how to maintenance and repair the contact variac regulator

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How to Maintenance and Repair The Contact Variac Regulator?

Contact variac regulator belongs to a small type of power supply machine with capacity 0.2kva,0.5kva, 1kva, ect. and adjustable output voltage 0-250v. This machine is widely applied in theelectrical experiment, electronic circuit experiment, ect. in the basic laboratory. The variac regulatorfailure rate is very high because of the production quality, voltage regulating mode, and student’sfrequent voltage regulating. However, essentially the majority of failures is caused by improper useand maintenance. Therefore, the maintenance and repair is very important. This article below isabout the analysis of the failures in maintenance and providing maintenance measures.

The structure theory of variac regulator

The auto coil of variac regulator is a coil of enameled wire tightly wound in the annular iron core.The coils are glued and fastened by insulating varnish, so the coils are insulated to each other. Thecircuit diagram as below. 220v AC electricity is input through the “a” terminal and “b” terminal andoutput through the “c” terminal and “d” terminal, and “c” is the carbon brush touch point. It can beseen from the diagram that the carbon brush is contacting the polished surface of winding coils.Users can get the different voltages from 0v to 250v by means of moving the carbon brushcontacting point.

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The failures of variac regulator

1. Poor contact of carbon brush

One possible cause is the carbon brush lead wire break-off or solder joint off due to long timeusage. Just to reconnect and solder the wire, and the problem can be solved. The other possiblecause is the screw loose between the rotating arm and the machine spin axis. In this condition, thespin axis spring will jack up the rotating arm, and the carbon brush cannot contact the winding coilsvery well to give output voltage. In order to solve this problem, we need to reset the rotating arm tothe appropriate location and tighten the screw.

It is found in repair that poor contact is usually caused by the situation that the small spring pressingthe carbon brush lost the elasticity because of over heat. And this is bad result of the lack of longtime machine maintenance. There is a circular-arc-shaped screw fixed stop dog between the zero



potential and the highest potential of the variac regulator auto winding coil. The function of the stopdog is to ensure that the carbon brush is moving always between “e” and “f”. It is very common thatthe stop dog gets loose and dislocated after long time use without maintenance.

But the consequences can be very serious. There is some current in the circuit when the machine isworking with loading, and it equals to breaking off the loading if the carbon brush is movingbeyond the highest potential, but the current in the conductance coil cannot change abruptly, whichwill inevitably result in arch discharging between the carbon brush and coil ends and very hightemperature. Gradually the spring will lose elasticity and even the end coil gets burnt.

To solve this problem, it is needed to stick the stop dog with insulation tape firstly, and then fix it withscrew to avoid dislocation or loosen-up. This will make sure that the carbon brush can not movebeyond the winding ends. Also, the broken spring must be changed and the burnt winding must berenewed.

2. Part coils of the winding get burnt

The burning of part coils is caused by the machine production quality, that’s to say, there is “wirejumping” on the sliding surface of winding. And this will lead to larger voltage difference betweenthe adjacent two coils. When the carbon brush passes the “wire jumping” point, there will be asudden change for the machine output voltage. The “wire jumping” point is not the usual workingplace for carbon brush, therefore there is not big influence for the machine normal performance ascarbon brush passes it very quickly.

However, if the output voltage requires the carbon brush to stay at the “wire jumping” point for along time, the machine failure is inevitable. This is because the voltage difference is large betweenthe adjacent two coils, and there will be a large short-circuit current when carbon brush contactsthese two coils. Consequently, the part coils will get heated, and copper loss gets bigger, thetemperature becomes higher then to form a vicious circle. In the course of time, the coils must getburnt.

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As for this problem, we need to remove the burnt coils and replace with the same size varnished wire,and no more “wire jumping”. And then stick and fasten the coils with insulating varnish, and polish thesliding surface.

3. The maintenance and repair of contact variac regulator

After long time of using there will be a lot of dust and carbon left inside and outside of the machine,which can make the machine get higher temperature to cause failure. Thus, it is very necessary totake periodical maintenance and repair in the later period.

a) When taking maintenance or repair, firstly we should open the shell and dismantle all the

parts to place them by sort.

b) Wipe off the dust and carbon on the coils alcohol cotton ball.

c) Clean every corner.

d) Rub down the carbon brush that gets wider due to abrasion with a fine grade sandpaper,

and re-install it for usage. Or change a new carbon brush if it is too broken for using.

e) Repair and maintain the rough sliding surface to make sure the carbon brush can move

smoothly.

f) Check if the lead wire screws are loose, and if the lead wire is tipping off.

Also it is needed to take precaution measurements for the potential problems. Only by this can themachine ensure the lifetime, and the experiments be conducted plainly.

how to maintenance and repair the contact variac regulator

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