Originally Posted by
familyguy
In testing the transformer have you thought about disconnecting everything from the secondary side of the transformer, then connect the primary directly to the mains through a 240v incandescent globe ie the globe is in series with one of the mains leads, before you power it up make sure everything is insulated and securely connected with terminal blocks etc, not crocodile clips or wires twisted together. About 75W or 100W globe should do it, it may come on dimly even if the transformer is good, check each of the taps this way, if the globe lights up full brightness then I'd say the transformer is toast, if the transformer is good you should be able to measure the welding voltage on the secondary side.