Field issues are rare, and when they happen it seems like they come out of nowhere. You look into the matter and find out the problem was with something as simple as a mounting bolt. We at Hill Tech have been examining these issues and providing solutions to keep assemblies and configurations running smoothly without easily avoidable hiccups. Today, we’re examining commonly looked over installation issues with toroidal transformer set ups.
Types of Toroidal Transformer Failures
We recently had a situation that involved toroidal transformer failures, and at first it seemed as if the malfunction was happening at random. When we looked closer, we found that the problem was linked to excessive torque being applied to the center bolt during its assembly.
When using disc-style mounting hardware to install toroidal transformers, it is essential to apply the correct amount of torque. We’ve seen issues arise whenever the installer unintentionally over-tightens the center bolt, especially in designs where the primary winding is made from a thinner gauge wire than the secondary one. With this added pressure, the internal windings can become too compressed. This leads to installation breakdown and, ultimately, a short in the primary.
What makes this especially difficult is that these issues are hard to find. They can start and build up in ways that are easy to miss. The problems might only reveal themselves when the unit is in operation. And these invisible difficulties can create catastrophic problems: if the primary fuse isn’t fast enough to blow, the insulation could completely melt down, creating a massive disaster.
Let Us Help
We at Hill Tech want to avoid invisible issues that build up like this. That’s why we aim to do more than just supply components- we want to inform about best practices, too.
To prevent toroidal transformer failure, we provide them pre-marked with the recommended torque specifications. We can even label the mounting plate with a clearly visible “Do Not Exceed” torque rating. Simple preventative measures can make a massive long-term difference.
If you’re assembling toroidal transformers and want to make sure you’re maintaining precision and care, let us help! We’ll get you set up with the right components and supply options for your design and assembly process.
Contact Us!
Let’s get you set up with the reliable system you need! Contact us today! Visit our website and submit a quote at https://hill-tech.com/, contact us at 847-255-4400, fax us at (847) 255-0192, or email us at sales@hilltech.com. And be sure to look at our social media pages, linked below!
Hill Technical Sales provides expert design and implementation of quality components for Electrical Power Conversion & Distribution, Thermal Management, UV Curing, and High-Speed Industrial Imaging for more information:
Connect with us: 
