NATIONAL ELECTRICAL CODE > CODE BASICS

Transformer Calculations
An understanding of basic transformer facts and NEC requirements
will help you avoid potentially tragic errors.
Mike Holt | Dec 14, 2015
A transformer transfers electrical energy from one system to another
by induction. Except for grounding and bonding connections, there’s no
physical connection between the two systems. For this reason, the NEC
refers to transformers as “separately derived systems,” as shown in Fig.
1.

The ratio of the number of turns in the primary (supply) side to the
number on the secondary (load) side determines how much the unit
transforms the power supplied to it. This is a key concept in
transformer theory and application.

Fig. 1. A transformer transfers electrical energy from one system to another by induction.

Related

Typically, a transformer raises or lowers the voltage. But isolation

transformers don’t; they simply decouple two systems. Let’s cover some
transformer basics before addressing NEC requirements.
Wye vs. delta

Wye-configured transformers have one lead from each of three

windings connected to a common point. The other leads from each of
the windings are connected to the line conductors. A wye-configured
secondary is often represented with a Y-shaped arrangement of the
windings.

Delta-connected transformers have three transformer windings

connected end-to-end with each other. The line conductors are
connected to each point where two windings meet. This system is
called a “delta” because when drawn it looks like a triangle (the Greek
letter delta).

High-leg conductor identi cation [110.15]

The terms “high-leg,” “wild-leg,” or “stinger-leg” are used to identify the

conductor of a delta-connected system that has a nominal voltage
rating of 208V to ground. The high-leg voltage is the vector sum of the
voltage of transformers A and C1, or transformers B and C2, which
equal (240V ÷ 2) × 1.732 = 208V for a 120/240V secondary (Fig. 2).
Fig. 2. The terms “high-leg,†“wild-leg,†or “stinger-leg†are used to identify the conductor
of a delta-connected system that has a nominal voltage rating of 208V to ground.

If the actual voltage of the delta-connected system isn’t 120/240V on the

secondary, the actual high-leg voltage would = (line voltage ÷ 2) × 1.732.
For example, what’s the actual voltage of the high-leg if the delta-
configured secondary is 115/230V, 3-phase?

High-leg voltage = (line voltage ÷ 2) × 1.732

High-leg voltage = (230V ÷ 2) × 1.732 = 199.18V

On a 4-wire, delta-connected, 3-phase system, where the midpoint of

one phase winding is grounded (high-leg system), the conductor with
208V to ground must be durably and permanently marked by an outer
finish orange in color or other effective means. Such identification
must be placed at each point on the system where a connection is made
if the neutral conductor is present [110.15 and 230.56].
When replacing equipment in existing facilities that contain a high-leg
conductor, ensure the high-leg conductor is replaced in its original
location. Prior to 1975, the high-leg conductor was required to
terminate on the “C” phase of panelboards and switchboards. Failure to
re-terminate the high-leg as it was in the existing installation can result
in 120V circuits inadvertently connected to the 208V high-leg, with
disastrous results.

Rating, voltage, current

Transformers are rated in kilovolt-amperes (kVA); 1 kVA = 1,000 volt-

amperes (VA). The voltage measured on the circuit conductors that
supply the primary side is the primary line voltage. The voltage
measured on the secondary side circuit conductors that feed the load is
the secondary line voltage. The single-phase formula for calculating the
line current of a transformer is: I = VA ÷ E. For 3-phase, I = VA ÷ (E ×
1.732). Convert kVA to VA by multiplying kVA × 1,000.

With this background, you can more readily make sense of the NEC
requirements for transformers.

Conductor identi cation

Where the premises wiring system contains feeders supplied from

more than one voltage system, each ungrounded conductor (at all
termination, connection, and splice points) must be identified by phase
or by line and system [215.12(C)]. Identification can be by color coding,
marking tape, tagging, or other means approved by the authority
having jurisdiction. The identification must be documented in a
manner that’s readily available, or it must be permanently posted at
each panelboard [215.12(C)(1)(a) and (b)]. Conductors with insulation
that’s green (or green with one or more yellow stripes) can’t be used for
an ungrounded or neutral conductor [250.119].
Overcurrent protection device (OCPD)

To protect the windings of a transformer against overcurrent, use the

percentages listed in Table 450.3(B) and its applicable notes. Article 450
is for the protection of the transformer windings, not the conductors
supplying the transformer or leaving it. Where 125% of the primary
current doesn’t correspond to a standard fuse or nonadjustable OCPD,
you can use the next higher rating, as listed in Sec. 240.6(A), but only
for currents of 9A or more.

Primary conductor sizing

Size primary conductors at least 125% of the continuous loads, plus

100% of the noncontinuous loads, based on the terminal temperature
rating ampacities as listed in Table 310.15(B)(16), before any ampacity
adjustment [210.19(A)(1)].

You must protect the conductors against overcurrent after ampacity

adjustment, as specified in Sec. 310.15 [240.4]. You can use the next
higher standard rating of OCPD (above the ampacity of the conductors
being protected) if the OCPD rating doesn’t exceed 800A [240.4(B)].

Let’s run through an example problem to clarify these points.

What size primary conductor can be used for a 45kVA continuous

loaded, three-phase, 480V transformer, where the primary OCPD is
sized at 70A?

Step 1: Size the primary conductor at 125% of the primary current

rating.

I = 45,000VA ÷ (480V × 1.732) = 54A

54A × 1.25 = 68A

A quick check of Table 310.15(B)(16) reveals that a 4 AWG conductor is
rated 70A at 60°C [110.14(C)(1)(a)(1)].

Step 2: Verify the conductors are protected per their ampacities [240.4].
A conductor rated 70A at 60°C can be protected by a 70A primary OCPD.

Secondary conductor sizing

The ampacity of the secondary conductor must be at least the rating of

the device supplied by the secondary conductors or the OCPD at the
termination of the secondary conductors [240.21(C)(2)]. Assume the
secondary conductors are intended to carry the full capacity of the
transformer continuously.

Step 1: Determine the rating of the device supplied by the secondary

conductors at 125% of the secondary rating [215.2(A)(1)(a)].

Step 2: Size the secondary conductors so their ampacity is at least that

of the device they supply [240.21(C)].

Again, let’s run through an example problem to clarify these points.

Fig. 3. The ampacity of the secondary conductor must be at least the rating of the device supplied by the
secondary conductors or the OCPD at the termination of the secondary conductors.

What size secondary conductor can be used for a 45kVA continuous

loaded, 3-phase, 480-120/208V transformer? (Fig. 3)

Step 1: Determine the secondary current rating.

Secondary current = transformer VA ÷ (secondary voltage × 1.732)

Secondary current = 45kVA ÷ (208V × 1.732) = 125A

Step 2: Size the secondary OCPD for a continuous loading (125% of the
secondary current rating) [215.3].

125A × 1.25 = 156A

In this case, we’ll choose a 175A OCPD device [240.6(A)].

Step 3: Size the secondary conductor so it has an ampacity at least that
of the 175A secondary OCPD (from Step 2) [240.21(C)(2)].

Conductor rated 175A at 75°C [Table 310.15(B)(16), 110.14(C)(1)(b)(1)]

Grounding and bonding

You must install a system bonding jumper at the same location where
the grounding electrode conductor (GEC) terminates to the neutral
point of a transformer. Size it per Sec. 250.102(C), based on the area of
the secondary conductors [250.30(A)(1) and 250.28(D)(1)].

A GEC must connect the neutral point of a separately derived system to

a grounding electrode of a type identified in Sec. 250.30(A)(4). Size the
GEC per 250.66 based on the area of the ungrounded secondary
conductor [250.30(A)(5)].

Can you be error-free? If you think of transformers as being the

electricity that goes through them, it’s easier to apply transformer
theory. Except for autotransformers, all transformers consist of two
sets of interacting coils. The turns ratio of the primary set to the
secondary set determines the degree to which the voltage is
transformed (raised or lowered).

To keep from making grounding and bonding errors, remember there’s

a difference between grounding and bonding. Grounding is the
connection to the earth. It’s accomplished with the grounding electrode
and the GEC. This connection to earth won’t provide an effective
ground fault return path. That’s the role of proper bonding.

With transformers, a vital link in the bonding path is the system

bonding jumper. It must be installed on the secondary of the
transformer, either in the transformer or in the panel. The system
bonding jumper completes the bonding path back to the source (the
transformer secondary) to provide an effective fault current path.

Holt is the owner of Mike Holt Enterprises, Inc. in Leesburg, Fla. He can
be reached at www.mikeholt.com .

Source URL: http://www.ecmweb.com/code-basics/transformer-calculations