Generator

Power in electrical safety
Electrical safety for low-voltage generating sets
Dipl.-Ing. W. Bender GmbH&Co.KG 35305 Grnberg Germany www.bender-de.com F80(GEN)_PPT_EN_200606 nderungen vorbehalten
When using mobile generators a high level of protection against hazards caused by electrical currents must be ensured ... despite lack of time despite temporary use despite cramped conditions despite different types and number of items of electrical equipment despite electrical equipment is operated by ordinary persons
Standards for low-voltage generating sets
IEC 60364-4-41 (DIN VDE 0100-410:1997-01) Erection of power installations with nominal voltages up to 1000V Part 41: Protection for safety IEC 60364-5-551 (DIN VDE 0100-551:1997-08) Selection and erection of electrical equipment Section 551: Low-voltage generating sets
Requirements based on practical experience
High personal safety shall be guaranteed. A trained electrician shall not be required. Neither shall there be a limit to the number of items of electrical equipment nor a limit to the cable lenght. The generator shall be ready for use immediately. An earth rod shall not be imperative, for example because of a solid ground like rock, stone, asphalt. The protective measure shall be applicable to each generator.
Possible protective measures
Applicable protective measures
According to clause 551 almost all protective measures in accordance with IEC 60364-4-41 are permitted.
But not every protective measure meets the practical requirements.

According to subclause 551.4 attention shall be paid to the following additional requirements: 551.4.3.2 The correct operation of protective devices must not be impaired by DC currents or by the presence of filters. Where installations are not permanently fixed, the following additional requirements apply: 551.4.4.1 Between separate items of equipment, protective conductors shall be provided, which are part of a suitable cord or cable. 551.4.4.2 In TN, TT and IT systems a residual current protective device with a rated residual operating current of not more than 30 mA shall be installed to provide automatic disconnection. Note: In IT systems, disconnection by means of a residual current protective device is not necessary.
The earthed system - TN system
All exposed conductive parts of the installation shall be connected to the earthed point of the power system (IEC 364-4-41, subclause 413.1.3.1). The impedance of the fault loop shall be such that automatic disconnection of the supply will occur within 0.2 s (400 V) or 0.4 s (230 V) (IEC 364-4-41 subclause 413.1.3.3). Only RCDs are permitted (IEC 364-5-551, subclause 551.4.4.2). Only TN-S systems are permitted (IEC 364-4-410, subclause 413.1.3.8).
TN-S system with RCD for low-voltage gen-sets
An earthing rod is required to connect the PE conductor to the earth electrode ! The conditions for disconnection shall be verified by a trained electrician ! The function of the RCD shall be verified by a trained electrician !
The unearthed system - IT system
No live conductor of the installation shall be directly connected to earth. Insulation monitoring to initiate an audible and/or visual signal shall be provided (IEC 364-4-41, subclause 413.1.5.4). Neither insulation monitoring nor disconnection in case of a double fault are necessary provided that all exposed conductive parts are connected via the PE conductor and earthing resistance 100 ; the voltage decreases to 50 V in the event of two faults occurring simultaneously (DIN VDE 0100-551 Annex ZB).
IT System with insulation monitoring
The insulation monitoring device recognizes and signals the first insulation fault at an early stage !
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IT system with RCD
Usually an RCD is ineffective in an IT system, since the condition of operation is influenced by system leakage capacitances upstream and downstream the measuring current transformer ! The system leakage capacitance is not sufficiently high to trigger an RCD ! Condition of operation CV >> CN
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Protection by electrical separation
Isolating transformer / motor generator with isolated windings (IEC 364-4-41 subclause 413.5.1.1). Live parts shall not be connected to earth (IEC 364-4-41, subclause 413.5.1.3). Socket outlets shall have a protective conductor contact (IEC 364-4-41, subclause 413.5.3.2). Except where supplying Class II equipment all flexible cables shall embody a protective conductor (IEC 364-4-41, subclause 413.5.3.3). The exposed conductive parts of the separated circuit shall be connected together by insulated nonearthed equipotential bonding conductors (IEC 364-4-41, subclause 413.5.3.1).
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Protection by electrical separation where one item of electrical equipment is supplied
The leakage current ICE is caused by parasitic system leakage capacitances. In view of the fact that system leakage capacitances caused by generating sets usually are negligible, capacitive currents are only caused by cords and electrical equipment.
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Summary
TN systems incorporating an RCD do not meet practical requirements owing to the fact that an earth rod is required a skilled electrician is required it cannot be applied by ordinary persons. In IT systems already the first fault is indicated by the insulation monitoring device, but an earth rod is required too ! Protection by electrical separation is the best solution where one item of electrical equipment is supplied ! Problem: protection by electrical separation where two or more items of electrical equipment are supplied ?
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Requirements for protection by electrical separation
If several items of electrical equipment are connected, the following requirements in accordance with DIN VDE 0100-551 ANNEX ZB will apply: If the insulation resistance between live parts and the equipotential bonding drops below 100 /V (= 23 k/230 V) (value determined by insulation monitoring), disconnection of supply within 1 s is required. No limit to the cable length. Requirements for disconnection in the event of two faults occurring simultaneously must not be met. or as an alternative The product of the nominal voltage of the circuit in volts and the length in metres of the wiring system should not exceed 100 000, and the length of the wiring system should not exceed 500m and requirements for disconnection in the event of two faults occurring simultaneously must be met (IEC 364-4-41, subclause 413.5.3.4) or voltage must drop to 50 V in the event of a fault.
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Requirements for protection by electrical separation
If two items of electrical equipment are connected, the following requirements in accordance with IEC 364-4-41 shall be met: Precautions shall be taken to protect the circuit against damage and insulation faults (subclause 413.5.3) The exposed conductive parts of the separated circuit shall be connected together by insulated non-earthed equipotential bonding conductors (subclause 413.5.3.1); All socket-outlets shall be provided with protective contacts (subclause 413.5.3.2); Except where supplying Class II equipment all flexible cables shall embody a protective conductor (subclause 413.5.3.3); The requirements for disconnection shall be met in the event of two faults occurring simultaneously (subclause 413.5.3.4);
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1st possibility DIN VDE 0100-551 Annex ZB
In the event of two faults occurring simultaneously, disconnection shall be ensured within 0.2 s/0.4s! The breaking current is approx. 50 A when a 16 A circuit breaker is used ! -> insufficient personel safety The product of the nominal voltage of the circuit in volts and length in metres of the wiring system should not exceed 100 000Vm, and the length of the wiring should not exceed 500m -> limit to the cable length;
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2nd possibility DIN VDE 0100-551 Annex ZB
Monitoring by means of an insulation monitoring device. Disconnection within 1s, if insulation resistance is 100/V. No limit to the cable length. Requirements for disconnection must not be met in the event of two faults occuring simultaneously. Already the first fault is detected
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Protection by electrical separation with insulation monitoring
The current flowing via the human body is limited to the value of the measuring current of the insulation monitoring
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Example: construction site
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Example: pipe-laying
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Example: Red Cross
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Example: fire brigade
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Response value Insulation monitoring
DIN VDE 0100-551 Annex ZB (Disconnection) 100 Ohm/Volt for 230V = 23 kOhm for 400V = 40 kOhm
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Example: gen-set fire brigade
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Comparison of the protective measures

Protective measure Earth rod Earthing resistance Requirements for disconnection yes Cable length Number of consumer unlimited Trained electrician required yes Personal protection
TN system with RCD
Installation of an RCD Installation of an IMD Generator and equipment Class II Isolated windings Isolated windings Circuit breakers Isolated windings IMD
yes
in compliance with tripping characteristic < 100 Ohm
approx.. 100m (2,5mm2) approx.. 100m (2,5mm2) approx.. 100m (2,5mm2) max. 500m approx.. 100m (2,5mm2) unlimited
high
IT systems with insulation monitoring device Protection by insulation
yes
yes
unlimited
yes
very high
no
no
unlimited
no
very high
Protection by electrical separation (one consumer) Protection by electrical separation (two consumer) Circuit breaker Protection by electrical separation (two consumer) IMD with disconnection
no
no
one
no
very high
no
yes
unlimited
no
low
no
no
unlimited
no
very high
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Summary
Protection by electrical separation is the best solution when one item of electrical equiment is supplied ! Protection by electrical separation with insulation monitoring and disconnection is the best solution when more then one item of electrical equipment is supplied.
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Have all the requirements been fullfilled ?
Protection by electrical separation with insulation monitoring and disconnection 9 High personal safety is ensured 9 No skilled person is required 9 There is neither a limit to the number of items of electrical equipment nor a limit to the cable length 9 The mobile generator is ready for use immediately 9 An earth rod need not to be provided 9 The protective measure is applicable to each generator
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Solutions for mobile
Typ Nominal voltage Supply voltage Response value RALARM1 Response value RALARM2 Response time Notes
IR423 AC 0 ...300V AC 230V 1 ... 200 kOhm
IR140AS AC 0 ...300V AC 230V 23 kOhm
IR470LY2-4061 3(N)AC 0 ...793V AC 230V 10 ... 100 kOhm
1 ... 200 kOhm
35 ... 500 kOhm
< 1s VerteilerEinbaugehuse
< 1s Resin encapsulated
< 1s Two response values 100 Ohm/V 150 Ohm/V
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Complete solutions
Typ Nominal voltage Connection Plugs Response value RALARM Response time
VG12 AC 50...60Hz 230V Schuko Plug or other plugs Two Schuko plugs or other plugs 23 k < 1s
VG20 3NAC 50...60 Hz 400/230V modular terminals 40 k < 1s
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A-ISOMETER IR423
Measuring function
Insulation monitoring for AC IT systems 0...300 V 30...460 Hz

Response values
Two individually adjustable response values 1...200 k

Device features
Indication range LCD display 1k...1 M Connection monitoring system/earth Password
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Sicherheitsverteiler VG12
Measuring function
Insulation monitoring for AC IT systems 0...300 V 42...460 Hz

Response values
Two individually adjustable response values 1...200 k

Device features
Indication range LCD display 1k...1 M Connection monitoring system/earth Password Mounting adapter for different generators
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Example IR423 - Disconnetion with overvoltage release
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Example IR423 Disconnection with contactor
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Vielen Dank Thank you Merci beaucoup

Dipl.-Ing. W. Bender GmbH&Co.KG Londorfer Strae 65 35305 Grnberg Germany Telefon: +49-(0)6401/807-0 Fax: +49-(0)6401/807-259 Email: info@bender-de.com
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Power in electrical safety

Electrical safety for low-voltage generating sets

Power in electrical safety

Standards for low-voltage generating sets

Requirements based on practical experience

Possible protective measures

Applicable protective measures

But not every protective measure meets the practical requirements.

The earthed system - TN system

TN-S system with RCD for low-voltage gen-sets

The unearthed system - IT system

IT System with insulation monitoring

IT system with RCD

Protection by electrical separation

Protection by electrical separation where one item of electrical equipment is supplied

Requirements for protection by electrical separation

Requirements for protection by electrical separation

1st possibility DIN VDE 0100-551 Annex ZB

2nd possibility DIN VDE 0100-551 Annex ZB

Protection by electrical separation with insulation monitoring

Example: construction site

Example: Red Cross

Example: fire brigade

Response value Insulation monitoring

Example: gen-set fire brigade

Comparison of the protective measures

TN system with RCD

in compliance with tripping characteristic < 100 Ohm

IT systems with insulation monitoring device Protection by insulation

Have all the requirements been fullfilled ?

Solutions for mobile

IR423 AC 0 ...300V AC 230V 1 ... 200 kOhm

IR140AS AC 0 ...300V AC 230V 23 kOhm

IR470LY2-4061 3(N)AC 0 ...793V AC 230V 10 ... 100 kOhm

1 ... 200 kOhm

35 ... 500 kOhm

< 1s Resin encapsulated

< 1s Two response values 100 Ohm/V 150 Ohm/V

VG20 3NAC 50...60 Hz 400/230V modular terminals 40 k < 1s

Insulation monitoring for AC IT systems 0...300 V 30...460 Hz

Two individually adjustable response values 1...200 k

Indication range LCD display 1k...1 M Connection monitoring system/earth Password

Insulation monitoring for AC IT systems 0...300 V 42...460 Hz

Two individually adjustable response values 1...200 k

Example IR423 - Disconnetion with overvoltage release

Example IR423 Disconnection with contactor

Power in electrical safety

Vielen Dank Thank you Merci beaucoup

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