WHITE PAPER

Low voltage products in high altitudes

Information and technical guidance for applications above
2000 m sea level

This white paper provides information including technical guidance for high
altitude applications of the following devices:

− Contactors associated with overload and/or short-circuit protective devices

− Starters associated with separate short-circuit protective devices
− Circuit-breakers and fuse-combination units used as short-circuit protective
devices

They are covered under the requirements of the IEC60947 series which gives
limitations related to the insulation coordination of the devices and their
performance.

References
The following documents are referred to for the
applications in this white paper:

− IEC Guide111{ed2.0}
− IEC 60071-2{ed3.0}
− IEC 60947-1{ed5.1}b
− IEC 60664-1{ed2.0}b
− Surge & lightning protection solutions
(1TXH000375C0202)
White Paper │ Low voltage products in high altitudes 2

Definitions
− Clearance
shortest distance in the air between two conductive parts
− Creepage distance
shortest distance along the surface of a solid insulating material between two conductive
parts
− Electrical breakdown
failure of insulation under electric stress when the discharge completely bridges the
insulation, thus reducing the voltage between the electrodes almost to zero
− Overvoltage
any voltage having a peak value exceeding the corresponding peak value of maximum steady-
state voltage at normal operating conditions
− R.m.s. withstand voltage
highest r.m.s. value of a voltage which does not cause breakdown of insulation under specified
conditions
− Rated impulse voltage
impulse withstand voltage value assigned by the manufacturer to the equipment or to a part
of it, characterizing the specified withstand capability of its insulation against transient
overvoltages
− Rated insulation voltage
r.m.s. withstand voltage value assigned by the manufacturer to the equipment or to a part of
it, characterizing the specified (long-term) withstand capability of its insulation
The significant parameters or items for the consideration of high altitude applications for these
industrial products are as follows:
− Rated operational voltage (Ue)
A rated operational voltage of an equipment is a value of voltage which, combined with a rated
operational current, determines the application of the equipment
− Rated insulation voltage (Ui)
The rated insulation voltage of an equipment is the value of voltage to which dielectric tests
and creepage distances are referred
− Rated impulse withstand voltage (Uimp)
The peak value of an impulse voltage of prescribed form and polarity which the equipment is
capable of withstanding without failure under specified conditions of test and to which the
values of the clearances are referred
− Rated operational current (Ie)
A rated operational current of an equipment is stated by the manufacturer and takes into
account the rated operational voltage, the rated frequency and the utilization category
− Overvoltage category
conventional number based on limiting (or controlling) the values of prospective transient
overvoltages occurring in a circuit
− Type of voltage system
− Installation altitude
White Paper │ Low voltage products in high altitudes 3

Important environmental parameters are:

− air pressure
− temperature
− pollution
− relative humidity
− condensation
Essential for high altitude applications are effects linked to dimensional parameters like clearances
and creepage distances due to reduced air pressure with increasing altitude. The electrical field stress
through solid insulation under dedicated environmental parameters is depending on the device
construction and is validated by test procedures according to the applicable product standards for
application altitudes of 2000 m only. Above 2000 m the stated parameters Ue, Ui, Uimp and Ie for the
devices have to be re-evaluated. With the application of the described correction factors and additional
measures however the devices can be used at higher altitudes. For application altitudes up to 2000 m
the correlation between the nominal voltage of the supply system and the rated impulse withstand
voltage of equipment is shown in Annex H1 of IEC60947-1.

—
Correspondence between the nominal voltage of the supply system and the equipment rated
impulse withstand voltage, in case of overvoltage protection by surge-arresters according to
IEC 60099-1
Max. value of Nominal voltage of the supply system Preferred values of rated impulse withstand voltage
rated operat. (≤ rated insulation voltage of the equipment) (1,2/50 µs) at 2000 m
voltage to earth kV
Overvoltage category

IV III II I
Origin of
a.c. r.m.s. a.c. r.m.s. a.c. r.m.s. a.c. r.m.s. a.c. r.m.s. installation
or d.c. or d.c. or d.c. level Load level Specially
(service Distribut. (appliance, protected
V V V V V entrance) circuit level equipment) level
12,5, 24, 25
50 – – 60-30 1,5 0,8 0,5 0,33
30, 42, 48
100 66/115 66 60 – 2,5 1,5 0,8 0,5
120/208 115, 120 220-110,
150 110, 120 4 2,5 1,5 0,8
127/220 127 240-120
220/380,
230/400 220, 230
300 240/415, 240, 260 220 440-220 6 4 2,5 1,5
260/440 277
277/480
347, 380,
347/600,
400
380/660
415, 440,
600 400/690, 480 960-480 8 6 4 2,5
480
415/720
500, 577,
480/830
600
660
1000 – 690, 720 1000 – 12 8 6 4
830, 1000
White Paper │ Low voltage products in high altitudes 4

The dimensioning of clearances aims to choose an air distance able to withstand the maximum peak
voltage across the air gap between two parts at different voltages.

According to Paschen’s law, the behavior of air to withstand a maximum voltage value is in relationship
with air pressure. Correction factors for altitudes above 2000 m are given in Table A.2 of IEC 60664-
1:2007.
When these correction factors for altitudes above 2000 m are applied for determining the clearances,
also the test voltage for the impulse voltage test is corrected accordingly. Therefore, the test voltage
for the impulse voltage test is determined with the interpolation of Table A.2 of IEC 60664-1:2007 and
applying the formulas of 6.1.2.2.1.3 of IEC 60664-1:2007.

—
Altitude correction factors ( extract)
Altitude Normal barometric pressure Multiplication factor
m kPa for clearances
2000 80,0 1,00
3000 70,0 1,14
4000 62,0 1,29
5000 54,0 1,48
6000 47,0 1,70
White Paper │ Low voltage products in high altitudes 5

Example
A device has following ratings suitable up to 2000 m:

Ue 690V
Ui 690V
Ie current AC-1 / AC-3
Uimp 8 kV
Pollution 3
Material class II

Intended application altitude: 4000 m

Ui consideration at 4000 m
For installation at an altitude higher than 2000 m above sea level, the insulation level of external
insulation under the standardized reference atmospheric conditions should be determined by
multiplying the insulation withstand voltages required at the service location by a factor Ka in
accordance with IEC 60071-2 chapter 4.2.2.

Where H is the altitude above sea level (in m) and the value of m = 0,5 switching impulse withstand
voltages.
For the determination of the applicable atmospheric correction factor, it may be assumed that the
effects of the ambient temperature and humidity tend to cancel each other out. Therefore, for
insulation co-ordination purposes, only the air pressure corresponding to the altitude of the location
needs to be taken into account for both dry and wet insulations.
The suitability of the low voltage product in high altitudes is therefore depending on the following
application specific parameters at the installation altitude:

To be suitable for e.g. 4000 m the Ka can be calculated:

H = 4000 m which gives a Ka of 1,2787

The required Ui (at 4000 m) is 690 V * 1,2787 = 888 V

The power frequency validation for this value Ui = 888 V is to be performed with an AC test voltage of
2200 V ac according to the table on the next page.
White Paper │ Low voltage products in high altitudes 6

—
Dielectric test voltage corresponding to the rated insulation voltage
Rated insulation voltage U i AC test voltage(r.m.s.) DC test voltage b ,c

V V V
U i ≤ 60 1000 1415
60 < U i ≤ 300 1500 2120
300 < U i ≤ 690 1890 2670
690 < U i ≤ 800 2000 2830
800 < U i ≤ 1000 2200 3110
1000 < U i ≤ 1500 a − 3820
a For d.c. only
b Test voltages based on 6.1.3.4.1, fifth paragraph of IEC 60664-1:2007
c A direct current test voltage may be used only if an alternating test voltage cannot be applied. See also 3) b) ii) of 9.3.3.4.1.

Concerning creepage distances for an Ui of 888 V the table 15 of IEC60947-1 applies.

The table specifies the rated insulation voltage of an equipment or working voltage a.c. r.m.s. related
to minimum creepage distances for equipment subject to long term stress.

The following table gives for 888 V an interpolated creepage distance value of 13,32 mm.
White Paper │ Low voltage products in high altitudes 7

—
Minimum creepage distances
Rated insulation voltage of Minimum creepage distances for equipment subject to long term stress
equipment or working voltage Printed wiring
a.c. r.m.s. material
or d.c. b ,c,d Pollution degree
1 2 1 2 3 4

Material groups
All except
All IIIb All I II III I II IIIa IIIb I II IIIa IIIb
V mm mm mm mm mm mm mm mm mm mm mm mm mm mm
10 0,025 0,04 0,08 0,4 0,4 0,4 1 1 1 1,6 1,6 1,6
12,5 0,025 0,04 0,09 0,42 0,42 0,42 1,05 1,05 1,05 1,6 1,6 1,6
16 0,025 0,04 0,1 0,45 0,45 0,45 1,1 1,1 1,1 1,6 1,6 1,6
20 0,025 0,04 0,11 0,48 0,48 0,48 1,2 1,2 1,2 1,6 1,6 1,6
25 0,025 0,04 0,125 0,5 0,5 0,5 1,25 1,25 1,25 1,7 1,7 1,7
32 0,025 0,04 0,14 0,53 0,53 0,53 1,3 1,3 1,3 1,8 1,8 1,8
40 0,025 0,04 0,16 0,56 0,8 1,1 1,4 1,6 1,8 1,9 2,4 3
50 0,025 0,04 0,18 0,6 0,85 1,2 1,5 1,7 1,9 2 2,5 3,2
63 0,04 0,063 0,2 0,63 0,9 1,25 1,6 1,8 2 2,1 2,6 3,4
80 0,063 0,1 0,22 0,67 0,95 1,3 1,7 1,9 2,1 2,2 2,8 3,6
100 0,1 0,16 0,25 0,71 1 1,4 1,8 2 2,2 2,4 3 3,8
125 0,16 0,25 0,28 0,75 1,05 1,5 1,9 2,1 2,4 2,5 3,2 4
160 0,25 0,4 0,32 0,8 1,1 1,6 2 2,2 2,5 3,2 4 5
200 0,4 0,63 0,42 1 1,4 2 2,5 2,8 3,2 4 5 6,3
250 0,56 1 0,56 1,25 1,8 2,5 3,2 3,6 4 5 6,3 8
320 0,75 1,6 0,75 1,6 2,2 3,2 4 4,5 5 6,3 8 10
400 1 2 1 2 2,8 4 5 5,6 6,3 8 10 12,5
500 1,3 2,5 1,3 2,5 3,6 5 6,3 7,1 8 10 12,5 16
630 1,8 3,2 1,8 3,2 4,5 6,3 8 9 10 12,5 16 20 a
800 2,4 4 2,4 4 5,6 8 10 11 12,5 16 20 25
1000 3,2 5 3,2 5 7,1 10 12,5 14 16 20 25 32
1250 4,2 6,3 9 12,5 16 18 20 25 32 40
1600 5,6 8 11 16 20 22 25 32 40 50
2000 7,5 10 14 20 25 28 32 40 50 63
2500 10 12,5 18 25 32 36 40 50 63 80
3200 12,5 16 22 32 40 45 50 a 63 80 100
4000 16 20 28 40 50 56 63 80 100 125
5000 20 25 36 50 63 71 80 100 125 160
6300 25 32 45 63 80 90 100 125 160 200
8000 32 40 56 80 100 110 125 160 200 250
10000 40 50 71 100 125 140 160 200 250 320
a Values of creepage distances in this area have not been established. Material group IIIb is in general not recommended for application in pollution
degree 3 above 630 V and in pollution degree 4
b As an exception, for rated insulation voltages 127 V, 208 V, 415/440 V, 660/690 V and 830 V, creepage distances corresponding to the lower values
125 V, 200 V, 400 V, 630 V and 800 V respectively may be used
c The values of creepage distances stated for 250 V can be used for 230 V (±10 %) nominal voltage
d It is appreciated that tracking or erosion will not occur on insulation subjected to working voltages of 32 V and below. However, the possibility of
electrolytic corrosion has to be considered and for this reason minimum creepage distances have been specified
NOTE Voltage values are selected in accordance with the R 10 series
White Paper │ Low voltage products in high altitudes 8

Uimp consideration at 4000 m

Concerning the suitability of devices in applications at installation altitudes above 2000 m the Uimp of
the device has to be considered which is correlated to the device spacing.
According to table A.2 of IEC 60664-1 a multiplication factor of 1,29 for clearances needs to be applied
if the device is intended to be used at 4000 m.

—
Altitude correction factors ( extract) IEC 60664-1:2007
and applying the formulas 6.1.2.2.1.3 of IEC 60664-1:2007
Altitude Normal barometric pressure Multiplication factor
m kPa for clearances
2000 80,0 1,00
3000 70,0 1,14
4000 62,0 1,29
5000 54,0 1,48
6000 47,0 1,70

For applications up to 2000 m a spacing of 8 mm is needed according to the table above.

—
Minimum clearances in air
Minimum clearances in mm
Rated impulse Case A Case B
withstand Inhomogeneous field conditions Homogeneous field ideal conditions
voltage (see 3.7.63) (see 3.7.62)
U imp Pollution degree Pollution degree
kV 1 2 3 4 1 2 3 4
0,33 0,01 0,01
0,5 0,04 0,2 0,04 0,2
0,8 0,1 0,8 0,1 0,8 1,6
1,5 0,5 0,5 1,6 0,3 0,3
2,5 1,5 1,5 1,5 0,6 0,6
4,0 3 3 3 3 1,2 1,2 1,2
6,0 5,5 5,5 5,5 5,5 2 2 2 2
8,0 8 8 8 8 3 3 3 3
12 14 14 14 14 4,5 4,5 4,5 4,5
NOTE The values of minimum clearances in air are based on 1,2/50 µs impulse voltage, for barometric pressure of 80 kPa, equivalent to
normal atmospheric pressure at 2 000 m above sea level.
White Paper │ Low voltage products in high altitudes 9

— —
IEC60664-1 / Table A.2 Minimum clearances in air
Altitude Normal Altitude correction Altitude for Uimp= for Uimp= for Uimp= for Uimp=
m barometric pressure factors for clearances m 4kV 6kV 8kV 12kV
2000 80,0 kPa 1 2000 3,0 mm 5,5 mm 8,0 mm 14,0 mm
3000 70,0 kPa 1,14 3000 3,4 mm 6,3 mm 9,1 mm 16,0 mm
4000 62,0 kPa 1,29 4000 3,9 mm 7,1 mm 10,3 mm 18,1 mm
5000 54,0 kPa 1,48 5000 4,4 mm 8,1 mm 11,8 mm 20,7 mm
6000
7000
47,0 kPa
41,0 kPa
1,7
1,95
 6000
7000
5,1 mm
5,9 mm
9,4 mm
10,7 mm
13,6 mm
15,6 mm
23,8 mm
27,3 mm
8000 35,5 kPa 2,25 8000 6,8 mm 12,4 mm 18,0 mm 31,5 mm
9000 30,5 kPa 2,62 9000 7,9 mm 14,4 mm 21,0 mm 36,7 mm
10000 26,5 kPa 3,02 10000 9,1 mm 16,6 mm 24,2 mm 42,3 mm
15000 12,0 kPa 6,67 15000 20,0 mm 36,7 mm 53,4 mm 93,4 mm
20000 5,5 kPa 14,5 20000 43,5 mm 79,8 mm 116,0 mm 203,0 mm

There are now two possibilities to address the use at 4000 m altitude. Declare a reduced Uimp or
validate with a Uimp test or measurement:

− At installation altitudes of 4000 m with application of the correction factor a spacing of 10,3mm
is needed to achieve a 8kV Uimp. As the device in the example is validated for 8 kV, the spacing
of min. 8 mm according to table 13 is proven. This means that this device can be used at 4000
m with a stated 6 kV Uimp only according to the table above (7.1 mm).

− To validate the suitable spacings for the final application altitude (see table above) it is possible
to either re-test the impulse withstand voltage with the requested level or validate the
requested spacings by measurement. In the example given, the 8 kV at 4000 m need to be
validated with an rated impulse withstand voltage of rated 12 kV and a test voltage of 14,8 kV
(sea level) or 10,3 mm spacing measurement.

As an additional option to improve Uimp the use of Surge Protective Devices (SPDs) is possible.

For the achievement of a necessary Uimp for a given overvoltage category the use of suitable type
1/Type 2 SPDs is recommended in combination with other measures like increased space to conductive
parts or other electric devices with opposite polarity or grounding.
White Paper │ Low voltage products in high altitudes 10

Ie consideration at 4000 m
At installation altitudes above 2000 m the reduced heat dissipation of conductors has to be corrected.
The correction is also dependent on the ambient temperature.
Concerning the reduced heat dissipation of conductors in high altitudes, reduction factors must be
applied depending on the Ie of the devices and the ambient temperature at the installation altitude.
Reduced air pressure with increasing altitude lowers the air density causing the reduction of the heat
dissipation. Assuming linear dependencies the following relations result:

Ploss h = Ploss n x Pn / Ph 𝐼𝐼ℎ = Ie �𝑃𝑃ℎ/𝑃𝑃𝑃𝑃 Ploss ~ I²

Ploss h Power loss at altitude h

Ploss n Power loss at altitude n (≤ 2000 m)
Ph Air pressure at altitude h
Pn Air pressure at altitude n (≤ 2000 m)
Ih current at altitude h
Ie current at altitude n (≤ 2000 m)

Reduction factors of the rated operational current Ie (IEC 60664-1:2007 and applying the formulas
6.1.2.2.1.3 of IEC 60664-1:2007):
—
Altitude correction factors (extract)
Altitude Temperature Ie
m °C reduction
2000 80,0 1,00
3000 70,0 1,14
4000 62,0 1,29
5000 54,0 1,48

Alternatively, appropriate larger wire sizes in combination with device separation may be used to
correct the reduced heat dissipation in high altitudes.
Regarding the thermal effects, particular attention should be paid to the following points:
− thermal exchanges by convection, conduction or radiation
− efficiency of heating or air-conditioning at installation site
For some applications, the reduction factor for continuous current is insignificant. Equipment is
normally not used at the limits of its continuous current capability, and the ambient temperature at
higher altitudes is often lower than the 40 °C ambient temperature according to the product standard
unless otherwise stated.
White Paper │ Low voltage products in high altitudes 11

Recommendations
The maximum continuous voltage (rated system voltage plus maximum overvoltage) must not exceed
the calculated voltage capability of the device at the site altitude.
Surge arrestors should be considered for all circuits to protect the installation, respectively the
equipment, from transient voltages and to give the limit for the system voltage including tolerated
overvoltage. The recommended back up protection of the SPD depending on the application has to be
used.
—
Example for use of SPD

The table on the next page gives a recommendation for use of the devices related to specified device
parameters and the measures taken at specific installation altitudes. This white paper is valid for the
present design.
White Paper │ Low voltage products in high altitudes 12

—
Recommendations for specific altitudes
TA<=60°C, AC-1, AC-3, pollution degree 3 Altitude
2000 m 2500 m
Device Ue/V Ui/V Ui test/V Uimp/kV Measures max Ue Uimp/kV Measures
MS116, 690 1000 2200 6 No 690 6 current reduction
MS132, 0,96* Ie
MS165
EF19, EF45 690 690 2200 6 No 690 6 device separation1)
current reduction
0,96* Ie
EF65-EF750 1000 1000 2200 8 No 690 8 current reduction
0,96* Ie
T16, TF42 690 690 2200 6 No 690 6 current reduction
0,96* Ie
TF65, TF96 690 690 2200 8 No 690 6 current reduction
0,96* Ie
TF140DU 690 690 2200 8 No 690 8 current reduction
0,96* Ie
TA200DU 690 690 2200 6 No 690 6 current reduction
0,96* Ie
TA450DU 690 1000 2200 8 No 690 8 current reduction
0,96* Ie
ESB24/40/63 500 500 2200 6 No 500 6 current reduction
0,96* Ie
B6/B7 690 690 2200 6 No 690 6 current reduction
0,96* Ie
AF116 – AF140 690 1000 1890 8 No 690 6 current reduction
A210 - A3002) 0,96* Ie
AF146, AF190- 1000 1000 2200 8 No 690 8 current reduction
AF370, AF400- 0,96* Ie
AF2650, A95 - A110,
A145 - A185

TA<=60°C, AC-1, AC-3, Altitude

pollution degree 3 3000 m 3500 m 4000 m
Device Ue/V Ui/V Ui test/V max Ue Uimp/kV Measures max Ue Uimp/kV Measures max Ue Uimp/kV Measures
MS116, 690 1000 2200 690 6 no disconnect function 690 6 device separation1) 690 6 device separation1)
MS132, current reduction no disconnect function no disconnect
MS165 0,93* Ie current reduction function
0,9* Ie1) current reduction
0,88*Ie
EF19, EF45 690 690 2200 690 6 current reduction 690 6 device separation1) 690 6 device separation1)
0,93* Ie current reduction current reduction
0,9* Ie 0,88* Ie
EF65-EF750 1000 1000 2200 690 8 current reduction 690 8 device separation1) 690 8 device separation1)
0,93* Ie current reduction current reduction
0,9* Ie 0,88* Ie
T16, TF42 690 690 2200 690 6 current reduction 690 6 device separation1) 690 6 device separation1)
0,93* Ie current reduction current reduction
0,9* Ie 0,88* Ie
TF65, TF96 690 690 2200 690 6 current reduction 690 6 device separation1) 690 6 device separation*)
0,93* Ie current reduction current reduction
0,9* Ie 0,88* Ie
TF140DU 690 690 2200 690 8 current reduction 690 6 device separation1) 690 6 device separation1)
0,93* Ie current reduction current reduction
0,9* Ie 0,88* Ie
TA200DU 690 690 2200 690 6 current reduction 690 4 device separation1) 690 4 device separation1)
0,93* Ie current reduction current reduction
0,9* Ie 0,88* Ie
TA450DU 690 1000 2200 690 8 current reduction 690 8 device separation1) 690 8 device separation1)
0,93* Ie current reduction current reduction
0,9* Ie 0,88* Ie
ESB24/40/63 500 500 2200 500 6 current reduction 690 6 current reduction1) 500 6 current reduction
0,93* Ie 0,9* Ie 0,88* Ie
B6/B7 690 690 2200 690 6 current reduction 690 6 current reduction1) 690 4 current reduction
0,93* Ie 0,9* Ie 0,88* Ie
AF116 – AF140, 690 1000 1890 690 6 current reduction 690 6 device separation1) 690 6 device separation1)
A210 - A3002) 0,93* Ie current reduction current reduction
0,9* Ie 0,88* Ie
AF146, AF190- 1000 1000 2200 690 6 current reduction 690 6 device separation1) 690 6 device separation1)
AF370, AF400- 0,93* Ie current reduction current reduction
AF2650, A95 - A110, 0,9* Ie 0,88* Ie
A145 - A185

1)
Device separation: minimum distance of 10 mm to conductive parts or other devices with the same Ue
2)
Data for AF09-16, AF26-38 and AF65-96 are available upon request
White Paper │ Low voltage products in high altitudes 13

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