Isolation transformer downstream of a UPS causes catastrophic damage

In data centers it is is common practice to install an isolation transformer between

the UPS and the IT equipment. This is because modern transformerless UPSs have
a common neutral connection and electrical noise on the input neutral could affect
the critical IT loads. The isolation transformer provides galvanic isolation between
the UPS input neutral and the IT load neutral.

A recent investigation at an insurance company data center showed up the dangers

of installing an isolation transformer downstream of a UPS. In this case a minor
fault led to the UPS switching from normal, inverter mode to static-bypass mode.
However, there was poor discrimination upstream of the UPS and the supply circuit
breaker feeding the UPS tripped. This resulted in the magnetizing current feeding
the isolation transformer being instantly cut off. This instant cessation of
magnetizing current acted rather like the ignition coil of a petrol engine and
generated a huge voltage across the UPS output. Judging by the damage to the UPS
static switch, UPS inverter and other UPS components the voltage was in the region
of 10,000 to 20,000 volts.

Whilst UPS suppliers will say that isolation transformers are unnecessary or that the
UPS can survive a temporary loss of neutral as occurs when there is an auto
change-over from mains to standby generator, the most secure design uses an
isolation transformer in the bypass feed upstream of the UPS. In normal mode
when the UPS is running on the rectifier and inverter, the rectifier input circuit is a
delta configuration and does not need a supply neutral. With this scheme there is no
connection between the incoming supply neutral and the UPS output neutral.
Neutral earth links will be required as shown.

The diagram shows the preferred arrangement for data center UPSs
Why install a Bypass Isolation Transformer?
When generators are installed, it is common to use four pole changeover switchgear or
contactors when transferring from mains to generator, resulting in the traditional neutral-
earth reference being lost during transition. This can cause the phase voltages to rise
alarmingly and any sensitive single phase loads could be damaged. By adding a bypass
isolation transformer it allows the electrical contractor to earth the UPS output neutral,
thereby eliminating this problem. Single phase bypass transformers are also installed on
small systems where the client requires the UPS output neutral to be earthed.

Transformer Isolation
July 31, 2015 by Marie Christiano

Electrical isolation is necessary to protect circuits, equipment, and

people from shocks and short circuits.
Recommended Level
Beginner

Introduction
Electrical isolation is necessary to protect circuits, equipment, and people from shocks and
short circuits as well as to make accurate measurements. Isolation, also referred to as galvanic
isolation, means no direct conduction path exists for the current to flow; no physical
connection exists. Isolation can be accomplished using electromagnetic, capacitive, or optical
devices. While physically and electrically isolating the circuitry from unwanted currents,
required signals and power need to be transferred across the separated circuits. To transfer
signals, transformers use magnetic flux, capacitive isolators use differential voltage and
optocouplers use light to bridge the gap. This article discusses the use of isolation
transformers.

Why Isolation?
Isolation transformers are used to:
*protect users from faulty equipment
*enable safe and accurate measurements
*avoid ground loops
*physically separate one part of an electrical system from another
Let's look at setups where isolation is needed and how it can be provided using an isolation
transformer:
Figure 1. shows how a measurement might be taken across Z1 at Test Points TP1 and TP2,
attempting to measure the voltage across impedance Z1. TP1 and TP2 are part of the
generator circuit; the generator ground, the oscilloscope ground and oscilloscope probe ground
are all in common. The cable shield (ground) of the oscilloscope probe is tied to ground via
the oscilloscope's chassis (which you can verify with an ohmmeter.) With the oscilloscope
probe connected at TP1 and the oscilloscope probe ground connected at TP2 as shown, Z2 is
shorted out of the circuit when the probe ground provides an alternate path to ground. This
means 1) the measurement of v1 is not accurate, and 2) if Z2 was the current limiting
impedance, the current through Z1 could rise to a dangerous level and damage the circuit. A
person, standing on a grounded floor, accidentally touching the circuit at TP2 would have the
same shorting effect (and feel it).
Fig. 1 Grounding at aTest Point
 Fig. 2 Isolated Test Point
The circuit in Figure 2 uses an isolation transformer. Powered through the isolation
transformer, the circuit with Z1 and Z2 no longer shares earth ground with the generator and
oscilloscope. Now connecting the test probe at TP1 and the probe ground at TP2 does not
complete a circuit and voltage v1 can be measured accurately. An isolated circuit is a live
circuit and when using grounded probes, you still need to be aware of the circuit(s) you are
working on and that the probes are not connected in a way that creates a ground loop within
the isolated circuit.
In plumbing, you sometimes hear of hot water coming out of cold water faucets, even though
there's not supposed to be a connection. Somewhere in the water pipe connections, there was a
common point where a crossover happened. The same surprising results can happen in an
electric circuit where an unintentional ground is introduced. It's not supposed to happen, but a
common point to ground was introduced. Knowing the circuit, using isolation transformers
where there a ground could be introduced, following safe working procedures, all work
to reduce unexpected results.
Sometimes the term isolation transformer is applied to transformers that isolate AC
spikes, transients and noise, but maintain an earth ground connection. This type of transformer
would not provide electrical isolation. You should verify the transformer you are using does
provide electrically isolated outputs and doesn't supply an earth ground; check there is no
continuity between the primary and secondary. If the transformer has a inter-winding screen,
the screen should be connected to earth ground; also it's common practice to connect the
transformer frame to earth ground as well.
When equipment under test is powered by an isolating transformer, its ground (equipment
ground) is separated from earth ground; the transformer isolates the device under test from the
common supply ground. A person working on the equipment (standing at earth ground) can't
accidentally provide a path to ground should they make contact with the circuit. This makes
the set up safer for users, eliminating the possibility of a shock. Should they touch a live part
of the circuit by accident, there's no conductive connection to earth ground.

Before ground fault circuit interrupter (GFCI) receptacles became 'code', consumer products
included isolation transformers and hotels had 'razors-only' sockets incorporating an isolation
transformer. The razor-only socket provided protection if a razor fell into the water or if
someone touched a conducting surface (like a wet faucet) while holding it. The isolation
transformer in the socket prevented current flow thru the user's body.
An isolation transformer can also be used to physically separate portions of an electrical
system. It would be dangerous to try to meter high voltage lines, where the voltages could be
above 30,000 V. You would risk making contact while trying to connect a measuring device.
By including an isolation transformer as part of the design, the voltage can be stepped down
to a lower voltage in the meter's range, as shown in Figure 3.
 Fig. 3 Step-Down Transformer used to meter High Voltage Line

In this case, a step-down isolation transformer is needed. The step-down ratio is determined by
the formula:

Ep(volts)Es(volts)=NpNsEp(volts)Es(volts)=NpNs
where, Ep is the primary voltage
Es is the secondary voltage
Np is the number of turns in the primary
Ns the number of turns in the secondary
Note:

NpNs=aNpNs=a
, the transformation ratio.
If the voltage was 30,000 volts, a step-down transformer with a = 300 would give a voltage of
100 volts, which could be safely measured.

Isolation Transformer Construction

Transformers can be described as two coils surrounding a core of ferromagnetic material, as
shown in Figure 4.
Fig. 4 Transformer
The schematic representation shows the primary and secondary coils; the electric source is
connected to the primary, the isolated output is taken from the secondary. The coils are
physically separate from each other and the core. Michael Faraday first used an early
transformer during his experiments investigating electromagnetism. Faraday found that a wire
carrying a current induces a magnetic field surrounding the wire and that when two separate
wires were coiled around a toroid of soft iron, a current in one induced a magnetic field, and
the changing flux in turn induced a voltage in the other. Now known as mutual induction,
Faraday is credited with discovering that an electromotive force is induced in a circuit by a
changing magnetic flux according to the formula:

E=dBdtE=dBdt
.
Sometimes this is shown using the absolute value of E:

|E|=dBdt|E|=dBdt
. The negative indicating the electromotive force opposes the current.
Because Faraday was working with DC voltage, he only saw the effect of electromagnetic
induction when a battery was initially connected or disconnected to the circuits, when the
magnetic flux was changing. With AC power connected to the primary, the varying current
creates a varying magnetic field, the magnetic flux is realized in the core, and that in turn
induces a voltage the secondary, with no electrical path between the two coils. The inductive
coupling provided by the changing magnetic flux between the two coils allows communication
across transformer. The magnetic field induced by a transformer depends on the number of
turns/unit length of the windings, the permittivity of the magnetic core, and the current
magnitude. The first commercially viable transformer was invented by William Stanley,
working for George Westinghouse in the 1880s.
Although any transformer consisting of two separate coils and no grounding
shields provide isolation, the term isolation transformer applies to transformers especially
designed for the purpose of providing electrical isolation; whose primary purpose is to isolate
an AC source from circuits, devices and equipment. The design of an isolation transformer
takes into account anything that may couple the primary and secondary windings. They often
have special insulation between the primary and secondary coils, and are specified to
withstand high voltage between windings. Because power line/transient voltage noise can be
coupled thru the capacitance and resistive paths of the coils, isolation transformers have
additional features to reduce common-mode noise (occurring on both the hot and neutral wires
referenced to ground), transverse mode noise ( occurring between the hot and neutral wires)
and electromagnetic noise. DC signals are blocked by the transformer as well as interference
caused by ground loops. For sensitive equipment ( computers or measuring instruments )
electrostatic shields are included to reduce any capacitance between the windings.
Isolation transformers used for safety usually have a turns ration of 1:1, with the number turns
in the primary and secondary windings equal, but step-up and step-down isolation
transformers are used when the voltage also needs to be changed. When choosing an isolation
transformer, check the specs for the features included, the ratings and how they are
constructed.

Special Purpose Isolation Transformers

Isolation transformers have been developed for specialized applications. Some examples are:
Pulse transformers: optimized for transmitting rectangular electrical pulses and provide
electrical isolation for digital signals. These are used in computer networks.
Austin transformers: invented by Arthur O. Austin, these power the air-traffic obstacle lamps
you see on an antenna structures. If not isolated, the lighting circuitry on the antenna mast
would conduct radio-frequency energy to ground. These transformers also completely isolate
the building AC mains from the tower.
Instrument transformers: to supply precise voltage for meters and are used to safely isolate
control circuitry from high voltages/currents. The primary winding of the transformer is
connected to the high voltage/current circuit and the meter is connected to the secondary
circuit much like the connections shown in Figure 3.
Note: Some transformers are made with only one winding which is tapped at different places
on the winding to divide it into primary and secondary portions. Known as auto-transformers,
these devices do not provide isolation, as the single winding is shared. Isolation transformers
have separate coils, with no physical connection between the coils, no earth ground.

Safety Always
Isolation transformers make working on AC equipment safer and can protect against
unintentionally introducing shorts in the circuit. Working on the principle of mutual induction,
they are used to break ground loops and remove unintended current paths where accidental
contact could cause problems. When choosing an isolation transformer, select one with
appropriate ratings and specs for your requirements.
The isolated circuit is still a live circuit! When using an isolation transformer, whether
powering the unit under test or an oscilloscope or other equipment, knowing the ground(s) in
use; checking voltages and current in your work area and your circuit, following all safety
measures, are still required!

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ISOLATION TRANSFORMER SAFETY ELECTRONIC ISOLATION

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Why isolation transformer is used at the output of online

UPS?
Saturday, July 25, 2015

An isolation transformer is a transformer used to transfer electrical power from a source of

alternating current (AC) power to some equipment or device while isolating the powered device
from the power source, usually for safety reasons.

What this means in reality is that a normal application for an isolation transformer is to either
keep the load from generating harmful harmonics back onto the distribution bus, or to keep
harmonics already on the bus from continuing downstream to sensitive loads.

All UPS systems are "online": that means they are sampling the incoming waveform and acting
upon it to provide "clean" power at the output. For the double-conversion UPS units, which are
like mini-AC drives coupled back-to-back across a small internal DC bus.
If the transformer is intended to isolate downstream loads (below the UPS itself) from potential
harm originating at the distribution bus, then the bypass connection would have to be examined
closely. In most cases, the bypass basically provides an alternate path directly to the load. This
means that in bypass mode (with a downstream of the UPS iso-XFR), there is a good chance that
anything on the bus will appear at the load with no mitigation. If the iso-XFR is between the bus
and the UPS, then anything generated by UPS or load is isolated from the bus, and anything on
the bus is isolated from load - even in bypass mode.

There are several reasons why an isolation transformer is used.

1. The UPS supply may be on a high resistance grounding system and the loads require
solid grounding.

2. The output of the UPS may be at a different voltage than the loads.

3. Used to limit the fault current for downstream equipment.

4. If a voltage transformation is required, having the transformer external to the UPS system
makes isolating the UPS for maintenance easier.

Most importantly as a step down/up voltage converter - but strictly speaking they are not
necessarily "isolation" class. The only real disadvantages I can see would cost (not always more
expensive) and space requirements which are typically outweighed by the advantages.

Most commonly isolation transformers are used where there are very sensitive instruments that
need protection from the "noise" on the grid. The classic examples are heart monitors in hospitals
and other hospital life monitors. The monitor is usually plugged directly into the isolation
transformers before even connecting to the UPS. Since probably 95% of UPS units are the "buck
and boost" type with the battery floating in parallel to the rectifier inverter connection rather than
in series between the rectifier and inverter the UPS grounding makes the unit useless for
isolation of harmonics. In a good many states it is a code violation in "critical infrastructure" to
have continuity of ground conductors. If you need grounding on the critical side you use a
separate earth ground. Good example is the old Mission Control Center at Johnson Manned
Spacecraft Center. Everything had to be isolated in order to qualify for "Manned Rated" space
flight. Some equipment was vacuum tube because solid state was too primitive in those days.
Even the substation on the HL&P grid serving JMSC had special grounding and circuit routing.
Tags: Transformer , UPS , FAQ , AC Power Source
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