Safe circuit design
As we saw earlier, a power system with no secure connection to
earth ground is unpredictable from a safety perspective: there's no
way to guarantee how much or how little voltage will exist between
any point in the circuit and earth ground. By grounding one side of
the power system's voltage source, at least one point in the circuit
can be assured to be electrically common with the earth and
therefore present no shock hazard. In a simple two-wire electrical
power system, the conductor connected to ground is called the
neutral, and the other conductor is called the hot:
As far as the voltage source and load are concerned, grounding
makes no difference at all. It exists purely for the sake of
personnel safety, by guaranteeing that at least one point in the
circuit will be safe to touch (zero voltage to ground). The "Hot"
side of the circuit, named for its potential for shock hazard, will
be dangerous to touch unless voltage is secured by proper
disconnection from the source (ideally, using a systematic
lock-out/tag-out procedure).
This imbalance of hazard between the two conductors in a simple
power circuit is important to understand. The following series of
illustrations are based on common household wiring systems (using DC
voltage sources rather than AC for simplicity).
If we take a look at a simple, household electrical appliance
such as a toaster with a conductive metal case, we can see that
there should be no shock hazard when it is operating properly. The
wires conducting power to the toaster's heating element are
insulated from touching the metal case (and each other) by rubber or
plastic.
However, if one of the wires inside the toaster were to
accidently come in contact with the metal case, the case will be
made electrically common to the wire, and touching the case will be
just as hazardous as touching the wire bare. Whether or not this
presents a shock hazard depends on which wire accidentally
touches:
If the "hot" wire contacts the case, it places the user of the
toaster in danger. On the other hand, if the neutral wire contacts
the case, there is no danger of shock:
To help ensure that the former failure is less likely than the
latter, engineers try to design appliances in such a way as to
minimize hot conductor contact with the case. Ideally, of course,
you don't want either wire accidently coming in contact with the
conductive case of the appliance, but there are usually ways to
design the layout of the parts to make accidental contact less
likely for one wire than for the other. However, this preventative
measure is effective only if power plug polarity can be guaranteed.
If the plug can be reversed, then the conductor more likely to
contact the case might very well be the "hot" one:
Appliances designed this way usually come with "polarized" plugs,
one prong of the plug being slightly narrower than the other. Power
receptacles are also designed like this, one slot being narrower
than the other. Consequently, the plug cannot be inserted
"backwards," and conductor identity inside the appliance can be
guaranteed. Remember that this has no effect whatsoever on the basic
function of the appliance: it's strictly for the sake of user
safety.
Some engineers address the safety issue simply by making the
outside case of the appliance nonconductive. Such appliances are
called double-insulated, since the insulating case serves as
a second layer of insulation above and beyond that of the conductors
themselves. If a wire inside the appliance accidently comes in
contact with the case, there is no danger presented to the user of
the appliance.
Other engineers tackle the problem of safety by maintaining a
conductive case, but using a third conductor to firmly connect that
case to ground:
The third prong on the power cord provides a direct electrical
connection from the appliance case to earth ground, making the two
points electrically common with each other. If they're electrically
common, then there cannot be any voltage dropped between them. At
least, that's how it is supposed to work. If the hot conductor
accidently touches the metal appliance case, it will create a direct
short-circuit back to the voltage source through the ground wire,
tripping any overcurrent protection devices. The user of the
appliance will remain safe.
This is why it's so important never to cut the third prong off a
power plug when trying to fit it into a two-prong receptacle. If
this is done, there will be no grounding of the appliance case to
keep the user(s) safe. The appliance will still function properly,
but if there is an internal fault bringing the hot wire in contact
with the case, the results can be deadly. If a two-prong receptacle must be used, a two- to three-prong receptacle adapter can be
installed with a grounding wire attached to the receptacle's
grounded cover screw. This will maintain the safety of the grounded
appliance while plugged in to this type of receptacle.
Electrically safe engineering doesn't necessarily end at the
load, however. A final safeguard against electrical shock can be
arranged on the power supply side of the circuit rather than the
appliance itself. This safeguard is called ground-fault detection,
and it works like this:
In a properly functioning appliance (shown above), the current
measured through the hot conductor should be exactly equal to the
current through the neutral conductor, because there's only one path
for electrons to flow in the circuit. With no fault inside the
appliance, there is no connection between circuit conductors and the
person touching the case, and therefore no shock.
If, however, the hot wire accidently contacts the metal case,
there will be current through the person touching the case. The
presence of a shock current will be manifested as a difference
of current between the two power conductors at the receptacle:
This difference in current between the "hot" and "neutral"
conductors will only exist if there is current through the ground
connection, meaning that there is a fault in the system. Therefore,
such a current difference can be used as a way to detect a
fault condition. If a device is set up to measure this difference of
current between the two power conductors, a detection of current
imbalance can be used to trigger the opening of a disconnect switch,
thus cutting power off and preventing serious shock:
Such devices are called Ground Fault Current Interruptors,
or GFCIs for short, and they are compact enough to be built into a
power receptacle. These receptacles are easily identified by their
distinctive "Test" and "Reset" buttons. The big advantage with using
this approach to ensure safety is that it works regardless of the
appliance's design. Of course, using a double-insulated or grounded
appliance in addition to a GFCI receptacle would be better yet, but
it's comforting to know that something can be done to improve safety
above and beyond the design and condition of the appliance.
- REVIEW:
- Power systems often have one side of the voltage supply
connected to earth ground to ensure safety at that point.
- The "grounded" conductor in a power system is called the
neutral conductor, while the ungrounded conductor is called
the hot.
- Grounding in power systems exists for the sake of personnel
safety, not the operation of the load(s).
- Electrical safety of an appliance or other load can be
improved by good engineering: polarized plugs, double insulation,
and three-prong "grounding" plugs are all ways that safety can be
maximized on the load side.
- Ground Fault Current Interruptors (GFCIs) work by
sensing a difference in current between the two conductors
supplying power to the load. There should be no difference in
current at all. Any difference means that current must be entering
or exiting the load by some means other than the two main
conductors, which is not good. A significant current difference
will automatically open a disconnecting switch mechanism, cutting
power off completely.
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