Help needed with Colchester Anilam DRO

Now then Gentlemen (and Ladies)

Being new on the forum I had intended to introduce myself via the appropriate part of the forum. However I find myself in a bit of a pickle and need some advice from those with more knowledge than me.

I own a nice Colchester Master 2500 which has run very happily for the last 8 years or so. I had it wired through a plug and socket which allowed me to swap the power with my grinders. I acquired a changeover switch to make life a little easier and set about installing said switch. The cable from the lathe to the switch contains 4 black wires ie 3 phase and neutral (I'm sure you can all see where this is going) I had all the cable ends labeled but I must have got a phase and neutral crossed. Started the motor, it sounded like a bag of hammers, stopped it very quickly thinking, its running backwards, change two phases. Did that, still the same, then I made the mistake of switching the DRO on to see if that was working. Loud bang and everything in the workshop went off as the RCD tripped.

Net result, blown transformer on the control side and blown fuse and I think it is a capacitor next to the fuse in the DRO box 9blue, about 12mmdia with two wires. The transformer is not a prob as I have located one and sent groats across the airwaves for a new one. My question is does anybody know a) is it a capacitor and b) what value. I have taken a pic but I'm not sure how to post it.

I realise I may have totaled the whole unit but worth an attempt if I can find the right component. Failing that has anybody got a surplus Anilam DRO box off a Colchester

Cheers

Dave Yates

I worked out how to post pics!!

Edited By JasonB on 01/04/2016 12:24:38

Edited By JasonB on 01/04/2016 12:25:00

Dave

That component looks more like a surge/spike arrestor. Depending on the working voltage they can be bought from the likes of CPC.

Cheers

Martin

Have you looked at the fuse on the Anilam ? Little 20mm long thing from distant memory.

If all else fails, I've had excellent help and a rapid turn around on an urgent repair from these guys :-

**LINK**

Nick.

You appear to have stuffed 400 volts across the DRO. The blue thing is a Varistor or VDR by the looks of it, and won't prevent the DRO from firing up.

As Chris says, check all the fuses, and depending on how fast they ruptured you may have got away with a cheap repair, but I somehow doubt it!

Not sure where you are in the world, but we've also had great service from these people: **LINK**

Andy

I agree with Andrew that it looks like a varistor. If the fuse that blew was a small one just feeding this transformer I am surprised that it destroyed the transformer.

Les.

Now then Gentlemen,

Thanks very much for the rapid replies.

Chris

The fuse is toast !!! it exploded and left very small pieces in the holder

Nick

That link looks good, I will contact them this afternoon

Andrew

That is exactly what I have done I will remove the bits from the fuse holder and attempt to clean it out before I do anything. Your link also looks promising (I am in Lincolnshire)

Les

The transformer is the 415 to 110 in the lathe control box that feeds the contactors. I was getting a cross phase dead short and I traced it back to this transformer. When I put the meter across the two 415v input terminals I got a 0 ohms reading I assume from this that the insulation is less than perfect

Thanks again for the help, I will let you know how I get on.

Cheers

Dave Yates

Hi Dave,
When you say 0 ohms how close to zero was it ? (10 ohms, 1 ohm, 0.1 ohm, 0.01 ohms) What sort of physical size or power rating is this transformer ? A large transformer can have quite a low winding resistance. Is this the transformere in the bottom right of your picture ? Do you have a schematic of the wiring that you can post ?

Les.

Les

I tried replying last night from my tablet thingy but it appears to have fled into cyberspace without trace.

The picture is of the inside of the DRO console box showing the fried component. The transformer in question is in the main control box behind the lathe headstock. It is a 50va 415/110v unit that supplies the contactors for the motor, pump and electric brake. The 415v obviously comes from two phases (L1 and L2 I think) with the input disconnected and measuring across the input terminals on every resistance scale on my meter I get 0 ohms, no fractions, no small numbers just a plain 0. I have located a replacement which thanks to the wonders of the internet is on its way to me so I should be up and running again by Tuesday.

The DRO however is another (expensive) kettle of fish. I spoke to Darren at Goodwin Technology via the link kindly supplied by Nick. He reckons that the chances of of retrieval are slim but is willing to have a look. They work on a no fix no fee basis so I have nothing to lose by trying. If fixable they charge #110+vat if not then #245 for a replacement guaranteed for 6 months.

This is a mistake I will not be making again anytime soon.

Once again thanks for all the help it is much appreciated.

Cheers

Dave Yates

Hi Dave,
I can't see how your error could have damaged the 415 to 110 volt transformer. I found a circuit diagram of your lathe on the web and it does not use neutral. I suspect the neutral is only used to feed the DRO with 230 volts. (I expect the DRO is connected between one of the phases and neutral.) I am assuming the picture is the inside of the DRO. I assume that the mains live (One of the phases.) comes in via the fuse that blew (And possibly a switch.) to one side of the transformer primary and the neutral goes directly to the other end of the primary. I also assume that the varistor is directly across the primary. Are these assumptions correct ? I have tried to find a schematic of the DRO on the web but failed. If you gave some rough idea of your location to near some major town (Do not give your address.) then there may be someone who lives near to that could help you.

Les.

Andrew, I have made a note of your link for future reference should I need them. Looking at the phone number they are only about 15 miles from me. I have a Heidenhein DRO with a lazy display on one number that will require sorting one day. The longer I am retired all my old contacts from when I was in engineering are going.

Chris, we've used them on a number of occasions for emergency repairs to industrial PLC's, VFD's, CNC controls etc. and I can't fault the service - they even offer a collect and return service.

No connection other than as a satisfied customer.

Andy

Now then chaps,

Update on the latest situation,

Transformer arrived yesterday (is'nt t'interweb wonderful !!) Installed it after checking resistances etc, held my breath and switched on. Eureaka!!, it works. The motor even ran the right way . DRO console despatched to Goodwin Technology for inspection so just have to wait for the verdict.

Les,

I decided to go with Goodwins as Darren knows exactly what he is talking about and can give a rapid turn round no matter what the result of the inspection, it will be expensive or very expensive !!! Like I said I will not make that mistake again in a hurry. I intend to connect the DRO via a separate 3pin plug to eliminate any possibility of a recurrence.

Cheers

Dave Yates

Further update

DRO is fixed !!! I got a call from Darren at Goodwin technology today. They managed to fix it and it is on its way back as I write. Cost a lot less than the replacement I was braced for. Super chap to deal with, thoroughly recommend the company.

That is a mistake I will not be making again.

Cheers

Dave Yates