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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

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  • Epilogue


    Spoke too soon!


    I managed to find a replacement motor on good old fleabay, but it didn't solve the problem so there was no alternative but to replace the VSD. With a bit of ingenuity and some changes in the control circuitry, I fitted an Eaton DE11 into the old enclosure and preserved the original controls. What a difference! The motor is now very much quieter. The learning point here is had I known how quiet it should be, I would have realised that something was amiss. (I had a similar experience with an old Rolls-Royce, but that is another story.)


    The only thing that I need to do now is to set the parameters for min and max speeds. Min = 0 is fine, but at very slow speeds it wouldn't take the skin off a rice pudding, or at least I can stop the spindle by grabbing hold of it. Problem is that I need to buy some proprietary hardware, either to set the parameters directly, or by their software which is available for nothing. Unless of course somebody in here knows how to speak to these devices (via the RJ45 socket and what is described as "The internal RS485 interface transmits Modbus RTU and for DE11... devices as well CANopen).


    P.S. Injection brake is working well, although this device could do it too!
Reply
  • Epilogue


    Spoke too soon!


    I managed to find a replacement motor on good old fleabay, but it didn't solve the problem so there was no alternative but to replace the VSD. With a bit of ingenuity and some changes in the control circuitry, I fitted an Eaton DE11 into the old enclosure and preserved the original controls. What a difference! The motor is now very much quieter. The learning point here is had I known how quiet it should be, I would have realised that something was amiss. (I had a similar experience with an old Rolls-Royce, but that is another story.)


    The only thing that I need to do now is to set the parameters for min and max speeds. Min = 0 is fine, but at very slow speeds it wouldn't take the skin off a rice pudding, or at least I can stop the spindle by grabbing hold of it. Problem is that I need to buy some proprietary hardware, either to set the parameters directly, or by their software which is available for nothing. Unless of course somebody in here knows how to speak to these devices (via the RJ45 socket and what is described as "The internal RS485 interface transmits Modbus RTU and for DE11... devices as well CANopen).


    P.S. Injection brake is working well, although this device could do it too!
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