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Acme Buck Boost Transformers
Where
Are Buck-Boost Transformers Used?
A typical buck-boost application is 120 volts in, 12 volts out for low
voltage lighting or control circuitry. In most applications, this low
voltage transformer is field connected as an autotransformer. Buck-boost
transformers provide tremendous capabilities and flexibility in KVA
sizes and input/output voltage combinations. Basically you get 75
different transformers... all in one convenient package. Other
buck-boost applications are, where (A) low supply voltage exists because
equipment is installed at the end of a bus system; (B) the supply system
is operating at or over its design capacity; and (C) where overall
consumer demands may be so high the utility cuts back the supply voltage
to the consumer causing a “brownout." Why Use Buck-Boost Instead of
Another Type Transformer ? Take a look at the advantages and
disadvantages of using a buck-boost transformer (autotransformer)
compared to a standard isolation transformer of the proper size and
voltage combination. As you can see, the advantages are many, the
economies
great. Buck- boost transformers are readily available from the stock of
your nearest Power Distribution Products Distributor.
| ADVANTAGES |
DISADVANTAGES |
| More efficient |
No circuit isolation |
|
Smaller & lighter |
Cannot create a
neutral |
5-10 times increase
in KVA |
Application voltages and
KVA don‘t match
the nameplate
voltages and KVA
|
Versatile, many
applications |
| Lower cost |
Proper Voltage Is Critical
With nearly two-thirds of all electrical loads being A.C. motor
loads, maintenance of the proper voltage to that motor is very
important. If the supply line voltage is not maintained, motor winding
current is increased causing reduced motor torque and escalating motor
temperature, all of which results in the rapid loss of insulation life
expectancy. In addition to motor loads, the detrimental effects of low
voltage on both resistive heating loads and incandescent lighting output
is illustrated in the chart. Anytime you have a lower than standard
voltage, equipment
damage and failure can result. Buck-boost transformers are an economical
way to correct this potentially very serious problem. Anytime a line
voltage change in the 5-20% range is required, a buck-boost transformer
should be considered as your first line of defense.
Questions & Answers About Buck-Boost Transformers
1.What is a buck-boost transformer?
Buck-boost transformers are small single phase transformers designed to
reduce (buck) or raise (boost) line voltage from 5 -20%. The most common
example is boosting 208 volts to 230 volts, usually to operate a 230
volt motor such as an air conditioner compressor, from a 208 volt supply
line. Buck-boosts are a standard type of single phase distribution
transformers, with primary voltages of 120, 240 or 480 volts and
secondary typically of 12, 16, 24, 32 or 48 volts. They are available in
sizes ranging from 50 volt amperes to 10 kilo-volt amperes.
Buck-boost transformers are shipped ready to be connected for a number
of possible voltage combinations.
2. How does a buck-boost transformer differ from an insulating
transformer?
A buck-boost transformer IS an insulating type transformer when it is
shipped from the factory. When it is connected at the job site, a lead
wire on the primary is connected to a lead wire on the secondary –
thereby changing the transformer’s electrical characteristics to those
of an autotransformer. The primary and secondary windings are no longer
“insulated” and secondary windings are no longer “insulated” and its KVA
capacity is
greatly increased.
3. What is the difference between a buck-boost transformer and an
autotransformer?
When a primary lead wire and secondary lead wire of a buck-boost
transformer are connected together electrically, in a recommended
voltage bucking or boosting connection, the transformer is in all
respects, an autotransformer. However, if the interconnection between
the primary and secondary winding is not made, then the unit is an
insulating type transformer.
Buck Boost Transformer Applications
4. Why are buck boost transformers used?
Electrical and electronic equipment is designed to operate on standard
supply voltage. When the supply voltage is constantly too high or too
low, (usually more than 55%), the equipment fails to operate at maximum
efficiency. A buck and boost transformer is a simple and ECONOMICAL
means of correcting this off-standard voltage.
5. What are the most common applications for buck-boost
transformers?
Boosting 208V to 230V or 240V and vice versa for commercial and
industrial air conditioning systems; boosting 110V to 120V and 240V to
277V for lighting systems; voltage correction for heating systems and
induction motors of all types. Many applications exist where supply
voltages are constantly above or below normal.
6. Can buck-boost transformers be used to power low voltage circuits?
Yes, low voltage control, lighting circuits, or other low voltage
applications requiring either 12V, 16V, 24V, 32V or 48V. The unit is
connected as an insulating transformer and the nameplate KVA rating is
the transformer’s capacity.
Buck Boost Transformer Operation and Construction
7. Why do buck-boost transformers have 4 windings?
To make them versatile! A four winding buck-boost transformer (2 primary
and 2 secondary windings) can be connected eight different ways to
provide a multitude of voltage and KVA outputs. A two winding (1 primary
& 1 secondary) buck-boost transformer can be connected only one way.
8. Will a buck-boost transformer stabilize voltage?
No. The output voltage is a function of the input voltage. If the input
voltage varies, then the output voltage will also vary by the same
percentage.
Buck Boost Transformer Load Data
9. Are there any restrictions on the type of load that can be
operated from a buck-boost transformer?
No, there are no restrictions.
10. Why can a buck-boost transformer operate a KVA load many times
larger than the KVA rating on its nameplate?
Since the transformer has been auto-connected in such a fashion that the
22V secondary voltage is added to the 208V primary voltage, it produces
230V output. The autotransformer KVA is calculated:
KVA = Output Volts x Secondary Amps
1000
KVA = 230 V x 41.67 Amps = 9.58 KVA
1000
The
picture to the left illustrates the difference in physical size between
the autotransformer of 1 KVA, capable of handling a 9.58 KVA load, and
an isolation transformer capable of handling a 7.5 KVA load.
To cite an example . . . a model T-1-11683 buck-boost transformer has a
nameplate KVA rating of 1 KVA, but when it’s connected as an
autotransformer
boosting 208V to 230V, its KVA capacity increases to 9.58 KVA.
The key to understanding the operation of buck-boost transformers lies
in
the fact that the secondary windings are the only parts of the
transformer
that do the work of transforming voltage and current. In the example
above, only 22 volts are being transformed (boosted) — i.e. 208V + 22V =
230V. This 22V transformation is carried out by the secondary windings
which are designed to operate at a maximum current of 41.67 amps
(determined by wire size of windings).
Maximum Secondary Amps =
nameplate KVA x 1000
secondary volts
Maximum Secondary Amps =
1.0 KVA x 1000
24 V
1000 VA = 41.67 amps
24
11. Can buck-boost transformers be used on motor loads?
Yes, either single or three phase.
12. How are single phase and three phase load Amps and load KVA
calculated?
Single phase Amps = KVA x 1000
Volts
Three phase Amps = KVA x 1000
Volts x 1.73
Single phase KVA = Volts x Amps
1000
Three phase KVA = Volts x Amps x 1.73
1000
Three-Phase
13. Can buck-boost transformers be used on three-phase systems as
well as single phase systems?
Yes. A single unit is used to buck or boost single phase voltage — two
or three units are used to buck or boost three phase voltage. The number
of units to be used in a three -phase installation depends on the number
of wires in the supply line. If the three-phase supply is 4 wire Y, use
three buck-boost transformers. If the 3 - phase supply is 3 wire Y
(neutral not available), use two buck-boost transformers.
14. Should buck-boost transformers be used to develop a three-phase 4
wire Y circuit from a three-phase 3 wire delta circuit?
No. A three phase “wye” buck-boost transformer connection should be used
only on a 4 wire source of supply. A delta to wye connection does not
provide adequate current capacity to accommodate unbalanced currents
flowing in the neutral wire of the 4 wire circuit.
15. Why isn’t a closed delta buck-boost connection recommended?
A closed delta buck-boost auto transformer connection requires more
transformer KVA than a “wye” or open delta connection and phase shifting
occurs on the output. Consequently the closed delta connection is more
expensive and electrically inferior to other three-phase connections.
Buck Boost Transformer Connection and Frequency
16. How does the installer or user know how to connect a buck-boost
transformer?
The connection chart packed with each unit shows how to make the
appropriate connections.
17. Can 60 Hertz buck-boost transformers be used on a 50 Hertz
service?
No. Acme buck-boost transformers should be operated only at the
frequencies recommended. However, units recommended for 50 cycle
operation are suitable for 60 cycle operation but not vice versa.
Buck Boost Transformer Nameplate Data
19. Why are buck-boost transformers shipped from the factory as
insulating transformers and not pre-connected at the factory as
autotransformers?
A four winding buck-boost transformer can be auto connected eight
different ways to provide a multitude of voltage and KVA output
combinations. The proper transformer connection depends on the user’s
supply voltage, load voltage and load KVA. Consequently, it is more
feasible for the manufacturer to ship the unit as an insulating
transformer and allow the user to connect it on the job site in
accordance with the available supply voltage and requirements of his
load.
20. Why is the isolation transformer KVA rating shown on the
nameplate instead of the autotransformer KVA rating?
The KVA rating of a buck-boost transformer when auto connected depends
on the amount of voltage buck or boost. Since the amount of voltage buck
or boost is different for each connection, it is physically impossible
to show all of the various voltage combinations and attainable KVA
ratings on the nameplate. A connection chart showing the various
attainable single phase and three-phase connections is packed with each
unit.
Buck Boost Transformer Safety
21. Do buck-boost transformers present a safety hazard usually
associated with autotransformers?
No. Most autotransformers, if they are not of the buck-boost variety,
change voltage from one voltage class to another. (Example 480V to 240V)
In a system where one line is grounded, the user thinks he has 240V; yet
due to the primary and secondary being tied together, it is possible to
have 480V to ground from the 240V output. A buck-boost transformer only
changes the voltage a small amount, such as 208V to 240V. This small
increase does not represent a safety hazard, as compared to a buck of
480V to 240V.
Buck Boost Transformer Sound Levels
22. Are buck-boost transformers as quiet as standard isolation
transformers?
Yes. However, an auto-connected buck-boost transformer will be quieter
than an isolation transformer capable of handling the same load. The
isolation transformer would have to be physically larger than the
buck-boost transformer, and small transformers are quieter than larger
ones. (Example) 1 KVA — 40 db; 75 KVA — 50 db. (db is a unit of sound
measure).
Buck Boost Transformer Cost and Life Expectancy
23. How does the cost of a buck-boost transformer compare to that of
an insulating transformer — both capable of handling the same load?
For the most common buck-boost applications, the dollar savings are
generally greater than 75% compared to the
use of an insulating type distribution transformer for the same
application.
24. What is the life expectancy of a buck boost transformer?
The life expectancy of a buck-boost transformer is the same as the life
expectancy of other dry type transformers.
25 What is the definition of an autotransformer and how does it
differ from an isolation transformer?
An autotransformer is a transformer in which the primary (input) and the
secondary (output) are electrically connected to each other. An
isolation transformer, also known as an insulating transformer, has
complete electrical separation between the primary (input) and the
secondary (output). An autotransformer changes or transforms only
a portion of the electrical energy it transmits. The rest of the
electrical energy flows directly through the electrical connections
between the primary and secondary. An isolation transformer
(insulating transformer) changes or transforms all of the electrical
energy it transmits. Consequently, an autotransformer is smaller,
lighter in weight, and less costly than a comparable KVA size insulating
transformer. Buck-boost transformers are frequently field-connected as
autotransformers.
26. Buck-boost transformers are almost always installed as
auto-transformers. Does the N.E.C. (National Electrical Code) permit the
use of autotransformers?
Yes. Please refer to N.E.C. Article 450-4, “Autotransformers 600 Volts,
Nominal, or Less.” Item (a) explains how to over current protect an
autotransformer; item (b) explains that an insulating transformer such
as a buck-boost transformer may be field connected as an
autotransformer.
27. When a buck-boost transformer is connected as an autotransformer
such as boosting 208V to 230V, the KVA is greatly increased. What is the
procedure for determining the size (ampere rating) of the overcurrent
protective device such as a fuse or circuit breaker?
The National Electrical Code Article 450-4 addresses over current
protection of autotransformers. A copy is reproduced below for easy
reference.
450-4. Autotransformers 600 Volts, Nominal, or Less. (a) Overcurrent
Protection. Each autotransformer 600 volts,
nominal, or less shall be protected by an individual overcurrent device
installed in series with each ungrounded input conductor. Such
overcurrent device shall be rated or set at not more than 125 percent of
the rated full-load input current of the autotransformer. An overcurrent
device shall not be installed in series with the shunt winding (the
winding common to both the input and the output circuits) of the
autotransformer between Points A and B as shown in Diagram 450-4.
Exception: Where the rated input current of an autotransformer is 9
amperes or more and 125 percent of this current does not correspond to a
standard rating of a fuse or non-adjustable circuit breaker, the next
higher standard rating described in Section 240-6 shall be permitted.
When the rated input current is less than 9 amperes, an overcurrent
device rated or set at not more than 167 percent of the input current
shall be permitted.
(b) Transformer Field-Connected as an Autotransformer. A transformer
field-connected as an autotransformer shall be identified for use at
elevated voltage.
28. I have noted the reprint of the N.E.C. (National Electrical
Code), Article 450-4 shown in the previous question covering
autotransformer overcurrent protection. Could you explain this article
in detail by citing an example?
An example of an everyday application is always a good way to explain
the intent of the “Code.” Example: A 1 KVA transformer Catalog No.
T-1-11683 has a primary of 120 x 240V and a secondary of12 x24V. It is
to be connected as an autotransformer at the time of installation to
raise 208V to 230V single phase. When this 1 KVA unit is connected as an
autotransformer for this voltage combination, its KVA rating is
increased to 9.58 KVA
(may also be expressed as 9,580 VA). This is the rating to be used for
determining the full load input amps and the sizing of the overcurrent
protect device (fuse or breaker) on the input.
Full Load Input Amps =
9,580 Volt Amps = 46 Amps
208 Volts
When the full load current is greater than 9 amps, the overcurrent
protective device (usually a fuse or non-adjustable breaker) amp rating
can be up to 125 percent of the full load rating of the autotransformer
input amps.
Max. amp rating of the overcurrent device
= 46 amps x 125% = 57.5 amps
The National Electrical Code, Article 450-4 (a) Exception, permits the
use of the next higher standard ampere rating of the overcurrent device.
This is shown in Article 240-6 of the N.E.C. Max. size of the fuse or
circuit breaker
= 60 amps
Steps for Selecting the Proper Buck-Boost Transformer
You should have the following information before selecting a buck-boost
transformer.
Line Voltage — The voltage that you want to buck (decrease) or
boost (increase). This can be found by measuring the supply line voltage
with a voltmeter.
Load Voltage — The voltage at which your equipment is designed to
operate. This is listed on the nameplate of the load equipment.
Load KVA or Load Amps — You do not need to know both —one or the
other is sufficient for selection purposes. This information usually can
be found on the nameplate of the equipment that you want to operate.
Frequency — The supply line frequency must be the same as the
frequency of the equipment to be operated — either 50 or 60 cycles.
Phase — The supply line should be the same as the equipment to be
operated — either single or three phase.
SELECTION CHART
GROUP I
120 X 240 PRIMARY VOLTS-12/24 SECONDARY VOLTS-60Hz
INSULATING
TRANSFORMER
RATING (KVA) |
CATALOG NO. |
| 0.05 |
T-1-81047 |
| 0.10 |
T-1-81048 |
| 0.15 |
T-1-81049 |
| 0.25 |
T-1-81050 |
| 0.50 |
T-1-81051 |
| 0.75 |
T-1-81052 |
| 1.00 |
T-1-11683 |
| 1.50 |
T-1-11684 |
| 2.00 |
T-1-11685 |
| 3.00 |
T-1-11686 |
| 5.00 |
T-1-11687 |
| 7.50 |
T-1-11688 |
| 10.00 |
T-1-11689 |
GROUP II
120 X 240 PRIMARY VOLTS-16/32 SECONDARY VOLTS-60Hz
INSULATING
TRANSFORMER
RATING (KVA) |
CATALOG NO. |
| 0.05 |
T-1-81054 |
| 0.10 |
T-1-81055 |
| 0.15 |
T-1-81056 |
| 0.25 |
T-1-81057 |
| 0.50 |
T-1-81058 |
| 0.75 |
T-1-81059 |
| 1.00 |
T-1-13073 |
| 1.50 |
T-1-13074 |
| 2.00 |
T-1-13075 |
| 3.00 |
T-1-13076 |
| 5.00 |
T-1-13077 |
| 7.50 |
T-1-13078 |
| 10.00 |
T-1-13079 |
GROUP II
240 X 480 PRIMARY VOLTS-24/48 SECONDARY VOLTS-60Hz
INSULATING
TRANSFORMER
RATING (KVA) |
CATALOG NO. |
| 0.05 |
T-1-81061 |
| 0.10 |
T-1-81062 |
| 0.15 |
T-1-81063 |
| 0.25 |
T-1-81064 |
| 0.50 |
T-1-81065 |
| 0.75 |
T-1-81066 |
| 1.00 |
T-1-37920 |
| 1.50 |
T-1-37921 |
| 2.00 |
T-1-37922 |
| 3.00 |
T-1-37923 |
| 5.00 |
T-1-37924 |
| 7.50 |
T-1-43570 |
| 10.00 |
T-1-43571 |
Power Transformer Information:
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