INFORMA

MENU

SEARCH

REGISTER FOR OUR FREE ONLINE BOOTCAMP BY AUG 1: You could win a Yeti Cooler! Register Today
X
RECENT
RECENT

Moving Violations Video No. 193: Foreign Invasion of Electrical Space

27-Jun-19

What’s Wrong Here? Hint: Hard-Pressed for Hard-Wiring Correctness

27-Jun-19
Code Quiz: EGC Sizing Requirements
27-Jun-19

Code Q&A: Properly Sizing Raceways to Prevent Conductor Damage

27-Jun-19
2019 Top 40 Electrical Design Firms
26-Jun-19
EDUCATION
Get EC&M in Print -- FREE
FEATURED
Top 25 Changes in the 2017 NEC
15-Feb-17

Top 10 Highest Paying Cities for Electricians

5-Apr-15

The 10 Biggest Grounding Mistakes to Avoid

20-Aug-14

12 Reasons Why Electricians Should Always be Looking for Trouble

 28-Mar-17

CONSTRUCTION

Transformer
Installation
Made Easy,
Sort of
OK, it won't be easy, but
these five steps will help
your next transformer
installation run more
smoothly.
Mike Holt | Jul 01, 2002
Installing transformers in accordance
with the NEC is critical to ensuring a
safe electrical installation as well as a
reliable power supply system —
especially for those applications where
power quality is an issue. The
installation of transformers is one of
the most common, yet complicated
installation practices that's cause for
considerable confusion when sizing
overcurrent protection devices
(OCPD) and bonding and grounding
conductors.
Many electrical installations can be a
challenge in terms of NEC
requirements, and transformers can
raise that challenge to a new level. A
safe installation that's properly
designed and installed will ensure that
the conductors and equipment are
properly sized and protected. In
addition, grounding is also an
overriding issue. Failure to properly
install transformers can lead to fires
from improper protection or
conductor sizes, as well as electric
shock from improper grounding, so
let's look at how to do it right the first
time.
Let's assume you're installing a 45kVA
and 112.5kVA, 480V delta primary to
a 208/120V 3-phase wye secondary
transformer in a new facility. Each
transformer supplies a lighting and
appliance branch-circuit panelboard
with continuous nonlinear loads
typically found in today's office
buildings. The length of the
conductors from the transformer
secondary to the lighting and
appliance branch-circuit panelboard
is less than 10 ft, and all terminals are
rated 75°C.
Step 1. First determine the primary
and secondary current rating of the
transformers (see Fig. 1 on page 30
and Fig. 2 at right).
For a 45kVA transformer, the primary
current would be
45,000VA÷(480×1.732)=54A.
For the same transformer, the
secondary current would be
45,000VA÷(208V×1.732)=125A.
For a 112.5kVA transformer, the
primary current would be
112,500VA÷(480V×1.732)=135A, and
for the same transformer, the
secondary current would be
112,500VA÷(208V×1.732)=312A.
Step 2. Next, you must protect the
primary winding of each transformer
against overcurrent, in accordance
with the percentages listed in Table
450.3(B) and all applicable notes.
Where 125% of the primary current
doesn't correspond to a standard
rating of a fuse or nonadjustable
circuit breaker as listed in 240.6(A),
the next higher rating in Table
450.3(B) is acceptable (Note 1).
For a 45kVA transformer,
54A×1.25=68A, so go to the next size
up, which is 70A.
For a 112.5kVA transformer,
135A×1.25=169A, so go to the next
size up, which is 175A.
Step 3. Now you must size feeder
conductors supplying continuous
loads no smaller than 125% of the
continuous loads based on the
conductor ampacity values listed in
Table 310.16 and before any ampacity
adjustment, in accordance with the
terminal temperature rating
[110.14(C) and 215.2(A)(1)].
For a 45kVA transformer,
54A×1.25=68A, so use a 4 AWG
conductor rated 85A at 75°C, per
Table 310.16.
For a 112.5 kVA transformer,
135A×1.25=169A, so use a 2/0 AWG
conductor rated 175A at 75°C, per
Table 310.16.
Size the equipment grounding
(bonding) conductor for the
transformer primary based on the size
of primary protection device, per
250.122(A):
45kVA transformer — Per Table
250.122, 70A primary protection
(Step 2) requires an 8 AWG copper
conductor.
112.5kVA transformer — Per Table
250.122, 175A primary protection
(Step 2) requires a 6 AWG copper
conductor.
Step 4. You can run secondary
conductors without secondary
overcurrent protection at the point of
supply for 10 ft if the secondary
conductors have an ampacity greater
than the rating of the termination
device. This means the next-bigger-
OCPD rule contained in 240.4(B)
doesn't apply to this application.
Although secondary overcurrent
protection isn't required in this
situation, you're required to install
overcurrent protection for lighting
and appliance branch-circuit
panelboards. You must locate this
protection on the secondary side of
the transformer, in accordance with
408.16(A) and (D). Where a feeder
supplies continuous loads, the rating
of the (secondary) overcurrent device
may not be less than 125% of the
continuous load (215.3) as listed in
240.6(A).
For a 45kVA transformer,
125A×1.25=156A, so use a 175A
protection device.
For a 112.5kVA transformer,
312A×1.25=390A, so use a 400A
protection device.
Since secondary overcurrent
protection is provided in this example,
the primary OCPD can be sized at as
much as 250% of the primary current
rating, in accordance with Table
450.3(B) and 240.21(B)(3).
Secondary conductors may not have
an ampacity rating less than the rating
of the OCPD at the termination of the
conductors in accordance with Table
310.16 based on 75°C terminal rating
[110.14(C)]. This means the next-size-
up rule contained in 240.4(B) doesn't
apply.
For a 45kVA transformer: 175A
protection device=2/0 AWG, rated
175Aa at
For 75°C. transformer: 400A
112.5kVA
OCPD=600 kcmil, rated 420A at
75°C.
But don't stop there. Where the
number of current-carrying
conductors in a raceway or cable
exceeds three, the allowable ampacity
shall be reduced in accordance with
Table 310.15(B)(2)(a). For our
examples, there are four current-
carrying conductors on the secondary.
The neutral is considered to be a
current-carrying conductor, per
310.15(B)(4)(c), so you can reduce the
ampacity by 20%. The conductor
ampacity after adjustment and based
on a 90°C ampacity rating [110.14(C)]
must be no less than 175A for the
45kVA transformer and 400A for the
112.5kVA transformer.
For a 45kVA transformer, use 3/0
AWG, rated 225A×0.80=180A, which
is greater than the 175A protection
device.
For a 112.5kVA transformer, use 700
kcmil, rated 520×0.80=416A, which is
greater than the 400A protection
device.
Step 5. You must bond a transformer
secondary that operates at more than
50V [250.20(A) and 250.112(I)] to an
effective ground-fault current path to
ensure dangerous voltage levels
imposed by lightning, line surges, or
unintentional contact with higher-
voltage lines won't remain [250.2(A)
(3)] on the system.
To provide the low-impedance path
necessary to clear a ground-fault on a
separately derived system, you must
bond the metal parts together
(equipment grounding conductor) and
connect them to the system ground
conductor (X0 terminal). You must
size the bonding jumper in accordance
with Table 250.66, based on the total
area of the largest ungrounded (hot)
conductor as follows:
For a 45kVA transformer: 3/0 AWG
secondary conductor=4 AWG copper
bonding jumper.
For a 112.5kVA transformer: 700
kcmil secondary conductor=2/0 AWG
copper bonding jumper.
The neutral-to-case bond can be made
at the source of a separately derived
system or at the first system
disconnecting means or OCPD. When
there's no secondary side
disconnecting means or overcurrent
device(s), the neutral-to-case bond is
made at the source of the separately
derived system.
The neutral-to-case connection for a
separately derived system can't be
made at more than one location if it
results in a parallel path for neutral
current flow [250.30(A)(1) Exception
No. 1]. Such multiple neutral current
return paths to the grounded (neutral)
conductor of the power supply can
create fire and shock hazards, as well
as power quality problems due to EMI
[250.6 and 250.142(A)].
You must size a grounding electrode
conductor for a single separately
derived system in accordance with
250.66, based on the total area of the
largest secondary ungrounded (hot)
conductor. This conductor shall
connect the grounded conductor of
the derived system to the grounding
electrode as specified in 250.30(A)(4).
The grounding electrode conductor
must terminate at the same point on
the separately derived system where
the neutral-to-case bonding jumper is
installed [250.30(A)(1)].
For a 45kVA transformer: 3/0
AWG=4 AWG copper grounding
electrode conductor.
For a 112.5kVA transformer: 700
kcmil=2/0 AWG copper grounding
electrode conductor.
You must connect the grounding
electrode conductor directly to the
grounded neutral conductor terminal.
It can't be terminated to the case of
the transformer.
You must terminate the grounding
electrode conductor to a grounding
electrode that's located as close as
practicable to, and preferably in the
same area as the nearest effectively
grounded metal member of the
structure or effectively grounded
metal water pipe within 5 ft from the
point of entrance into the building.
However, the grounding electrode
conductor can terminate at any point
on the water pipe system for
industrial and commercial buildings
where conditions of maintenance and
supervision ensure only qualified
persons service the installation, and
the entire length of the interior metal
water pipe used for the grounding
electrode is exposed.
If an effectively grounded metal
member of the building structure or
an effectively grounded metal water
pipe is not available, one of the
following electrodes must be used:
An electrode encased by at least 2 in.
of concrete, located within and near
the bottom of a concrete foundation
or footing that's in direct contact with
the earth, consisting of at least 20 ft of
one or more bare, zinc-galvanized, or
other electrically conductive coated
steel reinforcing bars or rods of not
less than ½ in. in diameter, or
consisting of at least 20 ft of bare
copper conductor not smaller than 4
AWG. See 250.52(A)(3).
A ground ring encircling the building
or structure, in direct contact with the
earth, consisting of at least 20 ft of
bare copper conductor not smaller
than 2 AWG. See 250.52(A)(4).
Rod or pipe electrodes not less than 8
ft in length. See 250.52(A)(5).
A plate electrode that exposes not less
than 2 sq ft of surface to exterior soil.
See 250.52(A)(6).
Other local metal underground
systems or structures like piping
systems and underground tanks. See
250.52(A)(7).
As you can see, installing
transformers properly can be done in
five steps, but sometimes it gets
tricky. But as long as you follow the
NEC rules outlined in this article, you
should be fine.

MENU

SEARCH

REGISTER FOR OUR FREE ONLINE BOOTCAMP BY AUG 1: You could win a Yeti Cooler! Register Today
X
RECENT
RECENT

Moving Violations Video No. 193: Foreign Invasion of Electrical Space

27-Jun-19

What’s Wrong Here? Hint: Hard-Pressed for Hard-Wiring Correctness

27-Jun-19
Code Quiz: EGC Sizing Requirements
27-Jun-19

Code Q&A: Properly Sizing Raceways to Prevent Conductor Damage

27-Jun-19
2019 Top 40 Electrical Design Firms
26-Jun-19
EDUCATION
Get EC&M in Print -- FREE
FEATURED
Top 25 Changes in the 2017 NEC
15-Feb-17
Top 10 Highest Paying Cities for Electricians
5-Apr-15

The 10 Biggest Grounding Mistakes to Avoid

20-Aug-14

12 Reasons Why Electricians Should Always be Looking for Trouble

28-Mar-17

NATIONAL ELECTRICAL
CODE>CODE BASICS

Step-by-Step
Guide to
Transformer
Installations
Do you really have to read
through all eight pages of
Art. 450 just to connect a
transformer?  
Mike Holt | Nov 18, 2014
All you wanted to do was install a
30kVA, 120/208V transformer to
supply receptacles in a new office
structure on the production floor. The
plant manager is adamant about
complying with the NEC, so you
turned to Art. 450. Not only does it
take up eight pages, but it also looks
like it could be a mind-bender because
it starts off by listing eight exceptions
to its scope.
The good news is this situation isn’t as
bad as it seems at first glance. Before
we look at a strategy for making short
work of this long text, let’s address
those eight exceptions. We’ll also look
at some changes from the previous
edition of the (2011) NEC, and we’ll
look at one of the major concerns with
transformers.
Fig. 1. Terminal bars are now required to
be installed inside most transformer
enclosures.
Article 450 covers most kinds of
power transformers and lighting
transformers. If you have any other
type of transformer, this NEC Article
probably doesn’t apply. You can scan
through that list of eight and see if
your transformer is there. If so, Art.
450 does not apply. In half of those
exceptions, another NEC Article does
apply.
Change
The 2014 NEC introduced some
changes to the requirements for
transformers. For example, now each
dry-type transformer must have a
place to terminate conductors
[450.10(A)]. When you consider the
number of green and bare wires that
are typically found in a transformer,
it’s really a wonder that this rule
hasn’t been in the NEC for 100 years.
The raceway containing the primary
conductors supplying the transformer
typically contains an equipment
grounding conductor as well. Included
with the secondary conductors, you’ll
find a supply-side bonding jumper.
There will (typically) be a system
bonding jumper inside the
transformer. There will also be
(typically) a grounding electrode
conductor in the transformer.
Wouldn’t it be nice if there were a
place to terminate these wires? Now
there has to be.
Where separate equipment grounding
conductors and supply-side bonding
jumpers are installed, a terminal bar
for these conductors must be installed
inside the enclosure. The terminal bar
must not cover any ventilation
openings (Fig. 1). But there is an
exception: Where a dry-type
transformer is equipped with wire-
type connections (leads), you don’t
have to install that terminal bar.
Another change is that the nameplate
requirements for transformers are
now in a list format [450.11(A)]. A
simple side-by-side comparison of the
2011 and 2014 editions of this section
will convince nearly anyone that lists
are better than long paragraphs.
Transformers must have a nameplate
that provides the following
information:
1) Name of the manufacturer.
2) Rated kilovolt-amperes (kVA).
3) Frequency.
4) Primary and secondary voltage.
5) Impedance of transformers 25kVA
and larger.
6) Required clearances for
transformers with ventilating
openings.
7) Amount and kind of insulating
liquid where used.
8) For dry-type transformers, the
temperature class for the insulation
system.
New with the 2014 NEC is the text
regarding secondary voltage-supplied
transformers. A transformer can be
supplied at the secondary voltage as
long as the manufacturer’s
instructions permit that arrangement
[450.11(B)].
Many people don’t realize that
transformers are suitable to be
supplied at the secondary voltage only
if the transformer is marked for this
application. For example, a
transformer that’s marked as 480V
primary, 208V secondary can’t be
wired with a 208V primary and 480V
secondary. According to UL 1561, only
transformers marked in this manner
can be installed this way.
The 2014 NEC also revised the
allowance for having a transformer
disconnect remote from the
equipment. The reason for this change
was to achieve consistency with
similar NEC rules. In this case, the
Code Making Panel added the new
Section 110.25. This section contains
the rules for disconnecting means that
aren’t within sight of their equipment.
By referring to it, we no longer have
different rules that cover the same
thing spread throughout the NEC.
Fig. 2. Locate the disconnect within sight
of the transformer.
A disconnect is required to disconnect
all transformer ungrounded primary
conductors, unless the transformer is
Class 2 or Class 3 (Fig. 2). You must
locate the disconnect within sight of
the transformer unless the location of
the disconnect is field marked on the
transformer and the disconnect is
lockable, as described in 110.25
[450.14] (Fig. 3). Within sight means
that it’s visible and not more than 50
ft from one to the other [Art. 100].
Fig. 3. You can locate the disconnect in a
remote location if it’s lockable and
you note its location on the transformer,
as described in Sec. 110.25.
Keeping your cool
The prevention of overheating is a
major concern with transformers.
Overheating means an efficiency loss,
but if the heat gets bad enough, the
transformer will fail — maybe even
catastrophically. While the NEC does
mention that you shouldn’t do
something such as orient a dry-type
transformer so its vent is facing a wall
only inches away [450.9], you don’t
get a whole lot more than that
regarding the many heat-related
issues that affect transformer
installation decisions.
So much of what it takes to “get it
right” with transformers simply is not
mentioned. Why doesn’t the NEC
completely address these issues?
The reason is the scope of the NEC.
Article 90 explains that the NEC isn’t
a design manual. It assumes the
person using it has a certain level of
expertise. Proper transformer
selection is an important part of
preventing a transformer from
overheating, and the NEC assumes
you have the expertise (or someone in
your company does) to correctly select
the right transformer for the
application.
When it presents the installation
requirements, the NEC assumes
you’ve already selected a transformer
suitable to the load characteristics.
For the NEC to tell you how to do that
would push it into the realm of a
design manual and/or engineering
tutorial.
However, Art. 450 picks up after
those kinds of “you should already
know this” issues. It takes you to the
next logical step by providing
requirements for overcurrent
protection and the proper
connections. Then it goes on to
provide ventilation requirements
[450.9] and accessibility requirements
[450.13]. At this point, you’re at the
end of Part I. Now you can think of a
strategy for quickly finding the
requirements relevant to your
particular installation.
Finding exactly what you
need
So how do you get to the requirements
you need for your particular
installation? Part I of Art. 450
contains the general requirements
such as guarding, marking, and
accessibility. Requirements for
autotransformers and ties are also in
there. Part II contains the
requirements for different types of
transformers. Part III covers
transformer vaults.
In the dry-type transformer example
we gave at the outset, you’re not using
a transformer vault. So you can ignore
Part III. It’s not an autotransformer,
and you aren’t doing ties — so you can
skip a big chunk of Part I. But Part II
still has quite a few requirements.
The key to Part II is realizing all of the
requirements are arranged by type of
transformer. That means each
subsection is exclusive to a particular
transformer type. The sole exception
to this pattern is the final subsection
[450.28] of Part II, which addresses
what you must do if you change the
type of transformer.
When you’re trying to find the
applicable requirements for your
transformer, you can look at the
headings in Part II. For your 30kVA
120/208V transformer, you’re in luck.
because right away you see 450.21
addresses dry-type transformers
installed indoors. Even luckier for
you, subsection (A) is for those not
greater than 112.5kVA. You can ignore
the rest of Part II.
But what if you were installing an
askarel-filled transformer indoors?
You would skip right past 450.21 and
450.22, which both address dry-type
transformers (installed indoors and
outdoors, respectively).
Don’t use this shortcut with all NEC
Articles. It works in this special case
and with a few other Articles. With
some Articles, you can’t cherry pick
this way without missing something
important. It just so happens you can
do that when trying to determine the
requirements for transformers.