In the industrial world, equipment relocation is common, but it often brings unexpected electrical challenges. Recently, we were called to a client site in the Joliet/Channahon area of Will County, Illinois to troubleshoot a Coffing hoist that had suddenly stopped functioning.
The hoist had been operating
for a month following its move to the new facility. However, this new location utilized a 480V Delta corner-grounded system, where L1 to ground measures approximately 277V. After the equipment quit, we were brought in to identify the failure point.
The Investigation: Identifying the Root Cause
Upon opening the hoist casing, the issue was clear: the secondary transformer had burned out. This was particularly surprising because this was the second transformer failure reported on this unit—one we had not originally installed. Coffing hoists are renowned for their rugged reliability and simplified control schemes, making repeated transformer failures highly unusual.
After a thorough inspection, we uncovered the source of the trouble: a marking on the casing indicated the unit was internally wired for 230V, despite being connected to a 480V supply at the new facility.
Resolving the Electrical Mismatch
Operating a 230V-configured control circuit on 480V will inevitably lead to component failure. To resolve this, more than just replacing the transformer is required. The entire control circuit must be reconfigured to match the supply voltage:
Transformer Replacement: We have sourced a new, compatible transformer to replace the damaged unit.
Electric Brake Reconfiguration: A critical step when converting from 230V to 480V is properly rewiring the electric brake assembly.
Solenoid Adjustment: The solenoid must be explicitly rewired from 230V to 480V operation to ensure safe and reliable engagement.
Professional Industrial Electrical Services in Will County
Equipment failure due to improper voltage configuration is a common pitfall during plant relocations. Whether you are dealing with Coffing hoist repairs, industrial motor drive systems, or PLC programming, ensuring your electrical infrastructure is correctly configured for your facility’s power supply is paramount to protecting your investment.
At TGEP, we specialize in building automation and PLC, Motor, controls, HMI, robots etc for clients throughout Joliet, Channahon, and the greater Will County area. If you are planning an equipment move or experiencing recurring failures with your industrial hoists and control systems, our team has the expertise to diagnose and resolve the issue correctly the first time.
We are currently awaiting the replacement transformer and will provide an update once the unit is back in full operation.
Need expert assistance with your industrial equipment? Contact us today at tgeponline.com to discuss your service needs.