How to wire an Isolation Transformer — Step-by-step guide for engineers & electricians

Wiring an trasformatore di isolamento correctly is essential for safety, EMC performance and reliable operation of downstream equipment. This guide walks you through practical, standards-aware steps—what to check before you wire, how to make common single-phase and three-phase connections, and which tests and safety precautions to perform. Always have a qualified electrician or technician carry out the work and follow local electrical codes.

Before you start — safety & verification

1. De-energize, lockout/tagout and verify zero voltage. Never work on live primary/secondary terminals.
2. Read the nameplate & datasheet. Confirm primary/secondary voltages, kVA, vector group, insulation class, rated current and terminal identification.
3. Check the installation environment. Adequate ventilation, clearance, ambient temp and altitude limits per datasheet.
4. Gather tools & PPE. Calibrated meter, megger, TTR (turns-ratio) tester (if available), torque wrench, correct-rated lugs, insulating gloves, eye protection.
5. Select correct cabling & protective devices. Cable gauge, breakers/fuses and protective relays sized for rated current and inrush characteristics.

Single-phase isolation transformer — common wiring (step-by-step)

Typical use: 230 V → 230 V 1:1 isolation, or step-down/up single-phase loads.

1. Identify terminals. Primary terminals typically labeled H1 / H2 (or L / N). Secondary labeled X1 / X2 (or L’ / N’). Earth/Shield terminal labelled PE or “Shield”.
2. Connect primary supply. Connect live (L) to H1 and neutral (N) to H2 according to the nameplate. Tighten terminals to manufacturer torque.
3. Connect protective earth. Bond the transformer frame and dedicated PE terminal to site protective earth. If an electrostatic shield is present, connect its drain terminal to earth per manufacturer instructions.
4. Connect secondary load. Connect load live to X1 and neutral to X2. If the transformer is 1:1 for isolation, you may choose to leave the secondary ungrounded (floating) for maximum isolation, or ground the secondary neutral if a solid neutral is required by the installation—only as dictated by the application and local code.
5. Install overcurrent protection. Place fuses or breakers on the primary side sized per transformer’s rated primary current; consider secondary protection where applicable.
6. Verify wiring. Continuity check (de-energized): confirm no continuity primary↔secondary. Megger test per datasheet if needed. TTR confirms ratio.

Important: Do not create parallel neutral/earth ties on the secondary without consulting the system design—doing so can defeat isolation and create ground loops.

Three-phase isolation transformer — common connection modes & wiring notes

Three-phase isolation transformers are often wired in Y (star) o Δ (delta) configurations and can be connected as Y-Y, Y-Δ, Δ-Y, etc. Your choice affects phase shift (vector group) and whether a neutral is available.

1. Confirm vector group (clock notation). Nameplate will show e.g., Dyn11, Yyn0. This defines the phase relationship between primary and secondary and whether a neutral is brought out. Never mix phases with mismatched vector groups—this causes circulating currents and damage.
2. Wiring examples:
   • Y-Y with neutral (Yyn0): Primary phases to H1/H2/H3, primary neutral to Hn. Secondary phases to X1/X2/X3, secondary neutral Xn grounded if required. Good when neutral required on both sides and no phase shift.
   • Δ-Y (D-y) step-down with neutral on secondary (Dyn11): Primary delta (no neutral), secondary star with neutral available—commonly used to create a grounded neutral on secondary.
3. Grounding & shields: If electrostatic shield (screen) exists, connect the shield to earth only, per manufacturer instructions—this suppresses common-mode interference while maintaining galvanic isolation.
4. Sequential wiring & phasing: When connecting, ensure proper phase sequence. Use a phase rotation tester to confirm correct orientation before energizing.

Tests & commissioning (de-energized & energized)

• Continuity check (de-energized): primary-to-secondary should read open.
• Insulation resistance (megger): verify MΩ between windings and to earth per datasheet.
• Turns-ratio test (TTR): confirm correct turns ratio and detect shorted turns.
• Hi-pot (dielectric) test: only by qualified personnel following standards if required.
• No-load energize & monitor: energize with no load; measure voltages, neutral/earth voltages, and look for unexpected heating or sound.
• Load test: apply expected load and verify temperature rise, regulation and protection trip settings.

Best practices & installation tips

• Utilizzo correct torque on all terminal connections to avoid overheating.
• Provide clear labels for primary/secondary terminals and grounding points.
• Keep primary and secondary conductors physically separated to reduce induced coupling and ease maintenance.
• For noise-sensitive equipment, use a transformer with an electrostatic shield and follow grounding instructions carefully.
• Keep manufacturer’s wiring diagrams and factory test reports with the unit.

Compliance & responsibility

Always follow local electrical codes (IEC, NEC, or regional equivalents), manufacturer installation manual, and site earthing rules. If the transformer powers medical, laboratory, or safety-critical systems, insist on factory test certificates and certified installers.

Domande frequenti

Q1 — Should I ground the secondary of an isolation transformer?
It depends. Leaving the secondary floating maximizes galvanic isolation but may complicate protective earth strategies. If a neutral is required for protective devices or equipment, ground the secondary neutral per local code and manufacturer guidance.

Q2 — How do I avoid phase shift or circulating currents in three-phase installations?
Match the transformer’s vector group exactly to system requirements. Never parallel transformers with different vector groups. Use correct delta/star connections and confirm phase rotation before energizing.

Q3 — Who should perform hi-pot and TTR tests?
Only trained, authorized technicians should perform hi-pot and TTR testing. These tests require proper safety procedures and calibrated equipment; improper testing can damage insulation or create hazards.