Troubleshooting: Overheating

Transformer insulation is generally rated for 220C but may be lower for some designs
including control or encapsulated. Standards permit the temperature of the transformer
enclosure cover to be 65C over ambient. When temperatures exceed the rating for the
insulation system or enclosure, overheating occurs.
Burned, darkened or damaged insulation may be apparent along with a burnt smell. The
hottest part of a transformer is the coil near the top of the core. Energized transformers should
not be touched. If the insulation is damaged or smoke is visible, the unit may need to be
returned for testing and replaced or repaired.
Check:

Solution:
Reduce size or load or replace with larger transformer. In
Verify total load doesnt
some cases fans can be added to increase cooling and
exceed transformer kVA rating.
maximum load.
Relocate to area with lower ambient temperature, reduce
Verify ambient temperature load, reduce ambient temperature at primary location or
does not exceed transformer replace with a low temperature rise transformer.
ratings.
Transformers installed in small rooms will need proper room
ventilation.
Verify tap connections are set
up identically on all coils.
Verify transformer is correctly
Reduce or remove harmonic loads or replace transformer
rated for harmonic load, check
with a larger unit or unit with the proper k-rating.
for high neutral currents.
Verify that the transformers
ventilation openings are not
Relocate the transformer to an area of better ventilation.
blocked.
Transformers
Move the transformer away from walls, equipment or
purchased as core and coil
overhead projections that may impede airflow. Do not install
units and placed in enclosures
fans to cool a transformer. Improperly installed fans may
not supplied by HPS require
actually impede airflow and could result in transformer
that the integrator properly size
damage.
the enclosure and cooling
requirements.
Verify taps are correctly set for the input voltage. Depending
Improper Input Voltages
on the load and transformer type, continuous overvoltages or
under voltages as low as 5-10% may cause overheating.
If no load current is high (varies with transformer efficiency
but no load current is typically less than 2-3% of total kVA),
inspect the core and coils for damage. In most cases you will
Check no load current.
not be able to inspect the insulation between the core and coil
without returning to the factory for testing and disassembly.
If there is a short between the core and coil, the unit will
have to be replaced or repaired.
Excessive
and
sustained Relocate the transformer to an area with less wind or block
airflow caused by exterior the wind.

Check:
Solution:
winds or fans generally moving
horizontally to the ground can
disrupt convection cooling and
cause overheating at high
loads.
Fan cooled transformers have
Fans need to be replaced or realigned.
broken or misaligned fans.
Low power factor can cause excessive current and higher
Low Power Factor
overall loads. Current meters need to be able to register
total current. Some digital meters may not be accurate.
Loads should be balanced to within 20 % of maximum kVA.
Unbalanced loads may cause
No individual load should exceed the load specific load for
excessive heating.
each phase (1/3 of total kVA for three phase units).
Move either the transformer or the heat source. Redirect the
Transformer is installed above
hot airflow from the lower object away from the
a heat source such as another
cooling entrances and surfaces of the higher object. Replace
transformer.
the top unit with a low temperature rise transformer.
A highly distorted output voltage may be a sign that there is a
turns to turns fault and the transformer is in danged of
Check if output voltage is
immediate failure. The transformer needs to be de-energized
distorted.
and meggered. The damaged coil may need to be
replaced or the transformer scrapped.
Check the output circuits to
If a fuse on one or more of the legs has opened, determine
make sure each leg of the
and clear the fault and replace the fuse. This is more
transformer is functioning and
common on delta transformer outputs, especially if three
Overcurrent
protection
is
single phase units are used in a Delta bank.
ok.
If a Drive Isolation
If motor HP is unknown, use .746 kW/HP to determine the
Transformer (DIT) is being
equivalent HP of the load. DITs are not current rated
used, verify the DIT kVA has
devices, the HP selection charts must be used to properly size
been derated per the HP sizing
a DIT. Extrusion applications tend to be the worst.
charts in the catalog.
Transformers operating in parallel are rare. Large circulating
Check if two or more currents
and
uneven
load
can
result
from
transformers are operating in transformers wired in parallel. The transformer s may have to
parallel to power one load.
replace with one unit capable of power the entire
load.
Cables should be periodically tightened. The surface should
Cable
connections
are be cleaned of any insulation applied during the vacuum
discoloured by heating.
pressure impregnation process. Rough edges must be
smoothed.
Sparks or smoke is visible
During the VPI process, icicles of insulation can form under
from the base of the
the transformer and occasionally act as a ground. If
transformer but the transformer
discovered early enough the icicle can be removed and the
has not failed and there isnt
transformer will not be damaged.
any sound of arcing.
Excessive dust could block air Dust needs to be blown out while transformer is de-

Check:
vents
Discoloured Insulation
Visible Flames or Smoke

Solution:
energized.
The transformers insulation may have been damaged and
may need to be repaired or replaced.
The transformers insulation may have been damaged and
may need to be repaired or replaced.

Troubleshooting: Noise & Vibration

Sound levels for transformers vary from 40 dbA for smaller distribution units to 68 dbA for
3000 kVA power transformers and higher for larger units. All transformers vibrate at 120 Hz
because the EMF vibrates the unit due to 60 Hz oscillations. The audible noise is measured at
no-load and tested in a low ambient noise environment with walls or reflecting surfaces at
least 10 away from the transformer per NEMA ST-20. When installed in more confining
electrical rooms and connected to a load, transformers will exhibit higher sound levels than
these standards. Transformers can be ordered that produce less noise that the NEMA ST-20
standard, generally at -3 and -5 dB but lower levels are also available. Rubber pads or springs
can also be installed between the enclosure and floor to further reduce vibrations and noise.
Harmonics generally dont increase noise too much.
Check:
High Input Voltage

Solution:
Verify taps are correctly set for the input voltage.
If power is coming from a local generator, adjust the
High Frequency
generator. If the frequency cant be adjusted, the transformer
may have to be rebuilt.
Loads should be balanced to within 20 % of maximum kVA.
Unbalanced Loads
No individual load should exceed the load specific load for
each phase (1/3 of total kVA for three phase units).
Check any core welds or clamped brackets when fully deenergized to make sure the welds are intact and the brackets
Damaged Core.
havent slipped. Loose brackets can be tightened on-site but
broken welds or cores that have shifted will need to be sent
back to the factory for repair.
All ventilated transformers should have rubber pads between
Missing Core to Enclosure
the core and coil. If these are missing they can either be field
anti-vibration pads.
replaced or the unit can be sent back to the factory.
Loose Enclosure
Tighten enclosure screws and bolts were necessary.
Transformer mounted on a
suspended floor or wall may Reinforce the floor/wall or move the transformer to a more
create and echo chamber and solid mounting area.
increase noise.
Multiple transformers in one area can sometimes resonate with
Multiple transformers
each other and increase the overall noise. The transformers
installed in one room.
either have to be moved further apart or isolation pads or
springs can be mounted under the transformer enclosure.
Transformer
is
running A low audible dB transformer can be used to replace the

Check:
Solution:
correctly but still producing existing unit and/or vibration isolation pads and springs can be
too much ambient noise.
installed between the transformer base and floor.

Troubleshooting: Physical Damage

Transformers can become physically damaged during installation or shipping.
Check:

Solution:
Minor damage can be repaired in the field with spray paint
(scratches) or individual enclosure pieces. Enclosure
components located in the base or replacing the entire
Enclosure is damaged but the
enclosure will require facilities capable of lifting the entire core
core and coil is intact.
and coil Units can also be returned to the plant for enclosure
repair and full testing. Encapsulated (potted) units that have
enclosure damage may not be repairable.
Jumpers are damaged.
Replace jumpers.
Voltage spikes such as lightning or utility transients caused
voltages to exceed the transformers BIL rating and caused
The coil has been damaged
arcing. If a conductive dust or liquid (water) is present, this
with arcing between the coil
may also cause arcing. The transformer will need to be repaired
taps.
or replaced. Voltage spikes can be mitigated with lightning
arrestors or transformers with higher BIL rates.
The insulation between the coils has failed. This may be due to
The coil has been damaged
age, overheating, overvoltage or damaged insulation. Each of
with arcing and physical
these failure modes will have to be checked and if found to be a
damage between the coils
problem fixed. The transformer will need to be repaired or
(turn to turn).
replaced.
The coil has been damaged The insulation between the coils has failed. This may be due to
with arcing and physical age, overheating, overvoltage or damaged insulation. Each of
damage between the coil these failure modes will have to be checked and if found to be a
layers or between the coil problem fixed. The transformer will need to be repaired or
and shield.
replaced.
Replace jumpers or lugs if they are damaged. Verify the
Connections points show
mounting surfaces are clean of insulation and smooth. Verify
signs of heat including
any mechanical components are tight. In some cases a braise
damaged
insulation
or
joint at a lug or pad point may be damaged and cause excessive
excessive corrosion.
heat.
Coil is damaged. Coil
damage
can
include Some units can return to HPS for repair or coil replacement. In
insulation that has been some cases it may be more economical to replace the unit than
ripped, worn or is burnt or to repair it.
discoloured from heat.

Troubleshooting: Secondary Voltage is too

high
Transformer secondary voltage can be too high, too low or there may be no voltage. Please
note that transformer voltage is a ratio of the primary voltage. If the primary voltage is too
high or too low, the secondary voltage will also be too high or too low.
Check:
Solution:
Verify the taps are set up the same or set Set up taps at the same level and for the correct
up incorrectly for the incoming voltage. primary voltage.
A different transformer with a larger tap range or
The voltage exceeds the ability of the higher input voltage may be needed. Adjust the
taps to tune the voltage.
input voltage to be within the range of the
transformer taps.
Verify the transformer being installed is the correct
The transformer is wired correctly per voltage for the application. If the nameplate matches
the input voltage.
the application, the transformer may be incorrectly
nameplate.
Verify the neutral connection is properly If the transformer neutral is damaged, it will have to
wired and grounded per the applicable repair. Wire and ground the neutral per applicable
codes. All three coils should be attached codes. A coil may have been inverted during
to a common neutral point.
manufacturing and would have to be replaced.
The transformer is wired correctly per
The transformer may be wired in reverse.
the input voltage.
If the power factor is above 1.0 (leading), high
Check the power factor.
voltages will result. This must be corrected at a
systems level.
The turns ratio may have been incorrectly wound or
Verify the coils are look similar and
one or more of the coils may be incorrect in
have similar resistance values.
comparison to the other coils.

Troubleshooting: Secondary Voltage is too

Low
Transformer secondary voltage can be too high, too low or there may be no voltage. Please
note that transformer voltage is a ratio of the primary voltage. If the primary voltage is too
high or too low, the secondary voltage will also be too high or too low.
Check:
Solution:
Verify that the taps are set up
the same and are set up
Change taps if necessary.
correctly for the incoming
primary voltage.
The voltage exceeds the If the primary voltage exceeds the ability of the taps to tune

Check:
Solution:
ability of the taps to tune the the voltage, a different transformer with a larger tap range or
voltage.
higher input voltage may be needed.
The transformer is wired Verify the transformer being installed is the correct voltage for
correctly per the input the application. If the nameplate matches the application, the
voltage.
transformer may be incorrectly nameplate.
Replace jumpers or lugs if they are damaged. Verify the
Verify all connection points
mounting surfaces are clean of insulation and smooth. Verify
(lugs and pads) are tight,
any mechanical components are tight. In some cases, a braise
smooth and cleaned of any
joint at a lug or pad point may be damaged and cause
insulation.
excessive heat.
Are there any large loads that
occur where total standard or During high current, such as when a large motor is started
momentary
inrush
load across the line or during a short circuit, the output voltage will
exceeds the kVA rating of the be lowered during these periods of high load.
transformer.
The transformer may be wired in reverse. Transformers that
are back fed will have different impedances than what is on
Is the transformer being back the nameplate. Also, the winding compensation on the turns
fed?
ratio that adjusts the voltage upward for planned resistive
voltage drop now lowers the voltage in addition to still having
the resistive voltage drop.
Verify the coils all look The turns ratio may have been incorrectly wound or one or
similar and have similar more of the coils may be incorrect in comparison to the other
resistance values.
coils.

Troubleshooting: Secondary Voltage Varies

Transformer secondary voltage can be too high, too low or there may be no voltage. Please
note that transformer voltage is a ratio of the primary voltage. If the primary voltage is too
high or too low, the secondary voltage will also be too high or too low.
Check:

Solution:
A transformer is a voltage ratio device so the secondary
Incoming line voltage varies.
voltage will generally vary as the primary voltage varies.
This is a systems issue a transformer cannot fix.
Verify all connection points (lugs Smooth or replace pads and lugs if damaged or rough.
and pads) are tight, smooth and Tighten any loose mechanical connections. Clean off any
cleaned of any insulation.
insulation remaining on electrical connection points.
Verify the neutral connection is
If the transformer neutral is damaged, it will have to
properly wired and grounded per
repaired. Wire and ground the neutral per applicable
the applicable codes. All three
codes. A coil may have been inverted during
coils should be attached to a
manufacturing and would have to be replaced.
common neutral point.
Are there any large loads that During high current, such as when a large motor is started
occur where total standard or across the line or during a short circuit, the output voltage
momentary inrush load exceeds will be lowered. The total load will either have to be

Check:

Solution:
decreased, limited by devices such as reduced motor
the kVA rating of the transformer. starting devices or a larger transformer will have to be
installed.

Troubleshooting: No Secondary Voltage

Transformer secondary voltage can be too high, too low or there may be no voltage. Please
note that transformer voltage is a ratio of the primary voltage. If the primary voltage is too
high or too low, the secondary voltage will also be too high or too low.
Check:
No secondary voltage.

Solution:
Verify the transformer primary is energized.
If a continuity check fails on the secondary, also perform a
Perform a continuity check on continuity check on the tap cables. If the tap cables are bad,
the primary and secondary replace the tap cables. If the continuity check fails and it is not
coils.
the result of the tap cables, the transformer will need to be
either repaired or replaced.
If one phase a delta secondary
has no voltage check to make If two legs are grounded, remove the ground from one of the
sure that one of the three legs legs.
are grounded.
Replace jumpers or lugs if they are damaged. Verify the
Verify all connection points
mounting surfaces are clean of insulation and smooth. Verify
(lugs and pads) are tight,
any mechanical components are tight. In some cases a braise
smooth and cleaned of any
joint at a lug or pad point may be damaged and cause
insulation.
excessive heat.
Inspect transformer for visual
signs of a short circuit If the transformer has been damaged, the transformer may
including damaged or burned need to be either repaired or replaced.
insulation or smoke.
Verify all connection points
Smooth or replace pads and lugs if damaged or rough. Tighten
(lugs and pads) are tight,
any loose mechanical connections. Clean off any insulation
smooth and cleaned of any
remaining on electrical connection points.
insulation.

Troubleshooting: Smoke is visible or

smelled
Smoke normally means the transformers insulation has been damaged or weakened and
failure could have already occurred. The transformer must be immediately de-energized to
prevent further damage.

Check:
Visible signs of
damaged or
failed insulation.

No visible signs
of damage.

No visible signs
of damage.

No visible signs
of damage.

Solution:
The transformer will have to be sent back to the factory for testing and
possible repair or replacement. In many cases, it may not be economically
possible to repair a damaged transformer and the unit will have to be
replaced.
The transform should be meggered. If the insulation values are lower than
required (consult the maintenance manual), the transformer will have to be
sent back to the factory for testing and possible repair or replacement. In
many cases, it may not be economically possible to repair a damaged
transformer and the unit will have to be replaced.
Check vertical air ducts in the transformer. If any metallic ferrous metal
(screws, nuts, washers, etc.) have fallen between the transformer coils,
these will heat through eddy currents and cause insulation damage and
eventual failure.
The transform should be meggered. If the insulation values are within the
required range and if the transformer was just manufactured (consult the
maintenance manual), the transformer may have some insulation that was
not cured during the bake cycle. Please call HPS for further instructions.

Troubleshooting: Tripping of Fuses or

Breakers at Energization
When a transformer is energized, it draws a large current for a few cycles to establish the
electromagnetic field. During this time, the transformer load has little to no effect on the
initial transformer inrush. Inrush can vary depending on where the sine wave is during initial
energization and how long the transformer was de-energized before being energized again.
Inrush current can be up to 12 times rated FLA current. In some cases custom transformers
can be built to have very low inrush values.
Check:

Solution:
Size Overcurrent devices correctly. NEC code should
be reviewed. In general buck-boost Overcurrent
Is Overcurrent device sized correctly protection should be sized NEC 450-4 which is also
per applicable codes.
found in the back of our buck boost section in the
catalog. 600 volt class distribution Overcurrent
protection should be sized per NEC Table 450.3(A).
If Overcurrent devices are quick trip, replace with time
Are Overcurrent devices time delay?
delay version.
Overcurrent devices are sized for a Overcurrent devices should be sized for the
load which is significantly lower than transformer amperage since inrush is dependent on
the rated transformer amperage.
transformer size and not load.
Is the transformer being back fed? Transformers being back fed will experience higher
Back feeding is generally done when inrush currents since the coil being energized
taking a standard step down (secondary) is further from the core. In this case the
transformer and using it to step up the Overcurrent devices should be sized to the maximum

Check:

Solution:
allowed per the applicable code requirements. In some
voltage which reverses the order of
cases a custom transformer may need to be used
energization for the windings.
instead of back feeding a standard transformer.
Lower the input voltage, adjust the taps or use a
Is the input voltage higher than the
transformer capable of adjusting for a higher input
input is set up for?
voltage.
Check in the input frequency, lower Adjust the input frequency or replace transformer with
input frequencies can cause higher a unit capable of using a lower frequency (us a 50/60
inrush currents.
Hz core).
If possible tighten any core clamps. If the core has
Check the core to make sure it is
shifted or is damaged, it may have to be repaired or
properly aligned, tight and has not
replaced. Bad core steel or a core built too small for
shifted.
the application would have similar problems.
Shorted turns can cause nuisance tripping initially but
Check the coil insulation.
this will quickly turn into a turn to turn fault which
will destroy the coil.
Check the primary power factor. Low
This is a systems problem that will require power
power factor can cause higher inrush
factor correction.
currents.

Troubleshooting: Transformer is covered in

dust
During normal operation, transformers can become covered in dust which needs to be
periodically cleaned off to prevent arcing and loss of cooling capacity.
Check:
Solution:
Is dust simple nonDe-energize and blow off with compressed air.
conductive dust.
Simply blowing off the dust may not be sufficient to protect the
transformer from corrosion. Megger checks may not diagnose some of
these problems. Transformers may need to be placed in a location away
Is dust corrosive
from corrosive dust. The transformer may need to be professionally
such as salt.
cleaned by manufacturer or replaced. Please consult factory. Certain
coatings such as epoxy (VPE) or encapsulated (potted) transformers are
available.
Is dust conductive Simply blowing off the dust may not be sufficient to protect the
such
as
coal, transformer from coronal discharge or short circuiting. Megger checks
carbon black or may not diagnose some of these problems. Transformers may need to be
metallic.
placed in a location away from conductive dust.

Troubleshooting: Transformer has been

back fed
HPS does not recommend that transformers be back fed due to safety issues. The nameplate
no longer matches the application and may violate electrical codes and common wiring
practices. Back fed transformer are susceptible to high inrush currents, voltage unbalances
and lower than expected output voltages.
Check:

Solution:
Size the fuse or breaker to the largest allowed by the local
Inrush current is causing electrical code and use time delay fuses or high short circuit trip
nuisance tripping.
points on breakers. Replace with a step up transformer is
problem persists.
Windings are turns compensated to take into account the natural
voltage drop which occurs in the wires. When a transformer is
Output voltage is lower
back fed, the voltage drop still occurs but the winding
than expected.
compensation works in reverse. If possible, use taps to adjust.
Replace with a step up transformer if the problem persists.
Is the transformer a delta- This application is not suggested and involves the removal of
wye transformer that is ground straps which would violate the UL listing of the
being back fed such that the transformer. This must be replaced with a custom step up
wye becomes the primary. transformer.

Troubleshooting: Transformer has been

stored in humid area or exposed to water
If a transformer has been stored de-energized in a humid area, the windings and insulation
may absorb water decreasing the dielectric strength of the insulation. In worst cases the
windings have been exposed directly to water or submerged in it. If a transformer has been
exposed to any liquid, immediately de-energize and remove from service.
Check:

Solution:
If the insulation ratings are lower than needed, consult the
If the transformer has been
factory. Dry hot air may need to be directed over the transformer
stored in a humid area,
for 24 hours ore more. In some cases, the transformer may need
Megger the transformer.
to be baked in industrial ovens to sufficiently dry out.
Immediately remove from service. Since liquid water can shift,
If the transformer coil has
even a proper Megger reading may not be sufficient. Consult the
been exposed to rain or
factory. Dry hot air may need to be directed over the transformer
other
dripping
water,
for 24 hours or more. In some cases, the transformer may need to
Megger the transformer.
be baked in industrial ovens to sufficiently dry out.
If the transformer has been Some chemicals may leave conductive or corrosive residue that
exposed to a liquid other weakens the insulation. In this case, the transformer may need to
than water, please consult be repaired or replaced.

Check:
Solution:
the factory.
If the transformer coil has
In this case, the transformer will usually need to be replaced or
been submerged in water,
returned to the factory for evaluation and possible repair.
consult the factory.

Troubleshooting: Excessive Conductor

Heating
Cabling attached to the transformer can have excessive heating that causes conductor
damage.
Check:
Solution:
Check conductor connections to make sure they Tighten conductor connections. Replace
are.
conductors if they are damaged.
Replace conductors if they need to be sized
Verify conductors are properly sized.
larger.
Check conductor insulation rating to make sure it
Replace with cabling with higher ambient
can withstand the high temperatures within the
rated conductors.
enclosure.
Reposition conductors in enclosure to
Verify conductors arent placed above the coils
avoid the hottest air existing from the top
where the warmest air will rise.
of the coils.

Troubleshooting: Corrosion Damage

Corrosion can damage the transformers enclosure, core and coils. This can be a consistent
problem in corrosive areas such as marine and waste water treatment.
Check:
Check for
enclosure and
mounting
hardware
corrosion.

Core steel is
corroded.

Coil and
conductor

Solution:
Replace corroded parts. In some cases they may need to be replaced with
stainless steel or other types of protected parts. Enclosures can be ordered
in various grades of stainless steel or with plated base mounting brackets.
In some cases, light corrosion may not severely damage the core function
although a more pressing concern may be conductive rust settling on the
coils and causing dielectric problems. In severe cases the core may need
to be replaced. Epoxy can be applied at the factory to protect the core
from corrosion. Transformers that overheat and damage the insulation are
more susceptible to corrosion.
Protectants such as No-LOX grease may be applied to exposed parts.
Only remove insulation from the taps that need to be used. Keep all

Check:
corrosion.

Solution:
connections tight. Utilize copper coils when possible. Epoxy coatings
(VPE) or encapsulated (potted) transformers can be used.

Troubleshooting: High Neutral Currents

High neutral currents can be caused by unbalanced and/or non-linear loads with high
harmonics. K-rated transformers have a 200% rated neutral. Amperage should be measured
with a meter capable of measuring true RMS currents.
Check:
Solution:
Check the load to make sure it is
Improve the load balance between the three phases.
balanced. Any load unbalance
General purpose transformers have a 125% rated neutral.
results in neutral currents.
Check the load to determine if it For non-linear loads, use k-rated transformers with 200%
has high amounts of harmonics rated neutrals. Select a k-rated transformer with a k-factor
from single phase sources.
suitable for the specific level of harmonics.
Check to make sure all three legs If a fuse is blown, clear the source of the fault and replace
of the transformer or transformer the fuse. If a breaker has tripped, clear the fault, check the
bank are operating. Check coil settings and turn on the breaker. If the transformer coil is
continuity and blown fuses or damaged, the transformer will have to be repaired or
tripped breakers.
replaced. Please contact HPS Customer Service.