NEC CodeFebruary 3, 2025• 11 min read

Transformer Sizing Guide: kVA Calculations & NEC Requirements

Proper transformer sizing ensures reliable power distribution. Learn kVA calculations and NEC Article 450 protection requirements.

PRIMARY480VSECONDARY208V75 kVA

Understanding kVA Ratings

Transformers are rated in kilovolt-amperes (kVA), representing their apparent power capacity. Unlike resistive loads measured in kW, kVA accounts for both real and reactive power.

kVA = (Volts × Amps) / 1000

Single-phase: kVA = (V × I) / 1000

Three-phase: kVA = (V × I × 1.732) / 1000

Sizing Steps

  1. Calculate total connected load — Sum all loads on the secondary
  2. Apply demand factors — Not all loads operate simultaneously
  3. Add growth allowance — Typically 20-25% for future expansion
  4. Select standard size — Choose next larger standard kVA rating

Standard Transformer Sizes

Common dry-type transformer ratings (kVA):

36915304575112.515022530050075010001500

Primary & Secondary Current

Once you know the kVA rating, calculate the full-load currents for conductor and protection sizing:

Single-Phase

I = kVA × 1000 / V

Three-Phase

I = kVA × 1000 / (V × 1.732)

Example: 75 kVA, 480V to 208V, 3-Phase

Primary current: 75,000 / (480 × 1.732) = 90.2A

Secondary current: 75,000 / (208 × 1.732) = 208.2A

Overcurrent Protection (NEC 450.3)

NEC Article 450 provides specific requirements for transformer overcurrent protection. Rules differ based on voltage and transformer type.

PRIMARYOCPD125%TSECONDARYOCPD125%≤1000VNEC 450.3(B) - Dry-Type Transformers

Transformers 1000V or Less (450.3(B))

Protection MethodPrimary OnlyPrimary + Secondary
Primary OCPD (9A or more)125%250%
Primary OCPD (less than 9A)167%300%
Secondary OCPD125%

Conductor Sizing

Size conductors based on the full-load current at each voltage level:

  • Primary conductors: Sized for primary full-load current
  • Secondary conductors: Sized for secondary full-load current
  • Apply ampacity correction factors for temperature and conduit fill

Example Installation

Size a transformer for 150A of 208V, 3-phase load

1. Calculate required kVA:

kVA = (208 × 150 × 1.732) / 1000 = 54 kVA

2. Add 25% growth: 54 × 1.25 = 67.5 kVA

3. Select standard size: 75 kVA transformer

4. Primary current (480V): 90.2A

5. Primary OCPD (125%): 90.2 × 1.25 = 112.75A → 110A breaker

6. Primary conductors: #2 AWG copper (115A @ 75°C)

Installation Considerations

  • Ventilation: Dry-type transformers require adequate airflow
  • Clearances: Maintain manufacturer-specified clearances
  • Grounding: Secondary must be grounded per NEC 250
  • Accessibility: Ensure access for maintenance and inspection

Calculate Transformer Sizing

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