I have a National refrigerator which runs on 110 volts . Since the local voltage supply in my country is 220 volts, my refrigerator has been powered by a step down transformer for the last many years and it was working fine. But now the transformer overheats, emits smoke and burns out. I have got it rewound many times but the same problem persists and the transformer burns after a few weeks . What might be the problem?
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Perhaps the fridge is at fault, drawing too much current from the line. That could be from a faulty compressor or defrost heater (more likely) or fan motors (less likely). Best way is to first check if everything is clean (coil outside/below the fridge should be free of all dust and dirt and if the coil inside should be free of any ice) and if the fridge maintains stable temperature. If that is all fine, then you need to load test with an Ammeter to see if the current draw is within the spec (should be on a label at the back or you can look it up online or in the manual). If the current load is too high, then it is most likely the compressor going bad and will need replacement.
You need to determine the actual load from your refrigerator, and compare it to the rating of the transformer. Most step-down transformers that one human being can carry without strain are rated at perhaps as much as 1,000 watts. Which is enough to handle the typical refrigerator while it is running, but not, perhaps, when it starts. A typical refrigerator uses between 700 and 1,100 watts, with a surge of between 1,400 and 2,200 watts when it starts. So if your transformer is marginal, and the unit is running more (summertime) or the door gasket is worn or anything similar, you could be overloading your transformer. You also state you have had it rewound - unless the rewinder uses the proper gauge wire, wrapping material and stabilzes the new windings with the correct varnish and epoxy, a rewind will not begin to last as long as the original. And if he/she shorted you a few coils, you will get the correct ratio - but not enough capacity. Just as a general rule-of-thumb, when it comes to motor-loads such as heavy appliances, if you need to use a step-up/down transformer, it should be rated at least at 200% of the steady-state load of the unit. 250% is better. Good luck with it.
