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These five steps will help your next transformer installation

run more smoothly.

Installing transformers in accordance with the NEC is


critical to ensuring a safe electrical installation as well as a
reliable power supply system — especially for those
applications where power quality is an issue. The
installation of transformers is one of the most common, yet
complicated installation practices that's cause for
considerable confusion when sizing overcurrent protection
devices (OCPD) and bonding and grounding conductors.
Many electrical installations can be a challenge in terms of
NEC requirements, and transformers can raise that
challenge to a new level. A safe installation that's properly
designed and installed will ensure that the conductors and
equipment are properly sized and protected. In addition,
grounding is also an overriding issue. Failure to properly
install transformers can lead to fires from improper
protection or conductor sizes, as well as electric shock from
improper grounding, so let's look at how to do it right the
first time.
Let's assume you're installing a 45kVA and 112.5kVA,
480V delta primary to a 208/120V 3-phase wye secondary
transformer in a new facility. Each transformer supplies a
lighting and appliance branch-circuit panelboard with
continuous nonlinear loads typically found in today's office
buildings. The length of the conductors from the
transformer secondary to the lighting and appliance branch-
circuit panelboard is less than 10 ft, and all terminals are
rated 75°C.
Step 1. First determine the primary and secondary current
rating of the transformers (see Fig. 1 on page 30 and Fig. 2
at right).
For a 45kVA transformer, the primary current would be
45,000VA÷(480×1.732)=54A.
For the same transformer, the secondary current would be
45,000VA÷(208V×1.732)=125A.
For a 112.5kVA transformer, the primary current would be
112,500VA÷(480V×1.732)=135A, and for the same
transformer, the secondary current would be
112,500VA÷(208V×1.732)=312A.
Step 2. Next, you must protect the primary winding of each
transformer against overcurrent, in accordance with the
percentages listed in Table 450.3(B) and all applicable
notes. Where 125% of the primary current doesn't
correspond to a standard rating of a fuse or nonadjustable
circuit breaker as listed in 240.6(A), the next higher rating
in Table 450.3(B) is acceptable (Note 1).
For a 45kVA transformer, 54A×1.25=68A, so go to the
next size up, which is 70A.
For a 112.5kVA transformer, 135A×1.25=169A, so go to
the next size up, which is 175A.
Step 3. Now you must size feeder conductors supplying
continuous loads no smaller than 125% of the continuous
loads based on the conductor ampacity values listed in
Table 310.16 and before any ampacity adjustment, in
accordance with the terminal temperature rating [110.14(C)
and 215.2(A)(1)].
For a 45kVA transformer, 54A×1.25=68A, so use a 4
AWG conductor rated 85A at 75°C, per Table 310.16.
For a 112.5 kVA transformer, 135A×1.25=169A, so use a
2/0 AWG conductor rated 175A at 75°C, per Table 310.16.
Size the equipment grounding (bonding) conductor for the
transformer primary based on the size of primary protection
device, per 250.122(A):
• 45kVA transformer — Per Table 250.122, 70A
primary protection (Step 2) requires an 8 AWG
copper conductor.
• 112.5kVA transformer — Per Table 250.122, 175A
primary protection (Step 2) requires a 6 AWG copper
conductor.

Step 4. You can run secondary conductors without


secondary overcurrent protection at the point of supply for
10 ft if the secondary conductors have an ampacity greater
than the rating of the termination device. This means the
next-bigger-OCPD rule contained in 240.4(B) doesn't apply
to this application.
Although secondary overcurrent protection isn't required in
this situation, you're required to install overcurrent
protection for lighting and appliance branch-circuit
panelboards. You must locate this protection on the
secondary side of the transformer, in accordance with
408.16(A) and (D). Where a feeder supplies continuous
loads, the rating of the (secondary) overcurrent device may
not be less than 125% of the continuous load (215.3) as
listed in 240.6(A).
For a 45kVA transformer, 125A×1.25=156A, so use a
175A protection device.
For a 112.5kVA transformer, 312A×1.25=390A, so use a
400A protection device.
Since secondary overcurrent protection is provided in this
example, the primary OCPD can be sized at as much as
250% of the primary current rating, in accordance with
Table 450.3(B) and 240.21(B)(3).
Secondary conductors may not have an ampacity rating less
than the rating of the OCPD at the termination of the
conductors in accordance with Table 310.16 based on 75°C
terminal rating [110.14(C)]. This means the next-size-up
rule contained in 240.4(B) doesn't apply.
For a 45kVA transformer: 175A protection device=2/0
AWG, rated 175A at 75°C.
For a 112.5kVA transformer: 400A OCPD=600 kcmil,
rated 420A at 75°C.
But don't stop there. Where the number of current-carrying
conductors in a raceway or cable exceeds three, the
allowable ampacity shall be reduced in accordance with
Table 310.15(B)(2)(a). For our examples, there are four
current-carrying conductors on the secondary. The neutral
is considered to be a current-carrying conductor, per
310.15(B)(4)(c), so you can reduce the ampacity by 20%.
The conductor ampacity after adjustment and based on a
90°C ampacity rating [110.14(C)] must be no less than
175A for the 45kVA transformer and 400A for the
112.5kVA transformer.
For a 45kVA transformer, use 3/0 AWG, rated
225A×0.80=180A, which is greater than the 175A
protection device.
For a 112.5kVA transformer, use 700 kcmil, rated
520×0.80=416A, which is greater than the 400A protection
device.
Step 5. You must bond a transformer secondary that
operates at more than 50V [250.20(A) and 250.112(I)] to
an effective ground-fault current path to ensure dangerous
voltage levels imposed by lightning, line surges, or
unintentional contact with higher-voltage lines won't
remain [250.2(A)(3)] on the system.
To provide the low-impedance path necessary to clear a
ground-fault on a separately derived system, you must bond
the metal parts together (equipment grounding conductor)
and connect them to the system ground conductor (X0
terminal). You must size the bonding jumper in accordance
with Table 250.66, based on the total area of the largest
ungrounded (hot) conductor as follows:
For a 45kVA transformer: 3/0 AWG secondary
conductor=4 AWG copper bonding jumper.
For a 112.5kVA transformer: 700 kcmil secondary
conductor=2/0 AWG copper bonding jumper.
The neutral-to-case bond can be made at the source of a
separately derived system or at the first system
disconnecting means or OCPD. When there's no secondary
side disconnecting means or overcurrent device(s), the
neutral-to-case bond is made at the source of the separately
derived system.
The neutral-to-case connection for a separately derived
system can't be made at more than one location if it results
in a parallel path for neutral current flow [250.30(A)(1)
Exception No. 1]. Such multiple neutral current return
paths to the grounded (neutral) conductor of the power
supply can create fire and shock hazards, as well as power
quality problems due to EMI [250.6 and 250.142(A)].
You must size a grounding electrode conductor for a single
separately derived system in accordance with 250.66, based
on the total area of the largest secondary ungrounded (hot)
conductor. This conductor shall connect the grounded
conductor of the derived system to the grounding electrode
as specified in 250.30(A)(4). The grounding electrode
conductor must terminate at the same point on the
separately derived system where the neutral-to-case
bonding jumper is installed [250.30(A)(1)].
For a 45kVA transformer: 3/0 AWG=4 AWG copper
grounding electrode conductor.
For a 112.5kVA transformer: 700 kcmil=2/0 AWG copper
grounding electrode conductor.
You must connect the grounding electrode conductor
directly to the grounded neutral conductor terminal. It can't
be terminated to the case of the transformer.
You must terminate the grounding electrode conductor to a
grounding electrode that's located as close as practicable to,
and preferably in the same area as the nearest effectively
grounded metal member of the structure or effectively
grounded metal water pipe within 5 ft from the point of
entrance into the building.
However, the grounding electrode conductor can terminate
at any point on the water pipe system for industrial and
commercial buildings where conditions of maintenance and
supervision ensure only qualified persons service the
installation, and the entire length of the interior metal water
pipe used for the grounding electrode is exposed.
If an effectively grounded metal member of the building
structure or an effectively grounded metal water pipe is not
available, one of the following electrodes must be used:
• An electrode encased by at least 2 in. of concrete,
located within and near the bottom of a concrete
foundation or footing that's in direct contact with the
earth, consisting of at least 20 ft of one or more bare,
zinc-galvanized, or other electrically conductive
coated steel reinforcing bars or rods of not less than ½
in. in diameter, or consisting of at least 20 ft of bare
copper conductor not smaller than 4 AWG. See
250.52(A)(3).
• A ground ring encircling the building or structure, in
direct contact with the earth, consisting of at least 20 ft
of bare copper conductor not smaller than 2 AWG.
See 250.52(A)(4).
• Rod or pipe electrodes not less than 8 ft in length. See
250.52(A)(5).
• A plate electrode that exposes not less than 2 sq ft of
surface to exterior soil. See 250.52(A)(6).
• Other local metal underground systems or structures
like piping systems and underground tanks. See
250.52(A)(7).
As you can see, installing transformers properly can be
done in five steps, but sometimes it gets tricky. But as long
as you follow the NEC rules outlined in this article, you
should be fine.

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