Trying to figure out all the Mesa cards and stepper drivers for Clausing Kondia

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1 month 4 weeks ago #349229 by Todd Zuercher
I agree with Tommy, transformers don't often fail. At least not without a good reason. This is partly why Tommy was asking about the fusing/circuit breakers. They are there to protect things like the transformer. If someone replaced the correct size fuses with larger ones because the correct ones kept blowing, this can lead to killing the transformer due to overload. There is likely a significant problem somewhere that needs to be identified and corrected first before using a new transformer. Maybe one of the drives has failed, maybe there is a shorted wire somewhere, but something is causing too much current to be drawn.
The following user(s) said Thank You: tommylight

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1 month 4 weeks ago #349233 by tommylight
To add to Todd's list:
-most often and by far the main reason such transformers fail is incorrect wiring, and no i do not mean messing the 3 wire plus ground wiring, i mean the input wiring on such transformers, reason being they all have multiple input voltages that can and should be set by moving metal bars on certain screw posts for certain voltages, giving two failure options:
1. incorrect voltage selection set - when set lower than actual voltage causes higher current draw and subsequent heat, so failure is slow and usually ignored until to late
2. incorrect windings set with the metal bars causing huge current draw and distinct buzzing noise from the transformer, leading to overheating and burning of the windings in a short time.
The thing is, in both cases the machine works, and due to the noises all machines make drowns the transformer noise, leading to failed transformer noticed only when it is to late to do anything about it.
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Personally from experience, that is the first thing i check on any machine with input transformer, seen to many go to waste as local "experts" will never learn that we do not have 3x220V here, we have 3x380V here, only when using neutral we have 220V. It is sickening the amount of transformers and spindles/VFD and servo motors/drives i have seen burned here because of that.

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