Low Voltage Transformers

Aluminum vs Copper
Aluminum is the predominant
winding material in
transformers 15kVA or larger.
Issues such as
incompatibility with copper
line and load cables,
reliability, higher hot-spot
temperatures, and higher
losses are not applicable to
low-voltage, dry-type
transformers.

CODE: NEC Article 450

Overcurrent Protection: Article 450.4, Table 450.3B (see below)
Note: Protection is for the transformer, not the conductors. Conductors are protected
per Article 240.21(C)
Secondary
Protection

Primary Protection
Protection Method

FLA>9A

FLA<9A

FLA<2A

FLA>9A

FLA<9A

125%
167%
300%
N/A
N/A
Primary only
250%
250%
250%
125%
167%
Prim. & Sec.
Note: Protection is for the transformer, not the conductors. Conductors are protected per Article 240.21(C) If 125% does not correspond to standard rating,
the next size up shall apply for 125% only.

Secondary overcurrent protection is not required if requirements are met for Article 240.21 (for common
applications , see sections.(B)(3), (C)(2) and (C)(6).)See diagram
Grounding: Per Article 450.6 (C), Transformers are separately derives systems, and should be grounded per
Article 250.30. Grounding Electrode conductor sized per Table 250.66. Non-current-carrying metal shall be
grounded per 450.10.
Specific provisions (Dry Type), Article 450.21: Transformers 112.5 kVA or less shall have 12 separation from
combustible materials. Transformers over 112.5 kVA must be installed in a room with a 1 hour fire rating.
K-Factor Transformers
-K-Factor transformer coils are designed to minimize stray losses and
reduce core losses, and have a neutral sized at 200% of the rated
current feeders.
-UL 1561 defines standard K-factor ratings of 4,9,13,20,30,40, and 50,
where higher ratings provide greater non-linear load handling common
with electronic loads. Standard ratings are 4,13 and 20.
- The K-factor of a transformer is calculated per IEEE 1100 (The emerald
book pages 93-96)

Transformer Insulation Class and Winding Temperature-Rise Data

- Class 220 150C rise transformers (if ambient temp is 40C, then the
average temp the insulation will be exposed to is190C but no greater
than 220C.
- Class 220 115C rise transformers can carry 15% continuous overload
without exceeding 150C rise above ambient temp.
- Class 220 80C rise transformers can carry 30% continuous overload
without exceeding 150C rise above ambient temp.
To increase transformer life and to provide for overloads during
emergency, 115C and 80C may be specified. They have larger
conductors, lower heat dissipation, and reduced noise but are larger in
size and weight.

Sound Levels
Low sound-level transformers can be expected to have longer, more
trouble free lives, but cost more and are heavier.
Maximum sound ratings per NEMA ST 20
1. 0-9kVA: 40dB
2. 10-50kVA: 45dB
3. 51-150kVA: 50dB
4. 151-300kVA: 55dB
5. 301-500kVA: 60dB
For critical sound-level applications, consult manufacturers about
available options for sound mitigation. Manufacturers can perform tests
on production units at an additional cost.

Where
Ih(pu) is the rms current at harmonic h, in per unit of rated load current of
the transformer.
h is the harmonic order
An example calculation is at the right. As long as the transformers rated
K-factor is greater than the calculated K-factor of the load, the
transformer is in compliance with the NEC.

Harmonic
Order h

Nonlinear
Load
Current
Ih(%)

Ih2

Ih(pu)=
sqrt(Ih2/sum(Ih2))

Ih(pu)2

Ih(pu)2 x h2

100

1.000

0.913

0.833

0.833

33

0.109

0.301

0.091

0.817

20

0.040

0.183

0.033

0.833

14

0.020

0.128

0.016

0.800

11

0.012

0.100

0.010

0.817

11

0.008

0.082

0.007

0.817

13

0.006

0.073

0.005

0.901

15

0.005

0.064

0.004

0.919

1.000

6.737

K-factor

6.737

Total

1.200

Energy Efficiency
Surveys show average transformer is loaded to 35%. NEMA TP-1
specifies minimum efficiency at this load level. Energy efficient
transformers perform better at this load loading level, but become less
efficient than 115C and 80C at loadings above 35%.

Mounting
Transformers 75kVA or less shall be suitable for wall, floor, or trapeze
mounting.

TRANSFORMER FULL LOAD CURRENT

Transformer Short Circuit Data (Bussman)

Voltag
e&
Phase

Transformers larger than 75kVA shall be suitable for floor or trapeze

mounting.

KVA
25
37.5

FLA
104
156

%Z
1.5
1.5

Short
Circuit
Amps
12175
18018

50

208

1.5

23706

75
100
167

313
417
696

1.5
1.6
1.6

34639
42472
66644

45
75
112.5
150
225

125
208
312
416
625

1
1
1.11
1.07
1.12

13879
23132
31259
43237
61960

300
500
750

833
1388
2082

1.11
1.24
3.5

83357
124364
66091

1000
1500
2000
2500
75

2776
4164
5552
6940
90

3.5
3.5
4
4
1

88121
132181
154211
162764
10035

112.5

135

15053

150
225

181
271

1.2
1.2

16726
25088

300
500
750
1000
1500

361
602
903
1204
1806

1.2
1.3
3.5
3.5
3.5

33451
51463
28672
38230
57345

2000
2500

2408
3011

4
4

66902
83628

120/
240
1 phase

If installing transformers in areas where seismic events may occur,

consider the following
-Transformers mounted directly to the building structure must be
attached rigidly and with enough strength to resist seismic forces.
-Transformers suspended with rod hangers must have supports that can
resist lateral seismic forces and the secondary buckling of vertical
supports that can result from lateral seismic forces.
-Unless rigidly attached to its base, or mounted to resist vertical and
horizontal forces, a transformer core assembly may detach from its
housing during a seismic event.

120/
208
3 phase

The manufacturers functional performance certification assumes that the

equipment is rigidly anchord to the building support system. Design of
the support system requires that detailed dimensional data, weights, the
location of the center of gravity, and mounting provisions be available.
Concrete strength, anchor-bolt type and location , and anchor installation
and testing are critical components of seismic-restraint systems.

120/
208
3 phase

Shielded Isolation Transformers

- Transformers shall include full width copper electrostatic shield with
ground wire to suppress high frequency signals and electrical
disturbances from being transmitted to the load circuits on the secondary
side of the transformer.
- Often specified for electronic equipment sensitive to radio frequency
interference.
- Shielding can be specified for K-factor and harmonic canceling
transformers.

KVA SINGLE PHASE KVA THREE PHASE

120V 240V 480V 600V

208V 240V 480V 600V

8.33 4.17 2.08 1.67

8.33 7.22 3.61 2.89

1.5

12.5 6.25 3.13 2.50

16.7 14.4 7.22 5.77

16.7 8.33 4.17 3.33

25.0 21.7 10.8 8.66

25.0 12.5 6.25 5.00

15

41.6 36.1 18.0 14.4

41.7 20.8 10.4 8.33

20

55.5 48.1 24.1 19.2

7.5

62.5 31.3 15.6 12.5

30

83.3 72.2 36.1 28.9

10

83.3 41.7 20.8 16.7

45

125 108 54.1 43.3

15

125 62.5 31.3 25.0

75

208 180 90.2 72.2

25

208 104 52.1 41.7 100

278 241 120 96.2

37.5 313 156 78.1 62.5 112.5 312 271 135 108
50

417 208 104 83.3 150

416 361 180 144

75

625 313 156 125

225

625 541 271 217

100

833 417 208 167

300

833 722 361 289

167 1392 696 348 278

500 1388 1203 601 481

480:208Y/120V THREE PHASE TRANSFORMERS

PRIMARY (480V)
KVA
RATING

FLA

PRI
BKR

COPPER CONDUCTORS

SECONDARY (208Y/120V)
ALUMINUM CONDUCTORS
FLA

WIRE (75C)

CONDUIT

WIRE

CONDUIT

SEC
BKR

COPPER CONDUCTORS

ALUMINUM CONDUCTORS

WIRE

CONDUIT

GEC

WIRE

CONDUIT

GEC

PANEL
BUS

15

(3)#12, #12G

1/2"

(3)#12, #12G

1/2"

15

(4)#12,#8G

1/2"

#8

(4)#12,#6G

1/2"

#6

60

15

(3)#12, #12G

1/2"

(3)#12, #12G

1/2"

17

25

(4)#10,#8G

3/4"

#8

(4)#10,#6G

3/4"

#6

60

11

20

(3)#12, #12G

1/2"

(3)#10, #10G

1/2"

25

35

(4)#8,#8G

3/4"

#8

(4)#8,#6G

3/4"

#6

60

15

18

30

(3)#10, #10G

1/2"

(3)#8, #8G

3/4"

42

60

(4)#6,#8G

1"

#8

(4)#6,#6G

1"

#6

100

30

36

50

(3)#8, #10G

3/4"

(3)#6, #8G

3/4"

83

100

(4)#2,#8G

1-1/2"

#8

(4)#1,#4G

1-1/2"

#4

100

45

54

70

(3)#4, #8G

1"

(3)#2, #6G

1-1/4"

125

150

(4)#1/0,#6G

1-1/2"

#6

(4)#3/0,#2G

2"

#2

225

75

90

125

(3)#1, #6G

1-1/2"

(3)#2/0, #4G

2"

208

225

(4)#4/0,#2G

2-1/2"

#2

(4)300kcmil,#1/0G

3"

#1/0

225

112.5

135

175

(3)#2/0, #6G

2"

(3)#4/0, #6G

2"

312

400

(4)500kcmil,#1/0G

3-1/2"

#1/0

(2) Sets (4)250kcmil, #3/0G

(2) 3"

#3/0

400

150

180

225

(3)#4/0, #4G

2"

(3)#300kcmil, #2G

2-1/2"

416

500

(2) Sets (4)250kcmil, #1/0G

(2) 2-1/2"

#1/0

(2) Sets (4)350kcmil, #3/0G

(2) 3"

#3/0

600

225

271

350

(3)500kcmil, #2G

3"

(2) Sets (3)#4/0, #1G

(2) 2"

625

800

(2) Sets (4)500kcmil, #2/0G

(2) 3-1/2"

#2/0

(3) Sets (4)400kcmil, #4/0G

(3) 3-1/2"

#4/0

800

300

361

500

(2) 3"

833

1000

(3) Sets (4)300kcmil, #3/0G

(3) 3"

#3/0

(4) Sets (4)350kcmil, #4/0G

(4) 3"

#4/0

1200

500

601

800

(2) 3"

1388

1800

(5) Sets (4)500kcmil,

350kcmil G

(5) 3-1/2"

#3/0

(5) Sets (4)600kcmil,

450kcmil G

(5) 4"

250kcmil

2000

(2) Sets (3)250kcmil,

#2G
(2) Sets (3)600kcmil,
#1/0G

(2) 2-1/2"
(1) 3-1/2"

(2) Sets (3)350kcmil,

#1/0G
(3) Sets (3)400kcmil,
#3/0G

Note: Secondary feeder schedule only applies if neutral is bonded to ground at the transformer. If Neutral is bonded to ground at transformers first disconnecting means, then standard feeder
schedules apply
480:208Y/120V THREE PHASE TRANSFORMERS K-RATED
PRIMARY (480V)
KVA
RATING

FLA

PRI
BKR

COPPER CONDUCTORS

SECONDARY (208Y/120V)
ALUMINUM CONDUCTORS
FLA

WIRE (75C)

CONDUIT

WIRE

CONDUIT

SEC
BKR

COPPER CONDUCTORS

ALUMINUM CONDUCTORS

WIRE

CONDUIT

GEC

WIRE

CONDUIT

GEC

PANEL
BUS

15

(3)#12, #12G

1/2"

(3)#12, #12G

1/2"

15

(3)#12,#8N,#8G

1/2"

#8

(3)#12,#8N,#6G

3/4"

#6

60

15

(3)#12, #12G

1/2"

(3)#12, #12G

1/2"

17

25

(3)#10,#6N,#8G

3/4"

#8

(3)#10,#6N,#6G

3/4"

#6

60

11

20

(3)#12, #12G

1/2"

(3)#10, #10G

1/2"

25

35

(3)#8,#4N,#8G

1"

#8

(3)#8,#2N,#6G

1"

#6

60

15

18

30

(3)#10, #10G

1/2"

(3)#8, #8G

3/4"

42

60

(3)#6,#1N,#8G

1-1/4"

#8

(3)#4,#2/0N,#6G

1-1/4"

#6

100

30

36

50

(3)#6, #8G

3/4"

(3)#4, #8G

3/4"

83

100

(3)#2,#2/0N,#8G

1-1/2"

#8

(5)#1/0,#4G

2"

#4

100

45

54

70

(3)#2, #6G

1-1/4"

(3)#2, #6G

1-1/4"

125

150

(5)#1/0,#6G

2"

#6

(5)#4/0,#2G

2-1/2"

#2

225

75

90

125

(3)#1, #6G

1-1/2"

(3)#2/0, #4G

2"

208

225

(5)#4/0,#2G

2-1/2"

#2

(5)350kcml,#1/0G

3"

#1/0

225

112.5

135

175

(3)#2/0, #6G

2"

(3)#4/0, #6G

2"

312

400

(5)600kcmil,#1/0G

4"

#1/0

(2) Sets (5)300kcmil,#3/0G

(2) 3"

#3/0

400

150

180

225

(3)#4/0, #4G

2"

(3)#350kcmil, #2G

2-1/2"

416

500

(2) Sets (5)250kcmil, #1/0G

(2) 3"

#1/0

(2) Sets (5)500kcmil, #4/0G

(2) 4"

#3/0

600

225

271

350

(3)500kcmil, #2G

3"

(2) Sets (3)#4/0, #1G

(2) 2"

625

800

(2) Sets (5)600kcmil, #3/0G

(2) 4"

#3/0

(3) Sets (5)500kcmil, #4/0G

(3) 4"

#4/0

800

300

361

500

(2) 3"

833

1000

(3) Sets (5)400kcmil, #3/0G

(3) 3-1/2"

#3/0

(4) 42"

#4/0

1200

500

601

800

(2) 3"

1388

1800

(5) Sets (5)500kcmil,

350kcmil G

(5) 4"

#3/0

(6) 4"

250kcmil

2000

(2) Sets (3)250kcmil,

#2G
(2) Sets (3)600kcmil,
#1/0G

(2) 2-1/2"
(1) 3-1/2"

(2) Sets (3)350kcmil,

#1/0G
(3) Sets (3)400kcmil,
#3/0G

(4) Sets (5)500kcmil,

250kcmil G
(6) Sets (5)600kcmil,
500kcmil G

Note: Secondary feeder schedule only applies if neutral is bonded to ground at the transformer. If Neutral is bonded to ground at transformers first disconnecting means, then standard feeder
schedules apply

COORDINATION
Short Circui Amps (FLA/%Z)

Impedance

Dimensions
H
(in.)
14
14

BTU Heat Loss

Weight (lbs.)
120
145

No Load
376
495

Full Load
563
939

KVA
3
6

%R
3.76
2.72

%X
1
1.72

%Z
3.89
3.22

208V
214
518

480V
93
224

W (in.)
15
15

D
(in.)
9
9

9
15

2.31

1.16
1.82

2.58
2.78

966
1498

419
649

19
20

12
16

15
27

235
200

666
529

1280
2270

2.04
1.97
2.1

4.27
3.37
3.2

1951
3710
6497

845
1308
2815

20
20
30

16
20
20

27
30
30

250
340
500

854
1024
1366

6128
5753
8654

30
45
75

2.1
3.75
2.73
2.42

112.5
150
225
300

2.56
1.94
1.95
1.7

3.69
4.07
4.8
4.96

4.49
4.51
5.18
5.24

6953
9235
12054
15882

3013
4002
5224
6882

30
32
35
41

24
27
29
32

37
44
50
50

750
800
1025
1450

2048
2390
3073
3755

13073
15124
19784
24120

500
750

1
1

4.8989
4.8989

5
5

27758
41636

12028
18042

48
56

36
41

71
74

2100
3950

5121
7169

23471
34447

1000

5.6623

5.75

48274

20919

72

54

94

6300

Transformer Equivalent Circuits

Fig. 1: Transformer Equivalent Circuit.