Professional Documents
Culture Documents
Introduction
When an arc fault occurs with personnel in the area, the harmful results can be
devastating and deadly for those who are not properly prepared. In addition equipment
damage is usually considerable, frequently resulting in extended down time for the
installation. Industry codes and standards have recently included measures to counter
the effects of arc flash. These codes and standards help facility operators to take
preventive steps.
The purpose of this paper is to identify the impact on arc flash by molded-case circuit
breakers (MCCBs) and methods of determining it.
The arc flash hazard
NFPA 70E-2000, Standard for Electrical Safety Requirements for Employee
Workplaces, defines arc flash hazard as: a dangerous condition associated with the
release of energy caused by an electric arc. It is an explosion involving an electric arc
operating at temperatures of several thousands degrees Celsius and a pressure wave
created by the arc. Within a few milliseconds of arc ignition, the energy from this
explosion can cause molten metal particles, equipment parts and other loose items to
be expelled from the arc area in addition to the expulsion of hot, ionized gas. Extensive
equipment damage frequently results in extended down time for an installation. More
devastating are the trauma, hearing and eyesight loss and burns to personnel in the
area which can result in catastrophic injuries or even death.
Installed equipment can have a significant impact on the degree of hazard present.
When equipment is expected to be serviced or opened while not in an electrically safe
work condition, an electrical safety program is required for such maintenance including
training, practices and analysis. Guidelines for practices and training are included in
OSHA, 29 Code of Federal Regulations Part 1910, Subpart S with how to detail in
NFPA 70E. NFPA 70E also provides basic information regarding arc flash analysis.
IEEE 1584-2002, Guide for Performing Arc-Flash Hazard Calculations, supports NFPA
70E and provides a dependable method of performing the calculations.
Section 110.16 of the 2002 National Electrical Code (NEC) requires switchboards,
panelboards, industrial control panels and motor control centers be field marked with a
warning of possible flash hazard. Proposals have been made for the 2005 NEC that
could require additional marking of the flash protection boundary distance and PPE
Category.
Flash Hazard Protection
There is only one sure way to protect against the potential devastating effects of arc
flash and that is to de-energize the equipment before approaching it for the purposes of
Page 1 of 14
opening it or for working on it. NFPA 70E describes several key steps in the process of
placing the equipment in an electrically safe work condition. Those steps include
turning off the supply, locking it off, measuring to verify that it is de-energized, and
assuring that stored energy such as from capacitors or induced voltage does not impact
workers.
These steps are done while the equipment is not yet considered to be in a safe
condition, which requires that appropriate protective precautions including use of
personal protective equipment (PPE) are applied during the de-energizing process. PPE
includes the clothing, gloves and headwear that help to mitigate the effects of an arc
flash event for a worker who is exposed. PPE is generally determined to protect the
head and body against thermal effects that would cause severe burn. It does not
necessarily protect from the possible impact of any harmful light, sound, or pressure
impulses, toxic gas by-products or ejected debris.
PPE is required by OSHA and NFPA 70E for operations that must be done with
equipment energized, including the steps to place the equipment in an electrically safe
work condition. Both OSHA and NFPA 70E acknowledge that some electrical work must
be done with equipment energized when it is either infeasible to de-energize or when
de-energizing would cause additional hazards. In those cases in which work is done on
energized equipment, there is increased risk of arc flash.
To address those cases, NFPA 70E requires among other things that employees who do
that work be trained and knowledgeable regarding the task and its hazard, that a
specific work plan be made and used and that appropriate PPE be used based on a
flash hazard analysis.
Arc Flash Energy
Energy is a critical factor in evaluating the potential effect of an arc flash occurrence.
These three definitions from NFPA 70E relate to energy:
Arc flash hazard: A dangerous condition associated with the release of energy caused
by an electric arc.
Flash hazard analysis: A study investigating a workers potential exposure to arc flash
energy, conducted for the purpose of injury prevention and the determination of safe
work practices and appropriate levels of PPE.
Incident energy: The amount of energy impressed on a surface, a certain distance from
the source, generated during an arc event. (Incident energy is measured in Joules/cm 2
or Calories/cm2)
The magnitude of energy available during an arc flash event is proportional to the
product of the current flowing times the system voltage times the duration of the event.
An analysis of the flash hazard must identify these three elements. By raising or
Page 2 of 14
lowering any of these elements, the available energy is also raised or lowered
proportionally.
Incident energy is determined by the three basic elements (arc current, system voltage
and duration). Other factors include system grounding, bus bar spacing, and whether
the arc is in a box radiating in a single direction, or in open air radiating in all directions.
Components or equipment parts located between the arc and a worker may also
provide some shielding from the arc, if these items do not become projectiles.
Overcurrent protective devices including MCCBs have a significant influence on the
incident energy. From their position in the system, they impact both the magnitude and
the duration of the arcing fault current.
Calculation method
A dependable method of performing the calculations is in IEEE 1584, Guide for
Performing Arc-Flash Hazard calculations. This method is based on extensive testing
and solid analytical work. It requires input of the following basic items:
The last two items are optional with default values assigned for most common
configurations where specific information is not provided.
IEEE 1584 provides equations to output the following information with input of the above
items. The complexity of the equations makes solving them by hand difficult. However,
IEEE 1584 provides an Excel spreadsheet with each copy of the standard that
automatically performs the calculations when basic information is input. This
spreadsheet allows multiple calculations to be done rapidly.
Output items:
Arc current. Arc current is quite different from bolted fault current, especially in lowvoltage systems. For example in a 480 V system, a bolted fault current of 50 kA
available will result in an arc current of only 26 kA. Arc current is used to determine the
time for the overcurrent protective device to clear the circuit. Since the time for the
overcurrent protective device depends on the value of current flowing, it could be quite
different for an arc than for a bolted fault.
Page 3 of 14
Incident energy. This value, defined above, is used to determine the hazard category for
selection of PPE.
Flash protection boundary. This boundary is defined in NFPA 70E as An approach limit
at a distance from exposed live parts within which a person could receive a seconddegree burn if an electric arc flash were to occur. An incident energy value of 1.2
calories/cm2 is the accepted maximum value at which a second-degree burn would be
expected. Only qualified workers are permitted within the flash protection boundary
and they are required to use appropriately rated PPE.
Hazard category. The hazard category is used to determine the kind of PPE required. It
is directly related to incident energy as indicated in Table 3-3.9.3 of Part II of NFPA 70E.
Input items
The most difficult input items to obtain are bolted fault current and arc clearing time or
duration. As we will see, it is essential to have accurate bolted fault current information
rather than a guess at maximum bolted fault current. Higher incident energy may
actually occur for certain lower bolted fault current conditions.
To obtain accurate bolted fault current, it is necessary to obtain the value of available
power from the utility. It is also necessary to obtain information about equipment and
conductors installed in order to determine their impedance. Modes of operation should
be well understood to know whether there are multiple potential sources or current
paths. With this information, a short circuit calculation can be made to determine the
bolted fault current. Another simple spreadsheet is provided with each copy of IEEE
1584 to make this calculation.
Knowing the bolted fault current and system voltage, a value for arcing fault current can
be determined from an equation in IEEE 1584. It is essential to use arcing current rather
than bolted fault current because there can be significant difference between the two.
Duration of arcing is determined by knowing how long the overcurrent protective device
will take to clear the circuit. This time can be taken from the time-current curves that are
available from the manufacturer. A typical, MCCB time-current characteristic appears in
figure 1. Using the arcing current, read the highest time from the band presented.
Remember, it is essential to use the calculated arcing current when determining the
clearing time!
Page 4 of 14
10 0 0
10 0 0 0
Thermal Region
10 0
10
Instantaneous
region
0 .1
0 .0 1
0 .0 0 1
1
10
10 0
10 0 0
Figure 1
Instantaneous versus thermal long-time region
As we look at figure 1, it is useful to compare the clearing time in the instantaneous
region with that in the thermal region. Notice that instantaneous region time is roughly
one electrical cycle or 0.016 seconds. The actual value will change slightly with each
circuit breaker. Contrast that very short time with tens or hundreds of seconds in the
thermal region. In considering the duration that must be taken into account, it is useful
to note this statement from IEEE 1584: It is likely that a person exposed to an arc flash
will move away quickly if it is physically possible and two seconds is a reasonable
maximum time for calculations. Recognize that it is possible to have a bolted fault
current well into the instantaneous region, such as 20 times rating. However, when an
arc occurs, the current could be well below 10 times and into the thermal region.
Figure 2 illustrates a typical relationship between incident energy and corresponding
bolted fault current available, Ib. This chart takes into account the reduced arc current
that would result from the available bolted fault current shown even though arc current
is not shown. Notice that between points I1 and I2 the line has only a modest slope. At
the point I1, it changes radically. This is the impact of the change from the instantaneous
region to the thermal region. The point is that if the equipment is operating near this
point I1, consideration should be given to performing the calculation with time as in the
thermal region.
Page 5 of 14
Incide nt en e rg y, E
5 Cal/cm2
Straight line
E=MIbf+N
1.2 Cal/cm2
I1
I2
13.8 kV
1.5 MVA,
208 V
225 A
4,190 A
Fault initiates
at branch
Page 6 of 14
If the fault is assumed to be at equipment on the load side of the branch circuit breaker
and is not located within the same enclosure or compartment with the circuit breaker, it
is reasonable to assume that the branch circuit breaker will clear. In our example, if we
assumed that the work were being performed at a motor located in a separate
enclosure or compartment from the 100 A circuit breaker and on its load side, it would
be reasonable to assume that the 100 A circuit breaker would clear the fault.
IEEE 1584 shortcut calculations for circuit breakers
For circuit breakers, it is possible to enter the IEEE spreadsheet using the time of
interruption for the specific circuit breaker. This interruption time is based on the arcing
current. An alternative is to enter the IEEE spreadsheet knowing only the circuit breaker
type. This shortcut method is based on simplified equations as described below. The
great advantage of the shortcut method is that you do not need to obtain or interpret
time-current characteristics for each circuit breaker.
The input information needed includes:
Bolted fault current
System voltage
Current rating of the circuit breaker
Type of trip unit (thermal-magnetic, magnetic only, or electronic)
Type of circuit breaker (molded-case or low-voltage power)
Tripping current setting for the circuit breaker (or default value)
Notice that input information does not include arc current or time to clear. The shortcut
makes worst case assumptions for system grounding, class of equipment, conductor
gap and enclosure. It assumes that all working distances are 18 inches, a normal
working distance. It requires an accurate determination of bolted fault current, as does
every other method. This method is published in IEEE 1584.
Shortcut equations
TABLE 1
Equations for Incident Energy and Flash protection boundary
1.1.1.1.1.1
Incident
energy
600 V
(cal/cm2)
0.045 Ib + 0.13
Flash
boundary
(mm)
9.16 Ib + 194
Incident
energy
(cal/cm2)
0.065 Ib + 0.04
Flash
boundary
(mm)
11.8 Ib + 196
TM or M
0.053 Ib + 0.38
8.45 Ib + 364
0.080 Ib + 0.09
11.4 Ib + 369
MCCB
E, LI
0.09 Ib + 0.324
12.5 Ib + 428
0.112 Ib + 11.0
14.3 Ib + 568
TM or E, LI
0.107 Ib + 0.72
11.1 Ib +696
0.164 Ib + 0.04
16.7 Ib + 606
800 6300
MCCB or
ICCB
LVPCB
E, LI
0.15 Ib + 0.88
14.5 Ib + 786
0.23 Ib + 0.070
19.1 Ib + 864
800 6300
LVPCB
E, LS
1.09 Ib + 6.51
47.2 Ib +2660
1.64 Ib + 0.519
62.4 Ib + 2930
Rating A
100 400
Breaker
Type
MCCB
Trip Unit
Type *
TM or M
600 1200
MCCB
600 1200
1600 6000
Page 7 of 14
L The long-time setting is for lower overcurrent conditions to allow for momentary
current surges. It usually has a current pick-up adjustment and a time-delay
adjustment.
S The short-time setting is for coordination purposes through the overload and
short circuit current levels. It usually has a current pick-up and a time-delay
adjustment.
I The instantaneous feature sets a current level above which tripping occurs with
no intentional delay. It is usually turned off or is absent when the short-time function
is used.
Page 8 of 14
(Eq. 1)
(Eq. 2)
and It is the tripping current setting for the circuit breaker, as illustrated in figure 4.
It Default Value
When the tripping current, It, is not known, use a default value of 10 times the
continuous current rating of the CB, except for CBs rated 100 A and below. For CBs
rated 100 A and below, use a default value of I t = 1300 A. Where an LS trip unit is used,
It is the short-time pick-up current.
Tim e (sec)
1000
100
10
1
0.1
0.01
100
It
1000
10000
100000
C urren t
Page 9 of 14
12
10
0-200A RK1
400A RK1
0-400A CB
Cat. 1 bdry
4
2
0
0
20
40
60
80
100
120
12
10
8
1200A L
1200A CB
Cat. 1 bdry
Cat. 2 bdry
2
0
0
50
100
150
Page 10 of 14
35
30
2000A L
25
2000A MCCB
20
Cat. 1
15
Cat. 2
10
Cat. 3
5
0
0
50
100
150
35
30
2000A L
25
Impact of lower
instantaneous
setting.
20
15
10
2000A MCCB
Cat. 1
Cat. 2
Cat. 3
5
0
0
50
100
150
Page 11 of 14
energy associated with instantaneous operation are seen. Ratings similar to this 1200 A
rating are normally seen at feeder locations.
Chart C shows an even greater impact of the thermal region. Devices of 2000 A are
frequently seen in main device applications.
Chart D shows a means of obtaining better arc flash protection by adjusting the
instantaneous trip setting of the circuit breaker to a low value when coordination will
permit the lower setting.
Current limitation and current-limiting circuit breakers
The shortcut calculation methods presented here and in IEEE 1584 all assume that
arcing short circuit current will flow for the entire duration shown of the maximum time
on the trip curve of the circuit breaker. That is the best assumption to be made when
more definite test information is not available. However, there are two considerations
that impact the incident energy that deserve review.
The first is that the time-current characteristic for an MCCB with current limiting
characteristics can be expected to show much faster clearing times than for a standard
MCCB. This point is bypassed in the shortcut method.
The second point is that a second arc is generated between the circuit breaker contacts
while it is clearing. This second arc significantly reduces the magnitude of current
flowing. This point is presently bypassed by both of the circuit breaker calculation
methods in IEEE 1584.
The first point is illustrated by the comparison of incident energy for a standard MCCB
compared to that for a current limiting MCCB in figure 5.
Std
2
1
0
0
20
40
60
80
100
120
Page 12 of 14
Page 13 of 14
the high arc fault levels, whereas it is critical to understand that higher incident energy
can result from lower fault current.
Page 14 of 14