it more satisfying to fix rather than replace?

eabde54935c495ab8feb4fb009758b5e-huge-20190425transformer.jpg

Parents
  • There are too many wires in that photo vs your description - where do they all go ?




    for double wound design, for a toroid 4 kg is about 400-500watts at 50Hz, for a conventional core like this, more like 250VA-300, so your estimates are about right, except, that would only be an amp at 230V or two (115V) in the windings, which does not match your observation about wire size.  Therefore  is it possible it could be an auto transformer rather than double wound ?  I know it has failed, but have you tried with a meter to see how do the windings meggar up - are primarily and secondary isolated? Or are these just short tails of multi-strand, that are sized for mechanical reasons, and the windings are actually in something much thinner.?


    If it is for the motor, then perhaps someone has stalled the motor in the past.
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  • There are too many wires in that photo vs your description - where do they all go ?




    for double wound design, for a toroid 4 kg is about 400-500watts at 50Hz, for a conventional core like this, more like 250VA-300, so your estimates are about right, except, that would only be an amp at 230V or two (115V) in the windings, which does not match your observation about wire size.  Therefore  is it possible it could be an auto transformer rather than double wound ?  I know it has failed, but have you tried with a meter to see how do the windings meggar up - are primarily and secondary isolated? Or are these just short tails of multi-strand, that are sized for mechanical reasons, and the windings are actually in something much thinner.?


    If it is for the motor, then perhaps someone has stalled the motor in the past.
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