When Good Grounds Go Bad

8/12/2019 When Good Grounds Go Bad

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AN108 Dataforth Corporation Page 1 of 7

DID YOU KNOW ?Hans Christian Oersted announced to the French Academy of Science on September 11,1820 that electric currents produced

magnetic fields. The young French mathematics professor, Andre Marie Ampere, was so taken by Oersteds announcementthat he repeated Oersteds experiment, developed a mathematical model, and discovered that current conducting parallelwires exerted a force on each other. Amazingly, he accomplished all this within one single week. Andre Marie Ampere isrecognized as the father of electrodynamics. In 1881 the unit of current ampere was chosen in his honor.

When Good Grounds Go Bad

Preamble Figure 1 shows a typical transformer secondaryconnection for the popular single-phase 240/120-voltagedistribution system. In this transformer topology, thesecondary is a center-tapped connection with 240 voltsdeveloped between lines L1-L2 and two 120-volt suppliesdeveloped between L1-neutral and L2-neutral. The centertap is neutral, (often referred to as the return line) and isearth grounded at this point. Loads that require a 240-voltsupply are connected between L1-L2 with no neutralconnection, consequently, no neutral current flows inthese 240-volt loads. All 120-volt loads are connectedeither between L1-neutral or between L2-neutral. Theneutral current flowing toward the supply Gnd-0 point atany instant in time is the vector sum/difference of all theneutral currents in all the individual 120-volt loads on

both L1 and L2. In theory, it is possible to have identical120-volt loads on L1 and L2 such that the neutral currentflowing toward Gnd-0 is zero. However, in practice, this

is never realized and there is always some current flowingin the neutral wire toward Gnd-0 at the supplytransformers.

The NEC, National Electrical Code (Ref. 4) requires theinstallation of grounds for safety and does not allow loadcurrents in ground lines. Unfortunately, unwanted groundcurrents (Ig) often exist creating undesirable Ig*Zgvoltage drops. The impedance (Zg) of grounding systemsis normally low; consequently, Ig*Zg drops generally areneglected. This is a normal assumption, since it isassumed that a ground wire represents ground, which isthe expected zero potential reference. This applicationnote illustrates some situations where unexpectedground voltages could cause instrumentation errors.

Typical Power Distribution Topologies

There are several general topologies used to supply smallto medium sized facilities with electrical energy. Power

companies use transformer connections to reduce theirhigh transmission voltages to meet the customers lowvoltage (less than 600 volts) system requirements. Thesevoltages (transformer secondary levels) are illustrated inFigures 1, 2, 3, and 4. These step-down transformer

banks are typically located on power poles near thefacilities or mounted on concrete pads located outside thecustomers facility. It is important to recognize fromFigures 1, 2, 3, 4 that these transformer configurationsground the facilitys supply neutral line to earth,illustrated as Gnd-0.

Gnd-0

L1

Neutral

L2

L3

T1 T2

T3

The 4-Wire Wye, 208 Volt 3-Phase System

Single Phase 240/120 Voltage Supply

L 2

L 1

N e u t r a l

G n d - 0

T 1

Figure 2Figure 1 3-Phase Wye 208-120 Volt Supply

Single Phase 240-120 Volt Supply


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This system is often used to provide single-phase 120 Vac voltages while simultaneously providing both single

phase 208 and 3-phase 208 voltages. Most modern 220-240 volt equipment is available for use at 208 volts.

L3

L1

Neutral

L2

Gnd-0

T 1

T 2

T 3

L3

L1

Neutral

L2

Gnd-0

T1

T3

Figure 2 is an illustration of the low voltage secondaryside of a three-phase transformer system, which is a wye-

connection used to supply 3-phase voltage between L1,L2, and L3. In addition, three each single-phase 208voltages are available between L1-L2, L2-L3, and L3-L1.In addition, this transformer connection provides threesingle phase 120-volt supplies; L1-neutral, L2-neutral,and L3-neutral. In this system, single-phase 208-voltloads and balanced three-phase loads, such as motors,welders, heaters, etc create no neutral line current.However, all individual single-phase 120-volt loadsconnected between lines L1, L2, L3 and neutral contributeto neutral currents flowing toward Gnd-0 at thetransformer source.

It is noteworthy to mention here that the mathematics ofsumming currents in the neutral wire for this topology is amessy complex number exercise and too involved for thisarticle. The results of this exercise show that if all 120-volt loads on L1, L2, and L3 are identical, then the neutralcurrent flowing toward Gnd-0 sums to zero; however, in

practice this is never realized and there is always somecurrent flowing in the neutral wire toward Gnd-0 at thesupply transformers.

The 3-Wire Delta 240-120 Volt 3-Phase System

Figure 33-Phase Delta 240-120 Volt Supply

Another popular supply topology is illustrated in Figure 3.In this system, the utilitys supply transformers have theirsecondary sides connected in a delta configuration,which constitutes a 3-phase voltage system. The threelines L1, L2, and L3 constitute a 3-wire 3-phase 240-voltsystem. Unlike the 4-wire wye 3-phase system, which hasa neutral, a 3-wire 3-phase delta voltage system has noneutral. To accommodate the customers additional needfor single phase 120 volts, one transformers 240-volt

secondary is center tapped, which provides two 120-voltsupplies with the single phase neutral grounded at Gnd-0.The topology shown in Figure 3 provides three lines; L1,L2, and L3, which supply 3-phase 240 volts. Single

phase 240 volts (without a neutral) is available betweenline pairs; (L1-L2), (L2-L3), and (L3-L1). The T3transformers 240-volt secondary is center-tapped,

providing the added feature of two single-phase 120voltages; L2-neutral and L1-neutral. Note: In this system,208 volts is developed between neutral and L3. This isoften referred to as the wild-leg voltage and is not used.

The 3-Wire Open Delta 240-120 Volt 3-Phase System

Figure 43-Phase Open Delta 240-120 Volt Supply

Figure 4 shows an open delta topology used to supply thesame system of voltages as the delta system in Figure 3.The open delta topology functions in an identical manneras the full delta described above. However,implementation of the open delta requires only twotransformers. Utility companies often use this scheme toeconomically develop 3-phase systems.

In summary, the voltage distribution topologies describedabove have the following features;

Manufactured three-phase equipment has balanced phases (equal impedance on each phase); therefore,these loads do not (should not) develop any neutralcurrent flowing in the neutral line back to supplyground, Gnd-0.

In the 4-wire 3-phase wye system shown in Figure 2,all the single-phase 120-volt loads on L1, L2, and L3form a composite 3-phase load. In practice, thiscomposite is never balanced; consequently, there isalways a net current flowing in the neutral linetoward the supply ground, Gnd-0.

The popular 240-120 single-phase supply systemshown in Figure 1 will have neutral current flowing


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in the neutral line toward supply ground, Gnd-0 since120-volt loads between L1-neutral and L2-neutral arenever truly identical.

3. All 3-phase un-balanced 4-wire wye equipment loadsdevelop neutral currents.

4. Single-phase 240-volt loads have no neutral current.5. All single-phase 120-volt loads between supply lines

(L1, L2, L3) and neutral have neutral currents.Both delta-configured supplies shown in Figures 3Figure 4 have two 120-volt sources that share acommon neutral. Consequently, single-phase 120-

volt loads on L1-neutral and L2-neutral developcurrent flowing in the neutral line toward the supplyground, Gnd-0. Again, this is true because these 120-volt loads on L1-neutral and L2-neutral can never betruly identical.

Voltage Distribution Panels

Voltages are distributed to the various loads within afacility through a main disconnect and circuit breaker

panel (some situations allow the use of special fuses).Distribution safety is mandatory; consequently, the safetyrequirements established by the National Electric Code(NEC) together with local building codes must befollowed. Figure 5 illustrates a generic panel and is

presented here to indicate how voltages are distributedand where ground connections are made.

The net conclusion of this brief review of distributionsystems is that;

1. All 3-phase 3-wire balanced or un-balanced deltaloads have no neutral current.

2. All 3-phase balanced 4-wire wye equipment loadshave no neutral current.

.

Wiring to Load Groups (home-runs)L1 L2 L3N

3-Pole 3-PhaseVoltage

L1- L2- L3,

2-Pole 1-PhaseVoltage L3- L2



1-Pole 1-PhaseVoltage

L1,2,3 - neutral

Neutral ( White)1 Wire per load group

Ground (green, bare)1 Wire per load group

Load Group A

Load Group B

Load Group C

Load Group D

Load Group E

a 12

3

b

Gnd-1

Figure 5Generalized Circuit Breaker Panel TopologyNote: Load E3 is not allowed for open delta


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Volume 1 Page 4 of 7

Figure 6 illustrates this situation using two additional points (w) and (x) connected to grounds somewherewithin the facility.

This voltage distribution concept shows that voltages aredistributed to various loads throughout the facility withwiring groups, which are often multiple wires bundledtogether and encased in various synthetic skins.

For example, voltages supplied to a specific load groupmight be distributed with a 12-3 w/Gnd UF cable. This

is an underground cable containing 4 each number 12gauge wires; a white wire used only as neutral, a redsupply wire, a black supply wire, and a bare (or green)wire used only as ground. Wiring groups, which distributevoltage to specific loads are often refer to as home-runs. Each home-run contains colored supply line wires(black, red, etc) for the appropriate L1, L2, L3 phasevoltage(s) needed and a neutral wire, always white, andgenerally a green or bare copper wire, for grounding.Ground wires are never allowed to conduct any loadcurrent. Each supply phase in a home-run wire group iscircuit breaker protected. In addition, both the whiteneutral (return) wire and the ground wire are continuous

and return to points (a) and (b) in the circuit breaker panel, see Figure 5. One could think of the white neutralwires and ground wires emanating from the panel box likespokes on a wagon wheel. Note that;

ReturnGnd-0

Supply Neutral Wire

(x )(w )

(a )

(b )

Gnd-1

Gnd-WGnd-X

Figure 6Ground Paths for Neutral Return Current

The network of ground return paths is very complex andimpossible to accurately model. Moreover, it is timedependent, affected by new construction, weather,corrosion, etc. If the main supply neutral wire and all itsconnections have a combined impedance (Zg) muchsmaller than the parallel web of ground paths, then that

portion of the return current, which splits (KirchhoffsCurrent Law) into these ground paths can be neglected.Consequently, voltage drops (Ig*Zg) associated with thissmall current can be neglected as well.

All home runs have their white neutral linesconnected at point (a) , which is connected to theutility company supply transformer neutral, Gnd-0.

All home runs have their ground lines connected at point (b), which is connected to an earth ground Gnd-1 located at the distribution circuit breaker panel. Interesting Phenomena

In the circuit breaker panel, points (a) and (b) areconnected resulting in connecting earth (Gnd-1) tothe white neutral wire. This is a NEC requirement.

The following are sample situations, which can ariseregarding unexpected voltages on ground lines. Equallysurprising phenomenon can occur on supply lines L1, L2,and L3; however the focus of this application note is onground lines and so surprises on L1, L2, and L3 will not

be illustrated.Resulting Situation:

All neutral (return) currents for all the loads throughoutthe total facility are vector summed at point (a) in themain distribution circuit breaker panel. The balance ofthis neutral current sum must then return to the utilitycompanys supply transformer neutral, shown as Gnd-0 inFigures 1,2, 3, and 4. The return path for this net neutralcurrent is the neutral wire installed by utility companiesand/or electrical contractors.

Case 1Given a small 30 horsepower, 240 volt, 60cycle, 3-phase,4-wire, wye connected induction motor used in a HVACsystem as an air handler. Assume that the motors averagerunning point has an efficiency of 87% and a power factorof 0.93. This operating situation requires 66.5 amps ofline current from each line (L1, L2, L3). The vector sum

of these currents in the neutral line is zero.The utility company has sized and installed this neutralwire to handle return load currents from a customersfacility. Since all the neutral wires at (a) and all theground wires at Gnd-1 (b) are connected in the circuit

breaker panels, there are additional parallel return pathsfor this net neutral current distributed throughoutstructural framing steel, concrete re-bars, plumbing pipes,and bare earth. All these paths lead back to Gnd-0 at thesupply transformers.

If for whatever the reasons; fire, heat, loose connections,etc, one of the motors 3-phase windings is lost (opens);an unbalanced 3-phase system is created. For thissituation, one line current drops to zero and 66.5 ampsflows in the other two supply lines. Surprisingly, thevector sum of these currents in the neutral wire nowsuddenly jumps from zero to 66.5 amps. WOW, what asurprise. This situation will not prevail, the motors


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ground loop. The values used are well within the range of possibilities. Surprisingly, the voltage generated by thisredistribution of charge (current surge) is approximately700 volts peak to peak. The results will be more severe

with an electrical storm direct hit. Will your signalconditioning modules and field sensor electronics takethis abuse?

12

500N 1.50U 2.50U 3.50U 4.50UTime, Microseconds

400

200

0

-200

-400

V - o u

t , V o

l t s

80.0

40.0

0

-40.0

-80.0

I - i n ,

A m p s

L1

1u

Voutvolts

R21

I1C11p

R110

Iinamps

I-in

V-out

Figure 8Computer Simulated Response of a Neutral -Ground Loop Model

Prevention and Protection Method

It is not possible to protect all facilities from all possiblenatural phenomenon and potential accidents such aselectrical storms, earthquakes, plant fires, and employeescareless work habits. Nonetheless, using proper groundingand isolation techniques will go a long way towardeliminating instrumentation errors caused by these

situations.

Dataforth is well aware of instrumentation problemscaused by noisy supplies with bad grounds and hasdeveloped a full line of isolated signal conditioningmodules with filtered inputs, which are overload, surge,and transient protected. These isolated signal conditioninginstrumentation modules provide isolation from both

power supply lines and ground lines; thus eliminatingmany of the problems associated with bad grounds andnoisy supply lines. In addition, the field side signals areisolated from the computer (reading) side.

Figure 9 shown below is an example of a Dataforthunique 4-way isolated signal-conditioning module.

Note that this module is isolated from its input power

(pins 16,17) and in addition;

supplies isolated power to the field side electronics,supplies isolated power to the computer sideelectronics,supplies isolated excitation for field sensors, andisolates the signal path from the computer sideelectronics.


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Figure 9Dataforth SCM5B42

Two-Wire Transmitter Signal Conditioning Four-Way Isolated Module

Dataforth References

The reader is encouraged to visit Dataforths web site andexplore their complete line of isolated signal conditioningmodules and related application notes, see referencesshown below.

1. Dataforth Corp., http://www.dataforth.com 2. Application Notes AN502, AN507 and AN508,

http://www.dataforth.com/catalog/sign.in.asp?route_to=app_notes

3. SCM5B42 Two-Wire Transmitter SignalConditioning Module, http://www.dataforth.com/catalog/doc_generator.asp?doc_id=67

4. National Electric Code controlled by National FireProtection Agency, NFPA http://www.nfpa.org/Home/Search/search_site.asp?query=NEC Application Note AN109 5.http://www.dataforth.com/catalog/sign.in.asp?route_to=app_notes
http://www.dataforth.com/http://www.dataforth.com/catalog/sign.in.asp?route_to=app_noteshttp://www.dataforth.com/catalog/sign.in.asp?route_to=app_noteshttp://www.dataforth.com/catalog/doc_generator.asp?doc_id=67http://www.dataforth.com/catalog/doc_generator.asp?doc_id=67http://www.nfpa.org/Home/Search/search_site.asp?query=NEChttp://www.nfpa.org/Home/Search/search_site.asp?query=NEChttp://www.dataforth.com/catalog/sign.in.asp?route_to=app_noteshttp://www.dataforth.com/catalog/sign.in.asp?route_to=app_noteshttp://www.dataforth.com/catalog/sign.in.asp?route_to=app_noteshttp://www.dataforth.com/catalog/sign.in.asp?route_to=app_noteshttp://www.nfpa.org/Home/Search/search_site.asp?query=NEChttp://www.nfpa.org/Home/Search/search_site.asp?query=NEChttp://www.dataforth.com/catalog/doc_generator.asp?doc_id=67http://www.dataforth.com/catalog/doc_generator.asp?doc_id=67http://www.dataforth.com/catalog/sign.in.asp?route_to=app_noteshttp://www.dataforth.com/catalog/sign.in.asp?route_to=app_noteshttp://www.dataforth.com/

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When Good Grounds Go Bad