IEEE 1584-20189 min read

Arc Flash at Minimum Fault Current: Why Generator Supply Can Give Eight Times More Energy

Part 4 of the arc flash series. On the transformer the arcing current trips the instantaneous element in 70 ms (2.7 cal/cm²). On a standby generator the current falls below it and the arc lasts 1.8 s (23 cal/cm²).

Scenario

Equipment415 V LV switchgear: gap 32 mm, enclosure 508 × 508 × 508 mm, working distance 610 mm
Bolted fault current37 kA on the transformer; 12 kA on the standby generator
ProtectionIEC Standard Inverse, pickup 2,500 A, TMS 0.3; instantaneous 15 kA (20 ms); breaker 50 ms

Step-by-step calculation

Step 1: Transformer supply (maximum)

Arcing current 23.3 kA is above the 15 kA instantaneous setting.

Step 2: Generator supply (minimum)

t = 0.14 × TMS / ((I/Ip)^0.02 − 1) + breaker
Arcing current 8.37 kA < 15 kA → IDMT: 0.14 × 0.3 / ((8370/2500)^0.02 − 1) + 0.05
t = 1.77 s → E = 23.0 cal/cm² (Category 3); the reduced arcing current 7.31 kA gives 1.99 s

Step 3: Fix: lower the instantaneous setting

Set the instantaneous element to 6 kA, above downstream devices' let-through and motor starting but below the minimum arcing current.

Result summary

CheckRequirementActualStatus
Transformer supply≤ 8 cal/cm²2.74 cal/cm²✓ PASS
Generator supply, inst 15 kA≤ 8 cal/cm²23.0 cal/cm²✗ FAIL
Generator supply, inst 6 kA≤ 8 cal/cm²0.91 cal/cm²✓ PASS
The lower fault current on generator supply drops the arcing current below the instantaneous pickup, so the arc lasts 1.8 s and the energy rises from 2.7 to 23 cal/cm². Lowering the instantaneous setting to 6 kA (or a generator-mode setting group) restores fast clearing.

Key insight: The highest incident energy often comes from the lowest fault current. Every operating mode — normal, one transformer out, generator only — must be studied.

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Frequently asked questions

Why compare the instantaneous setting with the arcing current, not the bolted current?

The protection sees the current that actually flows during the arc, which at LV can be half the bolted value.

Can setting groups help?

Yes. Many numeric relays switch to a generator setting group automatically when the incomer opens and the generator closes.

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