Transformers 6

Overcurrent Protection

Fusing and circuit breaker protection. How to overcurrent protect 600 Volt class transformers and associated wiring
per NEC 450-3(b) and NEC 240-3.

1. Primary protection only is required if the transformer is 2. If the branch circuit feeding the transformer has
single-phase and the secondary has only two wires. overcurrent protection to meet the individual protection
Overcurrent protection rating and location are shown in requirements in Example 1, then individual transformer
Diagram A. protection is not required.

Primary Current Overcurrent Protection Rating

Primary Current Overcurrent Protection Rating
Less than 2 amps 300% maximum
Less than 2 amps 300% maximum
2 to 9 amps 167% maximum
2 to 9 amps 167% maximum
125% of rated primary current (or
9 amps or more 125% of rated primary current (or
next highest standard rating) 9 amps or more
next highest standard rating)

Diagram A Diagram B

3. Primary and secondary protection is required if the 4. If the branch circuit feeding the transformer has
transformer has more than two wires on the secondary overcurrent protection to meet the individual primary
circuit. overcurrent protection requirements in Example 3, then
individual primary protection is not required. Secondary
OCP is required as shown below.

Primary Secondary Overcurrent

Current Current Protection Rating
250% primary current Less than 9 amps 167% maximum
125% (or next higher Overcurrent
Not more than 250% 9 amps or more Primary Current Secondary Current
standard rating) Protection Rating

Diagram C 250% primary current Less than 9 amps 167% maximum

125% (or next higher

Not more than 250% 9 amps or more
Section 240.6 (a) of the 2008 National Electrical Code* standard rating)

The standard ampere ratings for fuses and inverse time Diagram D
circuit breakers shall be considered 15, 20, 25, 30, 35, 40,
45, 50, 60, 70, 80, 90, 100, 110, 125, 150, 175, 200,
225, 250, 300, 350, 400, 450, 500, 600, 700, 800, 1000,
* Reprinted with permission from NFPA 70-2005, National Electri-
1200, 1600, 2000, 2500, 3000, 4000, 5000 and 6000
cal Code®, ©2008, National Fire Protection Association, Quincy, MA
amperes. Additional standard ratings for fuses shall be 02269. This reprinted material is not the complete and official position
considered 1, 3, 6, 10 and 601. The use of fuses and of the NFPA on the referenced subject which is represented only by the
inverse time circuit breakers with nonstandard ampere standard in its entirety.
ratings shall be permitted.

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 6 Transformers

Primary Fuse Recommendations

Primary Voltage

Vin 120 200 208 220 230 240 277 440 460 480 550 575 600
VA
50 1.25 (2) .75 (1.25) .6 (1.13) .6 (1.13) .6 (1) .6 (1) .5 (.8) .3 (.5) .3 (.5) .3 (.5) .25 (.4) .25 (.4) .25 (.4)

75 1.8 (3) 1.13 (1.8) 1 (1.8) 1 (1.6) .8 (1.6) .8 (1.5) .8 (1.25) .5 (.8) .4 (.8) .4 (.75) .4 (.6) .3 (.6) .3 (.6)

100 2.5 (4) 1.5 (2.5) 1.4 (2.25) 1.25 (2.25) 1.25 (2) 1.25 (2) 1 (1.8) .6 (1.13) .6 (1) .6 (1) .5 (.8) .5 (.8) .5 (.8)

150 3.5 (6.25) 2.25 (3.5) 2 (3.5) 2 (3.2) 1.8 (3.2) 1.8 (3) 1.6 (2.5) 1 (1.6) .8 (1.6) .8 (1.5) .8 (1.25) .75 (1.25) .75 (1.25)

200 5 (8) 3 (5) 2.8 (4.5) 2.5 (4.5) 2.5 (4) 2.5 (4) 2 (3.5) 1.25 (2.25) 1.25 (2) 1.25 (2) 1 (1.8) 1 (1.5) 1 (1.6)

250 3 (5) 3.5 (6.25) 3.5 (6) 3.2 (5.6) 3.2 (5) 3 (5) 2.5 (4.5) 1.6 (2.8) 1.6 (2.5) 1.5 (2.5) 1.25 (2.25) 1.25 (2) 1.25 (2)

300 4 (6.25) 4.5 (7.5) 4 (7) 4 (6.25) 3.5 (6.25) 3.5 (6.25) 3.2 (5) 2 (3.2) 1.8 (3.2) 1.8 (3) 1.6 (2.5) 1.5 (2.5) 1.5 (2.5)

350 4.5 (7) 5 (8) 5 (8) 4.5 (7.5) 4.5 (7.5) 4 (7) 3.5 (6.25) 2.25 (3.5) 2.25 (3.5) 2 (3.5) 1.8 (3) 1.8 (3) 1.75 (2.5)

500 6.25 (10) 4 (6.25) 4 (6) 3.5 (5.6) 3.5 (5) 3 (5) 5 (9) 3.2 (5.6) 3.2 (5) 3 (5) 2.5 (4.5) 2.5 (4) 2.5 (4)

750 10 (15) 6.25 (9) 6 (9) 5.6 (8) 5 (8) 5 (7.5) 8 (12) 5 (8) 4.5 (8) 4.5 (7.5) 4 (6.25) 3.5 (6.25) 3.5 (6.25)

1000 12 (20) 8 (12) 8 (12) 7.5 (10) 7 (10) 6.25 (10) 10 (17.5) 3.5 (5.6) 3.6 (5) 3 (5) 5 (9) 5 (8) 5 (8)

1500 17.5 (30) 12 (15) 12 (15) 10 (15) 10 (15) 10 (15) 15 (25) 5.6 (8) 5 (8) 5 (7.5) 4.5 (6.25) 4.5 (6.25) 4.5 (6.25)

2000 25 (40) 15 (25) 15 (20) 15 (20) 12 (20) 12 (20) 20 (35) 7.5 (10) 7 (10) 6.25 (10) 6 (9) 5.6 (8) 5 (8)

3000 35 (60) 20 (35) 20 (35) 17.5 (30) 17.5 (30) 20 (30) 35 (50) 10 (15) 10 (15) 10 (15) 9 (12) 8 (12) 8 (12)

5000 60 (100) 35 (60) 30 (60) 30 (50) 30 (50) 30 (50) 60 (90) 15 (25) 15 (25) 15 (25) 12 (20) 12 (20) 12 (20)

7500 80 (150) 50 (90) 45 (90) 45 (80) 45 (80) 40 (70) 90 (125) 25 (40) 25 (40) 20 (35) 20 (30)

10K 110 (200) 70 (125) 60 (110) 60 (110) 60 (110) 60 (100) 110 (175) 30 (50) 30 (50) 30 (50) 25 (45)

15K 175 (300) 100 (175) 90 (175) 90 (150) 90 (150) 80 (150) 175 (250) 45 (80) 45 (80) 40 (70) 35 (60)

25K 300 (500) 175 (300) 150 (300) 150 (250) 150 (250) 150 (250) 90 (250) 60 (70) 70 (125) 70 (125) 60 (110)

37K 200 (350) 100 (175) 80 (150)

50K 300 (500) 150 (250) 110 (200)

75K 400 (750) 200 (350) 175 (300)

100K 600 (1000) 300 (500) 225 (400)

167K 900 (1600) 450 (850) 350 (650)

Fuse = I*300% next size smaller if primary current is less than 2 amp. No secondary fusing required.
(Fuse) = (I*500%) next size smaller if used for a motor control circuit per NEC 430-72[C] exception No. 4

Fuse = I*167% next size smaller if primary current is less than 9 amp. No secondary fusing required.
(Fuse) = (I*250%) next size smaller if primary current is less than 9 Amps. Secondary fusing is required see chart for size.

Fuse = I*125% next size higher if primary current is 9 amp. or higher. No secondary fusing required.
(Fuse) = (I*250%) next size smaller if primary current is 9 Amps. or higher. Secondary fusing is required see chart for size.

Recommended fuse sizes per UL 508 and NEC450-3 (B) (1), NED 430-72 and commercially available type fuses.

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182 contact Technical Services at (800) 377-4384 with any questions.
 Transformers 6
Primary Overcurrent Protection Secondary Fuse Recommendations
A transformer has all the same component parts Secondary Voltage
as a motor, and like a motor, exhibits an inrush when
energized. This inrush current is dependent upon where V 24 110 115 120 220 230 240
OUT

in the sine wave the transformer was last turned off in VA Secondary Time Delay Dual Element Slow-Blow Fuse
relation to the point of the sinewave you are when you
50 3.2 0.75 0.6 0.6 0.3 0.3 0.3
energize the transformer. Although transformer inrush could
run up to 30 to 35 times full load current under no load, it 75 5 1.125 1 1 0.5 0.5 0.5
typically is the same as a motor...about 6 to 8 times normal 100 6.25 1.5 1.4 1.25 0.75 0.6 0.6
running current. For this reason it is important to use a dual
150 10 2.25 2 2 1.13 1 1
element slow blow type fuse - the same type of fuse you
would use with a motor. If using a circuit breaker, select a 200 12 3 2.8 2.5 1.5 1.4 1.25
breaker with a time delay – again the same type you would 250 15 3.5 3.5 3.2 1.8 1.8 1.6
use with a motor. If the time delay is not sufficient, you may
300 20 4.5 4 4 2.25 2 2
experience “nuisance tripping” – a condition where the
breaker trips when energizing the transformer but when you 350 20 5 5 4.5 2.5 2.5 2.25
try it again, it works fine. 500 30 7.5 7 6.25 3.5 3.5 3.2
750 40 10 10 10 5.6 5 5
Secondary Overcurrent Protection 1000 12 12 12 7 7 6.25
Overcurrent devices are used between the output terminals 1500 17.5 17.5 17.5 10 10 10
of the transformer and the load for three reasons:
2000 25 25 25 12 12 12
1. Protect the transformer from load electrical anomalies. 3000 35 35 35 17.5 17.5 17.5

2. Since short circuit current is minimized, a smaller gauge 5000 60 60 60 30 30 30

wire may be used between the transformer and the load. 7500 90 90 80 45 45 40
3. Per NEC, a larger primary fuse may be used to 10K 125 110 110 60 60 60
reduce nuisance tripping.
15K 175 175 175 90 90 80
25K 300 300 300 150 150 150
37.5K 400 200
50K 600 300
75K 800 400
100K 1200 600
167K 1800 900

Fuse = I*167% next size smaller if secondary

current is less than 9 amp.
Fuse = I*125% next size smaller if secondary
current is 9 amp. or higher.

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 6 Ventilated Distribution Transformers
The Energy Policy Act of 2005 (H.R. 6) requires Distribution
Transformers manufactured after January 1, 2007 to meet
specific energy efficiency requirements. EPAct 2005
defines the term “distribution transformers” as any
transformer which:

• Has an input voltage of 34.5 kVA or less

• Has an output voltage of 600 V or less
• Is rated for operation at a frequency of 60 Hz
• Has a capacity of 10 kVA to 2500 kVA for
liquid-immersed units and 15 kVA to 2500 kVA
for dry-type units
Figure 1
The following special purpose transformers are excluded
SolaHD offers the following family of transformers that meet
from the definition of “distribution transformers” and are,
the strict efficiency standards. The efficiencies of these trans-
therefore, not required to meet the energy efficiency stan-
formers are optimized for the load losses calculated
dards at this time:
at 35% of the name plate rating. This 35% represents an
industry average load of most LVGP transformers.
• Autotransformers
• Drive (isolation) transformers Applications
• Grounding transformers
Any situation where the available voltage must be changed
• Machine-tool (control) transformers to accommodate the voltage required by the specific
• Non-ventilated transformers electrical circuit or connected equipment. For many
• Rectifier and Regulating transformers electrical circuits, the National Electrical Code (NEC)
• Sealed transformers requires a separately derived neutral secondary connection
• Special-impedance transformers provided by Delta-Wye connected transformers.
• Testing transformers
Distribution transformers can be located close to the load.
• Transformer with tap range of 20% or more No vaults are required for installation and no long, expensive
• Uninterruptible power supply transformers feeder lines are needed. Common applications include
• Welding transformers inductive and resistive loads such as motors, lighting and
heating.
Benefiting from Higher Energy Efficiencies
General Purpose Transformers
Increasing the energy efficiency of a transformer allows the
unit to operate at the same level of power with less energy Transformers designed to meet the high energy efficiencies
being wasted in the process. Decreasing usage through required by NEMA Standard TP-1.
reduced waste by just .03% over the next 20 years cuts the
need for new power generation in the United States by 60 to Low Temperature Rise Transformers
66 million kw. Transformers designed to limit the temperature rise of the
core and coil assembly to either 80°C or 115°C above a
SolaHD has been engineering and producing energy 40°C ambient. Reduction in temperature rise increases
efficient transformers for the past six years. The SolaHD E reliability.
version transformers are optimized to meet NEMA’s TP-1
limits for load losses calculated to 35% of the name plate K-Factor Transformers
rating, yet are the same compact size and footprint as its’ Transformers designed to withstand the electrical anomalies
conventional 150˚C rise units. associated with solid state equipment and DC power
supplies (excluding SCR variable speed motor drives)
The example pictured in Figure 1 shows the differences in without derating the nameplate kVA.
efficiency for the old standard model compared to the
compliant model. At 35% load, the absolute difference in Copper Wound Transformers
efficiency is only 1.7%. However, that represents a 52%
SolaHD general purpose transformers have standard
reduction in wasted energy. Taking that 52% reduction in
aluminum coil windings. As an option, we offer a selection
wasted energy and multiplying it across all the energy
with copper windings.
consumed results in substantial savings.
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184 contact Technical Services at (800) 377-4384 with any questions.