Transformers are electrical devices that are used to change or "transform" the voltage of an electrical current.

They are composed of copper windings which in either series or parallel either step up or step down the incoming voltage of the transformer. The incoming voltage is called the primary the outgoing voltage is called the secondary. The common voltages in North America are as follows: Single Phase 120 volts 120/240 volts 1, 3w 240 volts Three Phase 120/208 volts 3, 4w 480 volts 277/480 volts 3, 4w 600 volts

Also, the higher voltages that are commonly used by the utility companies for power transmission are as follows: 2400/4160 volts 3, 4w 12,470volts 3w 13,800volts 3w

Copper Windings

The voltage, amperage and impedance are determined by the number of turns on the primary and secondary windings of the transformer. Typically the impedance remains constant. Therefore the output voltage and amperage is determined by the number of turns on both the primary and secondary sides of a transformer. A transformer's windings may be connected in a number of ways. The most commonly used transformer connections are Delta and Wye:

When using a wye-delta system, the higher voltage is connected in series and the lower voltage is connected in parallel.

Single Phase vs. Three Phase Output

Single Phase output from a transformer typically involves 120/240 volts 1, 3w. In commercial applications, this type of power is typically seen in hotel or condominium units, as those resemble a residential environment. This type of single phase power is also seen in certain industrial applications, such as a millwork shop where the equipment must be rated a minimum 230 volts. Single phase 120/240v output is neither a wye nor delta system. This means that on the secondary side of the transformer there will be 120volts between either one of the phases:

In order to size the transformer and the overcurrent protection that the phases are connected to, click here. Three phase transformers are more complicated than single phase. Click here to read about Three Phase Transformers.

Three Phase 120/240v Delta-Connected System (High Leg)

If you have been installing or designing this type of system, I promise you won't like what I have to say. I do not recommend using this system in any application. At one time this system was considered the "cheap" three phase. But the danger and potential damage caused by having unbalanced loads would far exceed the upfront cost to bring another phase conductor into the building. For more information about this, review NEC article 450 to read about the pitfalls of 120/240v 3, 3w systems. The basics of transformers have been discussed in this section. For more information, return to the main Transformers page to see the other relevant transformer data.

Before beginning to discuss the calculations involved with transformers, it is necessary to outline the most commonly available transformer sizes, in terms of KVA (kilo-volt-amps). This chart is not necessarily based on the code but is more of an industry standard held by most manufacturer's (GE, Square D, Eaton, etc.): 15 kva 30 kva 45 kva

75 kva 112.5 kva 150 kva 225 kva 300 kva

It is also important to define some terms that will be used throughout the calculations: connected load = total kilowatt load with no diversity taken into account. demand load = total kilowatt load with diversity calculated in. kva = kw (kilo-volt-amps = kilowatts) NEC = National Electrical Code (NFPA 70) Overcurrent Protection = Means of disconnect which prevents excess current on the conductor(s) to powered equipment. For more information about the primary side and secondary side of a transformer, click here.

Calculating the Transformer Size

Transformers are sized based on the total connected load on the secondary side and then selecting the next available kva size up from the connected load. Let's look at an example: Suppose we need to size a 480v-208v 3 transformer. There is a 100amp panelboard on the secondary side serving power receptacles and workstations where the total connected load is 23.50kva. By reviewing the transformer chart from above, you will find that 30kva is the next available size up from 23.50kva. Therefore a 30kva transformer is required for this system.

Calculating Overcurrent Protection on the Primary Side

Overcurrent protection for a transformer on the primary side is typically a circuit breaker. In some instances where there is not a high voltage panel, there is a fused disconnect instead. These are the two most common ways to provide overcurrent protection on the primary side. According to NEC 450.4, "each transformer 600 volts, nominal, or less shall be protected by an individual overcurrent device installed in series with each ungrounded input conductor. Such overcurrent device shall be rated or set at not more than 125 percent of the rated full-load input current of the autotransformer." Further, according to NEC Table 450.3(B), if the primary current of the transformer is less than 9 amps, an overcurrent device rated or set at not more than 167% of the primary current shall be permitted. Where the primary current is less than 2 amps, an overcurrent device rated or set at not more than 300% shall be permitted. From my experience, the primary current is rarely 9 amps or less, much less 2 amps. For the most part you will be using 125% to determine the primary overcurrent protection. Let's take a look at an example:

What size circuit breaker (overcurrent protection device) is required on the primary side to protect a 75kva 480v-208v 3 transformer? 75kva x 1,000 = 75,000va 75,000va / (480V x 3) = 90.21 amps (Note: 480V 3 is calculated as 480V x 3 or 831.38) The current (amps) is more than 9 amps so use 125% rating. 90.21 amps x 1.25 = 112.76 amps

Therefore: Use 125amp 3-pole circuit breaker (the next highest fuse/fixed-trip circuit breaker size per NEC 240.6).

**It is important to note that the overcurrent device on the primary side must be sized based on the transformer KVA rating and not sized based on the secondary load to the transformer.

Calculating Overcurrent Protection on the Secondary Side

In order to calculate the overcurrent protection on the secondary side, most of the same principles apply as with the primary calculations, with a few exceptions. Obviously the voltgae is different. For a 480v-208v 3 transformer, the calculations will use 208V x 3 instead of 480V x 3. Also, according to NEC Table 450.3(B), where the secondary current of a transformer is 9 amps or more and 125% of this current does not correspond to a standard rating of a fuse or circuit breaker, the next higher standard rating shall be required. Where the secondary current is less than 9 amps, an overcurrent device rated or set at not more than 167% of the secondary current shall be permitted. Let's take a look back at the previous example: What size circuit breaker (overcurrent protection device) is required on the secondary side to protect a 75kva 480v-208v 3 transformer?

*Note: Calculate the secondary overcurrent protection based on the size of the transformer, not the total connected load. 75kva x 1,000 = 75,000va 75,000va / (208V x 3) = 208.18 amps (Note: 208V 3 is calculated as 208V x 3 or 360.27) The current (amps) is more than 9 amps so use 125% rating. 208.18 amps x 1.25 = 260.24 amps

Therefore: Use 300amp 3-pole circuit breaker (per NEC 240.6).