Chapter 6
The Control Transformer
OBJECTIVES
After studying this chapter, the student will be able to
●● Discuss the use of control transformers in a control circuit.
●● Connect a control transformer for operation on a 240- or 480-volt system.
Most industrial motors operate on voltages that
range from 240 to 480 volts. Magnetic control
systems, however, generally operate on 120 volts.
A control transformer is used to step the 240 or
480 volts down to 120 volts to operate the con-
trol system. There is really nothing special about
a control transformer except that most of them
are made with two primary windings and one sec-
ondary winding. Each primary winding is rated at
240 volts, and the secondary winding is rated at
120 volts. This means there is a turns ratio of 2:1
(2 to 1) between each primary winding and the sec-
ondary winding. For example, assume that each
primary winding contains 200 turns of wire, and
the secondary ­winding contains 100 turns. There
are two turns of wire in each primary winding for
every one turn of wire in the secondary.
One of the primary windings of the control
transformer is labeled H1 and H2. The other pri-
mary winding is labeled H3 and H4. The secondary
winding is ­labeled X1 and X2. If the transformer
is to be used to step 240 volts down to 120 volts,
76
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the two primary windings are connected parallel
to each other as shown in Figure 6–1. Notice that
in Figure 6–1 the H1 and H3 leads are connected
together, and the H2 and H4 leads are connected
together. Because the voltage applied to each pri-
mary winding is the same, the effect is the same as
having only one primary winding with 200 turns of
wire in it. This means that when the transformer
is connected in this manner, the turns ratio is 2:1.
When 240 volts are connected to the primary wind-
ing, the secondary ­voltage is 120 volts.
If the transformer is to be used to step 480 volts
down to 120 volts, the primary windings are con-
nected in series as shown in Figure 6–2. With the
windings connected in series, the primary winding
now has a ­total of 400 turns of wire, which makes
a turns ratio of 4:1. When 480 volts is connected
to the primary ­winding, the secondary winding has
an output of 120 volts.
Control transformers generally have screw
terminals connected to the primary and second-
ary leads. The H2 and H3 leads are crossed to
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Chapter 6 The Control Transformer

H1 H3 X1

240 VOLTS AC 120 VOLTS AC

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H2 H4 X2

Figure 6–1
Primaries connected in parallel for 240-volt operation.

H1

H2 X1

480 VOLTS AC 120 VOLTS AC

H3 X2

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H4

Figure 6–2
Primaries connected in series for 480-volt operation.

make connection of the primary winding easier,

Figure 6–3. For example, if the transformer is to be
H4 H2 H3 H1 connected for 240 volt ­operation, the two primary
windings must be connected ­parallel to each other
as shown in Figure 6–1. This connection can be
made on the transformer by using one metal link to
connect leads H1 and H3, and another metal link
to connect H2 and H4 (Fig­ure 6–4).
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If the transformer is to be used for 480 volt

­o peration, the primary windings must be con-
nected in series as shown in Figure 6–2. This con-
X1 X2
nection can be made on the control transformer by
using a metal link to connect H2 and H3 as shown
Figure 6–3 in Figure 6–5. A ­t ypical control transformer is
Primary leads are crossed. shown in Figure 6–6.

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78
Chapter 6 The Control Transformer

H1 H2 H3 H4
H4 H2 H3 H1

208 V

277 V
0V

380 V
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X1 X2

Figure 6–4
Metal links used to make a 240-volt connection. 120 V

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X2 X1

H4 H2 H3 H1 Figure 6–6
Control transformer.

480 277 240 208 C

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X1 X2

Figure 6–5
Metal link used to make a 480-volt connection.

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X2 120 X1

Some control transformers contain a multi- Figure 6–7

tapped primary instead of two separate windings
(Figure 6–7). The transformer in this example is
designed to step voltages of 480, 277, 240, or 208
down to 120.
Power Rating
The power rating of control transformers generally
ranges from 0.75 kilovolt-ampere, or 75 volt-am-
peres, to 1 kilovolt-ampere, or 1000 volt-amperes.
The rating is indicated in volt-amperes, not watts,
because transformers generally supply power to
Control transformer with a multi-tapped primary
winding.
operate inductive devices such as the coils of re-
lays and motor starters (Figure 6–8). The volt-
ampere rating indicates the amount of current
the transformer can supply to operate control de-
vices. To determine the maximum output current
of a transformer, divide the volt-ampere rating by
the secondary voltage. The transformer shown in

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 79
Chapter 6 The Control Transformer

Figure 6–8 has a power rating of 250 volt-amperes.

If the secondary voltage is 120 volts, the maxi-
mum secondary current would be 2.08 amperes.
VA
I5
E
250
I5
120
I 5 2.08 A
A control transformer intended to operate a
single motor starter may have a rating of 75 to 100
volt-­a mperes. Transformers intended to supply
power to an entire relay cabinet have much higher
ratings, depending on the number of devices and

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their current requirements.

Grounded and Floating Control

Systems
Figure 6–8 One side of the secondary winding of a control
The power rating of a transformer is listed in transformer is often grounded (Figure 6–9). When
volt-amperes.
this is done, the control system, is referred to as a

L1 L2 L3

M OL

M OL
MOTOR
M OL

CONTROL TRANSFORMER

OL OL OL
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Figure 6–9
One side of the transformer has been grounded.

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80
Chapter 6 The Control Transformer
L1 L2 L3
M OL
M OL
M OL
CONTROL TRANSFORMER
M
Figure 6–10
Voltage can be measured by connecting one meter probe to any grounded point.
grounded system. Many industries prefer to ground
the control system, and it is a very common prac-
tice. Some technicians believe that it is an aid when
troubleshooting a problem. Grounding one side
of the control transformer permits one lead of a
­voltmeter to be connected to any grounded point
and the other voltmeter lead to be used to test
­voltage at various locations throughout the circuit
(Figure 6–10).
However, it is also a common practice to
not ground one side of the control transformer.
This is generally referred to as a floating system.
If one voltmeter probe were to be connected to a
grounded point, the meter reading would be erro-
neous or meaningless because there would not be
a complete circuit (Figure 6–11). High-impedance
voltmeters would probably indicate some amount
of voltage caused by the capacitance of the ground
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MOTOR
OL OL OL
M
VOLTMETER
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GROUNDED POINT
and induced voltage produced by surrounding
magnetic fields. These are generally referred to as
ghost voltages. A low-impedance meter such as a
plunger-type voltage tester would indicate no volt-
age. Accurate voltage measurement can be made in
a float control system, however, by connecting one
voltmeter probe directly to one side of the control
transformer (Figure 6–12). Because both grounded
and floating control systems are common, both are
illustrated throughout this text.
Transformer Fusing
Control transformers are generally protected
by fuses or circuit breakers. Protection can be
placed on the primary or secondary side of the
transformer, and some industries prefer protec-
tion on both sides. NEC Section 430.72(C) lists
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Chapter 6 The Control Transformer

L1 L2 L3

M OL

M OL
MOTOR
M OL

CONTROL TRANSFORMER

OL OL OL
M

M
VOLTMETER

© Cengage Learning 2014

GROUNDED POINT

Figure 6–11
Floating control systems do not ground one side of the control transformer. Connecting a voltmeter probe to a
grounded point would provide meaningless readings because a complete circuit would not exist.

EXAMPLE: requirements for the protection of transformers

employed in motor control circuits. This section
What is the maximum fuse size permitted basically states that control transformers that have
to protect the primary winding of a control a primary current of less than 2 amperes shall be
protected by an overcurrent device set at not more
transformer rated at 300 volt-amperes and
than 500% of the rated primary current. This large
connected to 240 volts? percentage is necessary because of the high inrush
current associated with transformers. To deter-
I 5 VA
E mine the rated current of the transformer, divide
the volt-ampere rating of the transformer by the
I 5 300 primary voltage.
240 NEC Section 430.72(C)(2) states that fuse pro­
tection in accordance with 450.3 is permitted also.
I 5 1.25 A
This section states that primary protection for
Fuse size 5 1.25 3 5 transformers rated 600 volts or less is determined
Fuse size 5 6.25 A in NEC Table 430.3(B). The table indicates a rating
NEC Section 240.6 indicates that a standard of 300% of the rated current.
The secondary fuse size can also be determined
fuse size is 6 amperes. A 6 ampere fuse
from NEC Table 450.3(B). The table indicates a rat-
would be used. ing of 167% of the rated secondary current for

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82
Chapter 6 The Control Transformer

L1 L2 L3

M OL

M OL
MOTOR
M OL

CONTROL TRANSFORMER

VOLTMETER

OL OL OL

© Cengage Learning 2014

M

Figure 6–12
Connecting one meter probe directly to one side of the transformer provides accurate readings on a floating
control system.

fuses ­protecting a transformer secondary with a
current of less than 9 amperes. Assuming a con-
trol voltage of 120 volts, the rated secondary cur-
rent of the transformer in the previous example
would be 2.5 amperes (300/120). The fuse size
would be:
2.5 3 1.67 5 4.175 A
The nearest standard fuse size listed in 240.6
without ­going over this value is 3 amperes. The sec-
ondary fuse size can be set at a lower percentage of
the rated current because the secondary does not
experience the high inrush current of the primary.
Because primary and ­secondary fuse protection is
common throughout in dustry, control circuits pre-
sented in this text illustrate both.

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●● Review Questions
1. What is the operating voltage of most magnetic
control systems?
2. How many primary windings do control trans-
formers have?
3. How are the primary windings connected when
the transformer is to be operated on a 240-volt
system?
4. How are the primary windings connected when
the transformer is to be operated on a 480-volt
system?
5. Why are two of the primary leads crossed on a
control transformer?
6. You are an electrician working in an industrial
plant. You are building a motor control cabinet
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83
Chapter 6 The Control Transformer
that contains six motor starters and six pi-
lot lamps. All control components operate
on 120 volts AC. Two of the motor starters
have coil currents of 0.1 amperes each and
four have coil currents of 0.18 amperes each.
The six pilot lamps are rated at 5 watts each.
The supply room has control transformers
with the following rating (in volt-amperes):
75, 100, 150, 250, 300, and 500. Which of
the available control transformers should
you choose to supply the power for all the
control components in the cabinet? (Choose
the smallest size that will supply the power
needed.)