"Jamie" wrote in message ...

something smells funny here. If You disconnected the load on the secondary
side and you are still getting heat on the secondary side? Something is
not correct.

No, I don't actually know which side the heat is on. I see smoke coming
from the transformer but it takes it 20 seconds or more to start and I can't
tell which winding it's coming from. The way it's setup, there is nothing
actually loading the transformer until you pull the trigger to start the
saw. When I first turned power on with the new transformer I measured input
and output voltages on the transformer and all looked good so I pulled the
trigger and the saw came on. I ran it 5 seconds or so and released the
trigger. A few seconds later I noticed a smell so I shut it down and looked
for obvious problems. I turned power back on and didn't pull the trigger
but the smoke came back after 20 to 30 seconds.

Going by memory, you stated you had 2 primaries that allows you to wire
for 120 or 240 on the input, that being the case you should have an
order of H1 H2 H3 H4 in your case, L1 = H1, H2+H3, L2/L3 = H4; in other
words, you use both primary windings but in series. If that was a 120 volt
source it would be L1 = H1+H3, L2/L3= H2+H4

Correct, it's wired in series and the output is correct so I'm fairly
certain I have it wired correctly.

Also, it may sound stupid however, make sure you do have the ground as the
ground on the plug coming in and no legs are grounded in the shop.

I'll check it but the saw has been working in the shop for over a year
without any problems until this incident.

If you knew how many times this kind of stupid error happen with
extension cords and equipment cords being missed wired like this, hot
attached to ground etc., you'd be shocked.

Oh no I wouldn't. :-D I've seen plenty of it myself. In fact, my home had
some outlets with the neutral on the wrong prong and a few other very
strange quirks when I moved in. The previous owner worked for a large,
national home improvement company and thought he knew how to wire, among
other things! You wouldn't believe some of the simple things he screwed
up!! He even ran 2 wires overhead to feed power from the house to the
garage and swapped neutral and ground on the feed lines so that everything
in the garage was backwards. And didn't even run a ground because most of
the outlets in the house are old 2-wire.