Transformer Terms and Definitions

A transformer is a static electrical apparatus, placed into an iron core consisting of thin steel

800.428.2626 • 313.567.8500 • FAX 313.567.8828 • www.dongan.com

DONGAN ELECTRIC MANUFACTURING CO. • 2987 FRANKLIN • DETROIT, MI 48207
without moving parts, which transfers energy from plates laminated and fastened together into a single
one alternating current source to one or more unit. Alternating current supplied to the line, or input
circuits - at the same frequency (Hz). Transformers side of the transformer creates a magnetic field
may be used to increase voltage (Step-Up), which induces a voltage in the load, or output side
decrease voltage (Step-Down) or to keep voltage of the transformer. This current flows even though
the same in electrically isolated circuits. This ability the two windings do not physically touch each
creates an effective match between the incoming other. The change of voltage from line side to load
line voltage and the required load voltage for a wide side is proportional to the turns ratio of the two
variety of devices in a wide variety of electrical windings. This turns ratio forms the basis for the
circuits. Transformers are designed to provide a various transformer voltage combinations depicted
long life when used under normal conditions of in this catalog.
load, temperature and line harmonic content. Unless noted, transformers in this catalog are
Transformers operate under the principles of wound as isolation or insulating type transformers.
electromagnetic induction. This means that primary and secondary windings
are physically separated, and electrically isolated,
Dry-Type Transformers: from each other. This physical separation of
Transformers are divided into two basic types, dry- windings makes isolation transformers distinct from
type and oil-filled. Dry-type transformers rely on autotransformers - whose windings are physically
various types of solid insulation materials, both connected to each other. Most installations of
natural (paper-based and various varnishes) and general purpose transformers require the use of an
synthetic (various polymers and silicones), and insulating or isolating type transformer. Buck-boost
pass their heat directly to air or indirectly through a applications are a noted exception.
heat conducting encapsulant such as epoxy.
Dry-type transformers require little or no
maintenance through their service life other than
Taps:
assuring that connections remain clean and tight, Installers of transformers in commercial and
that the loading on the transformer remains within industrial locations frequently encounter inherent
design limits, and that air flow through the high or low voltage conditions in which the use of a
transformer is not impeded by extraneous materials transformer would result in proportionally higher or
or dust. Dry-type transformers are therefore the lower voltage on the output side of the transformer.
primary choice for indoor locations, and can be This results because most transformers are
used anywhere a transformer is required. designed with fixed turns ratios. Transformer taps
Oil-filled transformers, on the other hand, have a are designed to compensate for these steady state,
sealed or pressure-vented enclosure with the high or low voltage situations while still allowing the
windings submersed in an oil-based fluid which transformer to deliver full nameplate rated output
serves as both insulation and a heat transfer current and voltage to the connected load. Taps are
(cooling) medium. Because the oil may pose a fire referred to as FCAN - Full Capacity Above Normal
hazard, oil-filled transformers are generally limited and FCBN - Full Capacity Below Normal and are
to outdoor use. The oil and its attendant cooling generally furnished on the primary winding. By
devices (pumps, fans, radiators, etc.) also require connecting to an above or below normal tap, the
regular maintenance and supervision. transformer’s turns ratio is changed.
Except for the very smallest sizes, all Dongan dry- For example, suppose line voltage in a 480 volt to
type enclosed transformers are fully approved for 120 volt step down installation is supposed to be
indoor or outdoor installation under normal 480 volts, but is measured and found to be only
conditions without any accessory purchase or 432 volts (a 48 volt -10% difference). Connecting a
modification (NEMA 3R rating). Some specialized transformer without taps would result in an output
types are supplied standard in NEMA 12 of about 10% reduced voltage, or 108 volts. While
enclosures. Enclosures for more severe locations, this may be acceptable for some installations, other
such as NEMA 4, 4X, and 12 are available on a equipment may not tolerate the low voltage.
special order basis. However, the same load connected to a transformer
with its primary wired to a 10% below normal tap
Construction: will see output of exactly 120 volts, as desired.
Transformers, in their simplest form, consist of two
or more windings of insulated magnet wire wound
around insulated forms. These forms are then 91
 Transformer Terms and Definitions

Polarity: Shielded isolation transformers attenuate common

800.428.2626 • 313.567.8500 • FAX 313.567.8828 • www.dongan.com
DONGAN ELECTRIC MANUFACTURING CO. • 2987 FRANKLIN • DETROIT, MI 48207

Polarity is the instantaneous voltage obtained from mode noise transients by providing a barrier, called
the secondary winding in relation to the primary a Faraday Shield, to the capacitive linking of the
winding. primary and secondary windings. The barrier
reduces, or attenuates, the amount of non 60 Hz
While Alternating Current (AC) does not have frequencies passed through the transformer in
polarity in the same sense as Direct Current (DC), either direction. This is accomplished by
polarity is involved whenever circuits or connecting the Faraday Shield to ground,
transformers are connected together. When two effectively reducing transmission of frequencies
wires in AC circuits are of like polarity, the voltage is other than 60 Hz.
rising simultaneously in both, with the current flow
in the same direction. Typical attenuation levels of 50:1 ( 34 DB ) are
achievable with Dongan shielded isolation
Polarity is normally only a consideration when transformers. This attenuation provides noise levels
connecting two or more transformers or windings in generally considered to solve many noise and
series or parallel. For example, the voltages of two transient caused problems. Most Dongan General
windings connected in series will add together if the Purpose transformers are furnished with shields at
start of the second winding is connected to the no additional cost. Shielded transformers are
finish of the first; if the finishes or starts are designated by the suffix SH or the prefix ES.
connected together, the lower voltage will subtract
from the higher. This is the principle upon which
Buck-Boost transformers and transformers with split Regulation:
primaries or secondaries operate. A transformer will generally provide a higher output
voltage when no load is attached to it than when
the transformer is fully loaded at nameplate
Shielding: capacity. Stated differently, under load, a
Most transformer installations today are used to transformer’s output voltage drops slightly.
power circuits containing solid state devices Regulation is the ratio of the difference between a
sensitive to electrical “noise”, transients and voltage transformer’s no load output voltage to its full load
spikes. While the possibility of voltage spikes due output voltage expressed as a percentage.
to lighting strikes on nearby transmission lines
exists, the more frequent threat to electronic For example, suppose a transformer has a no load
equipment comes from conducted electrical noise. voltage of 124 volts and a full load voltage of 120
Noise and transients can enter installations from volts. The transformer’s regulation is calculated as
distant external sources or from internal sources follows:
such as fluorescent ballasts and switch mode Regulation =
( No Load Voltage - Full Load Voltage )
power supplies. Shielded transformers mitigate the ( No Load Voltage )
harmful effects of certain types of transients.
Transients are high energy, short duration bursts of Regulation =
124 - 120
electrical energy covering a wide range of 120
frequencies other than the nominal domestic 60 Hz
distribution frequency. These bursts range from a Regulation = 3.33%
high of 20 kHz to a low or about 25 Hz. Distribution
systems encounter two types of transient noise:
transverse mode and common mode noise. Temperature and Insulation
Differences in the two are found in their reference to
ground. Ambient Temperature:
Transverse mode noise is noise occurring between The ambient temperature is the average
circuit supply lines. Shielded isolation transformers temperature of the air in the immediate area
have no significant effect in combating transverse surrounding the transformer. The transformer
noise. Generally, though, transverse mode noise dissipates its heat into this ambient air.
transients dissipate when loads are placed across All Dongan transformers are designed to operate in
the lines on which they appear. ambient temperatures of 40°C (104°F) maximum.
Common mode noise, on the other hand, contains Derating of transformers is necessary when
transients appearing between the wires of the ambients exceed 40°C (See Operations Section)
distribution system and ground. Common mode
noise is typically passed to the secondary, or output Temperature Rise:
side of the transformer through a capacitive link Temperature rise refers to the difference in
between the primary and secondary windings. temperature between the ambient air temperature
Circuits containing substantial common mode noise and the actual temperature of the windings or
will eventually cause failure to sensitive enclosure.

92 components.
Transformer Terms and Definitions

Insulation System: Insulation Class:

800.428.2626 • 313.567.8500 • FAX 313.567.8828 • www.dongan.com

DONGAN ELECTRIC MANUFACTURING CO. • 2987 FRANKLIN • DETROIT, MI 48207
An insulation system is a collection of insulating This is an older letter classification reference to an
components used to protect the transformer from insulation material’s ability to protect a transformer
the effects of heat and dielectric stress occurring operating at different temperature rises and various
during the normal operation of the transformer. total operating temperatures. The original letter
Typically these components include insulation designations have given way to numerical
coatings on magnet wire, insulation between Centigrade insulation system temperatures, the
winding layers and between windings, tape, and most popular of which are 105°C, 130°C, 180°C,
other components. 200°C, and 220°C. Please see Chart 1.2 to see how
these classes and temperature ratings are derived.
Hot-Spot Temperature:
The hot-spot temperature refers to the highest
temperature found inside the transformer winding. Average
Former Limiting
Hot-spot temperature allowances vary with Temperature
Designation Temperature
insulation classes. See the Total Winding Rise
Temperature, Chart 1.1, for a graphical
representation of hot spot temperature values. Class A 105° C 55° C
Class B 130° C 60° C
Total Winding Temperature (ºC)
220 Class F 155° C 85° C

30 Class H 180° C 115° C

Class N 200° C 135° C
180
Class R 220° C 150° C
25
Class C 240° C 150° C

130 Chart 1.2

10
150 A transformer operating within its insulation system
Coil
will have the same life expectancy as any other
Hot-Spot 105 115 insulation system. In other words, a high
Differential 10
80
temperature rise system is designed for the same
Average service life as the low temperature rise system.
Winding
Temp. 55
Rise
Basic Impulse Level (BIL) and
Ambient 40 40 40 40 Transformer Insulation Systems:
Basic Impulse Level (BIL) refers to a series of
UL/ANSI 1561 March 1987 dielectric tests performed on the transformer’s
insulation system. These tests measure the
Chart 1.1 insulation system’s ability to withstand line surges
Insulation System from such sources as the network grid and
lightning.
Temperature and Class: These tests are performed by applying a high
The insulation system temperature indicates the frequency voltage between windings and between
insulation system’s maximum operating windings and ground to look for weaknesses in the
temperature in service. This temperature is insulation system.
determined by the temperature rating of the
insulation components in a particular design Dongan transformers comply with NEMA standard
including tape, layer insulation, magnet wire 10 kV BIL ratings.
insulation coatings and impregnation materials. The
system temperature is determined by adding the Enclosure Temperatures:
ambient temperature, rise and the hot spot The temperature of the enclosure of enclosed
temperature. Transformers operated under normal transformers is not equivalent to the temperature of
operating conditions will not exceed this the transformer inside. In air-cooled transformers,
temperature, and will enjoy a long service life. much of the heat produced by the transformer is
Dongan transformers use UL approved insulation transferred to the air flowing through the cabinet.
systems whose constituent parts have been This allows the enclosure surface to be much
extensively tested for compatibility and long life. cooler than the transformer element inside.

93
 Transformer Terms and Definitions
In epoxy encapsulated transformers, the Nameplate kVA
800.428.2626 • 313.567.8500 • FAX 313.567.8828 • www.dongan.com
DONGAN ELECTRIC MANUFACTURING CO. • 2987 FRANKLIN • DETROIT, MI 48207

% Efficiency= x 100
transformer’s heat is conducted by the epoxy to the Nameplate kVA + Total Losses
enclosure. Because the surface area of the
enclosure is greater than that of the transformer, the In a typical enclosed, ventilated, dry-type
temperature at the enclosure surface tends to be transformer, air flow through and around the
significantly less than that found on the surface of enclosure transfers and dissipates the heat from the
the transformer element inside. core and windings. This assures that enclosure
UL and CSA standards strictly regulate the highest temperatures will remain well below internal
temperature which the case can reach. The winding temperatures.
enclosure temperature rise shall not exceed 50°C in
a 40°C ambient at full rated current. While these Inrush Current:
temperatures are quite warm to the touch, they are All transformers consume a higher amount of amps
completely within the allowed parameters of the than rated current for a very short duration when
insulation system, UL and NEMA standards. All first energized. This “inrush current” is highest when
Dongan transformers comply with these standards.

Enclosure Ratings: Enclosure

Provides a Degree of Protection Against: May be Used
NEMA and NEC® standards provide Rating
enclosure ratings which classify the NEMA 1 Incidental contact and falling dirt. Indoor
degree of protection afforded by
enclosures against various NEMA 2 Limited amounts of falling water and dirt. Indoor
environmental conditions. The chart NEMA 3 Rain, sleet, and windblown dust, and ice resistant. Outdoor
to the right indicates some of the
NEMA 3R Outdoor
most common ratings and their Rain, sleet, and ice resistant.

protection characteristics. NEMA 4

Windblown dust and rain, splashing or hose directed water
Indoor / Outdoor
and ice resistant.

Excitation Current, Losses NEMA 4X Same as NEMA 4 plus corrosion resistant Indoor / Outdoor

and Efficiency: NEMA 6

Entry of water during temporary, limited submersion and
damage from external ice.
Indoor / Outdoor
Excitation current in transformers is
Entry of water during prolonged, submersion at
the amount of current needed to NEMA 6P a limited depth and damage from external ice.
Indoor / Outdoor
magnetize and maintain the field in
the transformer’s core whether a NEMA 11 Oil immersion, corrosion resistance. Indoor
secondary load is connected or not. NEMA 12 Circulating dust, falling dirt, and dripping noncorrosive liquids. Indoor
Excitation current is normally
expressed as a percentage of the full NEMA 12k Same as NEMA 12 - with knockouts. Indoor
rated current of the winding in which NEMA 13 Dust, spraying water and oil, and noncorrosive coolant fluids. Indoor
it is measured and is frequently
referred to as “ no load current”,
although this term is not technically the transformer is energized under conditions of no
correct. secondary load. The magnitude of the inrush
Typical excitation current values range from about current is also affected by the point in the AC sine
10% in small, fractional kVA transformers to lows of wave in which the transformer power is switched
1% or 2% in larger dry-type transformers. on.
Excitation current has two components: a Because of this short duration burst, overcurrent
magnetizing component and a core loss protective devices supplying transformer primaries
component. Core losses are comprised of eddy should be of the time-delay type. Proper
current and hysteresis losses and are observed as overcurrent protection will minimize “nuisance” trips
dissipated heat. These losses (and heat) are attributed to transformer inrush. Please consult your
constant whether the load is connected or not. Dongan Representative or Dongan Customer
Under load conditions, energy is also consumed in Service for further advice on any inrush related
the windings due to the winding’s resistance. These questions.
losses, converted to heat, are called winding losses
and are proportional to the amount of load. The Computations with Impedance:
sum of core losses and winding losses constitute Impedance is the vector sum of the reactance and
the total losses developed by a transformer. resistance limiting current flow in an AC circuit.
Transformer efficiency is a reflection of the amount Impedance in transformers is expressed as a
of total losses inherent in the transformer. It is percentage and is indicated on nameplates as % IZ.

94 calculated as follows: Most distribution transformers have impedance

ranges of from 3% to 8%. Impedance is determined
Transformer Terms and Definitions
by inherent characteristics of the transformer Next Determine:

800.428.2626 • 313.567.8500 • FAX 313.567.8828 • www.dongan.com

DONGAN ELECTRIC MANUFACTURING CO. • 2987 FRANKLIN • DETROIT, MI 48207
including kVA, wire size, and other design
considerations. Maximum Short Circuit Current
The most important calculations using impedance
are those used in determining interrupting capacity Full Load Amps
=
of primary overcurrent devices (fuses and circuit Impedance
breakers). For example, suppose you are required
to determine the interrupting capacity of a single 36.08
=
phase, 15 kVA transformer with 5% impedance 6%
connected to a 480 volt supply.
36.08
=
Determine: .06

= 601.3 Amps
Full Load Amps (FLA):
This calculation confirms that the minimum
Nameplate kVA x 1000 interrupting capacity of the fuse or circuit breaker
FLA =
Primary Supply Voltage must be no less than 601.3 amps at 480 volts.
15 x 1000
FLA =
480 Transformer Operations
FLA = 31.25 Amps Overloading Transformers:
The life of a transformer is dependent on the life of
Next Determine: its insulation. Transformers loaded in excess of
nameplate rated kVA develop excessive heat.
Excessive heat will lead to degradation of the
Maximum Short Circuit Current
insulation system and premature failure of the
transformer. For this reason, transformers should
Full Load Amps
= not be overloaded. Transformers should be sized
Impedance with future loads in mind to reduce the possibility of
overloading and consequently reducing service life.
31.25
=
5% Operation of transformers in ambient
31.25
temperatures exceeding 40°C:
= Operating transformers in ambient air exceeding
.05 40°C will reduce operational life unless the
transformer is allowed to operate under conditions
= 625 Amps of reduced maximum load. The chart below
indicates recommended derating for various
This calculation confirms that the minimum ambient temperatures. While special designs for
interrupting capacity of the fuse or circuit breaker high ambient temperatures can be supplied,
must be no less than 625 amps at 480 volts. standard transformers derated are both more
Now suppose you are required to determine the economical and more readily available. Consult the
interrupting capacity of a three phase, 30 kVA factory for ambient temperatures exceeding 60°C.
transformer with 6% impedance connected to a 480
volt supply. Maximum Maximum
Ambient Percentage
Determine: Temperature of Loading

Full Load Amps (FLA): 40°C (104°F) 100 %

50°C (122°F) 92 %
Nameplate kVA x 1000 60°C (140°F) 84 %
FLA =
Primary Supply Voltage x 1.732
Chart 1.3
30 x 1000
FLA =
480 x 1.732

FLA = 36.08 Amps 95

 Transformer Terms and Definitions

Operation of transformers at frequencies Example:

800.428.2626 • 313.567.8500 • FAX 313.567.8828 • www.dongan.com
DONGAN ELECTRIC MANUFACTURING CO. • 2987 FRANKLIN • DETROIT, MI 48207

other than 60 Hz: Suppose we have a 10 kVA transformer with

Any transformer rated for use with 50 Hz, or 50/60 multiple single phase loads of both 120 and 240
Hz distribution systems, is suitable for operation at volts as follows:
either 50 Hz or 60 Hz. Transformers rated for 120 volts, 2 kVA
operation at 60 Hz only are not suitable for 120 volts, 1 kVA
operation at 50 Hz due to core saturation. This 120 volts, 1 kVA
causes higher losses and excessive heat inherently
created in transformers not engineered for 50 Hz 240 volts, 6 kVA
applications. The load must be divided so as not to overload any
Dongan transformers rated 50/60 Hz and 60 Hz are winding. The diagrams below indicate correct and
suitable for operation at frequencies up to and incorrect connection methods.
including 400 Hz provided supply voltages do not
exceed rated nameplate voltages. Transformers
used at 400 Hz will have output voltages slightly
higher than output voltage at standard frequency
ratings, and voltage regulation at 400 Hz will be
slightly less accurate.
General purpose transformers are designed to
change voltage. They are not capable of changing,
or converting frequency from one value to another.
Frequency converters or generators are necessary
if frequency conversion is required.

Operation of transformers at other than

nameplate voltages: Incorrect - one 120 V Correct - Both 120 V
Transformers must not be operated at voltages winding is loaded at 6 kVA. winding are loaded at 5
higher than indicated on the nameplate. The only (3 kVA of 120 volts, and 3 kVA. (2 kVA of 120 volts,
exception to this rule is when Full Capacity Above kVA of 240 Volts). and 3 kVA of 240 Volts).
Normal (FCAN) taps are provided to accommodate
higher voltage.
Balanced Loading of
Transformers may be operated at lower than
nameplate voltage provided the transformer’s Three Phase Transformers:
capacity is derated in the same ratio as the voltage Three phase transformers have balanced loading
reduction. For instance, suppose a 5 kVA considerations similar to single phase in that no
transformer with a 480 volt primary and 240 volt phase can be overloaded. Each phase must not be
secondary is connected to a 240 volt source, loaded at more than one-third of the nameplate kVA
resulting in a 120 volt output. Since the transformer of the transformer. For example, a 30 kVA
capacity must be derated in the same ratio as the transformer may be loaded at no more than 10 kVA
voltage, the capacity for this example will be 2.5 per phase (one-third of 30 kVA). Load per phase is
kVA, or a 50% reduction. determined by adding the single phase load on any
phase plus one-third of the total three phase load.
Balanced Loading of Single Phase, Suppose we have a three phase, 30 kVA
transformer with a 208 Y/120 secondary and
120 / 240 Volt Secondaries: multiple single and three phase loads as follows:
Many single phase transformers are wound with
120 / 240 volt secondaries suitable for 3 wire, 120 / 120 volts, 4 kVA, single phase
240 volt service. This feature means that the 120 volts, 2 kVA, single phase
transformer is wound with 2 separate 120 volt 120 volts, 6 kVA, single phase
windings designed for series or parallel connection.
120 volts, 5 kVA, single phase
When these 120 volt windings are connected in
series, the transformer is capable of delivering both 208 volts, 9 kVA, three phase
120 and 240 volts simultaneously. It is important to The load must be divided so as not to load any
assure that each 120 volt winding is not overloaded phase at more than 10 kVA. The diagram on the
since each 120 volt winding is designed to carry next page indicates correct and incorrect
only one-half of the nameplate kVA of the connections.
transformer.
Loading on each 120 volt winding is determined by

96 adding the 120 volt load(s) plus one-half of the 240

volt load.
Transformer Terms and Definitions
As you can see, applications of this type can

800.428.2626 • 313.567.8500 • FAX 313.567.8828 • www.dongan.com

DONGAN ELECTRIC MANUFACTURING CO. • 2987 FRANKLIN • DETROIT, MI 48207
severely limit three phase capacity. For this reason,
we recommend single phase loads not exceed 5%
of nameplate capacity. Installers should consider
the use of a separate single phase transformer
when single phase loads are excessive.

Duty Cycle:
Transformers produce heat during the course of
normal operations. Some of the heat produced is
directly related to the amount of load amps drawn
on the transformer. Duty cycle refers to the
percentage of time the transformer is loaded to its
maximum capacity as opposed to not supplying a
load.
Incorrect - Phase B has a total
load of 11 kVA when the maximum
Duty cycle is usually expressed over a period of an
allowed is 10 kVA hour, not including continuous shutdown periods
(overnight, weekends, etc.). Therefore, the duty
cycle refers to the amount of time the transformer is
producing maximum heat output vs. the amount of
time it has to cool off again. The most severe duty
cycle is, of course, 100%. In some cases,
transformers must be oversized in severe duty
cycle applications, and in a few cases they can be
down sized for light duty cycles.
The most important application of duty cycle is in
motor operation, where duty cycle must be
considered along with motor starting cycles. A
situation where a motor runs almost continuously,
(say, 85%) but starts several times per hour will
require an oversized transformer. This is because
the starting current will cause a momentary
overload, with attendant heat buildup, which cannot
Correct - Phase A Load = 9 kVA, be cleared from the transformer due to the high
Phase B Load = 9 kVA, and duty cycle percentage.
Phase C Load = 8 kVA Dongan’s technical and customer service staff can
advise you on proper transformer sizing where
Balanced Loading of a Three Phase severe duty cycle and/or frequent motor starts are
involved.
Transformer with a Center Tapped 240
Volt Delta Winding: Operating Transformers
A common application for three phase transformers with Motor Loads:
with a 240 volt Delta, center tapped winding is to
Transformers are well suited for providing power for
provide power for three phase 240 volt loads and
motor load applications provided a few sizing
single phase 120 volt lighting loads at the same
considerations are followed.
time. Balanced loading is essential to assure
transformer life is not compromised. Typical motors have inrush loads of 5 to 10 times
their running load requirements. Momentary inrush
For example, suppose a 45 kVA, three phase
loads of this magnitude will cause a similar
transformer is to have 36 kVA of three phase load.
momentary transformer output voltage drop.
We know that each phase can carry one-third of the
total nameplate kVA (15 kVA), and that the three Lower transformer output voltage results in lower
phase load splits one-third per phase. In this torque and lower horsepower output of the motor
example, each phase would see one- third of 36 proportionate to the square of the voltage drop. For
kVA, or 12 kVA per phase. This means that no more example, if the voltage drops to 90% of normal,
than 3 kVA of single phase load can be applied to torque and horsepower would be 81% of normal
the center tapped leg. (90%² = 81%)
Additionally, the single phase load must be equally Should the output voltage seen by the motor fall
divided on either side of the center tap so that 1.5 below 50% of nameplate requirements, overheating
and even failure of both motor and/or transformer
kVA is connected between X0 and X2 and 1.5 kVA
is connected between X0 and X3.
97
 Transformer Terms and Definitions
could result. Overheating and failure can occur single phase kVA ratings. For example, three single
800.428.2626 • 313.567.8500 • FAX 313.567.8828 • www.dongan.com
DONGAN ELECTRIC MANUFACTURING CO. • 2987 FRANKLIN • DETROIT, MI 48207

even in cases where correctly sized overcurrent phase 10 kVA transformers connected in this
devices employed in the circuit do not trip. manner will have a capacity of 3 x 10 kVA - or 30
For this reason, transformers should be sized with a kVA, three phase.
few rules in mind. Conversely, two transformer banks are connected
• For applications where one transformer is powering almost solely in an Open Delta (Delta Primary and
one motor, size the transformer so that the motor’s Delta Secondary) configuration. The capacity of the
running amps do not exceed 66% of the 2 unit, three phase bank is equal to the sum of the
transformer’s maximum full load amps. individual single phase kVA ratings multiplied by
• For applications of more than one motor being 86.6% (.866). For example, two single phase 10
powered by the same transformer, motor start up kVA transformers connected in this manner will
should be sequenced so that the motors do not have a capacity of 2 x 10 kVA x .866 - or 17.3 kVA,
start at the same time. If sequencing is not practical, three phase.
size the transformer so that the combined running
amps of all motors do not exceed 66% of the Three Phase to Single Phase:
transformer’s maximum full load amps. Transformers will not “convert” three phase to
• Increase transformer kVA by 20% when motors are single phase.
started more than once per hour. A single phase transformer may be connected to a
• Derate transformer kVA by .3% for each 330 feet three phase source to furnish single phase power.
over 3300 feet above sea level. The primary of the single phase transformer is
connected to any two of the three phase lines, or in
Parallel Operation: the case of a wye service, to any phase line and the
Transformers may be operated in parallel banks to neutral. Primary voltage of the single phase
achieve higher ampacities under the following transformer must be chosen appropriately to match
circumstances: phase-to-phase or phase-to-neutral voltages of the
• Transformer winding voltages must be exactly three phase source.
equal. If there is an imbalance in voltage, excessive Caution must be exercised to avoid unbalanced
current caused by the voltage imbalance will loading of the three phase system supplying power
circulate through the transformer bank, creating to these types of circuits. Examine all connected
heat which will quickly destroy the transformer loads at the three phase source before proceeding.
bank.
• Transformer impedances must be the same.
• Internal and external polarity must be identical on all Single Phase to Three Phase:
connections. Three phase power requires a three phase source.
• Ampacities of the transformers add arithmetically: You cannot use any combination of transformer
two 3 kVA transformers in parallel give a 6 kVA “magic” to produce three phase power from a
capacity. single phase source. When this is required, a
• In addition to the above, three phase transformers rotating phase adder or a special inductive/
must have the same angular displacement and capacitive device called a phase converter must be
phasing. used. This is a highly specialized area, and
In short, the safest way to achieve parallel operation equipment for this purpose should be specified with
is to use identical transformers of the same the advice of firms supplying the phase change
manufacturer. equipment.

Single-Phase Transformers used for Single-Phase Transformers used for Two-

Three-Phase Banks: Phase Operation:
Single phase, stock, general purpose transformers While it is seldom seen, there are areas, particularly
may be banked to achieve a variety of three phase on the East Coast, where two phase power is still
voltage combinations. These combinations are supplied by utility companies. Three phase
achieved by connecting two or three identical 240/ equipment can be operated from a two phase
480 volt, or 600 volt primary, single phase service by using a specialized transformer system
transformers into three phase banks. These banks called a “Scott-connected two-to three phase
provide isolation between primary and secondary transformer bank”.
just as a three phase, general purpose transformer Dongan Electric designs and builds these special-
would. order units for customers on a regular basis. If two-
Typically, banks of three single phase transformers phase power is found or suspected, please consult
are connected in a Delta Primary and Delta with our Engineering Department, because there
Secondary, or a Delta Primary and Wye Secondary are several different wiring configurations found,
configuration. The capacity of the three unit, three and transformer banks designed for each may be

98 phase bank is equal to the sum of the individual incompatible with the others.
Transformer Terms and Definitions

Reverse Connecting Transformers: secondaries. The SCR’s found in switchmode

800.428.2626 • 313.567.8500 • FAX 313.567.8828 • www.dongan.com

DONGAN ELECTRIC MANUFACTURING CO. • 2987 FRANKLIN • DETROIT, MI 48207
Because transformers are based on the ratio of power supplies commonly found in all types of
turns between two windings insulated from each electronic equipment today are a major source of
other, it would appear that there should be no this harmonic distortion. Electronic equipment is
problem with using what is designated as the often connected between a phase and the neutral,
primary for the secondary, and vice versa. For and the harmonic currents generated vary between
instance, someone needing 480 volts from a 120 the phases.
volt source should be able to use a transformer This imbalance in harmonic current generates heat
designed to transform 480 volts to 120 volts wired in the transformer because of extra neutral currents
backwards. and eddy current losses in the core. The effect of
Most transformers sized 1 kVA and above in this these nonlinear loads is expressed as a K-factor,
catalog can be used in this manner. However, with a totally linear load having a K-factor of 1.
because of certain design limitations inherent in Loads generating harmonics can have K-factors
transformers below 1 kVA, these should not be ranging from K=4 to K=50, with K=20 being the
reverse connected without checking with our most severe load commonly encountered. Dongan
engineering staff. Small transformers are usually transformers can be custom-made to serve three
made with a “turns compensation” to help offset phase wye loads with K-factors; please contact us
losses. This compensation will result in an output for details.
voltage that is significantly lower than the primary
voltage shown on the nameplate if the transformer Motor Drive Isolation Transformers:
is reverse connected. Transformers for Motor Drive Isolation are
specifically designed with additional cooling; the
Single Phase Transformers used for windings are designed with additional support so
as to better withstand the constant physical stress
Autotransformer Zig-Zag Ground on them caused by the heavy loads that occur each
Connections: time the thyristors in the drive fire. They are also
Three single phase isolation transformers may be shielded to keep the electrical noise created by the
connected into a three phase, Zig-Zag bank to drive unit from radiating back through the
obtain 277 volts by creating a neutral from an transformer into the building’s power system.
existing 480 volt, three phase, three wire service.
Please see Page 45 for details on this convenient Ordering a Transformer:
and economical hookup.
Several parameters must be established when
specifying a transformer:
Other Autotransformer Connections:
1. Phase Requirements (single or three phase).
There are many applications where single phase
2. Line Voltage from source.
transformers are conveniently used as
3. Load Voltage of load connected to transformer.
autotransformers for both single phase connections
4. Frequency (in Hertz) of current source. This must
and three phase banked connections. Typical three
match frequency requirements of connected load!
phase autotransformer banks may be found in this
5. Load amps of connected load.
catalog in the Three Phase Specialty Application
6. Type of service: General Purpose, Industrial Control,
Section on Page 42 and include 600 to 480, 480 to
in which the transformer is either open or enclosed.
240, and 380 to 240.
In most cases, transformers may be selected by
Common single phase applications include using a answering these six questions. Additional help in
standard General Purpose transformer with a 240 x sizing transformers is provided in each section of
480 volt primary and a 120 / 240 volt secondary to this catalog.
step 480 to 240, single phase, autotransformer
Special applications may require additional
connected. When used in this manner, the
information for sizing. Such cases might include
transformer’s nameplate kVA doubles from its
installations where the power factor is less than
original isolation transformer rating. For example,
unity, harmonics are present in significant amounts,
when autoconnected, a 3 kVA transformer will have
motors are started and stopped frequently, high
a capacity of 6 kVA.
ambient temperatures (above 40°C), or special a
temperature rise is desired.
Harmonics: In such instances, your Dongan Representative will
Most electrical and electronic equipment that is not assist you or you may contact Dongan Customer
a pure resistive or pure inductive load generates Service for additional help.
some amount of harmonic distortion of the basic
sine wave of the power system. These nonlinear
devices can generate levels of harmonic distortion
that are significant enough to cause problems for
three phase transformers with wye-connected
99
 Transformer Terms and Definitions

Receipt and Handling: ground. Proper grounding in transformer

800.428.2626 • 313.567.8500 • FAX 313.567.8828 • www.dongan.com
DONGAN ELECTRIC MANUFACTURING CO. • 2987 FRANKLIN • DETROIT, MI 48207

Upon receipt of shipment, dry type transformers installations is essential in increasing the safety of
should be thoroughly inspected for any external or personnel.
hidden damage. In the event a product is found to Grounding conductors are sized in accordance with
be damaged, contact the delivering carrier to file a the above cited codes. All ground connections
claim and notify your local Dongan Representative. must be free of paint and nonconductive materials
Save all shipping cartons, crates, and/or skids for including rust, dust and corrosion. In addition,
inspection by the delivering carrier. connections must be tight at all points in order to
Transformers may be extremely heavy. Care must maintain adequate bonds throughout.
be taken when moving, lifting, and handling to
avoid damage to either the transformer or the lifting Installing to minimize “Hum”:
apparatus. Ventilated, cabinet style transformers
must not be tipped over during movement. Lift truck All energized transformers hum due to the
forks should be placed under the skid provided to alternating magnetic field in the transformer’s core.
avoid enclosure damage. Dongan transformers are designed to minimize this
noise. While transformer noise is not avoidable,
Lifting provisions are provided on many certain installation techniques will reduce noise
transformers. In some cases, the enclosure top complaints.
cover must be removed to access lifting provisions
provided on the core brackets. A transformer should be installed where it will be
the least objectionable. This is generally away from
quiet areas of a facility. If the ambient sound levels
Installation: are required to be quieter than the transformer’s
Dry-type transformer installations must comply with all rated sound output, move the transformer to a
applicable national and local codes for overcurrent remote or noisier area. In addition, transformers
protection, enclosure bonding, grounding, etc. should be installed where sound will not reflect
Particular attention must be given to assure all from close surfaces such as nearby walls, ceilings
installations are provided with adequate clearance or floors.
from walls and ceilings, and ventilation is sufficient to Installations should not be chosen that will resonate
provide for free air circulation in and around each
sound. This might occur on thin walls or structures
transformer. Transformers installed in rooms must on which the transformer is mounted or from rigid
have enough ventilation to maintain ambient air
conduit connections. The best installations are
temperatures within established insulation those that most effectively isolate the transformer
temperature limits when measured at or near the
from its surrounding support structures and
transformer ventilation openings or enclosure. connections.
Accessibility to the transformer must be considered
Dongan
when locations for transformers are selected. transformers comply Transformer Average
Whenever possible, installation should be away
with ANSI and NEMA kVA Sound Level
from high traffic areas. Placement must allow standards for sound Range (Decibels)
unrestricted access to covers and panels for
requirements. These
inspection, maintenance, and testing. In addition, standards establish
0-9 40
area must be provided to allow installation of 10 - 50 45
maximum sound
guards for maintenance personnel and, if levels for various
51 - 150 50
necessary, for the removal of the transformer 151 - 300 55
transformer kVA
without major disassembly of other components. ratings as listed in
301 - 500 60
Outdoor applications should be in areas where the chart.
water will not pond or flood into or around the
enclosure or connections. Enclosure ratings must Maintenance:
be appropriate for outdoor use.
Periodic maintenance should be performed by
qualified personnel only. Ventilated openings and
Grounding: transformer enclosures must be kept free of dust
The National Electric Code® , Articles 250 and 450, and debris so as not to restrict the free flow of air
NEMA ST 20 and local electrical codes mandate throughout the transformer. Periodically the unit
methods and practices for providing adequate and should be de-energized and checked for loose
appropriate conductor grounds and enclosure connections and internal collections of dust and
bonds. dirt. Dust may be removed with the use of
Grounding is important because it increases the compressed air or with a vacuum cleaner.
safety of the installation by permitting a path to In addition, when de-energized, the transformer
ground should the transformer’s coil make contact may be periodically checked for terminal alignment,
with the transformer core or enclosure and for pitted or corroded terminals or wires, and tightness
100 passing accumulated static charge buildup to and condition of ground connections, mounting
bolts and all other hardware.