Republic of the Philippines

UNIVERSITY OF EASTERN PHILIPPINES

LAOANG CAMPUS
Laoang, Northern Samar

COLLEGE OF INDUSTRIAL TECHNOLOGY

Bachelor of Science in Industrial Technology

(BSIT)

Learning Modules
in Electrical
Technology 302
Power Wiring, Transforming Design &
Construction
Module 1: Basic Principles of Transformer &
Single-Phase Transformer
MODULE 1
INTRODUCTION

One of the main reasons that we use alternating AC voltages and currents in our
homes and workplace’s is that AC supplies can be easily generated at a convenient voltage,
transformed (hence the name transformer) into much higher voltages and then distributed
around the country using a national grid of pylons and cables over very long distances.

The reason for transforming the voltage to a much higher level is that higher
distribution voltages implies lower currents for the same power and therefore lower I2*R
losses along the networked grid of cables. These higher AC transmission voltages and
currents can then be reduced to a much lower, safer and usable voltage level where it can
be used to supply electrical equipment in our homes and workplaces, and all this is possible
thanks to the basic Voltage Transformer.

BASIC PRINCIPLES OF
LESSON 1 TRANSFORMERS

LEARNING OUTCOME:

▪ Describe the basic construction of a transformer

▪ Distinguish between the primary and secondary winding

PERFORMANCE STANDARDS
▪ Explain how and why transformers are used for the transmission and distribution of
electrical energy.
▪ Describe the basic construction of a transformer.
▪ Distinguish between the primary and secondary windings of a transformer.
▪ List, in order of sequence, the various steps in the in the operation of a step-up
transformers.
▪ Make use of appropriate information to calculate the voltage ratio, voltages, currents,
and efficiency for step-up and step-down transformers.
▪ Explain how the primary load changes with the secondary load.

It is neither efficient nor economically feasible to generate large quantities of direct-

current electrical energy. The invention of the transformer was a milestone in the
development of the electrical industry. The transformer increases or decreases the voltage
of large quantities of alternating-current energy efficiently, safely, and conveniently. A large
power distribution station is shown in Figure 1-1.

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 Figure 1-1 Substation with three oil-filled breakers.

Large amounts of alternating current energy may be generated at a convenient voltage

using steam, nuclear, or water power. Transformers are used first to increase this energy to
a high voltage for transmission over many miles of transmission wires, and then to decrease
this voltage to values that are convenient and safe for use by the consumer.

ELEMENTS OF TRANSFORMERS

A transformer consists of two or more conductor windings placed on the same iron
core magnetic path, as shown in Figure 1-2.

Figure 1-2 Parts of a transformer.

Laminated Core

The iron core of a transformer is made up of sheets of rolled iron. This iron is treated
so that it has a high magnetic conducting quality (high permeability) throughout the length of
the core. Permeability describes the ease with a material will conduct magnetic lines of force.
The iron also has high ohmic resistance across the plates (through the thickness of the core).
It is necessary to laminate the iron sheets (Figure 1-3) to reduce hysteresis and eddy currents
that cause heating of the core.

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Windings

A transformer has two windings: the primary winding and the secondary winding. The
primary winding is the coil that receives the energy. It is formed, wound, and fitted over the
iron core. The secondary winding is the coil that provides the energy at a transformed or
changed (increased or decreased) voltage.

Transformers by definition are used to transfer energy from one AC system to another
by electromagnetic means. They do not change the amount of power significantly; only minor
wattage losses occur in the transformer. If the transformer increases

Figure 1-3 “E” lamination used in transformer core construction.

the voltage, it is called a step-up transformer. If it decreases the voltage, it is called a step-
down transformer.

The secondary voltage is dependent on the following:

• voltage of the primary
• number of turns on the primary winding
• number of turns on the secondary winding
Certain core-type transformers have the primary and secondary wire coils wound on
separate legs of the core [see Figure 1-2(A)]. The primary and secondary wire coils can also
be wound on top of one another, as shown in Figure 1-2(B). Winding in this manner improves
transformer efficiency and conserves energy. When stating the transformer ratio, the primary
is the first factor of the ratio. This indicates which winding, high or low, is connected to the
power source,

CONSTRUCTION OF TRANSFORMERS

As shown in Figure 1-4, three major types of construction for transformer cores are
core, shell, and cross (or H).

Core Type

In a core transformer, the primary winding is on one leg of the transformer and the
secondary winding is on the other leg. A more efficient type of core construction is the shell,
in which the core is surrounded by a shell of iron [Figure 1-4(A) and (B)].

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 Figure 1-4 Major construction types for transformer cores

Shell Type

The shell or double-window core transformer [Figure 1-4 (C)] is probably used most
frequently in electrical work. In terms of energy conservation, this transformer design
operates at 98 percent or higher efficiency.

Cross or H Type

The cross or H core is also called the modified shell type [Figure 1-4 (D)]. The coils
are surrounded by four core legs. The cross type is really a combination of two shell cores
set at right angles to each other. The windings are located over the center core, which is four
times the area of each of the outside legs. This type of core is very compact and can be
cooled easily. It is used for large power transformers where voltage drop and cost must be
kept to a minimum. These units are usually immersed in oil for high insulation properties and
effective cooling. Another method of cooling the transformers is by forced air. Transformers
should never be immersed in water for cooling. Accidental flooding, such as in underground
transformer vaults, should be pumped.

ELEMENTARY PRINCIPLES OF TRANSFORMER OPERATION

According to Lenz's Law, a voltage is induced in a coil whenever the coil current is
increased or decreased. This induced voltage is always in such a direction as to oppose the
force producing it, called induction. This action is illustrated by arranging two loops of wire,
as shown in Figure 1-5.

Figure 1-5 Magnetic Induction (electron flow).

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 Note in Figure 1-5 the progressive enlargement of the magnetic field about one side
of each loop as the current builds up, the strength of the magnetic field increases as the
electrical current through the conductor increases from the power source, Figure 1-5 so
shows the le pattern during the period that the current decreases,

Figure 1-5 uses the left-hand rule for conductors the conductor in your left hand with
your thumb extended in the direction of the electron flow. Your fingers will indicate the
direction of the magnetic flux. The flux expands outward from the conductor as the current
flow increases, and contracts toward the conductor center as the current flow diminishes.

As the current builds up to its maximum value, the circular magnetic lines around the
wire move outward from the wire. This outward movement of magnetic lines of force cuts
across the conductor of the second loop. As a result, an EMF is induced and current circulates
in the loop, as indicated on the galvanometer located above the conductor.

When the current reaches its steady state in the first circuit, the flux is stationary and
no voltage is induced in the circuit. The galvanometer indicates zero current.

When the battery circuit is opened, current falls to zero and the flux collapses. The
collapsing flux cuts through the second circuit and again induces an EMF. The second
induced current has a direction opposite to that of the first induced current, as indicated by
the galvanometer needle. The final stage shows a steady state with no field and no induced
current. This action is automatic with AC applied.

The loops of wire may be replaced by two

concentric coils (loops with many turns) to form a
transformer. Figure 1-6 shows a transformer that
has a primary winding, an iron core, and a
secondary winding. When a changing or alternating
current is delivered to the primary winding, the
changing primary current produces a changing
magnetic field in the iron core. This changing field
cuts through the secondary coil and thus induces a
voltage; the value depends on the number of
conductors in the secondary coil cut by the magnetic
lines. This is called mutual inductance. Commercial
transformers generally have fixed cores that provide
complete magnetic circuits for efficient operation
where there is little flux leakage and high mutual
induction.

Figure 1-6 Single-phase

transformer showing mutual
inductance of two cells.
VOLTAGE RATIO

According to Lenz's Law, 1 volt is induced when 100,000,000 magnetic lines of force
are cut in 1 second. The primary winding of a transformer supplies the magnetic field for the
core. The secondary winding, when placed directly over the same core, supplies the load
with an induced voltage that is proportional to the number of conductors cut by the primary
flux of the core.

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 The shell transformer type shown in Figure 1-6 is designed to reduce the voltage of
the power supply. In Figure 1-6,

NP = number of turns in the primary winding

NS = number of turns in the secondary winding
IP = current in the primary winding
IS = current in the secondary winding
Assume that NP = 100 turns
NS = 50 turns
Esupply = 100 volts, 60 hertz
The alternating supply voltage (100 V) produces a current in the primary that
magnetizes the core with an alternating flux. (According to Lenz's Law, a counter EMF is
induced in the primary winding. This counter EMF is called self-inductance and opposes the
impressed voltage.) Because the secondary winding is on the same core as the primary
winding, only 50 volts is induced in the secondary as only half as many conductors are cut
by the magnetic field.

At no-load conditions, the following ratio is true:

NP (100) EP (100) 2 2
= ; =
NS (50) ES (50) 1 1

The ratio of 2 to 1 indicates that the transformer is a step-down transformer that will
reduce the voltage of the power supply. Transformers either step up or step down the supply
voltage.

Refer to Figure 1-7 for the following example. The primary winding of a transformer
has 100 turns, and the secondary has 400 turns. An EMF of 110 volts is applied to the
primary. What is the voltage at the secondary, and what is the ratio of the transformer?

EP NP
=
ES NS

110 100
=
ES 400

100 ES = 44,000

44,000
ES = = 440 volts
100

440 4
This transformer has a = . The setup ratio is 1:4.
110 1

CURRENT RATIO

The current ratio in a transformer is the inverse of the ratio for voltage transformation.
The transformer does not create power, and is not designed to consume power. The input

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power should be very close to the output power. Therefore, if the volt-amps input equals the
volt-amps output and the voltage level is increased, the current level is decreased. The
voltage ratio and the current ratio are inversely proportional.
If the load current of the transformer shown in Figure 1-7 is 12 amperes, the primary
current must be such that the product of the number of turns and the value of the current
(ampere-turns primary) equals the value of the ampere-turns secondary.

Figure 17-7 Elementary diagram of a transformer.

NP IP
NP IP = NS IS or =
NS IS

100 12
=
400 IS

100 IP = 4,800

IP = 48 amperes

Check of Solution for Current

NP IP = NS IS ; 100 x 48 = 400 x 12; 4,800 = 4,800

The current ratio is an inverse ratio; that is, the greater the number of turns, the less
the current for a given load. Practical estimates of primary or secondary currents are made
by assuming that transformers are 100 percent efficient.

For example, assume that

Watts input = Watts output

or

Primary watts = Secondary watts

or
EP x lP = ES x IS

Therefore, for a 1,000-watt, 100/200-volt step-up transformer:

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 1,000 W
IS = = 5 amperes
200 V

1,000 W
IP = = 10 amperes
100 V

The greater the current, the larger size the wire leads are on the transformer. From
this information, you can usually determine the high and low voltage sides.

Higher voltage = lower current, and 'therefore smaller wire size

Lower voltage = higher current, and therefore larger wire size

Example: A machine tool being relocated has a control transformer disconnected. The
nameplate is illegible due to corrosion. The motor power circuit is 480 volts. The motor
controller operates on 120 volts of control. Which is the primary and secondary of the control
transformer? The higher voltage has the smaller wire size. Therefore, this is to be connected
to the 480 volts.

The use of an ohmmeter can also tell you which winding has the greater resistance.
By measuring each winding, you find that the greater the resistance, the higher the voltage
connection because it has more turns of smaller wire. Remember, "primary" refers to the
supply side of the transformer. "Secondary" refers to the load side (Figure 1-8).

Figure 1-8 Schematic diagram of a step-up transformer.

SCHEMATIC DIAGRAM OR SYMBOL

A step-up transformer is usually shown in schematic form, as illustrated in Figure 1-8.

The ratio of turns, primary to secondary, is not usually listed. This figure could be a step-up
or step-down symbol representation.

PRIMARY LOADING WITH SECONDARY LOADING

The current in the secondary controls the current in the primary. When the secondary
circuit is complete by placing a load across it, the secondary EMF causes a current to flow.
This builds up a magnetic field in opposition to the primary field. This opposing, or
demagnetizing, action reduces the effective field of the primary flux, which in turn reduces
the primary CEMF, thereby permitting current to in the primary. The greater the current flow
in the secondary, the greater the field produced by the secondary. This results in a reduced
primary field; hence, a reduced primary CEMF is produced. This condition permits greater

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current flow in the primary. This entire process will repeat itself whenever there is any change
in the value of the current in the secondary circuit. A transformer adjusts itself readily to any
normal change in secondary load. However, if a direct short is placed across the secondary,
the abnormally large amount of current flowing causes the primary current to rise in a like
manner, resulting in damage to, or complete burn-out of, the transformer if it is not protected
properly.

EFFICIENCY

The efficiency of all machinery is the ratio of the output to the input:

output
Efficiency =
input

In general, transformer efficiency is about 97 percent. Only 3 percent of the total

wattage at the secondary winding is lost through the transformation. The loss in wattage is
due to core losses and copper losses.

The core loss is the result of hysteresis (magnetic friction) and eddy currents (induced
currents) in the iron core.

The copper loss is power lost in the copper wire of the windings (I2R). Therefore, taking
these losses into consideration,

Watts output (secondary)

% Efficiency = x 100
Watts input (primary)

where Watts input = Watts output + losses.

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 SUMMARY

Transformers are very useful in delivering the exact voltage needed by customers. DC
cannot be easily changed from one voltage level to another. There are no true DC
transformers. AC can be increased or decreased easily through the electromagnetic coupling
of the transformer coils. Transformers can be used to (1) step up the voltage; (2) step down
the voltage; or (3) simply isolate the transformer primary system from the transformer
secondary system.

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 Select the correct answer for each of the following statements and place the
corresponding letter in the space provided.

1. When the primary winding has more turns than the secondary, the voltage in the
secondary winding is
a. increased. c. decreased.
b. doubled. d. halved.

2. In the coils of a transformer, the motion of the flux is caused by the

a. direct current. c. moving secondary.
b. rotating primary. d. alternating current.

3. Energy is transferred from the primary to the secondary coils without a change in
a. frequency. c. current.
b. voltage. d. ampere-turns.

4. A control transformer is a step-down transformer type. Compared to the secondary

winding, the primary winding is
a. larger in wire size.
b. smaller in wire size.
c. the same size as the secondary.
d. connected to the load.

5. The current in the secondary winding

a. is higher than the current in the primary.
b. is lower than the current in the primary.
c. controls the current in the secondary.
d. controls the current in the primary.

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Solve the following problem

1. A 110/220-volt step-up transformer has 100 primary turns. How many turns does the
secondary winding have?

2. A transformer has 100 primary turns and 50 secondary turns. The current in the secondary
winding is 20 amperes. What is the current in the primary winding?

3. What is the ratio of a transformer that has a secondary voltage of 120 volts when connected
to a 2,400-volt supply?

4. A 7,200/240-volt step-down transformer has 1,950 primary turns. Determine the number
of turns in the secondary winding.

5. A 2,400/240-volt step-down transformer has a current of 9 amperes in its primary and 85

amperes in its secondary. Determine the efficiency of the transformer.

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 LESSON 2 SINGLE-PHASE TRANSFORMERS

LEARNING OUTCOME:

▪ Describe a single-phase double wound transformer.

▪ Define additive polarity and diagram the connection.
▪ Diagram the series and parallel methods of coil
connection for a double wound transformer.
▪ Explain the advantage of using solid state reduce
voltage starter.

PERFORMANCE STANDARDS
▪ describe a single-phase, double-wound transformer, including its primary
applications.
▪ diagram the series and parallel methods of coil connection for a double-wound
transformer and for primary and secondary dual-voltage connections.
▪ define subtractive polarity and diagram the connections and markings for this polarity.
▪ define additive polarity and diagram the connections and markings for this polarity.
▪ list the steps in the AC polarity test for a single-phase transformer.
▪ demonstrate good electrical safety practices.
▪ describe an autotransformer, including its primary applications.
▪ identify primary taps.
▪ Measure the highlight the manner of observing safety practices.
▪ Personal safety guidelines

A single-phase transformer usually has a core and at least two coils. The single-phase
autotransformer has only one coil. The specifications for single-phase transformers vary
greatly, and the applications of these transformers are unlimited.

THE DOUBLE-WOUND TRANSFORMER (ISOLATING AND INSULATING)

The double-wound transformer has a primary winding and a secondary winding. These
windings are independently isolated and insulated from each other. A shielded winding
transformer, on the other hand, is designed with a metallic shield between the primary and
secondary windings, providing a safety factor by grounding. This prevents accidental contact
between the windings under faulty conditions. The coils of double-wound transformers may
be connected in several different arrangements.

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 Figure 2-1 shows popular arrangements of single-phase transformer windings. Shown
in Figure 2-1 (A), two single coils are used for specific step-down or step-up applications,
including bell-ringing transformers, neon transformers, and component transformers for
commercial equipment, such as automatic machines, switchgear, and

Figure 2-1 Coil arrangements for single-phase transformers

other devices. Multiple coil primary and secondary windings, shown in Figure 2-1 (B), are
used in distribution transformers where dual voltage ratings are desired. Arrangements for
voltage ratings of 2,400//120/240 or 240/480//120/240 are common.

Double-wound transformers separate or insulate the high transmission voltages from

the typical consumer- voltages of 115/230/460. The National Electrical Code requires this
type of transformer in all distribution circuits with the exception of those circuits assigned to
autotransformers. Here, as in the Code, the voltage considered shall be that at which the
circuit operates, except for the examples given.

Polarity

A 460/115/230 transformer may be connected for two ratios: 460/115 or 460/230. To

obtain the 460/115 ratio, the secondary coils are connected in parallel; the 460/230 ratio is
achieved by connecting the secondary coils in series. To complete these connections, the
polarity of the leads must be determined.

Figure 2-2 shows how the transformer secondary series and parallel coil connections
are made. Note that instead of polarity indications such as (+, -, the coil leads are identified
here by S (start) and F (finish), or by I (start) and 2 (finish) as in H1, H2, X1, and X2 in Figure
2-3.

Figure 2-2 Series and parallel transformer and battery voltage connections.

The beginning or ending of a transformer coil is usually indicated by a tab placed on

the lead by the technician in charge of the winding process, when the transformer is

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assembled, other markings often replace the original ones. Before final inspection, a polarity
test must be made to be certain that the leads are marked correctly.

IDENTIFYING AN UNMARKED TRANSFORMER

Installed transformers often have missing or disfigured tabs. Every time a transformer
is to be reconnected following repairs or for other reasons, the polarity of the leads must be
checked.

Figures 2-3 and 2-4 illustrate two systems of marking polarity. In conventional usage,
polarity refers to the induced voltage vector relationships of the transformer leads as they are
brought outside of the tank. The American National Standards Institute (ANSI) standardized
the location of these leads to obtain additive and subtractive polarity conditions. All high-
voltage leads brought outside the case are marked H1, H2, and so forth,

Figure 2-3 Subtractive polarity. Figure 2-4 Additive polarity.

whereas the low-voltage leads are marked X1 and X2. The H1 lead is located on the left side
when facing the low-voltage leads. H1 and X1 are both positive at the same instant of time.

Subtractive Polarity. The tank diagram in Figure 2-3 shows the relationship of the
induced voltages in the primary and secondary windings for the subtractive polarity
conditions. Transformers connected in this manner have the H1 and X1 leads located directly
opposite each other. If H1and Xl are connected together [as shown in Figure 2-5 (A)] the
voltage measured between H2 and X2 is less than the primary voltage, the induced voltage
opposes the supply voltage and thus causes the secondary induced voltage to be subtracted
from the primary voltage.

Additive Polarity. The tank diagram in Figure 2-4 shows the voltage relationship of
the induced voltages for the additive polarity connection, When H1 and X2 are connected, the
voltage across H2 and X1 is greater than the primary voltage. The measured voltages add up
to the sum of the primary and secondary voltages as shown in Figure 2-5(B).

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 Figure 2-5 (A) Test used to determine subtractive polarity transformer.
(B) Test used to determine additive polarity transformer.

Transformers that are rated up to 200 kVA and have the value of the high-voltage
winding equal to 8,660 volts or less are additive. All other transformers are subtractive.

Test for Polarity. Transformer coils often must be connected in series or parallel as
in Figure 2-6. For these situations, the polarity of a transformer or any secondary coil can be
found by making the connections shown in Figure 2-5(A) and (B). Connect the adjacent left,
high- and low-voltage outlet leads facing the low-voltage side of the transformer. Apply a low-
voltage supply to the primary and note the voltage between the adjacent right-hand, high-
and low-voltage terminals.

• For subtractive polarity, the voltmeter reading (V) is less than the applied voltage. The
voltage is the difference between the primary and secondary voltages, Ep + Es [Figure
2-5 (A)].

• For additive polarity, the voltmeter reading (V) is greater than the applied voltage. The
voltage is the sum of the primary and secondary voltages, E p + Es [Figure 2-50)].

If the test shown in Figure 2-5(B) indicates additive polarity, the secondary leads inside
the tank must be reversed at the bottom of the bushings to obtain a true subtractive polarity,
If the transformer requires all additive polarity and the test indicates sub tractive, reverse the
secondary lead markers so that X2 is located opposite H1.

In all transformers, the H terminals are always the high-voltage terminals. The X
terminals are always the low-voltage terminals, Either the H or X terminals can be designated
as the primary or the secondary' depending on which is the source and which is the load, and
whether the transformer is used as a step up or step-down transformer.

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 A. Series connected secondary B. Parallel connected secondary

Figure 2-6 Single-phase transformer connections.

SINGLE-PHASE TRANSFORMER CONNECTIONS

Series Connection

If a 460/115/230-volt, single-phase transformer is to be connected to obtain 460/230

volts, the two secondary coils must be connected in series. The beginning and ending of each
coil must be joined, as shown in Figure 2-6(A). The "start" of each coil is identified by an odd-
numbered subscript.

Note: If the voltage is zero across X1—X4 after the series connections are complete,
the coils are opposing each other (the polarity of one coil is reversed). To correct this situation,
reverse one coil, and then reconnect and recheck the polarity.

Parallel Connection

To obtain 460/115 volts, the two secondary coils must be connected in parallel as
shown in Figure 2-6(B). The polarity of each coil must be correct before making this
connection. The parallel connection of two coils of opposite polarity will result in a short circuit
and internal damage to the transformer.

Note: An indirect polarity check can be made by completing the series connection and
noting the total voltage. As noted previously, zero voltage indicates opposite polarities.
Reverse one coil to remedy the condition and then recheck overall polarity. Retag leads if
necessary.

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PARALLEL OPERATION OF SINGLE-PHASE TRANSFORMERS

Single-phase distribution transformers can be connected in parallel only if the voltage

and percent impedance ratings of the transformers are identical. This information is found on
the nameplates of large transformers. It is recommended that this rule be followed when
making permanent parallel connections of all transformers.

TRANSFORMER PRIMARY TAPS

Taps are nothing more than alternative terminals that can be connected to more
closely match the primary supply voltage. These taps are arranged in increments of 2.5
percent or 5 percent of the primary nominal voltage rating of the transformer (Figure 2-7).
This provides a job-site adjustment to ensure that the transformer primary matches the supply
voltage. The secondary will then produce the desired secondary voltage.

The voltage received from the power utility may be low or high. Because the
transformer is a fixed voltage device, the output voltage is always in direct proportion to the
input voltage. If the ratio is 2:1 and the supply voltage is 480 volts, the output will be 240 volts.
If the primary voltage is 438 volts, the secondary is only 219 volts.

Figure 2-7 primary terminal taps.

High and low voltages can have serious effects on different connected loads.
Therefore, care must be taken to deliver a voltage as close as possible to the desired primary
so that the secondary voltage will match the equipment nameplate voltages. Consistently
high and low voltage problems can be solved by connecting the proper primary taps (Figure
2-8). If the voltage fluctuates consistently, tap changing is not the solution. A voltage
regulating transformer is needed.

Figure 2-8 Tap connections used on three-phase power transformer.

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REGULATION

A slight voltage drop at the secondary terminals from no load to full load, called
regulation, is caused by resistance and reactance drops in the windings. Regulation is
expressed as a percentage, Regulation of constant potential transformers is about 1 to 5
percent at the secondary terminals as follows:

no load E − full load E

% E regulation = x 100
full load E

Example: The secondary voltage of a transformer rises from 220 to 228 volts when
the rated load is removed. What is the regulation of the transformer?

228 − 220
% regulation = ( ) x 100 = 0.36 x 100 = 3.6%
220

AUTOTRANSFORMER

Transformers with only one winding are called autotransformers. In an

autotransformer, a part of the winding is common to both primary and secondary circuits. This
is the most efficient type of transformer because a portion of one winding carries the
difference between the primary and secondary currents. Figure 2-9 shows the current
distribution in an autotransformer used in a typical lighting application. The disadvantage of
an autotransformer is the fact that the use of only one winding makes it impossible to

FIGURE 2-9 Autotransformer used for lighting.

insulate the low-voltage section from the high-voltage distribution line. If the low voltage
winding opens, the full-line voltage appears across the load. According to the National
Electrical Code® the use of autotransformers is limited to certain situations, such as:

Module in ET 302 – Power Wiring, Transforming Design & Construction 20

 a. the system supplied contains an identified grounded conductor that is solidly
connected to a similar identified grounded conductor of the system supplying the
autotransformer.
b. an induction motor is to be started or controlled (Figure 2-10).
c. a dimming action is required, as in theater lighting.
d. the autotransformer is to be a part of a ballast for supplying lighting units.
e. a voltage is to be boosted or bucked under certain conditions.

Figure 2-10 An autotransformer used for motor-starting duty.

DRY AND LIQUID-FILLED TRANSFORMERS

Dry transformers are used extensively for indoor installations. These transformers are
cooled by air and are not encased in heavy tanks, such as those required for liquid filled
transformers. Dry transformers are used for bell-ringing circuits, current and potential
transformers, welding transformers, and almost all transformers used on portable or small
industrial equipment, or for separately derived systems within a facility.

Liquid-filled transformers consist of the core and coils immersed in a tank of oil or other
insulating liquid. Oil cooling is approximately fifteen times more effective than air cooling.
Many distribution transformers designed for outdoor installation are liquid filled.

METHODS OF COOLING

The method selected to cool a transformer must not only maintain a sufficiently low
average temperature, but must also prevent an excessive temperature rise in any portion of
the transformers. In other words, the cooling medium must prevent the formation of "hot
spots," For this reason, the working parts of the transformer are usually immersed in a high
grade of insulating oil. Because the oil must be free of any moisture, the oil must be filtered
to remove moisture as necessary. The electrical insulating value of the oil is checked
periodically.

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 Duct lines are arranged within the transformer to provide for the free circulation of oil
through the core and coils, the warmer and thus lighter oil rises to the top of the steel tank.
The transformer core and windings are placed near the bottom of the tank the cooler and
heavier oil settles to the bottom of the tank. This natural circulation provides for better cooling
(Figure 2-11).

Figure 2-11 An oil-filled power transformer with radiators.

Forced Cooling

Several methods of removing heat from a transformer involve forced cooling. Cooling
is achieved by using pumps to force the circulation of the oil or liquid, by forcing the circulation
of air past the oil-filled radiators (Figure 2-12), or by immersing water-containing coils in the
oil. Cold water circulating in the coils removes the heat stored in the oil. Figure 2-13 internal
construction of an oil-filled transformer. Forced air movement by the use of fans is a common
practice, Fans are generally controlled by thermostats (Figure 2-14).

Figure 2-12 Cross section of a shell-form transformer showing oil-forced air cooling
(FOA or OA/FA with typical temperature rises)

Module in ET 302 – Power Wiring, Transforming Design & Construction 22

 Figure 2-13 Assembly of a large, three-phase, oil-filled, station-class power
transformer, such as the one shown in Figure 2-11.

Figure 2-14 Transformer temperature indicators. (A) Winding temperature indicator.

(B) Liquid temperature indicator.

APPLICATION

Single-phase transformers are suitable for use in a wide variety of applications, as

shown by the examples in Figures 2-15, 2-16, 2-17, and 2-18.

Distribution transformers is the type of transformer that performs the last voltage
transformation in a distribution grid. It converts the voltage used in the transmission lines to
one suitable for household and commercial use, typically down to 240 volts. Usually oil filled
and mounted on poles, in vaults, or in manholes.

Module in ET 302 – Power Wiring, Transforming Design & Construction 23

 Figure 2-15 Pole mounted, single- Figure 2-16 Cutaway view of
phase distribution transformer distribution transformer

Figure 2-17 Control circuit transformer. Figure 2-18 Transformer used for
electronic equipment.

Compensator' starters are tapped autotransformers used for starting induction -

motors.

Instrument transformers are used in AC system for measurement of electrical

quantities i.e. voltage, current, power, energy, power factor, frequency. It also used with
protective relays for protection of power system..

Welding transformers is a step-down transformer that has thin primary winding with a
large number of turns and its secondary has more area of cross-section and less number of
turns ensuring less voltage and very high current in the secondary.

Constant-current transformers are used for series street lighting where the current
must be held constant with a varying voltage. The secondary is movable.

Module in ET 302 – Power Wiring, Transforming Design & Construction 24

SAFETY PRECAUTIONS

Although' there are no moving pans in a transformer, some maintenance procedures

must be performed. For a general overhaul of an operating transformer or when an internal
inspection is to be made, the transformer must be deenergized. Do not assume that the
transformer is disconnected or rely on someone else to disconnect it; always check the
transformer yourself. You must be sure that the fuses are pulled open or out and that the
switch or circuit breaker is open on both the primary and secondary sides. After the
transformer is disconnected, the windings should be grounded to discharge any capacitive
energy stored in the equipment. This step also protects you while you are at work. Grounding
is accomplished with a device commonly known as a "short and ground." This is a flexible
cable with clamps on both ends. The ground end is clamped first, and then, using a hook
stick, the other end is touched to the conductor. Do this with each leg on the primary and
secondary sides. The phases are then shorted together and grounded for your protection.

The tank pressure should be relieved. This may be done by bleeding a valve or plug
above the oil level. Any gas in the tank must be replaced with fresh air before a person enters
the tank. The absence of oxygen in a tank will cause asphyxiation quickly and without
warning. A second person should be on duty outside the transformer as a safety precaution
whenever someone must enter the transformer. Be sure to follow Occupational Safety and
Health Administration (OSHA) rules on hazardous entry and restricted work space. All tools
should have safety cords attached with the other end tightly secured. All pockets in clothing
should be emptied. Nothing must be allowed to fall into the tank. Great care must be
exercised to prevent contacting or coming close to the electrical conductors and other live
parts of the transformer unless it is known that the transformer has been deenergized. The
tank and cooling radiators should not be touched until it is determined that they are
adequately grounded (for both new and old installations).

Module in ET 302 – Power Wiring, Transforming Design & Construction 25

 SUMMARY

Single-phase transformers are used in a variety of applications. To connect them

correctly, the electrician must know how the AC polarities are established at the transformer
leads. Because the internal windings of the transformer are polarity checks must be made on
the external leads. The transformer leads are marked according to the standards for additive
or subtractive polarity. If the lead markings are not apparent or the voltages expected are not
obtained, then the polarity must be tested. If the lead markings are known, the transformer
coils may be connected in series or parallel to yield the desired voltage. Autotransformer
connections or tap-changing transformers may be used to bring the voltage within the desired
range. Much of a transformer's capability to operate satisfactorily depends on the capability
to dissipate the heat produced in- the windings. Many methods are used to dissipate this heat
and keep the transformer from overheating and being destroyed.

Module in ET 302 – Power Wiring, Transforming Design & Construction 26

 Select the correct answers for each of the following statements and place the
corresponding letter in the space provided.
1. Double-wound transformers contain a minimum of
a. one main winding.
b. one main winding -with two coils.
c. a primary and a secondary winding.
d. a primary and a double-wound secondary.
2. A transformer has subtractive polarity when the
a. two primary coil voltages oppose each other.
b. two secondary coils have opposite polarities.
c. Xl lead is opposite the H1 lead.
d. X2 lead is opposite the H1 lead.
3. A transformer has additive polarity when the
a. two primary coils are in series.
b. b. two secondary coils have aiding polarities.
c. X1 lead is opposite the H1 lead.
d. X2 lead is opposite the H1 lead.
4. Polarity should be tested before
a. energizing a transformer.
b. checking the ratio.
c. connecting the coils in series or parallel.
d. connecting the load to the secondary.
5. A 440/110/220-volt, step-down transformer is connected for 440/220 volts. Preliminary
tests show that each secondary coil has 110 volts but the voltage across X l—X4 is
zero.
The probable trouble is that
a. the voltages in the coils are equal and opposing.
b. their ratings are equal.
c. the load will divide in proportion to the capacities.
d. the voltage drops at full load will be proportional to their respective loads.
6. The autotransformer may be used as a
a. power transformer.
b. potential transformer.
c. current transformer.
d. compensator motor starter.
7. Insulation of transformers may be classed in two groups:
a. double-wound and autotransformers.
b. dry and oil-filled types.
c. core and shell types.
d. core and cross types.
8. Regarding cooling, transformers may be
a. air- and oil-cooled.
b. outdoor- and indoor-cooled.
c. self- and forced-cooled.
d. dry- and liquid-cooled.

Module in ET 302 – Power Wiring, Transforming Design & Construction 27

 9. Single-phase, double-wound transformers must be used for
a. distribution and compensator starters.
b. instrument and welding transformers.
c. welding and dimming in theater lighting.
d. constant current and reduced voltage motor starters.
10. For low voltage, the secondary of a single-phase transformer is connected:
a. X1 and X4 to load, X3 and X2 together.
b. X1 to X3 to load, X2 to X4 to load.
c. H1 to H4 to load, H3 to H2.
d. H1to H2, X1 to X2
11. A transformer in which part of the secondary is part of the primary is
a. a series and parallel connection.
b. a double-wound transformer.
c. an autotransformer.
d. an isolating transformer.
12. Parallel operation of single-phase transformers can be accomplished when the
a. voltage and percentage impedance ratings are identical.
b. voltage and current ratings are equal.
c. cooling methods are identical.
d. primary and secondary voltage ratings are equal.
13. Primary taps are designed to
a. raise the voltage of the secondary.
b. drain the oil.
c. lower the voltage of the secondary.
d. raise or lower the voltage of the primary.
14. A slight voltage drop at the secondary terminals from no load to full load is called
a. reactance.
b. regulation.
c. percentage.
d. Taps.
15. When working in a large transformer, the electrician should
a. ventilate it first.
b. short and ground all windings.
c. secure all tools and empty pockets.
d. all of the above.
16. When preparing to work on an oil-filled transformer
a. bleed the tank pressure.
b. disconnect the supply voltage and load.
c. disconnect all other connections.
d. check the disconnect switches yourself

Module in ET 302 – Power Wiring, Transforming Design & Construction 28

 THE SINGLE-PHASE, THREE-WIRE
LESSON 3 SECONDARY SYSTEM

LEARNING OUTCOME:

▪ Diagram the connection for a single phase three wire

secondary system.
▪ List the advantage of a three-wire service.
▪ Explain why there is a copper loss for a three-wire
system

PERFORMANCE STANDARDS
▪ diagram the connections for a single-phase, three-wire secondary system.
▪ list the advantages of a three-wire service.
▪ describe what occurs when the neutral of a three-wire secondary system opens.
▪ explain why there is less copper loss for a three-wire system.

Most homes are wired for three-wire service. Because electric ranges and clothes dryers
are designed for three-wire operation, any home to be provided with these appliances must have
three-wire service. The three wires terminate in the residence at the load center panel so that
most individual circuits carried through the house are at 120 volts, thus eliminating the dangers
with 240-volt circuits.

The double-wound transformer is used as the source for three-wire secondary distribution.
One of the important advantages of a transformer is its capability to provide a three-wire circuit
from the low-voltage secondary. A step-down transformer with a 2,400/240/120-volt rating is
commonly used in residential installations.

The advantages of using three-wire service in general distribution systems include (1) a
reduction in the cost of main feeders and sub feeders, (2) the provision of 120-volt service for
normal lighting circuits and 240-volt service for power and motor loads, and (3) the conservation
of electrical energy by reducing wattage loss in transmission.

Figure 3-1 is a schematic of a typical three-wire system. The secondary coils are connected in
series and each coil is rated at 120 volts. The junction N between the two secondary coils is
usually grounded. This precaution provides some protection to a person who may come into
contact accidentally with a transformer that has faulty insulation. The line wire carried from this

Module in ET 302 – Power Wiring, Transforming Design & Construction 29

junction to the several loads is known as the neutral or grounded conductor. The neutral wire
generally carries less current than wires L1 and L2, except when the load is on one side only, that
is, L1 to N or 142 to N. The 240-volt motor load does not affect the current flowing in the neutral
wire. The neutral is carried through the system as a solid conductor (not fused or switched). If the
neutral opens, and the loads in the 120-volt circuits are greatly unbalanced, then these 120-volt
circuits will be subjected to approximately 240 volts. The neutral is designed to carry not only the
unbalanced current in the two 120-volt circuits, but also the entire load on any one side should all
the load on the other side be cut off completely. This latter situation can occur if a fuse or circuit
breaker suddenly opens either line, Figure 3-1 shows the current distribution for the loads
indicated.

Figure 3-1 Schematic diagram of a three-wire system supplied form a single-phase

transformer.

OPEN NEUTRAL

As an example to show what occurs when the neutral of a three-wire system opens,
assume that the lighting load in Figure 19-1 is a pure resistive load.

E 120
Thus, the group of four lamps has a resistance of = = 4.8 ohms, and the
I 25

E 120
group of two lamps has a resistance of = = 8 ohms.
I 15

With the neutral open, these two groups combine as a series circuit with a resistance of
12.8 ohms connected across 240 volts. The current flow through this series circuit follows:

E 240
= = 18.75 amperes
R 12.8

Then, according to the laws for a series circuit, the voltage across the 8-ohm group (two
lamps) is equal to

I x R = 18.75 x 8 = 150 volts

and the voltage across the 4.6-ohm group (four lamps) is equal to

I x R = 18.75 x 4.8 = 90 volts

Module in ET 302 – Power Wiring, Transforming Design & Construction 30

 (Remember that in a series circuit, the highest voltage appears across the highest value
of resistance.) The lamps would probably burn out with this open neutral.

Sample Problem

Referring to Figure 3-1, assume that the upper 120-volt load is 25 amperes, the lower
load is 15 amperes, and the motor load is 30 amperes. If the power factor in all cases is unity
(1), calculate the current:

1. in line la,
2. in line 2b, and
3. in the neutral line N.
In addition, determine the power delivered
4. by transformer coil IN,
5. by transformer coil 2N, and
6. by the primary coil.
Finally, calculate the current
7. in the primary coil.

Solution

1. I1a = 25 + 30 = 55 amperes

2. I2b = 15 + 30 = 45 amperes

3. IN = 25 – 15 = 10 amperes

4. PIN = 55 x 120 = 6,600 watts

5. P2N = 45 x 120 = 5,400 watts

6. P2N = 6,600 + 5,400 = 12,000 watts

7. Ipri = 12,000/2,400 = 5 amperes

The distribution transformers used in industrial plants or network substations for three-wire
secondary systems are usually mounted on poles (Figure 3-2) or in transformer vaults. This type
of transformer is equipped with three low-voltage bushings and e series connection is made inside
the tank. The lower lines constitute the secondary three-wire systems.

Module in ET 302 – Power Wiring, Transforming Design & Construction 31

Figure3-2 Pole-top transformers used for
distribution voltages; three low-voltage bushings
are shown here

ECONOMICS OF THE THREE-WIRE SYSTEM FOR FEEDERS

AND BRANCH CIRCUITS

Using the three-wire system of the previous problem as an example, the total load transmitted
over the three wires is 1,500 W or 15 kW at a power factor of 100 percent. It is assumed that the
motor load is provided with power factor correction, if single conductor-type TW wire is used from
the transformer to the load, the following sizes are required:

Line I (55 amperes): No. 6 TW

Neutral (0.70 x 55 = 38.5): No. 8 TW
Line 2 (55 amperes): No. 6 TW

Although No. 8 TW wire is the actual size permitted for the neutral, a substitution of a No.
6 TW wire can be made so that three 6 lines are provided to simplify the installation.

If a two-wire distribution system is used for the same load, the total current is 11,500/120
= 96 amperes. Two lines are required. If the transmission distance is 100 feet, then a comparison
can be made of the weights of copper wire required for the two systems.

Three-Wire System

For a No. 6 TW line, the weight per 100 feet = 11.5 1b. Therefore, for three No. 6. TW 6
lines, the total weight = 3 X 11.5 = 34.5 lb.

Module in ET 302 – Power Wiring, Transforming Design & Construction 32

Two-Wire System

For a 1 line, the weight per 100 feet = 33 lb. For two I lines, the total weight = 2 x 33 = 66 lb.
Therefore, for the same load, the three-wire system uses less copper (66 — 34.5 = 31.5 pounds
less) than the two-wire system.

A similar conclusion can be reached by consulting a manufacturer's price list and noting the
lower prices for smaller conductors. The copper losses in the line are also considerably less for a
three-wire system for several reasons: the motor power is transmitted at a higher voltage requiring
less current for a given load; the neutral carries no current when the two lighting circuits are
balanced; and the copper losses are much less because less wire and current are required. These
line losses are of two types: (1) voltage drop (IR) and (2) wattage loss (I2R).

Module in ET 302 – Power Wiring, Transforming Design & Construction 33

 SUMMARY

The three-wire single-phase system is the most common residential electrical service. The
three wires constitute a single phase of AC delivered to the home. The transformer secondary
coil is tapped at the center point and grounded at that point to establish a ground reference. The
power can then be divided into two 120-volt supplies and can also be used as a 240-volt single
phase for higher power consumption appliances. Care must be taken to solidly ground the neutral
center-tapped point because an open neutral conductor can cause severe damage.

Module in ET 302 – Power Wiring, Transforming Design & Construction 34

Answer the following:

1. Cite two reasons why power companies must supply three-wire service to residential
occupancies.

2. How are the two secondary coils of a distribution transformer connected for three wire
service?

3. What are three advantages of a three-wire service as compared to a conventional two-wire

service?

4. Why must the neutral line be left unfused?

5. How many circuits are provided in a three-wire secondary system?

6. What is the voltage rating of each circuit in question 5?

Questions 7 through 9 are based on Figure 3-3: a three-wire system has one lighting load
of 40 amperes, one lighting load of 20 amperes, and a 240-volt motor load of 30 amperes.

Module in ET 302 – Power Wiring, Transforming Design & Construction 35

 Figure 3-3 Three-wire system for questions 7 through 9.

7. What is the current load in lines 1 and 2?

(1) (2)

8. What is the current in N?

9. If the neutral is open, indicate the voltages of the lighting circuits. Show your work.

1N 2N

10. A three-wire, 120/240-volt circuit supplies the following:

One 120-volt, 10-watt lamp to line 1 and neutral, and
one 120-volt, 120-watt TV set to line 2 and neutral. (See Figure 3-4.)

If the neutral opens while both the lamp and the TV set are operating, what will be the
voltages at the lamp and the TV set? (Assume a power factor of unity.)

Figure 3-4 Three wire system for

question 10.

Module in ET 302 – Power Wiring, Transforming Design & Construction 36

 (lamp voltage)
(TV voltage)

11. A manufacturer uses motors larger than 1 hp on 120 volts. Why does this require a three-
wire secondary system?

12. Theoretically, how much horsepower is on the unbalanced lines in Figure 3-5?
L1 L2 Neutral

Figure 3-5 Isolation transformer connection for question 12.

Module in ET 302 – Power Wiring, Transforming Design & Construction 37

 SINGLE-PHASE TRANSFORMERS
LESSON 4 CONNECTED IN DELTA

LEARNING OUTCOME:

▪ explain how single-phase transformers are connected in

a three-phase, closed delta-delta arrangement.
▪ describe the relationships between the voltages across
each coil and across the three-phase lines for both the
input (primary) and output (secondary) of a delta- delta
transformer bank.

PERFORMANCE STANDARDS
▪ explain, with the aid of diagrams, how single-phase transformers are connected in a
three-phase, closed delta-delta arrangement.
▪ describe the relationships between the voltages across each coil and across the three-
phase lines for both the input (primary) and output (secondary) of a delta- delta
transformer bank.
▪ list the steps in the procedure for checking the proper connection of the secondary
coils in the closed-delta arrangement, including typical voltage readings.
▪ describe how a delta-delta connected transformer bank can provide both a 240-volt,
three-phase load and a 120/240-volt, single-phase, three-wire load.
▪ describe, using diagrams, the open-delta connection and its use.
▪ identify primary taps for the three-phase connection.

Most electrical energy is generated by three-phase, alternating-current generators. Three-

phase systems are used to transmit and distribute the generated electrical energy. The voltage
on three-phase systems often must be transformed, either from a higher value to a lower value
or from a lower value to a higher value.

Voltage transformation on three-phase systems can be obtained with the use of three
single-phase transformers (Figure 4-1). These transformers can be connected in several ways to
obtain the desired voltage values.

A possible connection pattern that the electrician is often required to use for the three
single-phase transformers is the closed-delta connection.

Another connection pattern that is commonly used is the open-delta or V connection that
requires only two transformers to transform voltage on a three-phase system.

Module in ET 302 – Power Wiring, Transforming Design & Construction 38

Figure 4-1 Three large single-phase,
station-class, oil-filled power
transformers.

CLOSED-DELTA CONNECTION

When three single-phase coils are connected so that each coil end is connected to the
beginning of another coil, a simple closed-delta system is formed (Figure 4-2)

Figure 4-2 Simple delta connection.

When the three coils are marked Coil A, Coil B, and Coil C, the end of each of the e coils
is marked with the letter O. The beginnings of the coils are marked A, B, and C. Note that each
coil end is connected to another coil beginning. Each of the three junction points ties to a line
lead feeding a three-phase system.

If three single-phase transformers are to be used to step down 2,400 volts, three to 240
volts, three phases, a closed-delta connection is used. Each of the three transformers is rated at
2,400 volts on the high-voltage side and 240 volts on the low voltage side (Figure 4-3).

Module in ET 302 – Power Wiring, Transforming Design & Construction 39

 Figure 4-3 Elementary diagram of delta-delta transformer connections.

CONNECTING THE DELTA

The transformer leads on the high-voltage side of each single-phase transformer are
marked H1 and H2. The leads on the low-voltage side of each single-phase transformer are
marked X1 and X2.

To connect the high-voltage primary windings in the closed-delta pattern to a three-phase

source, the three windings are connected as follows: In making the connection, the end of one
primary winding is connected to the beginning of the next primary winding. In Figure 4-3, H1 is
the beginning of each coil and 1-12 is the end of each coil. Thus, each primary winding end H2
is connected to the beginning H1 of another primary winding. A three-phase line wire is also
connected at each junction point H1 – H2. Note that the primary winding of each transformer is
connected directly across the line voltage. This means that delta-connected transformers must
be wound for the full-line voltage. In Figure 4-3, each of the three-line voltages is 2,400 volts, and
the primary winding of each transformer is also rated at 2,400 volts. After the high-voltage primary
connections are made, the three-phase, 2,400-volt input may be energized. It is not necessary
to make polarity tests on the input side.

The next step is to connect the low-voltage output or secondary windings in the closed-delta
pattern. The secondary winding leads are marked X1 for the beginning of each coil and X2 for the
end of each coil. In making the connections on the secondary,
the following procedure must be followed:
1. Check to see that the voltage output of each of the three transformers is 240 volts.
2. Connect the end of one secondary winding with the beginning of another secondary
winding (Figure 4-4).
The voltage across the open ends shown in Figure 4-4 should be the same as the output
of each transformer or 240 volts. If one of the transformers has its secondary winding connections
reversed, the voltage across the open ends will be 1 .73 x 240 = 415 volts.

Figure 4-4 A voltmeter is used to check Figure 4-5 A voltmeter reading

indicates correct connections. incorrect connections.

Module in ET 302 – Power Wiring, Transforming Design & Construction 40

 Figure 4-5 illustrates an incorrect connection that must be changed so that it is the same as
the connection shown in Figure 4-4.

Figure 4-6 illustrates the correct connections for the secondary coil of the third transformer.
The voltage across the last two open ends should be zero if all the transformers are connected
as shown. If the voltage is zero across the last two open ends, they may be connected together.
A line lead is then connected at each of the three junction points X1 – X2. These three wires are
the 240-volt, three-phase output. Note that each of the three-line voltages and each of the three
transformer output voltages is equal to 240 volts.

When the secondary winding of the third transformer is reversed, the voltage across the
last two open leads would be 240 + 240 = 480 volts.

Figure 4-7 illustrates the incorrect connection that results in a reading of 480 volts. The
connections on the third transformer secondary must be reversed.

Figure 4-6 Voltmeter reading indicates Figure 4-7 A voltmeter reading indicates
correct connections. incorrect connections.

Caution: Never complete the last connection if there is a voltage difference greater than zero.
If the connections are correct, this potential difference is zero. Observe safety precautions.
Deenergize the primary while making connection.

When three transformers are connected with their primary windings in delta and their
secondary windings in delta, the total connection is called a delta-delta (Δ-Δ) connection. The first
delta symbol indicates the connection method of the primary windings, and the second delta
symbol shows how the secondary windings are connected. When two or three single-phase
transformers are used to step down or step up voltage on a three-phase system, the group is
called a transformer bank.

Figure 4-8 is another way of showing the closed-delta connection first illustrated in Figure 4-
3. By tracing through the connection, it can be seen that the high-voltage and low-voltage
windings are all connected in the closed-delta pattern. This type of transformer diagram is often
used by the electrician.

Module in ET 302 – Power Wiring, Transforming Design & Construction 41

 Figure 4-8 Wiring diagram of a delta-delta connection.

VOLTAGE AND CURRENT

In any closed-delta transformer connection, two important facts must be kept in mind.
• The line voltage and the voltage across the transformer windings are the same. A-study of
any delta connection shows that each transformer coil is connected directly across two-
line leads; therefore, the line voltage and the transformer coil voltage must be the same
• The line current is greater than the coil current in a delta-connected transformer bank. The
line current is equal to 1.73 x coil current. A study of a closed-delta transformer connection
shows that each line lead is fed by two transformer coil currents that are out of phase and
thus cannot be added directly.

In the arrangement shown in Figure 4-9, the coil current in each transformer secondary is
10 amperes. The line current, however, is 1.73 x 10 or 17.3 amperes. Because the coil currents
are out of phase, the total current is not 10 + 10, or 20, amperes. Rather, the total current is a
resultant current in a balanced closed-delta system and is equal to 1.73 x coil current (1.73 equals
the square root of three).

Three single-phase transformers of the same kilovolt-ampere (kVA) capacity are used in
almost all delta-delta connected transformer banks used to supply balanced three-phase
industrial loads. For example, if the industrial load consists of three-phase motors, the current in
each line wire is balanced. To determine the total kVA capacity of the entire delta-delta connected
transformer bank, add the three transformer kVA ratings. Thus, if each transformer is rated at 50
kVA, the total kVA is 50 + 50 + 50 = 150 kVA.

Figure 4-9 Line current is √𝟑 times the coil current in a delta connection.

POWER AND LIGHTING SERVICE FROM A DELTA-DELTA CONNECTED TRANSFORMER

BANK

A delta-delta connected transformer bank, with one transformer secondary center

tapped, may be used to feed two types of load: (1) a 240-volt, three-phase industrial power
load, and (2) a 120/240-volt, single-phase, three-wire lighting load.

The single-phase transformer that is to supply the single-phase, three-wire lighting load is
usually larger in size than the other two transformers in the bank. This takes care of the additional
lighting load placed here. A tap must be brought out from the midpoint of the 240-volt, low-voltage
winding so that the 120/240-volt, single-phase, three-wire service can be obtained. Many
transformers are designed with the low-voltage side consisting of two 120-volt windings. These
windings can be connected in series for 240 volts, in parallel for 120 volts, or in series and center
tapped, with the tap brought out to give 120/240-volt service.

Module in ET 302 – Power Wiring, Transforming Design & Construction 42

 Figure 20-10 illustrates three single-phase transformers connected as a delta-delta
transformer bank. Each transformer has two 120-volt, low-voltage windings. These 120volt
windings are connected in series to give a total output voltage of 240 volts for each transformer.
The connection scheme for the high-voltage input or primary windings is closed delta. The low-
voltage output or secondary windings are also connected in the closed-delta pattern to give three-
phase, 240-volt service for the industrial power load. Note in Figure 4-10 that the middle
transformer is feeding the single-phase, three-wire, 120/240-volt lighting load. This center
transformer has a middle tap on the secondary (output) side to give 120/240-volt service. Also
note that this tap feeds to the grounded neutral wire. Figure 4-11 shows a one-line diagram
representation.

The three-phase, 240-volt industrial power system is also connected to the transformer
bank shown in Figure 20-11. A check of the connections shows that both lines A and C of the
three-phase, 240-volt system have 120 volts to ground. Line B, however, has 208 volts to ground
(120 x 1.73 = 208). This situation is called the high phase.

Article 110.15 of the National Electrical Code® requires that the phase be marked orange
in color and be placed in the middle in a switchboard or panelboard as “B” phase.

Caution: The high-phase situation can be a serious hazard to human life as well as to any
120-volt equipment connected improperly between the high phase and neutral. When the voltage
to ground exceeds 250 volts on any conductor in any metal raceway or metal-sheathed cable, the
National Electrical Code® requires special bonding protection.

For example, if rigid conduit is used to connect the services, there must be two locknuts.
One locknut is used outside and one inside any outlet box or cabinet. The regular conduit end
bushing must also be used to protect the insulation on the wires in the conduit. Where the
conductors are above a given size, this conduit bushing must be the insulating type or equivalent,
according to the National Electrical Code® in the section on cabinets.

Figure 4-10 Closed-delta transformer bank feeding a single-phase,

three-wire lighting load and a three-phase, three-wire power load.

Module in ET 302 – Power Wiring, Transforming Design & Construction 43

 Figure 4-11 One-line diagram of ∆-∆ transformer with three-phase,
four-wire secondary.

Note that for ungrounded circuits, the greatest voltage between the given conductor and
any other conductor of the circuit is considered the voltage to ground.

OPEN-DELTA OR V CONNECTION

A three-phase transformation of energy is possible using only two transformers. This

connection arrangement is called the open-delta or V connection. The open-delta connection is
often used in an emergency when one of the three transformers in a delta-delta bank becomes
defective. When it is imperative that a consumer's three-phase power supply be restored as soon
as possible, the defective transformer can be cut out of service using the open-delta arrangement.

The following example shows how the open-delta

connection can be used in an emergency. Three 50-kVA
transformers, each rated at 2,400 volts on the high-voltage
winding and 240 volts on the low-voltage winding, are
connected in a delta-delta bank (Figure 4-12). This closed-
delta bank is used to step down a 2,400-volt, three-phase
input to a 240-volt, three-phase output to supply an
industrial consumer. Suddenly, the three-phase power
service is interrupted because lightning strikes and
damages one of the transformers. The service must be
restored immediately. This situation is shown in Figure 4-
13.
Transformer 3 is the defective transformer. If all the
leads of the damaged transformer are disconnected, the
closed-delta bank automatically becomes an open-delta
transformer bank. Figure 4-12 Three single-phase
transformers used to create
three-phase distribution system.

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 The schematic diagram of this open-delta connection is shown in Figure 4-14. Note that
with the one transformer removed, the triangular coil arrangement is open on one side. Because
the schematic diagram resembles the letter V, this arrangement is also called the V connection.

Although it appears that the total kVA of the open-delta bank should be two-thirds that
of a close-delta bank, the actual kVA rating of an open-delta bank is only 58 percent of the
capacity of a closed-delta bank. The reason for this is that the currents of the two transformers
in the open-delta connection are out of phase, resulting in the total available capacity of the
open-delta bank being only 58 percent instead of 66.7 percent.

Figure 4-13 Open-delta connection

Figure 4-14 Schematic diagram of the open-delta or V connection.

In the open-delta example, three 50-kVA are connected in a delta-delta bank. This gives a
total kVA capacity of 50 + 50 + 50 = 150 kVA for the closed delta bank. When one transformer is
disconnected, the bank changes to an open-delta configuration, and the total kVA capacity now
is only 58 percent of the original closed-delta capacity.

150 X 0.58 = 87 kVA

In some situations, an open-delta bank of transformers is installed initially. The third

transformer is added when the increase in industrial power load on the transformer bank warrants
the addition. When the third transformer is added to the bank, a closed delta bank is formed.

When two transformers are installed in an open-delta configuration, the total bank capacity
can be found by the use of the following procedure.

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 1. Add the two individual transformer WA ratings. (For the problem given, the single-phase
transformers are rated at 50 kVA.)

50 + 50 = 100 kVA

2. Multiply the total kVA value by 86.5 percent. This gives the total kVA capacity of the open-
delta transformer bank.

100 x 86.5% = 87 kVA

Therefore, an open-delta bank has a kVA capacity of 58 percent of the capacity of a closed-
delta bank; an open-delta bank has a kVA capacity of 86.5 percent of the capacity of two
transformers.

Another way to explain the reduced percentages of output kVA is to use the rated voltages
and currents. In an open-delta pattern, there is no vector addition of the current at the junction
point; the line current is equal to the coil current. Just as in the closed-delta pattern, the open-
delta voltage at the lines is the same as the coil voltages. The results can be seen in the following
example: If each of the transformers are rated at 50 kVA and the secondary voltages are 240
volts, then the coil current of each transformer is 50,000/240 = 208 A. In an open-delta pattern,
Line 1 equals Coil 1 and Line E equals Coil E The three-phase capacity of two transformers
connected open-delta is

Line E x Line 1 x 1.73 = 86.5 kVA

This is the same as 86.55 percent of the two-kVA added. This is also the same as 58 percent of
the original 150 kVA or 1.73 times the single 50 kVA.

THREE-PHASE TRANSFORMERS WITH PRIMARY TAPS

Some plant distribution transformers are preassembled and wired at the factory into a
three-phase bank in a single enclosure or as a single unit. These assemblies consist of three
single-phase transformers in one enclosure, usually the dry, air-cooled type. Some have primary
tap terminals so that the supply voltage can be matched more closely (Figure 4-15). The
electrician must make the adjustment on the job until the primary of the transformer matches the
measured supply voltage. The secondary will then produce the desired voltage to achieve a
closer match of the equipment nameplate voltages. Utilities do not always supply the desired
accurate voltages. There may also be a voltage drop within the plant.

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 Figure 4-15 Tap Connections for a three-phase bank

When using taps on a three-phase transformer or bank of transformers, it is important that

the same taps on each of the three primaries be connected in the same position on each coil.
The following problems may result if the taps are not connected properly:
• The output voltage on each of the three secondary voltages will not be the same. This will
produce high unbalanced currents that will cause overheating of induction motors.
• An undesirable circulating current will create a "false load" condition if the transformer is
connected delta-delta.

Taps are used for consistently high or low voltages. They are not used with voltages that
fluctuate or vary frequently.

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 SUMMARY

Single-phase transformers are often used to create various patterns to supply three-phase
loads. One pattern is the closed-delta pattern. In this pattern, the line voltage is the same as the
phase voltage, but the current on the lines is 1.73 times the coil current. Be sure the coil leads
are marked correctly and double-check the connection procedures before energizing the delta
transformer bank.

Single-phase transformers can be connected in an open-delta pattern to provide a reduced

capacity power supply to a system if one of the phase transformers fails. Single-phase
transformers connected in the closed- or the open-delta pattern do not need to be the same kVA
rating. Often, one transformer is larger if the system is to supply three-phase delta and some
single-phase, three-wire systems. If the proper nominal voltage is not available at the primary of
the transformer, primary taps may be needed to bring the voltage back to the proper level.

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Answer the following:

1. What is one practical application of single-phase transformers connected in a delta-delta

configuration?

2. What simple rule must be followed in making a delta connection?

3. Make a connection diagram for three single-phase transformers connected in a closed-

delta scheme. This transformer bank is used to step down 2,400 volts, three-phase to
240 volts, three-phase. Each transformer is rated at 50 kVA, with 2,400 volts on the high-
voltage winding and 240 volts on the low-voltage winding. Mark leads H1, Xl, and so forth.
Show all voltages.

4. What is the total kVA capacity of the closed-delta transformer bank in question 3?

5. What is one practical application of an open-delta transformer bank?

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 6. Make a connection diagram of two single-phase transformers connected in open delta.
Each transformer is rated at 10 kVA, with 4,800 volts on the high-voltage winding, and
240 volts on the low-voltage winding. This bank of transformers is to step down 4,800
volts, three phase to 240 volts, three phase, Mark leads H1, Xl, and so forth. Show all
voltages. Calculate the total kVA capacity of this open-delta transformer bank.

7. What problems are likely to result if taps are not connected properly on a three-phase
transformer bank?

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 REFERENCES

Keljik, Jeff, Electricity 3: Power Generation and Delivery, 8th Edition, Singapore: Cenage
Learning Asia Pte Ltd, 2008.

[Link]
al_Engineering_I_9648.pdf

[Link]

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