5188 E

BGI/GUV-I 5188 E

Information

Thermal hazards
from electric fault arc
Guide to the selection of personal protective
equipment for electrical work

October 2012


Imprint

About us Publisher:
German Social Accident
Insurance e.V. (DGUV)

Mittelstraße 51
10117 Berlin
Tel.: 030 288763800
Fax: 030 288763808
E-Mail: info@dguv.de
Website: www.dguv.de

Subcommittee „Electrical and precision engineering“, Expert Committee „Energy, textile electrical and media products sectors“ the DGUV.

Design
German Social Accident Insurance e.V. (DGUV), Media Production

English translation of the German edition from October 2012

BGI/GUV-I 5188 E available from the competent German social accident insurance institution
or on www.dguv.de/publikationen
 

Information

Thermal hazards from electric fault arc

Guide to the selection of personal protective
equipment for electrical work

BGI/GUV-I 5188 E October 2012

Table of Contents

Page

Preliminary remarks ................................................................................................................................................................. 5

1 Scope .................................................................................................................................................................................. 6
2 Definitions .......................................................................................................................................................................... 7
3 Procedures for selecting PPEgS ........................................................................................................................................... 10
3.1 Overview of the evaluation process .............................................................................................................................. 10
3.2 Work environment parameters ...................................................................................................................................... 10
3.3 Determination of system electric arc energy in the event of a fault ................................................................................. 11
3.4 Determination of equivalent arc energy ........................................................................................................................ 13
3.5 Selection of PPE ........................................................................................................................................................... 14
4 Instructions for practical application with practical examples ............................................................................................... 15
4.1 Instructions for practical application ............................................................................................................................ 15
4.2 Examples ..................................................................................................................................................................... 16
4.3 Examples of work locations for determining transmission factor kT ................................................................................ 35

Annex 1
Directives, regulations, literature ......................................................................................................................................... 37
Annex 2
Standardisation of PPE against the thermal effects of electric fault arcing ............................................................................ 38
A 2.1 Standards for protective clothing in Europe .................................................................................................................. 38
A 2.2 Standards for protective clothing outside the EU ........................................................................................................... 39
A 2.3 Standards for other types of PPE ................................................................................................................................... 40
A 2.4 Specification standards for product approval and selection .......................................................................................... 41
Annex 3
Parameters and risk analysis of thermal hazards to persons related to electric arcing ........................................................... 43
A 3.1 Energy parameters for thermal hazards to persons
related to electric arcing ............................................................................................................................................... 43
A 3.2 Process of risk analysis ................................................................................................................................................. 43
A 3.3 Work steps ................................................................................................................................................................... 44
A 3.4 Alternative test methods .............................................................................................................................................. 48
Annex 4
PPE selection support form .................................................................................................................................................. 50
Preliminary remarks

Persons working on or in the vicinity of live electrical equipment Each consequence, in itself, can endanger the health and even
are, in principle, exposed to hazards associated with electric the life of a person in proximity of the occurrence. The most se-
fault arc. While an electric arc flash is rare in the normal working rious personal risks are associated with the thermal effects of
environment, its occurrence cannot be ruled out completely. electric fault arcs.
For this reason, persons working in this environment will require
reliable protection, especially because incorrectly performed NOTE:
work tasks can cause such arcing. Electric arcs are not only in- Methodologies based on a selection criteria where PPE is test-
duced by short circuiting, but can also occur between two cur- ed according to VDE 0682-306-1-1 (see Annex 1) are already
rent-carrying components, when they are separated from each described in NFPA 70e (Standard for Electrical Safety in the
other (e. g. installation/removal of circuit protectors while under Workplace) and IEEE 1584-2002 (Guide for performing arc-flash
load). hazard calculations), among others, and, for this reason, are not
presented directly in this guide.
The information contained herein is intended to support em-
ployers in their selection of suitable equipment (e. g. protective NOTE:
clothing or face shields for electrical work, etc.) for protection Moreover, an overview of PPE selection is included in the ISSA
against the thermal effects of electric fault arcs. In so doing, a (International Social Security Association) Guideline for the se-
methodology has been adopted based on standardised Box test lection of personal protective equipment when exposed to the
procedures according to VDE 0682-306-1-2 (see Annex 1). thermal effects of an electric fault arc (2nd edition 2011).

Depending on the electrical network and equipment configura-

tion, electric arcing can be extremely hazardous:
• High levels of thermal energy.
• Shockwaves and associated fragments released by the explo-
sive propagation of an arc flash.
• High intensity electromagnetic radiation, particularly in the
ultraviolet (UV) and infrared (IR) radiation bands, but also in
the visible light band, which can lead to irreversible damage
to the eyes and skin.
• High levels of acoustic shock (bang).
• Toxic gases and particles produced by melting and vaporised
materials in the vicinity of the arc flash (including electrodes).

5
1 Scope

This information provides guidance for action in the appraisal Neither does it apply to the use of electrical equipment conform-
of potential thermal hazards due to electric fault arcs associated ing to pertinent guidelines or standards and having been de-
with electrotechnical work on electrical equipment. Accordingly, signed or installed for use by unskilled persons.
this document affords employers an element of support in the
selection of essential PPE. NOTE:
The determinations made herein also apply to work performed
This information is applicable for work performed on or in the on or in the vicinity of d. c. electrical equipment. Examination of
vicinity of electrical equipment > 50 V AC. the likely resulting energy and calculation formulas should be
continued within the framework of continuing scientific research
Examples: (see Section 3).
• Household installations,
• Power distribution circuits,
• Industrial power systems.

The information contained herein does not address potential

hazards associated with the side-effects of electric arcing, such
as impact and acoustic shock or gases.

6
2 Definitions

Personal protective equipment against the thermal effects of an Direct exposure incident energy Ei0
electric fault arc (PPEgS) Heat energy emanating directly from the electric fault arc per
Personal protective equipment against the thermal effects of unit of affected area.
an electric fault arc applies to any medium meant to be worn or
held by a person for protection against the thermal hazards as- NOTE:
sociated with electric fault arcs. Direct incident energy is expressed in kJ/m2 or kWs/m2
(cal/cm2)1).

Work
Any form of electrotechnical or non-electrotechnical activity Transmitted incident energy Eit
where the potential for electrical hazard exists. Incident energy that penetrates PPE when exposed to electric
arcing; a portion of the released incident energy.

Live working NOTE:

Any activity, by which a person, either physically or through the Transmitted incident energy is expressed in kJ/m2 or kWs/m2
use tooling, equipment or devices, knowingly comes in contact (cal/cm2)1).
with or enters a danger zone associated with live components.
(from DIN VDE 0105-100, 3.4.4)
Incident energy Ei
Heat energy (total heat) affecting a unit of area as a result of an
Work performed in the vicinity of live components electric arc.
Any activity, by which a person, either physically or through the
use of tooling, equipment or devices, knowingly enters a vicinity NOTE:
zone without entering the danger zone Incident energy is expressed in kJ/m2 or kWs/m2 (cal/cm2)1).
(from DIN VDE 0105-100, 3.4.5).

Electrical system
Working distance a Overall electric installations and equipment for producing, trans-
The distance between the electric arc and a person's body (tor- mitting, converting, distributing and utilizing electrical energy.
so), that is effective during activity in the working environment
being considered.
Electrode gap d
NOTE: Distance between the arc electrodes
Working distance is expressed in mm.
NOTE:
Electrode gap is expressed in mm.
Equivalent arc energy WLBä
Equivalent arc energy WLBä resulting from the test level WLBP at
a precise working distance a and transmission factor kT. Duration of exposure
Period of exposure to electric fault arc energy in time.
NOTE:
PPE protection level is expressed in kJ or kWs. NOTE 1:
Duration of exposure is expressed in s.

Normalised arc power kP NOTE 2:

Relationship of electric arc power to the short-circuit power in Exposure duration is normally significantly longer than arc duration.
the electrical network at the fault location.

1) Correlation:
1 cal/cm2 = 41,868 kJ/m2, 1 kJ/m2 = 0,023 885 cal/cm2.

7
Definitions

Short-circuit duration Prospective short-circuit current

Period of the short-circuit in time. Anticipated current that flows when the impedance at the
fault location is negligible (electrical supply short-circuit).
NOTE: [VDE 0682-306-1-2]
Duration of short-circuiting is expressed in s.
NOTE 1:
Prospective short-circuit current is expressed in kA.
Arc duration
Period of the arc flash in time NOTE 2:
There is a general difference between the actual electric arc cur-
NOTE: rent and the prospective short-circuit current. The actual electric
Duration of arcing is expressed in s. arc current flowing throughout the duration of arcing is lower
and fluctuates due to the nonlinear arc impedance that varies
stochastically over time.
Arc energy Warc
Electrical energy that causes and is converted into an arc flash;
the sum (integral) of the product of the instantaneous values of Test level WLBP
arc voltage and arc current, as well as the time differential, de- Electric arc energy set as part of the Box test (according to
termine the duration of arcing. VDE 0682-306-1-2) for either of the two electric fault arc test cat-
egories and leading to a direct incident energy Ei0P.
NOTE:
Electric arc energy is expressed in kJ or kWs. NOTE:
Electric arc energy is expressed in kJ or kWs.

Arc short-circuit current IkLB

Current actually flowing at the fault location throughout the du- Test current Iarc, class
ration of arcing (due to the arc flash); determined as the average Prospective short-circuit current in the electrical test current cir-
effective value over the duration of the short-circuit. cuit (anticipated current) used for setting a test category in the
Box test method; effective value (symmetrical a. c. component).
NOTE:
Electric arc short-circuit current is expressed in kA. NOTE:
Test current is expressed in kA.

Arc current Iarc

Current actually flowing in the test circuit during the arc duration R/X ratio
(through the arc flash); determined as the average effective val- Relationship of the resistance to the inductive reactance of a
ue over the duration of arcing. [VDE 0682-306-1-2] short-circuited electrical circuit.

NOTE 1:
Electric arc current is expressed in kA. PPE protection level
Protection level of the PPE resulting from the test level WLBP at a
NOTE 2: fixed working distance a and transmission factor kT.
Electric arc current flowing throughout the duration of arcing
is subject to stochastic time variations due to nonlinear arc NOTE:
impedance. Equivalent arc energy is expressed in kJ or kWs.

Material
Textile fabrics or other materials used to produce single or mul-
tilayer PPE.

8
Stoll curve Symbols and units
Correlation between thermal incident energy and exposure time
derived from data related to the tolerance behaviour of human
skin when exposed to heat; specifies the limits for the occur- a Working distance mm
rence of second-degree skin burns.
d Electrode gap mm

Ei Incident energy kJ/m2 or kW s/m2

Current limiting factor kB
Ei0 Direct exposure incident energy kJ/m2 or kW s/m2
Relationship between the actual electric arc short-circuit current (cal/cm2)
and the prospective short-circuit current.
Iarc Electric arc current kA

Iarc, class Test current kA

Fault arc
An independent electric discharge due to a faulty connection IkLB Electric arc short-circuit current kA
between components of different potential in electric power kB Current limiting factor
equipment.
kP Normalised arc power
NOTE: kT Transmission factor
Electric fault arcing in the context of the information herein is
considered to be an undesirable faulty occurrence caused by t Time s
short-circuiting. Warc Arc energy kJ, kWs

WLBä Equivalent arc energy, protection kJ or kWs

level
Fault arc protection classes
Categories of protective properties of the PPE against the ther- WLBP Test level kJ or kWs
mal effects of an electric fault arc as tested through Box test pro-
cedures (according to VDE 0682-306-1-2). The classes are distin-
guished by test energy levels.

Transmission factor kT
Factor describing the spatial propagation of the thermal impact
of an electric arc on the working environment. It is determined
by the geometric relationships between the equipment at the
workplace.

Transmission and exposure conditions

Totality of the influences on the heat transfer associated with an
electric fault arc.

9
3 Procedures for selecting PPEgS

3.1 Overview of the evaluation process

The first step entails an estimation of the arc energy WLB

that is converted in the event of a fault at the workplace.
This is then compared to the equivalent arc energy WLBä
with consideration given to the transmission character-
istics and working distance, up to the level where pro-
tection is provided by the PPE.

3.2 Work environment parameters

The electrical system working environment is character-

ised by the following parameters:

Work environment

Protection device Electrical network Electrical system

tk UNn Sk d

R/X
Fig. 1 Work environment parameters

tk Legend:

tk [s]: Protection device trip time

d
UNn [V]: Rated network voltage
UNn
R/X: Resistive/reactive
relationship related to
network impedance

Sk [kVA]: 3-phase short-circuit

Sk capacity

d [mm]: Distance between two live

components at the
workplace

Fig. 2 Electrical equipment parameters

10
3.3 Determination of system electric arc energy in the Consequently, the following correlations can be drawn
event of a fault with respect to electric arc energy in the event of a fault:

Work environment WLB = PLB ⋅ tk

= kP ⋅ Sk ⋅ tk
Protection device Electrical network Electrical system
= kP ⋅ 3 ⋅ UNn ⋅ Ik3 ⋅ tk
tk UNn Sk d
The decisive short-circuit current Ik3 is the prospective
R/X
3-pole short-circuit current at the workplace (fault loca-
tion). It is the outcome of a short-circuit current calcula-
tion (see Annex A.3.3.2.).
Normalised arc power kP
The actual short-circuit current IkLB in the low voltage
range is significantly lower than the calculated system
short-circuit current Ik3 (current limiting factor kB) due to
Electric arc energy the attenuating properties of the electric arc and cannot
be determined in certainty. In principle, the applicable
WLB
correlation is:
Fig. 3 Determination of electric arc energy IkLB = 0,5 ⋅ Ik3min (see Annex A.3.3.2)

In the > 1 kV range, the limiting properties of the electric

Electric arc energy WLB is determined by the electric arc arc can be disregarded. The following applies: kB = 1.
power PLB and the duration of arcing, meaning the time
tk until tripping by the protection device: The duration of arc combustion is determined by the
protection device and generally can be taken from the
WLB = PLB ⋅ tk
protective equipment manufacturer's selectivity calcula-
tions and/or the trip characteristic curves (current-time
Electric arc power PLB is dependent upon the type of arc curves).
formation and the geometry of the live components at
the fault location. It is determined with the help of the The low voltage range is generally considered to be safe
normalised arc power kP from the short-circuit power Sk. if one assumes a current limitation of 50 % and uses
this reduced current to ascertain the trip time from the
Normalised arc power kP can be determined with con- protection characteristic curve. The current limiting fac-
sideration given to the effective electrode gap d (dis- tor then equates to kB = 0.5; it follows that
tance between system conductors), (e. g. according to IkLB = 0,5 ⋅ Ik3min
the text in German, “Schau, H.; Halinka. A.; Winkler,
W.: Elektrische Schutzeinrichtungen in Industrienetzen The overcurrent protection device trip time should now
und -anlagen“). Reference values are specified in Annex be determined with the help of the characteristic curve
A.3.3.4. and the ascertained electric arc short-circuit current IkLB
(see A 2.3.3).
Worst-case examinations can be calculated using the
maximum value kPmax:

0,29
kPmax =
(R/X)0,17

11
Procedures for selecting PPEgS

tk

IkLB
Fig. 4 Example for determining the overcurrent protection device trip time

NOTE:
At short-circuit durations longer than 1 s, it can be assumed that
the person will be able to withdraw from the immediate danger
area, if applicable. For this reason, longer periods will not need
to be considered. This does not apply, however, if withdrawal of
the person from the working environment is precluded or re-
stricted (e. g. work in tight cable trenches or canals, narrow work
corridors, work from ladders or lifting mechanisms).

12
3.4 Determination of equivalent arc energy In a small-scale system, a directional propagation of
the electric arc thermal impact occurs. The more open
The equivalent arc energy is the protection level afford- or large-scale the system, the more omnidirectional the
ed by the PPE. It is determined by the test level for the electric arc thermal impact propagation will be.
PPE, working distance a and the equipment geometry
(Factor kT). Exemplary pictures of real system configurations are de-
picted in Section 4.3.
Working distance a is the distance between the electric
arc and the person's body (torso) that is effective during The test method used to verify the thermal impact of an
the work activity or must be maintained in the working electric fault arc is described in detail in Annex A 3.1.
environment being considered. Where different tasks
are being carried out in the working environment, the The test method differentiates between two class-
shortest distance emerging should be applied. (see An- es, which define the protective properties of the PPE
nex A 3.3.5) against the thermal effects of an electric fault arc (test
level). Both classes are verified through electric arc-
It can generally be assumed that the distance to the ing with subsequent electric arc energies, as well as
person's torso when working will not fall short of a = through the use of the test setups described in the test
300 mm and that, particularly in the low voltage range, method.
this can be applied as a reference value.
Class 1 WLBP1 = 158 kJ
The transmission factor kT takes into account the electri- Class 2 WLBP2 = 318 kJ
cal system's geometric configuration and describes the
spatial propagation of the electric arc thermal impact in
space.

Work enviroment PPE

Protection device Electrical network Electrical system PPE test

Electric fault arc class

tk UNn Sk d a kT

R/X

WLBP

Normalised arc power kP

Electric arc energy

≤ Equivalent arc energy

WLB WLBä

Fig. 5 Determination of equivalent arc energy with consideration given to working distance and geometry

13
Procedures for selecting PPEgS

Box V = 1,6 l Rear wall only or Electric arc burns

large combustion openly (very large
Side and rear walls space volume combustion space
volume)
low volume

kT = 1,0 kT = 1,5 … 1,9 kT = 2,4

Fig. 6 Transmission factor reference values for different equipment relationships

An equivalent arc energy WLBä, at which level protection 3.5 Selection of PPE
is still afforded by the PPE for the respective distance a,
can be determined for any working distance a over the In the risk assessment or when selecting the PPE test
experimentally verified reverse squared distance pro- category or protection class (Box test), the relation to
portionality, using the electric arc energy of the test the expected value for electric arc energy is to be con-
category WLBP2. In addition, the system configuration sidered based on the equivalent arc energy. The thermal
can be taken into consideration using factor kT. General- hazards associated with electric arching are deemed
ly valid for the Box test covered if

( )
a 2
WLBä = kT ⋅ ⋅ WLBP WLB ≤ WLBä
300 mm
applies.

The limits for PPE use in a chosen test category or pro-

tection class with respect to the short-circuit current
range, the permissible short-circuit duration or protec-
tion device trip time (and therewith the protective sys-
tem itself), as well as the permissible working distance,
can also be determined based on this relationship
using the above mentioned determinant values and
equations.

2) Feasibility study related to the testing and evaluation of pro-

tective gloves against the thermal hazards of electric fault
arcing (AG: BGFE; AN: STFI/TU Ilmenau), STFI final report from
30 May 2005.

14
4 Instructions for practical application with
practical examples

–– A separate protection device for electric fault

4.1 Instructions for practical application
arcs detects the electric arc by means of a
sensor system, immediately initiates a bolted
A worksheet (Excel) has been developed to support use
short-circuit and triggers the upstream protec-
of the methodology, which can be downloaded from the
tion device. The duration of arc combustion is
Internet at the BG ETEM homepage (www.dguv.de;
reduced in this manner to just a few
Webcode: d138299).
milliseconds.
The following basic conditions should be considered These devices can be foreseen for permanent
when implementing the evaluation process in practice: installation during the system planning stage
or can be used for mobile applications4).
• The requirements set forth in BGV/GUV-V A3 „Electri-
cal Systems and Equipment“ should be taken into –– If the working distance can be increased, this
account, particularly with respect to the use of addi- will greatly influence the equivalent arc energy.
tional PPE for work on live equipment or in the vicinity Thus, it may well make sense to consider
of live system components. whether an increase in the working distance
could be realised with the aid of additional
• The methodology only covers that protection afforded
auxiliary devices.
against the thermal effects of an electric fault arc.
Experience has shown these effects have the most –– Short-circuit power at the workplace can be
severe consequences. Electric fault arcs in high-ener- reduced by means of a modified circuit variant
gy systems can lead to further hazards caused by depending on the system configuration (e. g.
shockwaves, noise, optical radiation or escaping disconnection of a machine network connec-
electric arc gases. tion, removal of a parallel connection). Subse-
quent to these measures, the calculation pro-
• If use of the selection algorithm determines that the
cess should be applied again for the modified
protective properties of the PPE selected for the work
network parameters.
process being considered are not adequate, the fol-
lowing exemplary measures could be considered in • If the maximum value kPmax was used to determine
more detail: normalised arc power kP in the initial analysis, the
calculation will be on the safe side, but it may also
–– The protection device's characteristics and
result in exceeding the target in practice. In this case,
corresponding trip time have a significant in-
it is worthwhile calculating using a typical reference
fluence on the potential electric arc energy in
value or with consideration given to the practical
the event of a fault. Replacement of the up-
system configuration.
stream protection device with a fast-acting
industrial protection device or adjustment of • The geometry of the real system is entered into the
the circuit breaker tripping characteristics calculation. The transmission factor kT, which is nor-
during the work period might be considered in mally established at the start during the initial ap-
this context3). proximation, can then be adapted based on the actu-
al geometric system conditions and the working
environment. If a deviation from transmission factor
kT = 1 is intended, this determination must be
justified.

3) Strasse, U., Erfahrungen beim Einsatz von Arbeitssicherungen beim 4) Rotter, G., Bähnsch, R., Lichtbogenschutz-System DEHNarc –
AuS im Kabelnetz von Vattenfall Europe Berlin; ETG Fachbericht Fach- Geräte-System und Anwendung in der Praxis, 15 th BG ETEM Electrical
bereich 106 Arbeiten unter Spannung (AuS), Presentation for the Engineering Technical Meeting in Kassel, 2010.
ETG-Technical Meeting in Dresden from 19. to 20. September 2007.

15
Instructions for practical application with practical examples

If evaluation shows that the protective properties of 4.2 Examples

the clothing made available are inadequate for the
work process being considered and measures such The following examples depict work being carried out
as increasing the working distance, reducing the at different work locations in a typical municipal low
electric arc energy or introducing additional electric voltage supply system.
fault arc-resistant partition walls, can not be taken,
then work must not be performed if the system has 4.2.1 Work location 1: Low voltage distribution in a trans-
not been electrically isolated. former station
Work tasks are frequently carried on the low voltage
distribution system in a transformer station.
NOTE:
If observation reveals potential hazards associated
with system operation, such as during system isolation,
against which the available PPE does not offer adequate
protection, then special consideration should be made
in each individual case. Measures such as isolating the
upstream network may be conceivable in this context.

• The manufacturer's instructions must be observed to

ensure the PPE provides the appropriate protection in
the event of a fault. In particular, it is essential to
adhere to the instructions for proper usage, as well as
those specified by the manufacturer for proper care.
At the same time, it is recommended to wear cotton
underwear.
Fig. 8 Work on a low voltage distribution system

An increased degree of risk exists when performing such

work because, in the event of a fault at the workplace,
significant short-circuit power is generated directly be-
hind the transformer. The transformer output, as well
as the transformer fuses or power supply branch circuit
breaker trip times, are decisive for the energy released
in an electric arc. One important factor is influenced by
the structure or the switching status of the low voltage
network with relationship to the type of energy supply to
the low voltage stations (station meshing or per station
low voltage network supply). The short-circuit power and
the prospective short-circuit current at the workplace
depend on whether a unilateral or a multilateral supply
exists. It is often practical with meshed low voltage net-
works to neutralize the meshing prior to working on live
components in the low voltage distribution system and
to establish a unilateral energy supply, as is the case in
the example considered.

16
 Work location 1
Arbeitsort 1

Arbeitsort 3
Arbeitsort 2 Work location 3
Work location 2

Kabelverteilerschrank
Cable distribution
cabinet,
außenoutside

Netzstation
Network station

Trennstelle

Fig. 7 Municipal low voltage supply system being considered

17
Instructions for practical application with practical examples

Step 1: Data for the workplace being considered Step 2: Determination of Ik3, R/X
This example represents a municipal supply system Using the short-circuit current calculation according
(Fig. 8) where work location 1 is being considered. There to VDE 0102 (Short-circuit currents in three-phase a.c.
are 20/0.4 kV transformers present at the network sta- systems - Part 0: Calculation of currents), with a unilat-
tions with rated capacities SrT of 630 kVA or 400 kVA eral energy supply switching status for the work loca-
and short-circuit voltages uK of 4 %. The standard 1-kV tion results in a prospective short-circuit current (initial
aluminium cable cross-sections are 150 mm2 for the short-circuit alternating current) Ik3 of
mains cables and 35 mm2 for the house installation
cables. The drawing in Fig. 7 depicts the network sep- Ik3max = 23,1 kA (c = 1.05)
aration points, which can be opened during work on Ik3max = 20,9 kA (c = 0.95)
live components in order to establish a unilateral ener-
gy supply to the respective network areas in question. The R/X ratio for network impedance in the fault circuit
Work location 1 is supplied by a 630 kVA transform- equates to 0.2.
er over a 630 kVA NH (low voltage, high performance)
transformer fuse with operating class gTr AC 400 V. Step 3: Determination of Electric arc current
The fuse current-time curve is depicted in Fig. 10. The minimum fault current relevant for the NH fuse trip
time with an electric arc short-circuit current results
from the minimum prospective short-circuit current
20 kV Ik3min with the aid of limiting factor kB, which charac-
terizes the current-limiting effects of the electric arc in
the fault circuit. Because a low voltage system and a
20/0,4 kV worst-case examination are being dealt with in the in-
uk = 4 %
630 kVA itial ansatz, a current limiting factor of kB = 0,5 will be
assumed according to Section 3.3. For minimum fault
current, it follows that

IkLB = kB ⋅ Ik3min = 0,5 ⋅ 20,9 kA = 10,45 kA

The trip time for this current is taken from the protec-
NH-transformer fuse tion characteristic curve in Fig. 10 is t = 0,1 s. This time
630 kVA gTr AC 400 V equates to the short-circuit duration tk.

Power bus bar NOTE:

In practice, the characteristic curve for the overcurrent
Work location 1 protection device in use should be applied.

Fig. 9 Work location 1 equivalent circuit diagram

18
 630 kVA Transformer

400 kVA Transformer

Fig. 10 Mean time/current characteristic curves for the fgTr AC 400 V fuse in use

19
Instructions for practical application with practical examples

Step 4: Electric arc power at the workplace Step 7: Transmission factor, equivalent arc energy
Using the maximum prospective short-circuit current When working on low voltage distribution systems in
Ik3max, it follows for short-circuit power at the workplace transformer stations, it should be assumed that large-
that scale installations will be used with spatial limitations
primarily due to a rear wall structure. A transmission fac-
Sk = 3 ⋅ UNn = 3 ⋅ 400 V ⋅ 23,1 kA = 16,004 MVA tor of kT = 1,5 is assumed at this location. Using a work-
ing distance of a = 300 mm, it follows for equivalent arc
Under worst-case conditions, the maximum possible energy that
value for normalised arc power can be determined using

( ) ( )
a 2 300 mm 2
the formula kPmax = 0,29 / (R/X)0,17. This example re- WLBä = kT ⋅ ⋅ WLBP = 1,5 ⋅ ⋅ WLBP
sults in the computation kP,max = 0,38. 300 mm 300 mm

From this results an electric arc energy WLB: WLBä = 237 kJ for Electric fault arc protection class 1
WLBä = 477 kJ for Electric fault arc protection class 2
WLB = kP ⋅ Sk ⋅ tk = 0,38 ⋅ 16,004 MVA ⋅ 0,1 s = 608,2 kJ
Step 8: Selection of protection class
This energy is the anticipated value for electric arc ener- WLB = 608,2 kJ > WLBä,Kl2 = 477 kJ applies. Consequently,
gy at workplace 1 in the event of a fault. the system must be shutdown or measures must be tak-
en according to Section 4.1 and a new calculation must
Step 5: Establish the working distance be made.
A working distance of a = 300 mm is used for work on
low voltage distribution systems. This corresponds to
the minimum distance between a person's torso and
the frontal area of the opened equipment.

Step 6: Test level for the PPE

The test levels for PPE under standardised Box test con-
ditions according to VDE 0682-306-1-2 are

Electric fault arc protection class 1: WLB P1 = 158 kJ

Electric fault arc protection class 2: WLB P2 = 318 kJ

20
Execution of the required work steps will yield the results below.

Step Determination Parameter Result for Result for

worst-case precise calculation
examination according to5
1 Network parameter: Nominal network voltage UNn 400 V 400 V
Equipment geometry: Distance between conductors d 60 mm 60 mm
2 Short-circuit current calculation Ik3pmax 23,1 kA 23,1 kA
Ik3pmin 20,9 kA 20,9 kA
R/X 0,2 0,2
3 Current limitation kB 0,5 0,633
Minimum fault current IkLB 10,45 kA 13,23 kA
NH fuse characteristic curve (Fig. 10) tk 0,1 s 0,045 s
4 Short-circuit power Sk 16 MVA 16 MVA
Normalised arc power kP 0,38 0,338
Electric arc power PLB 6,1 MW 5,4 MW
Electric arc energy (anticipated value) WLB 608,2 kJ 243,4 kJ
5 Working distance a 300 mm 300 mm
6 Standardised PPE test level WLBPKl1 158 kJ 158 kJ

WLBPKl2 318 kJ 318 kJ

7 Transmission factor: small-scale system kT 1,5 1,5
Equivalent arc energy (protection level) WLbäKl1 237 kJ 237 kJ

WLbäKl2 477 kJ 477 kJ

8 Comparison: WLB ≤ WLBä? 608,2 kJ > 477 kJ 243,4 kJ < 477 kJ
PPE Electric fault arc protection class Take other measures or isolate Class 2

Table 1 Example summary: Work on the low voltage distribution system of a (630 kVA) transformer station; Work location 1

In the case of a station with a 400 kVA transformer A normalised arc power of kP = 0,38 results in an elec-
(short-circuit voltage 4 %; NH fuse 400 kVA gTr AC 400 V), tric arc power of PLB = 37 MW and an anticipated electric
the prospective short-circuit current - under arc energy value of WLB = 167,6 kJ. The same working
otherwise similar conditions as above - will fall within distance a = 300 mm and the same transmission rela-
the range Ik3 = 12,7 to 14,1 kA. tionships (kT = 1,5) as before means that PPE protection
class 1 will be required.
The R/X ratio equates to 0,2. The characteristic curve for
the NH fuse (Fig. 10) for kB = 0,5 and IkLB = 6,4 kA reveals
a short-circuit duration of tk = 0,045 s. Short-circuit pow-
er equates to Sk = 9,769 MVA.

5) Schau, H.; Halinka. A.; Winkler, W.: Elektrische Schutzeinrich-

tungen in Industrienetzen und -anlagen.

21
Instructions for practical application with practical examples

Step Determination Parameter Result Result for

precise calculation
according to5
1 Network parameter: Nominal network voltage UNn 400 V 400 V
Equipment geometry: Distance between conductors d 60 mm 60 mm
2 Short-circuit current calculation Ik3pmax 14,1 kA 14,1 kA
Ik3pmin 12,7 kA 12,7 kA
R/X 0,2 0,2
3 Current limitation kB 0,5 0,633
Minimum fault current IkLB 6,4 kA 8 kA
NH fuse characteristic curve (Fig. 10) tk 0,045 s 0,04 s
4 Short-circuit power Sk 9,8 MVA 9,8 MVA
Normalised arc power kP 0,38 0,338
Electric arc power PLB 3,7 MW 3,3 MW
Electric arc energy (anticipated value) WLB 167,6 kJ 132,1 kJ
5 Working distance a 300 mm 300 mm
6 Standardised PPE test level WLBPKl1 158 kJ 158 kJ

WLBPKl2 318 kJ 318 kJ

7 Transmission factor: small-scale system kT 1,5 1,5
Equivalent arc energy (protection level) WLbäKl1 237 kJ 237 kJ

WLbäKl2 477 kJ 477 kJ

8 Comparison: WLB ≤ WLBä? 167,6 kJ < 237 kJ 132,1 kJ < 237 kJ
PPE Electric fault arc protection class Class 1 Class 1

Table 2 Example summary: Work on the low voltage distribution system of a (400 kVA) transformer station; Work location 1

5) Schau, H.; Halinka. A.; Winkler, W.: Elektrische Schutzeinrich-

tungen in Industrienetzen und -anlagen.

22
4.2.2 Work location 2: Low voltage cabling
Work is frequently carried out on cable joints in the ca-
ble network (see Fig. 11). Work location 2 in this example
(T-joint at the end of approx. 100 m network cabling) is
depicted in Fig. 7. The level of fault current and electric
arc energy is greatly dependent on the distance be-
tween the work location and the network supply station
(transformer) and, for this reason, on the length of the
corresponding network cable.

Fig. 11 Work on a cable sleeve

23
Instructions for practical application with practical examples

Example 3
1,5 kA/4 s
NH 250 AgL

Example 2
2,85 kA/0,15 s
NH 250 AgL

Example 5
6,26 kA/0,022 s
NH 315 AgL

Fig. 12 Mean time/current characteristic curves for the NH gL/gG AC 400 V line fuse being considered

In this example, the work location is being fed through

a network cable from a 630 kVA transformer station.
The NH fuse in the supplying station's cable branch is
decisive for breaking the electric fault arc. In this con-
text, an NH 250 A full-range line fuse is used with oper-
ating class gG or gL AC 400 V. The characteristic curve is
depicted in Fig. 12.

24
Execution of the required work steps will yield the results below.

Step Determination Parameter Result Result for

precise calculation
according to5
1 Network parameter: Nominal network voltage UNn 400 V 400 V
Equipment geometry: Distance between conductors d 45 mm 45 mm
2 Short-circuit current calculation Ik3pmax 6,3 kA 6,3 kA
Ik3pmin 5,7 kA 5,7 kA
R/X 1,0 1,0
3 Current limitation kB 0,5 0,59
Minimum fault current IkLB 2,85 kA 4,25 kA
NH fuse characteristic curve (Fig. 12) tk 0,15 s 0,09 s
4 Short-circuit power Sk 4,365 MVA 4,365 MVA
Normalised arc power kP 0,29 0,24
Electric arc power PLB 1,266 MW 1,047 MW
Electric arc energy (anticipated value) WLB 189,9 kJ 94,2 kJ
5 Working distance a 300 mm 300 mm
6 Standardised PPE test level WLBPKl1 158 kJ 158 kJ

WLBPKl2 318 kJ 318 kJ

7 Transmission factor: large-scale system kT 1,9 1,9
Equivalent arc energy (protection level) WLbäKl1 300 kJ 300 kJ

WLbäKl2 604,2 kJ 604,2 kJ

8 Comparison: WLB ≤ WLBä? 189,9 kJ < 300 kJ 94,2 kJ < 300 kJ
PPE Electric fault arc protection class Class 1 Class 1

Table 3 Example summary: Work on a cable network joint; Work location 2

The work being performed at Work location 2 (cable

sleeves) under consideration requires PPE in the Electric
fault arc protection class 1 according to the appraisal in
Section 3 and with precise calculations.

5) Schau, H.; Halinka. A.; Winkler, W.: Elektrische Schutzeinrich-

tungen in Industrienetzen und -anlagen.

25
Instructions for practical application with practical examples

4.2.3 Work location 3: House junction box The branch fuse in the upstream cable distribution
The replacement of a house junction box is often as- cabinet is decisive for breaking the short-circuit; in
sociated with work on live equipment (Fig. 13 (inside/ this case, an NH 250 A fuse is used with operating
outside)). Such an example in Work location 3 is consid- class gG AC 400 V.
ered in Fig. 7. Energy is once again supplied to the work
location from an upstream network station with a 630
kVA transformer. In contrast to Example 2, the short-cir-
cuit current is significantly less because the house con-
nection cables have only comparatively small cross-sec-
tions. The house connection cable in the example has a
length of approx. 15 m.

Fig. 13 Work on a house junction box

26
Execution of the required work steps will yield the results below.

Step Determination Parameter Result Result for

precise calculation
according to5
1 Network parameter: Nominal network voltage UNn 400 V 400 V
Equipment geometry: Distance between conductors d 45 mm 45 mm
2 Short-circuit current calculation Ik3pmax 6,3 kA 6,3 kA
Ik3pmin 5,7 kA 5,7 kA
R/X 1,0 1,0
3 Current limitation kB 0,5 0,59
Minimum fault current IkLB 2,85 kA 4,25 kA
NH 250 A fuse characteristic curve (Fig. 12): tk 0,15 s 0,09 s
tk = 2,5 s*
4 Short-circuit power Sk 4,365 MVA 4,365 MVA
Normalised arc power kP 0,29 0,24
Electric arc power PLB 1,266 MW 1,047 MW
Electric arc energy (anticipated value) WLB 189,9 kJ 94,2 kJ
5 Working distance a 300 mm 300 mm
6 Standardised PPE test level WLBPKl1 158 kJ 158 kJ

WLBPKl2 318 kJ 318 kJ

7 Transmission factor: small-scale system kT 1,9 1,9
Equivalent arc energy (protection level) WLbäKl1 300 kJ 300 kJ

WLbäKl2 604,2 kJ 604,2 kJ

8 Comparison: WLB ≤ WLBä? 189,9 kJ < 300 kJ 94,2 kJ < 300 kJ
PPE Electric fault arc protection class Take other measures or isolate

Table 4 Example summary: Work on a opened house junction box; Work location 3

* Referencing the characteristic curve (Fig. 12), a trip time of t > 1 s results, so that it can be assumed that the maximum time relevant to the
exposure equates to tk = 1 s. (also refer to the note at the end of Section 3.3).

5) Schau, H.; Halinka. A.; Winkler, W.: Elektrische Schutzeinrich-

tungen in Industrienetzen und -anlagen.

27
Instructions for practical application with practical examples

It can be seen from the results in the example that PPE An NH 160 A aR/690 V - üf01 fuse is used for this exam-
in the Electric fault arc protection class 2 is not ade- ple, whereby a trip time of 6.87 ms results.
quate for work on a house junction box. The high antic-
ipated value of electric arc energy is brought about by a The performance of work tasks using PPE in the Elec-
long short-circuit duration, from which a long exposure tric fault arc protection class 1 is now made possible
duration emerges. through the use of the safe-work fuse.

In order to facilitate work in this case, The use of this fuse will yield the following results:
• protection devices guaranteeing defined and suffi-
ciently rapid breaking characteristics must be used or
• compliance with an adequate minimum distance
must be required or
• PPE tested for greater Incident energy levels must be
used.

The option mentioned at first will be singled out for con-

sideration below. For this, it must be ensured that the
NH 250 A gG branch fuse present in the network supply
station's cable branch is replaced with a safe-work fuse
with a low rated current and/or with fast-acting or su-
per-fast-acting operating characteristics for the duration
of the work task. This means that prior to beginning and
subsequent to completing the work task a fuse replace-
ment will be necessary. If an NH 160 A safe-work fuse is
used with an operating class aR (fast-acting: üf2, very-
fast-acting: üf1, super-fast-acting: üf01, hyper-fast-act-
ing: üf02) is used, a current-limiting break will occur in
any case. Regarding the calculations in this context, a
short-circuit duration of tk = 0,01 s is to be applied.

28
 Step Determination Parameter Result Result for
precise calculation
according to5
1 Network parameter: Nominal network voltage UNn 400 V 400 V
Equipment geometry: Distance between conductors d 45 mm 45 mm
2 Short-circuit current calculation Ik3pmax 3,4 kA 3,4 kA
Ik3pmin 3,0 kA 3,0 kA
R/X 2,0 2,0
3 Current limitation kB 0,5 0,554
Minimum fault current IkLB 1,5 kA 1,66 kA
NH fuse characteristic curve (Fig. 12) tk 0,01 s 0,01 s
4 Short-circuit power Sk 2,353 MVA 2,353 MVA
Normalised arc power kP 0,26 0,222
Electric arc power PLB 0,61 MW 0,5 MW
Electric arc energy (anticipated value) WLB 6,1 kJ 5,2 kJ
5 Working distance a 300 mm 300 mm
6 Standardised PPE test level WLBPKl1 158 kJ 158 kJ

WLBPKl2 318 kJ 318 kJ

7 Transmission factor: small-scale system kT 1 1
Equivalent arc energy (protection level) WLbäKl1 158 kJ 158 kJ

WLbäKl2 318 kJ 318 kJ

8 Comparison: WLB ≤ WLBä? 6,1 kJ < 158 kJ 5,2 kJ < 158 kJ
PPE Electric fault arc protection class Class 1

Table 5 Example summary: Work on an opened house junction box while using a safe-work fuse; Work location 3

5) Schau, H.; Halinka. A.; Winkler, W.: Elektrische Schutzeinrich-

tungen in Industrienetzen und -anlagen.

29
Instructions for practical application with practical examples

4.2.4 Work location 4: Electrical installation behind a house

junction box
As a rule, when working on live equipment or in the vi-
cinity of live components in the house electrical installa-
tion, basic protection, meaning PPE in the Electric fault
arc protection class 1, is sufficient. The following exam-
ple depicts the calculation for a typical configuration be-
hind an NH 63 A gL fuse.

Fig. 14 Work behind the house supply systemx

30
 Step Determination Parameter Result Result for
precise calculation
according to5
1 Network parameter: Nominal network voltage UNn 400 V 400 V
Equipment geometry: Distance between conductors d 25 mm 25 mm
2 Short-circuit current calculation Ik3pmax 3,4 kA 3,4 kA
Ik3pmin 3,0 kA 3,0 kA
R/X 2,0 2,0
3 Current limitation kB 0,5 0,554
Minimum fault current IkLB 1,5 kA 1,66 kA
NH 63 AgLfuse characteristic curve (Fig. 12) tk 0,04 s 0,04 s
4 Short-circuit power Sk 2,353 MVA 2,353 MVA
Normalised arc power kP 0,26 0,25
Electric arc power PLB 0,61 MW 0,56 MW
Electric arc energy (anticipated value) WLB 24,5 kJ 22,6 kJ
5 Working distance a 300 mm 300 mm
6 Standardised PPE test level WLBPKl1 158 kJ 158 kJ

WLBPKl2 318 kJ 318 kJ

7 Transmission factor: small-scale system kT 1 1
Equivalent arc energy (protection level) WLbäKl1 158 kJ 158 kJ

WLbäKl2 318 kJ 318 kJ

8 Comparison: WLB ≤ WLBä? 24,5 kJ < 158 kJ 22,6 kJ < 158 kJ
PPE Electric fault arc protection class Class 1

Table 6 Example summary: Work on an electrical installation behind a house junction box; Work location 4

5) Schau, H.; Halinka. A.; Winkler, W.: Elektrische Schutzeinrich-

tungen in Industrienetzen und -anlagen.

31
Instructions for practical application with practical examples

4.2.5 Work location 5: Low voltage distribution system for

industry
The following example depicts the calculation for a typ-
ical configuration behind an NH 315 A gG fuse. Various
tasks are carried out behind the NH fuse on the instal-
lation in this example. This ranges from simple adjust-
ments on protection devices and equipment to replace-
ment of the equipment itself.

The work location is on the electrotechnical equipment

for a cooling unit.

Transformer
10/0,4 kV
uk = 6 %
2000 kVA

Circuit breaker
IN = 3200 A

Power bus bar

NH NH NH
315 A 315 A 315 A
gG gG gG

4 x 185/95 mm2
NYCWY
I = 86 m
tion
oca
rk l
Wo

Cooling unit

Fig. 15 Industrial plant system overview

32
Fig. 16 Work on an industrial low voltage system (cooling unit control cabinet)

33
Instructions for practical application with practical examples

Step Determination Parameter Result Result for

precise calculation
according to5
1 Network parameter: Nominal network voltage UNn 400 V 400 V
Equipment geometry: Distance between conductors d 20 mm 20 mm
2 Short-circuit current calculation Ik3pmax 15,34 kA 15,34 kA
Ik3pmin 12,52 kA 12,52 kA
R/X 0,87 0,87
3 Current limitation kB 0,5 0,731
Minimum fault current IkLB 6,26 kA 9,15 kA
NH fuse characteristic curve (Fig. 12) tk 0,022 s 0,001 s
4 Short-circuit power Sk 10,63 MVA 10,63 MVA
Normalised arc power kP 0,297 0,149
Electric arc power PLB 3,16 MW 1,59 MW
Electric arc energy (anticipated value) WLB 69,43 kJ 15,86 kJ
5 Working distance a 300 mm 300 mm
6 Standardised PPE test level WLBPKl1 158 kJ 158 kJ

WLBPKl2 318 kJ 318 kJ

7 Transmission factor: small-scale system kT 1,5 1,5
Equivalent arc energy (protection level) WLbäKl1 237 kJ 237 kJ

WLbäKl2 477 kJ 477 kJ

8 Comparison: WLB ≤ WLBä? 69,43 kJ < 158 kJ 15,86 kJ < 158 kJ
PPE Electric fault arc protection class Class 1

Table 7 Example summary: Work on an industrial low voltage system

As a rule, when working on live equipment or in the

vicinity of live components in an Industrial plant electri-
cal installation, basic protection, meaning PPE in the
Electric fault arc protection class 1, is sufficient.

5) Schau, H.; Halinka. A.; Winkler, W.: Elektrische Schutzeinrich-

tungen in Industrienetzen und -anlagen.

34
4.3 Examples of work locations for determining transmission factor kT

Fig. 17 Work on a house junction box: kT = 1,0

Fig. 18 Replacement of a fuse panel in a control cabinet (close Fig. 19 Work on a cable distribution cabinet: kT = 1,5
to the side wall): kT = 1,0

35
Instructions for practical application with practical examples

Fig. 20 Work on a compact station: kT = 1,7 Fig. 22 Work on an electricity pole: kT = 2,4

Abb. 21 Muffenmontage: kT = 1,9

36
Annex 1
Directives, regulations, literature

DIN EN 61482-1-2/VDE 0682-306-1-2: Live working - Pro-

Below are listed the following sources:
tective clothing against the thermal hazards of an
electric arc - Part 1-2: Test methods - Method 2: De-
termination of arc protection class of material and
1. Directives
clothing by using a constrained and directed arc
(Box test) (2007-12).
Available from:
Bundesanzeiger Verlagsgesellschaft mbH, IEC 61482-2: Live working - Protective clothing against
Postfach 10 05 34 the thermal hazards of an electric arc - Part 2: Re-
50445 Köln quirements (2009-04).
DIN EN 60903/VDE 0682-311: Live working - Electric in-
Directives 89/686/EEC: Council Directive on the approx- sulating gloves (2004-07).
imation of the laws of the Member States relating to per-
NFPA 70e: Standard for Electrical Safety in the Work-
sonal protective equipment.
place (2009).
IEEE 1584: Guide for performing arc-flash hazard calcu-
2. Regulations lations (2002).
ASTM F2178-08: Standard Test Method for Determining
Available from: the Arc Rating and Standard Specification for Face
Your responsible accident insurance institution Protective Products.
or from www.dguv.de/publikationen.
Work Item ASTM/WK 14928: New Test Method for Test
Accident prevention regulations for "Electrical equip- Method for Determining the Arc Rating of Gloves 1.
ment and operating equipment" (BGV/GUV-V A3).

4. Literature
3. Standards/VDE provision
Schau, H.; Halinka. A.; Winkler, W.: Elektrische Schutzein-
Available from:
richtungen in Industrienetzen und –anlagen Hüthig &
Beuth-Verlag GmbH,
Pflaum Verlag Munich/Heidelberg 2008.
Burggrafenstraße 6, 10787 Berlin
or GS-ET-29, Supplemental requirements for the testing
VDE-Verlag, and certification of electrician face shields, status
Bismarckstraße 33, 10625 Berlin as of 2010-02, Expert committee for electrical engi-
neering testing and certification facility in DGUV Test,
www.bgetem.de/pruefstelle-et/pruefgrundsaetze.
DIN EN ISO 14116: Protective clothing - Protection against
heat and flame - Limited flame spread materials, ma- Strasse, U., Erfahrungen beim Einsatz von Arbeitssicherun-
terial assemblies and clothing (2008-08). gen beim AuS im Kabelnetz von Vattenfall Europe Ber-
lin; ETG Fachbericht Fachbereich 106 Arbeiten unter
prENV 50354: Electrical arc test methods for material
Spannung (AuS), Presentation for the ETG-Technical
and garments, for use by workers at risk from expo-
Meeting in Dresden from 19 to 20 September 2007.
sure to an electrical arc (2000).
Rotter, G., Bähnsch, R., Lichtbogenschutz-System
DIN EN 60909/VDE 0102: Short-circuit currents in three-
DEHNarc – Geräte-System und Anwendung in der
phase a.c. systems - Part 0: Calculation of currents
Praxis, 15th BG ETEM Electrical Engineering Technical
(2002-07).
Meeting in Kassel, 2010.
DIN EN 61482-1-1/VDE 0682-306-1-1: Live working - Pro-
Machbarkeitsuntersuchung zur Prüfung und Bewertung
tective clothing against the thermal hazards of an
von Schutzhandschuhen gegen thermische Gefahren
electric arc - Part 1-1: Test methods - Method 1: Deter-
von Störlichtbögen (Feasibility Study by AG: BGFE; AN:
mination of the arc rating (ATPV or EBT50) of flame
STFI/TU Ilmenau), STFI final report from 30 May 2005.
resistant materials for clothing (2010-03).
IVSS Guideline for the selection of personal protective
equipment when exposed to the thermal effects of an
electric fault arc; 2nd edition 2011.
37
Annex 2
Standardisation of PPE against the thermal effects of electric fault arcing

A 2.1 Standards for protective clothing in Europe Assessment criteria was comprised of:
• no specimen afterflame time > 5 s,
The testing of PPE in Europe with respect to electric fault
• no hole formation > 5 mm,
arcing is a comparatively young field. Contrary to test-
ing the effectiveness of protective clothing and head, • no melting through to the inside,
face or hand protection against a variety of other risks, • functionality of the garment closure system following
the detailed investigation into the options for protecting exposure.
against the thermal effects of an electric fault arc first
began in the 1990s. The method's greatest disadvantage, however, was
its lack of goal orientation towards making a definitive
statement as to the actual protective properties of PPE
against the thermal effects of electric fault arcing. The
method's intent was merely to confirm that, when test-
ed clothing is in use used when a fault occurs, no cloth-
ing-related injurious effects (e. g. due to burnt clothing)
are to be expected by the wearer. To that effect, the pos-
sibility for evaluating the risk of skin burn, as could be
experienced if protective clothing with inadequate ther-
mal insulation were used, was not included either.

These safety-relevant gaps in the testing and evalua-

tion of protective clothing against the thermal hazards
associated with electric fault arcing were subsequently
closed, however, with the drafting of the international-
ly harmonised standard VDE 0682-306-1-2. Consistent
with the advancement of the idea of directed electric arc
testing by means of a test box opened only in the direc-
tion of the specimen, this standard comprises the test-
ing of fabrics and garments over two protection classes
distinguished by respective levels of electric arc energy
and incident energy.

Fig. 23 Test setup, Box test method The table below provides an overview of the relevant pa-
rameters for each test category:

The standardisation process began with the initial de- Test Mean value Mean value Test Arc time
category of electric of incident current [ms]
sire to be able to safely and reproducibly test and eval- arc energy energy [kA]
uate that particular clothing used to protect against the Warc [kJ] Eio [kJ/m² ]
effects of an electric fault arc. To this end, testing was
begun in two classes based on the prENV 50354 draft Class 1 158 135 4 500
standard existing at the time as to the protection provid-
Class 2 318 423 7 500
ed by textile fabrics and products. This method already
employed a box with one side open for generating a di- Table 8 Box test method parameters
rected electric arc exposure at the textile fabric or prod-
uct specimens positioned at a distance of 300 mm. This The basic philosophy of this methodology consists
draft already defined the use of aluminium and copper of objective testing and evaluation of the protection
electrodes, as well, in order to be as consistent as pos- against electric fault arcs afforded by highly flame-re-
sible with real conditions. sistant materials or material combinations, as well as
testing of the protective properties of finished products.
Both the fabrics specimens and garments are posi-
tioned at a distance of 300 mm to the electric arc axis,

38
 which corresponds to a conceivable working distance Determination of the ATPV (Arc Thermal Performance
under realistic working conditions. The electric arc axis Value) arc rating according to IEC 61482-1-1 domi-
is defined by the two vertical electrodes positioned at a nates the field. This methodology, also published as
distance of 30 mm to each other. The electrode materi- VDE 0682-306-1-1, calls for a medium voltage source
al is comprised of aluminium (upper) and copper (low- and is based on three circularly arranged material spec-
er) in order to replicate system conditions as closely imens (120 ° offset) being exposed to an open, non-di-
as possible in practice. The desired focusing of the ex- rectional arc flash. The textile specimens are affixed
treme thermal effects associated with electric arc expo- to panels, on which two calorimeters are installed for
sure is created with the parabolic form of the test box, measuring transmitted incident energy. In addition,
which surrounds the electrode array on three sides. The each panel is outfitted with two unprotected calorim-
upper and lower sections of the plaster box construction eters mounted on the left and right sides of the speci-
are sealed by means of insulating boards. In accordance men, which simultaneously register the direct incident
with the testing current used for the respective test cate- energy. The centre of the circle is formed by 2 stainless
gory, an arc flash is ignited in a 400 V AC test circuit and steel electrodes at a distance of 300 mm to each panel
extinguished after a combustion duration of 500 ms. (electrode gap 300 mm).

A test plate with two integrated calorimeters for meas- As opposed to the Box test method, VDE 0682-306-1-1
uring transmitted incident energy is used to mount the does not specify defined classes of protection. The meth-
textile specimens. This enables measurement of the od determines variations in the arc duration from at least
heat transfer to the skin surface (rear side of sample) 20 individual values as well as a mathematical regres-
and, in so doing, allows for conclusions to be drawn as sion algorithm for each highly flame-resistant material
to the risk of second degree burning in comparison to for the respective arc rating (ATPV or EBT50). At the same
the limit values associated with the Stoll/Chianta cri- time, the rating represents an energy impacting the ma-
teria. In addition, a visual assessment is made of each terial, which, with 50 % probability, will not lead to sec-
specimen based on afterflame time, hole formation and ond-degree skin burns (ATPV) or to a breaking up of the
melting through to the inside. material down to the skin surface (EBT50).

Garments, such as jackets, overcoats, parkas, etc., Assessment criteria for each individual test sample are:
are tested on a standardised mannequin. Besides the • Hole formation/breaking up of the material in all
visual assessment criteria analogous to a surface in- positions,
spection, an additional functional test is performed on
• Heat transfer exceeding the limit values for skin burn
the garment’s closure system. This is required because
(Stoll curve).
only a functioning closure system enables the fastest
possible removal of garments following an electric arc
accident. Moreover, testing the finished product also After determining the rating for the material, product du-
serves as a test of other accessories, such as reflective rability is tested using the same arc duration and man-
strips, logos or emblems, with respect to their resist- nequin mounting instead of panel mounting.
ance to electric arcing.
In order to make a decision appropriate for the ATPV arc
This testing standard has been well-established for rating regarding the use of the clothing, the user of this
years and serves as the certification basis for numer- method must be able to safely and successfully apply
ous clothing articles used for protection against electric the results of a hazard or risk assessment, such as de-
arcing within the territory covered by Europe's mandato- scribed in NFPA 70e or IEEE 1584. Otherwise, the rated
ry Directive 89/686/EEC relating to personal protective value will not suffice for making a selection recommen-
equipment. dation for work on or in the vicinity of electrical equip-
ment. Similarly, there are no sure options to date for as-
sessing the comparability between the ATPV value and
A 2.2 Standards for protective clothing outside the EU the primary method used in Europe for testing and certi-
fying protective clothing according to VDE 0682-306-1-2.
Outside Europe, evaluation of electric fault arc pro-
tection is based primarily on one other test method.

39
Standardisation of PPE against the thermal effects of electric fault arcing

A 2.3 Standards for other types of PPE with calorimeters, an objective conclusion can be drawn
as to the risk of facial skin burn associated with a fron-
As opposed to protective clothing, there are neither pre- tal exposure, as well as with the suppression of flame
cise internationally harmonised requirements nor test- and gas clouds. Electric arc testing of the face shield is
ing or evaluation standards that address other means considered to have been passed when four of the test
of effective bodily protection against electric fault arc- specimens demonstrate an afterflame time ≤ 5 s, no
ing, such as face shields or gloves. Yet, a high burn risk melting through of the test objects and no appearance
still exists in the event of a fault, emphasizing all the of hole formation. At the same time, the value pairs of
more the necessity for appropriate personal protection. all test head calorimeters must lie below the limit values
For this reason, efforts are being made to implement according to the Stoll/Chianta criteria for the risk of skin
relevant procedures at both the national and the inter- burn. By testing electrician face shields in this manner,
national levels. the user can assume to be in possession of a product
proven to the current state of technology.
The common element among these efforts is that they
are based, to the greatest extent possible, on existing At the international level, the existing standard
international standards for protective clothing. A largely IEC 60903 for electrically insulating protective gloves,
complete selection of protective equipment is availa- currently under revision, is being considered for ex-
ble to the user today, whose electric fault arc protection pansion to include the testing and evaluation of resist-
properties have been tested and evaluated to the same ance to electric arcing and related protection afforded
basic principles. by gloves. It uses the basic system conditions for di-
rected exposure with the Box test method according to
A.2.3.1 Standards for Europe VDE 0682-306-1-2 while using specimen holders de-
Electrician face shields are covered by the most com- signed especially for gloves. Two side-by-side configured
prehensive testing and evaluation procedures to date in panels, each of which being outfitted with horizontally
the GS-ET-29 Principles of testing by the Electrical engi- and vertically oriented calorimeters centred at the mid-
neering testing and certification facility ETEM in DGUV dle of the electric arc axis, enable testing of complete
Test. It defines supplemental requirements for the test- gloves. In addition to testing programs for Classes 1 and
ing and certification of face shields for electrical work 2 related to clothing, a program for Class 3 is also pos-
and has been in use since 2009 for all approved prod- sible. It serves the evaluation of products exposed to
ucts in the Federal Republic of Germany. significantly higher direct incident energy (760 kJ/m²),
which appears justifiable for gloves, if only because
The Principles of testing use directed exposure with the of their anticipated close proximity to a potential fault
Box test method analogous to that of VDE 0682-306-1-2 source. The additional class ratting is achieved by reduc-
in both test categories for evaluation of thermal protec- ing the distance between the specimen and the elec-
tion with respect to the effects of an electric fault arc. In tric arc by 50 % (150 instead of 300 mm) while using the
contrast to the test of clothing, however, one test head respective Class 1 electric arc energy (158 kJ). This appli-
outfitted with four calorimeters is used for positioning cation is not limited to electrically insulating protective
test specimens (e. g. a helmet in combination with vi- gloves but, for this reason, can also provide important
sor). This is centred opposite to the electric arc axis, so safety-related information about other glove types, such
that the central calorimeter is located at a distance of as those made of leather. Procedures call for the test-
350 mm from the nose area. The vertical position of this ing of at least four gloves, none of which may exhibit an
calorimeter is also centred at the middle of the elec- afterflame time > 5 s, hole formation, melting through
tric arc axis. This guarantees the central impact of the to the inside or material shrinkage > 5 %, nor may they
electric arc energy being at the centre of the visor while exceed the limit values for skin burn corresponding to
simultaneously measuring the transmitted incident en- Stoll/Chianta criteria. Under these conditions, the user
ergy at different positions around the head. Besides the can assume the protective gloves have been tested
calorimeter in the area of the nose, the test head is also and evaluated according to latest and best knowledge
outfitted with two additional calorimeters in the areas available.
of the eyes and the chin. A 500 mm high and 600 mm
wide torso plate is used to simulate the area of a hu-
man's upper body. By measuring the incident energy

40
A.2.3.2 Standards outside the EU A 2.4 Specification standards for product approval and
Testing and evaluation options are also available for selection
clothing articles used as supplemental protective equip-
ment, which have been tested according to the ATPV arc Garments used for protection against electric arcing are
rating described in IEC 61482-1-1. high-tech textile products, often offering multifunction-
al protection. For this reason, the execution of a suita-
Head and face protection can be tested according to ble electric fault arc durability test when selecting such
the ASTM F2178-08 standard, which was published only clothing is not only sufficient in itself. Much more, it
in the USA. This methodology uses systems engineer- must be recognised and kept in mind that not one of the
ing for determining the ATPV for textiles, whereby the methods described to date is capable of reproducing
test specimens, including helmet and visor, are affixed the demands to which such PPE would be subjected.
to a head outfitted with four calorimeters. This is then
attached to a mannequin, similar to those used for du- All of the standards mentioned to this point are merely
rability testing for clothing. The central calorimeter is test standards, which may confirm the most essential,
horizontally and vertically centred opposite the electric but still not all characteristics related to safe clothing.
arc axis in the facial area of the head, analogous to the In an emergency situation, for example, an inner lining
Box test method. Direct incident energy and transmit- made of non-flame-resistant material or a seam made of
ted incident energy are determined for each test cycle 100 % polyester thread can cause significant serious in-
by means of unprotected calorimeters positioned on the jury to the wearer. Likewise, when too little current flow
sides of the head, allowing for an incremental calcula- resistance is present, such as when surface conducting
tion of the ATPV arc rating. fibres are used to enhance clothing electrostatic dissi-
pation capabilities, the protection against contact with
A U.S. draft standard6 for gloves is under discussion, live parts under certain circumstances may be lacking
whereby systems engineering for clothing would be and further secondary hazards may ensue.
used to enable a determination of the ATPV arc rating for
protective gloves. For this purpose, a ring-shaped struc- Moreover, the classic textile requirements, such as di-
ture with a quarter-circle opening has been designed on mensional stability when washing, maximum firmness
which four panels are located for affixing the test speci- and resistance to tear propagation, are, of course, not
men. Each glove panel is outfitted with a calorimeter, only quality-relevant to the user, but safety-relevant as
whose alignment is horizontally and vertically centred at well. Ultimately, only the use of suitable and appropri-
the middle of the electric arc axis and is used for meas- ately tested accessories, such as flame-resistant reflec-
uring the transmitted incident energy. Two each unpro- tive strips, logos or emblems, will avoid negatively influ-
tected calorimeters arranged on the sides of the panels encing a clothing article's protective function. In order
serve to determine direct incident energy for each indi- to achieve a degree of safety for the potential clothing
vidual test cycle, as is done with textile testing. Determi- user, both the manufacturer and the responsible cer-
nation of the ATPV arc rating then takes place analogous tification body must have considered these risks and,
to the methodology already described. by requiring suitable materials and appropriate design,
eliminated them to the greatest extent possible.
Nevertheless, the same restrictions apply to the ATPV
arc rating determined for face shields or gloves as for The international standard, IEC 61482-2, is presently re-
clothing. Its use requires experience in the application garded to be the best method for comprehensively test-
of U.S. directives related to the assessment of electric ing and evaluating clothing used for protection against
fault arc risks at the workplace. electric arcing. Even though a presumption of conform-
ity to the PPE Directive 89/686/EEC does not exist yet
for this standard, it provides the most extensive assess-
ment options at the present time.

6) Work Item ASTM WK14928 - New Test Method for Test Method
for Determining the Arc Rating of Gloves 1.

41
Standardisation of PPE against the thermal effects of electric fault arcing

An essential component of this product standard is the A European-wide, uniform methodology for the approv-
verification of electric fault arc protection properties al of clothing used for protection against electric arcing
through use of textile materials, as could be provid- can not yet be expected because of the still outstand-
ed for according to VDE 0682-306-1-2. A decisive basic ing, partial or complete conveyance of IEC 61482-2 into
requirement is the exclusive use of flame-resistant raw a generally compulsory harmonised EN standard (mean-
materials (Index 3 according to DIN EN ISO 14116) for the ing an EN standard with presumption of conformity to
outer and, if applicable, for the inner clothing layers. the PPE directives), as well as the different potential
Typical demands for protective clothing placed on di- experience levels of the certifying bodies. For this rea-
mensional stability and mechanical wear durability, as son, employers should ensure that the requirements of
well as on minimum requirements for maximum tensile this product standard have been taken into account and
strength and tear propagation resistance, supplement implemented into the product, accordingly, through an
the material-specific requirement profile. inspection of the certificate (EC type examination certifi-
cate), a thorough examination of the clothing, as well as
IEC 61482-2 also regulates important safety-relevant a direct enquiry by the manufacturer or dealer.
requirements related to the clothing design itself. The
subject of different protection classes for the front
and back sides, perhaps selected for wear comfort, is
also clearly regulated along with the exclusive use of
flame-resistant sewing thread for all main seams. If
special design requirements have been considered in
addition to the standard, such as sealable pockets to
protect against extensive molten metal splatter in case
of fault, the user is assured of comprehensively tested
and proved clothing to protect against the thermal risks
of an electric arc accident. This also applies for the re-
spective trousers or overalls as part of a complete pro-
tective suit. Even though none of the methods present-
ed provides for the testing of products as assembled
parts, the certification body will subject these products
to an intensive assessment as to their protective prop-
erties. For this, the use of identical raw materials for
pants and jackets, as well as the implementation of the
design stipulations adopted in IEC 61482-2 will be deci-
sive. If, in the results of a risk assessment, the use of a
complete protective suit or overalls has been dispensed
with, then the acceptability of pants selected separately
from the arc rated jacket must be tested by the user him-
self. In order to avoid related uncertainties and perhaps
risks, as the case may be, it is recommended to choose
a complete suit made up of a jacket and pants.

42
Annex 3
Parameters and risk analysis of thermal hazards to persons related
to electric arcing

A 3.1 Energy parameters for thermal hazards to persons test structure, the highest level of thermal incident en-
related to electric arcing ergy results.

The electrical energy fed into an electric fault arc is al-

most completely converted therein and emitted or re- A 3.2 Process of risk analysis
leased back in various forms. The impact of electric fault
arcing is, for this reason, determined primarily by the The electric arc energy WLB that is to be expected within
electric arc energy WLB. Electric arc energy clearly identi- the scope of application must be determined in the risk
fies the relationships associated with system short-cir- analysis. The maximum value of anticipated electric arc
cuit-related arcing. Different network and system condi- energy will be ascertained and is measured in kJ. Based
tions will result in different electric arc energies. on this, it must then be verified that the maximum oc-
currence of exposure (thermal impact) will not exceed
The significant level of exposure or risk a person is sub- the level of protection and strength afforded by the PPE.
jected to due to the direct thermal impact of an electric The related parameter is then the electric arc energy for
arc is the energy density impacting the exposed surface the test category being examined in the Box test. The
of the skin. This is the incident energy Ei that is pres- level of equivalent arc energy for the PPE test must cover
ent as direct incident energy Ei0 with the thermal im- this level. For specific applications, existing deviations
pact of a proximate electric arc. If the person is wearing from the distance, geometry and test transmission rela-
PPE, then the incident energy should be considered as tionships can be taken into account when determining
transmitted incident energy EiT. In the testing of PPE, a equivalent arc energy WLBä.
determination is made as to whether the transmitted
incident energy will exceed the limits for the onset of When selecting the PPE test or protection class, the re-
a second-degree skin burn. A successful test will veri- lation to the anticipated electric arc energy value must
fiy that the PPE is arc-resistant and provides protection be considered on the basis of the equivalent arc energy.
up to the level of direct incident energy, as per the test The thermal hazards associated with electric arching are
settings. deemed covered if

There is a complicated non-linear correlation between WLB ≤ WLBä

electric arc energy and direct incident energy, which is
determined through the specific transmission and expo- applies.
sure relationships, including system configuration and
the effective distance between the arc flash and the per- It should be explicitly pointed out that the test currents
son (transfer relations). The transmission and exposure used for the Box test categories do not correspond
conditions related to the thermal effects can be very to the usage limits of PPE with respect to the level of
diverse. A risk analysis must include or cover all related short-circuit current!
cases and require a „worst-case“ examination.
The risk analysis is comprised of the following work
The correlation between electric arc energy and direct steps:
incident energy is known for both protection classes for • Determination of the anticipated electric arc energy
the PPE Box test (protective textile and clothing) accord- value,
ing to VDE 0682-306-1-2. These are control parameters
• Examination of the PPE electric arc protection level,
for the test settings and characterize the transfer rela-
tions for the test setup. • Consideration of divergent exposure conditions.

The effects of radiation (including reflections) exist The determinations below will be comprised in the work
during the Box test, particularly as a result of arc flash steps for the workstation or area being analysed:
directivity (gas flow) resulting from the small-scale box • Nominal or stipulated network voltage.
structure and through „worst-case“ transfer conditions
• Prospective (metallic) short-circuit current.
due to the influence of electrode materials. Compara-
ble examinations using other configurations show that, • R/X ratio for network or short-circuited electrical cir-
with the same electric arc energy being fed into the Box cuit impedance.

43
Parameters and risk analysis of thermal hazards to persons related to electric arcing

• System geometry (electrode gaps and volume rela- NOTE:

tionships at potential fault locations). In the case of type tested switchgear for which the test
• Working distance (potential electric fault arc onset validation of arc resistance is available (medium volt-
and combustive locations, minimal effective distanc- age: electric arc testing according to VDE 0671-200,
es to arc flashing). low voltage: electric arc testing criteria 1-5 according to
EN 60439-1, Supplemental sheet 2), personal protection
• Type, model, settings and characteristics of the pro-
can always be assumed when operating or performing
tection device(s) (circuit breakers, fuses or other spe-
work tasks on a closed system; this does not need to be
cial protection devices upstream from the work area).
incorporated into the further analysis. On non-tested
• Protection level for the PPE test category. systems, it must not be assumed that the system will
remain closed in the event of an electric arc fault and/or
NOTE: that the effects of inadmissible electric arcing will
It should be pointed out that the different switching not occur outside the system (e. g. due to escaping
states of the distribution network or energy supply sys- hot gases, bursting parts, etc.); this situation must be
tem can lead to different short-circuit power readings treated as in the case of an opened system.
and energy levels. For this reason, it may be necessary
to analyse a number of such cases in a system. A.3.3.2 Calculation of short-circuit current at the workstations
being considered
Analysis of the energy supply system must take place A prerequisite for the risk analysis and the selection
for all work areas, generally meaning from the feed point of PPE is to be knowledgeable about the prospective
of the affected network up to the user outlet. short-circuit currents or short-circuit powers associat-
ed with the equipment (or network junction) potentially
being worked on.
A 3.3 Work steps
NOTE:
A.3.3.1 Ascertaining the general operating conditions As a rule, the risk analysis should be undertaken for
The starting point is to consider the general operating different workstations in a network or supply system. In
conditions. A list should first be compiled, including larger systems, it is often advisable to develop and ob-
network voltage levels, network equipment types and serve identical structures and parameters or similar ba-
locations, as well as work tasks. sic electrical configurations (circuitry).

NOTE: Short-circuit current calculations are to be performed

In so doing, it must be considered that, for different according to standardised procedures (VDE 0102). Cal-
network switching states and upstream supply systems, culation software is usually available for this process.
different prospective short-circuit current readings can Maximum and minimum prospective 3-phase initial
result. Short-circuit current is greatest when the network short-circuit AC currents
junction (switchgear bus bar or distributor) is supplied
Ik3max
through multiple feeders or transformers. Differing
short-circuit current values under different switching and
states in the same system must nevertheless be tak- Ik3min
en into account, because electric arc energy at lower
short-circuit current levels due to the longer protection are to be determined for each workstation/system area
device trip times may by all means be greater than that for the possible/relevant network switching states.
at the higher current levels. Standard determinations of these currents are made for
metallic, zero impedance short-circuits (impedance at
With respect to (electrotechnical) work activities, all the fault location is zero).
tasks performed on open electrical equipment or where
a system must be opened (work in the vicinity of live
components, live working) play a role.

44
Information regarding short-circuit current or short-cir- A.3.3.3 Determination of short-circuit duration (duration of
cuit power can also be obtained through the power arcing)
supply network operator. It is important to ensure that The arc flash or short-circuit duration tk is a significant
the fault location short-circuit currents apply to the work parameter and will be required for the risk analysis. It is
location being considered. determined by the protection device and generally can
be taken from the protective equipment manufacturer's
NOTE: selectivity calculations and/or trip characteristic curves
If the power supply network operator can only provide (current-time curves).
short-circuit current (or short-circuit power) at the sup-
plying step down transformer for the low voltage net- It must be considered that, in current-time dependent
work, then a calculation must be made of the short-cir- protection devices, the trip time will be influenced by
cuit current for work locations (fault locations) located the level of the actual short-circuit current and, thereby,
remotely from the low voltage network transformer, from the current limitation through the electric fault arc,
based on the technical data of the supplying medium itself. The actual short-circuit current in the low voltage
voltage to low voltage transformer with consideration range does not correspond to the prospective short-cir-
given to the type and length of low voltage cable used. cuit current, but to the electric arc short-circuit current
If applicable, a multi-source feed to the fault location IkLB and can be significantly limited. Determination of
should be taken into consideration. the actual short-circuit current IkLB, with consideration
given to a number of influencing variables, can only be
In the event of an actual short-circuit (with arc flashing), done by approximation5 and is subject to a degree of
a reduced current, the electric arc short-circuit current or uncertainty (see A.3.3.4).
fault current with an electric arc short-circuit, will flow as
a result of the electric fault arc (fault location impedanc- One is generally considered to be in a safe zone if a
es). If software is available that can be used for deter- current limitation of 50 % is assumed and this reduced
mining the short-circuit current associated with an elec- current is used to establish the trip time as taken from
tric arc short-circuit IkLB, then this current should also be the protection characteristic curve. The current limiting
determined for the relevant switching states. factor then equates to kB = 0,5; it follows that

Electric arc short-circuit current can be calculated based IkLB = 0,5 Ik3pmin
on Ik3min as well as with the help of a current limiting fac-
tor kB5. The following applies When using scatter range information for the cur-
rent-time curve for a protection device (e. g. fuse), the
IkLB = kBIk3pmin value from the upper range limit should be used for
short-circuit duration.
Factor kB is determined on the basis of the arc voltage
UB dependent on the network nominal voltage, the R/X NOTE:
ratio of the short-circuited electrical circuit impedance A protection device is considered to be a device posi-
and the electrode gap d (distance between neighboring tioned upstream from the respective work area, or a sep-
conductors in the electrical system)5. arate protection device installed or activated especially
in connection with a work task. With a multi-source feed
NOTE: to a fault location, the protection device with the long-
The reduction or limitation of the fault current resulting est trip time should be used to determine short-circuit
from an electric arc at the fault location plays a practi- duration.
cal role only in low voltage systems. In practice, current
limitations for medium or low voltage networks can be NOTE:
ignored (kB = 1). When using software tools (selectivity calculations), it
must be ensured that the calculation is made based on
the limited electric arc short-circuit current IkLB.

45
Parameters and risk analysis of thermal hazards to persons related to electric arcing

Regarding protection devices, their protection bounda- Electric arc energy is dependent on network conditions,
ries and selectivity levels should be taken into account. meaning from the network short-circuit power Sk at the
With non-current-limiting fuses and circuit breakers with potential fault location and the short-circuit duration tk,
direct actuation, the short-circuit duration can be taken as determined by the electric protection devices (trip
directly from the current-time curve or the selective trip- times for circuit breakers and fuses, as well as separate
ping schedule. With circuit breakers, the setting of time protection devices if applicable) as taken from the pro-
delay levels or selective tripping times must be taken tection characteristic curves:
into account where applicable. The following reference
values are considered to be typical for circuit breakers WLB = PLB ⋅ tLB = kP ⋅ Sk ⋅ tk
trip times without a time delay: = kP ⋅ 3 ⋅ UNn ⋅ Ik3pmax ⋅ tk

Circuit breaker Undelayed trip time Network short-circuit power at the fault location is the
Low voltage (< 1000 V) 60 ms result of the nominal or stipulated network voltage Un
and the maximum prospective 3-phase short-circuit cur-
Medium voltage (1 to 35 kV) 100 ms
rent Ik3max for the relevant network switching states.
High voltage (> 35 kV) 150 ms
NOTE:
Table 9 Typical circuit breaker trip times With a multi-source feed to a fault location, overall
short-circuit current Ik3max will be composed of the re-
Information provided by the manufacturer will provide spective partial currents. That share of the short-cir-
more specific related data. cuit current emanating from motors that could be fed
back to the fault location must be taken into account, if
Current limiting fuses feature a short-circuit duration of applicable.
less than 10 ms. The fuse current-time curves exhibit the
virtual melting times, meaning the actual trip times will In the case of a fault located within the switchgear or
not necessarily coincide. For safety reasons, fuses used distribution system, the line impedance between the
in current limiting situations should feature a short-cir- energy supply source (usually a transformer) and the
cuit duration of tk = 10 ms. This value is considered to system must generally be taken into account.
be on the safe side.
Furthermore, electric arc energy is dependent on system
NOTE: conditions characterised by factor kP, which accounts
At short-circuit durations longer than 1 s, it can be as- for the type of arc formation and the electrode geometry
sumed that the person will be able to withdraw from the at the fault location. This factor can be determined by
immediate danger area, if applicable. For this reason, approximation with the aid of arc voltage5. For arc volt-
longer periods will not need to be considered. This does ages, there are empirical conditional equations, which
not apply, however, if withdrawal of the person from the - aside from electrical circuit parameters - require knowl-
working environment is precluded or restricted (e. g. edge of system conductor wire spacing. The 50 % arc
work in tight cable trenches or canals, narrow work cor- voltage value determination can be assumed.
ridors, work from ladders or lifting mechanisms).
For a very rough estimation without considering the sys-
A.3.3.4 Determination of the anticipated electric arc energy tem geometry, the theoretical maxima of the parameter
value kP can be used, which can be determined according to
The determination to be made is the maximum value
0,29
of electric arc energy that can be anticipated at the re- kPmax =
spective fault location or within the scope of application (R/X)0,17
being considered.
this equation. R is the active component thereby,
while X is the reactive component of impedance in the
short-circuited electrical circuit5.

46
 Furthermore, it was determined that the following spec- considered to be any activity performed in the vicinity of
ified range of values kP are typical for conventional sys- live components or live working.
tem configurations, in practice, and can be used as
reference values: Typical working distances resulting from the work po-
sitions and the characteristic design or geometry and
Un d R/X kP dimensions of the electrical equipment are:

0,2 0,229 Equipment type Typical working distances

0,5 0,215 Low voltage distribution/house 300 to 450 mm
30 mm junction box, main control
1,0 0,199 cabinet

> = 2,0 0,181 Low voltage switchgear 300 to 600 mm

0,2 0,289 > 1 kV according to

DIN VDE 0105-100
0,5 0,263
400 V 45 mm Table 11 Typical working distances
1,0 0,240

> = 2,0 0,222 Distance relationships should be determined as accu-

rately as possible so that a determination of the work-
0,2 0,338
ing distance can be established. Yet, it can generally be
0,5 0,299 assumed that the distance to the person's torso will not
60 mm fall short of a = 300 mm while working and, particularly
1,0 0,270
in the low voltage range, that this can be applied as a
> = 2,0 0,253 reference value.
10 to 20 kV 120 to 240 0,1 0,04 to 0,08
NOTE:
Table 10 Reference values for normalised arc power Personal protection can always be assumed when work-
ing on closed systems that have passed a type test for
NOTE: arc resistance; consequently, a working distance does
When using the maximum value or the reference val- not need to be determined (see 4.3.1). In the case of
ue, the determination of geometric parameters is cir- non-tested systems, however, the potential for electric
cumvented at the cost of precision. Particularly with the arcing and related effects outside the system must be
ansatz for maximum value, a significant safe distance expected (e. g. when opening doors). The working dis-
can emerge under certain circumstances. tance that must then be provided for will be composed
of the distance to the system encasement and the typical
A.3.3.5 Determination of working distance working distances referenced above (values taken from
Working distance a is the distance between the electric the lower limits).
arc and the person's body (torso) that is effective during
the work activity or must be maintained in the working Establishing a working distance that the worker must
environment being considered. Where different tasks not fall short of represents a possible measure for facil-
are being carried out in the working environment, the itating work activities with PPE at a specific level of pro-
shortest distance emerging should be applied. The con- tection (test category or protection class).
figuration of the potential electric arc-related electrodes
in the system (conductor arrangement) is decisive in A.3.3.6 PPE electric arc protection level
determining the fault location (location of the electric It must be ensured during test setup for the Box test that
arc flash). the thermal transfer relations (including the effective-
ness of the electrode material) correspond with „worst
Those electrical systems at which persons perform work case“ conditions according to VDE 0682-306-1-2. The
tasks (repairs, service, maintenance, assembly, inspec- electric arc energies WLBP in the test setup correspond-
tion, measurement, etc.) are considered integral to the ing to the respective incident energies Ei0P in the test
working environment and workstations. A work task is can be used to establish utilisation limits for PPE:

47
Parameters and risk analysis of thermal hazards to persons related to electric arcing

Box test Statistical mean value The transmission factor for electric arc energy kT for Box
VDE 0682-306-1-2 Electric arc Direct incident test conditions equals kT = 1. For divergent combustion
energy energy and transmission conditions, a coefficient can also be
WLBP Ei0P1
used with the following values:
Class 1 158 kJ 135 kJ/m2
Type of system Transmission
Class 2 318 kJ 423 kJ/m2 factor for electric
arc energy kT
(Very) small-scale systems with side, 1
Table 12 Box test parameters rear and partition walls

NOTE: Large-scale systems, spatial limitations 1,5 to 1,9

primarily due to rear wall structure
The specified direct incident energy values Ei0, which
identify the Box test categories, do not correspond to the Open systems without significant limita- 2,4
ATPV values, which are determined in tests according to tions in the electrode chamber
VDE 0682-306-1-1 or in their subsequent procedures ac-
cording to NFPA 70E and IEEE 1584; neither do they com- Table 13 Transmission factor
pare with the established transmission and exposure
conditions, nor are analytical conversions or mathemat- A.3.3.8 Using the analysis results for risk assessment
ical transfers possible in these values. In the risk assessment or when selecting the PPE test
category or protection class (Box test), the relation to
At an effective distance of a = 300 mm (corresponding the expected value for electric arc energy is to be con-
to the test setup), the electric arc energy values WLBP sidered based on the equivalent arc energy. The thermal
lead to the applicable incident energies. Electric arc en- hazards associated with electric arching are deemed
ergy WLBP, which identifies the test category in the Box covered if
test, is used as a comparative parameter WLBä for the
ascertained electric arc energy WLB within the scope of WLB ≤ WLBä
application.
applies.
At the same time, it is presupposed that the use of PPE
is foreseen for working distances of a = 300 mm and for Starting with this relation together with the above men-
systems that are small-scale and limited by side, rear tioned determinant parameters and equations, the
and partition walls, analogous to the Box test setup limits for PPE applicability in a chosen test category
(with a volume of around V = 1,6 10-3 m3). Corrections or protection class can be determined with respect to
are possible with divergent conditions. short-circuit current range, permissible short-circuit
duration or protection device trip time (and therewith
A.3.3.7 Consideration of divergent exposure relationships the protective system itself) and permissible working
Equivalent arc energy WLBä can be determined for any distance.
working distance a by using an experimentally verified
reverse squared distance proportionality from the elec-
tric arc energy of the test category WLBP. It represents A 3.4 Alternative test methods
that level where protection provided by the PPE for a
respective distance a is still maintained. Moreover, the The procedures described herein are not applicable for
system configuration can be taken into consideration. alternative test methods to the Box test method. It is
The following is generally valid for the Box test then necessary to determine the correlation between
electric energy and direct incident energy (transmission

( )
a 2
WLBä = kT ⋅ ⋅ WLBP. function) generally valid for the affected test setup or to
300 mm ascertain the direct incident energy that can be expect-
ed in the event of a fault, and then to compare these
with the incident energy level from the PPE test.

48
In addition to the Box test, one test method is also used When using ATPV for selection of PPE, however, a risk
in accordance with VDE 0682-306-1-1 (ATPV test or Arc- analysis must be undertaken in which the anticipat-
Man test). As opposed to the Box test method, in which ed incident energy is ascertained. For this, NFPA 70E
a directed test arc is generated, similar to an arc that (Standard for Electrical Safety in the Workplace) and
might be expected in an accident when working on a IEEE 1584 (Guide for performing arc-flash hazard calcu-
control cabinet or distribution system, the electric arc lations), among others, provide relevant algorithms.
generated in the Arc-Man method is open and non-di-
rectional, meaning it is generated in a quasi free field. It must be noted, however, that ATPV-based testing
The two methods can not be compared directly and are and PPE selection are bound by the limitations of the
not transferrable or convertible among themselves. On methodology.
the one hand, this is due to the type of electric fault arc,
whose length and propagation are predetermined by
the test setup, the electrode materials used and many
other physical-technical differences. The heat transfer
that takes place in the Arc-Man test is primarily due to
radiation.

On the other hand, Arc-Man test results lead to the so-

called „Arc Thermal Performance Value“, or ATPV. In this
context, the incident energy is determined according
to a statistical methodology, by which a 50 % probabil-
ity exists of suffering second-degree skin burns behind
the PPE. Even if an electric fault accident is relatively
improbable, the EU directive regarding PPE allows no
interpretation of PPE that would tolerate such injury. For
this reason, as a matter of principle, such test methods
should not be used within the EU.

ATPV is the direct incident energy that emerges with the

special transfer relations existing in the test. It should
be noted that ATPV does not correspond to the levels of
direct incident energy associated with the test catego-
ries. The incident energy levels generated in the Box test
method are not ATPV values or limits of the ATPV range.

Products available on the international marketplace

have been tested under certain circumstances accord-
ing to both methods, meaning the Box test and Arc-Man
test methods. Even if the test results are not directly
comparable, they can nevertheless help in the selection
of suitable PPE, particularly when the maximum antici-
pated electric arc energy lies above the electric arc ener-
gy for the electric fault arc protection class WLBP or the
equivalent arc energy WLBä described in A.4.3.

For this reason, a manufacturer who tests its products

according to both methods can specify the ATPV real-
ised, even in the EU marketplace, in order to provide the
user with further selection criterion to help the selection
of suitable PPE.

49
Annex 4
PPE selection support form

PPE Electric ARC Protection Class Calculation Form

Work order: Replace NH fuse Responsible person: M. Mustermann

Work location: Transformer station 2 Date: 12.04.2012

Main low voltage distribution
system

Network voltage: 400 V

Max. short-circuit current: 23,10 kA

Min. short-circuit current: 20,90 kA

Distance between conductors: 60,0 mm

R/X ratio: 0,2 Rationale: none

(Section 3.2)

Current limiting factor kB: 0,38 Rationale: none

(Section 3.3)

Protection device: 315 A gTr AC 400 V fuse (... manufacturer ...)

Tripping time of the 0,100 s Note: Circuit breaker set value / trip time
protection device: taken from protection characteristiv curve

Transmission factor kT: 1,50 Rationale: none

(Abschnitt 3.4)

Distance of person from 300 mm

electric arc source location a:

Results: Isolate or take othe measures

The following measures would make work possible:

Shortening the upstream protection device trip time to < 0,039 s for PPE in Class 1 or
to < 0,078 s for PPE in Class 2.

Increasing the working distance to > 481 mm for PPE in Class 1 ot to > 339 mm for PPE
in Class 2.

50
Work order: Replace NH fuse Responsible person: John Doe

Work location: Transformer station 2 Date: 12.04.2012

Main low voltage distribution system

Calculation Parameter Result

Network parameter Network voltage UNn 400,0 V

Equipment geometry Distance between conductors d 60 mm

Short-circuit current calculation max. short-circuit current Ik3pmax 23,10 kA

min. short-circuit current Ik3pmin 20,90 kA

R/X ratio R/X 0,20

Current limitation kB 0,380 s

Minimum fault current IkLB = kB ⋅ Ik3pmin IkLB = 7,94 kA

Overcurrent protection device trip time tk 0,100 s

(circuit breaker/trip time set value taken from the protection device characteristic curve)

Short-circuit power Sk = 3 ⋅ UNn ⋅ Ik3pmax Sk = 16,00 MVA

Normalized arc power kP = 0,29 / (R/X)0,17 kP = 0,381

Electric arc power PLB = kP ⋅ Sk PLB = 6,10 MW

Electric arc energy (anticipated) WLB = kP ⋅ Sk ⋅ tk (Annahme: kP = kPmax) WLB = 610,18 kJ

Working distance a 300 mm

Standardized PPE test level WLBPKl2 = 318,0 kJ

WLBPKl1 = 158,0 kJ

Transmission factor kT 1,50

Protection level of clothing at the electric arc location WLBä = kT ⋅ (a/300 mm)2 ⋅ WLBP WLBäKl2 = 477,0 kJ
(projection of Bo test parameters to the electric arc
location) WLBäKl1 = 237,0 kJ

Comparison WLB < WLBäKl1 nein

WLB < WLBäKl2 nein

Results: Isolate or take othe measures

Rationale for R/X ratio:

none

Rationale for currentlimiting factor:

none

Ratioale for transmission factor:

none

Protection device:
315 A gTr AC 400 V fuse (... manufacturer ...)
Deutsche Gesetzliche
Unfallversicherung e.V. (DGUV)

Mittelstraße 51
10117 Berlin
Tel.: 030 288763800
Fax: 030 288763808
E-Mail: info@dguv.de
Internet: www.dguv.de