Anodzing Power Supply

     The isolation transformer just "floats" the 240VAC away from
GND. This means there is no longer a connection- as there is with
the line fed voltage. This does nothing to protect you from getting
zapped by the 240VAC 

As stated the isolation transformer “floats” the mains and “breaks”
any ground link. Touching a “live” mains wire will not cause a shock
unless there is some connection to ground or to the “neutral” or
other related phase. I have seen films of workers safely working on
cables energised at 100’s of thousands of volts because they were
isolated from ground. They were actually bonded to the high voltage
cables that they were working on for safety!

The reason that I specified contact to EITHER side of the winding is
safe is that if you get hooked across it (ie both sides of the
winding) then the transformer will just see you as another appliance
and happily fry you. I have a few 240 volt isolation transformers
(Australian mains is 240 volts) and I can assure you that they do
work as I stated to protect you against mains connection. I have on
more than one occasion inadvertently touched a “live” trace when
using an isolation transformer without receiving a shock. The old
rule for electrical testing of live circuits was to keep one hand in
your pocket to prevent touching BOTH sides of the mains or ground.

An isolation transformer works well exactly as stated if it is in
good condition. It is also essential that there is no ground
connection to the output winding - I have seen units that have had a
bond fitted for some reason. If you are going to use one for
isolation purposes then I would recommend getting an electrician to
insulation test (megger test) it to ensure no leakage to earth on
either side of the output before trusting your life to it.

The GFI - Ground Fault Interrupter, is also called Safety Switch,
RCD - Residual Current Device, ELCB -Earth Leakage Circuit Breaker,
Core Balance Relay and other names in different places.

Before these devices were readily available, the isolation
transformer was the only protective device available. It is still
widely used to work (repair) on circuits that have mains potential
circuitry or to isolate test equipment earths to prevent short
circuits when testing such circuitry.

I am an electrician and I fitted all of my power and light circuits
in my house with individual safety switch protection so I don’t
discount the effectiveness of that mode of protection. It is another
line of protection to me in case of an isolation transformer failing
but that hasn’t ever happened.

It is also important that only a single appliance is plugged into a
isolation transformer at any time. Although the chance is remote,
if two items had faults to opposite sides of the output winding (eg
to the case of each) and you touched both cases, then you would be
effectively connected across the full potential. In Australia,
isolation transformers with output sockets are supposed to have a
surround (often a pvc pipe fitting) to ensure that only a plug is
inserted and prevent double adaptors etc being used for that reason.

As a last point, you were to use a standard “non isolating” variac
with GFI protection and contact something earthed (say when
anodising), it is possible to trip the GFI.

Regards,
Brian.

For many years RMS sold the Mini Anodizer with a separate isolation
transformer. For the 3amp machine it was a 250VA transformer(about
$70). It was essentially one to one. 120 volts in 120 volts out. With
it in the circuit you could read only trace voltage between the
leads and the metal box that housed it. Ahhh, but if you plugged the
Mini directly in to the wall it was a different story. Full line
voltage+* was just hanging there waiting.

The scenario is:

You are happily anodizing away and a connection comes loose in the
bath. The anodizer is turned up to 100 volts. You pull the piece out
of the bath and adjust it with a finger of your right hand. Thew
phone rings you answer with your left hand. Wrong number! As you
turn back to your work you touch the case of the anodizer. Better
known as ground! You are know the fuse. End of story.

Bill

I am the proud owner of a Mini with a bit of the corner melted away
from contact with its own hot lead. It was just a quickie demo and I
took a short cut. Only once.

*The + is because the variable transformer in the Mini increased the
voltage by 30%.

Reactive Metals Studio, Inc.
PO Box 890 * Clarkdale, AZ 86324
Ph-928/634-3434 * Ph-800/876-3434 * Fax-928/634-6734
@Michele_Deborah_Bill

[...] if you take a voltmeter and  touch one probe to a grounded
surface and one probe to a hot lead you will read the line voltage.
If you you were to be unfortunate enough to touch both a grounded
surface and the hot lead you would be shocked and possibly killed. 

Agreed. When anodising niobium and titanium we are exposed to both
leads, the anode and (throught the electrolyte) the cathode. I
imagine that an isolator would be less than perfect an a safety
device for anodising as the danger we face is not so much
line-to-ground as line-to-neutral.

[...] The GFI - Ground Fault Interrupter, is also called Safety
Switch, RCD - Residual Current Device, ELCB -Earth Leakage Circuit
Breaker, Core Balance Relay and other names in different places.
Before these devices were readily available, the isolation
transformer was the only protective device available.  It is still
widely used to work (repair) on circuits that have mains potential
circuitry or to isolate test equipment earths to prevent short
circuits when testing such circuitry. 

Would you say then that a GFI (RDC etc) is VERY important in an
anodiser?

[...] As a last point, you were to use a standard "non isolating"
variac with GFI protection and contact something earthed (say when
anodising), it is possible to trip the GFI. 

Meaning it works as well as an isolation transformer?

Regards,
Brian as well.

B r i a n A d a m
e y e g l a s s e s j e w e l l e r y
518 South Titirangi Road
Auckland NEW ZEALAND
ph +64 9 817 6816
www.adam.co.nz

You really need both - particularly in the 240 volt world. The GFI
protects against grounding problems., but not against across the
line contact. The isolation transformer can reduce these risks a
little but not totally either. The GFI really does its thing with
faulty equipment-- the stuff where you feel little tingles when you
touch it. The devices disconnects the supply very rapidly. At lower
voltages dry skin protects against lethal shocks. Wet conditions
change this.

GFIs were a little expensive when they were first available and the
location requirements for their use was less than it might be if the
codes were adopted today. They are cheap in the US now and really
belong more places – particularly in workshop areas.

I just reposted comments “Electrical shocks” it goes into this
further particularly see the tutorial found at:
http://www.physics.udel.edu/~watson/scen103/colloq2000/safety.html

jesse

Just a couple of notes. A GFI can be tripped just by anodizing. It
is after all a short circuit through the bath. It is also a devise
that can wear out, malfunction and eventually fail. Bill

Reactive Metals Studio, Inc.
PO Box 890 * Clarkdale, AZ 86324
Ph-928/634-3434 * Ph-800/876-3434 * Fax-928/634-6734
@Michele_Deborah_Bill

 [...] if you take a voltmeter and  touch one probe to a grounded
 surface and one probe to a hot lead you will read the line voltage.
 If you you were to be unfortunate enough to touch both a grounded
 surface and the hot lead you would be shocked and possibly killed.
Agreed. When anodising niobium and titanium we are exposed to both
leads, the anode and (throught the electrolyte) the cathode. I
imagine that an isolator would be less than perfect an a safety
device for anodising as the danger we face is not so much
line-to-ground as line-to-neutral.

Not so, the danger is that you are surrounded by grounded objects
basically everything in our environment is at ground potential. All
objects have varying ability to conduct electricity even insulators
such as plastics can become conductors when dirty or wet or both. So
the potential to make a connection to ground via a conducting item
in a normal studio environment is great so the likelihood of
receiving a shock is fairly high if you are using a non isolated
power supply. If you use the isolated variety then you must make
contact with both leads at the same time which is less likely to
happen by accident.

 [...] The GFI - Ground Fault Interrupter, is also called Safety
 Switch, RCD - Residual Current Device, ELCB -Earth Leakage Circuit
 Breaker, Core Balance Relay and other names in different places.
 Before these devices were readily available, the isolation
 transformer was the only protective device available.  It is still
 widely used to work (repair) on circuits that have mains potential
 circuitry or to isolate test equipment earths to prevent short
 circuits when testing such circuitry.
Would you say then that a GFI (RDC etc) is VERY important in an
anodiser?

Yes, the GFCI will act as a safety of the last resort if you manage
to get a connection between ground and or the mains and the output
of the isolated power supply and you become part of the circuit it
may save your life.

 [...] As a last point, you were to use a standard "non isolating"
 variac with GFI protection and contact something earthed (say when
 anodising), it is possible to trip the GFI.
Meaning it works as well as an isolation transformer?

No, it is a last resort type of safety it may keep you from getting
seriously hurt but if you manage to trip it by being part of the
circuit you may still be hurt. Isolation transformers and GFCI’s
are last resort safety devices they are not a substitute for proper
safety practices when working with high voltages. Electricity will
always follow the path of least resistance, it is critical to not
place your body in that path.

Jim Binnion

James Binnion Metal Arts
Phone (360) 756-6550
Toll Free (877) 408 7287
Fax (360) 756-2160

@James_Binnion
Member of the Better Business Bureau

Sorry, James in SoFl, but you are wrong here.

An isolation transformer is isolated from ground on the secondary
side, the side you are getting your power from.

I was an electrician for 21 years and have installed them in some
hazardous locations like hospital rooms with oxygen tents.

I also anodize niobium using Reactive Metals’s old mini anodizer
plugged into an isolation transformer. When I anodize I am often in
contact with EITHER side of the circuit with no harm done. I’m in
Hawaii and work without gloves, barefoot on a concrete floor most of
the time. The one time in 17 years that I contacted both sides at
the same time I got “bit” as electricians call it. This would happen
with any circuit.

The big thing to remember is that you don’t want to be the device
that completes the circuit. With normal power that means getting
between the hot wire and the neutral or the ground. With an
isolation transformer the ground is not part of the circuit.

John Flynn

    Just a couple of notes. A GFI can be tripped just by
anodizing. It is after all a short circuit through the bath. It is
also a devise that can wear out, malfunction and eventually fail. 

Hi Bill,

A GFCI should not trip with a short circuit as it only senses

unbalanced loads not over current conditions. The mains supply
breaker or fuse will trip on over current to protect the circuit.
Also an anodizer will not appear as a short circuit unless the
output leads are truly shorted. The electrolyte bath provides a
resistance to the flow of current based on its conductivity and the
surface area of the electrodes this will determine the amount of
current drawn so it is no more a short circuit than any other device
that is operating properly on the line.

Jim Binnion

James Binnion Metal Arts
Phone (360) 756-6550
Toll Free (877) 408 7287
Fax (360) 756-2160

@James_Binnion
Member of the Better Business Bureau

G’day; My entire single story house is built on a single concrete
slab. There is heavy carpet with rubber underlay in all rooms except
the workshops and attached garage… All the workshop and garage
areas have bare or painted concrete floors. But those areas are all
protected by what we call an “Earth Leakage Breaker” or what you
call a “Ground Fault Switch” This means it sits between earth and
live cables and as soon as it detects any current flowing to earth,
it fires instantly, cutting off all power to the outlets. Since it
is the volts times amps that kills, I checked my installation and an
earth leak of 0.005amps (five milliamps) cuts off all power in a
fraction of a second. Thus if the earth fault occurred between you,
the ground and and the live wire, all you’d feel is a tiny instant
tingle as the switch flicks off with an audible bang. To restore
power the switch is simply reset to ‘ON’. If the switch immediately
goes to off, then you have an electrical fault and you had better
call in an electrician. If you touch the live and neutral wires
together, the main power circuit fuse will blow. The leak detector
switches are not very costly, but must be fitted by a registered
electrician. But you can also buy power extension sockets with a
built in earth leakage breaker.

Cheers for now,
JohnB of Mapua, Nelson NZ

Yes the GFI may well trip since your wet anodizing system is
allowing a leakage to ground the same as a faulty "tingling effect"
power tool is. The GFI compares the current flowing out to the
current flowing back. with a near instantaneous trip with any
inbalance. Your system is allowing current flowing out to go back
thru an unintended route. Fix the system so your bath doesn’t
provide a fault path.

The GFI is another of the inexpensive wonders that integrated
circuits make cheaply possible.

jesse

The internal resistance of a human body is about 500 Ohms. If your
skin were removed, it would then take about 50 volts to be lethal. 

This brings to mind an interesting point. U.S. Electrical Codes are
much more stringent for barns than they are for homes. The reason
being that it takes less current to kill a cow or a horse than it
does to kill a human. I wonder what this might mean for our in-house
(or studio) animals, such as dogs and cats. I really can’t imagine a
scenario in which a pet might get himself into an electrical
circuit, but it is something to think about when you have nothing
better to do.

Del Pearson in Beautiful South Texas, who was once accused of having
a “flypaper mind” by one of his psychology profs–asserting that
copious amounts of useless kept “sticking to my mind.”

Hi, its good to see safety issues are examined at all angles by
Orchid readers. It’s one of the reasons I like to keep reading it.
I’ve reviewed several of my practices because Orchid has made me sit
down and think!! I’ve been away but I’ll put my 2 cents in again.

In Australia (and NZ shares the same wiring rules), the commonly
fitted (and now legally required) Ground Fault Interrupter or Earth
leakage Circuit Breaker is meant to trip at 30 milliamps or .03 of
an amp. When there is any leakage in appliances and an entire
building is protected by a single breaker (leakage is not so uncommon
especially heating elements in humid climates and older appliances)
then the accumulated leakage “burden” reduces the leakage required
to trip the unit. This can be a cause for false tripping and nuisance
electricians calls where they may find nothing wrong if they either
don’t check the burden current (not often checked) or the appliances
are not on or have dried out in the mean time. I had a few calls like
that.

If you are going to use a Ground Fault Interrupter or Earth leakage
Circuit Breaker that goes onto the lead itself, I suggest that you
also buy one of the little testers with three lights that tell you
if the power outlet is correctly wired and test your outlets. I have
seen some lead units that would not trip if they were connected to
an outlet that had reverse polarity - ie the active and neutral were
swapped around to what they “should” be. In Australia the regulations
only specified correct polarity in the 1960’s - I don’t know about
the US but the testers are only cheap (less that $10 here) and an
extra test can never hurt.

I did my electrical training under my father and I can remember him
literally worried sick when a TV news story reported a man had been
fatally electrocuted on a farm that he had fitted a Safety Switch
(GFI, ELCB) the day before. The farm was run as a family trust
(extended family of several individual famillies) but the house was
owned by the one family (with several children). Dad had suggested
fitting protection to the shed but it was declined as the trust
would have to OK it. The husband was working on the back of a truck
with a lead light without a safety cage. It fell, the bulb
shattered…

Take care folks. Electricity can bite hard and may not let you think
about what you did afterwards.

Regards,
Brian.

For those of you still interested the Circuit Specialties power
supply ours is currently in the Kansas City area. It will be
inspected and burned in. Essentially we will find out how sturdy it
is and if the components will handle the stress of anodizing. I like
the unit. It is about twice the size of our old MINI and weighs in
at 13lbs. Bill

Reactive Metals Studio, Inc.
PO Box 890 * Clarkdale, AZ 86324
Ph-928/634-3434 * Ph-800/876-3434 * Fax-928/634-6734
E-mail- @Michele_Deborah_Bill
Catalog- www.reactivemetals.com