Transformer is an isolated 30kva 60hz 480 delta H.V. - 240 delta L.V. ungrounded. Machine requirements are 230 volt 23kva 60hz. Controls and controller are supplied by smaller transformers inside the machine. All voltage readings are within 5% of required. When the controller is replaced it is sent back to the manufacturer to be refurbished.
Trainwire,
you are correct, it has a lot of contactors and limit switches which makes for a lot of potential problems. This area was checked out quite extensively and a few questionable components were replaced. this corrected some of our other more minor glitches but the main problem remains.
Also another thing which just started happening more frequently is that for no apparent reason the operating software corrupts and becomes totally unusable till it is reinstalled. this happened to 2 different controllers in 2 days.
To my original question about turning the machine on and off with the transformer disconnect, This is no longer being done this way since the last new controller was installed. But the problems persist.
