Construction types

There are different construction types for transformers used in commercial

buildings. Our understanding of their general characteristics will allow the
designer and end user to make the proper selection for the electrical system
application. Following are some of the transformer types available in the
industry along with a few of their characteristics:

Ventilated dry-type transformers are

ventilated by air, use larger space for clearance, and use different insulating
materials to augment the dielectric strength of the air. They contain an
enclosure surrounding the windings for their mechanical protection and the
safety of personnel. This type is the most common to be used in the building
indoor electrical system distribution. See Table 1 for typical dry-type
transformer ratings, dimensions, and weights.

Sealed dry-type transformers are similar to dry type in most of their

characteristics. The difference is they contain an enclosed tank with nitrogen
or other dielectric gas to protect the windings. They can be installed outdoors
or indoors. They are useful in areas with a corrosive or dirty atmosphere.

Cast-coil transformers are constructed with the primary and secondary

windings encapsulated in reinforced resin. They can be installed where
moisture or airborne contaminants exist.

Nonventilated dry-type transformers are similar to the ventilated type but are
totally enclosed. This type can be installed in areas with corrosive or dirty
atmospheric conditions where it would be impossible to use a ventilated-type
transformer.

Oil-filled transformers are constructed with the windings encased in an oil-tight

tank filled with insulating mineral oil. It is good practice to regularly test this
type of transformer in order to determine dielectric breakdown, which affects
its useful life.

Application types

There are different ways in which transformers are installed and used as part
of a commercial building electrical system. These application types include:

Indoor distribution transformers are used with panelboards and are separately
mounted to supply the specific electrical load requirements in a system-
specific application within the system distribution. Several transformer types
rated higher than 600 V for oil insulated type, higher than 35,000 V for dry
type, and other transformers rated higher than 600 V are required to be
located in vault rooms, which must be built with fire-rated enclosures
depending on the transformer type and applicable local authority
requirements, when indoors. Transformers that are not over 600 V and are
part of the indoor building electrical system distribution have both primary and
secondary voltages below 600 V with the most common voltage level change
from 480 V to 208 Y/120 V.

Pad-mounted transformers are installed outside and are considered the first
option for supplying service entrance voltage to the building electrical system
based on the project size and requirements. They typically have primary
voltages higher than 600 V and secondary voltages lower than 600 V with
compartments for the associated protective devices assembled in an integral
tamper-resistant and weatherproof unit.

In addition, the size of the commercial facility will determine the appropriate
approach for designing the electrical distribution system for the specific
application. In this electrical system design, the transformer can be used as
part of a substation, primary unit substation, secondary unit substation, or
network configuration.

Sizing

The electrical size of the transformer load is rated in kVA. This rating provides
the associated power output delivered for a specific period by the loads
connected to the transformer on the secondary side of the equipment. The
loads, which are calculated as part of the building electrical system design
phase, are shown in the construction documents respective equipment
schedules in VA or kVA.

A general approach to determining transformer capacity and selecting the

proper rating for the design application is to obtain the calculated design load
from the respective electrical schedule and add 20% spare capacity for future
load growth to be shown in the equipment schedule, unless otherwise directed
by the facility based on design parameters. For example, the code-based
demand load of a 208 Y/120 V, 3-phase, 4-wire panelboard is 42 kVA, which
does do not include spare capacity for future growth. Therefore, the
transformer size required for converting the system voltage from 480 V, 3-
phase, 3-wire to 208 Y/120 V, 3-phase, 4-wire is:

Transformer size in kVA = 42 kVA x 1.25 = 52.5 kVA

Therefore, a 75 kVA transformer would be selected for this application out of

the available standard ratings for a 480 V primary to 208 Y/120 V secondary.
The most common building industry standard ratings are 3, 6, 9, 15, 30, 37.5,
45, 75, 112.5, 150, 225, 300, 500, 750, and 1,000 kVA.

The above simple calculation meets the intent to achieve the normal life
expectancy of a transformer, which is based on the following basic conditions:

The transformer is equal to or less than its rated kVA and rated voltage.
The average temperature of the cooling air during a 24-hour period is 86
F.
 The temperature of the cooling air at no time exceeds 104 F.

Selecting

Transformer selection starts with the kVA rating required to supply the loads
connected in the electrical system. Another consideration for indoor
distribution transformers is the type of load: linear or nonlinear. Linear loads
include resistive heating and induction motors; nonlinear loads are produced
by electronic equipment that contributes to the distortion of the electrical
power signals by generating harmonics. The harmonics resulting from
nonsinusoidal currents generate additional losses and heating of the
transformer coils, which reduce the transformer life expectancy.

Indoor transformers for nonlinear loads can be selected with a K rating, which
allows the transformer to withstand nonlinear conditions in the electrical
system. K-rated transformers do not mitigate or eliminate harmonics.
However, they do protect the transformer itself from damage caused by
harmonics. For harmonic mitigation, K-rated transformers can be combined
with harmonic filters or chokes. For linear load applications, transformers
should be selected with lower core losses. Other factors that should be
considered in selecting transformers are voltage ratings for both primary and
secondary, voltage taps, efficiency, impedance value, type of cooling and
temperature rise, voltage insulation class, basic impulse level, and sound
level.

Practical applications

In the past two years, two large projects in Miami Dade County have been
built: the Florida International University football stadium and Miami
International Airport South Terminal. Both projects included dry-type 480 V, 3-
phase to 208 Y/120V V step-down transformers (in NEMA 2 enclosures),
ranging from 15 kVA to 112.5 kVA in the electrical system distribution design.
The 18,688-seat FIU football stadium was designed with about 12
transformers as part of the electrical system distribution in order to supply
general-use receptacles, small motors, and other loads in the stadium building
structure and the attached field house building. The MIA South Terminal
expansion was designed with about 50 transformers with similar intent as the
stadiums but a more diverse group of loads for the 208 Y/120 V 3-phase, 4-
wire system, which also included lighting loads, signage, telecommunication,
security systems, and other loads part of this building project (Figure 1).
 Installation

The installation of power transformers and transformer vaults must comply

with the requirements of National Electrical Code (NFPA 70) article 450 and
specific local authority having jurisdiction requirements. Some principles to
consider for transformer installation include locating them in isolated rooms
with proper ventilation, clearances, and accessibility. Otherwise, they can be
installed on open walls or steel columns or above suspended ceilings.
In addition, there are other specific requirements based on the transformer
type, such as weatherproof enclosures for dry-type transformers installed
outdoors or a transformer vault room for oil-insulated transformers installed
indoors. In addition, a good design and installation require the proper
transformer feeder and overcurrent protection device size based on NEC
articles 240, 250, 450, and applicable sections of Article 310 (Figure 2).

Looking ahead

Transformers remain a fundamental component of electrical distribution

systems. Equipment operation characteristics will continue to change.
However, their operating principles will remain with the same. The industry
trend is to continue building transformers with less core losses, and that
comply with Energy Star efficiency requirements.

Baeza is a principal and senior electrical engineer at TLC Engineering for

Architecture in Miami. He is a registered professional engineer with more than
29 years of experience in electrical engineering, project management, building
design, and construction.

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