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CHAPTER
5
Connecting and
Troubleshooting
Transformers

Topics to Be Covered
5.1 Checking out a Transformer
5.1.1 Testing for Turns Ratio
5.1.2 Insulation Resistance and Continuity Testing
5.1.3 Changing Transformer Taps
5.1.4 Testing for Transformer Polarity
5.1.5 Always Check the Voltage
5.1.6 Checking Transformer Loading

5.2 Specific Hazards Working with Transformers


5.2.1 Energizing an Overhead Transformer
5.2.2 Energizing an Underground Transformer
5.2.3 Protection from Transformer Backfeed
5.2.4 Potential Explosive Flash at Transformer Secondary
5.2.5 Causes of Ferroresonance
5.2.6 Prevention of Ferroresonance

5.3 Single-Phase Transformer Connections


5.3.1 Transformer Protection
5.3.2 Making Neutral Connections and Ground Connections
5.3.3 Parallel or Series Connection of Center-Tapped Secondary Coil
5.3.4 Connecting Two Transformers in Parallel
5.3.5 Connecting a Transformer to a Secondary Network
5.3.6 Troubleshooting a Single-Phase 120/240-Volt Service

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5.4 Three-Phase Transformer Connections


5.4.1 Banking Three Single-Phase Units
5.4.2 Making Wye or Delta Connections?
5.4.3 Delta Primary Transformer Connections
5.4.4 Wye Primary Transformer Connections
5.4.5 Delta Secondary Transformer Connections
5.4.6 Open Delta Connections
5.4.7 Wye Secondary Transformer Connections
5.4.8 Three-Phase Secondary Voltages
5.5 Troubleshooting Transformers
5.5.1 Taking Voltage Checks at the Secondary
5.5.2 Troubleshooting a Wye Secondary (120/208, 240/416, or 347/600 Volt)
5.5.3 Troubleshooting a Delta Secondary (600, 480, or 240 Volt)
5.6 Working on a Voltage Conversion
5.6.1 Preparing the Circuit for Voltage Conversion
5.6.2 Working at Transformer Installations
5.6.3 Working at Underground Installations
5.6.4 Working at Primary Step-Down Transformer Installations

5.1 Checking out a Transformer


5.1.1 Testing for Turns Ratio
Check the transformer nameplate for the rated primary voltage and the expected sec-
ondary voltage. A test can confirm the actual turns ratio and will ensure that there
are no shorts between turns in the windings (figure 5.1). Energize the high voltage

Apply
120 Volts AC
H-1

H-2

Figure 51 Turns Ratio Field Test.


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Connecting and Troubleshooting Transformers 95

coil with a low voltage such as 120 volts. Measure the input voltage and the output
voltage with a voltmeter. The ratio is calculated as:
Input 4 Output = Transformer Ratio
CAUTION! Transformers work both ways! For this test, the low-input voltage
must be connected to the HIGH-voltage winding. If the input voltage was connect-
ed to the low-voltage winding, the transformer would be a step-up transformer, and
a lethal voltage will appear at the high-voltage terminal.

5.1.2 Insulation Resistance and Continuity Testing


Testing a transformer for damaged insulation or coil continuity can be carried out
using a 1000-volt insulation tester (megger). Remove any ground from the X2 ter-
minal for these tests.

Insulation Test
The readings between the high-voltage terminal and the low voltage ( X1, X2, or X3)
terminals should be infinite. Readings between the low voltage terminals and the
transformer tank should be infinite. The insulation test readings with a three-phase
transformer should be as shown in table 51.

Continuity Test
Readings between each of the primary terminals and each of the secondary terminals
should be zero as shown in table 52.

Table 51. Insulation Resistance Tests on Three-Phase Transformer


HV to LV Insulation Resistance LV Insulation Resistance to Tank
Test Connections Readings Test Connections Readings

H1 to X1, X2, or X3 Infinite () X1 to Tank Infinite ()

H2 to X1, X2, or X3 Infinite () X2 to Tank Infinite ()

H3 to X1, X2, or X3 Infinite () X3 to Tank Infinite ()

Table 52. Continuity Tests on Three-Phase Transformer Windings


Continuity Tests of HV Windings Continuity Tests of LV Windings
Test Connections Readings Test Connections Readings

H1 to H2 Zero X1 to X2 Zero

H2 to H3 Zero X2 to X3 Zero

H3 to H1 Zero X3 to X1 Zero
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Taps
%
105 A
102.5 B
100 C
97.5 D
95 E

Figure 52 Tap Settings as Shown on Name Plate.

5.1.3 Changing Transformer Taps


Some distribution transformers have no-load tap changers which can apply addition-
al or fewer turns to the primary winding. Depending on the manufacturer, each tap
will raise or lower the secondary voltage by 4.5 percent or 2.5 percent. The nameplate
shown in figure 5.2 has 2.5 percent taps.
Newer transformers have an external switch knob to change the taps, while the
cover must be removed to access the taps for changes on older transformers. The
transformer must be isolated before turning the knob.
Caution: The feeder voltage will change during the day and at different seasons.
Therefore, changing the taps at the transformer could produce extreme voltages
when the primary voltage returns to its normal level in off-peak periods.

5.1.4 Testing for Transformer Polarity


When installing a transformer on a secondary network or when banking the trans-
former together with other transformers, ensure that the transformers are connected
at the same polarity. An additive and a subtractive transformer (figure 5.3) can be
banked together by ensuring that the X-1 of one transformer is connected to the X-
1 of the other transformer (similarly with X-2 and X-3), regardless of the position of
the terminals on the transformer tank.

H-1 H-2 H-1 H-2

Subtractive Additive
Transformer Transformer

X-1 X-2 X-3 X-3 X-2 X-1

Figure 53 Subtractive and Additive Transformers.


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Testing a Transformer for Additive or Subtractive Polarity


Step 1. When facing the transformer (figure 5.4), install a jumper between the high-
voltage neutral (or the righthand-side high-voltage terminal) and the low-
voltage terminal on the righthand side.
Step 2. Apply 120 volts across the primary of the transformer.
Step 3. Measure the voltage between the left-side high-voltage terminal and the left-
side low-voltage terminal.

5.1.5 Always Check the Voltage


After the installation of a transformer, it is considered essential to perform a second-
ary voltage check as a final test to ensure that the customer is supplied with a proper
voltage. The American National Standards Institute (ANSI) voltage standard is to be
between + 6 percent or 13 percent for 120, 208, 277, 480, or 575-volt services.

5.1.6 Checking Transformer Loading


The actual load on a transformer can be measured as shown in figure 5.5 and calcu-
lated in the field.
Example: The expected current on the secondary of a transformer with a 120/240-
volt loaded to 100 percent can be calculated as follows;
Current @ 100% Load = kVA Transformer 3 1000
240

Apply
120 Volts AC
H-1

For a 10 to 1
Additive Transformer,
Voltmeter Will Read
132 Volts H-2
additive

120 V
+ 12 V V
132 V

X-3 X-1
Short Out H-2
and Adjacent
Secondary Terminal

Figure 54 Test for Transformer Polarity.


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H-1

H-2

V1 V2

I1 I2

Neutral

Figure 55 Calculating the Actual Transformer Load.

5.2 Specific Hazards Working with Transformers


5.2.1 Energizing an Overhead Transformer
An overhead transformer with a blown fuse is often checked by energizing it with
another fuse. If the transformer is defective, the fuse can blow backward violently.
Hot particles will blow back at the powerline worker. Precautions include staying out
from under the cutout, using a stick with an attached shield, and using an extra
length of hot stick. A current-limiting fuse in series with the cutout fuse will reduce
the risk of a violent transformer failure in locations where there is a high fault cur-
rent capability.

5.2.2 Energizing an Underground Transformer


There are very few transient faults on an underground transformer. On a dead-front
transformer, the bayonet-style fuse or the current-limiting fuse in a dry-well canister
have been known to fail explosively when using the fusing device to energize a fault-
ed transformer. This risk can be reduced by energizing the transformer with a load-
break elbow or from a remote location.

5.2.3 Protection from Transformer Backfeed


A secondary voltage feeding back into an isolated transformer is stepped up to a full
primary voltage at the transformer primary terminal. Sources of secondary backfeed
are not always obvious:
A portable generator connected into the customer system without opening the
customer main switch.
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A nearby recreational vehicle (RV) with a generator connected into a home


wiring.
An extension cord from a neighboring house.
When working on a transformer that is networked with other transformers to a
common secondary bus, the primary terminal remains alive if there are no net-
work protectors opened after the transformer is disconnected from the primary.

Protection from Transformer Backfeed


When working on a transformer, remove the secondary leads to ensure that
there is no possibility of backfeed into the transformer secondary terminals.
Shorting out the secondary with approved grounds can be effective. Placing
the grounds by hand can violate the minimum-approach distance to the pri-
mary bushing.
Removing meters from all customers fed from the transformer will eliminate
backfeed from customer operations but not from other transformers connect-
ed to the same bus.
A small portable generator (less than 5 kW) feeding back into a grounded cir-
cuit will continue to run and not short out. The resistance of the circuit
between the generator and the grounds is too high to short out the generator.
When working on a primary circuit, apply protective grounds. It can still be
safe to work on the grounded conductors because the voltage at the grounded
location has been lowered to an acceptable level. However, there will be cur-
rent flowing in the conductor, and the conductor must be jumpered before
cutting or opening the circuit.

5.2.4 Potential Explosive Flash at Transformer Secondary


A step-down transformer can generate a very high current on the secondary side if
the secondary wires are accidently shorted. The magnitude of the fault current avail-
able on a transformer secondary depends mostly on the size of the transformer. The
larger the transformer, the greater the capability to generate a large fault current.
If the secondary wires are shorted, the transformer can briefly carry a load more
than 10 times its rating and supply a high-fault current to the faulted location.
Depending on the impedance of the transformer, a short at the secondary terminals
of a 100 kVA can be as high as 18,000 amperes. The level of fault current at the loca-
tion of the short will depend on the distance from the transformer and the conduc-
tor size, as shown in the figure 5.6 example.

5.2.5 Causes of FerroresonanceFerroresonance occurs when there is practically


no impedance to current flow. This happens when the circuit has no load on it, and
the capacitive reactance (dependent on the length of the cable) is equal to, and in
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20
18
in Thousands of Amperes
240-Volt Short Circuit

16
14 167 kVA Transformer

12
10
8
6 75 kVA Transformer

0
20 40 60 80 100 120 feet
6 12 18 24 30 26 meters
Length of 4/0 Aluminum Service

Figure 56 Magnitude of Secondary Fault Current.

series (dependent on the transformer connections) with an inductive reactance


(dependent on the size of the transformer). The voltage on the circuit can increase
from two to nines times, thereby causing equipment damage.
The most common occurrence of ferroresonance involves a three-phase wye/delta
or delta/delta transformer bank fed with a length of underground cable as illustrated
in figure 5.7.
A certain length of underground cable can provide a critical amount of capacita-
tive reactance in the circuit. A transformer bank can provide an inductive reactance
that matches the capacitive reactance of the cable. The inductive load and capacitive
load must be in series with each other (figure 5.8) and this occurs when only one or
two phases are energized.

5.2.6 Prevention of FerroresonanceFerroresonance can be avoided by removing


one of the causes of the phenomenon as shown in table 5.3.

Table 5.3. Prevention of Ferroresonance


Causal Factor Action

Operating the source single-pole switches Install a three-phase gang-operated switch.


to energize or deenergize an underground
cable feeding a three-phase transformer
puts the transformer coils temporarily in
series during the switching operation.
(continued)
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Connecting and Troubleshooting Transformers 101

Current through Transformer


Windings in Series
A-Phase
Open

Resonating A-Phase
Circuit Completed through -
Cable Capacitance to Ground

A-Phase Open

Figure 57 Typical Ferroresonance Setup.

Inductive Load in Series Inductive Load in Series Not Subject to Ferroresonance


in Delta Primary When Wye Point Ungrounded When Wye Point Is Grounded

Inductive
Load
in
- - Parallel -

Cable Cable
Capacitance Capacitance
on Each Phase on Each Phase

Fuse Fuse Fuse


Open Open Open
Source Source Source

Figure 58 Sources of Inductive Reactance in Series.


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Table 5.3. Prevention of Ferroresonance (continued)


Causal Factor Action

If there is no load on the transformers Keep a load on the transformer when it is


when they are energized, the low being energized. The increased resistance
resistance in the circuit causes a higher in the circuit will lower the effects of
voltage when resonance occurs. resonance.
A wye primary with a floating Temporarily ground the floating neutral
(ungrounded) neutral is susceptible of the wye primary which will short out
to ferroresonance. a possible series circuit.

5.3 Single-Phase Transformer Connections


5.3.1 Transformer Protection
Always install the specified fuse, current limiting fuse, and surge arrester at a trans-
former. The specified fuse is fast enough to protect the transformer from the heat
generated by a secondary overload or fault and is slow enough to reduce nuisance
outages due to transient faults. The fuse is usually coordinated to trip before the
instantaneous trip on the feeder protection.

5.3.2 Making Neutral Connections and Ground Connections


Neutral connections have one purpose and the ground connections have another. A
neutral is a grounded conductor. Neutral connections are part of the electrical circuit,
and during normal operation, they carry the current back to the source. A ground
wire is a grounding conductor. Ground-wire connections provide a path for current
under abnormal conditions such as during a lightning storm when an arrester or an
insulator sparks over. The ground connections also bond the transformer tank and
related equipment to keep them all at the same potential.

5.3.3 Parallel or Series Connection of Center-Tapped Secondary Coil


A transformer with a center-tapped secondary coil will have a certain voltage induced
across the full length of the coil and half that voltage on each side of any center tap.
For example, on a 120/240-volt transformer, shown in figure 5.9, the secondary
provides 240 volts when the two coils are connected in series. Placing the two sec-
ondary coils in parallel allows the complete coil to be used to provide 120 volts at the
rated kVA capacity of the transformer.

5.3.4 Connecting Two Transformers in Parallel


Two smaller transformers are sometimes paralleled together to give the equivalent
capacity of one large single-phase transformer. In figure 5.10 the two secondary
coils in each transformer are connected parallel. One transformer feeds one leg at
a positive polarity while the other transformer feeds the other leg at a negative
polarity.
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5.3.5 Connecting a Transformer to a Secondary Network


A secondary bus that is fed radially should have bus breaks installed to prevent any
interconnection with other transformers. A secondary network system is fed from
many transformers connected in parallel to the same secondary bus.

+ +

+ +

+
X-3 X-3
X-2 X-1 X-2 X-1
Neutral Neutral
120V 120V
240V
120V
Series Connection Parallel Connection
Secondary Coils are in Series Secondary Coils are in Parallel

Figure 59 Series and Parallel Secondary Connections.

One Cutout
H-1
H-1

H-2 H-2

+ +
+ + + +

+
+
X-3 X-3
X-2 X-1 X-2 X-1
Neutral
120V
240V 120V

Figure 510 Single-Phase Transformers Connected in Parallel.


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The load is divided among all the transformers connected to the bus.
Individual customers with peak loads are supplied by the greater available
reserve capacity of the multiple transformers.
Fuses or network protectors on the secondary bus between transformers iso-
late faulted transformers and interrupt only the customers near the defective
transformer.

5.3.6 Troubleshooting a Single-Phase 120/240-Volt Service


If Then

A customer has intermittent Check for a voltage unbalance in the two 120-volt legs.
power and flickering lights. If one 120-volt leg is two or more volts different from
the other 120-volt leg, then turn on a large 120-volt
load. If the voltage increases on one leg and decreases
on the other, then there is a poor neutral connection.
A loose connection on either leg can increase resistance
to current flow and will also result in arcing and
intermittent power.

The lights in part of a A poor or open neutral connection is blocking the


customers premises are normal return path from 120-volt appliances. The
very bright and in another current will travel back to the source through the
part, the lights are very other 120-volt leg or through 240-volt equipment.
dim. Although the two voltages will be unbalanced, they
will add up to 240 volts. The 240-volt appliances will
operate normally.

A customer is receiving half If the voltage at the meter base is normal, then
power. Some of the lights one of the main fuses at the service entrance is likely
work and some do not. blown. A voltage reading of about 120 volts between
None of the 240-volt the top and the bottom of the fuse indicates that
appliances work. the fuse is blown.

A customer complains A poor connection could cause low voltage at various


about erratic or low voltage. times. Heavy duty equipment used by a neighbor
on the same bus can cause voltage problems for others
on the same bus.

5.4 Three-Phase Transformer Connections


5.4.1 Banking Three Single-Phase Units
There are four specifications to look for when choosing a transformer to interconnect
into a three-phase transformer bank:
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1. The voltage rating of the transformer primary coil must be compatible with
the applicable circuit. The voltage impressed across the primary coil will
depend on whether the coil is connected in a wye (phase-to-neutral) or a delta
(phase-to-phase) configuration.
2. The transformer must be able to deliver the needed secondary voltage (see
Table 5.3). The supplied secondary voltage will be dependent on:
the voltage rating of the secondary coil.
whether the transformer secondaries are interconnected in a wye or delta
configuration.
whether the secondary coils inside the transformer are connected together
in series or in parallel.
3. If equipped with tap changers, the transformers must be on the same voltage
tap. Dual voltage transformers must be set on the proper voltage.
4. The impedance of the transformers in the bank should be within 0.2 percent
of each other to avoid having the transformer with the lowest impedance tak-
ing a greater share of the load. In other words, if one transformer has an
impedance of 2 percent, then the impedance of the other transformer should
be between 1.8 percent and 2.2 percent.

5.4.2 Making Wye or Delta Connections?


There are two ways to get a voltage across a transformer coil:
1. When each of the three transformers have their coils connected between
phases A-B, B-C, and C-A (figure 5.11), the transformers are interconnect-
ed in a delta configuration.

+
Phase B
+ + +

+ Phase
C Phase A Phase B
Phase C
+
Phase
A

Figure 511 Delta Configurations.


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2. When each of the three transformers have their coils connected between a
phase and a common neutral (figure 5.12), the transformers are interconnect-
ed in a wye configuration.

5.4.3 Delta Primary Transformer Connections


The three ways to connect a transformer primary into a delta (phase-to-phase)
configuration is shown in figure 5.13. Note how labeling the polarity of the trans-
formers on a drawing will reduce confusion when making connections.
Each transformer coil in a delta primary or delta secondary is connected phase-
to-phase.
When two or more transformers are interconnected in a delta configuration, the
coils are connected in series with each other. To connect a coil in series, each
positive terminal of one coil is connected to a negative terminal of another coil.
To ensure a proper phase rotation, the coils must be connected in a sequence.

+ Phase A

+ + + +

Phase B
Neutral

Phase C Neutral Phase A Phase B Phase C


+

Figure 512 Wye Configurations.

+ + + + + +

Single Open Delta Closed Delta


Phase

Figure 513 Three Types of Delta Primary Connections.


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If a transformer primary is to be delta connected on a wye circuit, the voltage


rating of the primary coil must be equal to the phase-to-phase voltage of the
circuit.

5.4.4 Wye Primary Transformer Connections


The three ways to connect a transformer primary into a wye (phase-to-neutral)
configuration is shown in figure 5.14 Note how labeling the polarity of the trans-
formers on a drawing will reduce confusion when making connections.
Each transformer coil in a wye primary is connected phase-to-neutral. When
two or more transformers are interconnected in a wye configuration, the coils
are connected in parallel with each other. To connect a coil in parallel, each
positive terminal is connected to a phase, and each negative terminal is con-
nected to a common neutral.

5.4.5 Delta Secondary Transformer Connections


A typical delta secondary is shown in figure 5.15. This figure shows a three-phase
240-volt service with an optional 120-volt lighting load supplied from one trans-
former.
Each positive terminal is connected to a negative terminal.
On center-tapped secondaries, the ground strap is removed from the X-2 ter-
minal, and the terminal will be alive at 1/2 the full coil voltage.

5.4.6 Open Delta Connections


A three-phase delta service can be supplied with two single-phase transformers. This
hookup is sometimes used as an economical way to feed a small three-phase delta
service. This type of service is called an open delta because the delta configuration is
missing one side. Figure 5.16 shows the open delta loop with the availability of three
phases.

Neutral

+ + + + + +

Single Open Wye Wye


Phase

Figure 514 Three Types of Wye Primary Connections.


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+ + + + + +

X-1 X-3 X-1 X-3 X-1


X-3
+ X-2 + +
X-2 X-2

1
240V 240V 240-V
2 Delta Service
240V
3
120/240-V
120V 120V Single-Phase
240V Service

240-Volt Delta with a 120/240-Volt Lighting Service

Vector Drawing
24
0V

of Secondary
210V

0V
24

1 3
120V 120V
240V

Figure 515 Typical Delta Secondary Connections.

Three primary wires are needed to feed an open-delta, three-phase, secondary


service. A wye primary would need two phases and a neutral, and a delta primary
would need three phases. A three-phase wye secondary service cannot be fed from
two normal single-phase transformers.
When one transformer of a normal three-phase delta-delta or wye-delta trans-
former bank is found defective, the connections can be changed to configurations
shown in figure 5.16 and service restored as an open delta. The customer should be
told to reduce demand on service until the transformer is replaced because the two
good transformers will now have the capacity to supply only 57.7 percent of the
capacity of three transformers.

5.4.7 Wye Secondary Transformer Connections


A typical wye secondary is shown in figure 5.17. The figure shows a three-phase
120/208-volt service with an optional 120/240-volt lighting load supplied from one
transformer.
Each positive terminal becomes a separate phase and all negative terminals are
connected together.
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A
B A
C B
N C

H1 H2 H1 H2 H1 H2 H1 H2
+ + + +
X3 X1 X3 X1 X3 X1 X3 X1
X2 + X2 + X2 + X2 +

C A B C A B

Wye / Open Delta Delta / Open Delta

2
+

Vector Drawing
0V

of Secondary
24

-
1 3
+ 240V -

Figure 516 Open Delta Transformer Connections.


The phase-to-phase voltage is =3 or 1.73 times the phase-to-neutral voltage. The
voltage across each transformer coil is equivalent to the phase-to-neutral voltage
The primary neutral must be connected to the secondary neutral in a wye-wye
transformer bank. This neutral connection provides a path for any fault current
or current from an unbalanced load to get back to the source. There is a poten-
tially lethal voltage between the primary and secondary neutrals if they are not
connected together.
A standard single-phase 120/240-volt lighting service can be provided from a
three-phase 120/208-volt service. In figure 5.17, the internal secondary coils in
the center transformer are left in series to provide a 120/240-volt supply. The
kVA rating of the center transformer is usually increased to provide the capac-
ity for the extra load.

5.4.8 Three-Phase Secondary Voltages


The secondary voltage from a three-phase transformer bank depends on more than
just the transformer ratio. Three transformers with a given ratio can be interconnect-
ed to provide up to four different types of services (table 5.4).
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+ + + + + +

X-3 X-1 X-3 X-1 X-3 X-1


X-2 + X-2 + X-2 +

Neutral
120V 120V 120V
208V 208V
208V

120V 120V
240V
120/208-Volt Wye with 120/240 Lighting Service

Figure 517 Typical Wye Secondary Connections.

1. The secondary voltage is based on whether the transformer secondary is inter-


connected as wye or delta. The secondary phase-to-phase voltage is:
equal to the actual voltage across the transformer coil with a delta connection.
equal to 1.73 times the voltage across the transformer coil with a wye con-
nection.
2. The secondary voltage is also based on whether a transformer with a center-
tapped secondary coil has the two parts of the coil inside the tank arranged in
parallel or in series. The output voltage of series-connected coils is double the
output of two parallel connected coils.

Table 5.4 Standard North American Three-Phase Voltages


Transformer Type of Three- Coil Arrangements External
Secondary Phase Service Inside Tank Configuration

120/240 120/208 parallel Wye


240/416 series Wye
120 parallel Delta
240 series Delta

240/480 240/416 parallel Wye


277/480 series Wye
240 parallel Delta
480 series Delta

277 277/480 NA Wye

347 347/600 NA Wye

600 600 NA Delta


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5.5 Troubleshooting Transformers


5.5.1 Taking Voltage Checks at the Secondary
Troubleshooting transformers involves checking for problems on secondary services.
Many no power or partial power calls are due to internal customer problems. A utili-
ty responsibility normally ends at the service entrance. Opening the customers main
switch and taking a voltage reading will determine whether the utility is the cause of
the problem.

5.5.2 Troubleshooting a Wye Secondary (120/208, 240/416, or 347/600 Volt)

If Then

A customer has an Open the customers switch and check the voltage.
abnormal voltage. If the voltage on a phase-to-neutral reads zero, then
check for a defective transformer or an open phase on
the primary feeder. If the voltages on all three phases
are balanced, close the customer switch and check the
voltage. An unbalanced voltage indicates the customers
load is unbalanced.

Three-phase motors The usual cause of trouble on one phase is an


are overheating and the unbalanced load. This type of service has single-phase
thermal overload loads. Unbalance beyond 3 percent can cause the
protection trips out low-voltage leg to draw more current and create
the motor. equipment heating. A faulty winding in a three-phase
motor can cause high current on a phase.

The load is balanced at Open the customers main switch and check that the
the service entrance but utility supply voltage is correct. Close the customers
there is still a problem. circuit breakers, one circuit at a time, and take voltage
and current readings. A suspected circuit will have an
unbalanced voltage or abnormal current readings for
the equipment being fed.

All three-phase equipment One phase is probably out. A phaseout can be due
and some single-phase to a feeder problem, a transformer problem, or a blown
equipment will not fuse at the service entrance.
operate.

The single-phase A poor or broken neutral connection will cause


equipment has problems with single-phase loads. A customer-owned
intermittent power. secondary (dry) transformer which steps down the
The three-phase load higher 600 or 416-volt supply to 120/208 can be the
is operating normally cause of problems.
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112 Chapter 5

5.5.3 Troubleshooting a Delta Secondary (600, 480 or 240 Volt)


If Then

The customer has One or more phases feeding the customer is out of
abnormal voltage. service. Check the transformers and the primary feeder.
With the customers
switch open, the The customers switch must be open for this voltage
voltage on the supply check because the back feed in a delta service can show
side shows one or a voltage at the service entrance.
more of the phase-to-
phase voltages at
zero volts.

At the main panel, the When one phase of a primary feeder loses power, the
phase-to-phase voltage voltage at a wye-delta transformer bank will have
readings are lower than a reduced voltage on two of the phase-to-phase
normal and one phase- readings and zero volts on the third phase-to-phase
to-phase voltage reading reading.
is zero volts. For example,
on a 240-volt service, the On a wye-delta transformer bank, the primary neutral
readings are 210 volts, is not connected to the system neutral or the secondary
210 volts, and 0 volts. neutral, but it is left ungrounded or floating. If the
transformer neutral was grounded and one primary
phase is opened, the transformer bank would become
an open-delta bank and continue to supply three-phase
power at a 57 percent reduced capacity exposing the
bank to a burnout because of an overload.

At the main panel all A ground fault exists on a phase. When one phase
three phase-to-phase of a delta circuit is faulted to ground, it does not
voltage readings are blow a fuse because there is no path for a return current
normal but one phase- to the source. Both the phase and the ground are alive
to-ground is reading and, therefore, a faulted phase-to-ground voltage
very low or zero voltage. reading will show a very low or zero voltage difference.

Both the faulted phase and earth are alive in relation to


the other two phases.

A customer with a delta service often has a ground


fault indicating a light connected between each phase
and ground. The light will go out when there is a
ground fault and the ground becomes alive.
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Connecting and Troubleshooting Transformers 113

5.6 Working on a Voltage Conversion


5.6.1 Preparing the Circuit for Voltage Conversion
Work That Can Be Done on the Circuit before
the Day of the Voltage Conversion
1. If going to a higher voltage, change all insulators on the circuit where they have
not already been done through pre-building projects.
2. Change any switchgear that can handle the duties for both voltages.
3. If going to a higher voltage, change any surge arresters that are on the circuit.
The utility will need to decide if the risk of having the higher voltage arresters
on the circuit for a period of time is acceptable.
4. Primary underground cable that cannot accommodate the new voltage will
need to be replaced or planned to be fed at the original voltage using a primary
step-down transformer.

Work to Be Done on Voltage Conversion Day

1. If going to a higher voltage, existing voltage regulators and capacitors will need
to be removed or replaced.

5.6.2 Working at Transformer Installations


Work That Can Be Done at Transformer Installations
before the Day of the Voltage Conversion
1. Install dual voltage transformers. There may not be any dual voltage trans-
formers for 277/480 or 347/600 three-phase banks.
2. Install surge arresters for the new voltage.
3. Install cutouts and fuses for the new voltage.
4. There may be a need to install current-limiting fuses for a higher voltage dis-
tribution system.
5. Preparations need to be made if existing wye/delta transformer banks need
to be changed to wye/wye during conversion day to accommodate single
primary-bushing transformers. The customers service entrance will need to be
upgraded to accept a neutral.

Work to Be Done on Voltage Conversion Day


1. Isolate all transformers from the circuit, and energize the circuit at the new
voltage.
2. Change transformers that are not dual voltage.
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114 Chapter 5

3. Change the tap setting on the dual voltage transformers to the new voltage.
4. If the circuit has been energized at the new voltage, energize the transformer
and take voltage and phase rotation checks before the customer applies load
(remove meter or open customer breaker).
5. Or, if it is preferred to energize the new higher-voltage surge arresters from a
remote location, leave the circuit out under the clearance and attach the riser
and arrester to the circuit. Leave the customers disconnected and perform volt-
age checks at each transformer after the circuit is energized.
6. Or, if the transformer will be fed from a primary step-down transformer, ensure
that there is proper voltage and phase rotation before connecting customers.
7. Having the transformers on a check-off sheet will reduce the risk of forgetting
to change the tap on a transformer and leaving a customer with a high-
damaging voltage.

5.6.3 Working at Underground Installations


Work That Can Be Done at Underground Installations
before the Day of the Voltage Conversion
1. If using existing cable at the new voltage, cable size may not match the bush-
ing inserts of new switching cabinets or transformers. Non-standard equip-
ment may be needed.
2. If a new, higher-voltage cable is installed before conversion day, larger elbows
(separable connectors) may not match existing equipment. Non-standard
equipment may be needed.
3. Install dual-voltage transformers or plan a change during the outage.
4. There may be a need to install current-limiting fuses for a higher-voltage dis-
tribution system.
5. Replace switchgear and fusing to accommodate the new voltage.
6. Change surge arresters at riser poles and any elbow arresters installed at dual-
voltage transformers.

Work to Be Done on Voltage Conversion Day,


1. Change the tap setting on the dual-voltage transformers to the new voltage.
2. If the circuit has been energized at the new voltage, energize the transformer
and take voltage and phase rotation checks before the customer applies load.
3. If the transformer is to be fed from a primary step-down transformer, ensure
that there is proper voltage and phase rotation before connecting customers.
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Connecting and Troubleshooting Transformers 115

5.6.4 Working at Primary Step-Down Transformer Installations


Work That Can Be Done At Underground Installations
before the Day of the Voltage Conversion
During a voltage conversion project, primary step-down transformers are often
installed to delay the conversion of some line sections, especially underground. Do a
turns ratio test on the primary step-down transformer because setting the external
switch or tap does not always make the proper internal connection.

Work to Be Done on Voltage Conversion Day


Reduce the risk of causing damage to a customers appliance by isolating all the trans-
formers on the load side of the primary step-down transformer and doing a voltage
test and phase-rotation tests on an individual basis as the transformers are energized.
Make a clear separation at tie points between the two primary voltage levels.
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116 Chapter 5

Additional Local Safety Regulations

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