When productive capability is on the line, contact Osborne´s Emergency Repair Program immediately! If your production equipment is “off line” you´ll often want to get it back into use as soon as possible. If you need a fast solution, the Osborne Emergency Repair program is your best bet.
Please refer to this simple checklist:
- Do you understand the application well enough to properly describe the problem? If so, please give us a call on our toll free number (800) 229-9410.
- If not, do you have electrical schematics that can be used to help diagnose the problem?
- If you don´t have any information about the application, don´t worry. Osborne will run diagnostic tests on the transformer to determine what it was designed to do, and how. Then we can reproduce the unit, often even re-using some of the same materials from the old unit.
An Osborne reconditioned unit is as good as new, and often has far shorter lead times than buying a replacement unit. Don´t stand for 6 week, or even 2 week lead times on your special replacement transformer. Contact Osborne´s Emergency Repair Program and be back “on line” in days.
Question: Does Osborne perform complete machine diagnosis or repair?
Answer: No. Osborne understands many of your machines, but our business is electromagnetic components. Osborne relies on the services of your skilled technicians and maintenance providers. Osborne will work with your team to help correctly diagnose which aspects of the problem are associated with malfunctioning transformers, inductors, and other electromagnetic components.
Question: How do you to get us back on line in the shortest time possible?
Answer: We maintain a strategic stock of unusual transformer raw materials and components. Occasionally, however, we will need to priority ship specialty materials from our business partners. The sooner you let us know the nature of your problem the sooner we can identify and address potential production bottlenecks. Sometimes we can refurbish components which otherwise have considerable lead times and require special order. Generally, it makes good sense to reuse special components. By reusing these components, Osborne can get your machine on line sooner.
Question: If we don’t have schematics how do we know what the transformer is designed to do?
Answer: With over 75 years of experience working with specialty transformers, we have the capability to reverse engineer a replacement component based upon as analysis of the existing failed component. This diagnostic service is the fastest and most reliable means to replace defective electromagnetic components.
Question: My machine is from Germany (or Japan, Mexico, Italy, etc.) I think the transformer has failed. Can you fix it?
Answer: In nearly every case, yes. We’ve never encountered a transformer that we couldn´t reverse engineer and replace. The chances are very high that Osborne can provide an effective replacement part. The Osborne replacement part will be designed and manufactured with high quality construction techniques and materials. The resulting circuit will very likely surpass the performance of the original equipment.
Question: I know the input and output voltages of the transformer. Why can’t I just order an off-the-shelf transformer from my local electrical distributor?
Answer: If you have complete transformer specifications, these specs will include the input and output voltages, currents, frequency range, dielectric strengths, leakage inductance, phase relationship, core material, insulation materials, conductor construction and inter-connection schemes. Osborne designs and manufactures replacement units to meet the exact requirements of your specific application. Many applications require this level of precise engineering. Other applications do not.
For example, you would want to find an exact replacement for a failed highly-regulated power supply. But you would not worry about finding a highly engineered solution to replace the transformer that steps down your 240 volt source to run your 120 volt, 1/2 horsepower drill press. Please contact Osborne for specific advice regarding the complexity of your damaged equipment. We´ll help determine the specific requirements of your application.
Question: What are the common causes of transformer failures?
Answer: Although it´s difficult to generalize an answer to such a broad question, Osborne suggests that our customers consider the following common causes for transformer failure:
- Compromised ventilation system, eg. restricted air flow in electrical control panel.
- Poor transformer hygiene, eg. cutting fluids, lubricants and other liquid materials should not come in contact with electrical coils.
- Improper circuit protection of load components.
- Increased machine production rates, eg. machine tools are designed for long life at their full load rating. Increasing production rates beyond manufacturers guidelines will shorten the productive life of the machine components.
- Human error can cause a transformer failure due to faulty wiring.
- Failure of a load component such as a rectifier. If a rectifier fails, it will often short circuit a transformer and cause catastrophic damage due to overheating.