Buck - Boost Transformers - Royal Electric

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Buck - Boost TransformersContentsBuck - Boost Transformers - Terms & Definitions.48Buck - Boost Transformers - Sizing.50Quick Reference Chart - 208, 230, 240 Volts Single & Three Phase.52Single Phase Buck - Boost Sizing Tables.53Three Phase Buck - Boost Sizing Tables.56Buck - Boost Connection Diagrams.59Encapsulated Buck - Boost Transformers.64Ventilated Buck - Boost Transformers.65Series ODY Buck - Boost Transformers.661.800.428.2626 www.dongan.com47

Buck - Boost TransformerTerms & Definitions48Buck-Boost transformers are single phase, fourwinding transformers designed for two purposes.The first purpose is as a low voltage isolation transformer for use on 12, 16, 24, 32, or 48 volt circuits.When used as low voltage transformers, Buck-Boosttransformers have capacities of .050 kVA to 5.0 kVA.Their second, and more important use, is as a BuckBoost transformer. Buck-Boost means that thesetransformers are used to buck (lower) or boost (increase) line voltage to match required load voltage.Buck-Boost transformers are used to correct consistently low or high voltage conditions, where thevoltage difference ranges from approximately 5% to27%. Variation of the input voltage is passed throughto the output side of the transformer in the samepercentage. This concept is important because thequestion is frequently asked if Buck-Boost transformers will stabilize variable voltages. They will not!Low voltage conditions may be found at the endof long wire runs where a line voltage drop hasoccurred due to resistance in the wire. While highvoltage supply lines are less frequent, they may befound close to voltage distribution points. BuckBoost transformers offer a simple, economicalsolution to these common voltage problems andmitigate the harmful heating effects of low or highvoltage.Buck-Boost transformers are typically four windingisolation transformers as they leave the factory. Connected as an isolation transformer, these productsmay be used for many low voltage applications suchas low voltage control panels or indoor/outdoor lowvoltage lighting. Low voltage connection charts maybe found on Page 66. Type M, Type Y, and Type LMtransformers connected per these charts are isolating type transformers.When connected as a Buck Boost transformer,these transformers, with dual primaries of120 x 240, or 240 x 480, and dual secondaries of12 / 24, 16 / 32, or 24 / 48 volts, have literally hundreds of voltage matching applications.Buck-Boost connections result when a lead(s) fromthe primary winding is interconnected to a lead(s)from the secondary winding. This interconnectionmodifies the transformer from an isolation transformer into an autotransformer because the primaryand secondary windings are no longer electricallyisolated from each other. This distinction is depictedin the diagrams below.When used in this fashion, the Buck-Boost transformer’s kVA capacity is substantially greater thanwhen connected as a low voltage, isolation transformer, as a portion of the line current flows directlythrough to the connected load.Buck-Boost transformers are simple and straightforward to specify, size and connect. Buck-Boostconnections are achieved by interconnecting the 8copper lead wires supplied with each transformer inaccordance with the charts contained in this section.In addition, each transformer shipped from the factory is equipped with a similar chart to assure easeof use at the installation site.Isolation Transformer ConnectionsAutotransformer ConnectionsApplications:The most common applications for these transformers are boosting 208 volt lines to 230 or 240 volts,and vice-versa. These applications include bothsingle and three phase lines and are particularlycommon in HVAC applications for air-conditioningappliances. A chart is specifically provided for convenient sizing of these applications on page 52.Additionally, Buck-Boost transformers are very wellsuited to motor loads, boosting 240 to 277 for lighting loads and many applications where nominal voltage is above or below 120 volts. Their use should beconsidered where supply line voltage is found to beconsistently above or below desired nominal valuesof load voltage.Single Phase Applications:Single phase applications require the purchase ofone transformer. Charts are provided on Pages 53- 55 for sizing and specifying single phase applications.Three Phase Applications:Three phase applications require banking either 2 or3 Buck-Boost transformers. Charts are provided onPages 56 - 58 for sizing and specifying three phaseapplications.Series ODY Autotransformers provide an economical, factory preconnected installation for transforming three phase lines from 208 to 240, or 240 to 208.This series banks 2 Buck-Boost transformers intoone assembly for mounting and one assembly forconnecting. Simply bring in three wires on the lineside and take out three wires on the load side.Dongan Electric Manufacturing Company

Buck - Boost TransformerTerms & DefinitionsConnection/Configurations to Avoid:Some line/load distribution system combinationsare to be avoided. For instance, closed delta connections are not recommended because they maycause phase shifting to occur on the load side of thebank. In addition, they require larger transformersto accomplish similar results and are, therefore, lessefficient and more expensive. Also, a three phase, 4wire wye supply line should be connected to a wyeconfiguration, 3 transformer bank. This configurationwill assure sufficient current carrying capacity in theneutral of the wye circuit.The chart below indicates distribution system restrictions.Input(Supply System)Desired OutputConnectionWYE 4 wireWYE 3 or 4 wireOKWYE 3 or 4 wireOPEN DELTA 3 wireOKCLOSED DELTA 3 WireOPEN DELTA 3 wireOKDELTA 3 WireWYE 3 or 4 wireDO NOT USEOPEN DELTA 3 wireWYE 3 or 4 wireDO NOT USEWYE 3 or 4 wireCLOSED DELTA 3 WireDO NOT USEthe shunt winding (the winding common to boththe input and the output circuits) of the autotransformer between Points A and B as shown inFigure 450-4.Figure 450-4Fusing Buck-Boost Transformers:Exception: Where the rated input current of anautotransformer is 9 amperes or more and 125percent of this current does not correspond to astandard rating of a fuse or nonadjustable circuitbreaker, the next higher standard rating described in Section 240-6 (NEC) shall be permitted. Where the rated input current is less than 9amperes, an overcurrent device rated or set atnot more than 167 percent of the input currentshall be permitted.Buck-Boost kVA capacity is significantly higher thanthe low voltage isolation capacity listed on the nameplate of the transformer. Frequently, this disparityleads to questions of how to fuse the transformer.The Buck-Boost sizing charts on the following pagesconveniently provide a fuse size for each transformerapplication.In addition, paragraph 450-4 of the National ElectricCode provides more detailed information:450-4. Autotransformers 600 Volts,Nominal, or Less.(a) Overcurrent Protection. Each autotransformer600 volts, nominal, or less, shall be protectedby an individual overcurrent device installed inseries with each ungrounded input conductor.Such overcurrent device shall be rated or set atnot more than 125 percent of the rated full-loadinput current of the autotransformer. An overcurrent device shall not be installed in series withReprinted with permission from NFPA 70-1996, TheNational Electrical Code , Copyright 1995, NationalFire Protection Association, Quincy, MA 02269. Thisreprinted material is not the complete and official position of the National Fire Protection Association on thereferenced subject, which is represented only by thestandard in its entirety.1.800.428.2626 www.dongan.comThe drawing above indicates proper overcurrentplacement in a typical Buck-Boost application.(b) T ransformer Field-Connected as an Autotransformer. A transformer field-connected as an autotransformer shall be identified for use at elevatedvoltage.Sizing Buck-Boost Transformers:Please turn to the next page for the proper questionsto ask when sizing these installations. Sizing will beself evident when the examples are followed.49

Buck - Boost TransformerSizingDetermine the information below in order to selectthe correct buck- boost transformer for your application. Reference tables, sizing formulae, kVA, amps,and motor horsepower are provided on the dVoltageFrequencyLoad Ampsor kVASelectCorrectCatalog No.fromChartsConnectTransformerper SuppliedDiagrams50ing page. Any questions on sizing may be handledby your Dongan Representative or by contactingDongan Customer Service at( 800 ) Determine the supply or line voltage at the installationsite where the transformer will be connected. This is bestaccomplished by measuring the voltage with a suitablevoltmeter.106volts208voltsDetermine the voltage you require to operate the load to beconnected to the transformer. If you are unsure of the correct voltage, check the nameplate of the devices intendedfor operation.120volts240voltsBe certain the supply line frequency and the load frequency required are the same. Remember: a transformer is notcapable of changing frequency.60 Hz60 HzDetermine either load kVA or load amps by adding allloads to be supplied by the transformer. This is bestaccomplished by again referring to the equipment nameplates.4 kVA15 kVAExplanationDetermine load phase requirements Single phase Three phaseNow turn to the appropriate single or three phase buck- boost chart. Select the column closest to the line/loadvoltage combination for your application. Move downthe column until values of load kVA or load amps meet orexceed your load amps or load kVA required. Never sizesmaller than your requirements demand. Then read acrossthe row to select the correct catalog number for your application.Remember, three phase applications require banks oftwo or three transformers, while single phase applicationsrequire only one unit. The charts note the correct combination of units required at the bottom of the columns. Besure to specify and order the correct number of units foryour three phase applications.The transformer may now be connected per the diagramindicated at the bottom of the column from which you selected your line/load combination. A connection diagramis packaged with each Buck-Boost transformer for yourconvenience.Cat No. Cat No.85-Y030 85-Y040oror35-Y030 80-Y0401 Unit2 UnitsRequired RequiredDiagram DiagramSP-11TP-5Dongan Electric Manufacturing Company

Buck - Boost Sizing DataHow to Determine Transformer kVA RatingsTransformer Load expressed in amperes:Select the appropriate kVA size from the selection charts listed on thispage or by using the single phase or three phase sizing formula listedbelow. Be sure to select a transformer kVA rating equal to or greaterthan the anticipated connected load.Load Voltage x Load Amps1000Single Phase kVA Load Voltage x Load Amps x 1.731000Three Phase kVA kVA Volt Amperes1000VA kVA x 1000Transformer Load expressed in kVA:Select the appropriate size from the selection charts. Be sure to selecta transformer kVA rating equal to or greater than the anticipated connected load.Transformer Load expressed in wattage:Convert wattage into a kVA rating by using the formula listed below.Or you may refer to the equipment nameplate to obtain the ampererequirements of the connected load. Be sure to select a transformerkVA rating equal to or greater than the anticipated connected load.kVA Wattage(1000 x Power Factor of the Load)kVA / Ampacity Ratings forThree Phase AC 416361228208180150144Full Load Amperes Single Phase AC Motor VoltagesHPTransformer Load expressed in motor horsepower:Select the appropriate size kVA rating from the motor horsepowercharts on this page. Be sure to select a transformer kVA rating equalto or greater than the anticipated load requirements.Note:High Ambeint Tempurature Applications: Derate the transformernameplate kVA 8% for each 10 C above 40 C up to 60 C. Consult factory for ambients above 60 C.High Altitude Applications: To allow for reduced cooling at higherelevations derate the transformer nameplate kVA by .3% for each 330feet over 3300 feet above sea 200V208V230VStd.Dongan .66.91.6821169.28.881.9221 .10555632.230.8286.727.57 1/2804644409.60101010057.5555012.015kVA / Ampacity Ratings for Single Phase AC VoltageskVA115VMinimumTransformerkVAFull Load Amperes Three Phase AC Motor ngan 11.71.531 3.86516.715.27.66.16.395.07 312156125130150150396360180144150150Note:Increase transformer kVA by 20% when motors are started more than once per hour.Multiply motor ampacity by 1.1 and 1.25 respectively for 90% and 80% power factors.1.800.428.2626 www.dongan.com51

Quick Reference Chart - 208, 230, 240 VoltsSingle & Three Phase Buck - BoostThe most common buck - boost transformer uses arethose involving line/load combinations of 208, 230 and240 volts, in both single and three phase installations.These applications include air conditioning loads, motorloads, and machinery loads of all kinds.Three phase installations are easily accomplished withthe use of Series ODY factory pre-connected three phasebuck boost transformers. The ODY Series allows you toinstall and connect on pre-connected transformer for yourthree phase applications.The charts below provide sipmle solutions to these common applications with easy access data for kVA, line, andload amps information.Other voltage combinations may be found on the following pages.Single PhaseType M - 1 UnitThree PhaseType ODY - 1 UnitThree PhaseType Y - 2 Units35-Y005240208Max Ampsat 240 V.37 kVAMax Ampsat 208 V.1.85208V Fuse5Fuse Size4.535-M010Max Ampsat 230 V.3.935-Y010Max Ampsat 240 V.3.135-Y010Max Ampsat 240 V.2.7.90 kVAMax Ampsat 208 V.4.3.75 kVAMax Ampsat 208 V.3.61.12 kVAMax Ampsat 208 V.3.1208V Fuse8208V Fuse5Fuse Size535-M015Max Ampsat 230 V.5.935-Y015Max Ampsat 240 V.4.635-Y015Max Ampsat 240 V.4.01.36kVAMax Ampsat 208 V.6.51.12 kVAMax Ampsat 208 V.5.41.68 kVAMax Ampsat 208 V.4.6Fuse Size885-Y020Max Ampsat 240 V.6.72.8 kVAMax Ampsat 208 V.7.8CatalogNumber35-M005230208Max Ampsat 230 V.45 kVAMax Ampsat 208 V.2.1208V 08V Fuse12208V Fuse885-M020Max Ampsat 230 V.9.885-Y020Max Ampsat 240 V.7.52.2 kVAMax Ampsat 208 V.10.81.8 kVAMax Ampsat 208 V.9.034-280-ODYMax Ampsat 240 V.6.72.8 kVAMax Ampsat 208 V.7.835-Y005240208Max Ampsat 240 V.56 kVAMax Ampsat 208 V.CatalogNumberMaxAmps1.31.5208V Fuse15208V Fuse15Fuse Size15Fuse Size1585-M025Max Ampsat 230 V.19.785-Y025Max Ampsat 240 V.15.434-560-ODYMax Ampsat 240 V.13.585-Y025Max Ampsat 240 V.13.54.5 kVAMax Ampsat 208 V.21.73.7 kVAMax Ampsat 208 V.18.05.6 kVAMax Ampsat 208 V.15.65.6 kVAMax Ampsat 208 V.15.6208V Fuse30208V Fuse25Fuse Size25Fuse Size2585-M030Max Ampsat 230 V.29.585-Y030Max Ampsat 240 V.23.334-840-ODYMax Ampsat 240 V.20.285-Y030Max Ampsat 240 V.20.26.7 kVAMax Ampsat 208 V.32.65.6 kVAMax Ampsat 208 V.27.08.4 kVAMax Ampsat 208 V.23.48.4 kVAMax Ampsat 208 V.23.4208V Fuse45208V Fuse30Fuse Size30Fuse Size3085-M035Max Ampsat 230 V.39.485-Y035Max Ampsat 240 V.31.284-1120-ODYMax Ampsat 240 V.27.085-Y035Max Ampsat 240 V.27.09.0 kVAMax Ampsat 208 V.43.57.5 kVAMax Ampsat 208 V.36.011.2 kVAMax Ampsat 208 V.31.211.2 kVAMax Ampsat 208 V.31.2208V Fuse60208V Fuse40Fuse Size45Fuse Size4559.185-Y040Max Ampsat 240 V.46.684-1690-ODYMax Ampsat 240 V.40.585-Y040Max Ampsat 240 V.40.511.2 kVAMax Ampsat 208 V.54.016.9 kVAMax Ampsat 208 V.46.816.9 kVAMax Ampsat 208 V.46.860Fuse Size60Fuse Size6062.584-2250-ODYMax Ampsat 240 V.54.185-Y045Max Ampsat 240 V.54.122.5 kVAMax Ampsat 208 V.62.422.5 kVAMax Ampsat 208 V.62.480Fuse Size8081.185-Y050Max Ampsat 240 V.81.133.7 kVAMax Ampsat 208 V.93.685-M040Max Ampsat 230 V.13.5 kVAMax Ampsat 208 V.64.9208V Fuse90208V Fuse78.885-Y045Max Ampsat 240 V.15.0 kVAMax Ampsat 208 V.72.180Fuse Size93.784-3300-ODYMax Ampsat 240 V.33.7 kVAMax Ampsat 208 V.93.685-M045Max Ampsat 230 V.18.1 kVAMax Ampsat 208 V.87.0208V Fuse125208V Fuse118.285-Y050Max Ampsat 240 V.22.5 kVAMax Ampsat 208 V.108.085-M050Max Ampsat 230 V.27.1 kVAMax Ampsat 208 V.130.2208V Fuse175208V Fuse125Fuse Size125Fuse Size12585-M055Max Ampsat 230 V.197.085-Y055Max Ampsat 240 V.156.284-5600-ODYMax Ampsat 240 V.135.385-Y055Max Ampsat 240 V.135.345.3 kVAMax Ampsat 208 V.217.737.5 kVAMax Ampsat 208 V.180.256.2 kVAMax Ampsat 208 V.156.156.2 kVAMax Ampsat 208 V.156.1208V Fuse300208V Fuse200Fuse Size200Fuse Size200Qty. RequiredConnection Dia.Page52Single PhaseType Y - 1 Unit1SP- 1460Qty. RequiredConnection Dia.Page1SP- 1560Qty. RequiredConnection Dia.Page1TP-2563Qty. RequiredConnection Dia.Page2TP-2663Dongan Electric Manufacturing Company

Single Phase Buck - Boost Sizing TablesSingle Phase Buck - Boost Table, Type MSingle Phase / Single Unit - Type MType 5-M03085-M03585-M04085-M04585-M05085-M055Boost - Increase VoltageBuck - Decrease Line96100108109216218228208132144230252264Load ne Fuse5588557575575Load ne Fuse10101515881581577157Load .65Line Fuse15152020121220122012102012Load 275.252.75Line Fuse20203030151530153015153015Load 4.5510.505.50Line Fuse35356060303060306030306030Load 6.8315.758.25Line Fuse50508090454580458040408040Load 009.1021.0011.00Line Fuse7070125125606011060110606011060Load 013.631.516.5Line Fuse100100175175808017590175808017580Load 012.018.242.022.0Line Fuse150150250250125125225125225110110225110Load 27.133.018.027.363.033.0Line Fuse200200350350175175350175350175150350175Load 045.355.030.045.5105.055.0Line Fuse3503506006003003006003006003002506003001SP - 8591SP -12601SP - 7591SP -11601SP - 6591SP -10601SP - 5591SP -10601SP - 3591SP - 4591SP - 2591SP -1591SP - 259Qty. RequiredConnection Dia. PageConnection diagrams may be found on Pgs. 59 - 60.Connections found on this Page require ordering1 Buck - Boost TransformerThe appropriate size 35 or 80 Series Transformer may be substituted for the 85 Series where desired.1.800.428.2626 www.dongan.com53

Single Phase Buck - Boost Sizing TablesSingle Phase Buck - Boost Table, Type YSingle Phase / Single Unit - Type YBoost - Increase VoltageType 5-Y03085-Y03585-Y04085-Y04585-Y05085-Y055Buck - Decrease Line8895104106212224225208136152256272240Load ne Fuse5555555555555Load ne Fuse7812126101061051055Load Line Fuse101515159151591581588Load 1.87Line Fuse15252525152525152015201515Load .004.253.75Line Fuse3.035454525454525425402525Load 612.006.375.62Line Fuse40507070357070356030603530Load 516.008.507.50Line Fuse60709090459090508040804540Load .012.711.2Line Fuse801001501507012512570125601257060Load 7.09.532.017.0Line Fuse11012520020090175175100175801509080Load 525.514.248.025.522.5Line Fuse175200300300150300300150250125225150125Load 37.542.523.780.042.537.5Line Fuse3003505004502504504502504002004002502001SP - 8591SP -12601SP - 7591SP -11601SP - 10601SP - 5591SP - 9601SP - 6591SP - 3591SP - 4591SP - 1591SP - 2591SP -1360Qty. RequiredConnection Dia. PageConnection diagrams may be found on Pgs. 59 - 60.Connections found on this Page require ordering1 Buck - Boost TransformersThe appropriate size 35 or 80 Series Transformer may besubstituted for the 85 Series where desired.54Dongan Electric Manufacturing Company

Single Phase Buck - Boost Sizing TablesSingle Phase Buck - Boost Table, Type LMSingle Phase / Single Unit -Type LM03085-LM03585-LM04085-LM04585-LM05085-LM055Type LMBoost - Increase VoltageBuck - Decrease oad 01.10Line Fuse55875577757757Load 51.65Line Fuse771012661010105105105Load 1.505.252.75Line Fuse1010151510101515159159159Load 2.825.503.0010.505.50Line Fuse2020303015153030301530153015Load 04.238.254.5015.758.25Line Fuse2525454525254545402020204020Load 019.8710.545.6411.006.0021.00Line Fuse3535606030306060603060306030Load 15.818.4716.509.0031.5016.50Line Fuse5050909045459090804080408040Load 1.222.012.042.022.0Line Fuse70701251256060110110110601106011060Load .631.616.933.018.063.033.0Line Fuse1001001751759090175175175801758017580Load 8100.099.352.728.255.030.0105.055.0Line Fuse1751753003001501503003003001503001503001501SP - 8591SP -12601SP - 7591SP -11601SP - 6591SP -10601SP - 5591SP - 9601SP - 3591SP - 4591SP - 3591SP - 4591SP - 1591SP - 259Qty. RequiredConnection Dia. PageSingle Phase kVA Load Voltage x Load AmpskVA Volt Amperes1000 1000Three Phase kVA Load Voltage x Load Amps x 1.731000VA kVA x 1000Connection diagrams may be found on Pgs. 61 - 63.Connections found on this Page require ordering1 Buck - Boost TransformerThe appropriate size 35 or 80 Series Transformer may besubstituted for the 85 Series where desired.1.800.428.2626 www.dongan.com55

Three Phase Buck - Boost Sizing TablesThree Phase Buck - Boost Table, Type MThree Phase / Two or Three Units -Type 5-M03085-M03585-M04085-M04585-M05085-M055Type MBoost - Increase VoltageBuck - Decrease 49252264437Load .901.820.953.121.65Line Fuse5578575577757575Load .803.641.906.243.30Line Fuse78151271577.51515157157157Load .558.994.942.705.462.869.36Line Fuse10122020102012102020201020102010Load 7.5014.2614.998.234.509.104.7615.60Line Fuse15203030153015153030301530153015Load .4013.4915.0028.5229.9816.469.0018.209.5331.21Line Fuse30356060306030306060603060306030Load 2Line Fuse45508090458045458090804580458045Load 9Line Fuse6070110125601106060110110110601106011060Load 193.6449.50Line Fuse80100175175801758090175175175801758017580Load 5.653.960.0114.1119.965.836.072.838.1124.866.0Line 10Load 187.2Line 75Load .3312.1165.0Line 10622TP-9613TP-15623TP-1662Qty. RequiredConnection Dia. PageSingle Phase kVA Load Voltage x Load AmpskVA Volt Amperes1000 1000Three Phase kVA Load Voltage x Load Amps x 1.731000VA kVA x 1000Connection diagrams may be found on Pgs. 61 - 63.Connections found on this Page require ordering2 or 3 Buck - Boost TransformersThe appropriate size 35 or 80 Series Transformer may be substituted for the 85 Series where desired.56Dongan Electric Manufacturing Company

Three Phase Buck - Boost Sizing TablesThree Phase Buck - Boost Table, Type YThree Phase / Two and Three Units -Type 5-Y03085-Y03585-Y04085-Y04585-Y05085-Y055Type YBoost - Increase VoltageBuck - Decrease 35240256272Load 1.270.561.38.732.25Line Fuse5555555555554555.6Load .541.122.771.474.50Line Fuse5710125510512651051057Load 93.811.684.162.216.75Line Fuse810121589157.5159815715915Load Amps7.77.71

Buck - Boost Transformer Terms & Definitions Buck-Boost transformers are single phase, four winding transformers designed for two purposes. The first purpose is as a low voltage isolation trans-former for use on 12, 16, 24, 32, or 48 volt circuits. When used as low voltage transformers, Buck-Boost

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