ENCAPSULATED

DRY-TYPE MANUAL
 MANUAL FOR ENCAPSULATED DRY-TYPE TRANSFORMER
1

ALWAYS SAFETY FIRST

1. DO NOT ATTEMPT TO MOVE OR LIFT TRANSFORMERS WITHOUT THE PROPER SUPERVISION AND EQUIPMENT.

2. MAKE SURE THAT THE TRANSFORMER IS FULLY INSPECTED PRIOR TO INSTALLATION AND ENERGIZATION.

3. USE SUITABLE UL-LISTED TERMINALS FOR ELECTRICAL CONNECTIONS. MADDOX RECOMMENDS THE USE OF FLEXIBLE CONNECTORS.

4. CONNECTIONS SHOULD ONLY BE IN ACCORDANCE WITH THE NAMEPLATE DIAGRAM OR CONNECTION DRAWINGS.

5. DISCONNECT POWER BEFORE ATTEMPTING ANY WORK ON THE TRANSFORMER.

6. ALWAYS MAKE CERTAIN ALL GROUND CONNECTIONS ARE COMPLETE AND TIGHTENED BEFORE ENERGIZING THE TRANSFORMER.

7. NEVER CHANGE ANY TAPS -- PRIMARY OR SECONDARY -- WHILE THE TRANSFORMER IS ENERGIZED.

8. NEVER CHANGE CONNECTIONS WHEN THE TRANSFORMER IS ENERGIZED.

9. NEVER ADJUST OR REMOVE ANY ACCESSORIES OR COVER PLATES WHILE THE TRANSFORMER IS ENERGIZED.

TABLE OF CONTENTS

General Information Page 2

Handling Page 2
Receiving & Inspection Page 2
Storage Page 2
Installation Page 2
Ventilation Page 2
Accessibility Page 2
Sound Levels Page 2
Cable Connections Page 3
Grounding Page 3
Inspection Before Energization Page 3
Operation Page 3
Maintenance Page 3
Drawing 1 Page 4
Drawing 2 Page 4
Drawing 3 Page 5
Drawing 4 Page 5
Drawing 5 Page 6
Drawing 6 Page 6

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 MANUAL FOR ENCAPSULATED DRY-TYPE TRANSFORMER
2

INSTALLATION, OPERATION, AND MAINTENANCE OF

ENCAPSULATED TRANSFORMERS

GENERAL Mounting Instructions

Encapsulated transformers are made to provide a lifetime of trouble-free
performance. Attention should be paid to the following instructions for 1. Choose a location that is on a non-combustible surface. Make sure
safe and trouble-free operation. that the location allows for air circulation around the transformer for
cooling purposes.
ONLY qualified people should install, operate, and maintain
transformers. 2. Transformers up to 100lbs. will be boxed. Units over 100lbs. will be
bolted to a wooden pallet.
WARNING: The risk of electric shock is present whenever working in or
around transformers. Power must be shut off before any work is 3. Smaller transformers are shipped with the mounting ears in a down
conducted on a transformer. position to prevent damage in shipping. Loosen the bolts and position
the ears upwards. Tighten the bolts and install on selected surface.
As with any electrical device, transformers must be installed per the
requirements of the national and local electrical codes. Refer to 4. Medium-sized transformers have a side-positioned mounting bracket
ANSI/IEEE C57-94 for recommended installation, application, operation, that attaches to the back of the transformer. Loosen the pre-installed
and maintenance procedures of dry-type transformers. bolts on the back, place the bracket over the bolt head, and slide it into
the smaller spot. Retighten the bolts. Lift and position the transformer
HANDLING with bracket to the desired installation point and secure with bolts.
Smaller transformers are shipped in cartons. Larger transformers are
palletized. The palletized units can either be lifted using a forklift or by 5. On larger wall-mounted units, you will find the lifting brackets packed
the lifting lugs provided. On larger transformers, the lifting lugs are inside the wiring compartment. Secure the bracket to the side of the
removable and are packed inside the transformer wiring compartment. transformer and lift into place. On transformers with the wiring
Use the supplied bolts to attach. compartment on top, the units will come with lifting eye bolts in place of
the brackets. Remove two screws from the corners of the cover, and
The proper lifting equipment should be used in relation to the size and replace with the lifting eye bolts. Lift unit into place and secure to wall.
weight of each transformer. DO NOT attempt to lift or move a Remove and dispose of the eye bolts and replace the screws that were
transformer from any points on the unit other than those indicated. removed.

RECEIVING & INSPECTION 6. On floor-mounted units, secure the transformers to the floor using
BEFORE receiving the transformer, it should be inspected for any appropriate anchors.
damage and number matching the information on the shipping bill of
lading. 7. With the wiring compartment cover open, mark and drill the lower
mounting hole(s) into the mounting surface. Install the lower mounting
Each unit should be inspected carefully, looking for any breaks in its bolt(s).
packaging, dented or damaged enclosures, or missing parts from the
packing list. VENTILATION
Transformers are to be installed in areas where they can be cooled by
If damage is noted, ALL copies of the bill of lading should note the free circulation of air where the average ambient temperature is 30°C
damage and a more complete inspection should be performed. Proper (86°F) and should not exceed 40°C (104°F) at anytime.
paperwork should be filed with the local freight carrier's office.
Sufficient ventilation is essential for transformers to meet their
STORAGE nameplate kVA capability as well as life expectancy. To allow free, clean
Any transformer that will not be used quickly should be stored in a clean, circulation of air, all encapsulated general purpose transformers should
dry, and warm environment, away from any potential contaminants. be located away from walls or other obstructions. Units up to 10 kVA
should be located at least two inches away from walls; units over 10 kVA
We recommended that transformers be stored in a air-conditioned should be located at least four inches away from walls.
building. If the temperature reaches -40°C (-40°F), the units that are to
be energized after being stored at a low temperature must be warmed to ACCESSIBILITY
-25°C (-13°F) using warm air or radiant heat. NEC requires that transformers be accessible for inspection and located
in easily accessible areas. Transformers should never be in areas where
INSTALLATION stored items are likely to interfere with natural air convection.
All encapsulated transformers are supplied with a NEMA 3R enclosure.
NEMA 3R units may be installed indoors, or outdoors where applicable. TRANSFORMER SOUND LEVELS
Due to their construction and electrical energization, transformers will
For outdoor locations, the appropriate electrical codes must be followed, emit some sound.
including cable installation and hardware suitable for outdoor service.
Rain-tight connectors must be used at the knockouts. We strongly Transformers are required to meet NEMA standards for the maximum
recommend that a licensed, professional electrician do the installation. sound levels permissible. These sound level standards vary from 40 to
60 DB, and can be an annoyance if located in close proximity to where
It is required that encapsulated transformers be installed in an upright people work or reside.
position on walls, posts, beams, or other locations capable of supporting
their weight. All units must be oriented vertically with the wiring Care should therefore be exercised in selecting sites for transformers,
compartment down to prevent moisture from entering the transformer. particularly to avoid sensitive areas like hospitals, classrooms, medical
or office facilities.

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 MANUAL FOR ENCAPSULATED DRY-TYPE TRANSFORMER
3

Follow these guidelines: OPERATION

In normal installations, in a conditioned environment, encapsulated
1. Units should be mounted away from corners, reflecting walls, or transformers will function according to their design. If you are
ceilings. experiencing higher temperatures, please confirm that the following
conditions are not present:
2. Cable or flexible conduit should be used to make connections.
1. Motor starting more than twice per hour. For applications where there
3. Surface materials should be soft. Hard surfaces such as brick or tile are multiple starts, a larger kVa is required.
should be avoided for walls and ceilings around the unit. Additionally, the
unit should be located as far as practical from areas where sound levels 2. Higher supply side voltages can cause over-excitation of unit.
could be considered undesirable.
3. Ambient temperatures above the nameplate rating. For every 10%
CABLE CONNECTIONS above the nameplate ambient, you will reduce the life expectancy of the
1. Open the wiring compartment by loosening the cover screw and transformer.
sliding out the door.
ANSI C57.96 standards permit the temperatures of the enclosure to be
2. Electrical joint compounds are recommended for use on all electrical 65°C over ambient. Encapsulated transformers are designed to operate
connections. continuously attheir full nameplate kVA rating.

3. Make the appropriate electrical The enclosure temperature may rise in the following conditions:
connection to suit the desired
voltages per the connection 1. Ambient temperatures that are outside of the ambient temperatures
diagram as listed on the nameplate. recommended for transformer operation.

4. Make certain to insulate any 2. Short term overloads as it relates to time and temperature and the
unused wire leads with UL-listed applicable loss of life of the transformer.
wire connectors and electrical tape.
3 .Overloading that results in a reduction of the life expectancy of the
5. Close the wiring compartment transformer by 1/2. When energized, transformers may be very
and ensure that the cover screw is warm to the touch.
tightly secured.
4. Overload beyond ANSI C57.96 guidelines.
GROUNDING
Ensure that the core and coil assemblies are solidly grounded to the 5. Harmonic distortion of the supply side line voltage and currents.
enclosure internally so that all conductive metal parts have the same
potential. MAINTENANCE
Under normal operating conditions and environments, encapsulated
The transformer enclosure should also be securely and effectively transformers do not require maintenance, but periodic preventative
grounded as a safety precaution. This grounding should be in maintenance is a good practice, especially if the unit is installed in an
accordance with national electrical code standards. area exposed to extreme environmental conditions.

INSPECTION BEFORE ENERGIZATION Peripheral inspection and external dust and dirt removal may be carried
For the safe and proper operation of the transformer, we recommend out while the transformer is in operation. However, access covers must
that the following items be checked: not be opened under energized conditions.

a) Before energizing and connecting loads, measure the output voltage Normal accumulation of ice or snow will not adversely affect the
and make sure it matches nameplate voltages listed. operation of an encapsulated transformer. However, the accumulation
of dust or dirt can have an adverse effect with cooling of the transformer
b) When windings are connected in parallel (as with dual-voltage and can become a fire hazard.
primaries), the primary taps for all coils must be connected to the
identical percentage tap positions to avoid the shorting of turns. Refer to ANY internal maintenance must be done with the transformer
the nameplate on the transformer for tap positions. de-energized and isolated from the circuit.

c) Always ground the enclosure using the appropriately-sized conductor. ALWAYS check the ground connection to ensure a low impedance
connection.
d) On 3-phase transformers, verify that the total load among all phases
is balanced for problem-free performance. Any 3-phase or single-phase
load can be connected to the transformer, but the kVA loading per
phase should not exceed 33% of the total nameplate kVA rating.

e) The clearance and tightness of all electrical connections should be

checked.

f) For single-phase 3-wire 240/120 volt loads, verify that the neutral
current does not exceed 1/2 of the transformer’s kVA rating.

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 MANUAL FOR ENCAPSULATED DRY-TYPE TRANSFORMER
4

DIAGRAM 1

Details for mounting small single-phase

encapsulated transformers.
Upper
Upper
Mounting
Mounting
Holes
Holes

FRONT VIEW SIDE VIEW BACK VIEW

Wiring
Compartment Lower
Cover Screw Mounting
Hole (s)

Wiring Mtg. Hole

Compartment
Cover
(see diagram 2 below)

DIAGRAM 2

Details for mounting small single-phase

encapsulated transformers.
Upper Upper
Mounting Mounting
Holes Holes

FRONT VIEW SIDE VIEW BACK VIEW

Side
Knockout Rear Knockout
Mtg. Hole
Wiring
Compartment
Cover Screw Lower
Mounting
Hole (s)
Wiring
Compartment
Cover

(see diagram 2 below)

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 MANUAL FOR ENCAPSULATED DRY-TYPE TRANSFORMER
5

DIAGRAM 3

Details for mounting medium single-phase

Upper encapsulated transformers. Upper
Mounting Mounting
Holes Holes

FRONT VIEW SIDE VIEW BACK VIEW

Wiring
Compartment
Side Knockout Rear Knockout
Cover Screw
Mtg. Hole
Lower
Mounting
Wiring Hole (s)
Compartment
Cover

DIAGRAM 4

Lower wiring compartment mounting hole(s), mounting hardware

installation assembly diagram.

Mounting
Bolt

Lock
Washer

Flat
Washer
Transformer
Enclosure

Rubber
Washer

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 MANUAL FOR ENCAPSULATED DRY-TYPE TRANSFORMER
6

DIAGRAM 5

Details for mounting large single-phase

encapsulated transformers.
Remove Ct enclosure cover to access
the wiring compartment or to install
optional NEMA 4/12 gasket

Side Knockout
Upper
Mounting
Holes

BACK
Lower
Mounting
Holes

FRONT VIEW SIDE VIEW REAR VIEW

DIAGRAM 6

Details for large floor-mounted

encapsulated transformers.

Side Knockout

Rear Knockout

FRONT VIEW SIDE VIEW REAR VIEW

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