110v Tool Transformer exploded

Problem

We regularly work on American appliances which require 110-120v.

For this purpose we have a 110 V tool transformer to step down from our 220v supply.

While testing a 110v furnace/oven type machine, the 110v transformer suddenly and spectacularly failed.

Diagnosis

When I removed the lid of the transformer, I found the cause was very visible. A butt crimp connection was used inside to join the flexible neutral wire to the solid copper transformer winding.

This connection was making poor contact and had obviously increased in resistance to the point of burning. I expect this was a rapid demise brought on by years of thermal cycles.

Solution

Replacing the connection with a non insulated crimp and heat shrink tube to cover, I was able to solder the crimp to the solid winding and crimp the neutral wire into the other side of the crimp.

This transformer still gets regular use.

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