Transformer Design

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What

is neutral grounding transformer?


Despite the misleading answer of the earlier poster, neutral grounding transformers are used to
derive a neutraltoearth connection for systems that do not otherwise have one.

The grounding transformer can have a zigzag winding arrangement, or a wyedelta arrangement.

The transformer primary terminals (wye side) are connected to the power system, and its neutral
is connected to earth, perhaps through a controlled impedance. (Usually, with Wyedelta grounding
transformers, the impedance is connected inside the delta.) No other load is connected to the delta
of the transformer.

These transformers provide a high impedance to normal currents (positive & negative sequence),
but allow ground fault currents (zero sequence) to flow, thereby allowing protective devices to
operate if a ground fault occurs.
Understanding the Basics of Wye Transformer Calculations
Last month's Code Calculations article covered transformer calculation definitions and some
specifics of delta transformer calculations. This month we turn our attention to the differences
between delta and wye transformers and to wye transformer calculations. We'll close by looking at
why it's so important to know how to perform these calculations, but you'll likely see the reasons as
we go.
In a wye configuration, three singlephase transformers are connected to a common point (neutral)
via a lead from their secondaries. The other lead from each of the singlephase transformers is
connected to the line conductors. This configuration is called a wye, because in an electrical
drawing it looks like the letter Y. Unlike the delta transformer, it doesn't have a high leg.


Fig. 1. Wiring arrangements can have a considerable effect on output voltage.


Differences in wye and delta transformers. The ratio of a transformer is the relationship
between the number of primary winding turns to the number of secondary winding turns and
thus a comparison between the primary phase voltage and the secondary phase voltage. For typical
delta/delta systems, the ratio is 2:1 but for typical delta/wye systems, the ratio is 4:1 (Fig. 1
above).
If the primary phase voltage in a typical delta/delta system is 480V, the secondary phase voltage is
240V. If the primary phase voltage in a typical delta/wye system is 480V, the secondary phase
voltage is 120V.
Delta and wye transformers also differ with regard to their phase voltage versus line voltage and
phase current versus line current. In a delta transformer,
EPhase=ELine and ILine=IPhase3.
In a wye transformer,
IPhase=ILine and ELine=EPhase3.
These differences affect more than just which formulas you use for transformer calculations. By
combining delta/delta and delta/wye transformers, you can abate harmonic distortion in an
electrical system. We'll look at that strategy in more detail after addressing wye transformer
calculations.


Fig. 2. As this example shows, the line and phase currents are equal in a wye transformer.
Wye current and voltage calculations. In a wye transformer, the 3phase and singlephase 120V
line current equals the phase current (IPhase = ILine) (Fig. 2 on page C20).
Let's apply this to an actual problem. What's the secondary phase current for a 150kVA, 480V to
208Y/120V, 3phase transformer (Fig. 3 on page C20)? ILine=150,000VA(208V1.732)=416A, or
IPhase=50,000VA120=416A
To find wye 3phase line and phase voltages, use the following formulas:
EPhase=ELine3
ELine=EPhase3
Since each line conductor from a wye transformer is connected to a different transformer winding
(phase), the effects of 3phase loading on the line are the same as on the phase (Fig. 4 on page C21).
A 36kVA, 208V, 3phase load has the following effect:

Line power=36kVA
ILine=VALine(ELine3)
ILine=36,000VA(208V3)=100A
Phase power=12kVA (any winding)
IPhase=VAPhaseEPhase
IPhase=12,000VA120V=100A
Wye transformer balancing and sizing. Before you can properly size a delta/wye transformer,
you must make sure that the secondary transformer phases (windings) or the line conductors are
balanced. Note that balancing the panel (line conductors) is identical to balancing the transformer
for wye transformers. Once you balance the wye transformer, you can size it according to the load
on each phase. The following steps will help you balance the transformer:


Fig. 3. Note the fourfold increase in phase current when working with a delta/wye transformer.
Step 1: Determine the loads' VA ratings.
Step 2: Put onethird of the 3phase load on Phase A, onethird on Phase B, and onethird on Phase
C.
Step 3: Put onehalf of the singlephase, 208V load on Phase A and Phase B, or Phase B and Phase C,
or Phase A and Phase C.


Fig. 4. In this example, note that the line and phase power and current are the same, since each line
conductor from a wye transformer is connected to a different transformer winding.
Step 4: Place 120V loads (largest to smallest): 100% on any phase.

Now consider the following wye transformer sizing example: What size transformer (480V to
208Y/120V, 3phase) would you need for the following loads: 208V, 36kVA, 3phase heat strip; two
208V, 10kVA, singlephase loads; and three 120V, 3kVA singlephase loads?
a) three singlephase, 25kVA transformers
b) one 3phase, 75kVA transformer
c) a or b
d) none of these
Phase A=23kVA
Phase B=22kVA
Phase C=20kVA
The Table sums up the kVA for each phase of each load. Note that the phase totals (23kVA, 22kVA,
and 20kVA) should add up to the line total (65kVA). Always use a checksum like this to ensure
you have accounted for all items and the math is right.
If you're dealing with highharmonic loads, the maximum unbalanced load can be higher than the
nameplate kVA would indicate. Matching the transformer to the anticipated load then requires a
high degree of accuracy if you want to get a reasonable level of either efficiency or power quality.
One approach to such a situation is to supply highharmonic loads from their own delta/delta
transformer. Another is to supply them from their own delta/wye and double the neutral. The
approach you choose will depend on the characteristics of your loads and how well you lay out
your power distribution system.
For example, you might put your computer loads (which have switching power supplies) on a
delta/delta transformer, which you would feed from a delta/wye transformer. This would greatly
reduce the presence of harmonics in the primary system, partly due to the absence of a neutral
connection. But the behavior of the delta/delta transformer itself, combined with the interaction of
delta/delta and delta/wye, will also cause a reduction in harmonics. Notice the word might in the
question of whether to implement this kind of design. Grounding considerations can make it an
undesirable approach, depending on the various loads and the design of the overall electrical
system. Keep in mind that this is one of the many ways to mix and match transformers to solve
power quality problems.
Due to uptime or power quality concerns with complex loads, you may need to mix and match
transformer configurations as in the previous example. And that's something you can't do unless
you understand both delta and wye calculations.
Another issue is proper transformer loading. As a rule of thumb, 80% loading is a good target. If you
overload the transformer, though, it goes into core saturation and output consists of distorted
waveforms. The clipped peaks typical of saturated transformers cause excess heating in the loads.
This issue of transformer loading means you're going to have to perform the transformer
calculations just to get basic power quality and reasonable efficiency.
So it's important not to oversimplify your approach to transformer selection. It's usually best to do
all the calculations using the nameplate kVA. Then, design the distribution system as though all
loads are linear. When that's done, identify which loads are high harmonic, such as electronic
ballasts, computer power supplies, and motors with varying loads. At this point, you can efficiently
work with a transformer supplier to develop a good solution.

Now that you understand delta and wye transformer calculations, you can see how important they
are to being able to do a quality installation any time you're specifying transformers or considering
adding loads to existing transformers. This ability is also important if you're trying to solve a power
quality problem or a problem with unexplained system trips. You may wish to sharpen this ability
by purchasing an electrical calculations workbook or taking on this kind of work in your electrical
projects.

The Basics of DeltaWye Transformers
When it comes to making proper transformer connections, more industry professionals choose the
deltawye connection than any other 3phase transformer connection in power distribution. Why is
it so popular? You can use the secondary to provide a neutral point for supplying linetoneutral
power to serve singlephase loads and ground the neutral point for safety reasons.
The delta primary serves several useful functions. If the transformer secondary supplies large
amounts of unbalanced loads, the delta primary winding provides you with a better current balance
for the primary source. How can you be sure which transformer is right for your particular
application? Let's look at your options.
Drytype and liquidfilled transformers. Transformers fall into one of two categories drytype or
liquidfilled units. In drytype transformers, the most common cooling medium is air (some sealed
drytype transformers use nitrogen for cooling). You typically use them indoors and up to a
maximumrated voltage of 34.5kV.
You use liquidfilled transformers in medium and highvoltage applications especially outdoors.
The liquid makes an excellent cooling medium. Now let's look at a typical transformer makeup.
Core and winding characteristics. A transformer winding and its magnetic core are the two most
vital parts required for voltage transformation. The core consists of thin laminations of silicon steel,
which help reduce eddy current losses. Eddy currents are induced in the core structure as a result
of exposing the core to an alternating magnetic field.
Copper and aluminum are common materials used for transformer windings. Aluminum is a lighter
metal, but has a higher resistivity than copper. Copperwound transformer coils are more
mechanically rigid than aluminumwound coils, which help increase the transformer's reliability
when subjected to an external fault.
Harmonics. Third harmonic currents are common in facilities that house computer, communication,
and data processing loads. Ideally, the delta primary windings should trap the third harmonic
current in the closed delta winding; however, a low level of third harmonic current still passes to
the primary lines. The figure shows a deltawye transformer connection where the third harmonic
currents remain trapped in the primary delta winding.
Although deciding which transformer connection is right for you may seem like an easy task, take
time to research your options before you buy.
Understanding the Basics of Delta Transformer Calculations

Transformer configuration names like delta and wye derive from the way the windings are
connected inside the transformer. These connections determine the way the transformer will
behave, and they also determine the methods of calculation required for properly applying a given
transformer.
Deltaconnected transformers have the windings of three singlephase transformers connected in
series with each other to form a closed circuit. The line conductors are connected to the unit where
the two singlephase transformers meet. This configuration gets its name because in an electrical
drawing it looks like a triangle (Greek symbol for the letter delta). Many call it a highleg system
because the voltage from Line 2 to ground is higher than that of the other legs. For example, a 120V
delta transformer will have a 208V leg.


Fig. 1. Its important to note that the line current from a delta transformer doesnt equal the phase
current. In this example, the line current is 87A and the phase current is 50A.
Delta transformer current. In a delta transformer, the line current doesn't equal the phase
current (as it does in a wye transformer). Because each line from a delta configured transformer is
connected to two transformer phases, the line current from a 3phase load will be greater than the
phase current by the square root of 3. Note these formulas:
ILine= IPhase3
ILine= VALine(ELine 3)
IPhase= ILine3
IPhase= VAPhaseEPhase

Fig. 2. You can use the same formula to find both the primary and secondary line current.
If you plug some numbers in, you can more clearly see the effects of the delta configuration on
currents. Let's try this with a 240V, 36kVA, 3phase load (Fig. 1 above).
First, let's solve for the line current (total line power=36kVA).
ILine=VALine(ELine3)
ILine=36,000VA(240V3)
ILine=87A
Now, let's solve for the phase current (phase power=12kVA, per winding).
IPhase=VAPhaseEPhase
IPhase=12,000VA240V=50A
You can also find the line and phase currents using the other two formulas shown above.
ILine=IPhase3
ILine=50A 1.732=87A
IPhase=ILine3
IPhase=87A1.732=50A
We can also use the formula: ILine = VALine(ELine3). For example, what is the secondary line
current for a 480V to 240/120V, 150kVA, 3phase delta transformer (Fig. 2)? The answer is found
as follows:
ILine=VALine(ELine3)
ILine=150,000VA(240V1.732)= 360A


Fig. 3. When solving for phase current, dont forget to divide the overall transformer kVA rating by
3.
You can calculate the phase current of a delta transformer winding by dividing the phase VA by the
phase volts: IPhase = VAPhaseEPhase. The phase load in VA of a 3phase, 240V load is the line load

divided by three (one third of load on each winding). The phase load in VA of a singlephase 240V
load is the line load (all on one winding). The phase load in VA of a singlephase, 120V load is the
line load (all on one winding).
Let's look at another example problem. What is the secondary phase current for a 480V to
240/120V, 150kVA, 3phase delta transformer (Fig. 3 above)?
Phase power=150,000VA3 per phase
Phase power=50,000VA per phase
IPhase=50,000VA240V
IPhase=208A
To better understand what happens in a delta system, try running these numbers with a 10A load
and then with a 75A load.


Fig. 4. This diagram is showing transformer balancing. For the sake of simplicity, overcurrent
protection for these circuits isnt shown.
Delta transformer balancing. To properly size a delta/delta transformer, the transformer phases
(windings) must be balanced. You can do that with a twostep process:
Step 1. Determine the VA rating of all loads.
Step 2. Balance the loads on the transformer windings as follows:

3phase loads: onethird of the load on each of the phases.

240V, singlephase loads: 100% of the load on Phase A or B. You can place some of the 240V,
singlephase load on Phase C when necessary for balance.

120V loads: 100% of the load on C1 or C2.

To size the panelboard and its conductors, you must balance the loads in amperes. Why balance the
panel in amperes? Why not take the VA per phase and divide by phase voltage? Because line
current of a 3phase load is calculated by the following formula:

ILine=VA(ELine3)
ILine=150,000VA(240V1.732)= 208A per line.
If you took the per line power of 50,000VA and divided by one line voltage of 120V, you would
come up with an incorrect line current of 50,000VA 120V=417A.
Delta transformer sizing. Consider this method the next time you're sizing deltaconnected
transformers, where most of the loads are linetoline. Once you balance the transformer, size it to
the load of each phase. Size the C transformer using two times the highest of C1 or C2. The C
transformer is actually a single unit. If one side has a larger load, that side determines the
transformer size.


Refer to this load breakdown per phase for the practice problem below.
Let's try another practice problem to reinforce these concepts. What size 480V to 240/120V
transformer is required for the following loads: one 240V, 36kVA, 3phase heat strip; two 240V,
10kVA, 3phase loads; three 120V, 3kVA loads, singlephase (Fig. 4)?
(a) three singlephase, 25kVA transformers
(b) one 3phase, 75kVA transformer
(c) a or b
(d) none of the above
Phase winding A=22kVA
Phase winding B=22kVA
Phase winding C=(12kVA of C12) = 24kVA
The answer is (c), a or b. You can use one singlephase 75kVA transformer or three 25kVA
transformers for this load.
Now that you understand some transformer calculation basics and specifics on delta transformer
calculations, you'll be able to size delta transformers correctly when the majority of the loads are
linetoline. You find deltadelta transformers most often in special applications. The most common
configuration is the deltawye. In the case of a deltawye transformer, you now know how to size
the primary side. After next month's article, which will address the wye transformer calculations,
you'll be able to size any combination of delta and wye transformers.



Sidebar: Know Your Terms

To avoid confusion with transformer calculations, it's important to have a firm grasp of some basic
concepts (Fig. 5 below). Once you're comfortable with these terms, you should be ready to tackle
all types of transformer calculations.


Fig. 5. Knowing transformer terms is key to proper calculations.
Line The ungrounded (hot) conductor(s).
Line current The current on the ungrounded conductors (B1 and B2 in Fig. 6). In a delta system,
the line current is greater than the phase current by the square root of 3, which is about 1.732). In a
wye system, the line current equals the phase current.
Line voltage The voltage between any two line (ungrounded) conductors (A1 and A2 in Fig. 6).
In a delta system, the line voltage equals the phase voltage. But the delta system also has a highleg.


Fig. 6. Key voltage and current readings in a delta/delta system.
Phase current The current flowing through the transformer winding (D1 and D2 in Fig. 6). In a
delta system, the phase current is less than the line current by the square root of 3. In a wye system,
the phase current equals the line current.
Phase load The load on the transformer winding.

Phase voltage The internal transformer voltage generated across one winding of a transformer.
For a delta secondary, the phase voltage equals the line voltage. In a wye system, the phase voltage
is less than the line voltage by the square root of 3 (A2 and C2 in Fig. 6).
Ratio The number of primary winding turns divided by the number of secondary winding turns.
Unbalanced load (neutral current) The load on the secondary grounded (neutral) conductors.

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