ACME ELECTRIC

HARMONIC MITIGATING
TRANSFORMERS

THE FIRST NAME IN POWER SOLUTIONS

POWER QUALITY
A MAJOR CONCERN

The quality of the power we receive has become quite a

topic of discussion in recent years. Its hard to find anyone
that hasnt been touched by power quality problems to one
extent or another. It might just be the inconvenience of the
loss of power during a thunderstorm or it could
be fire or downed equipment caused by excessive
neutral currents.
Our market today is heavily impacted by electronic
systems, which are sensitive and vulnerable to power
quality problems in the electronic infrastructures. Although
electrical utilities attempt to provide clean, well-regulated
power, the simple truth is that our power demands are
outstripping our power supply. Bottom line, this means that
the power were getting is more prone to power anomalies.
Power quality issues can take a variety of forms: power outages, spikes/ electrical noise on the transmission line,
fluctuating voltages and harmonics. On average, a computer installation is subjected to over 120 disturbances a month;
luckily most of these are minor. Identification of different types of problems has created the need for the use of true
RMS meters, ground continuity meters, harmonic analyzers, oscilloscopes or specialized data logging equipment. It is
imperative that we correctly identify the issues before products can be put in place to combat them.
Annually, power quality problems in the United States account for over $35 billion in equipment damage, productivity loss
and loss in revenues. Surprisingly, less than 15% of these problems can be categorized as acts of God. The majority

of the problems are generated locally. It is not unusual to find 80% generated internal to a facility and an additional 20%
coming from the folks next door.
Take a look around your building and try to identify those devices that could, in some fashion, be causing power quality
problems. While youre doing that, also take inventory of those devices in the building that are susceptible to power quality
problems. What potential risks are you facing?

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HARMONICS
A MAJOR CULPRIT

Over twenty years ago, harmonic distortion was a minor

and infrequent annoyance. Electrical loads were primarily
linear (sinusoidal). General purpose transformers could
easily withstand the few additional losses caused by
limited harmonic currents. No one anticipated the
meteoric rise in electronic office equipment, specifically
personal computers.
The convenience and escalating use of electronic
equipment is causing severe harmonic distortion on
networks. Most electronic devices are non-linear loads,
which create harmonic currents. The major source of
harmonics is attributed to the switch-mode power supply
(SMPS). Although they generate harmonics, switchmode power supplies are responsible for the growth of
the electronics industry. These devices have enabled electronic products to decrease significantly in size, dramatically
decrease heat output and become universally affordable. Harmonics can cause a variety of problems ranging from
overheated transformers and motors (at what appears to be nameplate load or less), to equipment failure, tripping of
overcurrent devices and more.

What Are Harmonics?

Utilities distribute electricity in an alternating current format. Alternating current flows in the form of a sine wave. The
power we utilize in the United States is 60 hertz power, sometimes called 60 cycle power (60 cycles per second). Other
places in the world may receive 50 hertz power from their electrical utilities.

60 Hz
Fundamental

360

1/60th sec

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HARMONIC DISTORTION

60 Hz & 180 Hz
60 Hz

Fundamental

360

3rd Harmonic

180 Hz

1/60th sec

The pure power we receive (i.e. 60 Hz) is our fundamental power, sometimes referred to as the fundamental or first order
harmonic. Switch-mode power supplies have the ability to generate their own sine waves, which are multiples of the
fundamental, then feed them back onto the source power. This occurs because non-linear devices require current only
during part of a cycle. Second order harmonics on a 60 Hz system run at 120 Hz, third order 180 Hz, fourth order 240
Hz, fifth order 300 Hz, etc. Although there are more of them, they are of a lesser magnitude.

Sum of 60 Hz & 180 Hz

4

360

As these harmonics are fed back onto the primary or fundamental power, the wave forms are added together, resulting in
a distortion of our power. Of prime importance are odd numbered harmonics as even numbered harmonics only result in a
shifting of the fundamental waveform, odd numbered harmonics result in a distortion. As more non-linear loads are added
to the system, waveform distortion becomes more pronounced.

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HARMONIC DISTORTION

60 Hz & 180 Hz & Sum

360

So why the problem? Simply put, if we looked at the harmonic distortion of voltage, the voltage supplied to a device would
now be lowered. Any device requires a certain amount of power to operate. Electrical power has two major components,
voltage and amperage, if the load does not receive enough voltage, it tries to compensate by drawing more amperage.
This harmonic current draw coupled with normal current draw results in increased heat, shortened life and other problems
such as tripping of overcurrent devices.

What impact does harmonics have on a system?

Harmonics, or the effects of them, can pop up in different areas of an electrical system causing problems and possible
damage. Most of the harmonic generating equipment out there are single phase devices. Problems occur when harmonics
are fed back upstream onto a three phase distribution system.
The majority of three phase 600-volt class transformers being used on standard distribution systems have a delta
connected primary and a wye connected secondary. When harmonics reach the wye connected output one of these
transformers, the odd numbered, non-multiple of third harmonics begin to cancel themselves as they are out of phase
with one another. The more the system is balanced with harmonic producing loads, the more effective the cancellation
will be. The odd numbered, multiple of third harmonics... called triplens, are in phase with one another and pass from the
transformer secondary directly into the delta primary winding with little to no opposition.
Triplen harmonics trapped in the primary windings exhibit themselves as circulating currents causing transformers to run
above normal operating temperatures. The transformer appears to be overloaded even though checks on the loads show
it is not. Transformers are not the only targets. Any delta circuits in the distribution system are potential problem areas and
could exhibit overheating, motors are one example.

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MAINTAINING POWER QUALITY

WITH MORE ELECTRONIC DEVICES

Wye connected loads are supposed to be nearly balanced between the phases of a three phase transformer. Without
harmonics, the current flow in the neutral is insignificant. Even with the load currents unbalanced as is shown in the
following diagram, the neutral conductor rarely carries current more than one third the phase conductor current triplen.
Harmonics on the system changes the situation significantly. This neutral current could now be nearly twice the value of
the load current. Since the neutral is not over current protected, per NEC this excessive neutral current can cause wire
insulation to fail and in extreme cases even cause fires. The increase in harmonics is directly tied to the increased use of
electronics. Switch-mode power supply technology has made electronics affordable and desirable in the workplace. Desk
top computers, data processors, AC motor drives, copiers, fax machines, lighting ballasts, etc. have dramatically changed
our working environment. Electronic devices are regulated under IEEE specification 519, which limits the amount of
garbage that can be put back onto the line. Each device in itself does not produce enormous amounts of harmonics but
the rapid increase in the number of devices has produced the problems we see today.

figure 1
*Balanced Linear Loads

Balanced Non-Linear Loads

MAX

MAX

MAX

MAX
B
A
C

* *

MAX

MAX
Neutral Current = MAX x 1.73

Neutral Current = Zero AMPS

6
What happens to the transformers?
As we said earlier, the triplen harmonics take up residence in the first delta they can find in the distribution system, quite
frequently it is in the primary delta circuit of a transformer.
If the harmonic currents were evenly dispersed within a conductor, the quick and easy solution would be to utilize a
larger transformer. Unfortunately the harmonic currents remain on the conductor surface, a condition referred to as skin
effect. These harmonic currents result in excessive transformer heating, a breakdown in the transformers insulation and
eventually transformer failure. As the harmonic currents are coming from the load, the transformer will not be drawing
more from the supply side of the system. A transformer can fail even though the current the transformer draws from
the service appears to be well within the capacity of the unit. The good news is that the delta circuit of the transformer
contains the harmonics and prevents them from going further upstream.

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ACME ELECTRIC

HARMONIC MITIGATING TRANSFORMERS

The ultimate solution lies in the utilization of Acme Electric Harmonic Mitigating Transformers. Acme combines a unique
winding style construction with a special secondary winding connection to not only deal with harmonics but effectively
cancel triplen harmonics. The more balanced the system with harmonic devices and the more heavily loaded, the more
effective Acmes Harmonic Mitigating Transformers will be.

Industry leading technology - foil strip winding construction

The excess heating caused by harmonic currents in a transformers delta circuit can be eliminated by increasing the
amount of conductor surface or skin to promote more efficient cooling. Just increasing the size of the conductor wont
solve the problems. If we were to double the size of a wire, we would see that the cross sectional area grows at a much
more rapid rate than the wires circumference. To combat this situation, some manufacturers have gone to multiple parallel
conductors. By doing this, they can keep the cross sectional area of the conductor in check but increase the surface area.
It is effective but creates manufacturing challenges in trying to keep each of the single conductors the same length as
the others.
Most harmonic grade transformers are wound with insulated wire conductor. Acme electric uses foil conductor windings.
Utilizing a foil conductor does two very important things: maximize the conductor surface area for optimum cooling and
dramatically reducing voltage stress between winding layers. Instead of the multiple turns of wire per layer of winding, foil
winding has one turn. If a transformer design calls for 10 volts per turn, wire windings may contain ten 10-volt turns. If the
transformer had two layers of turns, the wire design would exhibit stresses of 200 volts (ten volts per turn times ten turns
times two layers).

layer
layer
layer

Wire conductor

layer

Axial height

turn
turn
turn
turn

Foil strip

Multiple turns per layer

One turn per layer

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THE ACME ADVANTAGE

FOIL STRIP WINDING CONSTRUCTION

With foil windings, one layer is a ten volt turn. The foil conductor design would exhibit stresses of 10 volts (one turn times
two layers). Since Acme Electric Harmonic Mitigating Transformers are foil wound, both the primary and secondary
windings can be wound to the same axial height, which greatly reduces eddy current losses. If the load current is 180
Hz (third harmonic current), eddy current losses will be nine times the square root of the third harmonic current. Acme
Harmonic Mitigating Transformers offer the best solution for combating harmonics associated with non-linear loads. These
foil wound transformers will, by nature, be smaller, more efficient, and have lower eddy current losses than their wire
wound counterparts.

Zig-Zag Secondary Winding Configuration

Conventional delta-to-wye constructed transformers are manufactured with one winding per phase on both the primary
and secondary circuits. Though a common style of manufacture, conventional one-winding-per- phase units encounter
problems when confronted with harmonics. Non-triplen harmonics are out of phase with one another and tend to cancel
at the wye connection of the transformer. The more balanced the harmonics are on the system, the more cancellation of
non-triplens will occur. Triplen harmonics, however, are in phase with our fundamental power and are coupled back into
the transformers primary circuit, resulting in circulating currents and overheating.
Acme Electric Harmonic Mitigating Transformers utilize a time proven zig-zag connection in the secondary circuit. This
construction results in a phase shift of the triplen harmonics, causing them to cancel one another. Rather than dealing
with harmonics, Acme Electric Harmonic Mitigating Transformers cancel triplen harmonics, and eliminate the overheating
and other problems associated with non-linear loads. This technology not only results in cooler operation and cleaner
power, but also provides a more energy efficient means of dealing with harmonic problems, than traditional non-linear or
K-rated transformers.

Diagram Showing Delta Primary & Zig-Zag Secondary

(zero degree angular displacement)
H2

X2

X0

H1

H3

X1

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X3

FEATURES & BENEFITS

AND APPLICATIONS

Features & Benefits

Unlike K-rated transformers, Acme Electric Harmonic
Mitigating Transformers actually treat the triplen

wound core
construction

zig-zag wye
secondary

ventilation
ducts for
cooler
operation

harmonics in the secondary windings; reduce supply

voltage flat topping caused by non-linear loads
Foil conductor to minimize skin effect
Electrostatically shielded for cleaner power
Improved overall power factor of supply system

foil wound
coils

Primary taps for voltage adjustment

Suitable for K-factor loads
220C insulation system, 150C temperature rise when
subjected to full nameplate load. Low temperature rise
models available upon request, consult factory
Superior energy efficiency meet NEMA TP -1 standards

vibration
isolation pads

low voltage
connections

at K-1 loading conditions

Copper conductor construction (aluminum
high voltage
connections

available upon request)

rigid tap
connections

9
Applications
Financial Facilities
Educational Facilities
Television Broadcast Facilities
Office Buildings
Hospitals
Health Care Facilities

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HARMONIC MITIGATING TRANSFORMERS

SPECIFICATIONS

480 Delta Primary Volts - 208Y/120 Secondary Volts

approx. dimensions

inches (cm.)
kva
catalog no.
height
width
depth
30.0
45.0
75.0
112.5
150.0
225.0

CMT-53312-4S 29.90 (75.9) 28.15 (71.5)

CMT-53313-4S 29.90 (75.9) 28.15 (71.5)
CMT-53314-4S 35.90 (91.2) 31.90 (81.0)
CMT-53315-4S 41.52 (105.5) 32.90 (83.6)
CMT-53316-4S 41.52 (105.5) 32.90 (83.6)
CMT-53317-4S 41.52 (105.5) 32.90 (83.6)

22.37 (56.8)
22.37 (56.8)
26.88 (68.3)
29.88 (75.9)
29.88 (75.9)
29.88 (75.9)

approx. type mtg. weather

wiring
ship weight w wall shield
diagram
lbs. (kg.) f floor
p/n design figure
535 (242.7)
600 (272.2)
760 (344.7)
1180 (535.2)
1340 (607.8)
1970 (893.6)

NEMA TP-1 compliant

F 1
F 1
F
F
F
F

WS-A-2
WS-A-2
WS-A-3
WS-A-4
WS-A-4
WS-A-4

81-E
81-E
81-E
81-E
81-E
81-E

* Consult factory for larger sizes.

Dimensional Drawing

Wiring Diagram
PRIMARY: 480 Volts Delta
SECONDARY: 208Y/120 Volts
TAPS: 2, 2% ANFC, 2, 2% BNFC
H2

H1
54 3 21

X1

10

Primary
Volts
504
492
480
468
456

X2

54 321

54 321

X3

Connect
Primary
Inter-
Lines To
Connect
H1, H2, H3
1
H1, H2, H3
2
H1, H2, H3
3
H1, H2, H3
4
H1, H2, H3
5

econdary Volts
S
208


120
1 phase

1

H3

Connect
Secondary
Lines To

X1, X2, X3
X1 to X0
X2 to X0
X3 to X0

Wall mounting bracket available, order PL-79912

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ACCESSORIES
BRACKETS & KITS
Accessories
Acme Electric is providing thermal switches and wall mounting brackets (where appropriate) with each Acme Harmonic
Mitigating Transformer. Surge Suppressors are available as optional equipment, contact factory for details.

Wall Mounting Brackets

Thermal Switch Kits

Required on:

Thermal switches are installed in the transformer

Ventilated Units:

winding ducts to detect abnormal temperatures. The

3, 30, and 75 KVA

thermal sensors are a normally closed contact that

Catalog Number: PL-79912

opens at 200C 10C and has a current capacity

of 5 amps @ 120V or 2.5 amps @ 240 volts. This
contact can activate any number of different types of
alarms or mechanisms that could warn of a potential
problem or failure. Catalog Number: PL-79900

11

COIL 1

COIL 3

COIL 2

CORE
BOTTOM OF CASE

KVA
30.0-
225.0

Mounting Position
bottom of
the case

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Illustration
figure 1

CLEANER POWER SOLUTIONS

FROM THE POWER QUALITY EXPERTS

Electrostatically Shielded Transformers

Computing equipment, process controllers and many
other microprocessor controlled devices are vulnerable to
damage or malfunction, when subjected to electrical
spikes or noise (transients). While the use of equipment
sensitive to transients is on the rise, the generation of
transients is also increasing.
Transients can be caused by lightning, switching surges
on the power network, operation of other loads at the
local site... especially start-stop motor operations,
switching of power factor correction capacitors and
welding operations. In fact, even operation of computer
devices such as disc drives or laser printers can contribute
to transient generation.
The increased usage of sophisticated electronic equipment has heightened the need for transient noise
suppression on power systems. Shielded winding isolation transformers fulfill this need and provide a strong
first line defense against power quality problems.
Acme Electric set the standard for the industry in providing electrostatic shielding on standard catalog
transformers at no additional charge and today manufactures the most inclusive line of 600-volt electrostatically
shielded transformers available in the market place. In sizes from 0.250 thru 1000 KVA, aluminum or copper

12

wound, energy efficient, NEMA TP-1 rated and low audible noise models, Acme Electric has the right
transformer for your application.

Shielded for
cleaner power

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UNIQUE POWER SOLUTIONS

FROM THE POWER QUALITY EXPERTS

Powerwise C3 Transformers
Acme Powerwise C3 transformers combine a K-13 rated
transformer with a higher efficiency design creating the
perfect solution of LEED and Green facilities. Acme
C3 transformers exceed the requirements of the US
Department of Energy Candidate Standardd Level (CSL)
3 and provide the lowest life cycle cost of any transformer
on the market. Through more efficient core material and
higher-grade electrical steel, losses are reduced and
performance is maximized. This can save you thousands
of dollars a year in energy costs; hundreds of thousands of
dollars over the life of an installation. For details visit
www.acmepowerdist.com/C3

Non-Linear Load
(K-Factor) Transformers
Non-linear loads generate high levels of harmonic
currents. When supplying power to these loads, a
special transformer design is necessary.
Acme Non-Linear Load Transformers utilize a foil wound
design to minimize eddy current losses generated by
harmonic currents. A double-sized neutral conductor
handles the excessive neutral currents found in nonlinear
load applications.
Available in sizes ranging from 15 thru 500 KVA, in all
common voltage combinations, aluminum or copper
wound, energy efficient low temperature rise or standard 150C rise. Acme Non-Linear Load Transformers are available
in K-Factor ratings of 4, 13 and 20, complete with electrostatic shielding at no additional charge.
When dealing with problems associated with harmonics on your distribution system, Acme Non-Linear Load Transformers
are an obvious choice to cleaner power. For details visit our website at www.acmepowerdist.com.

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13

SEVERE STRESS SOLUTIONS

FROM THE POWER QUALITY EXPERTS

Drive Isolation Transformers

Designed specifically to accommodate the special
voltages, KVA sizes and demands unique to AC and
DC motor drive applications. Acme Drive Isolation
Transformers incorporate strip conductors (above 7.5
KVA) to satisfy the severe electrical and mechanical
stress that can be found on motor drive systems.
Available in sizes ranging from 7.5 thru 880 KVA and in
all common voltage combinations. Acme Drive Isolation
Transformers come complete with electrostatic shielding
at no additional charge. For details visit our website at
www.acmepowerdist.com.

AC Line Reactors
Protect your equipment from harmful line disturbances
with Acme AC Line Reactors. Acme AC Line Reactors
help prevent equipment failure and downtime, and can
add years to the life of your equipment.
Designed to reduce or eliminate most line anamolies,

14

Acme AC Line Reactors protect against typical problems

like nuisance tripping of fuses and/or circuit breakers
(caused by DC bus overvoltage), inverter overcurrent and
overvoltage, harmonic distortion (resulting in poor total
power factor), line notching, etc.
Available in sizes ranging from 2 amp to 600 amp, in
standard 3% or 5% impedance versions, in a panel mount core & coil design or an epoxy encapsulated design (2 amp to
160 amp) for out of panel use, Acme AC Line Reactors can be used to provide both line and load power quality protection
for a wide range of applications. For details visit our website at www.acmepowerdist.com.

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CONSTANT VOLTAGE REGULATORS

FROM THE POWER QUALITY EXPERTS

Constant Voltage Regulators

Acme Constant Voltage Regulators consist of a leakage
reactance ferroresonant transformer, equipped with
additional pair of magnetic shunts and a filtered winding.
Together they develop a regulated low distortion sinusoidal
output. The second pair of shunts and the filter winding
soften the secondary core saturation effect, cancelling
the harmonic voltages that are present in conventional
constant voltage transformers.
Typical ferroresonant transformers have an input limited to
100-130 volts. Acme CVRs have an input range of + 10%/20% around nominal input voltages of 120, 208, 240 and
480 volts. At a 120 volt input, this relates to 95 to 132 volts.
Typical ferroresonant transformers have an audible hum that can be objectionable in most offices. Acme CVRs are epoxy
encapsulated to lower audible sound to acceptable levels.
Typical ferroresonant transformers have limited electrical noise suppression capability. Acme CVRs have the ability to
attenuate common mode noise by 120 db and transverse mode noise by 60 db. Typical constant voltage products have an
output regulation of 3% for input line changes only. Acme CVRs have an output regulation of 3% for input line and load
changes, making them suitable for operation at any load condition.
Available in sizes ranging from 250 VA thru 15 KVA, Acme CVRs feature a sinusoidal output with less than 3% harmonic
distortion improving input wave forms which have a total harmonic distortion greater than 5%, have a hold up time of
3 msec for complete loss of power, inherent overload and short circuit protection without thermal protectors or fuses or
circuit breakers and are UL listed and CSA certified. Acme CVRs truly are designed specifically for applications requiring
precise voltage regulation and excellent transient suppression. For details visit our website at www.acmepowerdist.com.

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15

Acme Electric The First Name in Power Solutions Since 1918, Acme Electric has been providing the
most reliable and efficient power solutions available. Headquartered in Lumberton, North Carolina, Acme
Electric has over 175,000 square feet of manufacturing in two plants: a 130,000 sq. ft. facility in Lumberton
and a 45,000 sq. ft. facility in Monterrey, Mexico. Our North American facilities are ISO 9001-2000 certified.

4815 West Fifth Street Lumberton, NC 28358

(910) 738-1121 Inside NC (800) 334-5214 Outside NC (910) 739-0024 Fax
ACM_BRO_002_0210

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