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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

  • mapj1:

    Glad you have restored it to operation, though it sounds like a bit of a beast, perhaps, given they could not draw a bridge rectifier correctly, the maker's datasheet was muddied with figures for a larger model. Thinking in terms of not cooking things, what stops the DC flowing  when it is all stationary and  no longer needed ?




    Mike, thank you for your typically helpful contribution.


    This was the company's only lathe which was fitted with DIB. Unfortunately, they went out of business 10 years ago, so no help available there.


    A series of contactors ensure that the brake cannot be applied when the motor is drawing power, but that it is applied when the motor is switched off. Then there is a device which allows the braking current to flow for up to 20 seconds (I have it set to 2 sec) after which there is the reassuring clunk of a contactor opening.


    It would be useful to know what happened in the past. I am a bit concerned by the motor. Sometimes it runs reasonably smoothly, sometimes it vibrates, and sometimes it has intermittent brief judders. I have replaced the bearings so I wonder whether the windings have deteriorated. Or could it perhaps be the variable speed drive?

Reply

  • mapj1:

    Glad you have restored it to operation, though it sounds like a bit of a beast, perhaps, given they could not draw a bridge rectifier correctly, the maker's datasheet was muddied with figures for a larger model. Thinking in terms of not cooking things, what stops the DC flowing  when it is all stationary and  no longer needed ?




    Mike, thank you for your typically helpful contribution.


    This was the company's only lathe which was fitted with DIB. Unfortunately, they went out of business 10 years ago, so no help available there.


    A series of contactors ensure that the brake cannot be applied when the motor is drawing power, but that it is applied when the motor is switched off. Then there is a device which allows the braking current to flow for up to 20 seconds (I have it set to 2 sec) after which there is the reassuring clunk of a contactor opening.


    It would be useful to know what happened in the past. I am a bit concerned by the motor. Sometimes it runs reasonably smoothly, sometimes it vibrates, and sometimes it has intermittent brief judders. I have replaced the bearings so I wonder whether the windings have deteriorated. Or could it perhaps be the variable speed drive?

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