Remanufacturing of transformers vs repairing

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Transformers are among the expensive assets used by industries in an electrical system. Usually replacement of transformer costs more than transformers repairing services. To compensate the cost, manufacturers bring the option of remanufacturing or restoring the transformers. Remanufacturing of transformers is the replacement of the faulty parts and equipments.

Repairing services offered by suppliers and manufacturers who are designing transformers for distinct customers are having resources, expert personnel, and equipment to instantly get the transformer unit back in service.

How manufacturers commence the process?

Transformer manufacturers start with the assessment of the transformer. They perform various tests and inspection to find all the defects in the unit. Once the defects are recognized, they start fixing them one by one.

They replace your transformer oil if it is very contaminated. They replace any broken part of the unit, and use genuine components made with quality materials. New windings and components are readily available at OEM’s store for installation. You can source these components and install them once the unit is dismantled.

Companies operate the unit throughout their system regardless of the location. Remanufacturing of transformers avoids the failure impact prior its occurrence and expand the lifecycle of the transformer at low cost and time.

Remanufacturing is different from repairing. If you have a transformer and it is not working, you can take it to the manufacturer’s facility. There experts will diagnose the entire unit and perform desired tests to avail the report of the unit. If you want to enhance any functionality, you can do it with the help of experts. This is remanufacturing.

If they just replace the damaged component and install the brand new or well-maintained used component to your unit, this process is known as repairing because they just installed the faulty part to your unit to make it functioning again.

Repairing of transformer includes working on its original electrical, mechanical, and thermal design. Whereas, restoration or remanufacturing is a different thing, you cannot take repairing as a light matter.

Repairing involves, but not limited to rewinding of coils, tap changer work, bushing replacement, re-gasket, install relays, etc.

Remanufacturing is a change to a unit’s electrical, mechanical, and thermal design. It includes, but not limited to re-designing of the coils to enhance kV, MVA, core modifications, etc.

For more updates on transformers repairing and remanufacturing, you can ask the manufacturers and suppliers online. They will share extra information about the subject.

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How to Perform Step down Transformer Lamp Repairing

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There are manufacturers across the world offering premium transformers repairing services. This post is about repairing the lamp of step down transformer at your own. This project will require the components of the lamp- bulb, transformer, and base. Apart from this, you will also require a soldering iron, power strip, and a little multipurpose tool used by technicians.

What’s inside the black box?

One of the lacking of the design of transformer lamp is the remote transformer inside a plastic box. The transformer is placed halfway between the ends of a power cord i.e. approx. 6 ft long. Transformer is a heavy component that the manufacturing company might have had a better design with reliable packaging. When the plastic case was unboxed, experts observed:

  • Damaged plastic black case
  • Step down coil with magnetic core
  • Fractured output connector
  • Primary side coil hardwired to AC power cord

Steps to Follow:

  1. Remove the potting material and access the leads of the primary side coil

Electrical component manufacturers rapidly pot their products with non-conductive material. This offers robustness to the product and make it safer for consumer. Electrical devices are built with sensitive components and with potting, manufacturers make them immobilize. This further helps them in making the device more robust and resistant to mechanical shock and abrasion.

High voltages can be a safety hazard, so potting material’s electrical isolation property prevents accidental electrical short circuits that can result in fire incident, fatalities, or injuries.

  1. Reconnecting the primary winding leads to the AC power cord

This is an additional step included in the troubleshooting process as the soldered connections may have been damaged by first step. Regardless of the time when leads were damaged or distorted, the connections were broken when inspected without potting material across the primary winding.

  1. Apply power to the transformer and check proper operation

Output Connector Story

Inspection of the lamp’s transformer revealed the damaged done to the output connector. However, when you see from the outside, you won’t find any disorder, but initially the connector has been fractured. This makes transformer unable to perform and function properly. You can hire some technicians if you are unable to perform Transformers Repairing job your own.

Royal Transformers is offering qualified engineers assistance to help you in repairing transformers and their critical components. They can also help in restoring your transformer. Connect with them to avail more details.