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What is needed to transform 208/3/60 volt power to 480/3/60?
This is a question that gets many different responses and I need some help. We have some used equipment ( both 240/3/60 and 480/3/60). We want to be able to show potential customers that the equipment is operational. We currently have a building with 208 3phase power and 200 amp service. Some of the equipment (large dryers and chillers) have big amperage draws.
We would like to know what transformer options are available. Is there someone doing this that can help out? Can we use a 220/440 transformer with large KVA?
Thanks
First, your electrical utility company may have sized their transformer based on the actual loads in your building. This means that even though you have a 200A panel, the utility's transformer might not be able to handle that full load. That is why you (probably) are required to let your utility company know when you are increasing the total load. They will upsize their facilities to match, usually at no additional cost to you.
Your 208V 200A panel should not be loaded continuously (meaning for three hours or longer) above 80% rated current, or 160A. That equals 57.6 kVA maximum. So spare capacity is 57.6 kVA less whatever your building requires. It would behoove you to look at the loads that you want to power. If they exceed the spare capacity, then using a step-up transformer is not an option.
For estimation purposes, large chillers run around 1.3 kW/ton (or less), so say 1.5 kVA/ton.
For reference, 57.6 kVA = 160A at 208V, 139A at 240V, and 69A at 480V.
A power transformer can be run in either direction (step-up or step-down voltage). It will require overcurrent protection (fused switch or breaker) both on the low-voltage side and the high-voltage side. If the load is non-inductive, the transformer kVA should equal or exceed the load kVA. For motor starting, the transformer needs to be sized larger, depending upon how much starting current is required and what voltage dip can be tolerated during starting. To obtain 480V, one can use a power transformer rated 208/120V (WYE) on the low voltage side and 480V (DELTA) on the high voltage side. If the 480V load cannot tolerate a delta connection that has one leg grounded, then an artificial ground will need to be established by connecting a zig-zag transformer (or equivalent) to the high voltage side of the power transformer. This method can be expensive an proposition.
The same method can be used to transform from 208/120Y to 240V delta. Alternative, you could use a boost autotransformer. Electrically the autotransformer size is a much smaller kVA and thus will be less expensive, but still requires overcurrent protection.
Other options to consider are these:
1. Rent or buy a generator. A 12-wire generator can be wired to any of the standard 3-phase voltage configurations (120/208V wye, 120/240V midpoint-grounded delta, 240V delta, 480/277V wye, 480V delta).
2. Ask the utility company what power they can provide. You may be able to take power at 480V and step it down to 120/208 for the building, and use 480V as test power. A 480/240V transformer could be added to provide 240V test power.
3. Arrange to use power from another company at their location.
4. See if you can rewire the loads to match your existing voltage.
5. 230V motors and 240V resistance heating equipment generally will operate on 208V. Motors won't tolerate a full 10% voltage drop (which you might not have), and heaters will produce less heat, but the performance of both might be sufficient to demonstrate operation.
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