LESSON NOTES

Isolation Transformers

CHAPTER 1: WHAT IS THE PRINCIPLE BEHIND ISOLATION TRANSFORMERS?

This chapter will explore the operation, design, and customization of isolation transformers, as well
as the key factors to consider when selecting one.

WHAT ARE ISOLATION TRANSFORMERS?

An isolation transformer is a stationary device designed to separate primary and secondary

windings, ensuring physical and electrical isolation between circuits. It transfers electrical energy through
magnetic induction, using a magnetic field to induce an electromotive force (EMF) in a secondary circuit while
maintaining the original frequency.

In transmission and distribution systems, isolation transformers are employed to adjust voltage
levels by stepping up or down, ensuring that voltage and current capacities match between the coils. A crucial
role of these transformers is to mitigate voltage spikes in supply lines, which could otherwise disrupt service
or damage equipment if they reach the load.

When placed between power supply lines, an isolation transformer helps diminish voltage spikes
before they impact the load. Additionally, it prevents grounding issues on the secondary side, thereby
reducing ground loop interference and minimizing noise e ects in the load equipment.
 An isolation transformer ensures electrical isolation between its primary and secondary coil
circuits. This design allows for the safe transfer of electrical power from an alternating current (AC) source to
equipment or devices while keeping the equipment electrically separate from the power source. This isolation
is primarily used for safety purposes or to reduce electrical transients and harmonics. Typically, in step-up
transformers, the secondary coil has more turns than the primary coil, whereas, in step-down transformers,
the primary coil has more turns than the secondary coil.

Isolation transformers adjust voltage output by altering the voltage input according to the required
voltage, current, and turns ratio. In single-phase AC systems, voltage fluctuations occur simultaneously,
making it less suitable for powering large motors and industrial machinery. In contrast, three-phase power
uses three distinct signals, each with a separate peak time, which helps to eliminate the oscillations present
in single-phase systems. This results in smoother operation, reduced vibration, and simplified equipment
design, making three-phase electricity more e ective for powering large motors and heavy industrial
equipment.
FUNCTION OF AN ISOLATION TRANSFORMER

An isolation transformer serves to physically and electrically separate two circuits, o ering
protection from mains electrical shock to both electronic circuits and individuals. It utilizes magnetic coupling
to transfer electrical energy from the primary to the secondary side.

The primary function of an isolation transformer is to mitigate voltage spikes in the supply lines.
Voltage spikes, which can be caused by illumination, static electricity, or sudden changes in voltage, are brief
increases in voltage levels that last for a short duration (typically 3 nanoseconds or more). The isolation
transformer helps to reduce these spikes and protect connected equipment from potential damage.

Voltage spikes can carry extremely high voltages, ranging from a few to several thousand volts. If
these high voltage spikes reach the load, they could lead to service disruptions or cause damage to the
equipment. By installing an isolation transformer between the power supply lines, these spikes can be
significantly reduced before they impact the load.

When a high-voltage spike with fast changes occurs on the primary side of the isolation transformer
(the supply side), the transformer handles it as follows: The spike, which passes through the primary winding,
is resisted by the inductor. This resistance results in an exponential rather than an instantaneous shift in
current. As the current increases, the flux rises, which in turn increases the voltage on the secondary side.

The inductive properties of both the primary and secondary windings prevent the spike from
transferring directly to the secondary side. The resistance to current flow increases with the rate of change,
meaning that because a voltage spike involves rapid changes, the generated resistance is also higher.
Consequently, the spike's impact on the secondary or load circuit is significantly reduced, protecting the load
equipment from potential damage.

Additionally, an isolation transformer prevents the grounding of load equipment or the secondary
side, eliminating ground loop interference and noise e ects. This feature makes isolation transformers
essential for protecting sensitive equipment in various applications, including measurements, laboratories,
and medical devices, from voltage spikes, ground loops, and other power line distortions.

An isolation transformer is constructed similarly to a standard core-type transformer, but with

additional features. It incorporates electrostatic shields that completely separate the secondary winding from
the primary winding, e ectively suppressing noise and interference. Unlike isolation transformers,
autotransformers—where the primary and secondary windings are electrically connected—cannot provide
the same level of isolation. This is because autotransformers lack the necessary physical separation between
the windings, which is crucial for true isolation.

DESIGN AND CUSTOMIZATION OF ISOLATION TRANSFORMERS

An isolation transformer can also come in a toroidal, or donut-shaped, configuration. Toroidal

transformers o er several advantages, such as their compact size and lightweight design, making them
suitable for a variety of applications. The windings in a toroidal transformer are distributed evenly around the
core, which passes through its center. The core itself can be made from materials like silicon iron or nickel-
iron alloys, contributing to the transformer’s e iciency and performance.
 For higher frequency applications, amorphous alloys and iron powder are better alternatives for the
core material. Additionally, toroidal transformers can reduce audible noise and stray field radiation. Toroidal
isolation transformers can be fitted with a metal band to further limit stray magnetic fields. An isolation
transformer may have extra insulation for equipment like patient monitoring systems that don't allow much
room for interference.
CHAPTER 2: WHAT ARE THE DIFFERENT TYPES OF ISOLATION TRANSFORMERS?

Various kinds of isolation transformers are available, including:

ULTRA ISOLATION TRANSFORMER

The ultra isolation transformer features a distinct design that eradicates various forms of electrical
interference, especially common mode noise. By isolating the primary and secondary sides and providing a
neutral ground on the secondary side, it helps create a separate power source to address current loops. It
e ectively diminishes transverse mode noise and reduces common mode noise through the use of advanced
insulating materials and specialized shielding methods.
 Ultra isolation transformers are designed for critical and sensitive equipment such as computers,
medical devices, digital communication systems, CNC machinery, and more. They mitigate disturbances
caused by noisy equipment that can interfere with the power supply. These transformers are specified with
high voltage ratings between 1000 to 4000 volts between their windings and are equipped with robust
insulation separating the primary and secondary sides.

These transformers are particularly beneficial for wireless communication stations and advanced
medical devices. They feature low coupling capacitance and are built with advanced shielding techniques to
ensure high noise attenuation. Their sophisticated design ensures they are highly e ective, durable, and
suitable for various operating voltages.

CONSTANT VOLTAGE TRANSFORMER

The constant voltage transformer (CVT), which employs ferroresonant technology, is a 1:1
transformer that operates at a high point on its saturation curve. It provides an output voltage that remains
largely una ected by variations in the input voltage. The CVT uses a tank circuit consisting of a high-voltage
resonant winding and a capacitor to transform a variable input into a nearly stable average output. Typically,
the input winding functions at relatively low flux linkage levels.
 The output winding features inherent energy storage that, in conjunction with the primary capacitor,
generates a self-contained AC flux field that is somewhat isolated from the input winding. Unlike traditional
stabilizers, the CVT does not use relays that could briefly interrupt the output voltage, making it a preferred
choice. The CVT provides comprehensive protection against voltage spikes by maintaining a regulated output
voltage.

GALVANIC ISOLATION TRANSFORMER

Galvanic isolation in electrical systems involves the physical and electrical separation between the
input and output power circuits. This is typically achieved using an isolation transformer, which ensures that
the output power wiring remains completely separated from the input wiring. Personal computers already
incorporate galvanic isolation between their power supply and internal logic circuits as mandated by
international safety standards to minimize shock hazards. Thus, adding an additional transformer for this
purpose is generally unnecessary.

While galvanic isolation is often believed to address noise on the ground (earth) wire, in reality,
isolation transformers only separate the power wires and do not a ect the ground wire, which continues to
pass through without obstruction. Although some uninterruptible power supply (UPS) systems provide
galvanic isolation, many online UPS models do not. For example, the online UPS systems from Exide, Unison,
and ON-LINE (Pheonixtec) do not feature galvanic isolation.
 Isolation is a feature that can be incorporated into any UPS system, regardless of its type. The main
benefit of adding an isolation transformer is the substantial reduction of common mode noise a ecting the
computer. Noise filters, such as those available in the APC Smart-UPS series, can also reduce common mode
noise e ectively. These filters can be as e icient as isolation transformers, especially at high frequencies
where computers and networks operate. However, isolation transformers tend to be more e ective at very low
(audio) frequencies.

Audio frequency noise on the power line generally does not a ect computers or their peripherals,
meaning that in such applications, an isolation transformer o ers no additional benefit compared to filters.
Additionally, isolation transformers can generate extra heat, which may shorten the lifespan of nearby UPS
batteries. Another consideration is that incorporating an isolation transformer adds significant weight to the
UPS system.
Drive Isolation Transformers

Drive isolation transformers supply power for both AC and DC variable frequency drives by shifting
the voltage to the required level for SCR (Silicon Controlled Rectifier) Drives, while providing magnetic
isolation between the incoming power line and the motor drive. SCR drives demand strong mechanical and
electrical design and testing due to the mechanical stresses, voltage distortions, and harmonics they
generate. While various types of motor drives exist, they all share a common requirement: incoming power
must be rectified to achieve a DC level.

The motor drive converts power through an AC-DC-AC to AC-DC process using a three-phase
rectifier bridge and an SCR. This conversion generates electrical noise and harmonics, which can be
particularly problematic for transformers used in isolation drive applications, as they can cause significant
heating and mechanical stress at higher frequencies. Drive isolation transformers are specifically designed to
withstand the thermal, voltage, and mechanical stresses associated with motor drives. They help mitigate
issues like motor bearing currents, line-to-ground voltage transients, and other noise problems caused by
common-mode voltages.
 Grounding the secondary side of the transformer can e ectively eliminate common-mode noise,
thereby enhancing both system reliability and safety. Delta-wye drive isolation transformers are capable of
establishing a ground reference on the secondary side. In a motor drive system, high-frequency currents often
return to the transformer winding, causing wave distortion on the line. These currents can significantly
increase eddy-current losses in the windings, which should be accounted for when selecting a new
transformer to ensure appropriate temperature rise calculations. Eaton's drive isolation transformers are
specifically designed to manage high-frequency currents, incorporating ThermoGuard protection within the
coils. This protection system alerts users to high temperatures that could otherwise reduce the transformer's
lifespan or lead to failure. ThermoGuard features a set of “N.O.” dry contacts to signal such conditions.

DRY ISOLATION TRANSFORMERS

Dry isolation transformers are encased in a sealed, pressurized container or epoxy resin, which
protects the core and windings. These transformers require minimal maintenance and are reliable, making
them ideal for applications where safety is critical, such as in schools, hospitals, factories, and the chemical
industry.

There are two main types of dry isolation transformers: cast resin and vacuum pressure. Cast resin
transformers have their windings encapsulated in epoxy resin for protection. Vacuum pressure transformers,
on the other hand, feature windings enclosed in a vacuum-sealed box with moisture protection to guard
against the e ects of moisture.
Some of the benefits of dry isolation transformers are:

 Changes voltages to match the load needs

 Protects electrical appliances by reducing power surges

 Blocks interference from ground loops

 Reduces noise

 Reduces earth leakage in wet locations

 Provides stable performance

 Low energy consumption

 High working e iciency

 Prevents electronic devices from polluting the power grid

Leading Isolation Transformers Manufacturers and Suppliers

 Triad Magnetics

 Hammond Power Solutions Inc.

 ELSCO Transformers

 Lenco Electronics, Inc.

 Jackson Transformer Company

CHAPTER 3: WHAT ARE THE CAUSES AND EFFECTS OF ELECTRICAL NOISE IN ISOLATION
TRANSFORMERS?

This chapter will explore the origins and impacts of electrical noise in isolation transformers, as
well as the maintenance practices associated with them.

Key factors contributing to electrical noise in isolation transformers include:

CAUSES OF ELECTRICAL NOISES IN ISOLATION TRANSFORMERS

 Changing electrical components such as capacitors, MCCBs, ACBs, etc. The magnitude of
electrical sounds increases with system inductance and current shift during switching.

 Significant switching noises are also produced by inductive loads such as large motors,
compressors, overhead cranes, elevators, presses, etc.

 Electrical noise is produced by switching thyristors, transistors, or relays or by switching

equipment like inverters, converters, SMPS, etc.

 Anomalies in power quality are caused by welding systems, which contaminate earthing
systems and alter waveforms by adding notches and high-frequency sounds.

 The natural causes of the production of diverse electrical noises include lightning, static
charge precipitation, and electrical discharges in the atmosphere.
EFFECTS OF ELECTRICAL NOISES IN ISOLATION TRANSFORMERS

 One can observe electrical noises across a large frequency range, from 1 KHz to 100 MHz
and above. On a three-phase supply system, a magnitude of up to 6000 volts was
measured.

 High-frequency noise can cause untraceable data mistakes, program changes, memory
loss, erratic behavior, etc., in digital electronic equipment.

 Thyristors or transistors, microprocessors, and other delicate equipment might malfunction

as a result of strong voltage spikes.

 Cranes, digital controls, and telecom equipment can all operate remotely but may
experience interference from the noise.
MAINTENANCE OF ISOLATION TRANSFORMERS

A power transformer is the most expensive and crucial piece of equipment in an electrical
substation. To maintain the transformer's high performance and long functional life, it is desirable to carry out
various preventative maintenance tasks. Measurements and tests of the transformer's numerous properties
are among the routine maintenance procedures needed for a power transformer.

Transformer maintenance can be categorized into two types: routine preventative maintenance,
which should be performed regularly, and reactive maintenance, which is carried out as needed. Additionally,
emergency or breakdown maintenance is only undertaken when absolutely necessary. However, regular
preventative maintenance significantly reduces the chances of requiring emergency interventions.

Condition maintenance involves the regular inspection and upkeep of transformers to prevent
emergencies and breakdowns. By focusing on thorough condition maintenance, technical sta can minimize
the need for emergency repairs, as ongoing maintenance helps ensure the equipment remains in good
working order and prevents unexpected failures.

ISOLATION TRANSFORMER DAILY BASIS MAINTENANCE

Daily maintenance should include checking the transformer's cleanliness, winding temperature, oil
temperature, and load hours. It is important to monitor readings from both the main tank and the conservator
tank’s Magnetic Oil Gauge (MOG). Additionally, the color of the silica gel in the breather should be inspected.
If the MOG indicates a low oil level, the transformer needs to be refilled with oil, and the transformer’s tank
should be checked for any leaks. If any oil leaks are found, appropriate measures must be taken to address
and repair them.

ISOLATION TRANSFORMER MONTHLY BASIS MAINTENANCE

Monthly maintenance should include checking the oil level in the cap located beneath the silica gel
breather. If the oil level in the cup is below the recommended mark, the transformer oil must be replenished.
Additionally, the silica gel breather's ventilation holes should be inspected weekly and cleaned if necessary to
ensure proper operation. For transformers with oil-filled bushings, manually check the oil levels in each
bushing using the connected oil gauge on a monthly basis. If needed, top o the bushing oil to the correct
level. Note that oil filling should be done during a planned shutdown.

ISOLATION TRANSFORMER YEARLY BASIS MAINTENANCE

Annually, the cooling system's automatic, remote, and manual functions—including the oil pumps,
air fans, and their control circuits—should be thoroughly inspected. If any issues arise, evaluate the physical
condition of the pumps and fans as well as the control circuitry. Additionally, soft cotton cloths should be
used to clean the transformer bushings each year, and while cleaning, inspect the bushings for any signs of
cracking.

Each year, check the condition of the OLTC oil by collecting a sample from the diverter tank’s drain
valve. The oil should be tested for dielectric strength (BDV) and moisture content (PPM). If the BDV is low or if
moisture levels exceed recommended limits, the OLTC oil should be either replaced or filtered.

All marshaling boxes should be cleaned thoroughly at least once a year. Additionally, inspect all
lighting, space heaters, and terminal connections for control and relay wires annually, ensuring that all
connections are secure and tightened as necessary.

The relays, alarms, and control switches within the relay and control panels, including the remote
tap changer control panel, should be cleaned with appropriate cleaning agents. Verify the functionality of the
Buchholz relay and pressure release device each year. Test the operation of relays in the remote panel by
momentarily short-circuiting trip and alarm contacts with a short wire. Use a battery-operated megger with a 5
KV range to measure transformer insulation resistance and polarization index annually. Also, perform annual
measurements of earth connection resistance with a clamp-on earth resistance meter. For transformers,
conduct Dissolved Gas Analysis (DGA) annually for 132 KV transformers, every two years for those below 132
KV, and twice every two years for transformers over 132 KV.

CHAPTER 4: WHAT ARE THE APPLICATIONS AND ADVANTAGES OF ISOLATION TRANSFORMERS?

This chapter will explore the various applications and advantages of isolation transformers. The
discussion will cover:

APPLICATIONS OF ISOLATION TRANSFORMERS

 To create security-related isolation within a power source, powered circuit, or powered

equipment

 To change the electrical power flowing between two circuit lines that are not electrically
connected, of the same or di erent voltage level

 As pulse transformers, i.e., in computer network configuration applications

  To protect against electrical shock in electrical circuits as electric lines

 To eliminate electrical noise in electrical and electronic circuits and a very small number of
sensitive equipment

 To prevent ground-level loop interference in a circuit

 To supply electricity to sensitive electronics, including computers, oscilloscopes, and

medical equipment

 To assist the function of electronic testing equipment, radars, levels, and communication
circuits

 To avoid damaging electrical sounds, spikes, etc., on computers, CNC machines, and
telecommunication equipment

 If the system's components' ground potentials di er from one another and they're
subjected to the impacts of instability at high frequencies

 If the equipment's ground cannot be earthed

 To protect many electronic devices from each other's electrical noise at a common busbar,
such as CNC machines, drives, hardening devices, etc.

 To avoid damage from internal noise interference due to NCTs’ ability to operate in both
directions

 To safeguard against powerful lightning, impulse noise, bus short-circuits, and

unintentional capacitor discharge

BENEFITS OF USING ISOLATION TRANSFORMERS

1. Reliable and Safe Equipment

Isolation transformers o er robust protection against power issues for various electrical devices. Voltage
fluctuations and sudden electrical surges can damage critical components, disrupting the normal operation
of equipment. By isolating the equipment from the power source, isolation transformers help prevent such
risks, thereby extending the lifespan and reliability of the equipment.

In medical settings such as hospitals, where electronic devices are crucial for diagnoses, treatments, and
patient care, the risk of sudden equipment failures is significant. Isolation transformers help mitigate these
risks, safeguarding not only expensive medical equipment but also the safety and well-being of patients and
medical sta .

2. Reduced Presence of Power Surges

Power surges can inflict significant damage on electrical devices, even though these spikes
in voltage are brief. Isolation transformers o er protection against such damage by providing galvanic
isolation, which shields the equipment from these surges. By isolating the DC power lines, these transformers
e ectively prevent any potential harm that might result from power surges.

3. Reduced Noise Disruption

Audio systems often experience noticeable noise interference when signals from amplifiers are
transmitted to the speakers. Isolation transformers can e ectively address these issues by reducing noise and
improving the performance of audio devices. These transformers incorporate Faraday shields, which are
designed to block electromagnetic interference by preventing disruptions in the electric field. This design
helps minimize electromagnetic noise and is valuable in various industries. Reliable isolation transformers
are especially crucial for the proper functioning of telecommunications, CNC machinery, remote control
systems, and other critical equipment.

4. Harmonics Correction

Electronic motors are used in a variety of industrial machinery types, and they cause harmonic voltage
distortions. The equipment breaks down as a result of these harmonic changes. The best options for
harmonics correction are isolation transformers. As a result, they are great protectors of industrial electric
and electronic machinery.

5. Prevention of Earthing Failures

One significant benefit of isolation transformers is their ability to prevent grounding failures. By using
these transformers, there is no direct conductive link between the ground and the secondary side.
Additionally, the Faraday shields incorporated in these transformers enhance their e iciency and
performance.
6. Improved Power Quality

Isolation transformers reduce the risk of current leakage, which enhances the quality of power supplied to
machinery. This improvement in power quality indirectly contributes to increased equipment longevity.

DISADVANTAGES OF ISOLATION TRANSFORMER

 When the isolation transformer is used as a pulse transformer and operated at a low
frequency, the secondary or output waveform produces distortion.

 The saturation property of the core is lessened when an isolation transformer is running at a
DC pulse signal.

 Due to their unique construction, isolation transformers cost more than standard
transformers.

CHAPTER 5: HOW TO CHOOSE AN ISOLATION TRANSFORMER?

Isolation transformers o er great flexibility and adaptability for various industrial power supplies,
communication hubs, data acquisition systems, and similar applications. Selecting the right isolation
transformer depends on the specific requirements and intended use. A thorough assessment of the
application helps in choosing the most suitable transformer for optimal performance.

CONSIDERATIONS WHEN CHOOSING ISOLATION TRANSFORMERS INCLUDE:

 Voltage: Carefully consider this element since transformers are utilized to adjust the
voltage of the primary power source. The primary power supply voltage will decide the
transformer's input voltage even though transformers can handle a range of voltages. The
output voltage can then be chosen based on the needs.

 Number of phases: Determine if there is a one-phase or three-phase requirement and then

select an option accordingly. The output demand will determine this. It shouldn’t require
more than single-phase power and single-phase transformers to carry current to a house, a
small residence, or an apartment building. A three-phase supply is required and should
select a three-phase transformer if supplying companies and industries that employ big
loads and heavy-duty machinery.

 Load requirement: To address the load factor, consider both the load’s size and type.
Ideally, this should be taken into account along with the prior consideration.

 Location: Before preparing the product for sale, consider whether the transformer will be
installed indoors or outdoors or positioned next to any toxic materials or other hazards.
Ensure that the transformer has the essential physical attributes to endure whatever the
environment might entail.

Understanding the di erent types of isolation transformers can help in selecting the most appropriate one for
your particular application:

 Single-Phase Transformers have a simple structure and small size that makes them suitable
for low-voltage distribution networks with small load density, such as residential areas.

 Harmonic Mitigation Transformers are appropriate for installations with several harmonic
loads, such as educational institutes, government buildings, commercial operations,
medical facilities, and call centers, which require consistent operation of computers,
printers, and communication equipment.

 Drive Isolation Transformers are used to isolate AC or DC motor circuits from the input
voltage system and are used with industrial heating.

 K-Factor Transformers are designed to function in high harmonic loads such as computer
rooms and areas with high levels of non-linear loads.

 Three-Phase Transformers are designed for power generation and electrical distribution
networks. They are used for high-power industrial loads such as rectifiers and motor drives.
CONCLUSION

An isolation transformer, just like typical transformers, is a non-moving device that transmits
electrical energy from one circuit to another without requiring any physical contact. It works on the idea of
magnetic induction, which uses a magnetic field to induce EMF in another circuit without a ecting the
frequency. Transformers are used in transmission and distribution networks to step up and down voltage
levels. An isolation transformer is a type of transformer that provides electrical isolation between two circuits
(primary and secondary) without modifying the secondary properties (voltage, current, and frequency levels).
Therefore, it’s important to be mindful of the type, characteristics, applications, and advantages of an
isolation transformer before selecting one.