Sherwin-Williams New Ohio Facility
Solving a Voltage Mismatch with Buck/Boost Transformers

Industry: Paint & Coatings Manufacturing

Location: New construction facility - Ohio

Challenge: 208V utility service; equipment required 240V three-phase and single-phase

Solution: Buck/boost transformers configured to boost 208V to 240V

The Challenge: Utility Voltage Didn't Match Equipment Requirements

When Sherwin-Williams began construction on a new manufacturing facility in Ohio, the project engineers identified a voltage problem before the first piece of equipment was installed.

The local utility delivered 208V three-phase power to the site. A standard commercial voltage found across much of the country. But the specialty equipment selected for this facility required 240V three-phase and 240V single-phase to operate correctly.

This wasn't a case where the equipment could tolerate running at a slightly lower voltage. The machines featured sensitive motors whose performance depended on receiving precise voltage. Operating them at 208V instead of 240V would cause reduced motor torque, inconsistent output, overheating risks, and premature equipment failure.

To make matters worse, the specialty equipment was purpose-built. It simply wasn't available in a 208V configuration. The machines were engineered for 240V. No alternative existed.

Why Couldn't They Just Use 208V?

The difference between 208V and 240V may sound small, but it represents a roughly 15% voltage gap. For sensitive motor-driven equipment, that gap creates real problems:

• Reduced torque: Motors produce less mechanical force, meaning equipment can't perform at rated capacity

• Overheating: Motors draw more current to compensate for lower voltage, generating excess heat

• Shortened lifespan: Chronic undervoltage wears out motors faster, driving up maintenance and replacement costs

• Inconsistent performance: Product quality suffers when machinery can't deliver the precision it was designed for

For a company that stakes its reputation on consistency and quality, none of these outcomes were acceptable.

The Solution: Buck/Boost Transformers

The engineering team specified buck/boost transformers, compact autotransformers designed specifically to correct minor voltage differences between a power source and connected equipment.

Buck/boost transformers work by adding (boosting) or subtracting (bucking) a small amount of voltage to align the supply with equipment requirements. In this case, they were configured to boost the incoming 208V to the 240V the equipment demanded.

Why Buck/Boost Transformers Were the Right Choice

Precise voltage correction. The 208V-to-240V boost falls well within the standard operating range for buck/boost transformers. The output is stable and consistent. Exactly what sensitive motors require.

Compact size and lower cost. Because buck/boost transformers operate as autotransformers. Only transforming the voltage difference, not the full load. They are significantly smaller, lighter, and more affordable than full isolation transformers rated for the same power capacity.

Three-phase and single-phase flexibility. The Sherwin-Williams facility needed both three-phase and single-phase 240V circuits. Buck/boost transformers can be wired for either configuration, giving the engineering team one consistent solution for every piece of equipment on site.

Built for permanent installation. Buck/boost transformers are UL-listed and designed for permanent installation. For new construction, this meant the transformers were integrated directly into the facility's electrical distribution plan. Clean, code-compliant, and easy to maintain.

The Results

With buck/boost transformers installed throughout the facility, every piece of specialty equipment came online at the correct operating voltage from day one.

• Motors operated at rated voltage: full torque, proper speed, no overheating

• Equipment lifespan was protected: no stress from chronic undervoltage

• Product quality remained consistent: machinery performed exactly as engineered

• Installation was clean and permanent: integrated into the original electrical design

• No utility upgrades were needed: the existing 208V three-phase service stayed in place, avoiding significant cost and schedule delays

The engineers planned for the voltage mismatch during the design phase rather than discovering it after equipment was installed. That proactive approach eliminated downtime and retrofit costs entirely.

Why Voltage Mismatches Happen in New Construction

Voltage mismatches between utility service and equipment requirements are among the most common electrical challenges in commercial and industrial construction. They happen because:

1. Utility voltage varies by region. What the local utility provides (208V, 240V, 277V, 480V) depends on the area and the type of service available

2. Equipment manufacturers standardize on specific voltages. Specialty machinery is often built for 240V, 460V, or other voltages that may not match the local supply.

3. Engineers know this in advance. On well-planned projects, the mismatch is identified during design and solved before construction. Exactly what happened at this Sherwin-Williams facility.

Buck/boost transformers are the standard solution for these mismatches when the voltage difference is within approximately 20%.

Frequently Asked Questions

What is a buck/boost transformer?

A buck/boost transformer is a small, efficient transformer used to raise (boost) or lower (buck) voltage by a small amount. It is commonly used to correct voltage mismatches between utility power and equipment requirements in commercial and industrial settings.

Can a buck/boost transformer convert 208V to 240V?

Yes. Boosting 208V to 240V is one of the most common applications for buck/boost transformers. The approximately 15% voltage increase falls within the standard operating range of these units.

Why not just ask the utility for 240V service?

Changing utility service voltage is expensive, time-consuming, and often not possible depending on the local utility's infrastructure. Buck/boost transformers solve the same problem at a fraction of the cost and can be installed as part of the building's electrical system.

Are buck/boost transformers a permanent solution?

Yes. Buck/boost transformers are UL-listed and designed for permanent installation. They are not temporary fixes. They are standard electrical equipment used in thousands of commercial and industrial facilities.

What happens if you run 240V equipment on 208V without correction?

The equipment will underperform. Motors produce less torque, draw excess current, overheat, and fail prematurely. Sensitive equipment may not function at all. Running equipment at the wrong voltage also voids most manufacturer warranties.

Key Takeaways

• 208V utility service and 240V equipment are frequently mismatched in commercial and industrial construction. This is one of the most common applications for buck/boost transformers

• Sensitive motors require exact voltage to deliver rated performance, efficiency, and full service life

• Buck/boost transformers provide a permanent, code-compliant solution that is more compact and cost-effective than full isolation transformers

• Planning for voltage correction during the design phase prevents costly retrofits and equipment downtime after construction

Buck/boost transformers are a proven solution for voltage correction in commercial and industrial facilities. To learn more about solving voltage mismatch challenges in your next project, contact Sanzo Sales.