Direct Current Electrical Shorting in 

Response to Exposure Fire 

(DESIREE-Fire): Test Results 

Final Report

Office of Nuclear Regulatory Research

NUREG/CR-7100

SAND2012-0323P
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E%&42<62F
Direct Current Electrical Shorting 

in Response to Exposure Fire 

(DESIREE-Fire): Test Results

Final Report 

Manuscript Completed: December 2011 

Date Published: April 2012 

Prepared by: 

Steven P. Nowlen, Jason W. Brown, Tara J. Olivier, and 

Francis J. Wyant 

Sandia National Laboratories 

Risk and Reliability Analysis Dept. 6761 

P.O. Box 5800 

Albuquerque, NM 87185-0748 

Gabriel Taylor, NRC Project Manager 

NRC Job Code N6579 

Office of Nuclear Regulatory Research 

NUREG/CR-7100 

SAND2012-0323P 

iii

ABSTRACT 

This report presents the results of a series of fire tests performed to assess cable failure modes 

and effects behavior for direct current (dc)-powered control circuits. The project, known as the 

Direct Current Electrical Shorting in Response to Exposure Fire (DESIREE-Fire) test project, 

was sponsored by the U.S. Nuclear Regulatory Commission Office of Nuclear Regulatory 

Research. The tests were performed by and at Sandia National Laboratories in Albuquerque, 

NM. The program was conducted with the collaboration of the Electric Power Research Institute 

(EPRI) and its member utilities. EPRI representatives participated in all phases of program 

planning, execution, data analysis, and data reporting by providing both peer review and in-kind 

material support. 

The test program involved a series of both small- and intermediate-scale fire tests. Each test 

exposed one or more electrical control cables commonly used in the existing fleet of U.S. 

nuclear power plants (NPPs) to fire exposure conditions. Each test cable was connected to one 

of several circuit simulator units designed to mimic the behavior of typical NPP components. 

The simulated dc-powered control circuits included motor-operated valves, solenoid-operated 

valves of various sizes, and a medium voltage circuit breaker unit. Cable electrical performance 

is monitored throughout each test to determine both the timing and mode of circuit faulting 

behavior. This report focused on a factual reporting of the test program and test data. Insights 

regarding dc-powered control circuit cable failure modes and effects are to be addressed 

separately via a Phenomena Identification and Ranking Table (PIRT) exercises to qualitatively 

rank fire-induced electrical circuit phenomena and an expert elicitation to provide quantitative 

numerical estimates to the likelihood of various fire-induced circuit failure configurations. One 

PIRT panel focused on electrical behavior and the second on implications for probabilistic risk 

assessment. 

v 

TABLE OF CONTENTS 

Section Page 

ABSTRACT ................................................................................................................................ iii

TABLE OF CONTENTS .............................................................................................................. v

LIST OF FIGURES ................................................................................................................... vii

LIST OF TABLES ..................................................................................................................... viii

EXECUTIVE SUMMARY ...........................................................................................................ix

ACKNOWLEDGMENTS ........................................................................................................... xiii

ACRONYMS ............................................................................................................................. xv

1. BACKGROUND AND INTRODUCTION ......................................................................... 1

1.1 Overview ................................................................................................................ 1

1.2 Background ........................................................................................................... 1

1.3 Purpose and Objectives ......................................................................................... 2

1.4 Project Planning and General Approach ................................................................ 3

1.5 Scope of this Report .............................................................................................. 4

1.6 Report Organization ............................................................................................... 4

2. OVERVIEW OF TESTING NEEDS ADDRESSED BY DESIREE-FIRE .......................... 7

2.1 Cable Failure Modes and Effects for dc-powered Control Circuits.......................... 7

2.2 Cable Failure Modes and Effects for ac Control Circuits ........................................ 8

2.3 Fire and Fire Response Characterization ............................................................... 8

2.4 Supplemental Data on Cable Failure Characteristics ............................................. 9

3. APPROACH ..................................................................................................................11

3.1 Project Planning and General Approach ...............................................................11

3.2 Penlight Small-Scale Radiant Heating Tests .........................................................12

3.3 Intermediate-Scale Open Fire Tests .....................................................................14

3.4 Cable Selection .....................................................................................................17

3.4.1 The DESIREE-Fire Cable Set ...................................................................17

3.4.2 The Japan Nuclear Safety Organization (JNES) Cable ............................. 18

4. DIAGNOSTIC INSTRUMENTATION SUMMARY ..........................................................21

4.1 dc-Powered Test Circuits ......................................................................................21

4.1.1 The dc Battery Bank ..................................................................................21

4.1.2 The dc Test Circuits ..................................................................................22

4.1.3 Current Transducers .................................................................................28

4.2 ac-Powered Test Circuits ......................................................................................29

4.3 Other General Instrumentation ..............................................................................30

5. TEST MATRICES ..........................................................................................................33

6. SUMMARY OF TEST RESULTS ...................................................................................47

6.1 dc Motor Starter (MOV) Results ............................................................................47

6.1.1 Penlight Small-Scale Tests ........................................................................47

6.1.2 Intermediate-Scale Tests...........................................................................51

6.2 Small dc SOV Results ...........................................................................................51

6.2.1 Penlight Small-Scale dc SOV Tests ..........................................................52

6.2.2 Intermediate-Scale SOV Tests ..................................................................54
vi

6.3 Large dc Coil and 1-Inch Solenoid Operated Valve (1”) Results ...........................55

6.3.1 Penlight Small-Scale dc Large Coil and 1” SOV Tests ..............................55

6.3.2 Intermediate-Scale dc Large Coil and 1” SOV Tests ................................. 57

6.4 Switchgear Results ...............................................................................................61

6.4.1 Penlight Small-Scale Switchgear Tests .....................................................61

6.4.2 Intermediate-Scale Switchgear Tests ........................................................63

6.5 Intercable Test Circuit Results ..............................................................................65

6.5.1 Penlight Small-Scale Intercable Tests .......................................................65

6.5.2 Intermediate-Scale Intercable Circuit Tests ...............................................67

6.5.3 Summary of the Intercable Circuit Tests ....................................................69

6.6 SCDU Test Results ...............................................................................................69

6.6.1 Penlight Small-Scale Tests ........................................................................70

6.6.2 Intermediate-Scale SCDU Tests ................................................................72

7. CONCLUSIONS AND GENERAL INSIGHTS ................................................................77

7.1 dc-Powered Circuits ..............................................................................................77

7.2 ac-Powered Circuits ..............................................................................................78

8. REFERENCES ..............................................................................................................79

APPENDIX A: TEST SUPPORT SYSTEMS ......................................................................... A-1 

APPENDIX B: MOTOR-OPERATED VALVE CIRCUITS ...................................................... B-1 

APPENDIX C: SOLENOID-OPERATED VALVE CIRCUITS ................................................. C-1 

APPENDIX D: 1-INCH SOLENOID-OPERATED VALVE (SOV) AND LARGE COIL 

CIRCUITS ..................................................................................................... D-1 

APPENDIX E: SWITCHGEAR CIRCUITS ............................................................................ E-1 

APPENDIX F: INTERCABLE CONFIGURATION CIRCUIT ................................................. F-1 

APPENDIX G: AC SURROGATE CIRCUIT DIAGNOSTIC UNITS........................................ G-1 
vii 

LIST OF FIGURES 

Figure Page 

3-1 The Penlight apparatus ..............................................................................................13

3-2 Schematic representation of the DESIREE-Fire intermediate-scale test 

structure. .................................................................................................................15

3-3 Schematic representation of the DESIREE-Fire intermediate test structure 

located within the outer test facility ..........................................................................16

3-4 Photo of ”sand box” diffusion burner...........................................................................16

4-1 The dc test circuit diagram for MOV-1 and MOV-2 .....................................................23

4-2 The dc test circuit diagram for SOV-1 and SOV-2 ......................................................23

4-3 The dc test circuit diagram for the 1-in. SOV ..............................................................24

4-4 The dc test circuit diagram for the large coil ...............................................................24

4-5 The dc test circuit diagram for the switchgear (including both the trip and close 

circuits) ....................................................................................................................25

4-6 Circuit diagram for the intercable shorting circuit ........................................................25

4-7 Circuit diagram for the SCDU as modified for use in DESIREE-Fire including an 

active electrical interlock on the contactor pair (K-1 and K-2)...................................26

6-1 Test #43 temperature profile .......................................................................................49

6-2 Test #43 MOV-1 and MOV-2 voltage/current plots .....................................................49

6-3 Test #43 additional MOV-2 voltage/current plots ........................................................50

6-4 Test #43 ground voltage monitoring circuit indication .................................................50

6-5 Penlight Test #11 temperature profile .........................................................................57

6-6 Penlight Test #11 1-inch SOV and large coil voltage/current plots ..............................59

6-7 Test #11 ground voltage monitoring circuit indication .................................................60

6-8 Penlight Test #47 cascade effect indicating intercable interaction ..............................67

6-9 Intercable target conductor voltages measured during intermediate-scale test 

IS10 .........................................................................................................................69

6-10 Penlight Test #17 SCDU-1 voltage and current plots ..................................................73

6-11 Test IS4 intracable target conductor current and voltage plots for SCDU 4 ................75
viii 

LIST OF TABLES 

Table Page 

3-1 Relationship between shroud temperature and shroud heat flux assuming an 

emissivity of 0.815. ..................................................................................................13

3-2 DESIREE-Fire cable list..............................................................................................19

5-1 The DESIREE-Fire small-scale Penlight test matrix. ...................................................34

5-2 The DESIREE-Fire intermediate-scale test matrix. .....................................................38

5-3 Chronology of DESIREE-Fire tests (both testing scales). ...........................................43

6-1 Small-scale test matrix – dc MOVs. ............................................................................47

6-2 Results summary – dc MOV. ......................................................................................48

6-3 Intermediate-scale test matrix for the dc MOV starters. ..............................................52

6-4 Intermediate-scale results summary – dc MOVs. ........................................................53

6-5 Small-scale test matrix – small dc SOVs. ...................................................................53

6-6 Small-scale test results summary – small dc SOVs. ...................................................54

6-7 Intermediate-scale test matrix for the small SOVs. .....................................................55

6-8 Small-scale test matrix – large coil and 1" SOV. .........................................................56

6-9 Small-scale test results summary – large coil and 1" SOV. .........................................56

6-10 Intermediate-scale test results summary – 1-in. SOV. ................................................58

6-11 Intermediate-scale test matrix for the large coil and 1” SOV. ......................................60

6-12 Intermediate-scale test results summary – large coil and 1” SOV...............................61

6-13 Small-scale test matrix – switchgear. ..........................................................................62

6-14 Small-scale test results summary – switchgear. .........................................................63

6-15 Intermediate-scale test matrix for the switchgear. .......................................................64

6-16 Intermediate-scale test results summary – switchgear. ...............................................65

6-17 Small-scale test matrix – intercable circuits. ...............................................................66

6-18 Small-scale test results summary – intercable circuits. ...............................................66

6-19 Intermediate-scale test matrix for the intercable circuits. ............................................68

6-20 Intermediate-scale test results summary – intercable circuits. ....................................68

6-21 Small-scale test matrix – ac MOVs. ............................................................................71

6-22 Results summary – ac MOV Penlight tests. ................................................................72

6-23 Intermediate-scale test matrix for the SCDU circuits. ..................................................74

6-24 Intermediate-scale test results summary – SCDUs. ....................................................74
ix

EXECUTIVE SUMMARY 

Overview 

Cables can be subject to damage induced by the exposure to fires from external ignition 

sources. In nuclear power plants (NPPs), hundreds of miles of cables are used to power, 

control room and monitor plant equipment. Fire-induced cable damage can cause required 

safety circuits to fail, and potentially in unique and undesired ways. Fire-induced cable failure 

can cause loss of function equipment failures (i.e., loss of system or component availability). 

However, fire-induced cable failures are unique because they can potentially cause spurious 

operation of plant equipment and/or false indications to control operators. This report describes 

the most recent effort by the U.S. Nuclear Regulatory Commission (NRC) Office of Nuclear 

Regulatory Research (RES) to investigate cable failure modes and effects for NPP control 

circuits. 

Several testing programs have studied cable failure modes and effects phenomena. This 

includes testing by the Nuclear Energy Institute (NEI) and Electric Power Research Institute 

(EPRI) during 2001 (with NRC/RES collaboration – see NUREG/CR-6776, “Cable Insulation 

Resistance Measurements Made During Cable Fire Test”), the NRC “Cable Response to Live 

Fire (CAROLFIRE)” (NUREG/CR-6931) testing of 2006, and the Duke Energy testing of 2006. 

Internationally, efforts were also undertaken by L'Institut de Radioprotection et de Sûreté 

Nucléaire (IRSN) in France during 1997 and 2008. These previous tests have all focused 

primarily on control circuits powered by an alternating current (ac) source, a common circuit 

type used for various NPP functions including safe shutdown. 

In addition to ac circuits, NPPs also rely on circuits powered from direct current (dc) sources 

such as the station batteries. This typically includes various circuits relied upon for post-fire 

safe shutdown. Of the previous test programs, only the Duke Energy tests included any testing 

of dc-powered control circuits and those tests were limited in scope and left many questions 

unanswered. The Duke tests did provide indications that failures in the dc-powered cables 

might be unique in comparison to ac-powered counterparts. Differences in circuit design 

practices between ac and dc systems coupled to the Duke results made it a questionable 

practice at best to extrapolate from ac-based test results to dc-powered circuits. Given the 

general lack of knowledge and the importance of dc-powered control circuits to post-fire safe 

shutdown, the NRC initiated this effort to investigate dc-powered cable failure modes and 

effects. 

The tests described in this report were conducted by Sandia National Laboratories (SNL) 

beginning in the July 2009 and continuing through February 2010. The project conducted 59 

small-scale tests and 17 intermediate-scale tests. In total, the tests involved over 225 individual 

circuit trials. All of the detailed test data is presented in Appendices B-G. The electronic data 

and photos are available in electronic format in the companion CD-ROM provided with this 

publication. 

This project provided enhanced quality through collaboration with the U.S. NPP industry as 

represented by EPRI and its member utilities. EPRI participated in all aspects of the program 

including providing peer review during development of the test plan, support in the design of the 

test circuits, in-kind material support, consulting through the course of the actual testing, peer 

review during the data analysis process, and peer review of this report. In-kind material support 

included samples of Kerite® cables, samples of armored cables, a medium-size (1-inch) 
x 

solenoid-operated valve (SOV), a coil assembly for a very large direct-acting SOV, two medium 

voltage switchgear breaker units, and the battery cells used in the dc power supply. EPRI

partners also supported the design of the test circuits to ensure they were both representative of 

actual plant practices and capable of detecting the failure behaviors. This collaborative 

research partnership greatly improved the overall testing approach and quality. 

dc-Powered Circuit Insights 

The dc circuit testing approach paralleled the recently completed CAROLFIRE project. As in 

the earlier project, two scales of fire testing were conducted. A small-scale radiant heating 

facility call Penlight was used to perform limited scope preliminary tests under closely controlled 

laboratory conditions. These early tests provided initial data on the dc-powered cable failure 

behaviors and also provided an opportunity to verify the operability and refine the dc test circuits 

and operating procedures. More complex tests at a larger, intermediate scale were also 

performed using an open flame test setup with more realistic exposure conditions involving 

cables in random fill cable trays and conduits. 

A variety of cables were used during testing in order to highlight any failure behaviors 

attributable to the polymeric formulations used in cable construction. Most of the tested cables 

were drawn from stocks left over from the CAROLFIRE project, and all are representative of the 

cables used in U.S. NPPs. As noted above, testing also included two types of cables, Kerite®

and armored, provided through EPRI. All of the tested cables were of a multi-conductor 

configuration and were predominantly of a control cable configuration. 

One unique aspect of this project was the use of a rather substantial battery bank as the dc 

power source. One of the major limitations of the dc tests conducted by Duke Energy was that 

those tests relied on a relatively small and non-representative set of batteries (a bank of ten 

12Vdc automotive batteries). Thanks to in-kind EPRI support and involvement, this project used 

a set of 60 much larger battery cells to form a nominal 125Vdc power supply. The battery cells, 

while not as large as a true set of Class 1E station batteries, were judged by EPRI collaborators 

to be a reasonable representation of such a battery set given the test conditions. To provide a 

sense of scale, the completed battery bank weighed over 2000 kg (over 4800 lb). The total 

available short circuit fault current at the output terminals of the battery bank was estimated at 

over 13,000 amperes (A). 

For testing, a total of eight dc-powered control circuits were developed. Seven of these were 

based on actual NPP-type electrical components; namely, two reversing motor-operated valve 

(MOV) circuits, two small pilot SOV circuits, one 1-inch SOV, one valve coil for a very large 

direct acting SOV, and two medium voltage switchgear breaker units. The eighth circuit was a 

purpose-built system looking for intercable hot shorts (HSs) (cable-to-cable conductor short 

circuits). 

The scope of this report is limited to the objective reporting of the test data. It is not the intent of 

this report to interpret the test results beyond a factual representation of the progression of 

events observed in each test. The NRC is conducting follow-on work that will use this test data 

to develop best estimate probabilities of spurious operations given cable damage via an expert 

elicitation panel. In addition, another project will evaluate the fire-induced electrical circuit 

failure phenomena by performing a Phenomena Identification and Ranking Table (PIRT) 

exercise. 
xi

That said, there are several general observations that were made through the course of testing 

that are worthy of note: 

 The arcing observed in conjunction with the cable faulting was more energetic for the 

dc-powered cables than was the corresponding behavior in ac-power cables. Both acand dc-powered cables displayed arcing, but the arcs formed by the faulting dcpowered cables were more substantial, more sustained, and more damaging. 

 Faulting of the dc-powered cables often led to destructive damage to the cable 

conductors (open circuit/conductor breakage). Destructive damage at this level has not 

been observed for ac-power control cables. 

 In some cases the dc-powered cables were left energized even after they had 

experienced destructive damage as described immediately above. This behavior was 

more common for tests involving larger (15A, 25A, or 35A) fuses. 

 For any given dc-circuit, the two paired fuses (one on the positive leg and one on the 

negative leg) did not necessarily clear at the same time. Many factors contribute to this 

behavior. For example, the time/current clearing relationship varies somewhat even 

within a single batch of like fuses so that one fuse may clear more quickly than another 

given the same fault current. Also, some fuse blows resulted from circuit-to-circuit 

interactions through the ground plane (multiple shorts to ground) so that the two fuses 

involved in the fault might be of different sizes (e.g., the fault currents might be routed 

through a 10A fuse from one circuit and a 5A fuse from another circuit). In such cases 

the lower amperage fuse would typically clear leaving the higher amperage fuse intact. 

 In general, more long-duration HSs and spurious operations were observed for the dcpowered circuits than had been observed in corresponding ac-powered circuits. 

ac-Powered Circuit Insights 

The final issue investigated during Direct Current Electrical Shorting in Response to ExposureFire (DESIREE-Fire) was the question of how the sizing of control power transformers (CPTs) 

would impact the likelihood of spurious operation in ac-powered control circuits. This was an 

issue that was also investigated in the prior CAROLFIRE test program with inconclusive results. 

During the original NEI/EPRI circuit tests of 2001, it had been noted that multiple current 

leakage paths that formed during the cable degradation process would lead to saturation of the 

power-limited CPTs and to degradation of the source voltage. In some cases the voltage 

degraded to below the minimum pick-up voltage of the motor contactors. This effect was 

attributed with reducing the Spurious Actuation (SA) probability by a factor of two compared to 

non-power-limited circuits. 

CAROLFIRE investigated a range of CPT sizes (i.e., 100VA to 250VA) but could not reproduce 

the voltage degradation effect to nearly the degree observed by NEI/EPRI. Differences in the 

characteristics of the motor contactors used in each program were thought to have been a 

contributing factor to the difference in test results. 

For DESIREE-Fire the control circuit simulator units used in CAROLFIRE were rebuilt using the 

same model of motor control contactors as the original NEI/EPRI tests. Two of the four 

contactor sets were provided by EPRI as a part of the collaboration. However, only one case 

out of a total of 42 total circuit failure trials appears to have experienced voltage degradation 

that actually prevented a SA; namely, Penlight Test #17. This case involved Surrogate Circuit 

Diagnostic Unit (SCDU)-1 with a 100VA CPT (note that larger 150VA CPTs were used in the 

original NEI/EPRI tests). A second test, intermediate-scale test 4, also showed signs of 
xii 

substantial source voltage degradation but only after SAs had already occurred. This second 

test involved SCDU-4 with a 75VA CPT. 

Overall, like CAROLFIRE, the DESIREE-Fire tests failed to reproduce the voltage degradation 

effect to nearly the degree observed by NEI/EPRI despite the inclusion of smaller CPTs in the 

testing protocol. None of the tests involving the two larger CPTs (150VA and 200VA) showed 

degradation of source voltage sufficient to prevent a SA. Other trials involving the smaller 75VA 

and 100VA CPTs (i.e., other than Penlight Test #17 and Test IS4) were conducted and did not 

experience sufficient voltage degradation to prevent SA. 
xiii 

ACKNOWLEDGMENTS 

The authors gratefully acknowledge the contributions of the many people who helped ensure 

the success of this project. Within the NRC we especially acknowledge the support and 

guidance provided by Harold “Harry” Barrett of NRR. His drive to see these tests through from 

beginning to end has been greatly appreciated. We also acknowledge the support of our Office 

of Nuclear Regulatory Research sponsors, Gabriel Taylor and Mark Henry Salley. Mark is a 

relentless supporter of the need for fire research and that is greatly appreciated. Gabe not only 

dealt with program oversight but also supported data analysis, which was no ordinary task. It is 

also important that we acknowledge the critical contributions of the Electric Power Research 

Institute (EPRI) collaborative team. It is clear that the collaboration was a major success, 

leading to many improvements in the quality of the test program. Many key aspects of the 

program were ultimately decided based on input from individuals brought to the project through 

the EPRI collaboration. Many organizations and individuals participated over the course of the 

project, but we want to especially acknowledge those who stuck with the project from beginning 

to end; namely, Ken Canavan, Dan Funk, Jeffro Wagner, Dennis Henneke, Kiang Zee, Ashley 

Mossa, Ken Caraway, Steve Graham, Dave Miskiewicz, and Ed McCann. Finally, we 

acknowledge the contributions made to the program via the in-kind material support also 

arranged via the EPRI collaboration and the relentless efforts of Ken Canavan. Kirtland Air 

Force Base kindly loaned us a switchgear-breaker unit for use in testing. EPRI arranged and 

paid for a replacement breaker when the Kirtland breaker was unexpectedly damaged in testing. 

Target Rock provided two solenoid valve assemblies. Duke Energy, VC Summer, Progress 

Energy, and Energy Northwest all provided cables for testing. 

The authors also acknowledge and thank the following individuals and organizations for 

providing peer review comments on the preliminary draft of this report: 

Dennis Henneke, GE-Hitachi 

Chris Pragman, Exelon Energy 

Dr. Vyto Babraskus, Fire Science and Technology Inc. 

Mano Subudhi, Brookhaven National Laboratory (BNL) 

Jeffro Wagner, SCANA Corp., South Carolina Electric & Gas, VC Summer 

Ken Caraway, Electric Power Research Institute (EPRI) 

Dr. Ogura, Dr. Kasahara and the Fire Protection Working Group, Japan Nuclear Energy 

Safety Organization (JNES) 

The authors also acknowledge and thank student intern, Roushan Ghanbari from Sandia 

National Laboratories for her help with assisting with this report. 

xv

ACRONYMS 

A ampere 

ac alternating current 

AOR air-operated valve 

ASTM American Society of Testing and Materials 

AWG American Wire Gauge 

CAROLFIRE cable response to live fire (an NRC/RES project) 

CPG chlorinated poly ethylene 

CPT control power transformer 

CSPE chloro-sulphorated polyethylene 

dc direct current 

DCCCS direct current control circuit simulators 

DESIREE-Fire direct current electrical shorting in response to exposure-fire 

DNF did not fail 

EMRV electromagnetic relief valve 

EPR ethylene propylene rubber 

EPRI Electric Power Research Institute 

FB fuse blow 

FR A cable insulation product designation of the Kerite company thought to 

stand for either “fire retardant” or “fire resistant” depending on the source 

consulted 

HS hot short 

HT or HTK A cable insulation product designation of the Kerite company standing for 

“high temperature” or “high temperature Kerite”

IN information notice 

IRMS Insulation Resistance Measurement System 

ISRN L'Institut de Radioprotection et de Sûreté Nucléaire 

JNES Japan Nuclear Safety Organization 

LC large coil 

LER licensee event report 

MOU memorandum of understanding 

MOV motor-operated valve 

NEI Nuclear Energy Institute 

NIST National Institute of Standards and Technology 

NOS new old stock 

NPP nuclear power plants 

NRC Nuclear Regulatory Commission 

NRR NRC Office of Nuclear Reactor Regulation 

PE polyethylene 

PIRT phenomena identification and ranking table 

PORV power-operated relief valve 

PRA probabilistic risk assessment 

PVC polyvinyl chloride 

RES NRC Office of Nuclear Regulatory Research 

RIS regulatory issue summary 

SA spurious actuation 

SCDU surrogate circuit diagnostic unit 

SDP significance determination process 

SNL Sandia National Laboratories 

SOV solenoid-operated valve 
xvi

SR silicone rubber 

SRV safety relief valve 

SWGR switchgear 

TP thermoplastic 

TS thermoset 

XLPE cross-linked polyethylene 

XLPO cross-linked polyolefin 
1 

1. BACKGROUND AND INTRODUCTION 

1.1 Overview 

This report describes a series of cable fire tests performed by Sandia National Laboratories 

(SNL) under the sponsorship of the U.S. Nuclear Regulatory Commission (NRC) Office of 

Nuclear Regulatory Research (RES). This effort was conducted in collaboration with the 

Electric Power Research Institute (EPRI) and its member utilities via a NRC-RES/EPRI 

Memorandum of Understanding (MOU). This effort is known as the Direct Current Electrical 

Shorting In Response to Exposure-FIRE (DESIREE-Fire) project and was designed to provide 

data to support the evaluation of potential risks associated with the fire-induced cable failure 

modes and effects for dc-powered electrical control circuits including, in particular, Hot Short 

(HS) and Spurious Actuation (SA) phenomena.1

While the DESIREE-Fire project involved collaboration between the RES and EPRI, SNL acted 

as the primary test laboratory and the contents of this report were produced exclusively by SNL. 

EPRI and its industry members provided peer review of this report in lieu of a full public 

comment process. 

The DESIREE-Fire project complements previous research conducted in the Cable Response 

to Live Fire (CAROLFIRE) project in 2006 [1]. As a result of these two testing project 

similarities, this report relies on the readers‟ understanding of the CAROLFIRE testing 

approach, as the DESIREE-Fire project applied similar test methods. Although this report does 

provide a general overview of the testing approach and detailed discussion on where DESIREEFire deviated from the CAROLFIRE approach, the reader unfamiliar with the CAROLFIRE 

testing should consult NUREG/CR-6931, “Cable Response to Live Fire (CAROLFIRE),” for full 

understanding of the testing approach and reasoning. 

1.2 Background 

In the late 1990s, a series of licensee event reports (LERs) identified plant-specific problems 

related to potential fire-induced electrical circuit failures that could affect equipment necessary 

to achieve and maintain safe shutdown. The NRC staff issued Information Notice (IN) 99-17, 

“Problems Associated with Post-Fire Safe-Shutdown Circuit Analyses,” on June 3, 1999, to 

document additional problems [2]. In 2001, the nuclear industry, under the coordination of the 

Nuclear Energy Institute (NEI), performed a series of cable functionality testing to advance the 

nuclear industry‟s understanding of fire-induced circuit failures, particularly spurious equipment 

actuations initiated by circuit failures. The results from these 18 tests were then presented to an 

expert panel, which developed risk insights into the phenomena of fire-induced failures of 

electrical cables. The results of the expert panel were documented in an EPRI Technical 

Report No. TR-1006961, entitled, “Spurious Actuation of Electrical Circuits Due to Cable Fires” 

[3]. 

Following this work, the NRC held a public workshop on risk-informing post-fire safe-shutdown 

circuit analysis inspection on February 19, 2003, at NRC headquarters offices in Rockville, 

Maryland. Information collected from stakeholders during the workshop was used by the NRC 

staff to risk-inform the inspection procedures. The results of the workshop were documented in 

Regulatory Issue Summary (RIS) 2004-03, “Risk-Informed Approach for Post-Fire Safe-

 

1

A “hot short” is defined as a short circuit between an energized “source” conductor and a normally non-energized 

“target” conductor. A “spurious actuation” is defined as inadvertent energization of a device due to a hot short.
2 

Shutdown Circuit Inspections” [4], which separated circuit configurations into three individual 

categories, or bins, of circuit failure likelihood based on research and test results: 

 Bin 1: Circuit configurations most likely to fail. 

 Bin 2: Circuit configurations that need more research. 

 Bin 3: Circuit configurations unlikely or least likely to fail. 

The CAROLFIRE project, completed in 2006, was undertaken by RES to provide additional data 

for resolving Bin 2 circuit configurations. The results of the 96 tests performed under 

CAROLFIRE are documented in NUREG/CR-6931 [1]. 

At the same time CAROLFIRE was ongoing, Duke Energy was conducting their own cable 

performance testing at Intertek ETL SEMKO testing laboratories (formerly known as Omega 

Point Laboratories) in San Antonio, Texas. Unlike previous testing, these tests also included 

limited testing of direct current (dc) circuits. The results from this testing suggested that the fireinduced cable failure modes and effects for dc circuits may differ from that observed for 

alternating current (ac) circuits. While the results of the Duke Energy tests remain proprietary, 

NRC did prepare a public report on the test effort [5]. 

Of the few fire induced-circuit failure tests projects recently conducted to explore failure modes 

and effects of control cables when damaged by fire, only the Duke Energy tests have included 

dc-powered control circuits, and in that one case the tests conducted were sharply limited in 

both scope and number. Circuits powered by a dc power source constitute a significant fraction 

of the safety-related circuits in commercial nuclear power plants (NPPs) and they are 

characterized by differences in operating characteristics and design as compared to ac control 

circuits. Based on industry feedback from the NFPA-805 pilot applications and other ongoing 

circuit analysis efforts (e.g., inspection and enforcement activities, other NFPA-805 transition 

projects, and Fire Probabilistic Risk Assessment [PRA] upgrade projects), some of the most 

challenging potential HS-induced SAs, from a consequence standpoint, are associated with 

control circuits powered by ungrounded dc sources (e.g., power-operated relief valves (PORVs), 

letdown valves, reactor head/pressurizer vent valves, safety relief valves (SRVs), and breaker 

circuits). 

What remained unclear was the extent to which the existing, largely ac, test data could be 

extrapolated to dc-powered control circuits. Parameters of interest include the likelihood of SA

and HS duration for dc-powered control circuits of various configurations. The lack of either a 

sufficient set of dc circuit test data or a technical basis for extrapolation of the ac test data 

represents a significant uncertainty associated with the analysis of dc circuits. 

1.3 Purpose and Objectives 

The primary objective of the DESIREE-Fire project is to address analytical uncertainties by 

providing fire-induced cable failure modes and effects data for dc-powered control circuits, and 

to provide that data in a manner that allows for a direct comparison to the previously developed 

ac-powered control circuit failure response data. The tests are designed to investigate a 

number of key variables that may influence the observed failure behavior including cable type, 

control circuit configuration, fire exposure conditions, and cable routing configuration. The tests 

are patterned on the recently completed CAROLFIRE tests. 

The DESIREE-Fire project also involved several secondary objectives. First, the ac circuit 

simulators developed for CAROLFIRE (the Surrogate Circuit Diagnostic Units, SCDUs) were 
3 

again used in the DESIREE-Fire testing to expand the data set for ac control circuits and to 

address Bin 2 Item D which was not fully addressed by the CAROLFIRE testing. Bin 2 Item D, 

related to control power transformer (CPT) sizing effects on SA likelihood. Second, similar to 

CAROLFIRE, thermal exposure and cable thermal response data was recorded such that the 

observed electrical failures can be correlated to the cable thermal response. These secondary 

objectives focus on expanding the existing data to support further development of cable thermal 

response predictive models and provide explicit data on cable electrical failure thresholds under 

dc power conditions. Lastly, the DESIREE-Fire provides test results on Kerite® FR control cable 

electrical performance during elevated thermal conditions. This data will be used to address 

questions related to the thermal performance of this specific cables type [6].2

1.4 Project Planning and General Approach 

The draft project plan for DESIREE-Fire was developed over the course of several months and 

included several rounds of review and revision. The first draft of the test plan was issued in July 

2008 and included a 30-day public comment period (see Federal Register notice 73 FR 53452) 

starting September 16, 2008, and ending October 24, 2008. A revised plan addressing the 

public comments was then circulated among the NRC staff and EPRI partners and underwent 

several revisions as details of the program developed. Input from EPRI led to refinements to 

various aspects of the test plan including, in particular, the design of the dc test circuits and 

battery power supply system. These aspects of the test plan continued to develop as EPRI inkind material support made available a number of NPP components that were incorporated into 

the test circuits (i.e., solenoid-operated valves [SOVs] and a switchgear breaker unit). Input 

from EPRI also helped to refine aspects of the test circuits to better represent industry practice 

(e.g., fuse selection and sizing). The peer review group during the planning process3

 included 

several industry representatives through EPRI and NRC technical experts specializing in the 

areas of post-fire safe-shutdown circuit analysis, fire PRA, fire protection, and electrical 

engineering. The peer review effort was a very detailed and extensive iterative process that

resulted in an improved project plan and overall testing approach. The final project plan,4 while 

unpublished, can be found on the enclosed CD and on the NRC website (www.NRC.gov). 

The tests were performed beginning with the small-scale tests performed during July 2009. The 

intermediate-scale tests began in October 2010 and continued through February 2010. All tests 

were performed using SNL fire test facilities in Albuquerque, New Mexico. 

The project employed basic quality assurance provisions, but was not subject to a strict quality 

assurance program. The instruments (voltage and current transducers) used in the SCDUs and 

the dc Control Circuit Simulator panels (dc-SIM panels) were covered by manufacturer-supplied 

certificates of calibration, but were not included in the SNL instrument calibration system for 

verification or recertification at the completion of testing. Hence, the SCDU and DC-SIM panels 

voltage and current data are to be taken as ”indication only” and should be viewed as providing 

absolute indications of circuit behavior during testing. All of the other instruments used in 

 

2

 A separate preliminary report on the Kerite cable testing has been published by SNL as cited here. The Kerite 

cable test results are included in this report, but only in the general context of dc cable failure modes and effects. 

Issues specific to the Kerite cable are deferred to the separate SNL report. 

3

 Peer reviewers were technical experts not directly involved in the original development of the project plan but could 

conduct a detailed independent review of the plan and provide objective comments to improve the overall research 

product. 

4

 The test plan has not been published but has been posted as a public document on the NRC web site. Citation is 

as follows: Nowlen, S.P., Wyant, F.J., Brown, J., Project Plan for Direct Current Electrical Shorting In Response to 

Exposure FIRE (DESIREE-Fire), July 10, 2009. 
4 

testing, and in particular the various thermocouples and temperature measurement 

instrumentation, were subject to the SNL calibration process, which provides calibration 

services traceable to the National Institute of Standards and Technology (NIST) standards. 

All tests followed a proscribed test protocol including pre- and post-test checklists. Field notes 

were maintained by the lead test engineer documenting all variable aspects of the individual 

tests and recording field observations during each test. All data processing and plotting was 

performed using commercial software (Microsoft Excel®, SigmaPlot®). The original data files in 

their native format have been preserved for archival purposes. All data from the testing 

program is publically available without restriction on the enclosed CDs at the back of this report 

and on the NRC website (www.NRC.gov). 

1.5 Scope of this Report 

This report includes a summary description of all tests performed including experimental setups, 

test matrices, and a description of instrumentation fielded during each experiment. The 

processed data can be found on the enclosed CD. The report also presents the data gathered 

for each test. Interpretation of the test data is limited to a factual description of the circuit 

faulting behavior. This includes a detailed timeline characterizing the circuit faulting behavior 

highlighting, in particular, the onset and duration of HSs and SA. This report does not delve into 

a statistical analysis of data trends nor into the interpretation of test results as they might apply 

to risk analysis. Those aspects of data analysis and interpretation lie outside the scope of this 

project and are the subject of planned RES follow-on activities (see Section 0 for additional 

discussion). 

1.6 Report Organization 

This balance of this report is organized as follows: 

 Section 2 provides general background discussions describing previous test programs 

investigating related phenomena. Section 2 also provides an overview of the testing 

needs addressed by DESIREE-Fire. 

 Section 3 describes the general approach taken by DESIREE-Fire. Included in Section 

3 are summary descriptions of the test facilities, test protocols, and cables used in 

testing. 

 Section 4 provides summary descriptions of the test circuits used to assess cable 

electrical performance, including both the dc and ac-based systems. A summary 

description of the dc battery bank is also provided. Note that detailed descriptions of 

the test circuits are provided in Appendix A. 

 Section 5 presents the two test matrices, one for the small-scale Penlight tests and one 

for the intermediate-scale tests. 
5 

 Section 6 provides summary descriptions of the test results for each of the various 

electrical test circuits. That is, the discussions in Section 6 are organized by test circuit 

rather than by test number or test date. More detailed presentation of the test data is 

deferred to Appendices B through G. 

 Section 7 presents summary discussions highlighting general insights gained from the 

testing. 

 Section 8 identifies referenced documents. 

 Appendix A provides detailed descriptions of the test circuits, the dc battery bank and 

other test support systems used in testing. There are five sub-appendices (Appendices 

A.1 through A.5) each covering a specific dc-powered control circuit. Appendix A.6 

covers the ac-powered SCDU systems. Appendix A.7 covers the battery bank. 

Appendix A.8 covers other test support systems including temperature monitoring, 

computers, software, and the data file formats and structure. 

 Appendices B through G are provided on the enclosed CDs and present, in detail, the 

test data for each individual test and test circuit. Together, these six appendices cover 

every test performed and every circuit tested. The appendices are organized by test 

circuit and, for each circuit, cover all of the tests that included that circuit. Each of these 

appendices is divided into two subsections, the first presenting the small-scale Penlight 

test data and the second covering the intermediate-scale tests. The appendices are 

associated with test circuits as follows: 

o Appendix B: The dc-powered motor-operated valve (MOV) circuits 

o Appendix C: The dc-powered SOV circuits 

o Appendix D: The dc-powered 1-inch SOV and large coil circuits 

o Appendix E: The dc-powered switchgear breaker circuit 

o Appendix F: The dc-powered intercable circuit 

o Appendix G: The ac-powered SCDU circuits 

7 

2. OVERVIEW OF TESTING NEEDS ADDRESSED BY DESIREE-FIRE 

2.1 Cable Failure Modes and Effects for dc-powered Control Circuits 

As discussed in Section 1.2 above, almost all of the previous testing for fire-induced cable 

failure modes and effects has focused on ac-powered control circuits. There are several 

characteristics associated with dc-powered control circuits that are unique as compared to ac 

control circuits. Hence, the extrapolation of the ac circuit test results to dc circuits might not be 

valid or appropriate if cable failure modes and effects for dc-powered control circuits differ from 

the corresponding behaviors in ac circuits. It was this particular area of uncertainty that was the 

primary focus of the DESIREE-Fire project; that is, to provide data on the failure modes and 

effects behavior for dc-powered control circuits that could be directly compared to the 

corresponding data already available for ac-powered control circuits. 

Without an understanding of how cable faults in dc circuits differ from ac circuits, the 

identification of important circuit characteristics for dc systems is, at best, speculative. Based 

on input obtained during the test plan development and peer review process, three dc circuit 

characteristics that differ from ac control circuits were identified before testing as those most 

likely to impact the cable failure modes and effects behaviors. These are the following: 

 Fusing: dc-powered control circuits tend to use larger fuse sizes for over-current 

protection than the comparable ac control circuits. Several factors contribute to this 

design choice. Ultimately, fuses are sized to protect the cables from current overload 

and breaker/fuse coordination is maintained consistent with the general treatment of 

coordination for other plant circuits. The result of this design difference may be that 

over-current protection devices would not open as readily as the corresponding devices 

in an ac circuit. This could allow dc circuit faults to persist for a longer period of time 

before a “fuse-blow” and circuit de-energizing as compared to a corresponding ac 

circuit. One observation made during testing was that the dc-powered cables displayed 

far more energetic arcing behaviors during the process of conductor-to-conductor and 

conductor-to-ground shorting. This behavior may be at least in part a reflection of the 

larger fuses in the circuits. Overall, fuse design practices may impact HS behaviors 

including both likelihood and duration, although the net effect of the higher fusing and 

the anticipated arcing-fault behaviors remains unknown. 

 No zero-crossing: By definition, ac circuits have “zero-crossing” points as a result of the 

sinusoidal waveform signal. In contrast, dc circuits use a constant voltage potential to 

operate and by definition have no “zero-crossing” behavior. The impact of a constant 

circuit voltage on the cable faulting behavior as compared to a zero-crossing fault 

behavior is unclear. The lack of a zero-crossing characteristic, especially when coupled 

to a higher amperage over-current protection device, may contribute to the observed 

arcing fault behavior. That is, as noted above, dc-powered conductors were observed to 

display more energetic and sustained arcing type faults and the lack of a zero-crossing 

feature might contribute to this behavior. Whether this behavior increases or decreases 

the duration of HSs is unknown. 

 Ungrounded power supply: The information gathered during the development of the 

test plan (i.e., EPRI input, NRC staff input, and our own research) confirmed that most 

plants utilize ungrounded dc power sources (i.e., ungrounded battery banks). In 

contrast, most ac power supply systems are grounded. The nature of the cable shorting 
8 

behaviors possible given an ungrounded power source may be more complicated than 

those associated with a grounded power source. For a grounded circuit, a short 

between the any single energized conductor and ground would induce a fault current 

and potentially trigger circuit protection (fuses or breakers) if the conductor-to-ground 

resistance was low enough. In contrast, for an ungrounded power supply, a single 

bolted fault between an energized (either positive or negative polarity) conductor and 

ground (i.e., a single low-resistance conductor-to-ground short) will not induce any fault 

current and will not trigger circuit over-current protection. Such a fault would only act to 

ground one side of the battery set. Furthermore, multiple shorts to a grounded raceway 

(i.e., a cable tray, conduit or grounded conductors if present) could result in the raceway 

acting as a conductor of power from one circuit to another. That is, if the battery bank 

becomes grounded on the positive potential, then the ground plane itself can act as a 

conductor directly to the positive side of the battery bank for any circuit connected to the 

same battery bank. These complexities could impact both HS duration and SA

likelihood. 

The intent of the test program was to provide data that will assist staff in assessing the potential 

risk implication of fire-induced damage to dc-powered cables and control circuits. The tests 

were designed to explore these and other relevant behaviors for a range of dc-powered control 

circuits and cables. Summary descriptions of the various dc-powered control circuits tested are 

provided in Section 0, and more complete descriptions are provided in Appendices A.1 through 

A.5. 

2.2 Cable Failure Modes and Effects for ac Control Circuits 

The testing included use of the ac-powered MOV control circuits, referred to as the SCDUs, 

originally developed for the CAROLFIRE project. The use of this equipment served two 

purposes. First, these tests represent, in effect, a “target of opportunity” to expand the existing 

ac control circuit data set. Second, the use of both the ac and dc-powered control circuits in the 

same tests allows for a direct cross-comparison of observed behaviors. Testing of the ac 

circuits also provides an opportunity to address one lingering issue not fully resolved by the 

CAROLFIRE study: namely, the impact of CPT sizing on the likelihood of spurious operations 

(Bin 2 Item D from RIS 2004-03 [4]). As noted in the CAROLFIRE report, the results for this 

specific item were ambiguous at best. The dc testing program offers an opportunity to further 

explore this behavior. 

The ac-based SCDUs were deployed in a manner similar to that employed in CAROLFIRE, 

although some changes were made. In particular, all four sets of motor contactors used in the 

original design were replaced by Joslyn-Clark contactor sets that are considered representative 

of those used during industry testing of 2001. Two of the four replacement contactor sets had 

been used during prior testing by Duke Energy and were provided by EPRI (i.e., as a part of 

EPRI‟s in-kind material support). Two additional contactor sets were purchased directly from 

the manufacturer. Section 0 provides a summary description of the SCDU and Appendix A.6 

provides a more detailed description that includes the system design changes implemented for 

DESIREE-Fire. 

2.3 Fire and Fire Response Characterization 

One of two major objectives of the CAROLFIRE project was to explore key behaviors 

associated with the thermal response of cables exposed to a fire environment. In particular, 
9 

CAROLFIRE included a substantial effort to characterize cable heating behavior under a range 

of fire conditions and to correlate the cable thermal response to electrical performance and 

failure. These efforts led to improvements in fire modeling techniques and development of the 

THIEF model as documented in Volume 3 of the CAROLFIRE report [1]. The DESIREE-Fire 

testing project also included the gathering of fire exposure and cable thermal response data. 

However, the level and extent of thermal monitoring was not as extensive as in the previous 

testing program. 

With respect to cable thermal response, the DESIREE-Fire testing again included cables 

instrumented for thermal response in a manner that will allow for correlation to electrical failure. 

Testing also included thermocouples and other instruments deployed to characterize the local 

thermal environment to which the cables are exposed. It was not generally anticipated that the 

failure thresholds for the electrical cables under dc conditions will differ substantially from the 

cable failure thresholds observed under ac conditions. Accordingly, the DESIREE-Fire tests‟

thermal exposure conditions were based on cable failure threshold data obtained during testing 

with ac-powered cables. 

2.4 Supplemental Data on Cable Failure Characteristics 

Several cable types were tested to evaluate the cables‟ thermal performance. Although not 

identified during the development of the DESIREE-Fire test plan, the addition of these tests 

required little effort and provided needed data for resolution of cable performance issues. The 

cables tested included samples of vintage (1970s) Kerite® HTK and Kerite® FR. These cables 

were supplied through the NRC-RES/EPRI MOU as new old stock (NOS). With the use of the 

electrical monitoring equipment, the failure point as these cables are exposed to a thermal insult 

can be determined. 

11

3. APPROACH 

3.1 Project Planning and General Approach 

An extended process of project planning was undertaken to ensure that the testing program and 

protocols would address the identified data needs. Preliminary planning involved several 

conference calls between the NRC (including both RES and NRC Office of Nuclear Reactor 

Regulation [NRR] staff) and SNL. Based on these early discussions a straw-man definition of 

the overall project goals and technical approach was developed. Several key parameters that 

would need to be dealt with as a part of test planning were identified, including: 

 selection of dc test circuits (i.e., focus on circuits used in safety related systems); 

 test circuit design parameters and objectives; 

 circuit monitoring objectives and instruments; 

 dc power source characteristics (e.g., voltage level, battery characteristics, and number 

of power supplies); 

 power source, circuit, and instrument grounding; and 

 cable types to be used in testing. 

From these discussions, SNL developed a preliminary test plan that was issued by the NRC for 

public comment in September 2008. Several comments were, in fact, received as a result of the 

public comment process and addressed in subsequent revisions. One key element that 

developed as a result of the public comment process was that industry, as represented by 

EPRI, cited their interest in establishing a collaborative involvement in the project. Subsequent 

discussions did lead to a formally established NRC-RES/EPRI MOU collaboration. 

The NRC-RES/EPRI MOU collaboration had a major impact on development of the final test 

plan. A series of conference calls between the NRC, SNL, and the EPRI collaborative team 

were held over the course of the next several months and during these calls detailed aspects of 

the test program were discussed. Several rounds of comment and revision of the test plan were 

undertaken to address concerns and design suggestions, and to incorporate the in-kind material 

support that developed over the course of these discussions (e.g., to incorporate NPP 

components made available through the collaboration into the design of the test circuits). 

The test plan was nominally finalized in July 2009, and that version is included on the enclosed 

CD located inside the back cover of this report. However, it should be noted that while the final 

test plan was “frozen” as a document, additional changes and adjustments were made through 

the course of the testing to address issues identified as the test plan was implemented. 

Beginning as early as December 2008 and continuing through July 2010, RES, NRR, SNL, and 

the EPRI collaborative team participated in weekly teleconferences during which issues were 

discussed and resolution strategies identified. 

To meet the project goals, a fairly large number of tests involving varied arrays of cable types, 

cable bundling arrangements, heating conditions, circuit types, and cable routing conditions 

were performed. Based on the success of the CAROLFIRE project approach, it was determined 

that two scales of testing would be the most beneficial for the DESIREE-Fire project. The two 

scales of testing are complementary and each provides unique advantages. 

Preliminary testing was conducted in a small-scale radiant heat testing apparatus known as 

Penlight. The small-scale test facility is described more fully in Section 3.2. Penlight allows for 

well controlled heat exposures that are beneficial for comparison purposes. Penlight tests can 
12

be conducted very efficiently, in a short time, and at relatively low cost. Small-scale testing also 

provided an opportunity to complete verification of all the test circuits, test procedures, safety 

procedures, data logging equipment and software. The intermediate-scale tests are far more 

complex, and therefore more time-consuming and costly. However, they provide more realistic 

fire exposure and cable loading configurations (e.g., actual open flaming exposure fires and 

random fill cable trays). Based on the CAROLFIRE results, both testing scales produced similar 

results relative to the cable failure modes and effects behavior. Hence, the same approach was 

applied to DESIREE-Fire. In all, of the DESIREE-Fire testing project consisted of 59 Penlight 

tests and 17 intermediate-scale tests. 

The test design was optimized to allow for considerable flexibility as the testing proceeded. As 

noted above, the test plan was nominally frozen as a document in July 2009. However, the 

actual implementation of the test matrix allowed for considerable flexibility. Changes were 

made to cable, circuit, and instrumentation configurations, and to the test procedures to reflect 

insights gained as the tests proceeded. That is, as experience was gained through the 

performance of the tests, opportunities for improvement were identified and implemented; 

hence, the final test plan matrices were modified. Section 5 presents the as tested test 

matrices. 

Each test was based on thermal/fire exposure of a set of sample cables where each cable is 

connected to one of several electrical performance monitoring systems. Summary descriptions 

of the various electrical performance monitoring systems are provided in Section 0, and more 

detailed descriptions are provided in Appendix A. In general, the Penlight tests involved the 

application of just one or two of the available systems per test. Through the course of the 

Penlight testing all of the available electrical performance systems were tested. The 

intermediate-scale tests generally involved simultaneous application of all of the available 

electrical performance monitoring systems, each connected to one of the sample cables present 

in the test. 

3.2 Penlight Small-Scale Radiant Heating Tests 

The small-scale tests for DESIREE-Fire were conducted at the Thermal Test Complex at SNL 

using a radiant heating apparatus known as Penlight. DESIREE-Fire duplicated the 

CAROLFIRE test setup in all regards and generally applied the same testing protocols. This 

section provides a summary description of the Penlight test facility. For a more complete 

description, refer to the CAROLFIRE report [1]. 

The Penlight apparatus is placed beneath a ventilation hood as shown in Figure 3-1 and uses 

computer-controlled, water-cooled quartz lamps to heat a stainless steel shroud. The shroud is 

painted flat-black and acts as a grey-body radiant heating source, re-radiating heat to a test 

sample located within the shroud. The exposure temperature is controlled and monitored based 

on thermocouples mounted on the inner surface of the shroud. Penlight creates a primarily 

radiant heating environment that is analogous to that seen by an object enveloped in a fireinduced hot gas layer. That is, the hot gas layer thermal exposure environment is dominated by 

radiant heat exchange between the hot, smoke-filled gases and any immersed objects. The 

hot, smoke-filled gases act largely as a gray-body radiator. Penlight simulates these conditions 

with the shroud temperature being analogous to the hot gas layer or smoke temperature. From 

Volume 2 of CAROLFIRE, Table 3-1 provides a summary of the temperatures and 

corresponding heat fluxes. Additional insights may be gleaned from that report. 
13

Figure 3-1 The Penlight apparatus 

Table 3-1 Relationship between shroud temperature and shroud heat flux assuming an 

emissivity of 0.815. 

Metric Units Equivalent values in

English Units

Temperature

(°C)

Temperature

(°K)

Heat Flux

(kW/m2)

Temperature 

(°F)

Heat Flux 

(BTU/ft2s)

260 533 3.7 500 0.33

295 568 4.8 563 0.42

300 573 5.0 572 0.44

325 598 5.9 617 0.52

330 603 6.1 626 0.54

350 623 7.0 662 0.62

400 673 9.5 752 0.84

425 698 11.0 797 1.0

460 733 13.4 860 1.2

470 743 14.1 878 1.2

475 748 14.5 887 1.3

500 773 16.5 932 1.5

525 798 18.8 977 1.7

600 873 26.9 1112 2.4

650 923 33.6 1202 3.0

665 938 35.8 1229 3.2

675 948 37.3 1247 3.3

700 973 41.4 1292 3.6

900 1173 87.5 1652 7.7

As in CAROLFIRE, most of the DESIREE-Fire tests were conducted using paired cable lengths 

supported on a 12-in. (30 cm) wide ladder-back style cable tray5 suspended through the center 

 

5

The cable trays procured for DESIREE-Fire were B-Line® Series 2 style steel trays with (per manufacturer 

specifications) a nominal 3" NEMA VE 1 loading depth, 4" side rail, and 9” rung spacing. The specific part number is 

248P09-12-144.
14

of the Penlight shroud. A limited number of tests were also conducted using the conduit 

configuration. No tests were conducted using the air drop configuration. The cable trays, 

conduits and other physical test conditions are effectively identical to those used in 

CAROLFIRE. 

As a general practice, cables were tested in symmetric pairs where one cable would be 

instrumented with type-K thermocouples inserted just below the outer cable jacket to measure 

the cable temperature response. A second length of cable would then be routed in a symmetric 

position on the tray (relative to the shroud) and connected to energized electrical integrity test 

circuits to monitor electrical performance. This cable pairing approach allows for a direct 

correlation of temperature response and electrical performance without compromising the 

electrical integrity of the energized cable. The electrical integrity test circuits used varied 

between tests and test samples, as further described below. 

The exact heating protocol (i.e., the shroud set point temperature) varied from test to test 

depending on factors such as specific test purpose (e.g., low temperature failure mechanism). 

In some cases a specific set point value was established and maintained through the entire test. 

In other cases, the set point was varied through the course of the test. That is, a test would be 

started at a particular set point value, but that value would be increased as the measured cable 

temperature approached equilibrium. Step-wise increases were continued at, typically, 10 to 

15-minute intervals until cable failure was observed. The actual test profile is unique for each 

test. The exact heating protocol for each test is specified in the detailed test descriptions 

provided in Appendices B through G.

3.3 Intermediate-Scale Open Fire Tests 

A complementary test set was conducted at a scale more representative of in-plant conditions. 

These tests involved a more realistic open burn of larger arrays of cable under more varied and 

representative exposures. These tests were referred to as the Intermediate-scale tests and 

represent a method of evaluating the fire-induced circuit failure effects at actual scale without 

expending the time and effort full-scale testing would require. The intermediate-scale test 

approach is, again, identical to that used during the CAROLFIRE project with only slight 

modifications. This section provides a summary description of the test facility. For a more 

complete description, refer to the CAROLFIRE test report [1]. 

The intermediate-scale testing approach was developed during the CAROLFIRE project where 

a key goal of the research was to assess different exposure conditions, including cable failures 

due to a hot gas layer exposure, flame impingement, and fire plume conditions. The design of 

the Intermediate-test enclosure was based off the American Society of Testing and Materials 

(ASTM) standard test room specified in ASTM Standard E-603, Standard Guide for Room Fire 

Experiments [7], but is not a true room structure. Rather, it is a far more open configuration that 

did not restrict air flow to the fire (well-ventilated fire conditions). The test structure is arguably a 

good analog for a very common in-plant configuration; namely, a beam pocket within a larger 

room (i.e., a typical in-plant situation where the floor above is supported by massive steel and/or 

concrete beams creating isolated ceiling-level beam pockets). 

The intermediate-scale test assembly is illustrated in Figure 3-2. The test structure consists of a 

steel framework of which only the upper 40% is enclosed. Overall, the test structure measures 

approximately 2.4m x 3.7m x 3.0m (8ft x 12ft x 10ft – W x L x H). The upper 1.2m (4ft) of the 

sides and the structure‟s top were covered with a 13mm- (1⁄2-in) thick “fireproof” wall board 
15

(trade name Durock®).6 Conduits and trays could be routed in any manner desired. For 

DESIREE-Fire all raceways were routed as a single straight section passing through the full 

width of the test structure (i.e., across the 2.4m (8ft) dimension). The raceways used are 

identical to those used in CAROLFIRE. This test structure acts to focus the fire‟s heat output 

initially to this confined volume, creating the desired hot gas layer exposure conditions. As the 

fire progresses the hot gas layer depth increases, and ultimately smoke and hot gasses spill out 

naturally from under the sides of the enclosed area. This again would be quite typical of the hot 

gas layer development behavior for a beam pocket configuration. 

Figure 3-2 Schematic representation of the DESIREE-Fire intermediate-scale test 

structure. 

For DESIREE-Fire five exposure locations7

 were used, namely locations A-E, as illustrated in 

Figure 3-2 (Note the illustrations of raceway locations A-E in the elevation view figure to the 

right. These letter designations are used in the test matrices (Section 5) to indicate test object 

locations.). The detailed test descriptions and test matrices identify cables by location 

consistent with these labels. Through-wall penetration holes were cut in the side panels to 

accommodate raceway routing and insulation was placed around the opening between the 

raceways and enclosure to maintain a hot gas layer within the enclosed portion of the test 

assembly. 

The intermediate-scale test structure was positioned within a larger fire test facility. An existing 

SNL facility (Building 9830) served as the outer test structure. This isolated the test structure 

from the ambient environment (e.g., wind effects), allowed for control of bulk air flow conditions 

through the facility to some extent, and made it possible to gather outlet stack data 

(temperature, velocity, and oxygen concentration). Figure 3-3 illustrates the placement of the 

test assembly within the larger facility, and provides overall dimensions for the larger facility. 

 

6

 Durock® is a low-density concrete-based material with fiber-mesh reinforcement. The same material in smaller 

panels is commonly used as a “„backer board” for tile installation. 

7 Note that two of the cable locations tested in CAROLFIRE were not used during the DESIREE-Fire program. The 

deleted locations were to the sides of the fire and directly below locations C and E. 
16

Figure 3-3 Schematic representation of the DESIREE-Fire intermediate test structure 

located within the outer test facility 

The fires in all intermediate-scale tests were initiated using the same gas burner setup as was 

used in CAROLFIRE. The fuel in all cases was propene (propylene, C3H6). The burner used 

was a square “sand box” diffusion burner. Figure 3-4 provides a photograph of the burner. The 

top surface of the burner measured 40cm (15.75in) on a side (outside dimensions). 

Figure 3-4 Photo of “sand box” diffusion burner 

For testing, the burner‟s top surface was about 0.84m (33in.) above the floor of the enclosure. 

The burner was always placed in the center of the test structure and directly below cable 

raceway location A (as shown in Figure 3-2). The flow of gas to the burner was measured and 

controlled using the same electronic flow control valve as was used in CAROLFIRE [1]. In 

general, the initial heat release rate allowed for the flame to reach the bottom of the cable tray 

located in raceway position A. For the majority of the tests, this heat release rate was 
17

maintained for 15 to 20 minutes. The propene flow was subsequently increased every 10 to 30 

minutes until the maximum flow rate, if necessary, was reached in order to cause the circuits in 

the wing positions (i.e., raceway positions C and E) to fail. For details on the heat release rates 

from each test, please refer to Appendix A. 

3.4 Cable Selection 

3.4.1 The DESIREE-Fire Cable Set 

The CAROLFIRE project undertook an extensive effort to identify and test a variety of 

representative cable types based on their popularity, thermal robustness, thermo-set (TS) and 

thermo-plastic (TP) types, tractability, and physical configuration. DESIREE-Fire relied on the 

CAROLFIRE results in this regard, and most of the cables tested were stocks of unused cables 

left over from CAROLFIRE. However, not all of the cables tested in CAROLFIRE were re-tested 

in DESIREE-Fire. Instead, testing focused on a smaller selection of the most popular cable 

products, and on the 12 American Wire Gauge (AWG) seven conductor cable configurations. 

The tested cables are described below with summary information provided in Table 3-2. For 

this testing project, two cable types were identified as the “core” cable samples, one TSinsulated and the second TP-insulated. These two core cables were the primary focus of the 

testing. To supplement the two core cable types used, a smaller number of tests used two 

additional TS-insulated cables and two TP-insulated cables also drawn from the CAROLFIRE 

materials. 

In addition to the CAROLFIRE cables, additional cable types were made available for testing by 

EPRI through the collaborative agreement. Three general types of cable were made available, 

namely Kerite® FR, Kerite® HT, and a selection of armored cables. 

For convenience, this report identifies the cable materials in the format “insulation/jacket” (e.g., 

a cable with polyethylene [PE] insulated conductors and a polyvinyl chloride [PVC] jacket would 

be identified as a PE/PVC cable).

General descriptions of the TS-insulated and -jacketed cables are as follows: 

 Cross-linked Polyethylene (XLPE)/Chloro-Sulphonated Polyethylene (CSPE) (Core TS): 

The most popular insulation material used in the U.S. NPPs is the TS material XLPE. 

The cable jacket consisted of a CSPE, which is also known by the trade name Hypalon. 

The cable tested was a Rockbestos-Surprenant Firewall® III product in a sevenconductor (7/c) 12 AWG configuration. 

 Ethylene Propylene Rubber (EPR)/Chlorinated-polyethylene (CPE): EPR is the second 

most popular insulation material and is another TS used during this testing. This EPRinsulated, CPE-jacketed cable was procured from the BICC-Brand® line of products 

(now marketed by General Cable). 

 Silicone Rubber (SR): SR insulation materials are used by a number of U.S. NPPs, 

particularly in applications inside containment. The SR cable procured consisted of an 

SR-insulated conductor with a fiberglass braid sheath over the insulated conductor and 

an overall Amarid braid jacket. This cable was procured as industrial grade from First 

Capital. 

 Cross-linked Polyolefin (XLPO)/XLPE Low Halogen Zero Smoke: An XLPO insulated 

cable was sought primarily on the basis of existing evidence that XLPO may represent 

the least robust of the TS materials. However, XLPO is a highly generic material 
18

classification that has been used to label a wide range of actual material formulations. 

For example, polyethylene is a specific type of polyolefin; hence, all XLPE materials are 

also legitimately bounded under the more generic classification XLPO. All of the 

currently available XLPO materials identified during our material search were of a “low 

halogen zero smoke” type. A Rockbestos XLPO insulated industrial-grade cable was 

selected and procured. Upon delivery, it was noted that the jacket markings were 

“XLPE” rather than “XLPO”. We contacted Rockbestos and were informed that the 

material was indeed an XLPE formulation that was being marketed under the more 

generic XLPO label. The material was tested in a limited number of tests for reference 

purposes only. 

Descriptions of the TP-insulated and -jacketed cables are as follows: 

 PE/PVC (Core TP): Of the TP materials, a non-cross-linked PE is one of the two most 

common general applications, and is considered the most common TP material in use 

at U.S. NPPs. This cable type is the core TP insulation material used during the 

DESIREE-Fire testing. This cable was procured as an industrial-grade cable from 

General Cable. 

 Tefzel® 280/Tefzel®200: Tefzel® is a tradename TP material produced by DuPont 

Chemical. The material is applied directly as supplied by the manufacturer without 

modification by the cable manufacturer. The cable tested was procured from Cable 

USA with a Tefzel® 280 insulation and a Tefzel®200 jacket. This configuration is 

considered typical of U.S. NPP usage. 

 PVC/PVC: PVC is a TP material very popular for use in the U.S. and abroad as a 

general commercial- and industrial-grade cable. The PVC/PVC cable used in 

DESIREE-Fire was procured as an industrial-grade cable from the BICC-Brand® line of 

products (now marketed by General Cable). 

The tested cables included two that were TS-insulated and TP-jacketed as follows: 

 XLPE/PVC: XLPE-insulated cables are available in a range of jacket material 

configurations. An XLPE-insulated and PVC-jacketed cable was procured from General 

Cable under the BICC-Brand® designation. The cable configuration is considered the 

most representative of a typical “mixed-type” cable (TS-insulated, TP-jacketed). 

 Armored Cable: This cable was provided by Duke Energy and as an XLPE-insulated, 

PVC-jacketed cable. This cable has a spiral-wound galvanized metal armor below the 

jacket (the armor is similar in structure and appearance to flexible metal conduit). 

The majority of the cables were seven-conductor control cables with a 12 AWG conductor size 

(7/C-12AWG). The exceptions are the Kerite cables, the armored cable, and the Japanese 

cable. The Japanese cable is described in Section 3.4.2. The Kerite cables are described in 

Section 3.4.3. Table 3-2 provides a complete listing of cables tested in DESIREE-Fire. 

3.4.2 The Japan Nuclear Safety Organization (JNES) Cable 

As part of NRC-Res international collaboration, cable samples provided by JNES were tested as 

part of the DESIREE-Fire Project. This cable was tested in three Penlight tests and one early 

limited-scope intermediate-scale test. These particular tests were not included in the original 

test planning but were conducted at the request of the NRC staff in response to interest 

expressed by JNES in the work being conducted. At the request of JNES, the cable 

manufacturer and details of the cable construction are being withheld as proprietary information. 
19

However, JNES did give the NRC and SNL permission to include the test results and a general 

description of the cable in the DESIREE-Fire report. Hence, the cables are included in the 

treatment of test data. 

The JNES cable was a six-conductor, control-type, metric-specification cable with a 2 mm2

(0.003 in2) conductor cross section (roughly equivalent to 14AWG). The insulation and jacket 

were both TS-type materials (i.e., they showed no melting behavior) but the exact material type 

is unknown. The cable included a spiral-wound copper shield wrap approximately 0.23mm 

(0.009 in) thick. Both inside and outside this shield wrap was a counter-wrapped thin natural 

fiber fabric strip (e.g., a cotton canvas type material). Additional filler materials at the center of 

the cable appeared to be natural fiber (e.g., jute). During testing the copper shield wrap was 

grounded. The three Penlight tests were run with dc-powered circuits (two with the breaker and 

one with the MOV circuits) and the one intermediate-scale test used three of the four acpowered SCDUs. 

Table 3-2 DESIREE-Fire cable list. 

Cable

Function

Insulation and 

Jacket 

Materials (I/J)

Material Type 

(2)

Conductor 

Size (AWG)

Number of 

Conductors

Manufacturer

Notes (3)

Control XLPE/CSPE TS/TS 12 7 RockbestosSurprenant

The XLPE cables were from the 

Firewall III product line, a nuclearqualified cable brand, but 

equipment qualification certificates 

were not requested

Control XLPO/XLPO TS/TS 12 7 Industrial-grade cable

Control SR/Aramid

Braid TS/TS 12 7 First Capital Industrial-grade cable from a sister company to Rockbestos Surprenant

Control Tefzel/Tefzel TP/TP 12 7 Cable USA Special-order cable with Tefzel-280 

insulation and Tefzel-200 jacket

Control EPR/CSPE TS/TS 12 7

General 

Cable

Industrial-grade cable

Control PE/PVC TP/TP 12 7 Industrial-grade cable

Control PVC/PVC TP/TP 12 7 Industrial-grade cable

Control

Kerite®FR/ 

Kerite®FR 

(with zinc

wrap)

Uncert. 12 5 Kerite®

Provided by EPRI 

40 mils FR insulation

65 mils FR jacket

OD ~1.9 cm (0.74 in) (max)

Control

Kerite®FR/ 

Kerite®FR 

(with zinc 

wrap)

Uncert. 12 10 Kerite®

Provided by EPRI

40 mils FR insulation

80 mils FR jacket

OD ~2.69 cm (1.06 in) (max)

Light 

Power

Kerite® HTK/ 

Kerite®FR Uncert. 6 3 Kerite®

Provided by EPRI 

55 mils HT insulation

65 mils FR jacket

OD ~2.2 cm (0.87 in) (max)

Control

Kerite®FR/ 

Kerite®FR 

(with zinc

wrap)

Uncert. 12 15 Kerite®

Provided by EPRI

60 mils FR insulation

80 mils FR jacket

OD ~3.02 cm (1.19 in) (max)
20

Table 3-2 DESIREE-Fire cable list (continued). 

Cable

Function

Insulation and 

Jacket 

Materials (I/J)

Material Type 

(2)

Conductor 

Size (AWG)

Number of 

Conductors

Manufacturer

Notes (3)

Control Kerite®

FR/ 

Kerite®FR Uncert. 14 9 Kerite®

Provided by EPRI

50 mils FR insulation

65 mils FR jacket

OD ~2.16 cm (0.85 in) (max)

Control

Kerite®FR/ 

Kerite®FR 

(with zinc

wrap)

Uncert. 12 7 Kerite®

Provided by EPRI

40 mils FR insulation

65 mils FR jacket

OD ~2.03 cm (0.80 in) (max)

Control

Kerite®FR/ 

Kerite®FRIIIUncert. 12 12 Kerite®

Provided by EPRI

60 mils FR insulation

80 mils FR jacket

OD ~2.39 cm (0.94 in) (max)

Control Kerite®

FR/ 

Kerite®FR-II Uncert. 16 10 Kerite®

Provided by EPRI

50 mils FR insulation

80 mils FR jacket

OD ~2.16 cm (0.85 in) (max)

Control Armored 

XLPE/PVC TS/TP 12 8

General 

Cable

Provided by EPRI

Control Proprietary TS/TS 2

mm2 6

Proprietary

(Japan)

Special heat-resistance insulation 

with radioactive shielding for 

control, and flame-retardant low 

hydrochloric acid and special heatresistance vinyl sheath provided by 

JNES (Japan) (Note 4)

Additional Notes:

 Bold text indicates the “core” program cables; that is, the cables used in the majority of tests.

(1) XLPE = Cross-linked polyethylene; CSPE = Chlorosulfunated polyethylene (also known as 

Hypalon); XLPO = Cross-linked polyolefin; SR = Silicone rubber; EPR = Ethylene propylene 

rubber; PVC = Polyvinyl chloride; 

PE = Polyethylene (non-cross-linked).

(2) TS = Thermoset; TP = Thermoplastic; shown as: (insulation type)/(jacket type).

(3) All cables are unshielded and unarmored unless specifically stated.

(4) The JNES cable is a metric specification cable. A conductor cross section of 2 mm2is roughly 

equivalent to a 14 AWG conductor.

(5) “Uncert.” stands for uncertain.
21

4. DIAGNOSTIC INSTRUMENTATION SUMMARY 

4.1 dc-Powered Test Circuits 

The primary focus of this project was on cable failure modes and effects testing for dc-control 

circuits. Hence, the core of the experimental diagnostic instrumentation was a set of dcpowered control circuit simulators. This section (and its subsections) provides summary 

descriptions of the dc test circuits and the battery set used to supply power to them during 

testing. More complete descriptions of the dc-powered test circuits are provided in Appendices 

A.1 through A.5. Appendix A.7 covers the battery bank. 

4.1.1 The dc Battery Bank 

The design of the battery bank evolved substantially through the course of the test planning 

process. The preliminary planning assumed an approach similar to that employed by Duke 

Energy in its dc tests (2006); namely, use of ten 12V dc deep-cycle automotive batteries 

connected in series. However, the EPRI collaborative team expressed concern that the 

automotive batteries would not supply nearly the same short-circuit fault currents that could be 

generated by an actual set of station batteries. The lower fault current potential was thought to 

have adversely impacted the Duke Energy tests and it was decided to pursue a more 

representative battery set if at all possible. In the end, EPRI identified and made available a 

more representative set of batteries for use in testing. 

The battery set made available by EPRI was comprised of 68 Exide model ES-13 calcium flatplate, lead/acid battery cells that were being taken out of service from the North Anna Nuclear 

Station technical support center (TSC). The batteries had reached their nominal end of life and 

were being replaced as a matter of preventative maintenance. The old cells, which were still in 

serviceable condition, were transported to SNL for use in this test project. All of the cells were 

tested for serviceability by an independent electrical contractor before receipt at SNL and all the 

cells used in the program were certified as fully functional in accordance with IEEE Standard 

450-2002 IEEE Recommended Practice for Maintenance, Testing, and Replacement of Vented 

Lead-Acid Batteries for Stationary Applications [10]. 

The battery bank needed to provide a nominal 125Vdc power output, this having been identified 

by the industry representatives as typical of the dc-control circuit power supplies used in U.S. 

NPPs. Hence, a total of 60 battery cells were used to construct the battery bank (detailed cell 

specifications are provided in Appendix A.7). For a sense of scale, each individual cell weighed 

about 36.7kg (81lb), and together the 60-cell battery bank weighed approximately 2200kg 

(4860lb). The batteries were housed within a 9.5m- (20ft-) long portable transportainer 

providing a temperature-controlled environment. The remaining eight cells were retained as 

replacement spares but were not used in testing because no cell failures occurred over the 

course of the tests. 

The completed battery bank provided an estimated short-circuit output current at the main 

terminals of over 13,000A. The collaborative partners and the NRC agreed that, while a true 

station battery set might provide roughly twice that fault current at the battery terminals, the set 

used was sufficient to meet the needs of testing and that the fault current available to the test 

circuits could be matched to typical installed end devices through proper sizing of the power 

supply lead cables. That is, the program used specified lengths of relatively large power cables 

to supply the individual test circuits (i.e., to connect the battery bank to the dc-SIM panels) so as 
22

to match the available fault current desired by controlling the impedance of the lead cables. 

Specific guidance regarding lead cable sizing was provided by the EPRI team and was 

implemented by SNL. Details on the cable dimensions for all of the lead cables used in testing 

is provided in Appendix A. 

The power supply system also included a manually initiated, automatic charging system able to 

provide both refresh charging and float charging to the battery bank. The charging system was 

isolated from the battery bank during testing. The batteries were charged regularly throughout 

the course of the testing program. 

Also note that a ground fault detection circuit was provided to detect conductor-to-ground faults 

that occurred during testing which resulted in grounding of either the positive or negative side of 

the battery bank. The ground fault circuit is described in Appendix A.7. 

4.1.2 The dc Test Circuits 

For testing, a total of eight individual dc-powered test circuits were developed. Appendices A.1 

through A.5 provide detailed descriptions of these test circuits. The basic circuit diagrams for 

each circuit as implemented in the testing are also presented. For convenience of reference, six 

circuit diagrams (Figure 4-1 through Figure 4-6) which reflect the eight different dc-powered 

circuits are presented collectively at the end of Section 0 (along with the circuit diagram for the 

ac-powered SCDU, Figure 4-7). The dc test circuits are summarized below. 

MOV-1 and MOV-2:

Two separate dc-powered MOV circuits were used in testing. They are referred to as MOV-1 

and MOV-2 in the balance of this report.8 Each MOV circuit was comprised of a matched pair of 

Joslyn-Clark-brand dc motor control contactors that were electrically and mechanically 

interlocked. One contactor is designated as the “open” contactor and the second as the “close” 

contactor (i.e., the contactors that, if energized, would cause the valve to open or close, 

respectively). The MOV circuit diagram is shown in Figure 4-1. Additional details for this circuit 

including full circuit and block diagrams are provided in Appendix A.1. 

 Note that during post-test evaluation of the test circuits it was discovered that one of the 

four individual contactors (the MOV-2 close contactor) was incomplete and nonfunctional. On disassembly, it was discovered that the unit as supplied by the 

manufacturer was lacking the “moving core” element of the contactor. This is the metal 

core attached to the moving parts of the contactor that is drawn down when the fixed 

core coil is energized, causing the contactor to close the main contact sets. Because 

the moving core was missing, this particular contactor was a passive (or inactive) target. 

That is, the contactor‟s magnetic coil was in place and would represent an inductive 

load on the circuit just as a fully functional contactor unit would. However, given a hotshort impacting the associated cable conductor, even if energized at full voltage the 

contactor would not close. This also means that neither the mechanical or electrical 

interlocks would be engaged, leaving the open contactor as an active target. The full 

implications of this test anomaly are covered in Appendix A.1. Data analysis has 

considered the as-operated circuit. The MOV-1 circuit operated as designed. 

 

8

 The reader should note that the dc-powered MOV circuits are consistently referred to as MOV1 and MOV2. As 

discussed in Section 4.2, testing also involved a set of ac-powered MOV circuits, which are uniformly referred to as 

the SCDU circuits or as SCDU1 through SCDU4. This convention is maintained throughout the report whenever the 

various test circuits are discussed. 
23

Figure 4-1 The dc test circuit diagram for MOV-1 and MOV-2 

Figure 4-2 The dc test circuit diagram for SOV-1 and SOV-2 

G

P

YC1

YO1

R

N

SP

A

A

A

A

V

V

V

V

V

V

V

NC

NC

1750

+

-

125 VDC

O

NO

NC

C

A

A

1750

DCCCS CABLE UNDER TEST

FROM DISTRIBUTION 

CIRCUIT BREAKER

FUSE BLOCK

DCCCS Layout for DC MOV Control Circuit

10A

10A

A

A

B

C

S1

G

R

S2

N

SP

A P

A

A

A

A

V

V

V

V

V

V

V

5A

5A

SOV

1750

1750

DCCCS Layout for Small DC SOV Circuit

+

-

125 VDC

DCCCS CABLE UNDER TEST

FROM DISTRIBUTION CIRCUIT BREAKER

FUSE BLOCK
24

Figure 4-3 The dc test circuit diagram for the 1-in. SOV 

Figure 4-4 The dc test circuit diagram for the large coil 

P

G

R

S

N1

N2

SP

A

A

A

A

A

V

V

V

V

V

V

V

5A

1-INCH

COIL

1750

1750

+

-

125 VDC

DCCCS CABLE UNDER TEST

FROM DISTRIBUTION 

CIRCUIT BREAKER

DCCCS Layout for DC 1-Inch Coil Circuit

FUSE BLOCK

5A

NC

NO A

P

G

R

S

N1

N2

SP

A

A

A

A

A

V

V

V

V

V

V

V

10A

LARGE

COIL

1750

1750

+

-

125 VDC

DCCCS CABLE UNDER TEST

FROM DISTRIBUTION 

CIRCUIT BREAKER

DCCCS Layout for DC Large Coil Circuit

FUSE BLOCK

10A

A
25

Figure 4-5 The dc test circuit diagram for the switchgear (including both the trip and 

close circuits) 

Figure 4-6 Circuit diagram for the intercable shorting circuit 

PC

C1

G

R

T

SP

N2

PT

N1

A

A

A

A

A

A

V

V

V

V

V

V

V

V

V

DCSIM Schematic Diagram for GE VB1 Switchgear DC Control Circuit

+

1

- 25 VDC 60 A BKR

15A

35A

DCSIM CABLE UNDER TEST FROM DISTRIBUTION CIRCUIT BREAKER

15A

35A 1800

1800

L3

L5 & L7

L11

L15

L9

L10, L12 & L16

L4 & L6

VB1 SWGR

SP V

A

+

1

- 25 VDC 50 A BKR

V

V

Layout for DC Intercable Interaction Detection Circuit

+

-

125 VDC

INTERCABLE DETECTION PANEL

FROM DISTRIBUTION CIRCUIT 

BREAKER PANEL

S1+

1

2

S1-

CABLE UNDER TEST

10A

10A

FUSE BLOCK

10A S2+

10A S2-

V

V

V

V

V

3

V

4

V

5

V

6

V

7

1800

1800

1800

1800

1800

1800
26

Figure 4-7 Circuit diagram for the SCDU as modified for use in DESIREE-Fire including 

an active electrical interlock on the contactor pair (K-1 and K-2)

SOV1 and SOV2: 

Two separate small SOV circuits were also used in testing (referred to as SOV-1 and SOV-2). 

The two circuits each include a working solenoid valve of the type commonly used as a pilot 

control valve, for example, for a larger air-operated valve (AOV). The two valve circuits differed 

in that one circuit, SOV-2, used a continuous duty “Class H” coil. Based on the manufacturer‟s 

literature, the Class H coils will accommodate continuous duty over a wider voltage range; 

namely, 12% over normal and 28% under normal rated coil voltage. For a nominal 125Vdc coil, 

this translates to a voltage range of 90 to 180Vdc. The SOV circuit diagram is shown in Figure 

4-2. Additional details for this circuit are provided in Appendix A.2. 

1-Inch Valve: 

One test circuit was built around a relatively large 25mm (1-in.) SOV that was provided by the 

Target Rock Corporation through the NRC-RES/EPRI collaboration. This was a normally open 

solenoid valve. The size (1-in.) refers to the nominal inlet and outlet pipe diameter. This was a 

fully functional valve and was similar to the type of valve that would be used as a head vent 

valve or in other safety relief applications (but smaller than a typical PORV). The valve 

assembly included open and close indicator switches that were wired into the valve circuit. The 

1-in. valve circuit diagram is shown in Figure 4-3. Additional details for this circuit are provided 

in Appendix A.3. 

2

Conductor

1

4

3

6

5

7

A

A

A

A

A

A

A

V

V

V

V

V

V

V

V

V

S1

S2

S3

S4

S5

S6

NC

NC

1.8K

K-2

K-1

A

A

1.8K

AC SCDU CABLE UNDER TEST CONTROL POWER 

TRANSFORMER

120 VAC 3A

10

2

(White)

Conductor

1

(Black)

4

(Green)

3

(Red)

6

(Blue)

5

(Orange)

7

(White-Black)

9

8

7

3

4

5

2

1

6

5

6

4

3

2

1

7

LEAD CABLE

Junction Box

SCDU 

Terminal 

Block

SCDU 

Terminal 

Block

N/C

N/C
27

 Note that during the course of testing both of the position indicator switches failed 

closed (first one and later the second). The switches are sealed magnetically activated 

reed switches and have not been disassembled as a part of postmortem equipment 

examination. It is suspected that faults propagating through those particular circuit 

paths may have caused arcing across the switch contact and likely caused the contacts 

to weld closed. Details on when the failures occurred, the tests impacted by the 

failures, and the implications for data processing are included in Appendix A.3. 

Large Coil: 

One circuit was built around the coil assembly for a large, direct-acting SOV. In this case only 

the coil assembly itself was available (no valve mechanical elements present). Hence, the coil 

acted as a passive target for HSs. For a sense of scale, the coil assembly itself had a core 

diameter of approximately 200mm (8-in.) and weighed approximately 114kg (250lb). This coil 

was also provided by the Target Rock Corporation via the NRC-RES/EPRI collaboration. 

Originally, one goal of the program was to include a representative PORV valve in the testing 

program, but a suitable valve was unable to be located. When this valve coil became available, 

it was decided to include it in the testing program even though it was much larger than a typical 

PORV would be. Between the 1-in. valve and the large coil, the test circuits are assumed to 

bound a typical PORV. The large coil circuit diagram is shown in Figure 4-4. Additional details 

on this circuit are provided in Appendix A.3. 

Switchgear: 

One test circuit was built around an actual switchgear breaker unit. The units used were fully 

functional and would open (trip) and close in accordance with the control signals they received. 

During the course of one particular test, failure of the test cable induced fault currents within the 

switchgear unit itself that exceeded the ampacity of the 14AWG internal control wiring. This 

severely damaged the internal unit wiring. The damaged unit was repaired, but was also 

replaced by a second switchgear unit with more robust internal wiring. The switchgear circuit 

diagram is shown in Figure 4-5. Appendix A.4 provides a detailed description of both 

switchgear circuits including a description of the faults that damaged the first unit. 

 Note that, as shown at the extreme left of Figure 4-5, the switchgear‟s trip and close 

circuits were powered through separate circuit breakers in the dc battery bank power 

distribution system. This is not typical of in-plant practice, but has no effect on circuit 

performance. None of the circuit breakers (for any test circuit) ever tripped during 

testing. Primary circuit protection is provided by the 15A and 35A fuses, also shown in 

the schematic, and the up-stream circuit breakers were installed as a personnel safety 

measure (e.g., allowing for individual test circuits to be isolated at the power source). 

Appendix A.7 provides additional detail on the power distribution system. 

Intercable Test Circuit: 

The last dc-powered circuit was not designed to mimic any particular control circuit, but rather 

was designed to monitor for the occurrence of intercable HSs. In particular, there was an 

interest expressed by the peer team to determine if testing could detect occurrence of the socalled “intercable smart dc hot short”; that is, a short between a target cable and one or more 

source cables that would result in at least one conductor in the target cable being energized to 

the positive battery potential and a second conductor in the same target cable being energized 
28

to the negative battery potential. This shorting configuration is the only cable failure mode that 

can induce spurious operation in certain types of dc circuits. 

The intercable test circuit provided for up to two (separately monitored) battery positive source 

cables/paths, two battery negative source cables/paths, and for a target cable of up to seven 

conductors. A circuit diagram is shown in Figure 4-6. Conductors 1-7 in this diagram represent 

the target cable and are generally referred to as T1-T7 in this report. T1 is the conductor at the 

center of the target cable. In this figure, the source cables/paths are shown as S1+, S2+, S1-, 

and S2- and the target cable is represented by circuit paths 1 through 7. In the report, these 

target conductors are typically referred to as T1-T7 and conductor T1 was connected to the 

center conductor within the target cable. 

Each of the six conductors in the outer ring of the target cable (conductors T2-T7) are 

connected to its two nearest neighbors through 1.8-kΩ resistors (the center conductor is 

excluded from the resistor network). As a result, conductors T2-T7 will act as a voltage-divider 

circuit should a smart dc HS form. That is, energizing one conductor (or group of conductors) to 

the positive battery potential and a second conductor (or group of conductors) to the negative 

battery potential would result in a voltage cascade from positive to negative across the 

remaining conductors. This behavior is described in greater detail in Appendix A.5, including 

illustrative examples. The result of primary interest for this circuit is whether or not such a 

voltage cascade formed during any given test. 

The physical configuration used in testing prevented ground interactions and interactions with 

the other test circuits. The test cables were placed on an insulating board isolating them from 

the grounded raceway. The intercable circuit was not co-located with any of the other test 

circuits, preventing circuit-to-circuit interactions, except to the extent a ground fault in any of the 

dc-powered circuits will shift the measurement reference potential (i.e., the ground potential 

relative to battery positive and negative) for all of the dc-powered circuits including the 

intercable circuit. The test configuration did allow for either hot-short interactions between the 

source and target cables or fuse blow (FB) failures given interactions between the positivesource cables and the negative-source cables. 

The test configuration was not intended to represent any anticipated in-plant conditions. Rather, 

it was designed to optimize the potential for, and detect, smart dc HSs. The intent is that given 

that the tests “stacked the deck” in favor of smart dc HS formation, should no such short circuits 

be observed, this could be taken as evidence that this is a low likelihood failure mode. Overall, 

caution must be taken in extrapolating from this test circuit to real-life conditions. 

4.1.3 Current Transducers 

A note needs to be made regarding the current transducers used for monitoring the dc-powered 

test circuits. The issues identified relative to these transducers are covered in detail in 

Appendix A.8. The intent here is to summarize the identified issues and the measures taken to 

address them. 

The current transducers used in the dc test circuits were Hall-effect current probes. Hall-effect 

probes were selected mainly because they are non-intrusive. Duke Energy had used current 

shunts in its testing. Shunts are low-resistance devices inserted into a circuit path that induce a 

small voltage drop proportional to current flow. Measuring the voltage drop provides a 

corresponding current flow. In the Duke Energy tests these shunts proved problematic, in some 

cases failing due to sustained short-circuit currents. The EPRI collaborative peer team also 
29

expressed concern that the presence of shunts in the various circuit paths could act to limit 

short-circuit currents, potentially compromising or altering the fuse-blow behavior for the circuits. 

Over the course of testing, three issues impacting these transducers were identified as follows: 

 Zero-point drift: While reviewing data from early tests, it was noted that the zero-point 

offset (i.e., the transducer output at zero current flow) would drift between the beginning 

and the end of a given test, and between the end of one test and the beginning of the 

next test. Discussion with the supplier revealed that dc current flows through the pickup coils would induce a certain degree of residual magnetism that would be reflected as 

a non-zero signal output. For ac circuits this effect is self-correcting due to the zerocrossing nature of the power signal, but for dc circuits the lack of a zero-crossing 

behavior (see Section 2.1 above) means the effect is not self-canceling. The 

magnetism will fade over time but is an inevitable aspect of the devices when used for 

dc circuits. This issue was discussed extensively among the peer team and was 

ultimately addressed through modifications of the testing protocol and during post-test 

data analysis. The processed data was corrected to reflect the true zero-point offset of 

each individual current transducer at the beginning of each test, but because the zeropoint offset drifts over the course of a given test, the data plots will typically show a 

slight non-zero current flow at the end of a test when the actual current flows are zero 

(e.g., fuses have blown and a circuit is deenergized). 

 Transducer sensitivity: The transducers selected were relatively high range (e.g., 

+/- 35A or higher) because the peer team wanted to capture the higher short-circuit 

currents that would be acting to clear circuit fuses. The early tests revealed that this 

rendered the transducers relatively insensitive to the lower current signals (e.g., those 

associated with spurious operations, nominally 1A or less) especially given general lowlevel noise in the data and the zero-point offset issue discussed immediately above. 

This issue was addressed by amplifying the current signals by making multiple 

conductor passes through the pick-up coils. This resulted in a corresponding reduction 

in the maximum range of the transducers (e.g., a +/- 35A transducer becomes a +/- 7A 

transducer given five loops of the conductor through the pick-up coil). Once the loops 

were made, the effective range is reduced and current increases above 7A would be 

reflected as transducer saturation. Reducing the upper limit of the current transducer 

was an acceptable sacrifice to the peer review committee. The processed data files 

and all of the plots presented in this report have been corrected for the amplification 

effect and show the actual (corrected) current values. 

 High-current transducers insensitive to transient behavior: Each of the main 

power supply conductors (i.e., between the battery bank and each of the test circuits) 

were equipped with both lower-range (+/- 35A) and high-range (+/- 500A) current 

transducers. Despite numerous efforts to address this problem, the high-range current 

transducers provided little or no data of value. While installation and operability of the 

transducers was verified (repeatedly) and high-speed data logging was attempted (i.e., 

at as high as 100 Hz), the 500A transducers were simply not capturing meaningful data 

signals from the transient short circuits observed. The root cause of this issue has not 

been traced. 

4.2 ac-Powered Test Circuits 

DESIREE-Fire included limited testing with the ac-powered SCDU circuits originally designed 

and built for use in the CAROLFIRE project. The SCDU circuits were nominally designed to 
30

simulate the behavior of a typical ac-powered reversing MOV control circuit. A total of four units 

were constructed, each representing one complete MOV control circuit. 

One issue that had not been fully addressed under CAROLFIRE was that of saturation of the 

CPTs and degradation of the available voltage to the point where a SA of the contactors was no 

longer possible. That is, in the EPRI/NEI tests of 2001, multiple leakage current paths led to 

current draws that exceeded the capacity of the CPTs. CPT voltage output in some EPRI/NEI 

tests was degraded below the pick-up voltage of the motor control contactors so that even when 

a HS occurred the contactors did not close. This effect was not observed in any of the 

CAROLFIRE tests, but one factor that was thought to have influenced the CAROLFIRE results 

was that the motor control contactors used in CAROLFIRE required far less than the nominal 

(advertised) power draw for the contactors. A secondary objective for DESIREE-Fire was to reinvestigate this aspect of the shorting behavior. 

The SCDU motor control contactors were all replaced with contactors identical to those used in 

the original EPRI/NEI tests.9

 Two of the contactor sets were obtained via the EPRI collaboration 

and were the units used by Duke Energy in its 2006 testing. Two additional contactor sets were 

obtained directly from Joslyn-Clark Controls. In addition, the four SCDU units each used a 

different size CPT; namely, a 75VA for SCDU-4, 100VA for SCDU-1, 150VA for SCDU-2, and 

200VA for SCDU-3.

The CAROLFIRE project report [1] and Appendix A.6 provide more detailed descriptions of the 

SCDU circuits. Appendix A.6 includes a description of the system modifications implemented 

for DESIREE-Fire. The general circuit schematic for the SCDU is illustrated in Figure 4-7, 

which, for convenience of reference, is presented along with the dc-powered circuit diagrams at 

the end of Section 0. 

4.3 Other General Instrumentation 

The other primary instrumentation utilized in testing was associated with the monitoring of 

various temperatures. In all cases, temperatures were monitored using Type-K thermocouples. 

All of the temperature monitoring was performed using calibrated data logging systems and the 

thermocouples used are batch calibrated. That is, not every thermocouple in a given batch is 

calibrated because the calibration process itself drives a thermocouple to its performance limits, 

which can actually alter its calibration. Instead, select samples for any given batch of 

thermocouples are run through the full calibration process, and, provided no anomalies are 

identified, the entire batch is considered calibrated. The actual thermocouples used in the 

calibration process are discarded. 

Typical temperature monitoring during the small-scale Penlight tests focused on the Penlight 

shroud temperature and sub-jacket temperatures for the thermal response sample cables. The 

intermediate-scale tests included both cable thermal response sample monitoring and the 

monitoring of the exposure environment (air temperatures) directly above and below the tested 

cables. The DESIREE-Fire approach temperature monitoring is essentially identical to that 

described in the CAROLFIRE test report. The major difference is that DESIREE-Fire took a 

somewhat more minimalistic approach because most of the cables tested in DESIREE-Fire had 

 

9

 Note that at the time of the EPRI/NEI tests the manufacturer of the contactor sets was AO Smith, Clark Controls 

Division. AO Smith subsequently merged with Joslyn Manufacturing Corp. to become Joslyn-Clark Controls. The 

same AO Smith model NEMA-1 motor control contactor sets as used by EPRI/NEI and with the exact same model 

designation (#30U31) remain available through Joslyn-Clark Controls. 
31

already been through extensive testing in CAROLFIRE and there was little need for additional 

thermal response data for those cables. For those cables that had not been tested before (the 

Kerite cables, armored cables and the Japanese cable) a somewhat more aggressive approach 

to cable thermal response measurements was taken (more thermal response cable samples 

and more thermocouples per sample). 

The main objective for DESIREE-Fire relative to cable thermal response was to assess whether 

the dc-powered circuits experienced faults at substantially different cable temperatures than did 

the ac-powered circuits from CAROLFIRE. The testing revealed no substantive differences in 

this regard between the ac and dc circuits. 

Beyond the temperature monitoring, the only other data system used was the fuel flow controller 

for the intermediate-scale gas burner test. Again, the test setup and equipment was the exact 

same equipment as was used in CAROLFIRE. As in CAROLFIRE, the gas burner flow was set 

and recorded manually. Flow recording is documented in the test engineer‟s field notes.

Appendix A.8 provides a more complete description of the various test support systems used in 

DESIREE-Fire. This includes descriptions of the data logging systems and data analysis 

processes. Appendix A.8 also describes the content and structure of the processed data files 

included on the CD provided with this report. 

33

5. TEST MATRICES 

Table 5-1 presents the matrix of small-scale Penlight tests performed. Table 5-2 provides the 

corresponding matrix of intermediate-scale tests. In these two tables the tests are arranged by 

test number. However, the tests were not performed sequentially in the same order as would 

be indicated by the test number. Hence, for convenience, Table 5-3 provides an alternate listing 

of both the Penlight and intermediate-scale tests arranged by the order in which tests were 

actually performed (i.e., by the date and time of each test). Table 5-3 also provides general 

comments relating to test anomalies, changes in the test configurations, or changes in the test 

protocols implemented during the course of testing. Changes in the test circuit configurations or 

test protocols, in particular, will impact all of the subsequent tests performed. 

Note, again, that for both the Penlight and intermediate-scale tests the intent was to mirror as 

closely as possible the test conditions from the CAROLFIRE project. The intent was to ensure 

that the results of the DESIREE-Fire tests could be compared directly to those from 

CAROLFIRE. 

In the case of the Penlight tests, the layout of cables, cable types, and exposure temperatures 

are all quite similar to those used in CAROLFIRE. In the case of the intermediate-scale tests 

the cable types, cable raceway locations, and gas burner flow rate (heat release rate) settings 

also mirrored those applied in CAROLFIRE. The primary difference in this regard is that 

DESIREE-Fire placed no particular emphasis on gathering additional data for use in fire model 

validation studies, the CAROLFIRE project having provided a wealth of such data. That is, 

DESIREE-Fire gathered basic cable response and thermal environment temperature data, 

especially when a cable type not used in CAROLFIRE was being tested (i.e., the Kerite®, JNES, 

and armored cables), but to a far less extent than did CAROLFIRE. Instead, for DESIREE-Fire 

resources were focused on providing a wider range, and greater number, of test circuits. This is 

reflected, for example in the Penlight tests, by DESIREE-Fire‟s focus on the simple single-cable 

test configurations as compared to CAROLFIRE, which involved more tests with various cable 

bundles. 

In effect, the same test protocols that were developed as a part of CAROLFIRE were applied in 

DESIREE-Fire for both test scales. The only significant differences relative to how each test 

was conducted were those relative to the dc-powered circuits and power supply system. These 

aspects of the test protocol were mainly associated with ensuring personnel safety during all 

aspects of testing (e.g., lock-out work procedures) and have no impact on the test conditions 

seen by the sample cables. 
34

Table 5-1 The DESIREE-Fire small-scale Penlight test matrix.

Burn Test #

Cable Insulation Material

Exposure shroud 

temperature (C)

Raceway 

type

Cable Diagnostic Sys

Thermosets Thermoplastics

XLPE / CSPE

EPR

SR

Kerite

® FR with 

zinc wrap

Kerite

® FR without 

zinc wrap

Kerite

® HTK

Armored

Tefzel

PE / PVC

PVC / PVC

Tray

Conduit

SCDU

2 OV

S and SOV1 

kV Breaker - 15

in. Large Coil and 1 

SOV

MOV2 and MOV1 

Pre-1 (P) X 470 X X 

Pre-2 (P) X 470 X X 

Pre-3 (P) X 325 X X 

Pre-4 (P) X 325 X X 

1 X 470 X X 

2 X 470 X X 

3 X 470 X X 

4 X 470 X X 

5 X 470 X X 

6 X 470 X X 

7 X 470 X X 

8 X 470 X X 

9 X 325 X X 

10 X 325 X X 

11 X 325 X X 

12 X 325 X X 
35

Table 5-1 The DESIREE-Fire small-scale Penlight test matrix (continued).

Burn Test #

Cable Insulation Material

Exposure shroud 

temperature (C)

Raceway 

type

Cable Diagnostic Sys

Thermosets Thermoplastics

CSPE XLPE /

EPR

SR

Kerite

® FR with 

zinc wrap

Kerite

® FR without 

zinc wrap

Kerite

® HTK

Armored

Tefzel

PE / PVC

PVC / PVC

Tray

Conduit

SCDU

SOV1 and SOV2

kV Breaker - 15

Large Coil and 

in. SOV - 1

MOV1 and MOV2

13_qual X Vary X X 

13 X 350 X X 

14 X 450 X X 

15 X 300 X X 

16 X 470 X X 

17_qual X Vary X X 

17 X 430 X X 

18 X 420 X X 

19 X 470 X X 

20 X 470 X X 

21 X 470 X X 

22 X 470 X X 

23 X 470 X X 

24 X 470 X X 

25 X 470 X X 

26 X 700 X X 

27 X 700 X X 

28 X 325 X X 
36

Table 5-1 The DESIREE-Fire small-scale Penlight test matrix (continued).

Burn Test #

Cable Insulation Material

Exposure shroud 

temperature (C)

Raceway 

type

Cable Diagnostic Sys

Thermosets Thermoplastics

CSPE XLPE /

EPR

SR

Kerite

® FR with 

zinc wrap

Kerite

® FR without 

zinc wrap

Kerite

® HTK

Armored

Tefzel

PE / PVC

PVC / PVC

Tray

Conduit

SCDU

SOV1 and SOV2

kV Breaker - 15

Large Coil and 

in. SOV - 1

MOV1 and MOV2

29 X vary X X 

30 X 325 X X 

31 X 325 X X 

32 X 325 X X 

33 X 325 X X 

34 X 525 X X 

35 X 525 X X 

36 X 525 X X 

37 X 525 X X 

38 X 450 X X 

39 X 450 X X 

40 X 450 X X 

41 X 525 X X 

42 X 430 X X 

43 X 275 X X 

44 X 325 X X 

45 X 460 X 

46 X 325 X 
37

Table 5-1 The DESIREE-Fire small-scale Penlight test matrix (continued).

Burn Test #

Cable Insulation Material

Exposure shroud 

temperature (C)

Raceway 

type

Cable Diagnostic Sys

Thermosets Thermoplastics

CSPE XLPE /

EPR

SR

Kerite

® FR with 

zinc wrap

Kerite

® FR without 

zinc wrap

Kerite

® HTK

Armored

Tefzel

PE / PVC

PVC / PVC

Tray

Conduit

SCDU

SOV1 and SOV2

kV Breaker - 15

Large Coil and 

in. SOV - 1

MOV1 and MOV2

47 X 350 X 

48 X 400 X 

49 X 400 X X 

50 X 450 X X 

JPN-1 325 X X 

JPN-2 350 X X 

JPN-3 350 X X 
38

Table 5-2 The DESIREE-Fire intermediate-scale test matrix.

Burn Test #

Cable Monitoring Devices

LOCATION

CABLE TYPE

RACEWAY 

TYPE

RA

LO

XLPE

EPR

PE

XLPO

TEFZELARMOR

ERITE

K

® FR with 

zinc wrap

ERITE

K

® FR 

without zinc wrap

JPN

TRAY

CONDUIT

Circuits Only (No 

Fill)

JPN 1

SCDU 1 E X X X

SCDU 2 B X X X

SCDU 3 A X X 

(IS) 1- Pre

Fill cable only A X

SCDU 3, 4 B X X X

Lg Coil, 1" Coil E X X X

Intercable Bundle D X X X

SWGR-C, SWGR-T B X X X

(IS)

2- Pre

Fill cable only B X

MOV-1, SOV-1 A X X X

SCDU 1, 2 D X X X

MOV-2, SOV-2 E X X X

1

Fill cable only A X

MOV-1, SOV-1, Lg Coil, 1" Coil B X X X

1

Intercable Bundle C X X 

MOV-2, SOV-2, SWGR-C

7

, SWGR-T

7 D X X 
39

Table 5-2 The DESIREE-Fire intermediate-scale test matrix (continued).

Burn Test #

Cable Monitoring 

Devices

LOCATION

CABLE TYPE

RACEWAY 

TYPE

RA

L

XLPE

EPR

PE

XLPO

TEFZELARMOR

ERITE

K

® FR with 

zinc wrap

ERITE

K

® FR 

without zinc wrap

JPN

TRAY

CONDUIT

Circuits Only (No 

Fill)

2

Fill cable only B X

MOV-1, SOV-1, Lg Coil, 1" Coil C X X 

Intercable Bundle D X X 

MOV-2, SOV-2 A X X 

3

No circuits in these positions C&E

MOV-1, SOV-1, Lg Coil, 1" Coil D X X 

Intercable Bundle A X X 

MOV-2, SOV-2, SWGR-C

7

, SWGR-T

7

B X X X

2

4

SCDU 1, 2, 3, 4 D X X 

MOV-1, SOV-1, Lg Coil, 1" Coil A X X 

Intercable Bundle B X X 

MOV-2, SOV-2, SWGR-C, SWGR-T C&E X X

3

5

Fill cable only A X

MOV-1, SOV-1, Lg Coil, 1" Coil B X X X

1

Intercable Bundle C X X 

MOV-2, SOV-2, SWGR-C

7

, SWGR-T

7 D X X 
40

Table 5-2 The DESIREE-Fire intermediate-scale test matrix (continued).

Burn Test #

Cable Monitoring 

Devices

LOCATION

CABLE TYPE

RACEWAY 

TYPE

RA

L

XLPE

EPR

PE

XLPO

TEFZELARMOR

ERITE

K

® FR with 

zinc wrap

ERITE

K

® FR 

without zinc wrap

JPN

TRAY

CONDUIT

Circuits Only (No 

Fill)

6

SWGR-C

7

, SWGR-T

7

B X X X

4

MOV-1, SOV-1, Lg Coil, 1" Coil C X X 

Intercable Bundle D X X 

MOV-2, SOV-2 A X X 

7

No circuits in these positions C&E

MOV-1, SOV-1, SWGR-C

7

, SWGR-T

7 D X X 

Intercable Bundle A X X 

MOV-2, SOV-2, Lg Coil, 1" Coil B X X X

5

8

SCDU 1, 2, 3, 4 D X X 

MOV-1, SOV-1, Lg Coil, 1" Coil A X X 

Intercable Bundle B X X 

MOV-2, SOV-2, SWGR-C, SWGR-T C X X 

9

Fill cable only A X

MOV-1, SOV-1, Lg Coil, 1" Coil B X X X X 

Intercable Bundle C X X 

MOV-2, SOV-2, SWGR-C

7

, SWGR-T

7 D X X X
41

Table 5-2 The DESIREE-Fire intermediate-scale test matrix (continued).

Burn Test #

Cable Monitoring 

Devices

LOCATION

CABLE TYPE

RACEWAY 

TYPE

RA

L

XLPE

EPR

PE

XLPO

TEFZELARMOR

ERITE

K

® FR with 

zinc wrap

ERITE

K

® FR 

without zinc wrap

JPN

TRAY

CONDUIT

Circuits Only (No 

Fill)

10

MOV-1, SOV-1 C X X 

Lg Coil, 1" Coil D X X 

Intercable Bundle A X X 

MOV-2, SOV-2, SWGR-C

7

, SWGR-T

7

B X X X 

11

SCDU 1, 2, 3 A X X 

MOV-1, SOV-1, Lg Coil, 1" Coil B X X 

Intercable Bundle C X X 

MOV-2, SOV-2 D X X 

12

SCDU 1, 2, 3 C X X 

MOV-1, SOV-1, Lg Coil, 1" Coil D X X 

Intercable Bundle A X X 

MOV-2, SOV-2 B X X 

Conting 

#1

Fill cable only A X

SWGR-C

7

, SWGR-T

7

B X X X

No circuits in other positions
42

Table 5-2 The DESIREE-Fire intermediate-scale test matrix (continued).

Burn Test #

Cable Monitoring 

Devices

LOCATION

CABLE TYPE

RACEWAY 

TYPE

RA

L

XLPE

EPR

PE

XLPO

TEFZELARMOR

ERITE

K

® FR with 

zinc wrap

ERITE

K

® FR 

without zinc wrap

JPN

TRAY

CONDUIT

Circuits Only (No 

Fill)

Conting 

#2

Fill cable only A X

SWGR-C

7

, SWGR-T

7

B X X X

No circuits in other positions

Notes for Table 5-2: 

1

 Location B: MOV and SOV circuits located in conduit without fill cables. Large Coil and 1" Valve located within fill tray. 

2

 Location B: MOV-2 and SOV-2 circuits in tray with fill cables. SWGR circuits in conduit without fill cables. 

3

 Location C: MOV-2 and SOV-2 circuits bundled in tray. Location E: Both SWGR circuits bundled in tray. 

4

 Location B: Fill cables in tray. SWGR-C and SWGR-T in conduit. 

5 

Location B: MOV-1 and SOV-1 circuits were tested in the tray. Large Coil and 1" Valve were tested in the conduit. 

6

 Location C: Cable Sample connected to the 35-A fuses tested on the side of the tray. 

7

 Replacement 4.16 kV GE Breaker 
43

Table 5-3 Chronology of DESIREE-Fire tests (both testing scales).

Date Test # Comments including changes to test protocols

Begin Penlight testing 7/13/2009

7/13/2009 Pre-3 (P)

7/13/2009 Pre-4 (P)

7/14/2009 Pre-1 (P)

7/14/2009 Pre-2 (P)

7/15/2009 1

7/16/2009 25

7/16/2009 23 SOV-2 was intentionally fused at 10A rather than 5A for this test only.

7/17/2009 31

7/17/2009 9

7/17/2009 2

7/20/2009 7

7/20/2009 8

7/21/2009 3

7/21/2009 10

7/22/2009 5

7/22/2009 11

7/22/2009 6

Anomalies detected on R conductor for the 1-in. solenoid; test was still 

conducted. R conductor acted as a positive source conductor.

7/23/2009 26

7/26/2009 13_qual

7/27/2009 13

7/28/2009 14

7/28/2009 15

7/28/2009 16

7/29/2009 24

Conductors passing through the switchgear CT35 transducers were 

wrapped around the hall effect device five times. The positive battery 

lead on the 35A switchgear fuse was wrapped twice around the 

CT500 hall effect device.

7/29/2009 29

7/30/2009 4

7/30/2009 17_qual

7/31/2009 17

7/31/2009 18

8/10/2009 19

8/10/2009 28 All circuits were rewired to include five turns around the CT35 and two 

turns around the CT500 transducers.

8/11/2009 20
44

Table 5-3 Chronology of DESIREE-Fire tests (both testing scales) (continued).

Date Test # Comments including changes to test protocols

8/11/2009 34

8/11/2009 38

8/12/2009 36

8/12/2009 40

8/12/2009 27

8/12/2009 33

8/12/2009 12

Penlight apparatus was not functioning properly and had to be shut 

down before being turned back on. Upon being turned back on, the 

circuits were experiencing degradation.

8/13/2009 30

8/13/2009 22

9/14/2009 41

9/15/2009 JPN-1

9/16/2009

JPN-2 & 

JPN-(IS)1 

On this day, both JPN-2 Penlight and JPN-(IS)1 intermediate-scale 

were run. This was an early intermediate-scale test. Intermediatescale testing did not resume until November 4, 2009.

9/23/2009 JPN-3

The electrical interlock on MOV-1 would not fully close, it was adjusted 

to perform as anticipated. The current transducer monitoring the 

green indication lamp on MOV-1 was replaced. Loose wiring was 

tightened.

9/23/2009 37

9/24/2009 43

9/24/2009 32

9/24/2009 39

9/25/2009 35

9/25/2009 42

9/28/2009 21

10/5/2009 44

10/8/2009 47

10/8/2009 48

10/8/2009 46

10/9/2009 45

10/9/2009 49

10/12/2009 50

Begin primary matrix of intermediate-scale tests 11/4/2009

11/4/2009 Pre-2 (IS)

11/6/2009 Pre-1 (IS)

11/12/2009 4
45

Table 5-3 Chronology of DESIREE-Fire tests (both testing scales) (continued).

Date Test # Comments including changes to test protocols

11/17/2009 8 The 15-kV Switchgear was damaged during Test IS8.

11/20/2009 12 Anomalies detected on R conductor for the 1-in. solenoid; test was still 

conducted.

11/25/2009 11 Removed connection to the R position switch on the 1" SOV before

test.

12/2/2009 2

CT-500 transducers connected to SCDU data acquisition system (no 

SCDU circuits). Large coil tested using the 15A fuses for the duration 

of testing. The voltage transducer monitoring the R conductor on the 

large coil circuit was replaced. Intercable configuration tested using 

5A fuses for the duration of testing. The current transducer monitoring 

R on the MOV-2 was replaced.

2/17/2010 3

The 5-kV switchgear was installed before Test IS3. The motor 

starters for both MOV-1 and MOV-2 were transferred to the chassis 

housing the 1" solenoid and large coil.

2/23/2010 1

3/1/2010 5 CT-35 transducer monitoring S conductor on the Large Coil started to 

perform off-normal. This was not detected until data analysis.

3/3/2010 6

3/4/2010 7

3/17/2010 9

3/25/2010 10

3/26/2010 Conting.-1 Contingency tests - Only cables for 5-kV switchgear were tested in 

Contingency tests 1 and 2. 3/29/2010 Conting.-2

47

6. SUMMARY OF TEST RESULTS

6.1 dc Motor Starter (MOV) Results 

6.1.1 Penlight Small-Scale Tests 

Fifteen small-scale tests were conducted using the dc MOV starters. Each test included two dc

MOV starter circuits. Each MOV circuit consisted of a “Close” contactor unit and an “Open” 

contactor unit. The contactors are operated via a coil that when energized pulls in a movable 

core assembly, which forces the main power contacts to close. The main power connections 

were not used during these tests. The MOV control circuits were designated as MOV-1 (open), 

MOV-1 (close), MOV-2 (open), and MOV-2 (close). 

Table 6-1 provides a summary of the small-scale test matrix. As shown in the table, the scope 

of these tests covered all of the cable types available for the DESIREE-Fire project. Five TSinsulated cable types and three TP-cables were included in the test series. The MOV circuit 

cables were exposed to the Penlight thermal environment in a cable tray configuration with the 

exception of Tests 37 and 41 where the cables were routed through a rigid metal conduit (both 

circuits and the thermal cable were co-located in the same conduit). 

Table 6-1 Small-scale test matrix – dc MOVs. 

Burn 

Test #

Cable Insulation Material Exposure 

Shroud 

Temp (oC)

Raceway Type Thermoset Thermoplastic

XLPE / 

CSPE EPR SR Kerite® Armored Tefzel PE / PVC

PVC / 

PVC Tray Conduit

7 X 470 X

8 X 470 X

12 X 325 X

22 X 470 X

25 X 470 X

27 X 700 X

30 X 325 X

33 X 325 X

37 X 525 X

41 X 525 X

43 X 275 X

44 FR 325 X

49 FR 400 X

50 FR 450 X

JPN-3 JNES-supplied cable 350 X

Table 6-2 provides a summary of the small-scale test results for the MOV circuits. Of the 30

circuit tests run, 20 resulted in SAs and 5 in clearing of one or both 10-A fuses as the initial fault 

mode. The summary table includes the first failure as well as the failure mechanism (e.g., SA or 

FB). Circuits with an asterisk (*) may have experienced multiple SAs; however, the appropriate 

appendices should be reviewed for more detailed information on the number of operations and 

duration of each operation. The longest duration SA was approximately 60 minutes and 

occurred in Test 43. This particular event preceded other SAs (i.e., locking in for a period of 

time and subsequently clearing for a period of time) of 23, 10, and 24 minutes, and 31 second 

durations. With the exception of the 31-second duration, the open coil on MOV-2 experienced 
48

each of the SAs. Figure 6-1 through Figure 6-4 show the temperature profile during the test, the 

current and voltage response of both MOV circuits during the test (two different time frames), 

and the behavior of the battery ground-fault monitoring system. Additional information for each 

test may be found in Appendix B. 

Table 6-2 Results summary – dc MOV. 

Test # MOV Mode Time to Damage

(seconds)

Duration

(seconds) Coil

7

1 SA 538 32 Open

2 FB 564 - - - - - -

8

1 SA 538 8 Open

2 FB 514 - - - - - -

12 1 SA 859 203 Open

2 DNF DNF - - - - - -

22 1* SA 585 2 Open

2* SA 596 37 Open

25 1 SA 613 10 Close

2* SA 570 2 Close

27 1 DNF DNF - - - - - -

2 DNF DNF - - - - - -

30 1 SA 1436 90 Open

2 SA 1076 1439 (~24 minutes) Open

33 1 FB 627 - - - - - -

2 FB 575 - - - - - -

37 1 SA 1681 30 Close

2 SA 1723 16 Close

41 1* SA 2699 60 Open

2* SA 1307 98 Close

43 1* SA 11266 94 Open

2* SA 2776 3583 (~60 minutes) Open

44 1 SA 9073 1203 Close

2 SA 10043 306 Open

49 1 SA 4394 7 Close

2 SA 4823 1 Open

50 1 FB 1334 - - - - - -

2 SA 1242 22 Close

JPN-3

1 SA 2626 240 Open

2 SA 2308 194 Open

SA = Spurious Actuation

FB = Fuse Blow

DNF = Did Not Fail
49

Figure 6-1 Test #43 temperature profile 

Figure 6-2 Test #43 MOV-1 and MOV-2 voltage/current plots 

Time (s)

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000

Temperature (C)

0

100

200

300

400

500

600

700

1st Cable Failure (2776s - 210C)

Penlight

Cable 1

Cable 2 

MOV-1 Voltage Plot

Time (s)

11200 11250 11300 11350 11400 11450

Voltage (Vdc)

-150

-100

-50

0

50

100

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-1 Current Plot

11200 11250 11300 11350 11400 11450

Current (Amps)

-0.5

0.0

0.5

1.0

MOV-2 Voltage Plot

Time (s)

2000 3000 4000 5000 6000 7000

Voltage (Vdc)

-150

-100

-50

0

50

100

MOV-2 Current Plot

2000 3000 4000 5000 6000 7000

Current (Amps)

-1.0

-0.5

0.0

0.5

1.0

Time (s) Time (s)
50

Figure 6-3 Test #43 additional MOV-2 voltage/current plots 

Figure 6-4 Test #43 ground voltage monitoring circuit indication 

MOV-2 Voltage Plot

Time (s)

9500 10000 10500 11000 11500

Voltage (Vdc)

-200

-150

-100

-50

0

50

100

MOV-2 Current Plot

9500 10000 10500 11000 11500

Current (Amps)

-2.0

-1.5

-1.0

-0.5

0.0

0.5

1.0

Time (s) Time (s)

MOV-2 Current Plot

7000 7500 8000 8500 9000 9500

Current (Amps)

-1.0

-0.5

0.0

0.5

1.0

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2 Voltage Plot

Time (s)

7000 7500 8000 8500 9000 9500

Voltage (Vdc)

-200

-150

-100

-50

0

50

100

Time (s)

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000

Voltage (VDC)

-180

-150

-120

-90

-60

-30

0

30

60

90

120

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
51

One test worth noting here is Test 27, during which neither cable failed. This test used the SRinsulated cable. The CAROLFIRE tests had already indicated that this cable was unlikely to fail 

during Penlight testing, but CAROLFIRE used exclusively ac-powered test circuits. Test 27 was 

included in DESIREE-Fire to see if the same behavior would apply to a dc-powered circuit. The 

results indicate that the SR cable behaves similarly for dc circuits as it did with ac circuits; that 

is, despite a prolonged high-temperature exposure (700 oC) the cable did not experience 

electrical shorting. The Penlight tests do not involve cable wetting, which CAROLFIRE showed 

would cause cable failure following such a thermal exposure. 

A second somewhat anomalous test worth noting is Test 43. At the request of the peer review 

committee, this test involved a TP cable (PE/PVC) and a relatively low Penlight shroud 

temperature (275 oC). Given this exposure, the failure time for one of the two test cables was 

quite extended (i.e., over three hours). This is simply indicative of an exposure placed the cable 

in thermal equilibrium at a temperature very near its failure threshold. The lower-exposure 

temperatures were used in testing to provide some assessment as to whether SA durations 

might be a function of the exposure conditions. Although this methodology differed from the 10- 

to 20-minute failure threshold used during CAROLFIRE, the peer review committee suggested 

that DESIREE-Fire provided the opportunity to investigate failure mechanisms for prolonged 

low-temperature exposures. The actual analysis and assessment of the data in this context lies 

beyond the scope of this report. 

6.1.2 Intermediate-Scale Tests 

Thirteen intermediate-scale tests were conducted using the dc MOV starters. Each test 

included two dc MOV starter circuits. However, unlike the Penlight tests, the two individual 

MOV circuit test cables were not routed through the intermediate-scale test cell together. For 

most cases, the MOV-1 cable was routed along with the SOV-1 test cable, and MOV-2 with 

SOV-2.

Only four TS-insulated cable types and one TP type were included in the intermediate-scale 

tests. SR, Tefzel, and PVC insulation cables were not connected to the MOV circuits during any 

of the intermediate-scale tests. Two of the intermediate-scale tests had the MOV-1 cable routed 

in rigid conduit. The rest of the tests were run with the MOV cables routed in cable trays, usually 

with other fill cables surrounding the test cables. 

Table 6-3 provides the test matrix used for the intermediate-scale tests of the MOV cables. 

Table 6-4 provides a summary of the intermediate scale test results for the MOV circuits. Of the 

26 circuit tests run, 13 resulted in SAs as the initial failure mode and 7 in clearing of one or both 

10A fuses. The longest duration of a SA was over 6.5 minutes. Circuits with an asterisk (*) may 

have experienced multiple SAs; however, the appropriate appendices should be reviewed for 

more detailed information on the number of operations and duration of each operation. 

Additional details about each of the MOV intermediate-scale tests are provided in Appendix B. 

6.2 Small dc SOV Results 

The dc solenoids are operated via an electromagnetic coil that when energized pulls in a 

movable core, which forces the valve stem to change position. The SOVs are spring-loaded so 

that when electric power is removed from the solenoid the valve returns to its unpowered 

condition. The two dc SOV control circuits were designated as SOV-1 and SOV-2.
52

Table 6-3 Intermediate-scale test matrix for the dc MOV starters. 

Burn 

Test # Device

Cable Insulation Material

Exposure 

Location

Raceway Type Thermoset Thermoplastic

XLPE / 

CSPE EPR SR Kerite® Armored Tefzel PE / PVC

PVC / 

PVC Tray Conduit

Pre-2

(IS)

MOV-1 X A X

MOV-2 X E X

1

MOV-1 X B X

MOV-2 X D X

2

MOV-1 X A X

MOV-2 X C X

3

MOV-1 X D X

MOV-2 X B X

4

MOV-1 X A X

MOV-2 X C X

5

MOV-1 X B X

MOV-2 X D X

6

MOV-1 X C X

MOV-2 X A X

7

MOV-1 X B X

MOV-2 X D X

8

MOV-1 X A X

MOV-2 X C X

9

MOV-1 FR B X

MOV-2 X D X

10

MOV-1 FR C X

MOV-2 FR

with 

zinc

B X

11 MOV-1 X B X

MOV-2 X D X

12 MOV-1 X A X

MOV-2 X B X

6.2.1 Penlight Small-Scale dc SOV Tests 

Ten tests were conducted in Penlight using two small SOV circuits per test for a total of 20 data 

points. Table 6-5 provides the matrix for the small-scale SOV circuit tests indicating the cable 

types, raceway configuration, and shroud exposure temperature (oC). As indicated in the table, 

only Kerite®and the JNES cables were not tested as one of the small SOV circuit cables. 

Table 6-6 provides a summary of the results of the dc SOV cable tests. Of the 20 circuit cables 

tested, 11 initially failed by SA of the valve, 6 first failed by clearing one or both of the 5A circuit 

fuses, and 3 cables did not fail. The longest of the SA durations was more than 21 minutes, 

occurring during Penlight Test #38. The test was concluded before the SA was cleared and 

denoted with a “greater than” (>) symbol in the summary table. Circuits with an asterisk (*) may 

have experienced multiple SAs; however, the appropriate appendices should be reviewed for 

more detailed information on the number of operations and duration of each operation. 

Additional insights may be gained from Appendix C. 
53

Table 6-4 Intermediate-scale results summary – dc MOVs. 

Test # MOV Mode Time to Damage

(seconds)

Duration

(seconds) Coil

Pre-2 (IS) 1 FB 343 - - - - - -

2 SA 820 401 Open

1

1 SA 1475 83 Open

2 HS 2617 44 Close

2

1 SA 4247 115 Open

2* HS 1116 26 Close

3

1 SA 2784 3 Open

2* SA 1078 12 Open

4

1 SA 1859 36 Open

2 HS 4967 7 - - -

5

1 SA 1717 17 Open

2* HS 1500 73 Close

6

1 SA 1480 27 Close

2 FB 336 - - - - - -

7

1 FB 324 - - - - - -

2 FB 535 - - - - - -

8

1 SA 1052 97 Close

2 FB 1743 - - - - - -

9

1 SA 2611 16 Close

2 SA 1253 24 Open

10 1* SA 3584 7 Open

2 HS 2798 37 Close

11 1 SA 1179 18 Open

2 FB 2749 - - - - - -

12 1 FB 3031 - - - - - -

2 HS 2233 107 Close

HS = Hot Short; SA = Spurious Actuation; FB = Fuse Blow; DNF = Did Not Fail

Table 6-5 Small-scale test matrix – small dc SOVs. 

Test 

#

Cable Insulation Material Exposure 

Shroud 

Temp (oC)

Raceway Type Thermoset Thermoplastic

XLPE / 

CSPE EPR SR Kerite® Armored Tefzel PE / PVC

PVC / 

PVC Tray Conduit

1 X 470 X

2 X 470 X

9 X 325 X

20 X 470 X

23 X 470 X

26 X 700 X

28 X 325 X

31 X 325 X

34 X 525 X

38 X 450 X
54

Table 6-6 Small-scale test results summary – small dc SOVs. 

Test # SOV Mode Time to Damage

(seconds)

Duration 

(seconds)

1

1 FB 597 - - -

2* SA 542 21

2

1 FB 648 - - -

2* SA 560 23

9

1 SA 864 22

2* SA 827 35

20 1 SA 502 24

2* SA 508 20

23 1 SA 487 5

2 FB 498 - - -

26 1 DNF - - - - - -

2 DNF - - - - - -

28 1 FB 3384 - - -

2 SA 3393 297

31 1 SA 517 3

2 FB 432 - - -

34 1* SA 1728 3

2 FB 1644 - - -

38 1 DNF - - - - - -

2 SA 1163 >1312

While no statistical analyses have been performed, there does not appear to be any obvious 

differences in behavior between the two valve circuits. That is, the presence of the Class H coil 

in SOV-2 does not appear to have grossly impacted circuit behavior. Both SOV circuits again 

show similar ratios of FB and spurious operation failures, and there is no obvious distinction 

relative to SA duration (i.e., neither valve showed an obvious trend towards longer or short 

duration spurious operation events). 

6.2.2 Intermediate-Scale SOV Tests 

Thirteen tests were conducted using the small dc SOVs during the intermediate-scale test 

series. Each test included two dc SOV circuits. Table 6-7 provides the intermediate-scale test 

matrix for the small SOV circuits indicating the cable types, raceway configuration, and location 

in the intermediate-scale test cell. As shown in the table, at least one test was run on a small 

SOV cable that included each of the available TS materials. On the other hand, the SOV 

circuits tested using TP materials only employed PE/PVC cables, not Tefzel or PVC. The SOV 

cables were generally run in cable trays, and bundled with other cables. Only two tests were 

conducted that routed a SOV-1 cable through the rigid metal conduit at location B in the 

intermediate-scale test cell. 

A summary of the SOV circuit responses to the cable damage caused by the intermediate-scale 

fire environments is provided in Table 6-7. Of the 26 SOV circuit cables tested, 14 resulted in 

an initial SA failure while the rest (12) were characterized by initially clearing of one or both 5A 

circuit fuses. The longest duration of a spurious SOV actuation occurred during Test IS9 on 

SOV-1 where the event lasted for just less than two minutes. Circuits with an asterisk (*) may 

have experienced multiple SAs; however, the appropriate appendices should be reviewed for 

more detailed information on the number of operations and duration of each operation. As was 
55

observed for the Penlight test, while no statistical analyses have been performed, there do not 

appear to be any obvious differences behavior between the two valve circuits. 

Table 6-7 Intermediate-scale test matrix for the small SOVs. 

Burn 

Test # Device

Cable Insulation Material

Exposure 

Location

Raceway Type Thermoset Thermoplastic

XLPE / 

CSPE EPR SR Kerite® Armored Tefzel PE / PVC

PVC / 

PVC Tray Conduit

Pre-2

(IS)

SOV-1 X A X

SOV-2 X E X

1

SOV-1 X B X

SOV-2 X D X

2

SOV-1 X C X

SOV-2 X A X

3

SOV-1 X D X

SOV-2 X B X

4

SOV-1 X A X

SOV-2 X C X

5

SOV-1 X B X

SOV-2 X D X

6

SOV-1 X C X

SOV-2 X A X

7

SOV-1 X B X

SOV-2 X D X

8

SOV-1 X A X

SOV-2 X C X

9

SOV-1 FR B X

SOV-2 X D X

10

SOV-1 FR C X

SOV-2 FR 

with 

zinc

B X

11 SOV-1 X B X

SOV-2 X D X

12 SOV-1 X D X

SOV-2 X B X

6.3 Large dc Coil and 1-Inch Solenoid Operated Valve (1”) Results

The dc solenoids are operated via an electromagnetic coil that when energized pulls in a 

movable core, which forces the valve stem to change position. The 1-in. SOV is spring-loaded 

so that when electric power is removed from the solenoid the valve returns to its unpowered 

condition. The large coil consisted solely of a large (approximately 0.4m high by 0.3m diameter) 

electromagnetic coil enclosed in a stainless steel container. No movable core was part of the 

large coil unit. The two control circuits for these devices were designated as Large Coil (LC) 

and 1-Inch SOV (1-in.).

6.3.1 Penlight Small-Scale dc Large Coil and 1” SOV Tests

Five tests were conducted in Penlight using the large coil and the 1-in. SOV circuits. Table 6-8 

provides the test matrix for the small-scale tests of these SOV circuits indicating the cable types, 
56

raceway configuration, and shroud exposure temperature (oC). As indicated in the table, only 

XLPE/CSPE and PE/PVC cables were tested with these circuits. 

The large coil is a low pick-up coil and the manufacturer10 (Target Rock) has designed the 

magnetics of the coil to pick between 60V to 70V. This large coil has a 36-ohm (+/- 6%) 

resistance. 

Table 6-9 provides a summary of the results of the large coil and 1” SOV cable tests. Of the ten 

circuit cables tested, seven initially failed by SA of the valve coil and three first failed by clearing 

one or both of the circuit fuses. The longest of the SA durations was just over one minute, 

occurring during Penlight Test #40. Circuits with an asterisk (*) may have experienced multiple 

SAs; however, the appropriate appendices should be reviewed for more detailed information on 

the number of operations and duration of each operation. Additional details may be found in 

Appendix D. 

Table 6-8 Small-scale test matrix – large coil and 1" SOV. 

Test 

#

Cable Insulation Material Exposure 

Shroud 

Temp (oC)

Raceway Type Thermoset Thermoplastic

XLPE / 

CSPE EPR SR Kerite® Armored Tefzel PE / PVC

PVC / 

PVC Tray Conduit

5 X 470 X

6 X 470 X

11 X 325 X

36 X 525 X

40 X 450 X

Table 6-9 Small-scale test results summary – large coil and 1" SOV. 

Test # SOV Mode Time to Damage

(seconds)

Duration 

(seconds)

5

LC SA 616 2

1”* SA 643 5

6

LC FB 677 - - -

1” SA 597 <1

11 LC* SA 1000 52

1”* SA 798 11

36 LC FB 1743 - - -

1” SA 1611 13

40 LC* SA 4100 64

1” FB 4167 - - -

During Penlight small-scale Test #11, both the large coil and the 1-inch SOV experienced 

multiple SAs during the course of the test run. For the large coil the first SA lasted 52 seconds 

and the second, which occurred about five minutes later, lasted over 1000 seconds, until the 

circuit fuse cleared. Similarly, the first 1-inch SOV SA lasted 11 seconds and the second lasted 

798 seconds, also starting about five minutes after the end of the first one. The end of the 

second SA of the 1-in. SOV was caused by the clearing of its circuit fuse. 

 

10 Point of contact is Steve Pauly. 
57

Figure 6-5 through Figure 6-7 provide the temperature profile during Penlight Test #11, the 

current and voltage response of both circuits during the test, and the behavior of the nominal 

125Vdc battery ground monitoring system. 

Figure 6-5 Penlight Test #11 temperature profile 

6.3.2 Intermediate-Scale dc Large Coil and 1” SOV Tests

Thirteen tests were conducted using the large coil and 1-in. SOV circuit cables. Table 6-10

provides the intermediate-scale test matrix for these large coil and 1-in. SOV circuits indicating 

the types of cables tested, the raceway configuration, and the location in the intermediate-scale 

test cell. As shown in the table, at least one test was run with the large coil and 1-in. circuit 

cables that included each of the available TS materials except for SR. On the other hand, these 

SOV circuits tested using TP materials only employed PE/PVC cables, not Tefzel or PVC. The 

large coil and 1-in. cables were generally run in cable trays bundled with other cables except for 

Test IS7, where the cables were routed through rigid metal conduit in test cell location B. 

A summary of the large coil and 1-in. SOV circuits‟ response to the cable damage caused by the 

intermediate-scale fire environments is provided in Table 6-12. Of the 13 1-in. SOV circuit 

cables tested, 7 resulted in an initial SA failure while 5 were characterized by initially clearing of 

one or both circuit fuses; no failures occurred during Preliminary Test 1 (Pre-1 (IS)). The 

longest duration of a spurious 1-in. SOV actuation occurred during Test IS6, where the event 

lasted for just less than 1.5 minutes. 

Time (s)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

100

200

300

400

500

600

700

Penlight 

Cable 1 

Cable 2 

1st Failure (1089s - 264C)
58

Table 6-10 Intermediate-scale test results summary – 1-in. SOV. 

Test # SOV Mode Time to Damage

(seconds)

Duration

(seconds)

Pre-2

1 FB 312 - - -

2 SA 953 67

1

1 FB 1375 - - -

2 SA 2512 11

2

1 SA 3909 68

2 SA 1030 79

3

1 FB 3066 - - -

2* SA 1361 2

4

1 FB 1671 - - -

2 SA 5216 33

5

1 FB 1556 - - -

2* SA 1646 12

6

1 SA 1400 101

2 FB 191 - - -

7

1 SA 302 61

2 FB 466 - - -

8

1 SA 960 92

2 FB 2354 - - -

9

1 SA 2584 112

2 SA 1552 28

10 1 FB 3646 - - -

2 FB 2502 - - -

11 1 FB 1569 - - -

2 SA 2858 59

12 1 SA 3131 5

2 FB 2314 - - -

Of the 13 large coil circuit cables tested, five resulted in an initial SA failure while seven were 

characterized by initially clearing of one or both circuit fuses; no failures occurred during Pre-1 

(IS). The longest duration of a spurious large coil actuation occurred during Test IS8, where the 

event lasted for just less than two minutes. Circuits with an asterisk (*) may have experienced 

multiple SAs; however, the appropriate appendices should be reviewed for more detailed 

information on the number of operations and duration of each operation. Additional insights 

may be gained from Appendix D. 
59

Figure 6-6 Penlight Test #11 1-inch SOV and large coil voltage/current plots 

1000 1200 1400 1600 1800 2000 2200 2400 2600

Voltage (Vdc)

-80

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(G) - V(Batt -) 

V(S) - V(Batt -) 

V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (s)

1000 1200 1400 1600 1800 2000 2200 2400 2600

Current (Amps)

-1

0

1

2

3

4

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

1000 1200 1400 1600 1800 2000 2200 2400 2600

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

V(P) - V(Batt -) 

V(G) - V(Batt -) 

V(S) - V(Batt -) 

V(N2) - V(Batt -) 

Lg Coil Circuit

Time (s)

1000 1200 1400 1600 1800 2000 2200 2400 2600

Current (Amps)

-1

0

1

2

3

4

5

P - Positive

G - Green Lamp

S - Coil

N2 - Negative
60

Figure 6-7 Test #11 ground voltage monitoring circuit indication 

Table 6-11 Intermediate-scale test matrix for the large coil and 1” SOV. 

Burn 

Test 

#

Cable Insulation Material

Exposure 

Location

Raceway Type Thermoset Thermoplastic

XLPE / 

CSPE EPR SR Kerite® Armored Tefzel PE / PVC

PVC / 

PVC Tray Conduit

Pre1

(IS)

X

E X

1 X B X

2 X C X

3 X D X

4 X A X

5 X B X

6 X C X

7 X B X

8 X A X

9 X B X

10

FR

with 

zinc

(LC), 

FR (1” 

SOV)

D X

11 X B X

12 X D X

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

-100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 
61

Table 6-12 Intermediate-scale test results summary – large coil and 1” SOV. 

Test # SOV Mode Time to Damage

(seconds)

Duration

(seconds)

Pre-1 (IS) 1” Circuits did not fail LC

1

1”* SA 1361 16

LC* SA 1449 1

2

1” FB 3975 - - -

LC FB 4492 - - -

3

1”* SA 2188 33

LC FB 2288 - - -

4

1” FB 1671 - - -

LC FB 1675 - - -

5

1” FB 655 - - -

LC SA 819 89

6

1” SA 1548 89

LC FB 1317 - - -

7

1” SA 1713 49

LC FB 1426 - - -

8

1” FB 1137 - - -

LC SA 943 117

9

1” SA 628 10

LC FB 765 - - -

10 1” SA 2635 9

LC FB 2890 - - -

11 1”* SA 1310 2

LC SA 1432 1

12 1” FB 3032 - - -

LC* SA 2746 51

6.4 Switchgear Results 

Medium voltage breakers, or “switchgear,” are designed to provide three-phase electrical power 

to big loads such as large pump motors. The large circuit breaker (switchgear) is operated by 

the action of one of two electromagnetic coils contained within the unit. The “close” coil controls 

the closing of the primary circuit breaker contacts. The other, the “trip coil,” controls the opening 

of the primary contacts. These circuits are typically associated with separate and independent 

cables connected to the control panel on the circuit breaker. These two control circuits are also 

fused separately as well with the trip circuit fused much higher than the closing circuit (e.g., 35A 

versus 15A). 

For DESIREE-Fire, the two circuit cables were kept separate with the exception of one 

intermediate-scale test. The two circuits were identified as “Close” and “Trip.”

6.4.1 Penlight Small-Scale Switchgear Tests 

Ten Penlight small-scale tests were conducted using the two circuit breaker circuit cables. The 

initial condition of the circuit breaker at the start of every Penlight test was Open with the 

actuating spring charged. Table 6-13 provides the test matrix for the small-scale tests of these 

circuits indicating the types of cables tested, the raceway configuration, and the shroud 

exposure temperature (oC). 
62

Table 6-13 Small-scale test matrix – switchgear. 

Test 

#

Cable Insulation Material Exposure 

Shroud 

Temp (oC)

Raceway Type Thermosets Thermoplastics

XLPE / 

CSPE EPR SR Kerite® Armored Tefzel PE / PVC

PVC / 

PVC Tray Conduit

3 X 470 X

4 X 470 X

10 X 325 X

21 X 470 X

24 X 470 X

29 X 325 X

32 X 325 X

35 X 525 X

39 X 470 X

42 X 430 X

JPN1

JNES cable only varies X

JPN2

JNES cable only 350 X

Table 6-14 provides a summary of the results of the switchgear cable tests. Of the 20 circuit 

cables tested, 9 initially failed by SA of the actuating coil and 10 first failed by clearing one or 

both of the circuit fuses. The longest of the SA duration was over 23 minutes, occurring during 

Penlight Test #29 on the close coil circuit. Circuits with an asterisk (*) may have experienced 

multiple SAs; however, the appropriate appendices should be reviewed for more detailed 

information on the number of operations and duration of each operation. Additional insights 

may be gained from Appendix E. 

During Penlight small-scale Test #21, both the close coil and the trip coil circuits experienced a 

very large fault wherein both the 15A and 35A negative side fuses cleared simultaneously. Both 

positive side fuses were found to be intact during the post-test examinations. 

Throughout the course testing, it was not uncommon to see the cable connected to the trip coil 

experience prolonged arcing behavior and conductor severance, but only a limited number of 

tests were investigated in greater detail. Photos from Penlight Tests 3, 10, 29, and JPN2 may 

be found in Appendix E under their respective test sections. It should be emphasized, however, 

that these tests were not the only ones to experience this type of arcing behavior or conductor 

severance. The photos from these experiments were to illustrate some of the behavior 

observed during the course of testing this particular circuit. 
63

Table 6-14 Small-scale test results summary – switchgear. 

Test # Coil Mode Time to Damage

(seconds)

Duration

(seconds)

3

Close SA 721 13

Trip FB 698 - - -

4

Close* SA 625 1

Trip* SA 626 6

10 Close FB 911 - - -

Trip DNF - - - - - -

21 Close FB 963 - - -

Trip FB 963 - - -

24 Close FB 2193 - - -

Trip FB 2288 - - -

29 Close SA 3530 1396

Trip FB 3488 - - -

32 Close SA 607 13

Trip SA 620 11

35 Close SA 1692 87

Trip FB 1738 - - -

39 Close FB 3616 - - -

Trip FB 4175 - - -

42 Close SA 6120 16

Trip SA 6137 26

6.4.2 Intermediate-Scale Switchgear Tests 

As shown in Table 6-15, 12 of the intermediate-scale fire tests included cables that provided 

control to the close and trip circuits for a large circuit breaker. Two different classes of circuit 

breaker were tested: 15kVac and 5kVac. For the most part, the circuit breakers were open with 

their trip springs charged at the beginning of the test. A few of the later tests were conducted 

with the circuit breaker starting in the closed position with the spring charged. Additionally, 

three tests were conducted with the breaker in the closed position and with conductor C1 

electrically connected to PC through a jumper. This arrangement was introduced in order to test 

the behavior of the anti-pump relay in the close circuit inside the breaker. 

Like the Penlight tests, the initial intermediate-scale tests involved the 15-kV circuit breaker. 

However, during one intermediate-scale test, IS Test 8, a severe short in the switchgear close 

test cable caused internal wiring inside the circuit breaker to overheat and generated a lot of 

smoke in the immediate vicinity of the circuit breaker. The test director immediately isolated 

both switchgear circuits by opening the 50- and 60-A breakers, providing battery power to the 

trip and close circuits. Appendix A.4 provides details of this incident and the results of the posttest investigation. After failure of the first breaker, a second, 5-kV class switchgear breaker was 

obtained by EPRI for use in the remainder of the intermediate-scale tests. 

A summary of the switchgear circuits‟ response to the cable damage caused by the 

intermediate-scale fire environments is provided in Table 6-16. Of the 12 switchgear circuit 

tests conducted, seven resulted in an initial SA failure while four were characterized by initially 

clearing of one or both circuit fuses. During Test IS8, a severe HS damaged the switchgear‟s 

internal panel wiring and both the close and trip circuits had to be isolated from the battery. 
64

Most of the SAs were of nominally short durations. Additional insights may be gained from 

Appendix E. 

Table 6-15 Intermediate-scale test matrix for the switchgear. 

Burn 

Test #

Cable Insulation Material

Exposure 

Location

Raceway Type Thermosets Thermoplastics

XLPE / 

CSPE EPR SR Kerite® XLPO Armored Tefzel PE / PVC

PVC / 

PVC Tray Conduit

Pre-1

(IS) X B X

1 X D X

3 X B X

4 X E X

5 X D X

6 X B X

7 X D X

8 X C X

9 X D X

10 FR

with 

zinc

B X

Cont-1 X B X

Cont-2 X B X

During the conduct of the intermediate-scale testing, it was decided to test the functionality of 

the anti-pump feature in the 5-kV switchgear unit. This was accomplished by installing a jumper 

between the terminal block points for PC and C1 in the dc-SIM panel before closing the dc

disconnect switch. This energized the anti-pump relay once dc power was applied to the circuit. 

The breaker was then closed using the manual push button on the front of the switchgear 

cabinet. This initial condition was implemented for IS Tests #10, Contingency-1, and 

Contingency-2.

The expectation was that once the breaker tripped open, then the continuous power being 

supplied to the anti-pump relay (52Y) through the closed 52Y/a contact would prevent a 

spurious reclosure of the circuit breaker main contacts. The anti-pump feature appeared to 

allow a reclosure of the breaker following a trip during the Contingency-1 test. Around the time 

of the three SAs, the battery negative was in a transition to becoming shorted to ground. If the 

potential difference between C1 and N1 momentarily dropped below the holding voltage and 

current needed to keep the anti-pump relay engaged, then it is possible that the relay dropped 

out, allowing voltage from C1 to re-energize the close coil. 
65

Table 6-16 Intermediate-scale test results summary – switchgear. 

Test # SWGR

Size

Bkr Cond

At Start Mode Time to Damage(seconds)

Duration

(seconds) Coil

Pre-1 (IS) 15 kV OPEN SA 502 1 Close

1 5 kV OPEN FB 1255 -.-.- Close

3 5 kV OPEN SA 1460 8 Close

4 15 kV OPEN FB 4766 -.-.- Close

5 5 kV OPEN SA 1424 5 Close

6 5 kV CLOSED SA 850 <1 Trip

7 5 kV CLOSED SA 1095 <1 Trip

8 15 kV OPEN HS 1102 35 Trip

9 5 kV CLOSED FB 1920 -.-.- Close

10 5 kV CLOSED w/

Jumper SA 3108 37 Trip

Cont-1 5 kV CLOSED w/

Jumper SA 406 1 Trip

Cont-2 5 kV CLOSED w/

Jumper FB 337 -.-.- Trip

*Note: The SWGR circuit was not tested in intermediate scale tests 2, 11, and 12.

6.5 Intercable Test Circuit Results 

The DESIREE-Fire tests included an “intercable” test circuit. The test circuit itself is described 

in brief in Section 4.1.2 and in detail in Appendix A.6. The test results for this circuit are 

described in detail in Appendix F. As noted in these descriptions, the circuit and test 

configurations optimized the potential for intercable interactions involving, in particular, the socalled “smart dc hot short”; that is, an intercable short such that one conductor (or group of 

conductors) in a target cable becomes energized at the positive battery potential and a second 

conductor (or group of conductors) in that same target cable becomes energized at the negative 

battery potential. Should such a short form that impacts the target cable, a voltage cascade 

from positive to negative across the outer ring of conductors would form. Hence, the test result 

of primary interest for this circuit is whether or not such a voltage cascade formed. 

6.5.1 Penlight Small-Scale Intercable Tests 

Four Penlight small-scale tests were conducted using the intercable circuit bundles. Table 6-17

provides the test matrix for the small-scale tests of these circuits indicating the cable types, 

raceway configuration, and nominal shroud exposure temperature (oC). For the penlight tests, 

the bundle of five cables was placed on a non-conductive piece of insulation to provide isolation 

from the grounded cable tray. The only way to clear the positive and negative fuses would be 

through intercable shorting; however, shorting through the target cable was the primary interest. 
66

Zip ties were used on the ends of the cable (i.e., far removed from the interior of Penlight) and 

therefore did not contribute to cable performance. Table 6-18 provides a summary of the results 

of the intercable cable tests. 

Table 6-17 Small-scale test matrix – intercable circuits. 

Burn 

Test #

Cable Insulation Material Exposure 

Shroud 

Temp (C)

Raceway Type Thermosets Thermoplastics

XLPE / 

CSPE EPR SR Kerite Armored Tefzel PE / PVC

PVC / 

PVC Tray Conduit

45 X 460 X

46 X 470 X

47 X 350 X

48 X 400 X

Table 6-18 Small-scale test results summary – intercable circuits. 

Test # Mode Time to Damage

(seconds)

45 HS 1550

46 HS 1000

47 HS 2240

48 HS 550

Of the four intercable bundles tested, all indicated cable-to-cable interactions between the target 

cable and one or more of the energized source cables. This was not unexpected given the test 

configuration, which, as noted above, was designed to optimize the potential for such 

interactions. In Tests 45, 46, and 48 the intercable interactions occurred only after the target 

cable had failed internally. This is apparent in that as the target conductors become energized 

(in either the positive or negative direction relative to ground) all of the conductors in the outer 

ring (conductors 2-7) will become energized to the same voltage level. Often in such cases, the 

central conductor, which was not a part of the target cable resistor network, would show an 

independent intermediate voltage, indicating that gross cable damage had not propagated fully 

to the center conductor. Previous testing has consistently shown that the conductors in the 

outer ring will generally fail first with the inner conductor (or conductors) failing some time later. 

Hence, the intercable test results are consistent with prior testing in this regard. 

Penlight Test 47, involving the PE/PVC TP cable, is the only test that shows signs of the 

anticipated voltage cascade across the target conductors beginning to form. Figure 6-8 

illustrates the results for this test. Approximately 2240 seconds into the test, initial intercable 

interactions were observed. It was not until 4350 seconds into the experiment, however, that 

positive and negative interactions occurred. The Target 5 conductor shorted to a positive 

source, which is indicated by the 10Vdc increase. Concurrently, Target 2 shorted to a negative 

source and decreased by approximately 10Vdc. This cascade effect illustrates the fact that the 

target cable had not completely failed internally before the interaction with two of the source 

cables. Had internal shorting occurred before intercable behavior, the conductors of the target 

cable would become energized to the same voltage level. 
67

Figure 6-8 Penlight Test #47 cascade effect indicating intercable interaction 

6.5.2 Intermediate-Scale Intercable Circuit Tests 

Thirteen intermediate scale tests were conducted using the five cable intercable bundles 

designed to reveal cable-to-cable interactions. Table 6-19 provides the test matrix for the 

intercable circuits indicating the cable types, raceway configuration and location in the 

intermediate-scale test cell. 

A summary of the intercable circuits‟ response to the cable damage caused by the intermediate 

scale fire environments is provided in Table 6-20. Of the 13 circuit tests conducted, seven 

resulted in an indication of intercable (source-to-target) interactions. However, in all 7 cases, 

the target cable had failed internally before the intercable interactions. The source circuit fuses 

cleared, indicating intercable shorting between the source cables, before any interactions with 

the target cable in five of the tests. No cable failures occurred during the intermediate-scale 

Preliminary Test 1 (Pre-1 (IS)).

Time (s)

2000 3000 4000 5000 6000 7000 8000

Voltage (Vdc)

40

50

60

70

80

T1-V(Batt-) 

T2-V(Batt-) 

T3-V(Batt-) 

T4-V(Batt-) 

T5-V(Batt-) 

T6-V(Batt-) 

T7-V(Batt-) 
68

Table 6-19 Intermediate-scale test matrix for the intercable circuits. 

Burn 

Test 

#

Cable Insulation Material

Exposure 

Location

Raceway Type Thermoset Thermoplastic

XLPE / 

CSPE EPR SR Kerite® Armored Tefzel PE / PVC

PVC / 

PVC Tray Conduit

Pre1

(IS)

X

D X

1 X C X

2 X D X

3 X A X

4 X B X

5 X C X

6 X D X

7 X A X

8 X B X

9 X C X

10 X A X

11 X C X

12 X A X

A typical case is illustrated by Test IS10. During this test it appears that the center conductor in 

the target cable had not shorted to the outer ring of conductors during the early part of the 

intercable interaction. Figure 6-9 provides a plot of the target conductor voltages measured 

during Test IS10, where T1 is the center conductor. Note that most of the voltage signals (T2 

through T7) overlap completely, indicating that all six conductors in the outer ring were shorted 

together. This case simply indicates that the outer ring of conductors in the target cable had all 

shorted together, and that the negative source cable was interacting with those conductors 

through a high-resistance intercable short. The center conductor of the target cable retained 

some degree of insulation resistance relative to the other conductor in the target cable; hence, it 

shows an intermediate voltage between the outer ring conductors and ground. At approximately 

750 seconds, the central conductor shorts more completely to the outer ring conductors and the 

positive source conductors become the predominant source for the intercable shorting. Again, 

the energizing voltages were insufficient to induce a SA for this case. 

Table 6-20 Intermediate-scale test results summary – intercable circuits. 

Test # Mode Time to Damage

(seconds)

Pre-1 (IS) n/a No failure

1 HS 2520

2 FB 1110

3 HS 461

4 FB 1675

5 FB 1760 & 2026

6 FB 336

7 FB 448

8 HS 1481

9 HS 1602

10 HS 514

11 HS 3184

12 HS 1222
69

Figure 6-9 Intercable target conductor voltages measured during intermediate-scale test

IS10 

6.5.3 Summary of the Intercable Circuit Tests 

The tests did show a number of intercable HSs occurring, but that is not unexpected given that 

the test configuration was designed to optimize the potential for intercable HSs. HSs were 

observed in 4-of-4 Penlight tests and 7-of-12 intermediate-scale tests (where failure occurred; in 

one intermediate-scale test the circuit did not fail). In no case was an intercable smart dc HS

observed. Penlight Test 47 involved the only substantive case where sign of a potentially 

forming smart dc HS appeared, and in that case the signs were rather weak. The energizing 

voltage difference observed on the target cable reached a maximum of only about 15Vdc, 

indicating that the cable-to-cable resistance values, while degrading, remained quite high. The 

voltages imposed on the target conductors in this case were not sufficient to induce a spurious 

operation. 

6.6 SCDU Test Results 

Four ac-powered SCDUs were used to simulate ac MOV control circuits. The four separate 

units were designated as SCDU-1, SCDU-2, SCDU-3, and SCDU-4. The units were originally 

built for, and used in, the CAROLFIRE project. Each SCDU includes a pair of ac-powered 

NEMA Class 1 motor starter contactor units and a CPT that provides 120Vac (nominal) power to

the control circuit. A detailed discussion of the SCDU systems is provided in Appendix A.6. 

For the purposes of DESIREE-Fire the original CAROLFIRE motor control contactor units were 

replaced with Joslyn-Clark units identical to those used in the original NEI-EPRI tests. Of the 

Time (s)

400 500 600 700 800 900

Voltage (Vdc)

-80

0

80

Int-Cab_VT7-T1 

Int-Cab_VT7-T2 

Int-Cab_VT7-T3 

Int-Cab_VT7-T4 

Int-Cab_VT7-T5 

Int-Cab_VT7-T6 

Int-Cab_VT7-T7 
70

four contactor sets, all had intact electrical interlocks, but only three of the four had intact 

mechanical and electrical interlocks in place. SDCU-1 utilized one of two contactor sets 

provided by EPRI and that particular set did not have mechanical interlocks in place. SNL 

tested the unit as received from EPRI. 

The primary objective for DESIREE-Fire relative to the SCDUs was to investigate the impact of 

CPTs effect on the likelihood of SAs. In the original NEI/EPRI tests of 2000 there was an 

apparent effect on SA likelihood due to saturation of the limited-power CPTs, which led to 

degradation of the source voltage to below the contactor minimum pick-up voltage before SAs 

could occur in some tests. Overall, the CPT effect was attributed with reducing SA likelihood by 

a factor of two based on expert judgment [3]. This same effect was not observed in any of the 

CAROLFIRE tests, but those tests had used different contactor sets that had lower power 

demand and lower pick-up voltages. DESIREE-Fire includes follow-up investigations on this 

specific issue. 

Each SCDU supplies circuit power through a CPT of specified rating: SCDU-1 used a 100VA 

CPT, SCDU-2 used a 150VA CPT, SCDU-3 used a 200VA CPT, and SCDU-4 used a 75VA 

CPT. The intent was to attempt to determine what, if any, impact on a nominal 100VA circuit 

that a CPT of a given rating might have on limiting the available voltage-current to induce a SA

of one of the two target motor starters. The secondary side of all CPTs was grounded on the 

return side and fused at 3A on the line side. For each of the circuits, the two MOV contactor 

coils were identified as Target 5 and Target 6. 

Note that after completion of Test IS12, the SCDU data logging capability was re-tasked to allow 

for high-speed monitoring of certain of the dc current transducer signals. Hence, the 

intermediate-scale tests performed after Test IS12 did not utilize the SCDUs. 

6.6.1 Penlight Small-Scale Tests 

Thirteen small-scale Penlight tests were conducted using the SCDUs. With the exception of 

Tests #13-Qual and #17-Qual, each Penlight test included two of the four available SCDU 

circuits. Table 6-21 provides a summary of the small-scale test matrix for these 13 tests. As 

shown in the table, the scope of these tests covered Kerite® cable types available for the 

DESIREE-Fire project; however, the four preliminary tests used XLPE/CSPE and PE/PVC 

cables. One armored cable test was included in the test series. 

Table 6-22 provides a summary of the small-scale test results for the SCDU circuits. Of the 24 

circuit tests run, nine resulted in SAs and 13 in clearing of the circuit fuse. The longest duration 

of a SA was 57 minutes. 

Figure 6-10 shows the current and voltage response of all the conductors of the cable 

connected to SCDU-1 during Penlight Test 17. Recall that SCDU-1 had a 100-VA CPT. In this 

one case it appears that the degradation in the source voltage, beginning around 1750 seconds, 

was sufficient to prevent the actuation of either target coil despite HSs to both target conductors. 

This voltage degradation effect is likely due to the limited capacity of the 100VA CPT to supply 

all of the leakage currents being developed at that time. This effect was not noted in any of the 

other Penlight test results. 
71

Table 6-21 Small-scale test matrix – ac MOVs. 

Burn 

Test #

Cable Insulation Material

Exposure 

Shroud 

Temp (oC)

Raceway 

Thermoset Thermoplastic Type

XLPE / 

CSPE

EPR

SR

Kerite

®

Armored

Tefzel

PE / PVC

PVC / 

PVC

Tray

Conduit

Pre-1 (P) X 470 X

Pre-2 (P) X 470 X

Pre-3 (P) X 325 X

Pre-4 (P) X 325 X

13_qual FR-z Varied X

13 FR-z 350 X

14 FR-z 450 X

15 FR-z 300 X

16 FR-z 470 X

17_qual HTK Varied X

17 HTK 430 X

18 HTK 420 X

19 X 470 X

Notes: FR-z refers to Kerite® FR with a zinc wrap. 

 HTK refers to Kerite® HTK (high temperature cable). 
72

Table 6-22 Results summary – ac MOV Penlight tests. 

Test # SCDU Mode Time to Failure

(seconds)

HS/SA Duration

(seconds) Coil

Pre-1 (P) 1 SA/HS 550 41 T6/T5

2 SA 563 41 T6

Pre-2 (P) 1 SA 1186 64 T6

2 SA 1226 54 T6

Pre-3 (P) 1 FB 886 - - - - - -

2 FB 912 - - - - - -

Pre-4 (P) 1 SA/HS 878 292 T6/T5

2 SA 845 27 T5

13-Qual 1 SA 3360 ~1440 T6

13 1 SA 4575 ~1 T6

2 FB 4590 - - - - - -

14 1 FB 964 - - - - - -

2 FB 964 - - - - - -

15 1 DNF - - - - - - - - -

2 DNF - - - - - - - - -

16 1 FB 834 - - - - - -

2 FB 750 - - - - - -

17-Qual 1 FB 2769 - - - - - -

17 1 FB 1848 - - - - - -

2 FB 1900 - - - - - -

18 1 FB 5807 - - - - - -

2 SA 5665 35 T6

19 1 FB 586 - - - - - -

2 FB 585 - - - - - -

6.6.2 Intermediate-Scale SCDU Tests 

Six intermediate-scale tests were conducted involving the SCDUs. Table 6-23 provides the test 

matrix for the intermediate scale tests that included the SCDUs. This matrix shows the cable 

types, raceway configuration, and location in the test cell. 

Table 6-24 summarizes the results of the intermediate scale SCDU tests. Of the 18 SCDU 

circuits tested, seven initially experienced a SA of one of the motor starter units, nine cleared 

the circuit fuse as the initial failure, and two circuits did not fail in one of the tests. The longest 

duration for a spurious operation was 102 seconds on SCDU-1 during Test IS8. 

Insofar as the effect that the CPTs had on limiting SAs in the SCDU circuits, it does not appear 

that the CPTs limited the ability of the circuit voltage-current to any degree that would prevent 

the occurrence of a SA during any of the intermediate-scale tests. Figure 6-11 illustrates one of 

the more pronounced cases where degradation of the source voltage was observed, but only 

after SAs had already occurred. Shown below in Figure 6-10 and Figure 6-11 are the voltage 

and current plots for SCDU-4 (75VA CPT) during Test IS4. 

Test IS4 does show substantial degradation of the source voltage, but only relatively late in the 

test and well after SA had occurred on contactor T5. As shown in Figure 6-11, the T5 motor 

starter experiences a HS and causes a SA at 4606 seconds. At 4619 to 4627 seconds, the T6 

motor starter conductor also experiences a HS but does not actuate because the energized T5 
73

device has locked the T6 contactor out mechanically and electrically. At 4657 seconds, the 

circuit voltage dropped below the drop-out threshold for SCDU-4 contactor T5 and shortly 

thereafter both T5 and T6 begin chattering in response to continued HSs, but neither contactor 

locked in. This occurred during the time that multiple leakage current flow paths have evidently 

developed, yet there is still enough source voltage and current available to elicit responses from 

the motor starters. The SCDU-4 circuit fuse clears at 4672 seconds. 

Figure 6-10 Penlight Test #17 SCDU-1 voltage and current plots 

0

20

40

60

80

100

120

140

1700 1750 1800 1850 1900

Volts AC

Time (s)

All Measured Voltages for Circuit 1

C1 V1

C1 V2

C1 V3

C1 V4

C1 V5

C1 V6

C1 V7

C1 V8

0

1

2

3

4

5

6

1700 1750 1800 1850 1900

Current (A)

Time (s)

All Measured Currents Circuit 1

C1 A1

C1 A2

C1 A3

C1 A4

C1 A5

C1 A6

C1 A7

C1 A8
74

Table 6-23 Intermediate-scale test matrix for the SCDU circuits. 

Burn Test #

SCDU ID

Cable Insulation Material

Exposure 

Location

Raceway 

Thermoset Thermoplastic Type

XLPE / 

CSPE

EPR

SR

Kerite

®

Armored

Tefzel

PE / PVC

PVC / 

PVC

Tray

Conduit

Pre-1

(IS)

3 X C X

4 X C X

Pre-2

(IS)

1 X D X

2 X D X

4

1 X D X

2 X D X

3 X D X

4 X D X

8

1 X D X

2 X D X

3 X D X

4 X D X

11

1 X A X

2 X A X

3 X A X

12

1 X C X

2 X C X

3 X C X

Table 6-24 Intermediate-scale test results summary – SCDUs. 

Test # SCDU Mode Time to Damage

(seconds)

Duration

(seconds)

Pre-1 (IS) 3 DNF* - - - - - -

4 DNF - - - - - -

Pre-2 (IS) 1 FB 628 - - -

2 FB 633 - - -

4

1 SA 4381 44

2 SA 4015 48

3 SA 4602 4

4 SA 4606 41

8

1 SA 1174 102

2 FB 2035 - - -

3 FB 515 - - -

4 FB 1732 - - -

11

1 SA 895 5

2 FB 921 - - -

3 FB 811 - - -

12

1 SA 3795 62

2 FB 3541 - - -

3 FB 2923 - - -

* DNF indicates SCDU did not fail. 
75

Figure 6-11 Test IS4 intracable target conductor current and voltage plots for SCDU 4 

0

20

40

60

80

100

120

140

4500 4550 4600 4650 4700

Volts AC

Time (s)

All Measured Voltages Circuit 4

C4 V1

C4 V2

C4 V3

C4 V4

C4 V5

C4 V6

C4 V7

C4 V8

0

1

2

3

4

5

6

4500 4550 4600 4650 4700

Current (A)

Time (s)

All Measured Currents Circuit 4

C4 A1

C4 A2

C4 A3

C4 A4

C4 A5

C4 A6

C4 A7

C4 A8

77

7. CONCLUSIONS AND GENERAL INSIGHTS 

As a part of the DESIREE-Fire project, a total of 59 small-scale tests and 17 intermediate-scale 

tests were conducted. In all, the combined small- and intermediate-scale tests represent a total 

of over 225 individual circuit failure trials considering the number of individual circuits used in 

each of the tests. The testing focused mainly on dc-powered control circuits, but also involved 

limited testing of ac-powered circuits as a follow-up to one unresolved issue from the previous 

CAROLFIRE test program. Additionally, the inclusion of Kerite®, armored, and Japanese cables 

provided an opportunity to gain further insights on their failure modes and effects. 

7.1 dc-Powered Circuits 

The scope of this report is limited to objective reporting of the test data. It is not the intent of this 

report to interpret the test results beyond a factual representation of the progression of events 

observed in each test. The NRC already has plans in place to assemble two expert panels 

whose charter will be to interpret the test results and assess their implications for various 

applications. One panel will focus on the electrical aspects of the data and the second will deal 

with the statistical and risk aspects. Both panels will be conducted using the Phenomena 

Expert Elicitation process. In addition, as part of the following work under the electrical expert 

panel, the NRC plans to issue a NUREG report with some ac and dc circuit testing results 

analysis. 

That said, there are four general observations on the behavior of the dc-powered cables as 

compared to previously tested ac-powered cables that were made through the course of 

DESIREE-Fire testing that are worthy of note: 

 The faulting behavior of the dc-powered cables was more energetic than comparable 

ac-power cables observed in prior testing efforts. Both ac- and dc-powered cables 

displayed arcing behavior when short circuits form. However, with the dc-powered 

cables, the arcs were more substantial, more sustained and more damaging. 

 Related to the first observation, short-circuit faulting in the dc-powered cables often led 

to destructive damage to the cable conductors. That is, it was often observed that the 

arc formed during faulting was sufficient to sever a conductor or even an entire 

multiconductor cable. The effect observed was analogous to welding operations where 

the welding rods are consumed in the process. This sort of destructive damage was not 

seen as the result of ac-power cable short circuits. Open circuits are a unique failure 

mode that was not observed in the ac testing but was common in the dc testing. 

 In some cases the dc-powered cables were left energized even after they had 

experienced destructive damage as described immediately above. This behavior was 

tied to the fuse sizes used. Typically, the smaller 5A and 10A fuses would clear, deenergizing the conductors once failures occurred. However, as the fuse size increased, 

it became more common for the conductors to be left severely damaged but still 

energized. This behavior was not observed for the ac-powered cables, but none of the 

ac-powered cable tests have used fuses as large as those used in some of the tested 

dc-powered circuits. 

 Corresponding to the prior observation, the positive and negative fuses for any given dc 

circuit did not necessarily clear at the same time. It was not uncommon to have one 

blown fuse while the other remained functional. An actively fused conductor could 

become grounded (through the tray, for example) and a transition of the relative ground 
78

potential (i.e., from positive to negative or vice versa) could generate a sufficient 

amount of current to cause the intact fuse to clear. 

 In general, more long-duration HSs and spurious operations were observed for the dcpowered circuits than had been observed in corresponding ac-powered circuits. 

7.2 ac-Powered Circuits 

The final issue investigated during DESIREE-Fire was the question of how the sizing of CPTs 

would impact the likelihood of spurious operation in ac-powered control circuits. This was an 

issue that was also investigated in the prior CAROLFIRE test program with inconclusive results. 

During the original NEI/EPRI circuit tests of 2000, it had been noted that multiple current 

leakage paths that formed during the cable degradation process would lead to saturation of the 

power-limited CPTs and to degradation of the source voltage. In some cases the voltage 

degraded to below the minimum pick-up voltage of the motor contactors. This effect was 

attributed with reducing the SA probability by a factor of two compared to non-power-limited 

circuits by an expert panel examining the NEI/EPRI data [3]. 

CAROLFIRE investigated a range of CPT sizes (i.e., 100VA to 250VA) but could not reproduce 

the voltage degradation effect to nearly the degree observed by NEI/EPRI. Differences in the 

characteristics of the motor contactors used in each program were thought to have been a 

contributing factor to the different test result. 

For DESIREE-Fire, the ac-powered MOV simulator circuits, the SCDUs, were rebuilt using the 

exact same model of motor control contactor as had been used by NEI/EPRI and additional 

tests were run. The motor contactor sets all included electrical interlocks, and three of the four 

included mechanical interlocks as well. 

For DESIREE-Fire only one case out of a total of 42 total circuit trials appears to have 

experienced a similar level of voltage degradation sufficient to have actually prevented a SA

despite formation of HSs to the target (contactor coil) conductors; namely, Penlight Test #17. 

This case involved SCDU-1 with a 100VA CPT. A second test, intermediate-scale Test IS4, 

also showed signs of substantial source voltage degradation, but only after SAs had already 

occurred in the target circuit. This second test involved SCDU-4 with a 75VA CPT. 

Overall, like CAROLFIRE, the DESIREE-Fire tests failed to reproduce the voltage degradation 

effect to nearly the degree that had been observed by NEI/EPRI despite the use of CPTs with 

just half the capacity of those used in the NEI/EPRI tests. None of the tests involving the two 

larger CPTs (150VA and 200VA) showed substantive degradation of source voltage sufficient to 

prevent a SA from locking in. Other trials of the smaller CPTs (75VA and 100VA) also did not 

experience sufficient voltage degradation to prevent SA lock-in. 
79

8. REFERENCES 

1. NUREG/CR-6931, “Cable Response to Live Fire (CAROLFIRE),” U.S. Nuclear Regulatory 

Commission, Washington, DC, April 2008, a report in three volumes: 

Volume 1: Nowlen, S.P., Wyant, F.J., Test Descriptions and Analysis of Circuit

Response, SAND2007-600/V1, U.S. NRC, Washington, DC, April 2008. 

Volume 2: Nowlen, S.P., Wyant, F.J., Cable Fire Response Data for Fire Model 

Improvement, SAND2007-600/V2. 

Volume 3: McGrattan, K., Thermally-Induced Electrical Failure (THIEF) Model, 

NISTIR 7472. 

2. Information Notice 99-17, “Problems Associated with Post-Fire Safe-Shutdown Circuit 

Analyses,” U.S. Nuclear Regulatory Commission, Washington, DC, June 3, 1999. 

3. Report TR-1006961, “Spurious Actuation of Electrical Circuits Due to Cable Fires, Results 

of an Expert Elicitation,” Electric Power Research Institute, Palo Alto, CA, 2002. 

4. Regulatory Issue Summary (RIS) 2004-03, Rev. 1, “Risk-informed Approach for Post-Fire 

Safe-Shutdown Circuit Inspections,” U.S. Nuclear Regulatory Commission, Washington, DC, 

December 29, 2004. 

5. U.S. Nuclear Regulatory Commission, “Results and Observations from Duke Armored 

Control Cable Fire-Induced Spurious Operation Testing,” U.S. NRC, available through the 

NRC Agency-Wide Document Access and Management System (ADAMS) using accession 

numbers ML071200168 and ML071200168. 

6. SAND2010-4936, Nowlen, S.P., and Brown, J., “A Preliminary Look at the Fire-Induced 

Electrical Failure Behavior of Kerite® FR Insulated Electrical Cables - A Letter Report to the 

U.S. NRC/RES,” Sandia National Laboratories, Albuquerque, NM, July 2010. 

7. Standard E 603-06, Standard Guide for Room Fire Experiments, American Society of 

Testing and Materials, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 

19428-2959, 2006. 

8. NUREG/CR-6850, EPRI TR 1011989, Nowlen, S.P., Najafi, B, et al., “EPRI/NRC-RES Fire 

PRA Methodology for Nuclear Power Facilities,” a report in two volumes, a joint publication 

of the U.S. Nuclear Regulatory Commission and Electric Power Research Institute, 

September 2005. 

9. Inspection Manual Chapter 06.09, Attachment F, “Fire Protection Significance 

Determination Process,” U.S. Nuclear Regulatory Commission, February 28, 2005 

(http://www.nrc.gov/readingrm/doc-collections/insp-manual/manual-chapter/index.html).

10. Standard 450-2002, “IEEE Recommended Practice for Maintenance, Testing, and 

Replacement of Vented Lead-Acid Batteries for Stationary Applications,” Published by The 

Institute of Electrical and Electronics Engineers, Inc., 3 Park Avenue, New York, NY 

10016-5997, April 2003. 

Appendix A. Test Support Systems
A-1

A.1 Direct Current (dc)-Powered Motor-Operated Valve (MOV) 

Circuits

A typical dc MOV control circuit is illustrated in Figure A-1. This drawing was derived from a 

Reactor Core Isolation Cooling (RCIC) MOV found at a currently operating U.S. nuclear power 

plant. This circuit has also been used as an analysis example during the annual Office of 

Nuclear Regulatory Research (RES)/Electric Power Research Institute (EPRI) fire probabilistic 

risk assessment (PRA) training course. The corresponding block diagram displayed in Figure

A-2 illustrates the basic MOV location with respect to the various control and power distribution 

cabinets. Note that the specific conductors present in each connecting cable are indicated on 

the block diagram (e.g., conductors P, N, YC1, G, R, etc.) and these designations correspond 

to the conductor designations in the circuit diagram. The target cable of concern to be studied 

in this test series is cable A, which is highlighted in the block diagram.

72C 72O 72C 72O

72O 72C

SHUNT

SERIES

ARM

HSCLOSEHSOPEN

72O 72C

C O

33L- 33UG R

125 VDC

P

N

F

S

A1 A2

YC1 YO1

G R

35A

10A

35A

10A

NC NO

NC NC

NO NO

NO NO NO NO NO NO

Figure A-1 Electrical schematic diagram of a typical dc MOV

Figure A-1 depicts the dc MOV control circuit with the valve position contacts in the condition 

they would be in when the valve is fully closed and not operating. The principal circuit failure

mode of concern is a hot short leading to the spurious opening of the MOV.
A-2

DC PNL-B

CB

MOV

B

C

P

A

P, N, YC1, YO1, G, R, SP

N

P, G, R

N, F, S, A1, A2

Figure A-2 Block diagram of a dc MOV

The right-hand portion of the circuit schematic diagram (Figure A-1) is of primary interest to this 

effort as this represents the control portion of the circuit. This is that portion of the circuit fed 

through the two 10-ampere (A) fuses. That portion to the left of center represents the motor of 

the MOV itself (that part fed through the 35-A fuses). The intent is not to simulate this portion 

of the circuit.

With respect to spurious actuation potential, Cable A as shown in the block diagram is the 

target of interest. This cable does contain all of the conductors necessary to cause a spurious 

actuation of the valve circuit, and the dc-simulator (dc-SIM) panel for this circuit is based on 

connections to this cable. The corresponding dc-SIM panel unit implementation is illustrated in 

Figure A-3. Table A-1 identifies the conductor-to-conductor interactions required to occur 

within Cable A to cause a specific circuit malfunction, including spurious opening of the valve.

Table A-1 Identification of specific intracable induced circuit failure modes for the dc

MOV.

Circuit Failure Effect

Will occur if any 

of these 

conductors...

Come into contact 

with any of these 

conductors...

Notes

Valve spuriously 

opens

P, G YO1

Loss of valve control N YO1, R

Circuit fuse(s) will blow if an 

attempt is made to open the valve 

while this internal short condition 

exists.

Loss of circuit power 

(blown fuse(s)) P, G N

Erroneous/spurious 

valve position 

indication

P, G R

Loss of valve position 

indication — —

Open circuit failure of conductor 

G or N.

It is also worthwhile noting that no immediate discernible effect occurs if conductors P, YO1, 

YC1, or R experience an open circuit failure (conductor break) as the initial failure mode.
A-3

The line drawing for the dc MOV control circuit layout may be found in Figure A-3 and the 

corresponding component arrangements may be seen in 

Figure A-4 and Figure A-5. The latter two drawings provide a visual depiction and orientation 

of components that were used to monitor the specific circuit performance.

G

P

YC1

YO1

R

N

SP

A

A

A

A

V

V

V

V

V

V

V

NC

NC

1750

+

-

125 VDC

O

NO

NC

C

A

A

1750

DCCCS CABLE UNDER TEST

FROM DISTRIBUTION 

CIRCUIT BREAKER

FUSE BLOCK

DCCCS Layout for DC MOV Control Circuit

10A

10A

A

A

B

C

Figure A-3 dc-SIM panel layout for the control circuit on a dc MOV

Figure A-4 dc-SIM panel component arrangement for the dc MOV circuit 

instrumentation bay

DCCCS COMPONENT LAYOUT FOR DC MOV CIRCUIT

Instrumentation Bay

From 10 A Fuse

From 10 A Fuse

To Contactors

From Contactors

508 mm X 457 mm

(20 in. X 18 in.)

Baseplate

Voltage

Transmitter

V

o

lta

g

e

T

ra

n

sm

i

t

te

r

Voltage

Transmitter

P

N

SP

To 

Cable 

Under 

Test

C

u

r

re

n

t

T

ra

n

sm

i

t

te

r

C

u

r

re

n

t

T

ra

n

sm

i

t

te

r

KEY

18 AWG

12 AWG

8 AWG
A-4

Figure A-5 dc-SIM panel component arrangement for the dc MOV circuit contactors 

bay

The motor starters for MOV circuits were procured through Joslyn Clark1and the details, 

including model numbers and description, may be found in Table A-2.

Table A-2 Description of the motor controller from Joslyn Clark.

250 Volts DC Max

NEMA 

Size Description Reference No.

1 Open Type dc Coil 2 Pole N.O. 7401-1020-12

Modification & Accessories

NEMA 

Size Description Reference No.

1 N.O. & N.C. Aux 5M65

1 Mechanical Interlock 5999-4737

1 Reversing Base Plate 23082.79-1

To confirm proper circuit wiring, a procedure was followed to verify current and voltage 

readings for both circuits. The results of the testing were as anticipated; however, they did not 

reveal a defect with one of the connected motor controllers. This defect was not observed until 

a subsequent equipment analysis. 

 

1

Additional information may be ascertained from the Joslyn Clark catalogue which is available at 

http://www.joslynclark.com/downloads.htm.

DCCCS COMPONENT LAYOUT FOR DC MOV CIRCUIT

Contactors Bay

OPEN CLOSE

To neg. lead

To NC Aux . Contact A on C -coil

From NC Aux . 

Contact A on C -coil

To NC Aux . Contact A on O -coil

From NC Aux . 

Contact A on O -coil

From pos . 

lead

To NC Aux . 

Contact C on O -coil

From NC Aux . 

Contact C on O -coil

From NO Aux . 

Contact B on O -coil

Coil

Power

508 mm X 457 mm

(20 in. X 18 in.)

Baseplate

Current

Transmitter

C

u

r

re

n

t

T

ra

n

sm

i

t

te

r

V

o

l

ta

g

e

T

ra

n

sm

i

t

te

r

Voltage

Transmitter

G

R

YC1

YO1

To NO Aux . 

Contact B on O -coil

Voltage

Transmitter

To 

Cable 

Under 

Test

R

E

A

R

FR

O

N

T

KEY

18 AWG

12 AWG

8 AWG

V

o

l

ta

g

e

T

ra

n

sm

i

t

te

r

C

u

r

re

n

t

T

ra

n

sm

i

t

te

r

C

u

r

re

n

t

T

ra

n

sm

i

t

te

r
A-5

As a part of post-test data analysis, pick-up and drop-out voltage tests were conducted for 

each of the four individual relay contactor units and the results are summarized in Table A-3. 

This was not performed before testing because the relay contactor units were delivered by 

Joslyn-Clark nearly three months late. By the time the units arrived, construction of the entire 

set of dc surrogate circuits had been completed (with the exception of these relays), and all 

preparations for testing had been completed. A decision was made to measure the coil 

resistance for each unit, but to defer the pick-up and drop-out testing and proceed with fire 

testing.

Table A-3 dc MOV coil characterizations.

Device

Cold Coil 

Resistance

()

Average Pickup 

Voltage (Vdc)

Average 

Pickup 

Current (A)

Average 

Dropout 

Voltage 

(Vdc)

Average 

Dropout 

Current (A)

MOV-1 (open) 154.9 29.0 0.1785 26.6 0.1625

MOV-1 (close) 154.6 89.3 0.4873 4.8 0.0263

MOV-2 (open) 155.3 50.7 0.2867 7.3 0.0420

MOV-2 (close) 155.3 N/A N/A N/A N/A

The close contactor unit for MOV-2 was found to not have a metal slug as part of its movable 

core assembly. Thus it was incapable of operating when the coil was energized. Current and 

voltage can still be monitored but implications are discussed below.

During the post-test examination, three of the four in-service relay contactor units tested out as 

expected, but the fourth unit, the ―close‖ unit in circuit MOV-2, failed to pick up (close) despite 

application of up to 170 Vdc. An external physical inspection revealed no obvious flaw and the 

contactor could be closed manually. Also, the voltage and current observed during the pick-up 

test indicated that the relay coil was in place and operating as expected. A coil resistance 

measurement also yielded a value that was consistent with pre-test readings.

At this point a decision was made to disassemble the non-functional unit. A second working 

unit was also disassembled for comparison. This inspection revealed that the moving core was 

missing from the non-functional unit. Figure A-6 shows the functional unit with the moving core 

in place and Figure A-7 shows the non-functional unit with the moving core absent. Figure A-8

shows the two units side by side. The relay was received from the manufacturer without the 

moving core. An inspection was also performed for a fifth (spare) relay contactor unit, and it 

was found that the spare contactor was also missing the moving core. Hence, two of five relay 

contactor units obtained directly from Joslyn-Clark were non-functional.

The implications for the data analysis are summarized as follows:

 Circuit MOV-1 is not effected in any way.

 For circuit MOV-2, the ―open‖ contactor was fully functional but the ―close‖ contactor 

was a non-functional passive coil target only. The ―close‖ contactor was present as 

an inductive load on the circuit, but the relay would never have closed during 

testing.

 The data can still be analyzed and interpreted, including for spurious actuations, but 

the following cases need to be considered:

o Given an initial hot short to the close coil, the electrical and mechanical 

interlocks will not engage. A subsequent hot short to the open coil would cause 

the open coil to close and would trip the close coil out of the circuit via the 

electrical interlock.
A-6

Figure A-6 Open motor controller with functional moving core for the MOV-2 circuit

Figure A-7 Close motor controller missing the metal driver for the moving core for the 

MOV-2 circuit

Moving core present 

in operational motor 

control contactor unit

Moving core absent from 

non- operational motor 

control contactor unit
A-7

Figure A-8 Side-by-side comparison of the open and closed motor contactors for the 

MOV-2 circuit

o Given an initial hot short to the open coil, the open contactor would close,

triggering both the mechanical and electrical interlocks. A subsequent hot short 

to the close coil would behave exactly as if the close contactor was fully 

functional (i.e., there would be an indication of voltage applied to that circuit path 

but no current flow).

o Overall, it was not possible to electrically engage (i.e., induce current flow) in 

both the open and close coils simultaneously despite the non-functional close 

contactor unit.
A-8

A.2 dc-Powered Solenoid-Operated Valve (SOV) Circuits

A.2.1 Circuit Used During Testing

A schematic of a typical small SOV control circuit is shown in Figure A-9. This schematic was 

derived from an actual plant circuit, and has been used as an example analysis case in the 

RES/EPRI fire PRA training program. The corresponding block diagram is shown in Figure 

A-10. The corresponding dc-SIM panel implementation for this circuit, assuming fire-induced 

failure of Cable B as shown in the block diagram, is the potential concern, is illustrated in 

Figure A-11. The potential component layout for the SOV circuits may be seen in Figure A-12.

5A

5A

PB

(OPEN)

125 VDC

R

SOV

PB

(CLOSE)

33UENERGIZE

TO OPEN

33L- 33UP

N

S2

S1

G R

G

+

-

NC NO

NO

SMALL DC SOLENOID OPERATED VALVE 

(SOV) ELECTRICAL SCHEMATIC DIAGRAM

AOV Position Contacts

Figure A-9 Electrical schematic diagram for a small SOV

The small solenoid valve is shown in its normally closed position. Table A-4 identifies the 

conductor-to-conductor interactions required to occur within Cable B to cause a specific circuit 

failure mode, including spurious opening of the valve.

It is also worthwhile noting that no immediate discernible effect occurs if conductors P, N, S1, 

S2, or R experience an open circuit failure (conductor break) as the initial failure mode.
A-9

PNL-B

CB

A

P, N

P, N, R, G,S1, 

S2, SP

V

B

Figure A-10 Block diagram of a small SOV

S1

G

R

S2

N

SP

A P

A

A

A

A

V

V

V

V

V

V

V

5A

5A

SOV

1750

1750

DCCCS Layout for Small DC SOV Circuit

+

-

125 VDC

DCCCS CABLE UNDER TEST

FROM DISTRIBUTION 

CIRCUIT BREAKER

FUSE BLOCK

Figure A-11 dc-SIM panel layout for a small SOV dc circuit
A-10

DCCCS COMPONENT LAYOUT FOR SMALL DC SOV CIRCUIT

508 mm X 457 mm

(20 in. X 18 in.)

Baseplate

Voltage

Transmitter

From 5 A 

Fuse

From 5 A 

Fuse

Current

Transmitter

SOLENOID 

VALVE

Current

Transmitter

Current

Transmitter

Current

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

N

S2

SP

R

P

S1

G FRONT

REAR

KEY

18 AWG

12 AWG

 8 AWG

Current

Transmitter

Voltage

Transmitter

To

Cable

Under

Test

Figure A-12 dc-SIM panel component arrangement for a small SOV dc circuit

Table A-4 Identification of specific intracable induced circuit failure modes for the 

small SOV.

Circuit Failure Effect Will occur if any of 

these conductors...

Come into contact 

with any of these 

conductors...

Notes

Valve spuriously opens P, S1, G S2

Loss of valve control N S2, R

Circuit fuse(s) will blow

if an attempt is made to 

open the valve while 

this internal short 

condition exists.

Loss of circuit power 

(blown fuse(s)) P, S1, G N

Erroneous/spurious 

valve position indication P, S1, G R

Loss of valve position 

indication — —

Open circuit failure of

conductor G.

A.2.2 Alternate SOV Circuit Designs That Were Not Tested but May Exist in 

Plants

One variation of the basic small solenoid valve circuit is one where the connections to the valve 

position limit switches and status-indicating lamps are reversed (see Figure A-13). This 

change then results in a slight change to the conductors connecting the control board (CB) to 

the valve (V) as shown in Figure A-14. Note that Cable B now does not require conductor P at 

the valve. P has been replaced with a second spare conductor. Figure A-15 shows the 

resulting layout of the dc-SIM panel for this modified control circuit for a small SOV. Note that 

the dc-SIM panel layout for this SOV control circuit scheme requires the use of a separate and 
A-11

independent cable conductor that is protected and isolated from the fire. It is needed to 

provide power to one side of the resistors that simulate the status-indicating lamps and tie into 

the R and G conductors of the cable under test at the other end.

5A

5A

PB

(OPEN)

125 VDC

R

SOV

PB

(CLOSE)

33UENERGIZE

TO OPEN

33L- 33UP

N

S2

S1

G R

G

+

-

NO

NC NO

Figure A-13 Electrical schematic diagram for a small SOV with position contacts and 

status-indicating lamps reversed (not tested)

PNL-B

CB

A

P, N

N, R, G,S1, 

S2, 2SP

V

B

Figure A-14 Block diagram of a small SOV with position contacts and status-indicating

amps reversed (not tested)
A-12

S1

G

R

S2

N

SP

A

A

A

A

A

A

A

A

A

V

V

V

V

V

V

V

V

V

S1

S2

S3

S4

S5

S6

5A 5A

SOV

NO

NC

N/C

1750

1750

+

-

125 VDC

DCCCS CABLE UNDER TEST

BATTERY BANK DC

POWER SUPPLY

Separate, protected cable

SP

Figure A-15 dc-SIM panel layout for a small SOV dc circuit with position contacts and 

status-indicating lamps reversed (note the use of a separate independent 

and protected cable to make needed circuit connections) (not tested)

The small solenoid valve with the valve position limit switches and status-indicating lamps 

reversed is shown in its normally closed position. Table A-5 identifies the conductor-toconductor interactions required to occur within Cable B to cause a specific circuit failure mode, 

including spurious opening of the valve. Note that no immediate discernible effect occurs if 

conductors N, S1, S2, or R experience an open circuit failure (conductor break) as the initial 

failure mode.

Table A-5 Identification of specific intracable induced circuit failure modes for the 

small SOV with position contacts and lamps reversed. (not tested)

Circuit Failure Effect Will occur if any of 

these conductors...

Come into contact 

with any of these 

conductors...

Notes

Valve spuriously opens S1 / P S2

Loss of valve control N, G S2

Circuit fuse(s) will blow 

if an attempt is made to 

open the valve while 

this internal short 

condition exists.

Loss of circuit power 

(blown fuse(s)) S1 N, G

Erroneous/spurious 

valve position indication N R

Loss of valve position 

indication — —

Open circuit failure of 

conductor G.
A-13

Although reversing the indicating lights is an option, because of the specific valve chosen for 

creation of the SOV circuit, the circuits may only be tested in the normal configuration. After 

experimental results and experiences are gleaned, this possibility may be revisited.

The SOV circuits utilized two ASCO RedHat2general service solenoid valves throughout the 

testing program. Information for these two solenoids may be found in Table A-6.

Table A-6 SOV information.

Circuit Item Series Part Order 

Number

SOV-1 Solenoid Operated Valve ASCO RedHat Series 

8320 8320G172

SOV-2 Solenoid Operated Valve with Class H Coil ASCO RedHat Series 

8320 EFHT8320G172

Based on recommendations from the peer review committee, SOV-2 used a continuous-duty 

Class H coil. Continuous-duty Class H coils are required for battery-charging circuits where 

wider voltage ranges are typically encountered. Based on the manufacturer’s literature, the 

Class H coils will accommodate continuous duty over a wider voltage range; namely, 12% over 

normal and 28% under normal rated coil voltage. For a nominal 125-Vdc coil, this translates to 

a voltage range of 90 to 180-Vdc.

Also note that the wiring of the dc SOVs was not polarity-specific. That is, the two lead wires to 

the solenoid coil could be connected without consideration of the power source polarity. A 

member of the peer team clarified that dc solenoids are often configured with an integral 

(internal) rectifier, so that they will operate correctly regardless of whether the source applied is 

alternating current (ac) or dc, and regardless of the dc polarity applied. The SOVs used in 

DESIREE-Fire appear to be of this type (internally rectified). Hence, a ―reverse polarity‖ dc hot 

short on an SOV such as those tested here would still cause a spurious operation. A reverse 

polarity short on a dc solenoid without the internal rectifier would not cause a spurious 

operation.

Note that the test data has been reviewed for this effect, and no cases were observed that 

appeared to involve a reverse polarity short to the SOVs. Given the test configurations, a 

reverse polarity short would require, at a minimum, the following events to occur:

 A positive source conductor must short to the (nominally) negative side of the valve 

coil. That is, a positive source must short to either conductor N or G as shown in 

the circuit schematic, thereby ―back-feeding‖ a positive potential to the nominally 

negative side of the coil. Further, this short circuit must result in clearing of the 

negative fuse for this circuit (i.e., instead of the positive fuse). Note that the positive 

source could come from intracable shorting (i.e., with conductor S1) or from 

intercable shorting to a second cable.

 Because the negative fuse must clear, an independent negative energizing source 

would need to come into contact with the (nominally) positive side of the valve coil 

(conductor S2). Given the test configuration, this would require either an intercable 

hot sort or multiple shorts to ground on the negative battery potential that included 

conductor S2.

 

2

Additional information may be ascertained from the ASCO catalogue, which is available at 

http://www.ascovalvenet.com/AscoValvenet/Applications/LiteratureRequest/PublicSite/LRPublicWeb.aspx?action=a

dd.
A-14

The SOV solenoids were electrically characterized following the intermediate scale tests in 

order to determine their actual pick-up and drop-out voltage and current thresholds. Table A-7

provides a summary of each SOV’s electrical characteristics. Note that the two valves have 

essentially identical electrical characteristics; that is, the Class H coil appears to have no 

impact on pick-up voltage, pick-up current, or drop-out voltage.

Table A-7 Small dc SOV solenoid characterizations.

Device Cold Coil 

Resistance

Average Pickup Voltage 

(Vdc)

Average 

Pick-up 

Current (A)

Average 

Dropout 

Voltage 

(Vdc)

Average 

Dropout 

Current (A)

SOV-1 1280 56.9 0.042 43.8 0.033

SOV-2 1270 55.2 0.042 43.8 0.033
A-15

A.3 dc-Powered 1-Inch Solenoid Valve and Large Coil

A.3.1 Alternate PORV and 1-inch SOV Circuit Designs Not Tested

The power-operated relief valve (PORV) simulated circuit, Figure A-16, was of similar 

construction to that shown for the SOV in Figure A-9. This design was also based on circuits 

used in the fire PRA training course. For the PORV circuit, the valve coil is much larger coil 

and the fusing is correspondingly larger. The block diagram, Figure A-17, is also similar. The 

dc-SIM panel implementation of this circuit is shown in Figure A-18. Again, the dc-SIM panel 

implementation assumes that fire-induced failure of Cable B in the block diagram is the 

potential spurious actuation concern. 

10A

PB

(OPEN)

125 VDC

G R

PCV ENERGIZE

TO OPEN

33L- 33UP

N1

S

G R

10A

N2

N

NC NO

Figure A-16 Electrical schematic diagram of a typical PORV

PNL-A

CB

A

P, N

P, N1, N2, G, 

R, S, SP

PCV

B

Figure A-17 Block diagram of a dc PORV
A-16

P

G

R

S

N1

N2

SP

A

A

A

A

A

A

A

A

A

V

V

V

V

V

V

V

V

V

S1

S2

S3

S4

S5

S6

10A 10A

PCV

NO

NC

N/C

1750

1750

+

-

125 VDC

N/C

DCCCS CABLE UNDER TEST

BATTERY BANK DC

POWER SUPPLY

Figure A-18 dc-SIM panel layout of a typical dc PORV control circuit

Figure A-18 shows the PORV in its normally closed position. Table A-8 identifies the 

conductor-to-conductor interactions required to occur within Cable B to cause a specific circuit 

failure mode, including spurious opening of the valve.

It is also worthwhile noting that no immediate discernible effect occurs if conductors P, N1, S, 

or R experience an open circuit failure (conductor break) as the initial failure mode.

Table A-8 Identification of specific intracable induced circuit failure modes for the 

PORV.

Circuit Failure Effect

Will occur if any of 

these 

conductors...

Come into contact 

with any of these 

conductors...

Notes

Valve spuriously opens P, G S

Loss of valve control N1, N2 S, R

Circuit fuse(s) will blow if an 

attempt is made to open the 

valve while this internal short 

condition exists.

Loss of circuit power 

(blown fuse(s)) P, G N1, N2

Erroneous/spurious 

valve position indication P, G R

Loss of valve position 

indication — —

Open circuit failure of 

conductor N2 or G.
A-17

One variation of the basic PORV circuit is one where the connections to the valve position limit 

switches and status-indicating lamps are reversed (see Figure A-19). This change then results 

in a slight change to the conductors connecting the control board (CB) to the valve (V) as 

shown in Figure A-20. Note that Cable B now does not require conductor P at the valve. P 

has been replaced with a second spare conductor. Figure A-21 shows the resulting layout of 

the dc-SIM panel for this modified control circuit for a PORV. Note that the dc-SIM panel layout 

for this valve control circuit scheme requires the use of a separate and independent cable 

conductor that is protected and isolated from the fire. It is needed to provide power to one side 

of the resistors that simulate the status-indicating lamps and tie into the R and G conductors of 

the cable under test at the other end. A second conductor in that separate cable is used to tie 

the downstream ends of the position switch contacts to N2 in the test cable.

10A

PB

(OPEN)

125 VDC

G R

PCV ENERGIZE

TO OPEN 33L- 33UP

N1

S

G R

10A

N2

N

NC NO

Figure A-19 Electrical schematic diagram for a PORV with position contacts and 

status-indicating lamps reversed (not tested)

PNL-A

CB

A

P, N

N1, N2, G, R, 

S, 2SP

PCV

B

Figure A-20 Block diagram of a PORV with position contacts and status-indicating 

lamps reversed (not tested)
A-18

SP

G

R

S

N1

N2

SP

A

A

A

A

A

A

A

A

A

V

V

V

V

V

V

V

V

V

S1

S2

S3

S4

S5

S6

10A 10A

PCV

NO

NC

1750

1750

+

-

125 VDC

DCCCS CABLE UNDER TEST

BATTERY BANK DC

POWER SUPPLY

Separate, protected cable

Figure A-21 dc-SIM panel layout for a PORV dc circuit with position contacts and 

status-indicating lamps reversed (not tested)

The PORV with the valve position limit switches and status-indicating lamps reversed is shown

in Figure A-21 in its normally closed position. Table A-9 identifies the conductor-to-conductor 

interactions required to occur within cable B to cause a specific circuit failure mode, including 

spurious opening of the valve. Note that no immediate discernable effect occurs if conductors 

N1, S, or R experience an open circuit failure (conductor break) as the initial failure mode.

Table A-9 Identification of specific intracable induced circuit failure modes for the 

PORV with position contacts and lamps reversed. (not tested)

Circuit Failure Effect

Will occur if any of 

these 

conductors...

Come into contact 

with any of these 

conductors...

Notes

Valve spuriously opens — —

No energized conductors in 

Cable B.

Loss of valve control N1, N2 S

Circuit fuse(s) will blow if an 

attempt is made to open the 

valve while this internal short 

condition exists.

Loss of circuit power 

(blown fuse(s)) — —

No energized conductors in 

Cable B.

Erroneous/spurious 

valve position indication N1, N2 R

Loss of valve position 

indication — —

Open circuit failure of 

conductor N2 or G.

Another variant of the basic PORV circuit to be explored is one where the valve actuating coil is 

isolated by double switch contacts (see Figure A-22). This change is implemented to assess 
A-19

how much less vulnerable this design is to a spurious operation over the standard, non-isolated 

design. Cable B, connecting the control board (CB) to the valve (V) as shown in Figure A-23, 

is still the target cable of concern. Figure A-24 shows the resulting layout of the dc-SIM panel

for this version of the PORV control circuit. 

HS 

(OPEN)

125 VDC

G R

PCV

33L- 33UP1

N2

S

G R

10A

10A

P

N

P2

N1

ENERGIZE

TO OPEN

HS 

(OPEN)

NC NO

Figure A-22 Electrical schematic diagram of a PORV with double contacts (not tested)

PNL-A

CB

A

P, N

P1, P2, N1, 

N2, G, R, S

PCV

B

Figure A-23 Block diagram of a PORV with double contacts (not tested)
A-20

P2

G

R

S

N1

N2

P1

A

A

A

A

A

A

A

A

A

V

V

V

V

V

V

V

V

V

S1

S2

S3

S4

S5

S6

10A 10A

PCV

NO

NC

1750

1750

+

-

125 VDC

N/C

N/C

DCCCS CABLE UNDER TEST

BATTERY BANK DC

POWER SUPPLY

Figure A-24 dc-SIM panel layout for the PORV with double contacts (not tested)

The PORV with the dual isolation switches is shown in Figure A-24 in its normally closed 

position. Table A-10 identifies the conductor-to-conductor interactions required to occur within 

Cable B to cause a specific circuit failure mode, including spurious opening of the valve.

Table A-10 Identification of specific intracable induced circuit failure modes for the 

PORV with double contacts. (not tested)

Circuit Failure Effect Will occur if any of 

these conductors...

Come into contact 

with any of these 

conductors...

Notes

Valve spuriously 

opens

P1, P2, G

AND

N2

S

N1

Loss of valve control N2 S, R

Circuit fuse(s) will 

blow if an attempt is 

made to open the 

valve while this 

internal short 

condition exists.

Loss of circuit power 

(blown fuse(s)) P1, P2, G N2

Erroneous/spurious 

valve position 

indication

P1, P2, G R

Loss of valve position 

indication — —

Open circuit failure of 

conductor N2 or G.
A-21

Note that no immediate discernible effect occurs if conductors P1, P2, N1, S, or R experience 

an open circuit failure (conductor break) as the initial failure mode.

A.3.2 Tested Circuits for 1-inch SOV ASSEMBLY and Large Coil

Two valves were obtained for the purposes of Direct Current Electrical Shorting in Response to 

Exposure-Fire (DESIREE–Fire), namely a ―1-Inch Valve‖ and a ―Large Coil.‖ The line 

illustrations providing the overall description of the circuits may be found in Figure A-25 and 

Figure A-27. Potential component layouts for each of the two valves may be found in Figure 

A-26 and Figure A-28. Because of time constraints and the limited amount of experiments, it 

was decided to focus on the normal configuration rather than the reversed indicating light 

option. After initial results and experimental experiences, this option may be revisited.

P

G

R

S

N1

N2

SP

A

A

A

A

A

V

V

V

V

V

V

V

5A

1-INCH

COIL

1750

1750

+

-

125 VDC

DCCCS CABLE UNDER TEST

FROM DISTRIBUTION 

CIRCUIT BREAKER

DCCCS Layout for DC 1-Inch Coil Circuit

FUSE BLOCK

5A

NC

NO

A

Figure A-25 Line drawing of the dc-SIM panel layout for a 1-inch coil circuit
A-22

DCCCS COMPONENT LAYOUT FOR DC 

1-INCH COIL CIRCUIT

508 mm X 457 mm

(20 in. X 18 in.)

Baseplate

Voltage

Transmitter

From 10 A 

Fuse

From 10 A 

Fuse

Current

Transmitter

Current

Transmitter

Current

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

N1

S

N2

SP

P

G

R

FRONT

REAR

Current

Transmitter

Current

Transmitter

Voltage

Transmitter

To

Cable

Under

Test

KEY

18 AWG

12 AWG

 8 AWG

Current

Transmitter

6, 8

217

5

To Valve

Figure A-26 Component layout for the dc 1-inch coil circuit

P

G

R

S

N1

N2

SP

A

A

A

A

A

V

V

V

V

V

V

V

10A

LARGE

COIL

1750

1750

+

-

125 VDC

DCCCS CABLE UNDER TEST

FROM DISTRIBUTION 

CIRCUIT BREAKER

DCCCS Layout for DC Large Coil Circuit

FUSE BLOCK

10A

Figure A-27 Line drawing for the dc large coil circuit
A-23

DCCCS COMPONENT LAYOUT FOR DC 

LARGE COIL CIRCUIT

508 mm X 457 mm

(20 in. X 18 in.)

Baseplate

Voltage

Transmitter

From 10 A 

Fuse

From 10 A 

Fuse

Current

Transmitter

Current

Transmitter

Current

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

N1

S

N2

SP

P

G

R

FRONT

REAR

Current

Transmitter

Current

Transmitter

Voltage

Transmitter

To

Cable

Under

Test

KEY

18 AWG

12 AWG

 8 AWG

21

To Coil

Figure A-28 Component layout for the dc large coil circuit

The 1-Inch SOV solenoid was electrically characterized following the intermediate-scale tests 

in order to determine its actual pick-up and drop-out voltage and current thresholds. Table A-8 

provides a summary of the SOV’s electrical characteristics. Since it has no moving parts to 

determine when pick-up or drop-out occurs, the large coil was not characterized electrically.

Table A-11 1-inch SOV solenoid characterizations.

Device Cold Coil 

Resistance

Average Pickup Voltage 

(Vdc)

Average 

Pick-up 

Current (A)

Average 

Dropout 

Voltage 

(Vdc)

Average 

Dropout 

Current (A)

1-inch coil 158.8 47.9 0.30 17.2 0.11

Large Coil 36 N/A N/A N/A N/A
A-24

A.4 dc-Powered Switchgear Breaker Circuit

A.4.1 General Design Information

There were two different SWGR breaker circuits used during DESIREE testing. The first 

SWGR circuit is displayed in Figure A-29. The internal manufacturer’s wiring of this SWGR was 

reversed based on the assumed manufacturer’s wiring displayed in Figure A-31. The second 

SWGR circuit is displayed in Figure A-30. During intermediate scale test #8, the first SWGR 

had an incident which acknowledged this wiring defect. This is described in detail in Section 

A.4.2. The reverse wiring did not affect the functionality of the SWGR. The block diagram 

provided in Figure A-32 depicts the location of the switchgear in the NPP and Cable A 

represents the test cable. The corresponding dc-SIM panel implementation is illustrated in 

Figure A-33. Note that the dc-SIM panel breaker design includes both 15-A and 35-A fuses,

each set feeding different portions of the control circuit. In this case, the larger fuse set powers 

the breaker trip circuit and the smaller set powers the breaker close portion of the circuit.
A-25

15A

15A

35A

35A N1 N2

C1

PC PT

G R T A5 A3 A10 A8 A11

A6 A4 A9 A12

G R

M

52

TC 52Y

52X

CB HS-C

52IS-2 52IS-1

Anti- Pump Relay

Close Coil Trip

Coil

Charging Motor

52Y

a 52a 52Y

b

52

b

52LS

aa 52LSbb

52

a 52b

52

a

CB

HS-T

[1]

[4]

[3]

[2]

[M]

[63]

[64X]

[64]

[8] [6] [9]

[7] [10]

[66]

125 VDC BUS

Figure A-29 Line Drawing for dc SWGR 1 Circuit
A-26

Figure A-30 Line Drawing for dc SWGR 2 Circuit
A-27 52

b

52LS

aa

15A

15A

PC

CB

HS-C

125 VDC BUS

35A

35A

G R

G

PT

C1

N1

A5

52IS-2

52Y

52X

Close

Coil

52Y

b

[3]

[64X]

[64]

[63]

52Y

a

52

a

A6

[4]

A3

52IS-1

52LS

bb

M

Charging 

Motor

[M]

A4

[2]

[1]

A10 A8

52

a

52

b

A9

[8] [6]

[7]

N2

CB

HS-T

A11

52

TC

Trip

Coil

52

a

A12

[9]

[66]

[10]

R T

AntiPump 

Relay

15KVAC DSE SWITCHGEAR ELECTRICAL SCHEMATIC DIAGRAM

Figure A-31 Electrical schematic diagram for typical 4160-VAC switchgear, 

manufacturer’s wiring

CB SWGR

PC, C1, N1

A

M

P

T1, T2, T3

B

PT, T, G, R, N2, 2SP

Figure A-1532

KVAC DSE SWITCHGEAR BLOCK DIAGRAM Block diagram for typical 4160-VAC switchgear
A-28

PC

C1

G

R

T

SP

N2

PT

N1

A

A

A

A

A

A

V

V

V

V

V

V

V

V

V

DCCCS Layout for 15KV DSE Switchgear DC Control Circuit

+

-

125 VDC

15A

35A

DCCCS CABLE UNDER TEST

FROM DISTRIBUTION 

CIRCUIT BREAKER

15A

35A

1750

1750

A3

A5

A10

A8

A11

A9/

A12

A6/

A4

FUSE BLOCK 15KV SWGR

SP

V

Figure A-33 dc-SIM panel layout for the control circuit on a typical 4160-VAC

switchgear

Figure A-34 shows a representative schematic of a dc control circuit for a 4.16-kV vacuumoperated circuit breakers. The anti-pumping circuitry shown in red is of interest in this test 

program to determine the effects that it has on limiting the occurrence of multiple repetitive 

spurious actuations, or actuation after the breaker had been tripped by operator actions. 

This aspect of the circuit, the anti-pumping feature, was not simulated; rather, it was an 

inherent feature of the breaker units used in testing. Breaker spurious actuation status and the 

―Y‖ anti-pumping coil status were monitored during the testing and recorded on the data 

acquisition system.

Note that in practice, the trip and close circuits were powered through separate breakers in the 

dc battery bank power distribution system. This is not typical of in-plant practice, but has no 

effect on circuit performance. Primary circuit protection is provided by the 15-A and 35-A 

fuses, and the breakers were installed as a personnel safety measure. Appendix A.7 provides 

additional detail on the power distribution system.
A-29

Figure A-34 4.16-kV circuit breaker schematic

Figure A-35 and Figure A-36 represent the layout of components for the switchgear circuit 

within the simulator racks.

A.4.2 15-kV Circuit Breaker Damage Post-Event Investigation

A.4.2.1 Introduction and Purpose

This section describes the events leading up to and the post-event investigation of the 

DESIREE-Fire intermediate-scale test that led to damage occurring to the 15-kV circuit breaker 

being used as part of the test series.

On November 17, 2009, Test IS8 was conducted. This test consisted of 13 separate test 

circuits being served by 17 different test cables. All of the test cables were seven-conductor, 

No. 12 AWG wires with polyethylene (PE) insulation and enclosed within a polyvinyl chloride 

(PVC) outer jacket. All of the test cables were laid in standard ladder-type trays with other, socalled ―fill‖ cables. The fill cables were used to provide additional fuel during the fire and were 

typically of the same type (i.e., TS or TP) to the cable under test. These additional cables were 

not grounded. The two cables supporting the switchgear (SWGR) close and trip circuits were 

located in the C position of the intermediate-scale test cell (Figure 3-2 in the main body of this 

report). They were bundled together with two other test cables—one supporting the MOV-2 

circuit and the other supporting the SOV-2 circuit—along with additional fill cables. The 

principal thermal exposure mode at the C position in the test cell is by hot gas layer rather than 

by direct plume impingement. The heat source for the test cell is a gas burner located at the 
A-30

intersection of the long and short centerlines of the cell, and located directly below the center of 

the cable tray at Position A. The heat release rate is controlled by a gas flow control valve.

DCCCS COMPONENT LAYOUT FOR 15KV SWGR CIRCUIT

Close Circuit (15 A) Bay

From 15 A 

Fuse

From 15 A 

Fuse

To A6/A4

To A5

To A3

508 mm X 457 mm

(20 in. X 18 in.)

Baseplate

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

C1

N1

PC

REAR

FRONT

KEY

18 AWG

12 AWG

 8 AWG

Current

Transmitter

Current

Transmitter

Figure A-35 dc-SIM panel component arrangement for the switchgear control circuit—

close circuit (15-A) bay

DCCCS COMPONENT LAYOUT FOR 15KV SWGR CIRCUIT

Trip Circuit (35 A) Bay

From 35 A 

Fuse

From 35 A 

Fuse

To A10

To A8

To A9/A12

To A11

508 mm X 457 mm

(20 in. X 18 in.)

Baseplate

KEY

18 AWG

12 AWG

 8 AWG

FRONT

REAR

Voltage

Transmitter

N2

T

SP

SP

PT

G

R

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Current

Transmitter

Current

Transmitter

Current

Transmitter

Current

Transmitter

1.8 K

1.8 K

Figure A-36 dc-SIM panel component arrangement for the switchgear control circuit—

trip circuit (35-A) bay

Briefly, the test was started at 11:34:25 a.m. At 11:55:34 (approximately 21 minutes into the 

test) smoke was discovered coming from the interior of the circuit breaker. Flame was not 

observed. Power to both the close and trip circuits was isolated by opening the 50-A and 60-A

circuit breakers. The test run continued for another 21 minutes before being shut down.
A-31

A.4.2.2 Test Setup

The 15-kV circuit breaker was connected to the two test cables by a single return cable from 

the back side of the intermediate-scale Test Cell. Appendix A.7 provided additional detail on 

the characteristics (wire gauge and lengths) for the various lead cables and a general 

description of the overall battery power system. To summarize, the two switchgear circuit 

cables (close and trip) were connected to the circuit lead cables, run from the dc-SIM panels in 

the instrument trailer to the igloo test bunker, by use of a junction box located on the floor of the 

test bunker. Battery power to the switchgear circuits came into the dc-SIM panels via load 

cables from the two breaker panels located on the side of the battery trailer. The switchgear’s 

close circuit was routed through a 50-A circuit breaker in the breaker panel and the trip circuit 

through a 60-A circuit breaker. The cables feeding the individual circuit breakers were run 

through conduit from the main battery disconnect switch, also located on the outside of the 

battery trailer. It should be noted that these breakers were provided mainly for personnel 

protection and were not intended to provide primary protection to the test circuit. Primary 

protection is provided by the individual trip and close circuit fuses.

Elementary Diagram for DSE 15KV Switchgear 125VDC Control Circuit (from Fig. 1-6 in SU-6150-2A, MARCH 1978)

52

a

15A

15A

125 VDC BATTERY CABLES

35A

35A

G PT C1

N1

52IS-2

Close Coil L1

A5 Charging Motor

A6

A10 A8

N2

A11

52

TC Trip

Coil

A12

R T

Anti- Pump Relay 52Y

52Y

a

L21 52IS-1

A3

A4 A9

PC 1800 1800

50A 60A 200A

200A

52LS

aa

50A

52

b 52a 52

a

60A

BATTERY DISCONNECT SWITCH

BREAKER SHOWN ―OPEN‖ WITH CLOSING SPRING ―CHARGED‖

CT35

VT7 CT35 CT35

CT500

CT35

VTU

VT7 VT7 VT7 VTU

VTU CT35 VTU CT35

10K

10K

VTU VTU

VT7

M

52LS

bb

[1]

[M]

[2]

[3]

52Y

b

52X

[63]

[64]

52

b [64X] [8] [6]

[4] [7]

[9]

[66]

[10]

BREAKER: OPEN OPEN CLOSED CLOSED

SPRING: DISCHG'D CHARGED DISCHG'D CHARGED

52/a X X

52/b X X

52LS/aa X X

52LS/bb X X

52IS-1# X X X X

52IS-2# X X X X

52Y/a X* X*

52Y/b X X * *

* APPLIES ONLY WITH A SUSTAINED SHORT ON C1

#

 REQUIRES INTERLOCK TO BE DEFEATED

SWITCH CONTACTS

50A

50A

Figure A-37 Elementary diagram for the 15-kV switchgear showing normal connections 

to the test cables

Figure A-37 shows the normal configuration of the switchgear circuit connections to the dc-SIM

panel and the interfacing test cables. In the figure, the diagnostic information is represented by 

boxes designated as ―CT35‖ for current transmitters, ―VT7‖ for bidirectional voltage 

transmitters, and ―VTU‖ for unidirectional voltage transmitters. Also indicated in the figure are 
A-32

the various isolation devices for the circuits, including fuses, circuit breakers, and the main 

battery disconnect switch. The ground monitoring circuit is also shown. The positions of the 

contacts internal to the switchgear shown in the figure represent the configurations for the 

breaker in its normal pre-test setup (i.e., OPEN with the spring charged).

Figure A-38 shows the normal connections made from the switchgear return cable at the A

connector panel on the front of the switchgear unit. None of the other connector pins on the B, 

C, or D connector panels were used during any of the DESIREE-Fire tests.

CLOSE CIRCUIT CABLE PC connects to A3 C1 connects to A5 N1 connects to A4 & A6 SP1 not connected SP2 not connected SP3 not connected SP4 not connectedTRIP CIRCUIT CABLE PT not connected G connects to A10 R connects to A8 T connects to A11 SP1 not connected SP2 not connected N2 connects to A9 & A12 BKR CONTROL CONNECTOR CLOSE CIRCUIT

TRIP CIRCUIT

VIEW FROM BACK OF BREAKER A

3

5

7

9

11

4

6

8

10

12

PC

C1 N1

R

G T N2

Figure A-38 Normal connection arrangement of the switchgear return cable to the 

switchgear connection panel

A.4.2.3 Description of Event

Figure A-39 provides the current and voltage plots for PT, N2, and G at the time of the event. 

Notice that the current rise for PT and N2 cuts off at 7 A. This is because the current 

transducer is rated at 35 A and was set up with five turns of the conductor through its pick-up

coil; thus there is a multiplication effect associated with the transducers. A 7-A conductor 

current is amplified by a factor of five and appears to the transducer to be a 35-A current, which 

saturates the transducer. The drop-off occurred because one of the switchgear internal panel 

wires that was also exposed to that current acted as a slow-blow fuse and opened because so 

much heat was generated that the copper conductor in the 16-gauge panel wire melted. That 

phenomenon is what stopped further damage from occurring.
A-33

Figure A-40 provides the plot of the data generated by the CT-500 current transducer over the

period of the event. Note that no indication of high current input from the battery was recorded

during the time of the event.

A.4.2.4 Event Investigation

On November 18, 2009, an investigation of the event took place. The scope of the 

investigation included the wiring of the switchgear from the test and return cables, the interior 

wiring of the switchgear, and the connection of the test cables to the dc-SIM panels. 

Attachment 2 provides the handwritten notes taken by one of the investigators during this 

activity.

One of the first things discovered by the investigators was that the connections made at the 

terminal block from the switchgear return cable were reversed (left to right) from what they 

should have been. This is explained above.

Figure A-41 shows a photo of the front of the switchgear. No physical damage is evident in this 

view. Figure A-42 and Figure A-43 show different views of the damaged panel wires 

immediately behind the connector block. Figure A-44 shows damage to some of the wires 

inside the bundle behind the connector block. Figure A-45 and Figure A-46 show damage to 

the wires located in the wireway between the connector block and the auxiliary contacts. 

Figure A-47 shows wire damage near the auxiliary contact and Figure A-48 shows wire 

damage at the auxiliary contacts.

Time (s)

1060 1080 1100 1120 1140

Current (Amps)

-2

0

2

4

6

8

SWGR-T PT 

SWGR-T G 

SWGR-T N2

1060 1080 1100 1120 1140

Voltage (Volts)

-40

0

40

80

120

160

SWGR-T V(PT) - V(Batt -) 

SWGR-T V(G) - V(Batt -) 

SWGR-T V(N2) - V(Batt -) 

Figure A-39 Test IS8 current/voltage plots for SWGR PT, N2, and G at 1100 seconds

Current Transducers Saturated 
A-34

CT500

Time (s)

1060 1080 1100 1120 1140

Current (A)

-6

0

6

SWGR_CT500

Figure A-40 Data recorded from the CT-500 current transducer during the event

Figure A-41 Front of the switchgear unit. The return cable connections are being made 

at the left side.
A-35

Figure A-42 Damaged panel wires immediately behind the connector block

Figure A-43 Another view of damaged panel wires immediately behind the connector 

block
A-36

Figure A-44 Damage to some of the wires inside the bundle behind the connector block

Figure A-45 Damage to the wires located in the wireway between the connector block 

and the auxiliary contacts
A-37

Figure A-46 Another view of damage to the wires located in the wireway between the 

connector block and the auxiliary contacts

Figure A-47 Panel wire damage near the auxiliary contacts
A-38

Figure A-48 Panel wire damage at the auxiliary contacts

Severe damage was experienced by the internal conductors leading from G at connection 

panel point A10 to the 52/b auxiliary contact and then to N2 at connection point A9. These 

wires are identified as 8 and 7, respectively, in Figure A.4-8. Other internal panel wires located 

and routed in close proximity to 7 and 8 also incurred some damage, but to a much lesser 

extent.

Figure A-49 and Figure A-50 are analogs of Figure A-37 and Figure A-38 showing the actual 

circuit configuration versus the expected circuit configuration. These figures show the effect of 

reverse connecting the return cable conductors to the switchgear connection panel. Figure 

A-49 shows the internal wiring of the switchgear close and trip circuits turned over because of 

the reverse wiring. Figure A-50 shows the reverse connections made at the switchgear 

connection panel.

Because the same internal panel wires 7 and 8 were connected between conductors G and N2 

the interposing auxiliary contact 52/b is closed. This condition did not depend on the correct 

wiring of the return cable. Thus it was determined that the internal switchgear damage would 

likely have occurred given the same shorting circumstances even if the return cable had been 

correctly connected to the circuit breaker control connector.
A-39

Elementary Diagram for DSE 15KV Switchgear 125VDC Control Circuit Showing Reversed Connections

15A

15A

125 VDC BATTERY CABLES

35A

35A

G PT C1

N1

Close Coil

L1

A6

Charging Motor

A5

A9 A7

N2

A12

Trip

Coil

A11

R T

Anti- Pump Relay L21

A4

A3 A10

PC 1800 1800

50A 60A 200A

200A

52LS

aa

50A 60A

BATTERY DISCONNECT SWITCH

BREAKER SHOWN ―OPEN‖ WITH CLOSING SPRING ―CHARGED‖

CT35

VT7 CT35 CT35

CT500

CT35

VTU

VT7 VT7 VT7 VTU

VTU CT35 VTU CT35

10K

10K

VTU VTU

VT7

[1]

[M]

[2] 52X

[63]

[64]

[64X] [8]

[7]

[9]

[66]

[10]

BREAKER: OPEN OPEN CLOSED CLOSED

SPRING: DISCHG'D CHARGED DISCHG'D CHARGED

52/a X X

52/b X X

52LS/aa X X

52LS/bb X X

52IS-1# X X X X

52IS-2# X X X X

52Y/a X* X*

52Y/b X X * *

* APPLIES ONLY WITH A SUSTAINED SHORT ON C1

#

 REQUIRES INTERLOCK TO BE DEFEATED

SWITCH CONTACTS

50A

50A

52

a

52

TC 52LS

bb

M

52IS-1 A8

52

a 52

b

[6] 52IS-2

[4]

52Y

52Y

a 52

a

52

b

52Y

b

[3]

DAMAGED INTERNAL CONDUCTORS

Figure A-49 Internal switchgear wiring connections resulting from reverse connections 

at the terminal panel

A.4.2.5 Summary and Conclusions

The results of the investigation determined a number of issues regarding the use and operation 

of the 15-kV circuit breaker unit as part of the DESIREE-Fire tests:

 No double-check of the connection to the circuit breaker was made after the final 

hookup.

 It was determined that the sizes of the fuses on the close and trip circuits were too

large to protect the 16-gauge internal panel wiring.

 The instrumentation being used on the switchgear circuits was not able to provide 

the data needed to clearly identify the cause of the large current that resulted in 

damage.

 It is likely that the damage would have occurred even if the connection to the 

breaker’s control panel had been installed correctly.
A-40

CLOSE CIRCUIT CABLE PC connected to A4 C1 connected to A6 N1 connected to A3 & A5 SP1 not connected SP2 not connected SP3 not connected SP4 not connectedTRIP CIRCUIT CABLE PT not connected G connected to A9 R connected to A7 T connected to A12 SP1 not connected SP2 not connected N2 connected to A10 & A11 BKR CONTROL CONNECTOR CLOSE CIRCUIT

TRIP CIRCUIT

VIEW FROM BACK OF BREAKER A

3

5

7

9

11

4

6

8

10

12

PC

C1 N1

R

G T N2

REVERSED CONNECTION DIAGRAM

Figure A-50 Reversed connections made at the terminal panel

A.4.3 The Replacement 4.16-kV GE PowerVac® Breaker 

After damaging the 15-kV breaker, a refurbished medium voltage circuit breaker configured 

with a 125-VDC control circuit that uses 20-A and 35-A fuses for the close and trip circuits was 

donated through the EPRI collaboration. The breaker was a -5kV class GE PowerVac®, Model 

VB1-4.16-250, 1200 A, 4.16 kV.

From the manufacturer’s summary description, the vacuum circuit breaker uses sealed vacuum 

power interrupters to establish and interrupt a primary circuit. Primary connections to the 

associated metalclad switchgear are made by horizontal bars and disconnect fingers, 

electrically and mechanically connected to the vacuum interrupters. The operating mechanism 

provides direct motion at each phase location in order to move the movable contact of the 

vacuum interrupters from an open position to a spring-loaded closed position and then back to 

the open position on command.

The ML-18 and ML-18H mechanisms are of the stored-energy type and use a gear motor to 

charge a closing spring. During a closing operation, the energy stored in the closing spring is 

used to close the vacuum interrupter contacts, compress the wipe springs that load the 

contacts, charge the opening spring, and overcome bearing and other friction forces. The 

energy then stored in the wipe springs and opening spring will open the contacts during an 

opening operation.
A-41

Closing and opening operations are controlled electrically by the metalclad switchgear or 

remote relaying. Mechanical control is provided by manual close and trip buttons on the circuit 

breaker. The closing spring may be manually charged.

Figure A-51, Figure A-52, and Figure A-53 provide representative drawings for the new 

switchgear.

PC

C1

G

R

T

SP

N2

PT

N1

A

A

A

A

A

A

V

V

V

V

V

V

V

V

V

DCSIM Schematic Diagram for GE VB1 Switchgear DC Control Circuit

+

1

-

25 VDC

60 A BKR

15A

35A

DCSIM CABLE UNDER TEST

FROM DISTRIBUTION 

CIRCUIT BREAKER

15A

35A

1800

1800

L3

L5 & L7

L11

L15

L9

L10, L12 

& L16

L4 & L6

VB1 SWGR

SP

V

A

+

1

-

25 VDC

50 A BKR

Figure A-51 dc-SIM panel layout for the control circuit on the GE VB1 SKV switchgear 

dc control circuit
A-42

52Y 52Y 52_

SM/LS 52_SM/LS 52Y 52_

CL/MS

CLOSE COIL 52Y 52

b

52_

LCS 52_

IL/MS

52_

CHG

52

a

52

a

TRIP COIL M

7

1

3

9 7

4

L7 3

4

L5 L2

1

2

1

2

1

2 L1

L21 B

A 5 6 L6 L8

Y

Y Y D

Y

LC

P

CC D

1

2

1

2

1

2

1

2

L3

L4

S

T

D

M

MOTOR

CLOSE SCHEME

P

P

TC

3

4

8

7

1

2

L9

L10

TRIP SCHEME

52

b 52a

L12 L16

L11 L15

P P 9

10 1112

INDICATION

BL1 L

R

CLOSE CIRCUIT CABLE PC connects to L3 C1 connects to L5 & L7 N1 connects to L4 & L6 SP1 not connected SP2 not connected SP3 not connected SP4 not connected TRIP CIRCUIT CABLE PT not connected G connects to L11 R connects to L15 T connects to L9 SP1 not connected SP2 not connected N2 connects to L10, L12 & L16 4 3 2 1 8 7 6 5 12 11 10 9 16 15 14 13 20 19 18 17 24 23 22 21

CONNECTION PANEL ―L‖

VIEW FROM BACK OF BREAKER Elementary Diagram for GE VB1 Switchgear 125VDC Control Circuit (from Fig. 18 in GEK-86132G) Figure A-52 GE VB1 5-kV circuit breaker elementary diagram
A-43

CLOSE CIRCUIT CABLE PC connects to L3 C1 connects to L5 & L7 N1 connects to L4 & L6 SP1 not connected SP2 not connected SP3 not connected SP4 not connectedTRIP CIRCUIT CABLE PT not connected G connects to L11 R connects to L15 T connects to L9 SP1 not connected SP2 not connected N2 connects to L10, L12 & L16

4 3 2 1 8 7 6 5 12 11 10 9 16 15 14 13 20 19 18 17 24 23 22 21

BKR CONNECTION PANEL ―L‖ PC

N1

N2

G

R

T CLOSE CIRCUIT TRIP CIRCUIT C1

VIEW FROM BACK OF BREAKER Figure A-53 GE VB1 5-kV circuit breaker connection diagram
A-44

A.5 dc-Powered Intercable Short Detection Circuit

One specific goal of the CAROLFIRE tests was to explore the potential for risk-relevant 

electrical shorting interactions between two separate cables (i.e., intercable shorts that might 

cause a spurious operation). DESIREE-Fire provided an opportunity to explore similar 

behaviors for dc-powered cables. Limited exploration of intercable interaction potential using 

the dc battery bank was performed.

Figure A-54 depicts a simple configuration, contrived to provide a solid chance of inducing 

proper polarity shorting within the target cable from the positive and negative source cables. 

Note that all of the conductors in a particular source cable were energized to the same polarity 

and their voltage being monitored as a group (i.e., one voltage monitor per source cable). The 

seven individual conductors in the target cable were monitored for voltage. Additionally, the 

outer six conductors of the target cable (2 through 7) were connected together in a resistance 

network so that ―float‖ voltages were distributed among the separate conductors. Figure A-55, 

Figure A-56, and Figure A-57 provide the electrical schematic and resistor connection 

arrangement, respectively. Also note that conductor number 1 was not part of the resistance 

network, but was monitored for changes in voltage. 

During the Penlight testing, the marinate board provided electrical isolation from the ground 

plane so that multiple shorts to ground do not result in a fuse actuation and to limit the 

possibility of forming a ground bias of the battery by the first short to ground, by either of the 

source cables. Throughout the intermediate-scale experiments, however, the intercable bundle 

was placed in various locations in the cable tray (i.e., in direct contact with the tray, positioned 

between fill cables, and on top of the fill cables). The specifics for each test can be found in 

Appendix F. 

In these intercable tests, the target cables were not connected to anything other than voltage 

monitoring instruments. In this configuration, shorting between the source and target cables 

will be indicated by a change in voltage potential. Figure A-58, Figure A-59, and Figure A-60

show examples of how the voltage readings on individual target conductors are expected to 

vary depending upon which of the target conductors are directly energized by the positive and 

negative sources. These are ideal conditions and do not assume any intracable interactions 

have occurred within the target. Both thermoset (TS) and thermoplastic (TP) cables were used

throughout the Penlight and intermediate-scale experiments. 

2

1

5

7 3

6 4

INSULATOR (e.g., MARINITE BOARD)

S1+

S1+

S1+

S1+ S1+

S1+ S1+

S2-

S2-

S2-

S2- S2-

S2- S2-

S2+

S2+

S2+

S2+ S2+

S2+ S2+

S1-

S1-

S1-

S1- S1-

S1- S1-

Positive 

Source 

Cable #2

Positive 

Source 

Cable #1

Negative 

Source 

Cable #2

Negative 

Source 

Cable #1

Figure A-54 Cable grouping with multiple source cables surrounding the target
A-45

Figure A-55 Intercable monitoring and power circuit where four source cables are 

separately powered and fused from the battery; the seven conductors of 

the target cable are individually monitored for voltage and interconnected 

with a resistance network

V

V

Layout for DC Intercable Interaction Detection Circuit

+

-

125 VDC

INTERCABLE DETECTION PANEL

FROM DISTRIBUTION CIRCUIT 

BREAKER PANEL

S1+

1

2

S1-

CABLE UNDER TEST

10A

10A

FUSE BLOCK

10A S2+

10A S2-

V

V

V

V

V

3

V

4

V

5

V

6

V

7

1800

1800

1800

1800

1800

1800
A-46

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

COMPONENT LAYOUT FOR DC INTERCABLE INTERACTION 

DETECTION CIRCUIT

508 mm X 457 mm

(20 in. X 18 in.)

Baseplate

From Circuit Fuse-1

Voltage

Transmitter

FRONT

REAR

KEY

18 AWG

12 AWG

 8 AWG

Voltage

Transmitter

From Circuit Fuse-1

From Circuit Fuse-2

From Circuit Fuse-2

S1+(A)

S2+(B)

1

2

3

4

5

6

S1-(A)

S2-(B)

7

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

S1+(B)

S2+(A)

S1-(B)

S2-(A)

Figure A-56 Component layout for intercable monitoring and power circuit where four 

source cables are separately powered and fused from the battery; the 

seven conductors of the target cable are individually monitored for voltage 

and interconnected with a resistance network

2

1

5

7 3

6 4

Figure A-57 Intercable configuration showing the network of resistors connected to 

the individual conductors of the target cable

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter

Voltage

Transmitter
A-47

2

1

5

7 3

6 4

S+

S2

7

6

5

3

4

S+

SIf S+ = +60 Volts and if 

S- = - 60 Volts, then 

V2 = S+ = +60 Volts, 

V3 = V7 = +20 Volts, 

V4 = V6 = -20 Volts, 

V5 = S- = -60 Volts

Equivalent Network

Analysis 

Summary

Figure A-58 Cable network analysis for the case of a positive interaction on conductor 

2 and a negative interaction on conductor 5 (180-degree separation)

2

1

5

7 3

6 4

S+

S2

7

6

3

4

5

S+

SIf S+ = +60 Volts and if 

S- = - 60 Volts, then 

V2 = S+ = +60 Volts, 

V3 = +30 Volts,

V4 = 0 Volts, 

V5 = -30 Volts,

V6= S- = -60 Volts,

V7 = 0 Volts

Equivalent Network

Analysis 

Summary

Figure A-59 Cable network analysis for the case of a positive interaction on conductor 

2 and a negative interaction on conductor 6 (120-degree separation)
A-48

2

1

5

7 3

6 4

S+

S2

7

6

3

4

5

S+

SIf S+ = +60 Volts and if 

S- = - 60 Volts, then 

V2 = S+ = +60 Volts, 

V3 = +36 Volts,

V4 = +12 Volts, 

V5 = -12 Volts,

V6= -36 Volts,

V7 = S- = -60 Volts

Equivalent Network

Analysis 

Summary

Figure A-60 Cable network analysis for the case of a positive interaction on conductor 

2 and a negative interaction on conductor 7 (60-degree separation)
A-49

A.6 ac-Powered Surrogate Circuit Diagnostic Unit

Figure A-61 depicts the electrical schematic drawing of a simplified ac MOV control circuit. The 

block diagram is shown in Figure A-62 with the target Cable B highlighted. The contacts 

shown in Figure A-61 indicate that the valve is in the closed position; therefore the failure 

modes of concern are those cases wherein the valve could be made to spuriously open.

MOV Position Contacts

Control Board Hand Switches and Indication

X

U

G

HSCLOSE

HSOPEN

FU

G

C

R

R

O

NC NO

NO NO

NC NC

C O

33U42O 42C

33LControl Power 

Transformer

Figure A-61 Simplified ac-powered MOV control circuit, with control panel transformer 

(CPT)
A-50

MCC

CB

MOV A

P

B

X, N, G, R, C, O, SP

X, G, R

T1, T2, T3

Figure A-62 Block diagram for simple ac-powered MOV control circuit

Figure A-63 shows an analog of the simulated ac MOV control circuit that was employed during 

the early EPRI/Nuclear Energy Institute (NEI) tests and during CAROLFIRE. An 120V ac

power source, a 1750-ohm resistor representing an indicator lamp, and two relay coil targets 

are connected to the simulated circuit. A seven-conductor cable connected to the Surrogate 

Circuit Diagnostic Unit (SCDU) is the device under test. Although it is possible to encounter a 

circuit in a NPP that is supplied with power directly for a power source, typically a CPT is used. 

Testing of the circuit in Figure A-63 would provide little to no information on the effects of a 

CPT in limiting the probabilities of spurious actuation and therefore was not tested in this 

testing program.

1

2

3

4

5

7

6

A

A

A

A

A

A

A

A

A

V

V

V

V

V

V

V

V

V

S1

S2

S3

S4

S5

S6

JUMPER

3A

K1

K2

AC

1750 ohms

1750 ohms

AC SCDU CABLE UNDER TEST

120 VAC Power Supply

Figure A-63 Simulated ac MOV control circuit, without CPT (not tested)
A-51

Figure A-64 shows the same control circuit being powered through a CPT. It should be noted 

that by changing the switch arrangements, these cable configurations can be easily changed, 

for example, to connect the ungrounded spare conductor (#7) to ground, or, if desired, to 

change conductor #2 from an energized state to an ungrounded spare.

G

X

C

O

R

U

SP

A

A

A

A

A

A

A

V

V

V

V

V

V

V

V

V

S1

S2

S3

S4

S5

S6

NC

NC

N/C

1750

120 VAC

3A

N/C

O

NO

NC

C

A

A

1750

AC SCDU CABLE UNDER TEST

CONTROL POWER

TRANSFORMER

Figure A-64 Simulated ac MOV control circuit, with CPT

The motor starters used during CAROLFIRE were, in hindsight, found to require far less motive 

power to lock in and hold a spurious actuation signal than anticipated. The intent in 

CAROLFIRE had been to obtain motor starters that required a nominal 100 VAC of power to 

lock in a relay actuation. In practice, while the relays obtained were cited as 100 VAC relays, it 

actually took a much smaller power level to lock in an actuation (on the order of 60 VAC). As a 

result, CAROLFIRE was unable to resolve one of the original Regulatory Information Summary 

(RIS) 2004-03, ―Risk-Informed Approach for Post-Fire Safe-Shutdown Circuit Inspections,‖ 

unresolved issues; namely, that item related to how CPT size relative to the nominal circuit 

required power would impact spurious actuation likelihood. The CPT units used in 

CAROLFIRE were sized against the anticipated 100-VAC power requirement for the relays. 

Given the actual power requirement of the relays, the CPTs were, in effect, over-sized. As a 

result, the CAROLFIRE tests did not experience the same type of CPT power drawdown 

observed in the original NEI/EPRI testing program.

To rectify this problem the existing motor starter relays were replaced with Joslyn-Clark3

(current part number is T30U031) for the DESIREE-Fire test series. SCDU-1 and SCDU-2 

were replaced with the original motor starter sets used during the NEI tests while SCDU-3 and 

SCDU-4 were replaced with newly purchased motor starter sets, identical sets of these 

 

3 Note that the EPRI test report (TR-1003326, page 4-13) cites ―AO Smith (Clark Controls Division) Catalog 

#30U031‖ as the make and model of the motor starters used in that test program. AO Smith has since merged with 

Joslyn controls. The combined company is known as Joslyn-Clark Controls. The same model motor starter relays 

are sold under the Joslyn-Clark brand using essentially the same catalog number (T30U031).
A-52

controllers. All of the sets of motor starters included the mechanical interlock devices except 

SCDU-2, which was used as shipped by EPRI.

These interlocks more realistically represented the actual plant circuit implementation and 

provided a new aspect to the test data not previously explored. Although the original intention 

was to test the ac systems for each intermediate-scale experiment, a decision was made to 

shift the large ranged dc-rated current transducers (i.e., CT500) for each dc circuit onto the 

SCDU’s high-speed data acquisition system. As such, only the first seven tests (i.e., JPN-IS1, 

Prelim1, Prelim2, ISTest4, ISTest8, ISTest11, and ISTest12) included the SCDU circuits.

Table A-12 identifies the conductor-to-conductor interactions required to occur within Cable B 

to cause a specific circuit malfunction, including spurious opening of the valve. It is also 

worthwhile noting that no immediate discernible effect occurs if conductors X, O, C, or R 

experience an open circuit failure (conductor break) as the initial failure mode.

Table A-12 Identification of specific intracable induced circuit failure modes for the ac 

MOV.

Circuit Failure Effect Will occur if any of 

these conductors...

Come into contact 

with any of these 

conductors...

Notes

Valve spuriously opens X, G O

Loss of valve control U O, R

Circuit fuse(s) will blow 

if an attempt is made to 

open the valve while 

this internal short 

condition exists.

Loss of circuit power 

(blown fuse(s)) X, G U

Erroneous/spurious 

valve position indication X, G R

Loss of valve position 

indication — —

Open circuit failure of 

conductor G or U.

The MOV contactors were electrically characterized following the intermediate-scale tests in 

order to determine their actual pick-up and drop-out voltage and current thresholds. Table 

A-13 provides a summary of each MOV contactor’s electrical characteristics.

Table A-13 ac MOV contactor coil pick-up and drop-out characteristics.

Device

Average Pickup Voltage 

(Vdc)

Average 

Pick-up 

Current (A)

Average 

Drop-out 

Voltage 

(Vdc)

Average 

Drop-out 

Current (A)

SCDU-1 (T5) 93.9 0.07 71.7 N/A

SCDU-1 (T6) 80.5 0.08 67.1 N/A

SCDU-2 (T5) 81.1 0.08 60.1 N/A

SCDU-2 (T6) 79.7 0.08 69.5 N/A

SCDU-3 (T5) 82.3 0.09 64.6 N/A

SCDU-3 (T6) 83.2 0.08 57.5 N/A

SCDU-4 (T5) 85.1 0.08 59.7 N/A

SCDU-4 (T6) 85.0 0.08 57.2 N/A
A-53

A.7 The dc Battery Bank and Power Distribution System

A.7.1 Overview

The battery bank was built to supply a nominal 125-Vdc power source. The batteries were 

obtained through the NRC-RES/EPRI memorandum of understanding (MOU) and were being 

taken out of service from the North Anna Nuclear Station Technical Support Center as a part of 

preventative maintenance. The battery cells had reached their nominal end-of-life conditions, 

but were still in serviceable condition and were transported to Sandia National Laboratories 

(SNL) for use in this test project.

A.7.2 Basic Design Parameters

The dc power supply battery bank was constructed using a set of Exide model ES-13 calcium 

flat plate, lead/acid, nominal 2.1-Vdc uninterruptible power supply (UPS) battery cells. Each 

cell contains approximately 9.1 liters (2 gallons) of sulfuric acid as the electrolyte. A total of 60 

cells were used in the main battery bank. Eight spare cells were also available, but were not 

used in the program as no cell failures occurred during testing.

Before installation, all of the individual battery cells were tested by an independent testing 

laboratory using IEEE Standard 450-1995, IEEE Recommended Practices for Maintenance, 

Testing and Replacement of Vented Lead-Acid Batteries for Stationary Applications [1]. All of 

the cells used in testing, including the spare cells, were certified as being in good working 

condition. 

Cell handling was performed in accordance with IEEE Standard 484-2002, IEEE 

Recommended Practice for Installation Design and Implementation of Vented Lead-Acid 

Batteries for Stationary Applications [2]. Load/capacity calculations were performed in 

accordance with IEEE Standard 485-1997, IEEE Recommended Practice for Sizing Lead-Acid 

Batteries for Stationary Applications [3].

The basic design parameters of the battery bank are summarized as follows:

 Cell type: Exide ES-13, lead alloy acid-filled cells

 Nominal open circuit voltage: 2.06 V 

 Nominal cell float voltage: 2.17–2.26 V

 Total cell count in main battery bank: 60

 Nominal bank float voltage: 125 V

 Available short circuit current at the battery terminals: approximately 13,680 A

 Cell-to-cell connections: Exide lead-plated copper bars and bolts 

Table A-14 and Table A-15 provide additional physical information for the individual battery 

cells as provided by Exide.

Table A-14 Exide battery cell dimensions from the manufacturer's literature.

(in.) (mm) (in.) (mm) (in.) (mm)

4.87 124 10.8 274 18.7 475

ES-13

Exide Calcium Flat Plate Battery Cell

Model Type Container Length Container Width Height

Overall Dimensions
A-54

Table A-15 Exide battery cell weight from the manufacturer's literature.

(lbs) (kg) (lbs) (kg) (lbs) (kg) (gal) (liters)

81 36.7 83 37.6 20 9.1 2.0 7.6

ES-13

Exide Calcium Flat Plate Battery Cell

Model Type Unpacked Domestic Packed Electrolyte Only

Weights -- Volumes

A.7.3 Battery Banking Housing and Connections

The battery cells were installed in a portable transportainer providing personnel protection, spill 

containment (in the event of a cell leak or rupture), environmental protection to the cells, and 

the ability to transport the cells between testing sites. The transportainer was provided with 

both heating and cooling to ensure that the cells did not deviate from the manufacturerspecified operating or storage conditions. Figure A-65 provides a nominal schematic of the 

battery cell layout within the transportainer.

Intercell connections were removed during transport. Once in place on site, the intercell 

connection plates were installed in accordance with manufacturer specifications. The 

connections were also tested for continuity using a micro-ohm meter and in accordance with 

manufacturer specifications. Any out of compliance connections were reworked to ensure an 

acceptable level of terminal-to-terminal resistance and consistency between connections. 

Figure A-66 provides a photograph of the battery cells during work to install the cell-to-cell 

connector plates.

#1

#60

#21 #20 Safety Interrupt Location

#40 #41 Safety Interrupt Location

120 Volt Battery Bank Spares Figure A-65 Battery enclosure layout
A-55

Figure A-66 Photo of the battery assembly

An automatic charging system capable of recharging the cells over night was also installed. 

The charger was capable of providing both a freshening charge and float charging. All cells 

received a freshening charge when they arrived at SNL. Once installed, the battery bank also 

received a freshening charge. The bank was then recharged periodically throughout the 

course of testing. In general, the bank would be recharged at least weekly during the smallscale tests where the loads on the cells were relatively modest. During the larger--scale tests, 

the cells would be charged as a minimum after completion of two tests. The charger was 

secured and disconnected from the battery bank during testing.

The battery bank was ungrounded, although ground faults during testing were expected and a 

ground-fault monitoring circuit was included in the test design and monitored during testing.

A.7.4 Power Distribution

The battery bank was connected to the dc-SIM panels via a series of fuses and breakers. The 

power distribution system is illustrated schematically in Figure A-67. In order, progressing from 

the battery cells to the dc-SIM panels, were the following electrical features:

 The main terminal of the battery bank was connected to the power distribution system 

via two single-conductor 4/0 power cables (the battery bank was ungrounded).

 A primary disconnect switch.

o 250 - 125 VDC bus - 200-A contacts.

 200-A fuse on each of the main output cables (integral to the disconnect switch).

o Two each Littelfuse fuse, part number JTD-200ID. 

 A dc breaker distribution panel fed by 4/0 cables from the output of the 200A fuses and

with separate breakers for each test branch circuit.

o Two-pole dc circuit breakers rated at 250 Vdc.

o Circuit breaker capacities range from 30 A to 60 A depending on the specific 

circuit.
A-56

Latching 4PST Relay

DPDT Relay Controls

60 Volt 10 Amp Charger 60 Volt 10 Amp Charger

30 Volt Battery Bank 30 Volt Battery Bank

30 Volt Battery Bank 30 Volt Battery Bank

50 Amp 2 Pole 50 Amp 2 Pole 50 Amp 2 Pole 50 Amp 2 Pole

50 Amp 2 Pole Distribution Panel

+ +

Electrical Safety Break Electrical Safety Break 200 Amp Safety Disconnect

200 Amp Littelfuse KLNR 200

4/0 Wire

12 Hour Timer 20'x8'x8' Steel Battery Enclosure

Figure A-67 dc power skid schematic

 3/C, 8 American Wire Gauge (AWG) power cables connecting the dc breaker panel to 

the dc-SIM panels (each test circuit was serviced by an individual cable).

 A fuse on each incoming power feed cable to the dc-SIM panel.

o Fuse sizes are specific to each test circuit. Refer to the corresponding circuit 

descriptions for details.

 12 AWG cables connecting the dc-SIM panels to the test cables.
A-57

Figure A-68 provides a second schematic of the connections and cable lengths for each connection from the battery to the dc-SIM panels 

and to the test cables, including the lead cable to the switchgear unit itself. This figure includes specification of each cable’s wire gauge 

and length (e.g., for use in calculating voltage drops).

INSTRUMENT TRAILER IGLOO / TEST BUNKER

BATTERY TRAILER SWITCHGEAR TRAILER BATTERY BANK

DISCONNECT PANEL

DC SIM

BREAKER PANEL 1

MOV-1 MOV-2 1-in Coil Lg Coil IC-1 IC-2 BREAKER PANEL 2SOV-1 SOV-2 SWGR-C Gnd Det SWGR-T

PANELS JB JB JB JB JB INTER- MEDIATE SCALE TEST CELL

SWITCH GEAR

Battery Cables 2 cables, 1 conductor per cable Conductor size = 4/0 Cable length = 15 feet Power Cables 2 cables, 1 conductor per cable Conductor size = 4/0 Cable length = 3 feet Feeder Cables 1 2 cables, 1 conductor per cable Conductor size = 4/0 Cable length = 2 feet Load Cables 1 6 cables, 2 conductors per cable Conductor size = #8 AWG Cable length = 100 feet

Feeder Cables 2 2 cables, 1 conductor per cable Conductor size = 4/0 Cable length = 2 feet

Load Cables 2 5 cables, 2 conductors per cable (third conductor in Ground Detector cable connects DC Sim cabinet to Breaker Panel structure for ground continuity) Conductor size = #8 AWG Cable length = 100 feet

Circuit Lead Cables 10 cables, 7 conductors per cable Conductor size = #12 AWG Cable length = 75 feet (9 cables); 55 feet (1-inch valve circuit) Test Cables 10 cables, 7 conductors per cable Conductor size = #12 AWG Cable length = 30 feet

SWGR Return Cable 1 cable, 7 conductors Conductor size = #12 AWG Cable length = 150 feet

11/23/2009

200 A Fuse 200 A Fuse Disconnect Switch

Figure A-68 dc power connection layout for the intermediate-scale tests
A-58

It should be noted that for each of the test circuits, the primary circuit protection is provided by 

the individual circuit fuses. These fuses are intended to represent typical plant practices. The 

other circuit protection features (i.e., the breakers, 200-A main output fuses, and primary 

disconnect switch) are all provided for personnel protection and safety. These additional 

protective devices were selected to provide appropriate breaker-fuse coordination, but are not 

intended to represent in-plant practice.

A.7.5 Battery Bank Ground Fault Detection Circuit

The dc battery bank was nominally an ungrounded power supply system. A ground fault 

detection circuit provided the opportunity to monitor for shorts between the battery bank and 

ground (ground faults). Figure A-69 and Figure A-70 illustrate the line drawing as well as the 

component layout for this circuit.

V

V

10K

10K

Layout for DC Ground Detection Circuit and Battery Voltage 

Monitoring Circuit

+

-

125 VDC

GROUND DETECTION PANEL

FROM DISTRIBUTION CIRCUIT 

BREAKER PANEL

V

Figure A-69 Line drawing for the dc ground detection circuit

In practice, the ground detection circuit provides a monitored high-resistance (10,000-Ω) path 

between each side of the battery bank and the local ground plane. Under normal conditions 

(i.e., no ground faults present) the voltage monitor on the far right will read a nominal 125-VDC 

battery voltage, and each of the other two voltage transducers, those measuring across the two 

ballast resistors, reads exactly one-half that value. Should a ground fault occur on either side of 

the battery bank, the overall bank voltage would not change, but the voltages across the ballast 

resistors would both change. If, for example, there is a ground fault on the positive leg of the 

battery bank, the voltage across the positive-side ballast resistor would drop to zero, and that 

across the resistor on the negative side would rise to the full battery bank potential of 125-VDC.

To ensure proper operation, all experimental systems and equipment were connected to a 

common ground plane (e.g., facility ground). The voltage transducers for the various dc circuit 

simulator panels measured circuit path voltages relative to this same common ground plane. 

This is important to the data analysis because, while the dc battery bank is nominally 

ungrounded, the ground fault monitoring circuit does establish a nominal reference ground for 
A-59

the battery bank. That is, when measured relative to ground, the positive side of the battery 

bank is nominally +62.5Vdc and the negative side is nominally -62.5Vdc. Any battery ground 

faults that form over the course of testing (i.e., due to shorting between a conductor connected 

to battery positive or battery negative and ground) will result in changes to measured voltages 

on various individual circuit/conductor traces. These changes may not indicate a fault in that 

particular circuit/cable, but rather, may be strictly an artifact of the battery ground fault. This 

effect is illustrated in detail in the discussion of individual test results. 

COMPONENT LAYOUT FOR DC GROUND DETECTION CIRCUIT 

AND BATTERY VOLTAGE MONITORING CIRCUIT

From Circuit Breaker

508 mm X 457 mm

(20 in. X 18 in.)

Baseplate

From Circuit Breaker

10 K

10 K

Ground Connection

Voltage

Transmitter

Voltage

Transmitter

FRONT

REAR

KEY

18 AWG

12 AWG

 8 AWG

Voltage

Transmitter

Figure A-70 Component layout for the dc ground detection circuit
A-60

A.8 Other Systems and Additional Information

This section of the appendix is dedicated to the other support systems that were necessary for 

the successful implementation and completion of the experimental series.

A.8.1 Transducers

A.8.1.1 Current Transducers

A note should be made regarding the current transducers4used for monitoring the dc-powered 

test circuits. The transducers were based on Hall-effect current probes. Hall-effect probes were 

selected mainly because they are non-intrusive. Duke Energy had used current shunts in its 

testing. Shunts are low-resistance devices inserted into a circuit path that induce a small 

voltage drop proportional to current flow. Measuring the voltage drop provides a method to 

calculate current flow. In the Duke Energy tests these shunts proved problematic, in some 

cases failing due to sustained short-circuit currents. The EPRI peer team also expressed 

concern that the presence of shunts in the various circuit paths could act to limit short-circuit 

currents, potentially compromising or altering the fuse-blow behavior for the circuits.

The current transducers were selected in two sizes. Most had a range of +/– 35 Adc (Ohio 

Semitronics Model CTL-51/35, signal conditioner Model CTA201RX5), but the main input power 

leads to each circuit were also equipped with larger +/– 500 A transducers (Ohio Semitronics 

Model CTL-601/500, signal conditioner Model CTA201X5). The intent was for the smaller 

transducers to pick up the smaller currents associated with normal circuit operation and early 

faulting behavior, and the larger transducers would pick up the higher-current behavior 

anticipated as gross cable failures occurred. Through the course of testing, three separate 

issues arose that impact the analysis and interpretation of the test data.

The first issue encountered was an apparent drift in the zero-point offset of the transducers 

between the beginning and the end of a given test, and between the end of one test and the 

beginning of the next test. This problem was observed early during the Penlight test series. 

The supplier’s technical support was contacted and the source of the problem was identified. 

The Hall-effect sensors are basically magnetic coils that react to the fields created by the flow of 

electrical current producing a proportional voltage signal. When these devices are subjected to 

dc current flows, they will retain a certain degree of residual magnetism that is reflected as a 

non-zero voltage output. The magnetism will fade over time, and can be reversed by sending a 

reverse current signal through the pick-up core, but is an inevitable, but unadvertised, aspect of 

the devices when used for dc circuits. A separate drift existed during the first few minutes that 

instrument power (i.e., 120 VAC to turn on the equipment) was applied. These two unique 

occurrences prevented the uniform application of a zero-point offset.

These issues were discussed among the full peer team and potential options were explored. 

One option was to replace the Hall-effect transducers with shunts, but this was rejected for the 

same reasons that Hall-effect transducers were selected in the first place (as described above). 

Instead, a decision was made to continue the test program using the Hall-effect transducers and 

to deal with the offset issue in data analysis. To support the required data analysis adjustments, 

the testing protocol was modified in two ways. First, the transducers were energized up to 30 

 

4

All transducers were procured through Ohio Semitronics. Additional information may be ascertained from their 

catalog found on their website: https://www.ohiosemitronics.com/.
A-61

minutes before the beginning of a test to ensure that they were fully ―warmed up‖ before testing. 

Second, data logging was initiated before energizing the test circuits and a set of baseline test 

data without any current flow was collected. Third, once the test circuits were energized (i.e., 

the connections to the battery bank were closed) an additional period of baseline data logging 

was allowed. Finally, after the completion of a given test, a period of post-test data was 

gathered with the battery engaged and continuing until after the battery bank was disconnected 

from the circuits.

The analysis of test data has ―corrected‖ the current transducer data by subtracting out the pretest, pre-battery initiation, zero current offset value for each transducer. That is, the pre-test 

zero condition data are used to calculate an average zero-point offset for each current 

transducer, and that value is subtracted from all test readings. Note that this approach provides 

a nominal correction but is imperfect. This is because, as noted, the zero-point offset drifts 

through the course of a test depending on the current flow experienced by the transducer. No 

attempts were made to correct the data beyond reflecting the pre-test offset. The result is that 

the current measurements at the end of the test may indicate a small current flow even after the 

circuits are fully de-energized.

The second issue identified was related to transducer sensitivity. The 35-A transducers were 

chosen at the outset because the peer team was interested in the characteristics of the short 

circuit currents, which were expected to be much larger than the normal circuit operating 

currents. However, this meant that the transducers were not especially sensitive to the normal 

circuit operating currents (typically 1 A or less). The early tests also showed that the transient 

short circuit current pulses were simply too fast for the data logging system to fully catch (i.e., 

the transducers would ―see‖ the fault, but there was no assurance that the true peak current was 

being captured). After discussion with the peer team, a decision was taken to increase the 

sensitivity of the current transducers by looping the conductors repeatedly through the Halleffect sensor coils. That is, by looping a conductor through the transducer five times, the signal 

strength sensed by the transducer is multiplied by five. In this manner, all of the 35-A 

transducers were amplified by a factor of five (five loops) and the 500-A transducers by a factor 

of two (two loops). This amplification effect was reversed during data processing so that the 

processed data files and all of the plots presented in this report show the corrected data and the 

actual (corrected) current values.

The final issue that was identified for the current transducers impacted the larger 500-A 

transducers only. The data from early tests showed that these transducers did not appear to be 

picking up the current signals at all. Diagnosis of the installed transducers showed that they 

were properly wired and that they could detect a steady current flow as expected. However, 

even after amplification of the signal by a factor of two, the transducers still appeared insensitive 

to the current transients. That is, even when a 35-A transducer (effectively reduced to +/-7 A 

transducers by the amplification) saturated, the 500-A transducers will not show a 

corresponding current flow. Several measures were taken in an attempt to address this issue. 

The final measure taken was to shift all of the 500-A transducers to a data logging system 

capable of much higher logging speeds (100 Hz). The system used for monitoring the highranged current transducers was, in fact, the system normally used to record data from the 

SCDU circuits. Even this change did not yield the desired result. Again, operability of the 

revised data logging system was verified, but still the 500-A transducers were not providing 

meaningful data signals when the transient short circuits were observed. The root cause of this 

issue has not been traced. It is thought that the larger Hall-effect coils may simply not be fast 

enough to respond to the transient faulting behaviors that seem to be manifested in tenths of a

second. Overall, the 500-A transducers provided little or no data of value.
A-62

A.8.1.2 Voltage Transducers

Two types of voltage transducers were used for each circuit. When directly fed from a pole off 

the battery, a unidirectional transducer (Ohio Semitronics Model VTU-005X5) was used for 

monitoring the voltage. Typically, as an example, positive and negative source conductors were 

monitored using these types of transducers.

When a conductor was not tied to a specific battery terminal, such as a spare, a bi-direction 

transducer (Ohio Semitronics Model VT7-005X5-11) was used to monitor the voltage. This 

provided an opportunity to learn how the conductor was being affected by the other failing 

conductors.

A.8.2 Fuses, Fuse Holders, and Terminal Blocks

The fuses for the dc circuits were ordered through Ferraz-Shawmut.

5

 The MOV circuits were 

fused with 10-A, fast-acting, midget fuses (Model Number ATM10) and connected with a twopole fuse block (Model Number 30352). The SOV circuits were typically fused with 5-A, fastacting, midget fuses (Model Number ATM5). The 1-inch valve and the switchgear close circuits 

were fused at 15 A using the ATM15, fast-acting, midget fuses. The large coil was fused with 

25-A, fast-acting, midget fuses. The switchgear trip circuit was fused at 35 A, Model Number 

FRZ A2Y35-1.

Except for the 35-A fuses on the switchgear circuit, the fuses were housed within two-pole fuse 

blocks (Model Number 30352). The 35-A fuses were connected by two-pole fuse blocks, Model 

Number 20606.

The terminal blocks (Buchanan Model 223) used in each circuit were rated for up to 600 VDC.

A.8.3 Thermocouples

This test series provided additional cable thermal response data for the fire model improvement 

effort started in the CAROLFIRE test program.6 In this particular program, providing cable 

thermal response data was a secondary objective. However, measurements of the cable 

thermal response are important to characterize the environmental conditions leading to the 

failure, and additional data in this regards is considered quite valuable. As a ―target of 

opportunity,‖ cable thermal response data was gathered during the tests in a manner similar to 

that employed in CAROLFIRE, albeit with somewhat less instrument density.

As noted for CAROLFIRE, it is not appropriate to instrument any single cable for both thermal 

and electrical response. This is because installation of a thermocouple on, or within, a cable 

could impact the electrical failure behavior. Instead, the approach applied involves mirroring a 

cable being monitored for electrical performance with a second cable (in an adjacent or 

symmetric location) that monitored thermal response. Figure A-71 provides a graphical 

depiction of this dual-cable setup. In the majority of the small-scale tests, however, the 

orientation more often resembled Figure A-72.

 

5

Additional information on the Ferraz-Shawmut fuses may be ascertained from their website at 

http://us.ferrazshawmut.com/.

6 CAROLFIRE Final Report, 2007.
A-63

TC

~25mm.

Electrically Monitored 

Cable

Temperature Monitored 

Cable

Figure A-71 Example thermocouple arrangement for temperature monitoring of sevenconductor cable located near the electrically monitored cable in tray. 

Cables were in contact during conduit tests

~25mm ~25mm

TC TC Electrically Monitored Cable Electrically Monitored Cable Temperature Monitored Cable

Figure A-72 Alternative orientation for the two electrically monitored cables and the 

thermally monitored cable

Thermocouples measured the thermal response of cables upon heating. In Penlight, Type K 

thermocouples placed just below the outer cable jacket were used for cable thermal response 

monitoring, a technique proven during the CAROLFIRE tests. In this process, a small slit is cut 

in the jacket, allowing insertion of the thermocouple bead. The bead itself can typically be 

inserted to a distance of approximately 2.5 to 10 cm (1 to 4 in.) along the length of the cable,

placing it well away from the cut in the outer jacket. Placement distance does vary depending 

on the cable type. The slit was then closed and secured with a single layer of fiberglass tape.

For the armored cables, a pilot hole was drilled through the armor to allow for the insertion of a 

thermocouple next to the conductors. After the hole was drilled, a probe was used to further 

widen the gap for the thermocouple. In similar fashion, the bead was inserted approximately 2.5 

cm to 10 cm(1 to 4 in.) and the pilot hole was sealed with fiberglass tape. 
A-64

Where it was necessary to do so, such as in the Kerite®tests, the configurations of the 

thermocouple-instrumented cables/bundles exactly mimicked the configurations employed by 

the electrically monitored cables/bundles. The principal exceptions to this approach were those 

cases where three-cable bundles were run through a conduit. Here only a single thermocoupleinstrumented cable was included with the bundle due to space constraints within the conduit.

Thermocouples were also widely used throughout the intermediate-scale experiments; however, 

because of the extensive effort expelled on circuit preparation, thermally monitored cables were 

not as prevalent. Instead, air temperatures were gathered at each test position. In Position A 

and Position B, the middle of the tray was assumed to be the hottest exposure area for the 

involved circuits and, as such, only the air temperatures at the center of the tray were 

monitored. In the three remaining positions, air temperatures were captured at 0.91 m (3 feet), 

the middle, and 2.13 m (7 feet) of the 3.05 m (10-foot) tray. The only tests that contained 

thermocouple instrumented cables were ISTest9 and ISTest10, the Kerite®and armored cable 

tests, respectively.

During the course of testing, there were instances when the recorded thermocouple data 

yielded erratic results, such as pronounced increases and/or decreases in temperature. An 

example of this may be observed in the air temperature for B-Position in ISTest10 at 

approximately 2800 seconds. Possible causes of this behavior may include failure at the 

junction point between the thermocouple connector and the thermocouple lead (e.g., debris 

interference, thermal impact) or interaction with electrical arcing; however, subsequent 

investigation of the off-normal readings did not occur upon the conclusion of this test or others 

with similar results. The data from the effected thermocouple should be discarded after the 

gross failure. 

A.8.4 Data Acquisition System7

The dc circuits were connected to a National Instruments screw terminal block (Model Number 

SCXI-1300), 32-channel amplifier (Model Number SCXI-1102), and 12-slot chassis (Model 

Number SCXI-1001). The temperature data was collected by a similar system; however, it used 

a 4-slot chassis (Model Number SCXI-1000) rather than the 12-slot. The SCDU circuits, and 

later the CT500 current transducers, were monitored on a National Instruments SCB-100.

These system interfaces were controlled by LabVIEW Developer Suite, a software program 

developed by National Instruments. 

A.8.5 Computers/Software

Individual computers were connected to the data acquisition systems for the dc circuits, ac

circuits, and temperature data. This was to prevent data loss in the event of a system or power 

failure.

 

7

Additional information about the National Instruments data acquisition systems may be ascertained from their 

product website at http://www.ni.com/.
A-65

The dc system was connected to a Hewlett-Packard desktop, Workstation XW4100 with a 

Pentium 4 Processor.

The ac system was connected to a Dell desktop, Precision 350 with a Pentium 4 Processor.

The temperature data acquisition system was connected to a Hewlett Packard laptop, Compaq 

nc6230 with an Intel Centrino Processor.

All three systems were operated on Windows XP.

A.8.6 Data Files

A list of the data files for each test may be found in Table A-16 and Table A-17.

Table A-16 Matrix of the Penlight data files.

DESIREE-Fire Penlight Data Matrix

Burn 

Test #

Data Files Date 

Completed

Circuit Temperature

Pre-1 

(P) SCDU-1-2_July-14-2009_Prelim-1

Temperature data was not gathered 

during the preliminary Penlight tests

July 14, 2009

Pre-2 

(P) SCDU-1-2_July-14-2009_Prelim-2 July 14, 2009

Pre-3 

(P) SCDU-1-2_July-13-2009_Prelim-3 July 13, 2009

Pre-4 

(P) SCDU-1-2_July-13-2009_Prelim-4 July 13, 2009

1 PLTest1_SOV_Circuit.xlsx PLTest1_SOV_Temperature.xlsx July 15, 2009

2 PLTest2_SOV_Circuit.xlsx PLTest2_SOV_Temperature.xlsx July 17, 2009

3 PLTest3_SWGR_Circuit.xlsx PLTest3_SWGR_Temperature.xlsx July 21, 2009

4 PLTest4_SWGR_Circuit.xlsx PLTest4_SWGR_Temperature.xlsx July 30, 2009

5

PLTest5_1-

inch_Large_Coil_Circuit.xlsx

PLTest5_1-

inch_Large_Coil_Temperature.xlsx July 22, 2009

6

PLTest6_1-inchLong_Coil_Circuit.xlsxPLTest6_1-inchLong_Coil_Temperature.xlsx July 22, 2009

7 PLTest7_MOV_Circuit.xlsx PLTest7_MOV_Temperature.xlsx July 20, 2009

8 PLTest8_MOV_Circuit.xlsx PLTest8_MOV_Temperature.xlsx July 20, 2009

9 PLTest9_SOV_Circuit.xlsx PLTest9_SOV_Temperature.xlsx July 17, 2009

10 PLTest10_SWGR_Circuit.xlsx PLTest10_SWGR_Temperature.xlsx July 21, 2009

11

PLTest11_1-

inch_Large_Coil_Circuit.xlsx

PLTest11_1-

inch_Large_Coil_Temperature.xlsx July 22, 2009

12 PLTest12_MOV_Circuit.xlsx PLTest12_MOV_Temperature.xlsx

August 12, 

2009

13_qual PLTest13-Qual_SCDU_Circuit.xlsx

PLTest13-

Qual_SCDU_Temperature.xlsx July 27, 2009

13 PLTest13_SCDU_Circuit.xlsx PLTest13_SCDU_Temperature.xlsx July 27, 2009

14 PLTes14_SCDU_Circuit.xlsx PLTest14_SCDU_Temperature.xlsx July 28, 2009
A-66

Table A-16 Matrix of the Penlight data files (continued).

DESIREE-Fire Penlight Data Matrix

Burn 

Test #

Data Files Date 

Completed

Circuit Temperature

15 PLTest15_SCDU_Circuit.xlsx PLTest15_SCDU_Temperature.xlsx

July 28, 

2009

16 PLTest16_SCDU_Circuit.xlsx PLTest16_SCDU_Temperature.xlsx

July 28, 

2009

17_qual PLTest17-Qual_SCDU_Circuit.xlsx

PLTest17-

Qual_SCDU_Temperature.xlsx

July 30, 

2009

17 PLTest17_SCDU_Circuit.xlsx PLTest17_SCDU_Temperature.xlsx

July 31, 

2009

18 PLTest18_SCDU_Circuit.xlsx PLTest18_SCDU_Temperature.xlsx

July 31, 

2009

19 PLTest19_SCDU_Circuit.xlsx PLTest19_SCDU_Temperature.xlsx

August 10, 

2009

20 PLTest20_SOV_Circuit.xlsx PLTest20_SOV_Temperature.xlsx

August 11, 

2009

21 PLTest21_SWGR_Circuit.xlsx PLTest21_SWGR_Temperature.xlsx

September 

28, 2009

22 PLTest22_MOV_Circuit.xlsx PLTest22_MOV_Temperature.xlsx

August 13, 

2009

23 PLTest23_SOV_Circuit.xlsx PLTest23_SOV_Temperature.xlsx

July 16, 

2009

24 PLTest24_SWGR_Circuit.xlsx PLTest24_SWGR_Temperature.xlsx

July 29, 

2009

25 PLTest25_MOV_Circuit.xlsx PLTest25_MOV_Temperature.xlsx

July 16, 

2009

26 PLTest26_SOV_Circuit.xlsx PLTest26_SOV_Temperature.xlsx

July 23, 

2009

27 PLTest27_MOV_Circuit.xlsx PLTest27_MOV_Temperature.xlsx

August 12, 

2009

28 PLTest28_SOV_Circuit.xlsx PLTest28_SOV_Temperature.xlsx

August 11, 

2009

29 PLTest29_SWGR_Circuit.xlsx PLTest29_SWGR_Temperature.xlsx

July 29, 

2009

30 PLTest30_MOV_Circuit.xlsx PLTest30_MOV_Temperature.xlsx

August 13, 

2009

31 PLTest31_SOV_Circuit.xlsx PLTest31_SOV_Temperature.xlsx

July 17, 

2009

32 PLTest32_SWGR_Circuit.xlsx PLTest32_SWGR_Temperature.xlsx

September 

24, 2009

33 PLTest33_MOV_Circuit.xlsx PLTest33_MOV_Temperature.xlsx

August 12, 

2009

34 PLTest34_SOV_Circuit.xlsx PLTest34_SOV_Temperature.xlsx

August 11, 

2009

35 PLTest35_SWGR_Circuit.xlsx PLTest35_SWGR_Temperature.xlsx

September 

25, 2009

36

PLTest36_1-

inch_Large_Coil_Circuit.xlsx

PLTest36_1-

inch_Large_Coil_Temperature.xlsx

August 12, 

2009

37 PLTest37_MOV_Circuit.xlsx PLTest37_MOV_Temperature.xlsx

September 

23, 2009

38 PLTest38_SOV_Circuit.xlsx PLTest38_SOV_Temperature.xlsx

August 11, 

2009

39 PLTest39_SWGR_Circuit.xlsx PLTest39_SWGR_Temperature.xlsx

September 

24, 2009

40

PLTest40_1-

inch_Large_Coil_Circuit.xlsx

PLTest40_1-

inch_Large_Coil_Temperature.xlsx

August 12, 

2009

41 PLTest41_MOV_Circuit.xlsx PLTest41_MOV_Temperature.xlsx

September 

14, 2009
A-67

Table A-16 Matrix of the Penlight data files (continued).

DESIREE-Fire Penlight Data Matrix

Burn 

Test #

Data Files Date 

Completed

Circuit Temperature

42 PLTest42_SWGR_Circuit.xlsx PLTest42_SWGR_Temperature.xlsx

September 

25, 2009

43 PLTest43_MOV_Circuit.xlsx PLTest43_MOV_Temperature.xlsx

September 

24, 2009

44 PLTest44_MOV_Circuit.xlsx PLTest44_MOV_Temperature.xlsx

October 5, 

2009

45 PLTest45_Intercable_Circuit.xlsx PLTest45_Intercable_Temperature.xlsx

October 9, 

2009

46 PLTest46_Intercable_Circuit.xlsx PLTest46_Intercable_Temperature.xlsx

October 8, 

2009

47 PLTest47_Intercable_Circuit.xlsx PLTest47_Intercable_Temperature.xlsx October 8, 

2009

48 PLTest48_Intercable_Circuit.xlsx PLTest48_Intercable_Temperature.xlsx

October 8, 

2009

49 PLTest49_MOV_Circuit.xlsx PLTest49_MOV_Temperature.xlsx

October 9, 

2009

50 PLTest50_MOV_Circuit.xlsx PLTest50_MOV_Temperature.xlsx

October 12, 

2009

JPN 1 PLJPN-1_SWGR_Circuit.xlsx PLJPN-1_SWGR_Temperature.xlsx

September 

15, 2009

JPN 2 PLJPN-2_SWGR_Circuit.xlsx PLJPN-2_SWGR_Temperature.xlsx

September 

16, 2009

JPN 3 PLJPN-3_MOV_Circuit.xlsx PLJPN-3_MOV_Temperature.xlsx September 

23, 2009

Table A-17 Matrix of the intermediate-scale experimental data files.

DESIREE-Fire Intermediate Scale Data Matrix

Burn 

Test #

Data Files Date 

Completed

DC Data File AC Data File Temperature

JPN 1 Not Used

9-16-09_Test-JPN-Igl_SCDU-1-2-3

9-16-09_Test-JPN-Igl-2_SCDU-1-2-3

9-16-09_Test-JPN-Igl-3_SCDU-1-2-3

9-16-09_JPN-Igl.csv

9-16-09_J-igl2.csv

9-16-09_J-Ig3.csv

09/16/09

Pre-1 (IS) 11-06-09_Prelim-1_Burnsite.csv 11-06-09_Prelim1_Burnsite 11-06-09_1335.csv 11/06/09

Pre-2 (IS) 11-04-09_Prelim-1_Burnsite.csv 11-04-09_Prelim1_Burnsite 11-4-09_1630.csv 11/04/09

1 02-24-2010_Test-1_Burnsite.csv 02-23-2010_Test-1_Burnsite 2-24-10_1301.csv 02/23/10

2 12-03-09_Test-2_Burnsite.csv 12-03-09_Test-2_Burnsite 12-3-09_1230.csv 12/03/09

3 02-17-2010_Test-3_Burnsite.csv 02-17-2010_Test-3_Burnsite 2-17-10_1327.csv 02/17/10

4 11-12-09_Test-4_Burnsite.csv 11-12-09_Test-4_Burnsite 11-12-2009_1030.csv 11/12/09

5 03-01-2010_Test-5_Burnsite.csv 03-01-2010_Test-5_Burnsite 3-1-10_1340.csv 03/01/10

6 03-03-2010_Test-6_Burnsite.csv 03-03-2010_Test-6_Burnsite 3-3-10_1405.csv 03/03/10

7 03-09-2010_Test-7_Burnsite.csv 03-09-2010_Test-7_Burnsite 3-9-10_1315.csv 03/09/10
A-68

Table A-18 Matrix of the intermediate-scale experimental data files (continued).

DESIREE-Fire Intermediate Scale Data Matrix

Burn 

Test #

Data Files Date 

Completed

DC Data File AC Data File Temperature

8 11-17-09_Test-8_Burnsite.csv 11-17-09_Test-8_Burnsite 11-17-2009.csv 11/17/09

9 03-17-2010_Test-9_Burnsite.csv 03-17-2010_Test-9_Burnsite 3-17-10_.csv 03/17/10

10 03-25-2010_Test-10_Burnsite.csv 03-25-2010_Test-10_Burnsite 3-25-10_1040.csv 03/25/10

11 11-25-09_Test-11_Burnsite.csv 11-25-09_Test-11_Burnsite 11-25-09_1330.csv 11/25/09

12 11-23-09_Test-12_Burnsite.csv 11-23-09_Test-12_Burnsite 11-23-09_1505.csv 11/23/09

Contin 1

03-26-2010_ContingencyTest1_Burnsite.csv03-26-2010_ContingencyTest1_Burnsite 3-26-10_1137.csv 03/26/10

Contin 2

03-29-2010_ContingencyTest2_Burnsite.csv03-29-2010_ContingencyTest2_Burnsite 3-29-10_1134.csv 03/29/10

A.8.7 Data Processing and Analysis

Both the Penlight and intermediate-scale experiments have associated circuit files that contain 

the date and test number. The temperature data files (located on the cd) contain the date and 

nominal test start time of each test. The AC files are analyzed in similar fashion to the 

CAROLFIRE SCDU files. Essentially, a Microsoft Excel®template was created and may be 

populated with the relevant data captured from the SCDU system through the ―Import Raw 

Data.‖ As with SCDU files from CAROLFIRE, specific test information had to be included on the 

Test Conditions sheet in order to correctly synchronize the circuit and fire data start times. 

Graphs located on separate sheets populate automatically.

The data processing was significantly more complicated on the dc circuit systems. For each 

pair of circuits (i.e., MOV-1 and MOV-2, SOV-1 and SOV-2, etc.), there was a separate Excel®

template and graphing template developed to aid in data analysis. Similar to the SCDU 

template, a Test Conditions page with specific information, such as circuit data acquisition and 

fire start times, must be filled out for each experiment. Once this information is entered, the 

circuit offset, fire offset, and the test duration are calculated and displayed. Time, circuit, and 

ground data from the raw circuit file may then be copied and pasted into the Raw Data sheet. 

As described in previous sections, the current offset must be adjusted for each test. Typically, 

the last 100 seconds before the battery was turned on was averaged and used as the offset. 

The Processed Data worksheet was used for data manipulation, such as incorporating the 

current offset information, adjusting the negative voltages monitored on the unidirectional 

transducers, and the filtering of the ground fault activity. In order to clearly interpret the data, it 

is important to filter out the ground fault behavior. Figure A-73, Figure A-74, and Figure A-75

display the progression of data analysis beginning with the raw positive, negative, and coil 

voltage and extending through the filtering of the ground detection circuit. The spurious 

actuation may be clearly observed in the final graph.
A-69 YC Voltage

0 1000 2000 3000 4000

Voltage (VDC)

-150

0

150

MOV-1a_VTU_1_P

MOV-1a_VTU_2_N

MOV-1b_VT7_4_YC1

Figure A-73 Unedited voltage data including the positive and negative sources

YC Voltage

0 1000 2000 3000 4000

Voltage (VDC)

-150

0

150

MOV-1b_VT7_4_YC1

Figure A-74 Raw voltage plot for the MOV-1 close coil

YC Voltage Modification

Time (s)

0 1000 2000 3000 4000

Voltage (VDC)

-150

0

150

{MOV1} V(YC1) - V(Batt -)

{MOV1} V(YC1) - V(N)

Figure A-75 Voltage with the ground filtered out

The specific ground, current, and voltage information may be copied and pasted into the Final 

Data worksheet. This worksheet is then used to populate the graphing templates.

SigmaPlot®11 was used to create the graphs for each circuit, excluding the SCDU. Each circuit 

pair had a separate graphing template developed to facilitate the analysis process. Each 

template contains graphs that may be edited to narrow in on failure behavior. In the subsequent 

appendices for each circuit pair, voltages are primarily displayed with the ground filtered out. In 

the caption for these graphs, the word ―Modified‖ is displayed to differentiate between the 

original and modified data.
A-70

A.8.8 Intermediate-Scale Cable Loading Diagrams

Cable grouping and bundling was widely used for the circuit cables throughout the intermediate 

scale tests. When looking at the test data in subsequent sections, the orientation (e.g., in direct 

contact the tray, on top of fuel cables) of the cable bundle within the tray is important to note. 

The loaded cable tray orientation diagrams represents trays filled with 30 to 40 filler cables used 

to facilitate hot gas production. The bundled cable tray orientation diagrams illustrate trays that

were modified with brackets to contain small bundles of fuel cables as well as the circuits. The 

specialized cable tray orientation defines the circuit location for two tests, ISTest9 and ISTest10. 

In both tests, unique cables (i.e., Kerite®and armored cables, respectively) were tested and 

specific orientations were necessary for the desired test objectives. These tests included

thermally monitored cables as well as air temperature data.

In all three tray conditions, the gray background represents filler cables and the white circles 

represent the circuit cables. For each test, the filler cables surrounding the circuit cables and

within the tray were of similar type. In other words, for example, thermoset circuit cables were 

grouped with the thermoset filler cables. The only exception to this was the cable trays 

containing only filler cable. In these trays, it was most common to have similar cable types, but 

a limited amount of dissimilar cables were added if deemed necessary. As the data is 

presented in subsequent sections, Figure A-76 illustrates the location of the circuit cables within 

the filler cables. Figure A-77 illustrates the fill cable tray orientations. Figure A-78 and Figure A79 illustrate the bundled cable tray orientations. Figure A-80 illustrates the specialized fill cable 

tray orientations. 

Figure A-76 Circuit cable orientation within the cable trays
A-71

Figure A-77 Fill cable tray orientation

Fill Tray A Fill Tray B

Fill Tray C Fill Tray D

Fill Tray E Fill Tray F

Fill Tray G Fill Tray H
A-72

Figure A-78 Bundled cable tray orientation

Bundled Tray B

Bundled Tray C

Bundled Tray E Bundled Tray F

Bundled Tray D

Bundled Tray G Bundled Tray H

Bundled Tray A
A-73

Figure A-79 Bundled cable tray orientation (continued)

Bundled Tray I Bundled Tray J

Bundled Tray K
A-74

Figure A-80 Specialized tray fill orientation

1 2 TC 3 4

Specialized Tray 

A

1 TC 2

3 TC 4 TC

Specialized Tray 

B

1 TC 2 TC 3 TC

Specialized Tray 

C
A-75

A.9 Intermediate-Scale Burner System

Nearly identical to the propylene (propene, C3H6)fuel system used in CAROLFIRE, the 

propylene fuel system was used to feed the gas from externally secured tanks to the sand 

burner within the bunker facility (Figure A-81). The sand burner was identical to the one used 

during the CAROLFIRE testing program. Typically, six bottles of propene were connected to 

100-psig (6.80 atm) regulators attached to stainless steel flex line. This line connected to 

Swagelok®fittings and was piped through a ventilation valve, an isolation valve, and pressure 

gauge before penetrating a through-way into the bunker. The line was connected to an Omega 

Mass Flow Controller,

8 which regulated the flow of propylene to the sand burner. The digital 

readout was run from within the bunker to the instrumentation transportainer just outside the 

bunker.

LPI LP

V

PRV

Regulato

r

PRV = pressure relief valve

LPI = low presure isolation

LPV = low pressure vent

Process Gas

Cylinder

6ea propylene bottles w / 

manifolds

1psig check valves

100psig relief valve

Swagelok 1⁄2‖ T and elbow fittings

1⁄2‖, 0.035 wall, SS tubing

1⁄2‖ SS flex line

Omega Mass Flow Controller 0-

1000L/min, MAWP 500psig

Burner

Igloo Wall

vent valve

isolation

valve

pressure

gauge

Figure A-81 Illustration of the propene pressure system for the intermediate-scale 

experiments

 

8

Additional information may be ascertained from Omega’s product literature found on the following website 

http://www.omega.com/manuals/index.html?s=all.
A-76

The top surface of the burner measured 400 mm (15.75 in.) on a side (outside dimensions). A 

metal lip around the upper edge of the burner was turned to the inside of the burner on all sides 

and measures 12 mm (1/2 in.) wide (a piece of standard mild steel angle iron was used to form 

the top rail of the burner). The sand box burner is illustrated in Figure A-82.

Figure A-82 Illustration of the sand box burner

By itself, the burner stood a total of 400 mm (15.75 in.) high (a nominal cube). The lower half of 

the burner was an open support framework, while the upper half was an enclosed box section. 

That is, the upper 200 mm (7.8 in) of each side of the support framework was enclosed with thin 

steel sheet panels welded and sealed with high-temperature caulk. Below this upper section a 

four-sided funnel shaped section was welded below the side panels. The lower funnel section 

acted as a plenum for gas entering the burner. A coarse copper screen was placed at the top of 

the funnel section and was supported by an X-shaped metal framework at the interface between 

the funnel section and the upper section side panels. A layer of 6 to 9 mm (1/4 to 3/8 in.) gravel 

was placed on top of the first screen filling the lower two-thirds of the upper box section. A 

second (finer) screen was placed on top of the gravel and a layer of course sand filled the upper 

one-third of the upper box section flush to the top lip of the burner. Gas flowed into the bottom of 

the sand box, percolated up through the gravel, through the sand, and then burned as a 

diffusion flame above the sand surface.

For testing, the burner was elevated above the floor of the test enclosure. The top surface of the 

burner was about 840 mm (33 in.) above the floor of the enclosure. The burner was always 

placed in the center of the test structure and directly below cable raceway Location A. The flow 

of gas to the burner was measured and controlled by an electronic flow control valve.9

The single largest source of uncertainty associated with the intermediate-scale test conditions 

was that associated with conversion of the gas burner measure flow rate into an effective HRR. 

That is, while the gas flow rate was monitored in all tests, the HRR must be calculated. The 

HRR (MW) can be estimated based on the measured fuel flow rate as follows:

HRR Vg Hc     , (A-1)

 

9

The flow controller used was from Omega Controls and is electronic flow controller model FMA5545.
A-77

where η is the combustion efficiency, Hc is the heat of complete combustion (45.79 MJ/kg), ρ is 

the fuel gas density as standard conditions (1.802 kg/m3), and Vg is the measured fuel gas 

volume flow rate (m3/s). All but one of these parameters was either well known or directly 

measured, the exception being the combustion efficiency. The intent had been to estimate the 

burner efficiency based on cross-calculation of the HRR based on both the fuel flow rate and 

oxygen consumption calorimetry based on stack measurements. This proved to be impractical 

given the extremely long residence times for combustion products in the outer test cell that led 

to an untenably long delay between gas burner changes and the achievement of steady-state 

conditions at the stack. 

Typical values for this parameter for a sand burner and a fuel such as propene will generally 

range from 0.8 to 0.9. Note that throughout this report, whenever a value or plot of the nominal 

gas burner HRR has been cited, the calculation has assumed a combustion efficiency of 0.85

(85%). The relatively low combustion efficiency reflects two factors. First, the sand burner 

creates a diffusion flame that is less efficient than a pre-mixed gas-air flame. Second, propene 

was chosen as the fuel gas specifically because under diffusion flame burning conditions 

propene burns with a luminous, sooty flame. However, such burning behavior is also indicative 

of a less complete, hence less efficient, combustion process than would be obtained with a 

cleaner-burning fuel gas such as propane. Based on these conditions, 0.85 is considered a 

reasonable estimate of the overall combustion efficiency of the propene sand burner. Given the 

range of typically measured sand burner efficiencies, the resulting HRR calculations are 

estimated to have a nominal uncertainty of ± 5%.

Gas flow to the gas burner was provided through a set-point flow control valve. The flow rate 

was recorded in standard liters per minute of gas. In practical application, the volume flow rate 

of the gas as reported by the mass flow meter must be multiplied by a constant ―correction 

factor.‖ The correction factor was specified by the flow controller’s manufacturer and corrects for 

the flow of propene gas as compared to the flow of nitrogen gas against which the valve was 

calibrated. Hence, Equation A-2 is modified in application as follows:

HRR Vg reported Hc      0.4  

(A-2)

where 0.4 is the calibration correction factor and Vg-reported is the measured fuel gas volume flow 

rate as reported by the flow meter.

A.10 Intermediate-Scale Test Burner Settings

The heating protocol for each intermediate scale test is described in Tables A-18 through A-32. 

It should be noted that the flow rates did not stabilize on one value, but fluctuated by 

approximately +/–- 3 liters per minute. Additionally, the ambient temperatures (e.g., extreme 

colds of 0 °F) impacted the performance of the pressure system. These conditions will be noted 

as appropriate.
A-78

Table A-19 Inputs for the heat release rate equation.

Initial Inputs

Condition Symbol Units Value

Combustion Efficiency ŋ 0.85

Heat of Combustion Hc MJ/kg 45.79

Fuel Gas Density ρ kg/m31.802

Correction Factor 0.4

Table A-20 Heat release rate for Intermediate-Scale Test 1.

Intermediate Scale Test 1

Time (minutes into 

test)

Burner Flow 

(L/min)

Heat Release Rate 

(kW)

0 148.4 173

15 187.2 219

29 214 250

45 239.2 280

60 269.6 315

63 0 0
A-79

Table A-21 Heat release rate for Intermediate-Scale Test 2.

Intermediate Scale Test 2

Time (minutes into 

test)

Burner Flow 

(L/min)

Heat Release Rate 

(kW)

0 146.4 171

15 182 213

25 214 250

33 240 281

41 260 304

46 280 327

49 240 281

52 212 248

56 184 215

60 156 182

64 137.6 161

68 126 147

70 120 140

74 110 129

79 104.4 122

82 99.2 116

87 92 108

97 75.6 88

101 0 0

Intermediate Scale Test 2 was conducted during frigid ambient temperatures. After 

approximately 46 minutes into the test, the burner flow rate declined steadily until test 

termination. The cold ambient conditions caused two issues; namely, minor leaking of propene 

gas from the valves and the freezing of the gas regulators.

Table A-22 Heat release rate for Intermediate-Scale Test 3.

Intermediate Scale Test 3

Time (minutes into 

test)

Burner Flow 

(L/min)

Heat Release Rate 

(kW)

0 148.4 173

15 180.4 211

28 212.4 248

51 244 285

56 0 0
A-80

Table A-23 Heat release rate for Intermediate-Scale Test 4.

Intermediate Scale Test 4

Time (minutes into 

test)

Burner Flow 

(L/min)

Heat Release Rate 

(kW)

0 124 145

55 244 285

112 0 0

Table A-24 Heat release rate for Intermediate-Scale Test 5.

Intermediate Scale Test 5

Time (minutes into 

test)

Burner Flow 

(L/min)

Heat Release Rate 

(kW)

0 148 173

15 181.2 212

25 212 248

37 244.8 286

44 0 0

Table A-25 Heat release rate for Intermediate-Scale Test 6.

Intermediate Scale Test 6

Time (minutes into 

test)

Burner Flow 

(L/min)

Heat Release Rate 

(kW)

0 147.6 173

18 181.6 212

31 212 248

41 0 0

Table A-26 Heat release rate for Intermediate-Scale Test 7.

Intermediate Scale Test 7

Time (minutes into 

test)

Burner Flow 

(L/min)

Heat Release Rate 

(kW)

0 147.6 173

15 182.8 214

25 210.8 246

36 240.8 281

40 0 0
A-81

Table A-27 Heat release rate for Intermediate-Scale Test 8.

Intermediate Scale Test 8

Time (minutes into 

test)

Burner Flow 

(L/min)

Heat Release Rate 

(kW)

0 149.2 174

24 182.8 214

34 0 0

Table A-28 Heat release rate for Intermediate-Scale Test 9.

Intermediate Scale Test 9

Time (minutes into 

test)

Burner Flow 

(L/min)

Heat Release Rate 

(kW)

0 148 173

15 180 210

29 213.6 250

39 241.2 282

55 0 0

Table A-29 Heat release rate for Intermediate-Scale Test 10.

Intermediate Scale Test 10

Time (minutes into 

test)

Burner Flow 

(L/min)

Heat Release Rate 

(kW)

0 148 173

15 182.4 213

25 215.6 252

35 243.2 284

45 260.4 304

57 272 318

66 0 0

Table A-30 Heat release rate for Intermediate-Scale Test 11.

Intermediate Scale Test 11

Time (minutes into 

test)

Burner Flow 

(L/min)

Heat Release Rate 

(kW)

0 148 173

16 184.4 216

36 211.6 247

46 242.4 283

56 257.2 301

75 0 0
A-82

Table A-31 Heat release rate for Intermediate-Scale Test 12.

Intermediate Scale Test 12

Time (minutes into 

test)

Burner Flow 

(L/min)

Heat Release Rate 

(kW)

0 147.2 172

15 184 215

25 215.6 252

35 246 288

45 262.4 307

65 0 0

Table A-32 Heat release rate for Intermediate-Scale Test Contingency 1.

Intermediate Scale Test Contingency 1

Time (minutes into 

test)

Burner Flow 

(L/min)

Heat Release Rate 

(kW)

0 143.6 168

17 0 0

Table A-33 Heat release rate for Intermediate-Scale Test Contingency 2.

Intermediate Scale Test Contingency 2

Time (minutes into 

test)

Burner Flow 

(L/min)

Heat Release Rate 

(kW)

0 119.6 140

17 0 0
A-83

A.11 References

Standard 450-1995, ―IEEE Recommended Practice for Maintenance, Testing and Replacement 

of Vented Lead-Acid Batteries for Stationary Applications,‖ Published by The Institute of 

Electrical and Electronics Engineers, 3 Park Avenue, New York, NY 10016-5997, June 1995.

Standard 484-2002, ―IEEE Recommended Practice for Installation Design and Implementation 

of Vented Lead-Acid Batteries for Stationary Applications,‖ Published by The Institute of 

Electrical and Electronics Engineers, 3 Park Avenue, New York, NY 10016-5997, September 

2002.

Standard 485-1997, ―IEEE Recommended Practice for Sizing Lead-Acid Batteries for 

Stationary Applications,‖ Published by The Institute of Electrical and Electronics Engineering, 3 

Park Avenue, New York, NY 10016-5997, May 1997.
Appendix B. Motor-Operated Valve Circuits
B-1

B.1 Small-Scale Results

The purpose of this section is to provide the paired circuit analysis for each test of the smalland intermediate-scale experiments. Every test has a nominal summary of the specific 

experimental parameters, sequence of events, and data supporting the sequential events. It 

should be noted that circuit grounding observations were included for Penlight since only two 

circuits were tested and ground faults were, in general, simple and easily identifiable. In the 

intermediate-scale experiments, however, the number of commonly grounded circuits and wide 

variety of failure times overcomplicates including observations.

The results from the Penlight tests are presented below. The data is presented sequentially by 

experiment number rather than chronologically by the date experiments were completed. 

B.1.1 Penlight Test #7

A post-test inspection of the fuses indicated that all fuses had cleared.

Table B-1 Penlight Test #7 parameters.

Test Date July 20, 2009

# Current Transducer turns CT500 = 1 CT35= 1

Cable Type XLPE/CSPE, 7c, 12AWG MOV-1, MOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 470 °C

Battery Voltage 124.8Vdc (Pre-test) 124.3Vdc (Post-test)

Thermocouple Channels TC1=Ch3 (MOV-1) TC2=Ch4 (MOV-2)

Table B-2 Penlight Test #7 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

282 Cable Ignition

513-522 Chatter – MOV-1 – Open Coil

513 & 519 False Indication – MOV-1 – Green OFF

513-549 HS MOV-1 – Conductor G (10s longest duration)

521 Momentary grounding of negative battery terminal

521-572 SA MOV-1 – Open Coil (33s duration)

False Indication – MOV-1 – Green lamp ON

524-538 False Indication – MOV-1 – Green lamp OFF

552-572 HS MOV-1 Conductor G (20s duration)

565 Negative Fuse Clear – MOV-2 

573 Negative Fuse Clear – MOV-1

826 Penlight off

MOV-1 TC MOV-2
B-2

Figure B-1 Penlight Test #7 ground monitoring circuit voltages

Figure B-2 Penlight Test #7 temperature profile

Time (s)

480 500 520 540 560 580

Voltage (VDC)

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 

Time (s)

0 200 400 600 800

Temperature (C)

0

200

400

600

800

1st Cable Failure (513s - 588C)

Penlight

Cable 1

Cable 2 
B-3

Figure B-3 Penlight Test #7 MOV-1 and MOV-2 current/modified voltage plots

MOV1

480 500 520 540 560 580

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2

480 500 520 540 560 580

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

P - Positive

N - Negative

YO - Open Coil

YC1 - Close Coil

Time (seconds)

480 500 520 540 560 580

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

480 500 520 540 560 580

Voltage (VDC)

-40

0

40

80

120

160

V(YO1) - V(Batt -) 

V(YC1) - V(Batt -) 

V(P) - V(Batt -) 

V(N) - V(Batt -) 
B-4

Figure B-4 Penlight Test #7 MOV-1 & MOV-2 current/modified voltage (indicating lamps)

480 500 520 540 560 580

Voltage (Vdc)

-80

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

480 500 520 540 560 580

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

G - Green Lamp

R - Red Lamp

MOV1

480 500 520 540 560 580

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

480 500 520 540 560 580

Current (Amps)

-0.2

0.0

0.2

0.4

G - Green Lamp

R - Red Lamp

MOV2
B-5

B.1.2 Penlight Test #8

Note the cable configuration within the cable tray. MOV-1 and MOV-2 are on the same side of 

the thermocouple (TC) cable with MOV-1 closer to the TC cable. This deviated from the 

standard configuration. A post-test inspection of the fuses indicated that all fuses had cleared.

Table B-3 Penlight Test #8 parameters.

Test Date July 20, 2009

# Current Transducer turns CT500 = 1 CT35= 1

Cable Type XLPE/CSPE, 7c, 12AWG MOV-1, MOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 470 °C

Battery Voltage 123.9Vdc (Pre-test) 123.8Vdc (Post-test)

Thermocouple Channels MOV-1 : Channel 3 MOV-2 : Channel 4

Table B-4 Penlight Test #8 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

300 Cable Ignition

465-512 HS MOV-2 – Conductor G (4s longest duration)

465-512 SA MOV-2 – Open Coil (4s longest duration)

465-514 Chatter – MOV-2 – Open & Close Coils

467-513 False Indication – MOV-2 – Green & Red lamps flicker ON/OFF

470-510 HS MOV-2 – Close Coil (<1s longest duration)

498-504 HS MOV-1 – Conductor G (3s longest duration)

501-504 SA MOV-1 – Open Coil (1s longest duration)

502 False Indication – MOV-1 – Green Flickers Off/On

505-538 False Indication – MOV-1 – Green lamp OFF

513 Negative Fuse Clear – MOV-2

539-545 SA MOV-1 – Open Coil (6s duration)

False Indication – MOV-2 – Green lamp ON & Red lamp OFF

540-545 HS MOV-1 – Conductor G (5s duration)

546 Negative Fuse Clear – MOV-1

780 Penlight off

MOV-2 MOV-1 TC
B-6

Figure B-5 Penlight Test #8 temperature profile

Time (s)

0 200 400 600 800 1000

Temperature (C)

0

200

400

600

1st Cable Failure (465s - 396C)

Penlight

Cable 1

Cable 2 
B-7

Figure B-6 Penlight Test #8 current/modified voltage (actuating devices)

MOV1

420 440 460 480 500 520 540 560 580 600

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV2

420 440 460 480 500 520 540 560 580 600

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

P - Positive

N - Negative

YO - Open Coil

YC1 - Close Coil

Time (seconds)

420 440 460 480 500 520 540 560 580 600

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

420 440 460 480 500 520 540 560 580 600

Voltage (VDC)

-40

0

40

80

120

160

V(YO1) - V(Batt -) 

V(YC1) - V(Batt -) 

V(P) - V(Batt -) 

V(N) - V(Batt -) 
B-8

Figure B-7 Penlight Test #8 MOV-1 and MOV-2 current/modified voltage (indicating 

lamps)

420 440 460 480 500 520 540 560 580 600

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

420 440 460 480 500 520 540 560 580 600

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

G - Green Lamp

R - Red Lamp

MOV1

420 440 460 480 500 520 540 560 580 600

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

420 440 460 480 500 520 540 560 580 600

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

G - Green Lamp

R - Red Lamp

MOV2
B-9

Figure B-8 Penlight Test #8 ground monitoring circuit voltages

Time (s)

0 200 400 600 800

Voltage (VDC)

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-10

B.1.3 Penlight Test #12

Laboratory notes indicate that Penlight was turned off at 1355 seconds, followed by electrical 

activity on the open coil on MOV-1. At 1635 seconds Penlight was turned back on and set to 

the original temperature setpoint of 325 °C. Interpretations from output screen indicated that 

MOV-1 negative lead and MOV-2 positive lead were still operating.

A post-test inspection of the fuses indicated that the positive fuse on MOV-2 remained 

functional while all other fuses cleared. Ignition did not occur during the test.

Table B-5 Penlight Test #12 parameters.

Test Date August 12, 2009

# Current Transducer turns CT500 = 2 CT35= 5

Cable Type PE/PVC, 7c, 12AWG MOV-1, MOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 325 °C

Battery Voltage 123.4Vdc (Pre-test) 123.4Vdc (Post-test)

Thermocouple Channels TC1=Ch3 (MOV-1) TC2=Ch4 (MOV-2)

Table B-6 Penlight Test #12 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

863-1065 SA MOV-1 – Open Coil (202s duration)

863-1065 HS MOV-1 – Conductor G (202s duration)

863-966 False Indication (Red off – No Voltage Pickup on R)

946-1065 HS MOV-1 – Close Coil (119s duration)

990-1066 Grounding of Positive battery lead

1066 Grounding of Negative battery lead

1066 Current increase to 0.08A on Negative of MOV-2 

1335 Penlight off

1350 Negative Fuse Clear – MOV-2

1350-1497 HS MOV-1 – Conductor R (42s longest duration)

1350-1497 HS MOV-1 – Close Coil (42s longest duration)

1351-1508 Interactions between MOV-1 and MOV-2 circuit

1635 Penlight turned back on

1619-1841 HS MOV-1 – Conductor R (184s longest duration)

1619-1841 HS MOV-1 – Close Coil (184s longest duration)

1843-2349 HS MOV-1 – Conductor R (47s longest duration)

1843-2349 HS MOV-1 – Close Coil (47s longest duration)

2351 Negative Fuse Clear – MOV-1

2400 Penlight off

MOV-1 TC MOV-2
B-11

Figure B-9 Penlight Test #12 temperature profile

Time (s)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

200

400

1st Failure (863s - 236C)

Penlight

Cable 1

Cable 2 
B-12

Figure B-10 Penlight Test #12 current modified voltage (actuating devices)

MOV1

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV2

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

Time (seconds)

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative
B-13

Figure B-11 Penlight Test #12 MOV-1 and MOV-2 current/modified voltage (indicating 

lamps)

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Current (Amps)

-0.04

-0.02

0.00

0.02

0.04

0.06

0.08

G - Green Lamp

R - Red Lamp

MOV1

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Current (Amps)

-0.2

0.0

0.2

0.4

G - Green Lamp

R - Red Lamp

MOV2
B-14

Figure B-12 Penlight Test #12 ground monitoring circuit voltages

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (VDC)

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-15

B.1.4 Penlight Test #22

A post-test inspection of the fuses indicated that all fuses had cleared.

Table B-7 Penlight Test #22 parameters.

Test Date August 13, 2009

# Current Transducer turns CT500 = 2 CT35= 5

Cable Type Armored, 8c, 12AWG MOV-1, MOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 470 °C

Battery Voltage 123.4Vdc (Pre-test) 123.3Vdc (Post-test)

Thermocouple Channels TC1=Ch3 (MOV-1) TC2=Ch4 (MOV-2)

TC3=Ch5 (TC Cable Top Beneath Armor)

Table B-8 Penlight Test #22 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

174 Smoke observed

285-572 Cable ignition of the outer jacket material

585-592 Intermittent grounding of battery positive and negative

585-622 SA MOV-1 – Open Coil (29s longest duration)

585-622 HS MOV-1 – Close Coil (29s longest duration)

585-622 HS MOV-1 – Conductor G (29s longest duration)

586-595 Chatter – MOV-1 & MOV-2 – Open & Close coils

586-589 HS MOV-2 – Open Coil (<1s longest duration)

586-591 SA MOV-2 – Close Coil (<1s longest duration)

587 HS MOV-2 – Conductor G (<1s duration)

588 HS MOV-2 – Conductor R (<1s duration)

589-632 SA MOV-2 – Open Coil (39s longest duration)

590-632 HS MOV-2 – Close Coil (39s longest duration)

592 HS MOV-2 – Conductor R (<1s duration)

593-623 HS MOV-2 – Conductor G (36s longest duration)

595-631 Grounding of positive lead

593-633 Battery Positive shorts to ground

595-633 False Indication – MOV-2 – Green lamp ON

623 Negative Fuse Clear – MOV-1

633 Negative Fuse Clear – MOV-2

785 Penlight off

MOV-1 TC MOV-2
B-16

Figure B-13 Penlight Test #22 temperature profile

Figure B-14 Penlight Test #22 ground monitoring circuit voltages

Time (s)

0 200 400 600 800

Temperature (C)

0

200

400

600

800

1st Cable Failure (586s - 339C Beneath Armor, 399C under Jacket)

Penlight

Cable 1

Cable 2 

Beneath Armor 

Time (s)

0 200 400 600 800

Voltage (VDC)

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-17

Figure B-15 Penlight Test #22 current/modified voltage (actuating devices)

MOV1

520 540 560 580 600 620 640 660

Current (Amps)

-0.4

0.0

0.4

0.8

1.2

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV2

520 540 560 580 600 620 640 660

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

P - Positive

N - Negative

YO - Open Coil

YC1 - Close Coil

Time (seconds)

520 540 560 580 600 620 640 660

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

520 540 560 580 600 620 640 660

Voltage (VDC)

-40

0

40

80

120

160

200

V(YO1) - V(Batt -) 

V(YC1) - V(Batt -) 

V(P) - V(Batt -) 

V(N) - V(Batt -) 

Peak ~4 Amps
B-18

Figure B-16 Penlight Test #22 MOV-1 and MOV-2 current/modified voltage (indicating 

lamps)

520 540 560 580 600 620 640 660

Voltage (Vdc)

-40

0

40

80

120

160

200

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

520 540 560 580 600 620 640 660

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

0.5

G - Green Lamp

R - Red Lamp

MOV1

520 540 560 580 600 620 640 660

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

520 540 560 580 600 620 640 660

Current (Amps)

0.0

0.5

1.0

1.5

2.0

2.5

G - Green Lamp

R - Red Lamp

MOV2
B-19

B.1.5 Penlight Test #25

A post-test inspection of the fuses indicated that all fuses had cleared.

Table B-9 Penlight Test #25 parameters.

Test Date July 16, 2009

# Current Transducer turns CT500 = 2 CT35= 5

Cable Type EPR/CSPE, 7c, 12AWG MOV-1, MOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 470 °C

Battery Voltage 123.Vdc (Pre-test) 123.2Vdc (Post-test)

Thermocouple Channels TC1=Ch3 (MOV-1) TC2=Ch4 (MOV-2)

Table B-10 Penlight Test #25 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

100 Smoke Observed

542 Cable Ignition

580-582 SA MOV-2 – Close Coil (2s duration)

582 HS MOV-2 – Open Coil (<1s duration 

583-588 HS MOV-2 – Close Coil (5s duration)

584-588 SA MOV-2 – Open Coil (4s duration)

589 Negative Fuse Clear – MOV-2

613-623 SA MOV-1 – Close Coil (10s duration)

False Indication – MOV-1 – Red lamp ON

613-623 HS MOV-1 – Conductor G (10s duration)

613-623 HS MOV-1 – Open Coil (10s duration)

628 Negative Fuse Clear – MOV-1

690 Penlight off

MOV-1 TC MOV-2
B-20

Figure B-17 Penlight Test #25 temperature profile

Time (s)

0 200 400 600

Temperature (C)

0

200

400

600

800

1st Cable Failure (579s - 435C)

Penlight

Cable 1

Cable 2 
B-21

Figure B-18 Penlight Test #25 current/modified voltage (actuating devices)

MOV1

560 580 600 620 640

Current (Amps)

-1.6

-1.4

-1.2

-1.0

-0.8

-0.6

-0.4

-0.2

0.0

0.2

0.4

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV2

560 580 600 620 640

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO - Open Coil

YC1 - Close Coil

Time (seconds)

560 580 600 620 640

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

560 580 600 620 640

Voltage (VDC)

-40

0

40

80

120

160

V(YO1) - V(Batt -) 

V(YC1) - V(Batt -) 

V(P) - V(Batt -) 

V(N) - V(Batt -) 
B-22

Figure B-19 Penlight Test #25 ground monitoring circuit voltages

Time (s)

0 200 400 600 800

Voltage (VDC)

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-23

Figure B-20 Penlight Test #25 MOV-1 and MOV-2 current/modified voltage (indicating 

lamps)

560 580 600 620 640

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

560 580 600 620 640

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

0.25

0.30

G - Green Lamp

R - Red Lamp

MOV1

560 580 600 620 640

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

560 580 600 620 640

Current (Amps)

-0.2

0.0

0.2

0.4

G - Green Lamp

R - Red Lamp

MOV2
B-24

B.1.6 Penlight Test #27

The cable did not fail, no fuses were blown, and no cable interactions occurred. As shown in 

CAROLFIRE, silicon rubber cable exhibits a strong resistance to thermal damage in the 

absence of water exposure. As opposed to this previous testing program, which only looked at 

alternating current (ac) circuits, DESIREE-Fire explored the possibility of direct current (dc) 

circuit failures when connected to the silicon rubber cable.

After extreme exposure temperatures were applied to the sample cable, the test yielded similar 

resistance to thermal damage; however, the effects of water were not reinvestigated. 

Table B-11 Penlight Test #27 parameters.

Test Date August 12, 2009

# Current Transducer turns CT500 = 2 CT35= 5

Cable Type SR/Aramid, 7c, 12AWG MOV-1, MOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint Varied (700-750 °C)

Battery Voltage 123.3Vdc (Pre-test) 123.2Vdc (Post-test)

Thermocouple Channels TC1=Ch3 (MOV-1) TC2=Ch4 (MOV-2)

Table B-12 Penlight Test #27 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

151-601 Cable Ignition

696 Penlight Temperature Increased to 750 °C

1151 Penlight off

MOV-1 TC MOV-2
B-25

Figure B-21 Penlight Test #27 temperature profile

Time (s)

0 200 400 600 800 1000 1200

Temperature (C)

0

200

400

600

800

1000

Penlight

Cable 1

Cable 2 
B-26

Figure B-22 Penlight Test #27 current/modified voltage (actuating devices)

MOV1

0 200 400 600 800 1000 1200

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV2

0 200 400 600 800 1000 1200

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

P - Positive

N - Negative

YO - Open Coil

YC1 - Close Coil

Time (seconds)

0 200 400 600 800 1000 1200

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

0 200 400 600 800 1000 1200

Voltage (VDC)

-40

0

40

80

120

160

V(YO1) - V(Batt -) 

V(YC1) - V(Batt -) 

V(P) - V(Batt -) 

V(N) - V(Batt -) 
B-27

Figure B-23 Penlight Test #27 MOV-1 current/modified voltage (indicating lamps)

0 200 400 600 800 1000 1200

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

0 200 400 600 800 1000 1200

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

G - Green Lamp

R - Red Lamp

MOV1

0 200 400 600 800 1000 1200

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

0 200 400 600 800 1000 1200

Current (Amps)

-0.2

0.0

0.2

0.4

G - Green Lamp

R - Red Lamp

MOV2
B-28

Figure B-24 Penlight Test #27 ground monitoring circuit voltages

Test #27 Additional Information

Post test inspections found all fuses to be in good condition with none actuated.

Time (s)

0 200 400 600 800 1000 1200

Voltage (VDC)

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-29

B.1.7 Penlight Test #30

A post-test inspection of the fuses identified all fuses had cleared.

Table B-13 Penlight Test #30 parameters.

Test Date August 13, 2009

# Current Transducer turns CT500 = 2 CT35= 5

Cable Type Tefzel/Tefzel, 7c, 12AWG MOV-1, MOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 325 °C

Battery Voltage 123.3Vdc (Pre-test) 123.4Vdc (Post-test)

Thermocouple Channels TC1=Ch3 (MOV-1) TC2=Ch4 (MOV-2)

Table B-14 Penlight Test #30 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

1045-1526 HS MOV-1 – Close Coil (481s duration) – no current to indicate actuation

1076-2515 SA MOV-2 – Open Coil (1038s longest duration)

1076-2515 HS MOV-2 – Close Coil (1063s longest duration)

1231-2515 HS MOV-2 – Conductor G (1063s longest duration)

1231-2515 False Indication – MOV-2 – Green lamp ON

1317-1526 False Indication – MOV-1 – Red lamp ON

1317-1435 HS MOV-1 – Conductor R (117s duration)

1436-1526 HS MOV-1 – Conductor G (74s longest duration)

1436-1526 SA MOV-1 – Open Coil (90s duration)

False Indication – MOV-1 – Green lamp ON 

 (may be due to auxiliary contact not functioning)

1438 HS MOV-2 – Open Coil (<1s duration)

1444-1526 HS MOV-1 – Conductor G (74s longest duration)

1455-1475 HS MOV-2 – Open Coil (<1s longest duration)

1527 Negative Fuse Clear – MOV-1

2515 Negative Fuse Clear – MOV-2

2612 Penlight off

MOV-1 TC MOV-2
B-30

Figure B-25 Penlight Test #30 temperature profile

Time (s)

0 500 1000 1500 2000 2500

Temperature (C)

0

200

400

1st Cable Failure (1076s - 290C)

Penlight

Cable 1

Cable 2 
B-31

Figure B-26 Penlight Test #30 current/modified voltage (actuating devices)

MOV1

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV2

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

P - Positive

N - Negative

YO - Open Coil

YC1 - Close Coil

Time (seconds)

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Voltage (VDC)

-80

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Voltage (VDC)

-80

-40

0

40

80

120

160

V(YO1) - V(Batt -) 

V(YC1) - V(Batt -) 

V(P) - V(Batt -) 

V(N) - V(Batt -) 
B-32

Figure B-27 Penlight Test #30 MOV-1 and MOV-2 current/modified voltage (indicating 

lamps)

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Voltage (Vdc)

-80

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Current (Amps)

-1

0

1

2

3

4

G - Green Lamp

R - Red Lamp

MOV1

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Voltage (Vdc)

-80

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Current (Amps)

-0.4

-0.2

0.0

0.2

0.4

G - Green Lamp

R - Red Lamp

MOV2
B-33

Figure B-28 Penlight Test #30 ground monitoring circuit voltages

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (VDC)

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-34

B.1.8 Penlight Test #33

A post-test inspection of the fuses indicated that both positive fuses cleared while the negative 

MOV-2 fuse remained operational. Cable ignition did not occur.

Table B-15 Penlight Test #33 parameters.

Test Date August 12, 2009

# Current Transducer turns CT500 = 2 CT35= 5

Cable Type PVC/PVC, 7c, 12AWG MOV-1, MOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 325 °C

Battery Voltage 123.6Vdc (Pre-test) 123.5Vdc (Post-test)

Thermocouple Channels TC1=Ch3 (MOV-1) TC2=Ch4 (MOV-2)

Table B-16 Penlight Test #33 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

0-626 HS MOV-1 – Conductor R (626s duration)

0-548 HS MOV-2 – Conductor R (548s duration)

538-626 Battery Negative Shorts to Ground

574 HS MOV-2 – Conductor G (<1s duration)

574 HS MOV-2 – Close Coil (<1s duration)

574 SA MOV-2 – Open Coil (<1s duration)

611-626 HS MOV-1 – Close Coil (15s duration) – no corresponding current

625-626 HS MOV-1 – Open Coil (1s duration)

705 Penlight off

MOV-1 TC MOV-2
B-35

Figure B-29 Penlight Test #33 temperature profile

Figure B-30 Penlight Test #33 ground monitoring circuit voltages

Time (s)

0 200 400 600

Temperature (C)

0

200

400

1st Cable Failure (562s - 222C)

Penlight

Cable 1

Cable 2 

Time (s)

0 200 400 600 800

Voltage (VDC)

-200

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-36

Figure B-31 Penlight Test #33 current/modified voltage (actuating devices)

MOV1

500 520 540 560 580 600 620 640 660

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.12

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV2

500 520 540 560 580 600 620 640 660

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.12

P - Positive

N - Negative

YO - Open Coil

YC1 - Close Coil

Time (seconds)

500 520 540 560 580 600 620 640 660

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

500 520 540 560 580 600 620 640 660

Voltage (VDC)

-40

0

40

80

120

160

V(YO1) - V(Batt -) 

V(YC1) - V(Batt -) 

V(P) - V(Batt -) 

V(N) - V(Batt -) 
B-37

Figure B-32 Penlight Test #33 MOV-1 and MOV-2 current/modified voltage (indicating 

lamps)

500 520 540 560 580 600 620 640 660

Voltage (Vdc)

-200

-160

-120

-80

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

500 520 540 560 580 600 620 640 660

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

G - Green Lamp

R - Red Lamp

MOV1

500 520 540 560 580 600 620 640 660

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

500 520 540 560 580 600 620 640 660

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

G - Green Lamp

R - Red Lamp

MOV2
B-38

B.1.9 Penlight Test #37

A post-test inspection of the fuses indicated that all fuses had cleared.

Table B-17 Penlight Test #37 parameters.

Test Date September 23, 2009

# Current Transducer turns CT500 = 2 CT35= 5

Cable Type XLPE/CSPE, 7c, 12AWG MOV-1, MOV-2, TC

Cable Fill 3 cables MOV-1, TC, MOV-2

Raceway Configuration Conduit (2.5 in. Dia.)

Penlight Setpoint 525 °C

Battery Voltage 123V (Pre-test) 

Thermocouple Channels Conduit Top:Ch3 Bottom Conduit: Ch 4

TC Cable: Ch 5

Table B-18 Penlight Test #37 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

1681-1711 SA MOV-1 – Close Coil (30s duration)

1681-1711 HS MOV-1 – Conductor G (30s duration)

1681-1711 HS MOV-1 – Open Coil (30s duration)

1692-1712 False Indication – MOV-1 – Red ON

 (note: auxiliary contact failure)

1712 Negative Fuse Clear – MOV-1

1723 HS MOV-2 – Close Coil (<1s duration)

1724-1739 SA MOV-2 – Close Coil (15s duration)

1731-1739 HS MOV-2 – Conductor R (8s duration)

1731-1739 False Indication – MOV-2 – Red ON

 (note: auxiliary contact failure)

1740 Negative Fuse Clear – MOV-2

1830 Penlight off
B-39

Figure B-33 Penlight Test #37 temperature profile

Time (s)

0 500 1000 1500 2000

Temperature (C)

0

200

400

600

1st Cable Failure (1681s - 425C)

Penlight

Conduit Top

Conduit Bottom

TC Cable
B-40

Figure B-34 Penlight Test #37 current/modified voltage (actuating devices)

MOV1

1200 1300 1400 1500 1600 1700 1800

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

0.16

0.18

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV2

1200 1300 1400 1500 1600 1700 1800

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO - Open Coil

YC1 - Close Coil

Time (seconds)

1200 1300 1400 1500 1600 1700 1800

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

1200 1300 1400 1500 1600 1700 1800

Voltage (VDC)

-40

0

40

80

120

160

V(YO1) - V(Batt -) 

V(YC1) - V(Batt -) 

V(P) - V(Batt -) 

V(N) - V(Batt -) 
B-41

Figure B-35 Penlight Test #37 MOV-1 and MOV-2 current/modified voltage (indicating 

lamps)

1200 1300 1400 1500 1600 1700 1800

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

1200 1300 1400 1500 1600 1700 1800

Current (Amps)

-0.15

-0.10

-0.05

0.00

0.05

0.10

0.15

0.20

G - Green Lamp

R - Red Lamp

MOV1

1200 1300 1400 1500 1600 1700 1800

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

1200 1300 1400 1500 1600 1700 1800

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

G - Green Lamp

R - Red Lamp

MOV2
B-42

Figure B-36 Penlight Test #37 ground monitoring circuit voltages

Time (s)

0 500 1000 1500 2000

Voltage (VDC)

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-43

B.1.10 Penlight Test #41

A post-test inspection of the fuses indicated that both positive fuses had cleared with both 

negative fuses remaining operational.

Table B-19 Penlight Test #41 parameters.

Test Date September 14, 2009

# Current Transducer turns CT500 = 2 CT35= 5

Cable Type PE/PVC, 7c, 12AWG MOV-1, MOV-2, TC

Cable Fill 3 cables TC, MOV-1, MOV-2

Raceway Configuration Conduit (2.5 in. Dia.)

Penlight Setpoint 525 °C

Battery Voltage 123V (Pre-test) 

Thermocouple Channels Three Top Conduit: Channel 3

Bottom Conduit: Channel 4

TC Cable: Channel 5

Table B-20 Penlight Test #41 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

317 Smoke observed

1307-1405 SA MOV-2 – Close Coil (98s duration)

2463-2893 HS MOV-2 – Open Coil (430s duration)

2463-2893 HS MOV-2 – Conductor G (430s duration)

2560-2649 Battery Negative shorts to ground

2562-2895 Cable thermocouple within conduit displaying off-normal readings

2626-2652 HS MOV-2 – Close Coil (26s duration)

2653 HS MOV-1 – Conductor G (<1s duration)

2687 HS MOV-1 – Conductor G (<1s duration)

2692-2755 Battery Positive shorts to ground

2694-2790 HA MOV-1 – Close Coil (31s longest duration)

2699-2791 HS MOV-1 – Conductor G (60s longest duration)

2702-2791 SA MOV-1 – Open Coil (29s longest duration)

2753-2763 HS MOV-2 – Close Coil (10s duration)

2760 HS MOV-2 – Close Coil (<1s duration)

2755-2790 Battery Negative shorts to ground

2790-2840 Battery Positive shorts to ground

2792 Negative Fuse Clear – MOV-1

2828 HS MOV-2 – Close Coil (<1s duration)

2872-2874 HS MOV-2 – Close Coil (2s duration)

2892 HS MOV-2 – Close Coil (<1s duration)

3255 Penlight off
B-44

Figure B-37 Penlight Test #41 temperature profile

Time (s)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

200

400

600

800

1000

1st Cable Failure (1291s - 451C)

Penlight

Conduit Top

Conduit Bottom

TC Cable
B-45

Figure B-38 Penlight Test #41 MOV-1 and MOV-2 current/modified voltage (actuating 

devices)

MOV1

1200 1400 1600 1800 2000 2200 2400 2600 2800 3000

Current (Amps)

-1

0

1

2

3

4

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV2

1200 1400 1600 1800 2000 2200 2400 2600 2800 3000

Current (Amps)

-0.5

0.0

0.5

1.0

1.5

2.0

2.5

P - Positive

N - Negative

YO - Open Coil

YC1 - Close Coil

Time (seconds)

1200 1400 1600 1800 2000 2200 2400 2600 2800 3000

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

1200 1400 1600 1800 2000 2200 2400 2600 2800 3000

Voltage (VDC)

-40

0

40

80

120

160

V(YO1) - V(Batt -) 

V(YC1) - V(Batt -) 

V(P) - V(Batt -) 

V(N) - V(Batt -) 

Transducer

saturation

Transducer

saturation
B-46

Figure B-39 Penlight Test #41 ground monitoring circuit voltages

Time (s)

0 500 1000 1500 2000 2500 3000 3500

Voltage (VDC)

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-47

Figure B-40 Penlight Test #41 MOV-1 and MOV-2 current/modified voltage (indicating 

lamps)

2000 2200 2400 2600 2800 3000

Voltage (Vdc)

-160

-120

-80

-40

0

40

80

120

160

200

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

2000 2200 2400 2600 2800 3000

Current (Amps)

-2.0

-1.5

-1.0

-0.5

0.0

0.5

1.0

1.5

2.0

G - Green Lamp

R - Red Lamp

MOV1

2000 2200 2400 2600 2800 3000

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

2000 2200 2400 2600 2800 3000

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

G - Green Lamp

R - Red Lamp

MOV2
B-48

Test #41 Additional Data

TC cable was not situated between MOV-1 and MOV-2 cable. Instead, MOV-1 was located in 

the center with MOV-2 on one side and the TC cable on the other.

B.1.11 Penlight Test #43

Post-test evaluation of the fuses indicated that both negative fuses had cleared while both 

positive fuses remained operational.

Table B-21 Penlight Test #43 parameters.

Test Date September 24, 2009

# Current Transducer turns CT500 = 2 CT35= 5

Cable Type PE/PVC, 7c, 12AWG MOV-1, MOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint Varied (initially set to 275 °C)

Battery Voltage 122.8Vdc (Pre-test) 122.4Vdc (Post-test)

Thermocouple Channels TC1=Ch3 (MOV-1) TC2=Ch4 (MOV-2)

Table B-22 Penlight Test #43 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

2776-6359 SA MOV-2 – Open Coil (3583s duration)

2776-6359 HS MOV-2 – Close Coil (3583s duration)

2776-6359 HS MOV-2 – Conductor G (3570s longest duration)

6580 Penlight increased to 300 °C

7180 Penlight increased to 325 °C

7686-7800 HS MOV-2 – Conductor G (79s longest duration)

7686-8341 HS MOV-2 – Close Coil (655s duration)

7686-8341 SA MOV-2 – Open Coil (655s duration)

8138-8211 HS MOV-2 – Conductor G (73s duration)

8323-8340 HS MOV-2 – Conductor G (17s duration)

8349-8509 HS MOV-2 – Conductor G (140s longest duration)

8349-8509 SA MOV-2 – Open Coil (160s duration)

8349-8509 HS MOV-2 – Close Coil (160s duration)

8539 HS MOV-2 – Close Coil (<1s duration)

8539 HS MOV-2 – Open Coil (<1s duration)

8540-9099 HS MOV-2 – Conductor G (46s longest duration)

8540-9099 HS MOV-2 – Open Coil (559s duration)

MOV-1 TC MOV-2
B-49

Table B-23 Penlight Test #43 sequence of events (continued).

Time (seconds) Event/Observation

8651-9099 HS MOV-2 – Close Coil (448s duration)

8980 Penlight increased to 350 °C

9102-9254 HS MOV-2 – Close Coil (<1s longest duration)

9580 Penlight increased to 375 °C

9619-9897 HS MOV-2 – Conductor R (75s longest duration)

9865-9899 Chatter – MOV-2 – Open Coil

9865-11340 HS MOV-2 – Conductor G (1440s longest duration)

9865-11340 SA MOV-2 – Open Coil (1440s longest duration)

9865-9898 HS MOV-2 – Open Coil (2s longest duration)

9867-11341 HS MOV-2 – Close Coil (1444s longest duration)

10480 Penlight increased to 450 °C

11215-11265 HS MOV-1 – Conductor R (50s duration)

11266-11360 SA MOV-1 – Open Coil (94s duration)

11330 Cable Ignition

11337-11350 HS MOV-1 – Close Coil (13s duration)

11337-11425 Grounding of Positive lead

11342-11369 SA MOV-2 – Close Coil (27s duration)

11357 HS MOV-2 – Open Coil (<1s duration)

11358 HS MOV-2 – Conductor G (<1s duration)

11361 HS MOV-2 – Open Coil (<1s duration)

11361-11372 HS MOV-1 – Conductor R (11s duration)

11372 Negative Fuse Clear – MOV-2

11373-11382 HS MOV-1 – Conductor G (9s duration)

11373-11382 SA MOV-1 – Close Coil (9s duration)

HS MOV-1 – Open Coil (~107 Vdc)

11383 Negative Fuse Clear – MOV-1

11425 Penlight off
B-50

Figure B-41 Penlight Test #43 temperature profile

Figure B-42 Penlight Test #43 ground monitoring circuit voltages

Time (s)

0 2000 4000 6000 8000 10000 12000

Temperature (C)

0

200

400

600

800

1st Cable Failure (2776s - 210C)

Penlight

Cable 1

Cable 2 

Time (s)

0 2000 4000 6000 8000 10000 12000

Voltage (VDC)

-200

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-51

Figure B-43 Penlight Test #43 MOV-1 and MOV-2 current/modified voltage (actuating 

devices)

MOV-1

11200 11250 11300 11350 11400 11450

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2

2000 3000 4000 5000 6000 7000

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

P - Positive

N - Negative

YO - Open Coil

YC1 - Close Coil

Time (seconds)

2000 3000 4000 5000 6000 7000

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

11200 11250 11300 11350 11400 11450

Voltage (VDC)

-40

0

40

80

120

160

V(YO1) - V(Batt -) 

V(YC1) - V(Batt -) 

V(P) - V(Batt -) 

V(N) - V(Batt -) 
B-52

Figure B-44 Penlight Test #43 MOV-2 current/modified voltage (actuating devices)

MOV-2

7000 7500 8000 8500 9000 9500

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2

9500 10000 10500 11000 11500

Current (Amps)

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO - Open Coil

YC1 - Close Coil

Time (seconds)

9500 10000 10500 11000 11500

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

7000 7500 8000 8500 9000 9500

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative
B-53

Figure B-45 Penlight Test #43 MOV-1 and MOV-2 current/modified voltage (indicating 

lamps)

11000 11100 11200 11300 11400

Voltage (Vdc)

-160

-120

-80

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

11000 11100 11200 11300 11400

Current (Amps)

-1.0

-0.8

-0.6

-0.4

-0.2

0.0

0.2

0.4

0.6

0.8

G - Green Lamp

R - Red Lamp

MOV1

2000 3000 4000 5000 6000 7000

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

2000 3000 4000 5000 6000 7000

Current (Amps)

-0.2

0.0

0.2

0.4

G - Green Lamp

R - Red Lamp

MOV2

1.04A
B-54

Figure B-46 Penlight Test #43 MOV-2 current/modified voltage (indicating lamps)

7000 7500 8000 8500 9000 9500

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

7000 7500 8000 8500 9000 9500

Current (Amps)

-0.6

-0.4

-0.2

0.0

0.2

0.4

G - Green Lamp

R - Red Lamp

MOV2

9500 10000 10500 11000 11500

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

9500 10000 10500 11000 11500

Current (Amps)

-0.4

-0.2

0.0

0.2

0.4

0.6

0.8

G - Green Lamp

R - Red Lamp

MOV2
B-55

B.1.12 Penlight Test #44

A post-test inspection of the fuses indicates that the negative fuse on MOV-2 remained 

operational while all other fuses had cleared.

Table B-24 Penlight Test #44 parameters.

Test Date October 5, 2009

# Current Transducer turns CT500 = 2 CT35= 5

Cable Type Kerite, 9c, 14 AWG MOV-1, MOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 325 °C

Battery Voltage 123.2Vdc (Pre-test) N/A (Post-test)

Thermocouple Channels TC1=Ch3 (MOV-1) TC2=Ch4 (MOV-2)

Table B-25 Penlight Test #44 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

396 Liquid observe exiting end of TC cable

821 Smoke observed

1993 Increased flow of liquid exiting TC cable

2760 Penlight increased to 350 °C

4560 Penlight increased to 375 °C

5760 Penlight increased to 400 °C

6660 Penlight increased to 430 °C

7260 Penlight increased to 470 °C

7860 Penlight increased to 485 °C

9073-10268 HS MOV-1 – Open Coil (1195s duration) (~101Vdc)

9073-10270 HS MOV-1 – Conductor G (1197s duration)

9073-10270 SA MOV-1 – Close Coil (1197s duration)

10043-10348 SA MOV-2 – Open Coil (305s duration)

HS MOV-2 – Close Coil (~88Vdc)

10204-10276 False Indication – MOV-1 – Red lamp ON

 Note: auxiliary contacts not functioning.

10271 Negative Fuse Clear – MOV-1

Arching – Cable Ignition

10950 Penlight off

MOV-1 TC MOV-2
B-56

Figure B-47 Penlight Test #44 temperature profile

Figure B-48 Penlight Test #44 ground monitoring circuit voltages

Time (s)

0 2000 4000 6000 8000 10000

Temperature (C)

0

200

400

600

800

1st Cable Failure (9073s - 441C)

Penlight

Cable 1

Cable 2 

Time (s)

0 2000 4000 6000 8000 10000 12000

Voltage (VDC)

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-57

Figure B-49 Penlight Test #44 current/modified voltage (actuating devices)

MOV1

8500 9000 9500 10000 10500

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV2

8500 9000 9500 10000 10500

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

P - Positive

N - Negative

YO - Open Coil

YC1 - Close Coil

Time (seconds)

8500 9000 9500 10000 10500

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

8500 9000 9500 10000 10500

Voltage (VDC)

-40

0

40

80

120

160

V(YO1) - V(Batt -) 

V(YC1) - V(Batt -) 

V(P) - V(Batt -) 

V(N) - V(Batt -) 

Transducer

saturation

Transducer

saturation
B-58

Figure B-50 Penlight Test #44 MOV-1 and MOV-2 current/modified voltage (indicating 

lamps)

Test #44 Additional Information

 TC Channel 4 was oriented on the top of the TC cable instead of on the side nearest 

the MOV-2 cable.

 The cable samples used in this testing were taken from the outer portion of the 

donated Kerite®cable supply.

8500 9000 9500 10000 10500

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

8500 9000 9500 10000 10500

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

G - Green Lamp

R - Red Lamp

MOV1

8500 9000 9500 10000 10500

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

8500 9000 9500 10000 10500

Current (Amps)

-0.2

-0.1

0.0

0.1

0.2

G - Green Lamp

R - Red Lamp

MOV2

Transducer

saturation
B-59

B.1.13 Penlight Test #49

A post-test inspection indicated that all negative fuses had cleared and all positive fuses 

remained operational.

Table B-26 Penlight Test #49 parameters.

Test Date October 9, 2009

# Current Transducer turns CT500 = 2 CT35= 5

Cable Type Kerite, 9c, 14 AWG MOV-1, MOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 400 °C

Battery Voltage 123.2Vdc (Pre-test) N/A (Post-test)

Thermocouple Channels TC Cable1=Ch3 

Table B-27 Penlight Test #49 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

755 Liquid exiting TC cable

2400 Penlight increased to 440 °C

4388-4401 HS MOV-1 – Conductor G (13s duration)

4394-4400 SA MOV-1 – Close Coil (6s duration)

4402-4824 Battery Negative shorts to ground

4620 Penlight off

~4820 Interactions between MOV-1 and MOV-2 circuits

4823 HS MOV-2 – Close Coil (<1s duration)

4823 SA MOV-2 – Open Coil (<1s duration)

MOV-1 TC MOV-2
B-60

Figure B-51 Penlight Test #49 temperature profile

Figure B-52 Penlight Test #49 ground monitoring circuit voltages

Time (s)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800 1st Failure (4394s - 416C)

Penlight

Cable 1

Plot 1 1st Failure (4394s - 416C) Time (s)

0 1000 2000 3000 4000 5000 6000

Voltage (VDC)

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-61

Figure B-53 Penlight Test #49 current/modified voltage (actuating devices)

MOV1

4300 4350 4400 4450 4500

Current (Amps)

-2

0

2

4

6

8

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV2

4740 4760 4780 4800 4820 4840

Current (Amps)

-0.5

0.0

0.5

1.0

1.5

2.0

2.5

P - Positive

N - Negative

YO - Open Coil

YC1 - Close Coil

Time (seconds)

4740 4760 4780 4800 4820 4840

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

4300 4350 4400 4450 4500

Voltage (VDC)

-40

0

40

80

120

160

V(YO1) - V(Batt -) 

V(YC1) - V(Batt -) 

V(P) - V(Batt -) 

V(N) - V(Batt -) 
B-62

Figure B-54 Penlight Test #49 MOV-1 current/modified voltage (indicating lamps)

4000 4200 4400 4600 4800 5000

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

4000 4200 4400 4600 4800 5000

Current (Amps)

-2

0

2

4

6

8

G - Green Lamp

R - Red Lamp

MOV1

4740 4760 4780 4800 4820 4840

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

4740 4760 4780 4800 4820 4840

Current (Amps)

-0.2

-0.1

0.0

0.1

0.2

0.3

0.4

G - Green Lamp

R - Red Lamp

MOV2

Peak 3.14 Amps
B-63

B.1.14 Penlight Test #50

A post-test inspection of the fuses indicated that both negative fuses had cleared and both 

positive fuses remained operational.

Table B-28 Penlight Test #50 parameters.

Test Date October 12, 2009

# Current Transducer turns CT500 = 2 CT35= 5

Cable Type Kerite, 9c, 14 AWG MOV-1, MOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 450 °C

Battery Voltage 123.2Vdc (Pre-test) N/A (Post-test)

Thermocouple Channels TC Cable1=Ch3 

Table B-29 Penlight Test #50 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

420 Liquid exiting end of TC cable

822 Cable Ignition

1164-1181 False Indication MOV-2 – Red lamp ON

1164-1180 HS MOV-2 – Conductor R (16s duration)

1241-1264 SA MOV-2 – Close Coil (23s duration)

1242-1334 Battery Positive shorts to ground

1267 Negative Fuse Clear – MOV-2

1276-1300 HS MOV-1 – Conductor R (24s duration)

1279-1300 False Indication – MOV-1 – Red lamp ON

1334 Negative Fuse Clear – MOV-1

1440 Penlight off

MOV-1 TC MOV-2
B-64

Figure B-55 Penlight Test #50 temperature profile

Figure B-56 Penlight Test #50 ground monitoring circuit voltages

Time (s)

0 200 400 600 800 1000 1200 1400

Temperature (C)

0

200

400

600

800

1st Cable Failure (1242s - 573C)

Penlight

TC Cable

Time (s)

0 200 400 600 800 1000 1200 1400 1600

Voltage (VDC)

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-65

Figure B-57 Penlight Test #50 current/modified voltage (actuating devices)

MOV1

1000 1100 1200 1300 1400

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV2

1000 1100 1200 1300 1400

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO - Open Coil

YC1 - Close Coil

Time (seconds)

1000 1100 1200 1300 1400

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

1000 1100 1200 1300 1400

Voltage (VDC)

-40

0

40

80

120

160

V(YO1) - V(Batt -) 

V(YC1) - V(Batt -) 

V(P) - V(Batt -) 

V(N) - V(Batt -) 

Peak ~2.77 Amps

Peak ~4.93 Amps
B-66

Figure B-58 Penlight Test #50 MOV-1 and MOV-2 current/modified voltage (indicating 

lamps)

1000 1100 1200 1300 1400

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

1000 1100 1200 1300 1400

Current (Amps)

-1

0

1

2

3

4

G - Green Lamp

R - Red Lamp

MOV1

1000 1100 1200 1300 1400

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

1000 1100 1200 1300 1400

Current (Amps)

-0.2

0.0

0.2

0.4

G - Green Lamp

R - Red Lamp

MOV2
B-67

B.1.15 Penlight Test #JPN-3

A post-test inspection of the fuses indicated that the positive fuse on MOV-1 remained 

operational while all other fuses had cleared.

Table B-30 Penlight Test #JPN-3 parameters.

Test Date September 23, 2009

# Current Transducer turns CT500 = 2 CT35= 5

Cable Type Japanese, 6c, 14AWG (2mm) MOV-1, MOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 350 °C

Battery Voltage 122.7Vdc (Pre-test) 122.4Vdc (Post-test)

Thermocouple Channels TC1=Ch3 (MOV-1) TC2=Ch4 (MOV-2)

Table B-31 Penlight Test #JPN-3 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

1974-2501 Battery Positive shorts to ground

2225 HS MOV-1 – Conductor R (<1s duration)

2308-2310 SA MOV-2 – Open Coil (2s duration)

2308-2501 HS MOV-2 – Close Coil (193s duration)l

2310 HS MOV-2 – Open Coil (<1s duration)

2312-2501 SA MOV-2 – Open Coil (189s duration)

2318-2501 HS MOV-2 – Conductor G (136s longest duration)

2318-2501 False Indication – MOV-2 – Green lamp ON

2320-2501 HS MOV-1 – Conductor R (181s duration)

2320-2502 False Indication – MOV-1 – Red lamp ON

2463 Cable Ignition

2502 Negative Fuse Clear – MOV-2 

2626-2759 False Indication – MOV-1 – Red lamp OFF & Green lamp ON

2626-2865 HS MOV-1 – Conductor G (239s duration)

2631-2865 SA MOV-1 – Open Coil (234s duration)

2761-2866 Battery Negative shorts to ground

False Indication – MOV-1 Red lamp OFF & Green lamp ON

2866 Negative Fuse Clear – MOV-1

2930 Penlight off

MOV-1 TC MOV-2
B-68

Figure B-59 Penlight Test #JPN-3 temperature profile

Figure B-60 Penlight Test # JPN-3 ground monitoring plots

Time (s)

0 500 1000 1500 2000 2500 3000 3500

Temperature (C)

0

200

400

1st Failure (1974s - 266C)

Penlight

Cable 1

Cable 2 

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (VDC)

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-69

Figure B-61 Penlight Test # JPN-3 MOV-1 and MOV-2 modified voltage current plots

MOV1

1600 1800 2000 2200 2400 2600 2800 3000

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2

1600 1800 2000 2200 2400 2600 2800 3000

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

P - Positive

N - Negative

YO - Open Coil

YC1 - Close Coil

Time (seconds)

1600 1800 2000 2200 2400 2600 2800 3000

Voltage (VDC)

-40

0

40

80

120

160

YO1 - Open Coil

YC1 - Close Coil

P - Positive

N - Negative

Time (seconds)

1600 1800 2000 2200 2400 2600 2800 3000

Voltage (VDC)

-40

0

40

80

120

160

V(YO1) - V(Batt -) 

V(YC1) - V(Batt -) 

V(P) - V(Batt -) 

V(N) - V(Batt -) 
B-70

Figure B-62 Penlight Test # JPN-3 ground voltage monitoring circuit indication

1600 1800 2000 2200 2400 2600 2800 3000

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

1600 1800 2000 2200 2400 2600 2800 3000

Current (Amps)

-0.04

-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.12

G - Green Lamp

R - Red Lamp

MOV1

1600 1800 2000 2200 2400 2600 2800 3000

Voltage (Vdc)

-40

0

40

80

120

160

P - Positive

G - Green Lamp

R - Red Lamp

N - Negative

Time (seconds)

1600 1800 2000 2200 2400 2600 2800 3000

Current (Amps)

-0.2

0.0

0.2

0.4

G - Green Lamp

R - Red Lamp

MOV2
B-71

B.2 Intermediate-Scale Results

The results from the intermediate-scale tests are presented below. As in the previous section, 

the data is presented in numerical as opposed to chronological order.

B.2.1 Intermediate-Scale Test Prelim #2

It should be noted that “North Mid” was the nomenclature for the thermocouple used to monitor 

the air temperature for this test. This was later changed to be more specific for subsequent

tests.

Table B-32 Intermediate-Scale Test Prelim #2 parameters.

Cable Type for MOV-1 PE/PVC, 7c, 12AWG

MOV-1 Position Position A

Cable Fill Type Fill Tray H, Circuit 1

Cable Type for MOV-2 PE/PVC, 7c, 12AWG

MOV-2 Position Position E

Cable Fill Type Fill Tray H, Circuit 1

Battery Voltage (Pre-test) 123.12 Vdc

Battery Voltage (Post-test) 122.83 Vdc

Table B-33 Intermediate-Scale Test Prelim #2 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

343 Negative Fuse Clear – MOV-1

343 Air thermocouple displaying off-normal readings

821-1220 SA MOV-2 – Open Coil (399s duration) (0.10A)

843-1220 HS MOV-2 – Conductor G (377s duration)

888-1220 HS MOV-2 – Close Coil (332s duration)

1221 Negative Fuse Clear – MOV-2 

1360 Fire Off
B-72

Figure B-63 Intermediate-Scale Test Prelim #2 temperature profile

Time (s)

0 200 400 600 800 1000 1200 1400 1600

Temperature (C)

0

200

400

600

800

1000

North Mid 

First MOV-1 Cable Failure (343 s - 762 C) First MOV-2 Cable Failure (820 s - 495 C)
B-73

Figure B-64 Intermediate-Scale Test Prelim #2 MOV-1 and MOV-2 current/voltage plots

MOV-1 Current Plot

150 200 250 300 350 400 450

Current (Amps)

-0.01

0.00

0.01

0.02

0.03

0.04

0.05

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2 Current Plot

700 800 900 1000 1100 1200 1300

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

0.16

0.18

MOV-2 Modified Voltage Plot

Time (seconds)

700 800 900 1000 1100 1200 1300

Voltage (VDC)

-40

0

40

80

120

160

MOV-1 Modified Voltage Plot

Time (seconds)

150 200 250 300 350 400 450

Voltage (VDC)

-40

0

40

80

120

160
B-74

Figure B-65 Intermediate-Scale Test Prelim #2 ground voltage monitoring circuit 

indication

B.2.2 Intermediate-Scale Test #1

Table B-34 Intermediate-Scale Test #1 parameters.

Cable Type for MOV-1 XLPE/CSPE, 7c, 12AWG

MOV-1 Position Position B

Cable Fill Type Conduit

Cable Type for MOV-2 XLPE/CSPE, 7c, 12AWG

MOV-2 Position Position D

Cable Fill Type Bundled Tray B

Battery Voltage (Pre-test) 123.31 Vdc

Battery Voltage (Post-test) 120.72 Vdc

Time (s)

0 200 400 600 800 1000 1200 1400 1600

Voltage (VDC)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-75

Table B-35 Intermediate-Scale Test #1 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1476-1514 HS MOV-1 – Conductor G (38s duration)

1479-1558 SA MOV-1 – Open Coil (79s duration) (0.33-0.65A) 

1516 Current Decrease on Open Coil – MOV-1

1516-1558 HS MOV-1 – Close Coil (42s duration)

1544-1558 HS MOV-1 – Conductor G (14s duration)

1560 Negative Fuse Clear – MOV-1

2617-2661 SA MOV-2 – Close Coil (44s duration) (0.50-0.75A) 

2627-2663 Current Increase on Green – MOV-2

2652-2659 HS MOV-2 – Open Coil (7s duration)

2654-2661 HS MOV-2 – Conductor G (7s duration)

2663 Negative Fuse Clear – MOV-2

4380 Fire Off

Figure B-66 Intermediate-Scale Test #1 temperature profiles

Time (s)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

1000

1200

1400

1st MOV-1 Failure (1475s - 461C)

B Position - Tray - Middle

B Position - Conduit - Middle

D Position - Middle

1st MOV-2 Failure (2617s - 560C)
B-76

Figure B-67 Intermediate-Scale Test #1 MOV-1 and MOV-2 voltage/current plots

MOV-1 Current Plot

1200 1300 1400 1500 1600

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2 Current Plot

2500 2550 2600 2650 2700

Current (Amps)

-0.6

-0.4

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

MOV-2 Modified Voltage Plot

Time (seconds)

2500 2550 2600 2650 2700

Voltage (VDC)

-40

0

40

80

120

160

MOV-1 Modified Voltage Plot

Time (seconds)

1200 1300 1400 1500 1600

Voltage (VDC)

-40

0

40

80

120

160
B-77

Figure B-68 Intermediate Scale Test #1 ground voltage monitoring circuit indications

B.2.3 Intermediate-Scale Test #2

Table B-36 Intermediate-Scale Test #2 parameters.

Cable Type for MOV-1 XLPE/CSPE, 7c, 12AWG

MOV-1 Position Position C

Cable Fill Type Bundle Tray A

Cable Type for MOV-2 XLPE/CSPE, 7c, 12AWG

MOV-2 Position Position A

Cable Fill Type Fill Tray C, Circuit 1

Battery Voltage (Pre-test) 121.77 Vdc

Battery Voltage (Post-test) 122.97 Vdc

Time (s)

0 1000 2000 3000 4000 5000

Voltage (VDC)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-78

Table B-37 Intermediate-Scale Test #2 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1116-1138 Current Increase on Green Light (up to 1.435A max) – MOV-2

1116-1136 SA MOV-2 – Close Coil (20s duration) (0.70A) 

1133-1136 HS MOV-2 – Open Coil (3s duration)

1135-1175 HS MOV-2 – Conductor G (19s longest duration)

1138-1175 HS MOV-2 – Close Coil (19s longest duration)

1139-1142 False Indication Red Light ON (0.1053A) – MOV-2

1140 HS MOV-2 – Conductor R (<1s duration)

1145-1175 SA MOV-2 – Open Coil (19s longest duration) (~0A)

1145-1152 False Indication Red Light ON (0.7784A) – MOV-2

1156-1174 False Indication Red Light ON (18s duration) (0.3879A) – MOV-2

1159 Positive Current Transducer Saturation – MOV-2

1162 Positive Current Transducer Saturation – MOV-2

1176 Positive Fuse Clear – MOV-2

3600-4245 MOV-1 – Gradual Current Increase on Positive, Negative, Close, Open 

Coil

4247-4361 SA MOV-1 – Open Coil (114s duration) (0.09A) 

4247-4361 HS MOV-1 – Close Coil (114s duration)

4322-4361 False Indication Green Light ON (39s duration) – MOV-1

4324-4361 HS MOV-1 – Conductor G (37s duration)

4492 Negative Fuse Clear – MOV-1

6060 Fire Off
B-79

Figure B-69 Intermediate-Scale Test #2 temperature profiles

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Temperature (C)

0

200

400

600

800

1000

1st MOV-2 Failure (1116s-677C) 1st MOV-1 Failure (4247-330C)

A Position - Middle

C Position - 3' 

C Position - Middle

C Position - 7' 

1st MOV-2 Failure (1116s-677C)

1st MOV-1 Failure (4247-330C)
B-80

Figure B-70 Intermediate-Scale Test #2 MOV-1 and MOV-2 voltage/current plots

MOV-1 Current Plot

3600 3800 4000 4200 4400 4600

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

0.5

0.6

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2 Current Plot

900 950 1000 1050 1100 1150 1200

Current (Amps)

-2

0

2

4

6

8

MOV-2 Modified Voltage Plot

Time (seconds)

900 950 1000 1050 1100 1150 1200

Voltage (VDC)

-40

0

40

80

120

160

MOV-1 Modified Voltage Plot

Time (seconds)

3600 3800 4000 4200 4400 4600

Voltage (VDC)

-40

0

40

80

120

160

Currrent

Transducer

Saturated
B-81

Figure B-71 Intermediate-Scale Test #2 ground voltage monitoring circuit indications

B.2.4 Intermediate-Scale Test #3

Table B-38 Intermediate-Scale Test #3 parameters.

Cable Type for MOV-1 XLPE/CSPE, 7c, 12AWG

MOV-1 Position Position D

Cable Fill Type Bundle Tray B, Circuit 1

Cable Type for MOV-2 XLPE/CSPE, 7c, 12AWG

MOV-2 Position Position B

Cable Fill Type Fill Tray D, Circuit 1

Battery Voltage (Pre-test) 121.59 Vdc

Battery Voltage (Post-test) 121.55 Vdc

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Voltage (VDC)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-82

Table B-39 Intermediate-Scale Test #3 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1076 MOV-2 – False Indication Red Light ON [1s duration]

1077 HS MOV-2 – Conductor R (<1s duration)

1078-1128 HS MOV-2 – Conductor G (31s longest duration)

1078-1128 SA MOV-2 – Open Coil (27s longest duration) (0.12A) 

Note: MOV-2 – auxiliary contacts faulted, no Red Indication 

Light

1092-1130 MOV-2 – Current Fluctuation Increasing on Green (up to 

4.436A)

1103-1128 HS MOV-2 – Close Coil [25s duration]

1097 SA MOV-2 – Close Coil (<1s duration)

1097 HS MOV-2 – Open Coil (<1s duration)

1108-1109 MOV-2 – False Indication Red Light ON [1s duration]

1128 MOV-2 – False Indication Red Light ON [1s duration]

1361 Negative Fuse Clear – MOV-2

2784-2785 SA MOV-1 – Open Coil (1s duration) (0.76A) 

2784-2785 HS MOV-1 – Conductor G (1s duration)

2787 Negative Fuse Clear – MOV-1

3370 Fire Off

Figure B-72 Intermediate-Scale Test #3 temperature profiles

Time (s)

0 1000 2000 3000 4000

Temperature (C)

0

200

400

600

800

1st MOV-2 Failure (1078s - 350C)

B Position - Middle

D Position - 3' 

D Position - Middle

D Position - 7' 

Plot 1 1st Failure (s - C)

1st MOV-1 Failure (2784s - 546C)
B-83

Figure B-73 Intermediate-Scale Test #3 MOV-1 and MOV-2 voltage/current plots

MOV-1 Current Plot

2600 2650 2700 2750 2800 2850 2900

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2 Current Plot

1000 1050 1100 1150 1200

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

MOV-2 Modified Voltage Plot

Time (seconds)

1000 1050 1100 1150 1200

Voltage (VDC)

-40

0

40

80

120

160

MOV-1 Modified Voltage Plot

Time (seconds)

2600 2650 2700 2750 2800 2850 2900

Voltage (VDC)

-40

0

40

80

120

160

Transducer

Saturation
B-84

Time (s)

0 1000 2000 3000 4000

Voltage (VDC)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 

Figure B-74 Intermediate-Scale Test #3 ground voltage monitoring circuit 

indications

B.2.5 Intermediate-Scale Test #4

Table B-40 Intermediate-Scale Test #4 parameters.

Cable Type for MOV-1 XLPE/CSPE, 7c, 12AWG

MOV-1 Position Position A

Cable Fill Type Fill Tray A, Circuit 1

Cable Type for MOV-2 XLPE/CSPE, 7c, 12AWG

MOV-2 Position Position C

Cable Fill Type Bundled Tray I, Circuit 1

Battery Voltage (Pre-test) 121.83 Vdc

Battery Voltage (Post-test) 122.74 Vdc
B-85

Table B-41 Intermediate-Scale Test #4 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1857-1893 HS MOV-1 – Conductor G (36s duration)

1859-1893 SA MOV-1 – Open Coil (34s duration) (0.78A) 

4967-4972 HS MOV-2 – Conductor R (5s duration)

4967-4972 MOV-2 – False indication: Red light ON [5s duration]

5307 Negative Fuse Clear – MOV-1

5307 Negative Fuse Clear – MOV-2

6720 Fire Off

Figure B-75 Intermediate-Scale Test #4 temperature profile

Time (s)

0 2000 4000 6000 8000

Temperature (C)

0

200

400

600

800

1st MOV-1 Failure (1859s - ~500C)

A Position - Middle

C Position - 3' 

C Position - Middle 

C Position - 7' 

Plot 1 1st Failure (s - C)

1st MOV-2 Failure (4967s - 540C)
B-86

Figure B-76 Intermediate-Scale Test #4 MOV-1 and MOV-2 voltage/current plots

MOV-1 Current Plot

1200 1400 1600 1800 2000

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2 Current Plot

4400 4600 4800 5000 5200

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

0.5

MOV-2 Modified Voltage Plot

Time (seconds)

4400 4600 4800 5000 5200

Voltage (VDC)

-40

0

40

80

120

160

MOV-1 Modified Voltage Plot

Time (seconds)

1200 1400 1600 1800 2000

Voltage (VDC)

-40

0

40

80

120

160
B-87

Figure B-77 Intermediate-Scale Test #4 ground voltage monitoring circuit indications

B.2.6 Intermediate-Scale Test #5

Table B-42 Intermediate-Scale Test #5 parameters.

Cable Type for MOV-1 PE/PVC, 7c, 12AWG

MOV-1 Position Position B

Cable Fill Type Conduit

Cable Type for MOV-2 PE/PVC, 7c, 12AWG

MOV-2 Position Position D

Cable Fill Type Bundled Tray B, Circuit 1

Battery Voltage (Pre-test) 124.02 Vdc

Battery Voltage (Post-test) 122.74 Vdc

Time (s)

0 2000 4000 6000 8000

Voltage (VDC)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-88

Table B-43 Intermediate-Scale Test #5 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1500-1573 SA MOV-2 – Close Coil (73s duration) (0.75A) 

1509-572 HS MOV-2 – Open Coil (32s longest duration) (0.12A) 

1511-1573 HS MOV-2 – Conductor G (31s longest duration)

1538-1573 MOV-2 – False Indication Red Light ON [35s duration]

1539 HS MOV-2 – Conductor R (<1s duration) 

1588 Negative Fuse Clear – MOV-2

1717-1733 SA MOV-1 – Open Coil (16s duration) (0.10A) 

1722-1733 HS MOV-1 – Close Coil (11s duration)

1722-1733 HS MOV-1 – Conductor G (11s duration)

1722-1734 MOV-1 – False Indication Green Light ON [12s duration]

1734 Negative Fuse Clear – MOV-1

2640 Fire Off

Figure B-78 Intermediate-Scale Test #5 temperature profile

Time (s)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

200

400

600

800

1st MOV-2 Failure (1500s - 588C)

B Position - Conduit - Middle

D Position - Middle

Plot 1 1st Failure (s - C)

1st MOV-1 Failure (1717s - 602C)
B-89

Figure B-79 Intermediate-Scale Test #5 MOV-1 and MOV-2 voltage/current plots

MOV-1 Current Plot

1600 1650 1700 1750 1800

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2 Current Plot

1450 1500 1550 1600 1650

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

MOV-2 Modified Voltage Plot

Time (seconds)

1450 1500 1550 1600 1650

Voltage (VDC)

-40

0

40

80

120

160

MOV-1 Modified Voltage Plot

Time (seconds)

1600 1650 1700 1750 1800

Voltage (VDC)

-40

0

40

80

120

160
B-90

Figure B-80 Intermediate-Scale Test #5 ground voltage monitoring circuit indications

B.2.7 Intermediate-Scale Test #6

Table B-44 Intermediate-Scale Test #6 parameters.

Cable Type for MOV-1 PE/PVC, 7c, 12AWG

MOV-1 Position Position C

Cable Fill Type Bundled Tray B, Circuit 1

Cable Type for MOV-2 PE/PVC, 7c, 12AWG

MOV-2 Position Position A

Cable Fill Type Fill Tray D, Circuit 1

Battery Voltage (Pre-test) 123.56 Vdc

Battery Voltage (Post-test) 123.04 Vdc

Table B-45 Intermediate-Scale Test #6 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

217-229 SA MOV-2 – Close Coil (12s duration)

231 Negative Fuse Clear – MOV-2

1481-1505 SA MOV-1 – Close Coil (24s duration) (0.10A) 

1507 Negative Fuse Clear – MOV-1

2460 Fire Off

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (VDC)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-91

Figure B-81 Intermediate-Scale Test #6 temperature profiles

Time (s)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

200

400

600

800

1000

1st MOV-2 Failure (336s-788C) 1st MOV-1 Failure (1480s-329C)

A Position - Middle

C Position - Middle

1st MOV-2 Failure (336s-788C)

1st MOV-1 Failure (1480s-329C)
B-92

Figure B-82 Intermediate-Scale Test #6 MOV-1 and MOV-2 voltage/current plots

MOV-1 Current Plot

1400 1450 1500 1550 1600

Current (Amps)

-0.08

-0.06

-0.04

-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2 Current Plot

400 600 800 1000 1200

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

MOV-2 Modified Voltage Plot

Time (seconds)

400 600 800 1000 1200

Voltage (VDC)

-40

0

40

80

120

160

MOV-1 Modified Voltage Plot

Time (seconds)

1400 1450 1500 1550 1600

Voltage (VDC)

-40

0

40

80

120

160
B-93

Figure B-83 Intermediate-Scale Test #6 ground voltage monitoring circuit indications

B.2.8 Intermediate-Scale Test #7

Table B-46 Intermediate-Scale Test #7 parameters.

Cable Type for MOV-1 PE/PVC, 7c, 12AWG

MOV-1 Position Position B

Cable Fill Type Fill Tray D, Circuit 1

Cable Type for MOV-2 PE/PVC, 7c, 12AWG

MOV-2 Position Position D

Cable Fill Type Bundled Tray B, Circuit 1

Battery Voltage (Pre-test) 121.98 Vdc

Battery Voltage (Post-test) 122.83 Vdc

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (VDC)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-94

Table B-47 Intermediate-Scale Test #7 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

302-322 HS MOV-1 – Conductor R (16s longest duration)

302-322 MOV-1 – False Indication Red Light ON (20s duration)

324 Negative Fuse Clears – MOV-1

535 Negative Fuse Clears – MOV-2

2400 Fire Off

Before the loss of the positive fuses on the MOV circuits, the positive side of the battery was 

shorted to ground. At about 1286 seconds this situation changed abruptly and the negative side 

of the battery became shorted to ground. If the P or G conductors in the MOV cables were in 

contact with ground (e.g., through the cable trays) at that time, then the transition of the relative 

ground potential from positive to negative could have generated sufficient current through the 

positive fuses to cause them to blow.

Figure B-84 Intermediate-Scale Test #7 temperature profile

Time (s)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

200

400

600

800

1st MOV-1 Failure (324s - 256C)

B Position - Tray - Middle

D Position - Middle

Plot 1 1st Failure (s - C)

1st MOV-2 Failure (535s - 533C)
B-95

Figure B-85 Intermediate-Scale Test #7 MOV-1 and MOV-2 voltage/current plots

MOV-1 Current Plot

200 250 300 350 400

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2 Current Plot

400 450 500 550 600

Current (Amps)

-0.04

-0.02

0.00

0.02

0.04

0.06

0.08

MOV-2 Modified Voltage Plot

Time (seconds)

400 450 500 550 600

Voltage (VDC)

-40

0

40

80

120

160

MOV-1 Modified Voltage Plot

Time (seconds)

200 250 300 350 400

Voltage (VDC)

-40

0

40

80

120

160
B-96

Figure B-86 Intermediate-Scale Test #7 ground voltage monitoring circuit indications

B.2.9 Intermediate-Scale Test #8

Table B-48 Intermediate-Scale Test #8 parameters.

Cable Type for MOV-1 PE/PVC, 7c, 12AWG

MOV-1 Position Position A

Cable Fill Type Fill Tray A, Circuit 1

Cable Type for MOV-2 PE/PVC, 7c, 12AWG

MOV-2 Position Position C

Cable Fill Type Bundle Tray A, Circuit 1

Battery Voltage (Pre-test) 121.78 Vdc

Battery Voltage (Post-test) 122.56 Vdc

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (VDC)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-97

Table B-49 Intermediate-Scale Test #8 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated, MOV-2 – Red Light Not Functioning Properly

0-1743 HS MOV-2 – False Indication (843s longest duration)

1054-1149 SA MOV-1 – Close Coil (35s longest duration) (0.23A) 

1054-1149 HS MOV-1 – Open Coil (83s longest duration)

1054-1149 HS MOV-1 – Conductor G (95s duration)

1097-1101 MOV-1 – False Indication Red Light ON [4s duration]

1116-1151 MOV-1 – Current Increase on Green Light (to 0.5065A)

1151 Negative Fuse Clears – MOV-1

1745 Negative Fuse Clears – MOV-2

1743-2354 MOV-2 – Current Decrease on Positive (to 0.0811A)

2352 MOV-1 – Current Decrease on Positive (to 0.0016A)

2354-2495 MOV-2 – Current Increase on Positive (gradually to 0.7574A)

2495 Fire Off

Figure B-87 Intermediate-Scale Test #8 temperature profile

Time (s)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

200

400

600

800

1000

1st MOV-1 Failure (1052s - 791C)

A Position - Middle 

C Position - 3' 

C Position - Middle

C Position - 7' 

Plot 1 1st Failure (s - C)

1st MOV-2 Failure (1743s - 372C)
B-98

Figure B-88 Intermediate-Scale Test #8 MOV-1 and MOV-2 voltage/current plots

MOV-1 Current Plot

1000 1050 1100 1150 1200

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

0.5

0.6

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2 Current Plot

1600 1800 2000 2200 2400 2600

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

MOV-2 Modified Voltage Plot

Time (seconds)

1600 1800 2000 2200 2400 2600

Voltage (VDC)

-40

0

40

80

120

160

MOV-1 Modified Voltage Plot

Time (seconds)

1000 1050 1100 1150 1200

Voltage (VDC)

-40

0

40

80

120

160
B-99

Figure B-89 Intermediate-Scale Test #8 ground voltage monitoring circuit indications

B.2.10 Intermediate-Scale Test #9

Table B-50 Intermediate-Scale Test #9 parameters.

Cable Type for MOV-1 Kerite, 10c, 12AWG, without zinc wrap

MOV-1 Position Position B

Cable Fill Type Fill Tray C, Circuit 1

Cable Type for MOV-2 Armored Cable, 8c, 12AWG

MOV-2 Position Position D

Cable Fill Type Bundled Tray, Circuit 1

Battery Voltage (Pre-test) 122.15 Vdc

Battery Voltage (Post-test) 122.41 Vdc

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (VDC)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-100

Table B-51 Intermediate-Scale Test #9 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated, MOV-2 – Positive Current Transducer Not 

Functioning Properly

1253-1278 SA MOV-2 – Open Coil (25s duration) (0.12A) 

1253-1278 HS MOV-2 – Conductor G (25s duration)

Note: MOV-2 auxiliary contacts faulted, no Red Indication Light

1271-1277 MOV-2 – Voltage Increase on Red [6s duration]

1280 Negative Fuse Clears – MOV-2

2613-2625 SA MOV-1 – Close Coil (7s longest duration) (0.24A) 

2613-2620 HS MOV-1 – Open Coil (7s duration)

2613-2634 HS MOV-1 – Conductor G (21s duration)

2639 Negative Fuse Clears – MOV-1

3300 Fire Off

Figure B-90 Intermediate-Scale Test #9 temperature profile

Time (s)

0 500 1000 1500 2000 2500 3000 3500

Temperature (C)

0

200

400

600

800

1000

1st MOV-2 Failure (1253s - 290C)

B Position - Middle

B Position - Kerite 10c w/o

D Position - Middle

D Position - Armored 5' 

Plot 1 1st Failure (s - C)

1st MOV-1 Failure (2611s - 418C)
B-101

Figure B-91 Intermediate-Scale Test #9 MOV-1 and MOV-2 voltage/current plots

MOV-1 Current Plot

2500 2550 2600 2650 2700 2750 2800

Current (Amps)

-0.3

-0.2

-0.1

0.0

0.1

0.2

0.3

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2 Current Plot

1100 1150 1200 1250 1300 1350 1400

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

0.25

0.30

MOV-2 Modified Voltage Plot

Time (seconds)

1100 1150 1200 1250 1300 1350 1400

Voltage (VDC)

-40

0

40

80

120

160

MOV-1 Modified Voltage Plot

Time (seconds)

2500 2550 2600 2650 2700 2750 2800

Voltage (VDC)

-40

0

40

80

120

160

Transducer

saturation
B-102

Figure B-92 Intermediate-Scale Test #9 ground voltage monitoring circuit indications

B.2.11 Intermediate-Scale Test #10

Table B-52 Intermediate-Scale Test #10 parameters.

Cable Type for MOV-1 Kerite 9c, 12AWG, without zinc wrap

MOV-1 Position Position C

Cable Fill Type Bundled Tray A, Circuit 1

Cable Type for MOV-2 Kerite, 10c, 12AWG, with zinc wrap

MOV-2 Position Position B

Cable Fill Type Fill Tray

Battery Voltage (Pre-test) 121.96 Vdc

Battery Voltage (Post-test) 122.21 Vdc

Time (s)

0 500 1000 1500 2000 2500 3000 3500

Voltage (VDC)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-103

Table B-53 Intermediate-Scale Test #10 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

2781-2835 SA MOV-2 – Close Coil (37s longest duration)

2795-2818 HS MOV-2 – Open Coil (7s longest duration)

2797-2819 HS MOV-2 – Conductor G (7s longest duration)

2802-3651 Air and cable thermocouples displaying off-normal readings

2823-2835 MOV-2 – False Indication Red Light ON [12s duration]

2890 Negative Fuse Clear – MOV-2

3579-3644 HS MOV-1 – Conductor G (65s duration)

3594-3604 HS MOV-1 – Open Coil (10s duration) (0.53 A)

3594-3642 SA MOV-1 – Close Coil (48s duration) (0.09A) 

Note: Transducer MOV-1 Positive current transducer not functioning 

properly.

Current transducer remains fully saturated after an initial increase.

3960 Fire Off

Figure B-93 Intermediate-Scale Test #10 temperature profile

Time (s)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

1000

1200

1400

1600

1st MOV-2 Failure (2798s - 334C)

B Position - Tray - Middle

B Position - Kerite 10c w

C Position - Middle

C Position - Kerite 9c wo - 5' 

Plot 1 1st Failure (s - C)

1st MOV-1 Failure (3579s - 360C)
B-104

Figure B-94 Intermediate-Scale Test #10 MOV-1 and MOV-2 voltage/current plots

MOV-1 Current Plot

3500 3550 3600 3650 3700

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2 Current Plot

2200 2400 2600 2800

Current (Amps)

-2.0

-1.5

-1.0

-0.5

0.0

0.5

1.0

1.5

2.0

MOV-2 Modified Voltage Plot

Time (seconds)

2200 2400 2600 2800

Voltage (VDC)

-40

0

40

80

120

160

MOV-1 Modified Voltage Plot

Time (seconds)

3500 3550 3600 3650 3700

Voltage (VDC)

-40

0

40

80

120

160

Transducer 

Saturation
B-105

Figure B-95 Intermediate-Scale Test #10 ground voltage monitoring circuit indications

B.2.12 Intermediate-Scale Test #11

Table B-54 Intermediate-Scale Test #11 parameters.

Cable Type for MOV-1 EPR/CPE, 7c, 12AWG

MOV-1 Position Position B

Cable Fill Type Fill Tray A, Circuit 1

Cable Type for MOV-2 EPR/CPE, 7c, 12AWG

MOV-2 Position Position D

Cable Fill Type Bundle Tray I, Circuit 1

Battery Voltage (Pre-test) 122.93 Vdc

Battery Voltage (Post-test) 123.14 Vdc

Time (s)

0 1000 2000 3000 4000 5000

Voltage (VDC)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-106

Table B-55 Intermediate-Scale Test #11 sequence of events.

Time (seconds) Event/Observation

0 Fire Ignited

1179-1197 HS MOV-1 – Open Coil (18s duration) (0.05A) 

1183-1197 HS MOV-1 – Close Coil (14s duration)

1187-1197 MOV-1 – False Indication Green Light ON [10s duration]

1198 Negative Fuse Clear – MOV-1

2749 Negative Fuse Clear – MOV-2

3069-3098 MOV-2 – Current Increase on Positive (up to 2.032A)

4500 Fire Off

Figure B-96 Intermediate-Scale Test #11 temperature profile

Time (s)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

1st MOV-1 Failure (1179s - 461C)

B Position - Middle

D Position - 3' 

D Position - Middle

D Position - 7' 

Plot 1 1st Failure (s - C)

1st MOV-2 Failure (2749s - 641C)
B-107

Figure B-97 Intermediate-Scale Test #11 MOV-1 and MOV-2 voltage/current plots

MOV-1 Current Plot

1100 1200 1300 1400 1500

Current (Amps)

-0.2

-0.1

0.0

0.1

0.2

0.3

0.4

0.5

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2 Current Plot

2700 2800 2900 3000 3100 3200

Current (Amps)

-0.5

0.0

0.5

1.0

1.5

2.0

2.5

MOV-2 Modified Voltage Plot

Time (seconds)

2700 2800 2900 3000 3100 3200

Voltage (VDC)

-40

0

40

80

120

160

MOV-1 Modified Voltage Plot

Time (seconds)

1100 1200 1300 1400 1500

Voltage (VDC)

-40

0

40

80

120

160
B-108

Figure B-98 Intermediate-Scale Test #11 ground voltage monitoring circuit indications

B.2.13 Intermediate-Scale Test #12

Table B-56 Intermediate-Scale Test #12 parameters.

Cable Type for MOV-1 EPR/CPE, 7c, 12AWG

MOV-1 Position Position D

Cable Fill Type Bundle Tray A, Circuit 1

Cable Type for MOV-2 EPR/CPE, 7c, 12AWG

MOV-2 Position Position B

Cable Fill Type Fill Tray C, Circuit 1

Battery Voltage (Pre-test) 122.31 Vdc

Battery Voltage (Post-test) 122.86 Vdc

Time (s)

0 1000 2000 3000 4000 5000

Voltage (VDC)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
B-109

Table B-57 Intermediate-Scale Test #12 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

2154-2300 MOV-2 – False Indication Red Light ON [146s duration]

2157-2340 HS MOV-2 – Conductor R (142s longest duration)

2157-2340 MOV-2 – Current Increase on Negative [183s duration]

2233-2342 SA MOV-2 –Close Coil (109s duration) (0.74A) 

2284-2340 MOV-2 – Current Increase on Positive [56s duration]

2310-2340 MOV-2 – Current Increase on Green Light [30s duration]

2342 Negative Fuse Clear – MOV-2 

3129 Negative Fuse Clear – MOV-1 

3894 Fire Off

Figure B-99 Intermediate-Scale Test #12 temperature profile

Time (s)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

1000

1st MOV-2 Failure (2233s - 444C)

B Position - Middle

D Position - 3' 

D Position - Middle 

D Position - 7' 

Plot 1 1st Failure (s - C)

1st MOV-1 Failure (3031s - 667C)
B-110

Figure B-100 Intermediate-Scale Test #12 MOV-1 and MOV-2 voltage/current plots

MOV-1 Current Plot

3000 3050 3100 3150 3200

Current (Amps)

-0.5

0.0

0.5

1.0

1.5

P - Positive

N - Negative

YO1 - Open Coil

YC1 - Close Coil

MOV-2 Current Plot

2100 2150 2200 2250 2300 2350 2400

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

MOV-2 Modified Voltage Plot

Time (seconds)

2100 2150 2200 2250 2300 2350 2400

Voltage (VDC)

-40

0

40

80

120

160

MOV-1 Modified Voltage Plot

Time (seconds)

3000 3050 3100 3150 3200

Voltage (VDC)

-40

0

40

80

120

160

Transducer 

Saturation
B-111

Figure B-101 Intermediate-Scale Test #12 ground voltage monitoring circuit indications

Time (s)

0 1000 2000 3000 4000 5000

Voltage (VDC)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
Appendix C. Solenoid-Operated Valve Circuits
C-1

C.1 Small-Scale Results

The purpose of this section is to provide the paired circuit analysis for each test in the smalland intermediate-scale experiments. Every test has a nominal summary of the specific

experimental parameters, sequence of events, and data supporting the sequential events. It 

should be noted that circuit grounding observations were included for Penlight since only two 

circuits were tested and ground faults were, in general, simple and easily identifiable. In the 

intermediate-scale experiments, however, the number of commonly grounded circuits and wide 

variety of failure times overcomplicates detailed observations. As such, the intermediate-scale 

ground behavior was not described in as much detail as the Penlight tests. It should be noted 

that the green dashed line that appears in many of the graphs represents the pick-up voltage for 

the device. 

The results from the Penlight tests are presented below. The data is presented in numerical as 

opposed to chronological order.

C.1.1 Penlight Test #1

This test evaluated thermoset cables located in a cable tray. This was the first direct current 

(dc) solenoid-operated valve (SOV) circuit test conducted in the DESIREE-Fire project. At the 

end of the test the negative fuses on both circuits (SOV-1 and SOV-2) had cleared while the 

positive fuse for both circuits had not cleared.

Table C-1 Penlight Test #1 parameters.

Test Date July 15, 2009

# Current Transducer turns CT500 = 1 CT35 = 1

Cable Type XLPE/CSPE, 7c, 12AWG SOV-1, SOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 470 °C

Battery Voltage 123.4 Vdc (Pre-test) 123.5 Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

SOV-1 TC SOV-2
C-2

Table C-2 Penlight Test #1 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

286 Cable Ignition

542-589 SA SOV-2 – Conductor S2 (21s longest duration) (~0.0876 A)

558-564 SOV-2 False Indication Red Lamp ON

558-589 HS SOV-2 – Conductor R (9s longest duration)

559-596 HS SOV-1 – Conductor R (22s longest duration)

559-583 SOV-1 False Indication Red Lamp ON

580-590 SOV-2 False Indication Red Lamp ON

590 Negative Fuse Clear – SOV-2

591-597 SOV-1 False Indication Red Lamp ON

597 Negative Fuse Clear – SOV-1, w/ battery positive shorting to ground

1018 Penlight off

Figure C-1 Penlight Test #1 temperature profile

Time (seconds)

0 200 400 600 800 1000

Temperature (C)

0

100

200

300

400

500

600

700 1st Failure (542s - 506C)

Penlight 

Cable 1 

Cable 2 
C-3

Figure C-2 Penlight Test #1 ground monitoring circuit voltages

Time (seconds)

0 200 400 600 800 1000

Voltage (Vdc)

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-4

Figure C-3 Penlight Test #1 SOV-1 and SOV-2 coil modified voltage/current plots

Time (Seconds)

540 560 580 600 620

Current (Amps)

-0.4

0.0

0.4

0.8

1.2

1.6

2.0

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

540 560 580 600 620

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

Time (Seconds)

460 480 500 520 540 560 580 600 620

Current (Amps)

-0.5

0.0

0.5

1.0

1.5

2.0

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

460 480 500 520 540 560 580 600 620

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-5

Figure C-4 Penlight Test #1 SOV-1 and SOV-2 indicating lamps modified voltage/current

SOV-1 Time (seconds)

540 560 580 600 620

Current (Amps)

-0.5

0.0

0.5

1.0

1.5

2.0

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

540 560 580 600 620

Voltage (Vdc)

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 

Time (seconds) SOV-2

460 480 500 520 540 560 580 600 620

Current (Amps)

-0.5

0.0

0.5

1.0

1.5

2.0

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

460 480 500 520 540 560 580 600 620

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 
C-6

C.1.2 Penlight Test #2

This test evaluated thermoset cables located in a cable tray. At the end of the test all fuses 

(negative and positive) on both circuits (SOV-1 and SOV-2) had cleared.

Table C-3 Penlight Test #2 parameters.

Test Date July 17, 2009

# Current Transducer turns CT500 = 1 CT35 = 1

Cable Type XLPE/CSPE, 7c, 12 AWG SOV-1, SOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 470 °C

Battery Voltage 123.5Vdc (Pre-test) 123.6Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table C-4 Penlight Test #2 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

283 Cable Ignition

559-596 SA SOV-2 – Conductor S2 (24s longest duration) (~0.0536 A)

582-647 HS SOV-1 – Conductor R (20s longest duration)

587-590 SOV-2 False Indication Red lamp ON

587-595 HS SOV-1 Conductor R (4s longest duration)

591-594 SOV-2 False Indication Red Lamp ON

597 Negative Fuse Clear – SOV-2

639 SOV-1 False Indication Red Lamp ON

648 Negative Fuse Clear – SOV-1

687 Penlight off

SOV-1 TC SOV-2
C-7

Figure C-5 Penlight Test #2 ground monitoring circuit voltages

Figure C-6 Penlight Test #2 temperature profile

Time (seconds)

0 200 400 600

Voltage (Vdc)

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 

Time (seconds)

0 200 400 600

Temperature (C)

0

200

400

600

800

1000 1st Failure (560s - 472C)

Penlight 

Cable 1 

Cable 2 
C-8

Figure C-7 Penlight Test #2 SOV-1 and SOV-2 coil modified voltage/current plots

Time (Seconds)

500 520 540 560 580 600 620 640 660

Current (Amps)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

500 520 540 560 580 600 620 640 660

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

Time (Seconds)

500 550 600 650 700

Current (Amps)

-0.5

0.0

0.5

1.0

1.5

2.0

2.5

3.0

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

500 550 600 650 700

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-9

Figure C-8 Penlight Test #2 SOV-1 and SOV-2 indicating lamps modified voltage/current

SOV-1 Time (seconds)

500 550 600 650 700

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

500 550 600 650 700

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 

Time (seconds) SOV-2

460 480 500 520 540 560 580 600 620

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

480 520 560 600

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 

Peak ~2.90 Amps

Peak ~2.80 Amps
C-10

C.1.3 Penlight Test #9

This test evaluated thermoplastic cables located in a cable tray. During the test, the Penlight 

temperature was increased from 325 °C to 350 °C. At the end of the test all fuses (negative and 

positive) on both circuits (SOV-1 and SOV-2) had cleared.

Table C-5 Penlight Test #9 Parameters.

Test Date July 17, 2009

# Current Transducer turns CT500 = 1 CT35 = 1

Cable Type PE/PVC, 7c, 12AWG SOV-1, SOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 325 °C

Battery Voltage 123.8Vdc (Pre-test) 123.8Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table C-6 Penlight Test #9 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

753-886 Battery Positive Short to Ground

827-862 SA SOV-2 – Conductor S2 (35s duration) (~0.095 A)

864-886 SA SOV-1 – Conductor S2 (22s duration) (~0.065 A)

887 Negative Fuse Clear – SOV-1

1091 Positive Fuse Clear – SOV-1

1271-1630 SOV-2 False Indication Red ON

1271-1629 HS SOV-2 – Conductor R (358s duration)

1136 Penlight Increased to 350 °C

1602-1629 SA SOV-2 – Conductor S2 (27s duration) (~0.083A)

1630 Negative and Positive Fuse Clear – SOV-2

1666 Penlight off

SOV-1 TC SOV-2
C-11

Figure C-9 Penlight Test #9 ground monitoring circuit voltages

Figure C-10 Penlight Test #9 temperature profile

Time (seconds)

0 200 400 600 800 1000 1200 1400 1600 1800

Voltage (Vdc)

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 

Time (seconds)

0 200 400 600 800 1000 1200 1400 1600 1800

Temperature (C)

0

50

100

150

200

250

300

350

400 1st Failure (827s - 246C)

Penlight 

Cable 1 

Cable 2 

1st Failure (753 s – 246C)
C-12

Figure C-11 Penlight Test #9 SOV-1 and SOV-2 coil modified voltage/current plots

Time (Seconds)

700 750 800 850 900 950

Current (Amps)

-0.2

-0.1

0.0

0.1

0.2

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

700 750 800 850 900 950

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

Time (Seconds)

800 1000 1200 1400 1600

Current (Amps)

-0.2

-0.1

0.0

0.1

0.2

0.3

0.4

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

800 1000 1200 1400 1600

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-13

Figure C-12 Penlight Test #9 SOV-1 and SOV-2 indicating lamps modified voltage/current

SOV-1 Time (seconds)

0 200 400 600 800 1000 1200 1400 1600 1800

Current (Amps)

-0.2

-0.1

0.0

0.1

0.2

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

0 200 400 600 800 1000 1200 1400 1600 1800

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 

Time (seconds) SOV-2

0 200 400 600 800 1000 1200 1400 1600 1800

Current (Amps)

-0.2

-0.1

0.0

0.1

0.2

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

0 200 400 600 800 1000 1200 1400 1600 1800

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 
C-14

C.1.4 Penlight Test #20

This test evaluated an armored thermoset-insulated and thermoplastic-jacketed cables located 

in a cable tray. The armor was connected to electrical ground. At the end of the test all fuses 

(negative and positive) on both circuits (SOV-1 and SOV-2) had cleared.

Table C-7 Penlight Test #20 parameters.

Test Date August 11, 2009

# Current Transducer turns CT500 = 2 CT35 = 5

Cable Type Armored, 8c, 12AWG SOV-1, SOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 470 °C

Battery Voltage 123.4Vdc (Pre-test) 

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table C-8 Penlight Test #20 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

250 Cable Ignition

483-526 Battery Positive Shorts to Ground

483-524 HS SOV-1 – Conductor R (41s duration)

484-526 SOV-1 False Indication Red lamp ON

502-524 SA SOV-1 – Conductor S2 (22s duration) (~0.078 A)

508-555 SA SOV-2 – Conductor S2 (25s duration) (~0.059 A) – Inter-Cable

524-528 SOV-2 False Indication Red lamp ON

524-555 HS SOV-2 – Conductor R (25s duration)

525 Negative Fuse Clear – SOV-1

529-556 Battery Positive Shorts to Ground

530-556 and 

SOV-2 False Indication Red Lamp ON

556 Negative Fuse Clear – SOV-2

646 Penlight off

SOV-1 TC SOV-2
C-15

Figure C-13 Penlight Test #20 temperature profile

Figure C-14 Penlight Test #20 ground monitoring circuit voltages

Time (seconds)

0 100 200 300 400 500 600 700

Temperature (C)

0

100

200

300

400

500

600

700 1st Failure (483s - 415C TC Cable - 300C Beneath Armor)

Penlight 

Cable 1 

Cable 2 

Beneath Armor 

Time (seconds)

0 100 200 300 400 500 600 700

Voltage (Vdc)

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-16

Figure C-15 Penlight Test #20 SOV-1 and SOV-2 coil modified voltage/current plots

Time (Seconds)

400 450 500 550 600

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

400 450 500 550 600

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

Time (Seconds)

400 450 500 550 600

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

0.5

0.6

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

400 450 500 550 600

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit

Peak ~0.77 Amps

Peak ~1.84 Amps
C-17

Figure C-16 Penlight Test #20 SOV-1 and SOV-2 indicating lamps modified 

voltage/current

SOV-1 Time (seconds)

400 450 500 550 600

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

0 100 200 300 400 500 600 700

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 

Time (seconds) SOV-2

400 450 500 550 600

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

400 450 500 550 600

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 

Peak ~ 0.77 Amps

Peak ~1.75 Amps
C-18

C.1.5 Penlight Test #23

This test evaluated thermoset cables located in a cable tray. At the end of the test the negative 

fuses on both circuits (SOV-1 and SOV-2) had cleared while the positive fuse for both circuits 

had not cleared. 

Table C-9 Penlight Test #23 parameters.

Test Date July 16, 2009

# Current Transducer turns CT500 = 1 CT35 = 1

Cable Type EPR, 7c, 12AWG SOV-1, SOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 470 °C

Battery Voltage 123.0 Vdc (Pre-test) 123.4 Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table C-10 Penlight Test #23 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

483 Cable Ignition

488-492 SA SOV-1 – Conductor S2 (4s duration) (~0.080 A)

488-492 SOV-1 False Indication Red lamp ON

489-489 HS SOV-1 – Conductor R (3s duration)

493 Negative Fuse Clear – SOV-1

494-498 SOV-2 False Indication Red lamp ON

495-497 HS SOV-2 – Conductor R (2s duration)

498 Negative Fuse Clear – SOV-2

600 Penlight off

SOV-1 TC SOV-2
C-19

Figure C-17 Penlight Test #23 temperature profile

Time (seconds)

0 200 400 600 800 1000 1200

Temperature (C)

0

100

200

300

400

500

600

700 1st Failure (487s - 488C)

Penlight 

Cable 1 

Cable 2 
C-20

Figure C-18 Penlight Test #23 SOV-1 and SOV-2 coil modified voltage/current plots

Time (Seconds)

460 470 480 490 500 510 520

Current (Amps)

-0.2

-0.1

0.0

0.1

0.2

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

460 470 480 490 500 510 520

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

Time (Seconds)

460 470 480 490 500 510 520

Current (Amps)

-0.08

-0.04

0.00

0.04

0.08

0.12

0.16

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

460 470 480 490 500 510 520

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-21

Figure C-19 Penlight Test #23 ground monitoring circuit voltages

Time (seconds)

0 100 200 300 400 500 600 700

Voltage (Vdc)

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-22

Figure C-20 Penlight Test #23 SOV-1 and SOV-2 indicating lamps modified 

voltage/current

SOV-1 Time (seconds)

460 470 480 490 500 510 520

Current (Amps)

-0.2

-0.1

0.0

0.1

0.2

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

460 470 480 490 500 510 520

Voltage (Vdc)

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 

Time (seconds) SOV-2

460 470 480 490 500 510 520

Current (Amps)

-0.08

-0.04

0.00

0.04

0.08

0.12

0.16

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

460 470 480 490 500 510 520

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 
C-23

C.1.6 Penlight Test #26

The cable evaluated in this test did not fail, no fuses were blown and no cable interactions 

occurred. As shown in CAROLFIRE, silicon rubber cable exhibits a strong resistance to thermal 

damage in the absence of water exposure. As opposed to this previous testing program, which 

only looked at alternating current (ac) circuits, DESIREE-Fire explored the possibility of dc

circuit failures when connected to the silicon rubber cable.

After extreme exposure temperatures were applied to the sample cable, the test yielded similar 

resistance to thermal damage; however, the effects of water were not reinvestigated. One will 

notice the drift from the current transducers; however, this does not have any direct impact on 

the results.

Table C-11 Penlight Test #26 parameters.

Test Date July 23, 2009

# Current Transducer turns CT500 = 1 CT35 = 1

Cable Type SR, 7c, 12AWG SOV-1, SOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 700 °C

Battery Voltage 123.9Vdc (Pre-test) 

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table C-12 Penlight Test #26 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

120-720 Cable Ignition and Burning

1560 Penlight off

SOV-1 TC SOV-2
C-24

Figure C-21 Penlight Test #26 temperature profile

Time (seconds)

0 200 400 600 800 1000 1200 1400 1600

Temperature (C)

0

200

400

600

800

1000

Penlight 

Cable 1 

Cable 2 
C-25

Figure C-22 Penlight Test #26 SOV-1 and SOV-2 coil modified voltage/current plots

Time (Seconds)

0 200 400 600 800 1000 1200 1400 1600

Current (Amps)

-0.2

-0.1

0.0

0.1

0.2

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

0 200 400 600 800 1000 1200 1400 1600

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

Time (Seconds)

0 200 400 600 800 1000 1200 1400 1600

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

0 200 400 600 800 1000 1200 1400 1600

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-26

Figure C-23 Penlight Test #26 SOV-1 and SOV-2 indicating lamps modified 

voltage/current

SOV-1 Time (seconds)

0 200 400 600 800 1000 1200 1400 1600

Current (Amps)

-0.4

-0.2

0.0

0.2

0.4

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

0 200 400 600 800 1000 1200 1400 1600

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 

Time (seconds) SOV-2

0 200 400 600 800 1000 1200 1400 1600

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

0 200 400 600 800 1000 1200 1400 1600

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 
C-27

Figure C-24 Penlight Test #26 ground monitoring circuit voltages

C.1.7 Penlight Test #28

This test evaluated thermoplastic cables located in a cable tray. At the end of the test all fuses 

(negative and positive) on both circuits (SOV-1 and SOV-2) had cleared. 

Table C-13 Penlight Test #28 parameters.

Test Date August 10, 2009

# Current Transducer turns CT500 = 2 CT35 = 5

Cable Type Tefzel, 7c, 12AWG SOV-1, SOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint Various

Battery Voltage 123.4 Vdc (Pre-test) 123.0Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table C-14 Penlight Test #28 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

2400 Penlight Increased to 350 °C

2959-3383 HS SOV-1 Conductor R (424s duration)

3360 Penlight Increased to 375 °C

3384 Negative and Positive Fuse Clear – SOV-1

3393-3690 SA SOV-2 – Conductor S2 (297s duration) (~0.071 A)

3597-3690 SOV-2 False Indication Red lamp ON

3598-3690 HS SOV-2 – Conductor R (92s duration)

3691 Positive and Negative Fuse Clear – SOV-2

3820 Penlight off

Time (seconds)

0 200 400 600 800 1000 1200 1400 1600

Voltage (Vdc)

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 

SOV-1 TC SOV-2
C-28

Figure C-25 Penlight Test #28 temperature profile

Figure C-26 Penlight Test #28 ground monitoring circuit voltages

Time (seconds)

0 1000 2000 3000 4000

Temperature (C)

0

100

200

300

400

500 1st Failure (2958s - 292C)

Penlight 

Cable 1 

Cable 2 

Time (seconds)

0 1000 2000 3000 4000

Voltage (Vdc)

-200

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-29

Figure C-27 Penlight Test #28 SOV-1 and SOV-2 coil modified voltage/current plots

Time (Seconds)

2800 3000 3200 3400 3600 3800

Current (Amps)

-0.1

0.0

0.1

0.2

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

2800 3000 3200 3400 3600 3800

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

Time (Seconds)

2800 3000 3200 3400 3600 3800

Current (Amps)

-0.08

-0.04

0.00

0.04

0.08

0.12

0.16

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

2800 3000 3200 3400 3600 3800

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-30

Figure C-28 Penlight Test #28 SOV-1 and SOV-2 indicating lamps modified 

voltage/current

SOV-1 Time (seconds)

2800 3000 3200 3400 3600 3800

Current (Amps)

-0.2

-0.1

0.0

0.1

0.2

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

2800 3000 3200 3400 3600 3800

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 

SOV-2 Time (seconds)

2800 3000 3200 3400 3600 3800

Current (Amps)

-0.08

-0.04

0.00

0.04

0.08

0.12

0.16

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

2800 3000 3200 3400 3600 3800

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 
C-31

C.1.8 Penlight Test #31

This test evaluated thermoplastic cables located in a cable tray. At the end of the test all fuses 

(negative and positive) on both circuits (SOV-1 and SOV-2) had cleared. 

Table C-15 Penlight Test #31 parameters.

Test Date July 17, 2009

# Current Transducer turns CT500 = 1 CT35 = 1

Cable Type PVC/PVC, 7c, 12AWG SOV-1, SOV-2, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 325 °C

Battery Voltage 124.6Vdc (Pre-test) 

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table C-16 Penlight Test #31 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

414-431 Battery Positive Shorts to Ground and

SOV-1 False Indication Red lamp ON (Inter-Cable)

414-520 HS SOV-1 – Conductor R (106s duration)

433 Negative Fuse Clear – SOV-2

455-420 Battery Positive Shorts to Ground and

SOV-1 False Indication Red lamp ON

518-520 SA SOV-1 – Conductor S2 ( 2s duration) (~0.084 A) 

521 Negative Fuse Clear – SOV-1

579 Penlight off

SOV-1 TC SOV-2
C-32

Figure C-29 Penlight Test #31 temperature profile

Figure C-30 Penlight Test #31 ground monitoring circuit voltages

Time (seconds)

0 100 200 300 400 500 600

Temperature (C)

0

50

100

150

200

250

300

350

400 1st Failure (414s - 203C)

Penlight 

Cable 1 

Cable 2 

Time (seconds)

0 100 200 300 400 500 600

Voltage (Vdc)

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-33

Figure C-31 Penlight Test #31 SOV-1 and SOV-2 coil modified voltage/current plots

Time (Seconds)

350 400 450 500 550

Current (Amps)

-0.2

-0.1

0.0

0.1

0.2

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

350 400 450 500 550

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

Time (Seconds)

350 400 450 500 550

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

0.25

0.30

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

350 400 450 500 550

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-34

Figure C-32 Penlight Test #31 SOV-1 and SOV-2 indicating lamps modified 

voltage/current

SOV-1 Time (seconds)

350 400 450 500 550

Current (Amps)

-0.2

-0.1

0.0

0.1

0.2

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

350 400 450 500 550

Voltage (Vdc)

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 

Time (seconds) SOV-2

350 400 450 500 550

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

350 400 450 500 550

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 
C-35

C.1.9 Penlight Test #34

This test evaluated thermoset cables located inside a rigid steel conduit. At the end of the test 

all fuses (negative and positive) on both circuits (SOV-1 and SOV-2) had cleared. 

Table C-17 Penlight Test #34 parameters.

Test Date August 11, 2009

# Current Transducer turns CT500 = 2 CT35 = 5

Cable Type XLPE/CSPE, 7c, 12AWG SOV-1, SOV-2, TC

Cable Fill 3 cables

Raceway Configuration Conduit

Penlight Setpoint 525 °C

Battery Voltage 123.4 Vdc (Pre-test) 

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table C-18 Penlight Test #34 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

1623-1644 SOV-2 False Indication Red lamp ON

1632-1643 HS SOV-2 – Conductor R (11s duration)

1644 Positive and Negative Fuse Clear – SOV-2

1650 Cable Ignition

1697-1755 HS SOV-1 – Conductor R (58s duration)

1697-1755 SOV-1 False Indication Red Lamp ON

1728-1754 SA SOV-1 – Conductor S2 (7s longest duration) (~0.082 A) 

1756 Positive and Negative Fuse Clear – SOV-1

1830 Penlight off

TC

SOV-2

SOV-1
C-36

Figure C-33 Penlight Test #34 temperature profile

Figure C-34 Penlight Test #34 ground monitoring circuit voltages

Time (seconds)

0 500 1000 1500 2000

Temperature (C)

0

100

200

300

400

500

600 1st Failure (1632s - 429C)

Penlight 

Conduit Top 

Conduit Bottom 

TC Cable 

Time (seconds)

0 500 1000 1500 2000

Voltage (Vdc)

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-37

Figure C-35 Penlight Test #34 SOV-1 and SOV-2 coil modified voltage/current plots

Time (Seconds)

1500 1550 1600 1650 1700 1750 1800

Current (Amps)

0.0

0.5

1.0

1.5

2.0

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

1500 1550 1600 1650 1700 1750 1800

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

Time (Seconds)

1500 1550 1600 1650 1700 1750 1800

Current (Amps)

-0.04

0.00

0.04

0.08

0.12

0.16

0.20

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

1500 1550 1600 1650 1700 1750 1800

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-38

Figure C-36 Penlight Test #34 SOV-1 and SOV-2 indicating lamps modified 

voltage/current

SOV-1 Time (seconds)

1500 1550 1600 1650 1700 1750 1800

Current (Amps)

-0.5

0.0

0.5

1.0

1.5

2.0

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

1500 1550 1600 1650 1700 1750 1800

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 

Time (seconds) SOV-2

1500 1550 1600 1650 1700 1750 1800

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

0.16

0.18

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

1500 1550 1600 1650 1700 1750 1800

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

V(G) - V(Batt -) 

V(R) - V(Batt -) 
C-39

C.1.10 Penlight Test #38

Test evaluated thermoplastic cables located inside a rigid steel conduit. The test was 

terminated before taking the circuits to complete failure. A post-test inspection indicated that all 

fuses were good. The SOV-1 circuit did not fail during the test.

Table C-19 Penlight Test #38 parameters.

Test Date August 11, 2009

# Current Transducer turns CT500 = 2 CT35 = 5

Cable Type PE/PVC, 7c, 12AWG SOV-1, SOV-2, TC

Cable Fill 3 cables

Raceway Configuration Conduit

Penlight Setpoint 450 °C

Battery Voltage 123.5Vdc (Pre-test) 

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table C-20 Penlight Test #38 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

1164-2428 SA SOV-2 – Conductor S2 (1264s duration) (~0.086 A) 

1382-2475+ SOV-2 False Indication Red lamp ON [>1093s duration]

1382-2428 HS SOV-2 – Conductor R (1046s duration)

2475 Penlight off

TC

SOV-1

SOV-2
C-40

Figure C-37 Penlight Test #38 temperature profile

Figure C-38 Penlight Test #38 ground monitoring circuit voltages

Time (seconds)

0 500 1000 1500 2000 2500

Temperature (C)

0

100

200

300

400

500

600 1st Failure (1163s - 259C)

Penlight 

Conduit Top 

Conduit Bottom 

TC Cable 

Time (seconds)

0 500 1000 1500 2000 2500

Voltage (Vdc)

-150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-41

Figure C-39 Penlight Test #38 SOV-1 and SOV-2 coil modified voltage/current plots

Time (Seconds)

0 500 1000 1500 2000 2500

Current (Amps)

-0.4

0.0

0.4

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

0 500 1000 1500 2000 2500

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

Time (Seconds)

1000 1200 1400 1600 1800 2000 2200 2400 2600

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

0.25

P - Positive

S1 - Positive

G - Green Lamp

S - SOV

N - Negative

1000 1200 1400 1600 1800 2000 2200 2400 2600

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(S) - V(Batt -) 

V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-42

Figure C-40 Penlight Test #38 SOV-1 and SOV-2 indicating lamps modified 

voltage/current

SOV-1 Time (seconds)

0 500 1000 1500 2000 2500

Current (Amps)

-0.05

0.00

0.05

0.10

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

0 500 1000 1500 2000 2500

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 

Time (seconds) SOV-2

0 500 1000 1500 2000 2500

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

0.25

P - Positive

S1 - Positive

G - Green Lamp

N - Negative

0 500 1000 1500 2000 2500

Voltage (Vdc)

-40

0

40

80

120

160

V(G) - V(Batt -) 

V(R) - V(Batt -) 
C-43

C.2 Intermediate-Scale Results

The results from the intermediate-scale tests are presented below. Similar to the previous 

section, the data is presented in numerical as opposed to chronological order.

C.2.1 Intermediate-Scale Test Prelim #2

It should be noted that the nomenclature for the thermocouple used to monitor the air 

temperature for this test was subsequently changed to be more specific for the other tests. The 

north thermocouples represent the air temperatures for SOV-1 in Position A while the south 

thermocouples represent the air temperatures for SOV-2 in Position E.

Table C-21 Intermediate-Scale Test Prelim #2 parameters.

Cable Type for SOV-1 PE/PVC, 7c, 12AWG

SOV-1 Position Position A

Cable Fill Type Fill Tray H, Cable 2

Cable Type for SOV-2 PE/PVC, 7c, 12AWG

SOV-2 Position Position E

Cable Fill Type Fill Tray H, Cable 2

Battery Voltage (Pre-test) 123.12Vdc

Battery Voltage (Post-test) 122.83 Vdc

Table C-22 Intermediate-Scale Test Prelim #2 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

393 Battery negative shorts to ground

789-951 HS SOV-2 – Conductor R (162s duration)

953 Negative Fuse Clear – SOV-2

1020 Negative Fuse Clear – SOV-1

1020 Battery positive shorts to ground

1361 Fire Off
C-44

Figure C-41 Intermediate-Scale Test Prelim #2 temperature profile

Time (seconds)

0 200 400 600 800 1000 1200 1400

Temperature (C)

0

200

400

600

800

1000

1st SOV-1 Failure (312s -720C)

north top 

north mid 

north bottom 

south top 

south mid 

south bottom 

Plot 1 1st Failure (s - C)

1st SOV-2 Failure (953s - 277C)
C-45

Figure C-42 Intermediate-Scale Test Prelim #2 SOV-1 and SOV-2 current/voltage plots

Time (Seconds)

200 300 400 500 600

Current (Amps)

-0.08

-0.06

-0.04

-0.02

0.00

0.02

0.04

SOV-1_CT35_1_P 

SOV-1_CT35_2_S1 

SOV-1_CT35_3_G 

SOV-1_CT35_4_S2 

SOV-1_CT35_5_N 

200 300 400 500 600

Voltage (Vdc)

-40

0

40

80

120

160

{SOV1} V(P) - V(Batt -) 

{SOV1} V(S) - V(Batt -) 

{SOV1} V(N) - V(Batt -) 

Time (Seconds)

700 800 900 1000 1100 1200 1300

Current (Amps)

-0.04

0.00

0.04

0.08

0.12

0.16

0.20

0.24

0.28

SOV-2_CT35_1_P 

SOV-2_CT35_2_S1 

SOV-2_CT35_3_G 

SOV-2_CT35_4_S2 

SOV-2_CT35_5_N 

700 800 900 1000 1100 1200 1300

Voltage (Vdc)

-40

0

40

80

120

160

{SOV2} V(P) - V(Batt -) 

{SOV2} V(S) - V(Batt -) 

{SOV2} V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-46

Figure C-43 Intermediate-Scale Test Prelim #2 ground voltage monitoring circuit 

indication

C.2.2 Intermediate-Scale Test #1

Table C-23 Intermediate-Scale Test #1 parameters.

Cable Type for SOV-1 XLPE/CSPE, 7c, 12AWG

SOV-1 Position Position B, Cable 2

Cable Fill Type Conduit

Cable Type for SOV-2 XLPE/CSPE, 7c, 12AWG

SOV-2 Position Position D

Cable Fill Type Bundled Tray B, Cable 2

Battery Voltage (Pre-test) 123.31 Vdc

Battery Voltage (Post-test) 120.72 Vdc

Time (seconds)

0 200 400 600 800 1000 1200 1400

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-47

Table C-24 Intermediate-Scale Test #1 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1375 Negative Fuse Clear – SOV-1

1375-1386 SOV-1 – False Indication Red Light ON [11s duration]

1389-1391 SOV-1 – False Indication Red Light ON [2s duration]

2458-2523 SOV-2 – Voltage Increase from 21.1V to 75.2V on Red Light

2491-2523 HS SOV-2 – Conductor R (32s duration)

2512-2523 SA SOV-2 – Conductor S2 (11s duration) (0.09A) 

2649 Negative Fuse Clear – SOV-2

2964 Positive Fuse Clear – SOV-1

2964 Positive Fuse Clear – SOV-2

4380 Fire Off
C-48

Figure C-44 Intermediate-Scale Test #1 Temperature Profile, B-Position – Tray – Middle 

appears to be failing around 3200 s

Time (seconds)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

1000

1200

1400

1st SOV-1 Failure (1375s - 436C)

B Position - Tray - Middle

B Position - Conduit - 3'

B Position - Conduit - Middle

B Position - Conduit - 7'

D Position - 3' 

D Position - Middle 

D Position - 7' 

Plot 1 1st Failure (2958s - 292C)

1st SOV-2 Failure (2512s - 578C)
C-49

Figure C-45 Intermediate-Scale Test #1 SOV-1 and SOV-2 current/voltage plots

Time (Seconds)

1300 1350 1400 1450 1500

Current (Amps)

-0.10

-0.05

0.00

0.05

0.10

0.15

0.20

SOV-1_CT35_1_P 

SOV-1_CT35_2_S1 

SOV-1_CT35_3_G 

SOV-1_CT35_4_S2 

SOV-1_CT35_5_N 

1300 1350 1400 1450 1500

Voltage (Vdc)

-40

0

40

80

120

160

{SOV1} V(P) - V(Batt -) 

{SOV1} V(S) - V(Batt -) 

{SOV1} V(N) - V(Batt -) 

Time (Seconds)

2100 2200 2300 2400 2500 2600 2700

Current (Amps)

-0.2

-0.1

0.0

0.1

0.2

SOV-2_CT35_1_P 

SOV-2_CT35_2_S1 

SOV-2_CT35_3_G 

SOV-2_CT35_4_S2 

SOV-2_CT35_5_N 

2100 2200 2300 2400 2500 2600 2700

Voltage (Vdc)

-40

0

40

80

120

160

{SOV2} V(P) - V(Batt -) 

{SOV2} V(S) - V(Batt -) 

{SOV2} V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit

-2.4359A at 2647s

N = 2.5837A at 2647s

S = 1.4182A at 2647s
C-50

Figure C-46 Intermediate-Scale Test #1 ground voltage monitoring circuit indication

C.2.3 Intermediate-Scale Test #2

Table C-25 Intermediate-Scale Test #2 parameters.

Cable Type for SOV-1 XLPE/CSPE, 7c, 12AWG

SOV-1 Position Position C

Cable Fill Type Bundle Tray A, Cable 2

Cable Type for SOV-2 XLPE/CSPE, 7c, 12AWG

SOV-2 Position Position A

Cable Fill Type Fill Tray C, Cable 2

Battery Voltage (Pre-test) 121.77 Vdc

Battery Voltage (Post-test) 122.97 Vdc

Time (seconds)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-51

Table C-26 Intermediate-Scale Test #2 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1030-1109 SA SOV-2 – Conductor S2 (79s duration) (0.11A) 

1039-1107 HS SOV-2 – Conductor R(68s duration)

1041-1093 SOV-2 – False Indication Red Light ON [52s duration]

1164 Negative Fuse Clear – SOV-2

1759 Positive Fuse Clear – SOV-2

3909-3977 SA SOV-1 – Conductor S2 (68s duration) (0.078A) 

3979 Positive Fuse Clear – SOV-1

5605 Fire Off

Figure C-47 Intermediate-Scale Test #2 temperature profile

Time (seconds)

0 1000 2000 3000 4000 5000 6000 7000

Temperature (C)

0

200

400

600

800

1000

1st SOV-2 Failure (1030s - 527C)

A Position - Middle

C Position - 3'

C Position - Middle

C Position - 7'

Plot 1 1st Failure

1st SOV-1 Failure (3909s - 357C)
C-52

Figure C-48 Intermediate-Scale Test #2 SOV-1 and SOV-2 current/voltage plots

Time (Seconds)

3600 3800 4000 4200 4400

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

SOV-1_CT35_1_P 

SOV-1_CT35_2_S1 

SOV-1_CT35_3_G 

SOV-1_CT35_4_S2 

SOV-1_CT35_5_N 

3600 3800 4000 4200 4400

Voltage (Vdc)

-40

0

40

80

120

160

{SOV1} V(P) - V(Batt -) 

{SOV1} V(S) - V(Batt -) 

{SOV1} V(N) - V(Batt -) 

Time (Seconds)

900 950 1000 1050 1100 1150 1200

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

SOV-2_CT35_1_P 

SOV-2_CT35_2_S1 

SOV-2_CT35_3_G 

SOV-2_CT35_4_S2 

SOV-2_CT35_5_N 

900 950 1000 1050 1100 1150 1200

Voltage (Vdc)

-40

0

40

80

120

160

{SOV2} V(P) - V(Batt -) 

{SOV2} V(S) - V(Batt -) 

{SOV2} V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit

Transducer

Saturation
C-53

Figure C-49 Intermediate-Scale Test #2 ground voltage monitoring circuit indication

C.2.4 Intermediate-Scale Test #3

Table C-27 Intermediate-Scale Test #3 parameters.

Cable Type for SOV-1 XLPE/CSPE, 7c, 12AWG

SOV-1 Position Position D

Cable Fill Type Bundle Tray B, Cable 2

Cable Type for SOV-2 XLPE/CSPE, 7c, 12AWG

SOV-2 Position Position B

Cable Fill Type Fill Tray D, Cable 2

Battery Voltage (Pre-test) 121.59 Vdc

Battery Voltage (Post-test) 121.55 Vdc

Time (seconds)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-54

Table C-28 Intermediate-Scale Test #3 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1361-1363 SA SOV-2 – Conductor S2 (2s duration)

1375-1406 SA SOV-2 – Conductor S2 (31s duration)

1385-1406 HS SOV-2 – Conductor R [21s duration]

1420 Negative Fuse Clear – SOV-2

2286 Positive Fuse Clear – SOV-2

2860-2879 SA SOV-1 – Conductor S2 (19s duration)

2881 Positive Fuse Clear – SOV-1

3278 Negative Fuse Clear – SOV-1

3370 Fire Off

Figure C-50 Intermediate-Scale Test #3 temperature profile

Time (seconds)

0 1000 2000 3000 4000

Temperature (C)

0

200

400

600

800

1st SOV-2 Failure (1361s - 375C)

B Position - Middle

D Position - 3'

D Position - Middle

D Position - 7'

Plot 1 1st Failure 

1st SOV-1 Failure (3066s - 558C)
C-55

Figure C-51 Intermediate-Scale Test #3 SOV-1 and SOV-2 current/voltage plots

Time (Seconds)

3000 3050 3100 3150 3200

Current (Amps)

-0.10

-0.05

0.00

0.05

0.10

SOV-1_CT35_1_P 

SOV-1_CT35_2_S1 

SOV-1_CT35_3_G 

SOV-1_CT35_4_S2 

SOV-1_CT35_5_N 

3000 3050 3100 3150 3200

Voltage (Vdc)

-80

-40

0

40

80

120

160

200

{SOV1} V(P) - V(Batt -) 

{SOV1} V(S) - V(Batt -) 

{SOV1} V(N) - V(Batt -) 

Time (Seconds)

1200 1300 1400 1500 1600

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

SOV-2_CT35_1_P 

SOV-2_CT35_2_S1 

SOV-2_CT35_3_G 

SOV-2_CT35_4_S2 

SOV-2_CT35_5_N 

1200 1300 1400 1500 1600

Voltage (Vdc)

-40

0

40

80

120

160

{SOV2} V(P) - V(Batt -) 

{SOV2} V(S) - V(Batt -) 

{SOV2} V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit

5.925A at 3064s

2.455A at 1406s
C-56

Figure C-52 Intermediate-Scale Test #3 ground voltage monitoring circuit indication

C.2.5 Intermediate-Scale Test #4

Table C-29 Intermediate-Scale Test #4 parameters.

Cable Type for SOV-1 XLPE/CSPE, 7c, 12AWG

SOV-1 Position Position A

Cable Fill Type Fill Tray A, Cable 2

Cable Type for SOV-2 XLPE/CSPE, 7c, 12AWG

SOV-2 Position Position C

Cable Fill Type Bundled Tray I, Cable 2

Battery Voltage (Pre-test) 121.83 Vdc

Battery Voltage (Post-test) 122.74 Vdc

Time (seconds)

0 1000 2000 3000 4000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-57

Table C-30 Intermediate-Scale Test #4 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1550 SOV-1 – Current Increase on S1 to 1.5984A, followed by decline

1567 SOV-1 – Current Increase on S1 to 2.4899A, followed by decline

1585 SOV-1 – Current Increase on S1 to 2.8446A, followed by decline

1586 SOV-1 – Current Increase on G to 4.1831A, followed by decline

1586 SOV-1 – Voltage Increase on R, 46.41V, followed by decline

1669-1673 HS SOV-1 – Conductor R (4s duration)

1673 SOV-1 – Voltage and Current Increase on S2, 49.10V, 0.0287A

1763 Positive Fuse Clear – SOV-1

4800-5249 SOV-2 – Voltage Increase from 3.14V to 58.86V on Red Light

5216-5249 SA SOV-2 – Conductor S2 (33s duration) (0.14A) 

5251 Positive Fuse Clear – SOV-2

5307 Negative Fuse Clear – SOV-2

5307 Negative Fuse Clear – SOV-1

6720 Fire Off

Figure C-53 Intermediate-Scale Test #4 temperature profile

Time (seconds)

0 2000 4000 6000 8000

Temperature (C)

0

200

400

600

800

1st SOV-1 Failure (1671s - 468C)

A Position - Middle

C Position - 3'

C Position - Middle

C Position - 7'

Plot 1 1st Failure

1st SOV-2 Failure (5216s - 539C)
C-58

Figure C-54 Intermediate-Scale Test #4 SOV-1 and SOV-2 current/voltage plots

Time (Seconds)

1300 1400 1500 1600 1700 1800

Current (Amps)

-1

0

1

2

3

4

5

SOV-1_CT35_1_P 

SOV-1_CT35_2_S1 

SOV-1_CT35_3_G 

SOV-1_CT35_4_S2 

SOV-1_CT35_5_N 

1300 1400 1500 1600 1700 1800

Voltage (Vdc)

-40

0

40

80

120

160

{SOV1} V(P) - V(Batt -) 

{SOV1} V(S) - V(Batt -) 

{SOV1} V(N) - V(Batt -) 

Time (Seconds)

4800 4900 5000 5100 5200 5300 5400

Current (Amps)

-0.04

0.00

0.04

0.08

0.12

0.16

0.20

SOV-2_CT35_1_P 

SOV-2_CT35_2_S1 

SOV-2_CT35_3_G 

SOV-2_CT35_4_S2 

SOV-2_CT35_5_N 

4800 4900 5000 5100 5200 5300 5400

Voltage (Vdc)

-40

0

40

80

120

160

{SOV2} V(P) - V(Batt -) 

{SOV2} V(S) - V(Batt -) 

{SOV2} V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-59

Figure C-55 Intermediate-Scale Test #4 ground voltage monitoring circuit indication

C.2.6 Intermediate-Scale Test #5

Table C-31 Intermediate-Scale Test #5 parameters.

Cable Type for SOV-1 PE/PVC, 7c, 12AWG

SOV-1 Position Position B, Cable 2

Cable Fill Type Conduit

Cable Type for SOV-2 PE/PVC, 7c, 12AWG

SOV-2 Position Position D

Cable Fill Type Bundled Tray B, Cable 2

Battery Voltage (Pre-test) 124.02 Vdc

Battery Voltage (Post-test) 122.74 Vdc

Time (seconds)

0 2000 4000 6000 8000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-60

Table C-32 Intermediate-Scale Test #5 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1637-1649 SA SOV-1 – Conductor S2 (12s duration) (0.057A) {Intercable

Shorting}

1646-1857 SA SOV-2 – Conductor S2 (190s longest duration) (0.12A) 

1651 Negative Fuse Clear – SOV-1

1859 Negative Fuse Clear – SOV-2

2640 Fire Off

Figure C-56 Intermediate-Scale Test #5 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

200

400

600

800

1st SOV-1 Failure (1556s - 535C)

B Position - Conduit - 3'

B Position - Conduit - Middle

B Position - Conduit - 7'

D Position - 3'

D Position - Middle

D Position - 7'

Plot 1 1st Failure (s - C)

1st SOV-2 Failure (1646s - 629C)
C-61

Figure C-57 Intermediate-Scale Test #5 SOV-1 and SOV-2 current/voltage plots

Time (Seconds)

1500 1550 1600 1650 1700

Current (Amps)

-0.1

0.0

0.1

SOV-1_CT35_1_P 

SOV-1_CT35_2_S1 

SOV-1_CT35_3_G 

SOV-1_CT35_4_S2 

SOV-1_CT35_5_N 

1500 1550 1600 1650 1700

Voltage (Vdc)

-40

0

40

80

120

160

{SOV1} V(P) - V(Batt -) 

{SOV1} V(S) - V(Batt -) 

{SOV1} V(N) - V(Batt -) 

Time (Seconds)

1600 1800 2000 2200 2400

Current (Amps)

-0.08

-0.04

0.00

0.04

0.08

0.12

0.16

SOV-2_CT35_1_P 

SOV-2_CT35_2_S1 

SOV-2_CT35_3_G 

SOV-2_CT35_4_S2 

SOV-2_CT35_5_N 

1600 1800 2000 2200 2400

Voltage (Vdc)

-40

0

40

80

120

160

{SOV2} V(P) - V(Batt -) 

{SOV2} V(S) - V(Batt -) 

{SOV2} V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-62

Figure C-58 Intermediate-Scale Test #5 ground voltage monitoring circuit indication

C.2.7 Intermediate-Scale Test #6

Table C-33 Intermediate-Scale Test #6 parameters

Cable Type for SOV-1 PE/PVC, 7c, 12AWG

SOV-1 Position Position C

Cable Fill Type Bundled Tray B, Cable 4

Cable Type for SOV-2 PE/PVC, 7c, 12AWG

SOV-2 Position Position A

Cable Fill Type Fill Tray D, Cable 2

Battery Voltage (Pre-test) 123.56 Vdc

Battery Voltage (Post-test) 123.04 Vdc

Time (seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-63

Table C-34 Intermediate-Scale Test #6 sequence of events

Time (seconds) Event/Observation

0 Fire Initiated

166-109 HS SOV-2 – Conductor R (24s duration)

170-190 SOV-2 – False Indication Red Light ON [20s duration]

191 Negative Fuse Clear – SOV-2

1400 Negative Fuse Clear – SOV-1

2640 Fire Off

Figure C-59 Intermediate-Scale Test #6 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500

Temperature (C)

0

200

400

600

800

1000

1st SOV-2 Failure (191s - 165C)

A Position - Middle

C Position - 3'

C Position - Middle

C Position - 7'

Plot 1 1st Failure

1st SOV-1 Failure (1400s - 792C)
C-64

Figure C-60 Intermediate-Scale Test #6 SOV-1 and SOV-2 current/voltage plots

Time (Seconds)

1300 1400 1500 1600 1700 1800

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

SOV-1_CT35_1_P 

SOV-1_CT35_2_S1 

SOV-1_CT35_3_G 

SOV-1_CT35_4_S2 

SOV-1_CT35_5_N 

1300 1400 1500 1600 1700 1800

Voltage (Vdc)

-40

0

40

80

120

160

{SOV1} V(P) - V(Batt -) 

{SOV1} V(S) - V(Batt -) 

{SOV1} V(N) - V(Batt -) 

Time (Seconds)

100 150 200 250 300

Current (Amps)

-0.04

0.00

0.04

0.08

0.12

0.16

0.20

0.24

0.28

0.32

0.36

SOV-2_CT35_1_P 

SOV-2_CT35_2_S1 

SOV-2_CT35_3_G 

SOV-2_CT35_4_S2 

SOV-2_CT35_5_N 

100 150 200 250 300

Voltage (Vdc)

-40

0

40

80

120

160

{SOV2} V(P) - V(Batt -) 

{SOV2} V(S) - V(Batt -) 

{SOV2} V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit

4.656A at 1557s
C-65

Figure C-61 Intermediate-Scale Test #6 ground voltage monitoring circuit indication

C.2.8 Intermediate-Scale Test #7

Table C-35 Intermediate-Scale Test #7 parameters.

Cable Type for SOV-1 PE/PVC, 7c, 12AWG

SOV-1 Position Position B

Cable Fill Type Fill Tray D, Cable 2

Cable Type for SOV-2 PE/PVC, 7c, 12AWG

SOV-2 Position Position D

Cable Fill Type Bundled Tray B, Cable 4

Battery Voltage (Pre-test) 121.98 Vdc

Battery Voltage (Post-test) 122.83 Vdc

Time (seconds)

0 500 1000 1500 2000 2500

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-66

Table C-36 Intermediate-Scale Test #7 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

302-363 SA SOV-1 – Conductor S2 (61s duration) (0.08A) 

324 SOV-1 – Current Increase on Positive Source S1 (1.5A)

363 Negative Fuses Clear – SOV-1

466 Negative Fuse Clear – SOV-2

2400 Fire Off

Figure C-62 Intermediate-Scale Test #7 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500

Temperature (C)

0

200

400

600

800

1000

1st SOV-1 Failure (302s - 246C)

B Position - Tray - Middle

D Position - 3'

D Position - Middle

D Position - 7'

Plot 1 1st Failure 

1st SOV-2 Failure (466s - 427C)
C-67

Figure C-63 Intermediate-Scale Test #7 SOV-1 and SOV-2 current/voltage plots

Time (Seconds)

250 300 350 400 450

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

SOV-1_CT35_1_P 

SOV-1_CT35_2_S1 

SOV-1_CT35_3_G 

SOV-1_CT35_4_S2 

SOV-1_CT35_5_N 

250 300 350 400 450

Voltage (Vdc)

-40

0

40

80

120

160

{SOV1} V(P) - V(Batt -) 

{SOV1} V(S) - V(Batt -) 

{SOV1} V(N) - V(Batt -) 

Time (Seconds)

400 420 440 460 480 500

Current (Amps)

-0.04

0.00

0.04

0.08

SOV-2_CT35_1_P 

SOV-2_CT35_2_S1 

SOV-2_CT35_3_G 

SOV-2_CT35_4_S2 

SOV-2_CT35_5_N 

400 420 440 460 480 500

Voltage (Vdc)

-40

0

40

80

120

160

{SOV2} V(P) - V(Batt -) 

{SOV2} V(S) - V(Batt -) 

{SOV2} V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit

1.5119A at 324s
C-68

Figure C-64 Intermediate-Scale Test #7 ground voltage monitoring circuit indication

C.2.9 Intermediate-Scale Test #8

Table C-37 Intermediate-Scale Test #8 parameters.

Cable Type for SOV-1 PE/PVC, 7c, 12AWG

SOV-1 Position Position A

Cable Fill Type Fill Tray A, Cable 2

Cable Type for SOV-2 PE/PVC, 7c, 12AWG

SOV-2 Position Position C

Cable Fill Type Bundle Tray A, Cable 2

Battery Voltage (Pre-test) 121.78 Vdc

Battery Voltage (Post-test) 122.56 Vdc

Table C-38 Intermediate-Scale Test #8 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated, SOV-2 Red light was not functioning properly

0-2291 HS SOV-2 – False Indication (1391s longest duration)

960-1050 SA SOV-1 – Conductor S2 (90s duration) (0.09A) 

969-1050 HS SOV-1 – Conductor R (81s duration)

1052 Negative Fuse Clear – SOV-1

2354 Negative Fuse Clear – SOV-2

2495 Fire Off

Time (seconds)

0 500 1000 1500 2000 2500

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-69

Figure C-65 Intermediate-Scale Test #8 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500

Temperature (C)

0

200

400

600

800

1000

1st SOV-1 Failure (960s - 803C)

A Position - Middle

C Position - 3'

C Position - Middle

C Position - 7'

Plot 1 1st Failure

1st SOV-2 Failure (2354s - 480C)
C-70

Figure C-66 Intermediate-Scale Test #8 SOV-1 and SOV-2 current/voltage plots

Time (Seconds)

900 950 1000 1050 1100

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

SOV-1_CT35_1_P 

SOV-1_CT35_2_S1 

SOV-1_CT35_3_G 

SOV-1_CT35_4_S2 

SOV-1_CT35_5_N 

900 950 1000 1050 1100

Voltage (Vdc)

-40

0

40

80

120

160

200

{SOV1} V(P) - V(Batt -) 

{SOV1} V(S) - V(Batt -) 

{SOV1} V(N) - V(Batt -) 

Time (Seconds)

2000 2100 2200 2300 2400 2500

Current (Amps)

-0.04

0.00

0.04

SOV-2_CT35_1_P 

SOV-2_CT35_2_S1 

SOV-2_CT35_3_G 

SOV-2_CT35_4_S2 

SOV-2_CT35_5_N 

2000 2100 2200 2300 2400 2500

Voltage (Vdc)

-40

0

40

80

120

160

200

{SOV2} V(P) - V(Batt -) 

{SOV2} V(S) - V(Batt -) 

{SOV2} V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-71

Figure C-67 Intermediate-Scale Test #8 ground voltage monitoring circuit indication

C.2.10 Intermediate-Scale Test #9

Table C-39 Intermediate-Scale Test #9 parameters.

Cable Type for SOV-1 Kerite, 10c, 12AWG, without zinc wrap

SOV-1 Position Position B

Cable Fill Type Specialized Tray B, Cable 4

Cable Type for SOV-2 Armored Cable, 8c, 12AWG

SOV-2 Position Position D

Cable Fill Type Specialized Tray A, Cable 2

Battery Voltage (Pre-test) 122.15 Vdc

Battery Voltage (Post-test) 122.41 Vdc

Time (seconds)

0 500 1000 1500 2000 2500

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-72

Table C-40 Intermediate-Scale Test #9 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1487-1580 SOV-2 – Voltage Increase from 3.04V to 58V on Red Light

1500-550 SOV-2 – Voltage Increase from 3.17V to 28.23V on Solenoid

1552-1580 SA SOV-2 – Conductor S2 (28s duration) (0.1218A) 

1581 Negative Fuse Clear – SOV-2

1750 Positive Fuse Clear – SOV-2

2101-2225 SOV-1 – Voltage Increase from 1.58V to 12.05V on Solenoid

2227-2418 SOV-1 – Voltage on Solenoid Nominally Steady from 12 – 14V

2421-2582 SOV-1 – Voltage on Solenoid Nominally Steady from 39 – 45V

2422-2696 HS SOV-1 – Conductor R (274s duration)

2429-2432 SOV-1 – False Indication Red Light ON [3s duration]

2435-2698 SOV-1 – False Indication Red Light ON [263s duration]

2584-2696 SA SOV-1 – Conductor S2 (112s duration) (0.0519A) 

2698 Negative Fuse Clear – SOV-1

3300 Fire Off
C-73

Figure C-68 Intermediate-Scale Test #9 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500 3000 3500

Temperature (C)

0

200

400

600

800

1000

1st SOV-2 Failure (1552s - 336C)

B Position - Middle

B Position - Kerite 10c w

D Position - Middle

D Position - Armored 5'

Plot 1 1st Failure

1st SOV-1 Failure (2584s - 446C)
C-74

Figure C-69 Intermediate-Scale Test #9 SOV-1 and SOV-2 current/voltage plots

Time (Seconds)

2300 2400 2500 2600 2700 2800

Current (Amps)

-2

0

2

4

6

8

SOV-1_CT35_1_P 

SOV-1_CT35_2_S1 

SOV-1_CT35_3_G 

SOV-1_CT35_4_S2 

SOV-1_CT35_5_N 

2300 2400 2500 2600 2700 2800

Voltage (Vdc)

-40

0

40

80

120

160

200

{SOV1} V(P) - V(Batt -) 

{SOV1} V(S) - V(Batt -) 

{SOV1} V(N) - V(Batt -) 

Time (Seconds)

1500 1520 1540 1560 1580 1600

Current (Amps)

-0.04

0.00

0.04

0.08

0.12

0.16

0.20

0.24

SOV-2_CT35_1_P 

SOV-2_CT35_2_S1 

SOV-2_CT35_3_G 

SOV-2_CT35_4_S2 

SOV-2_CT35_5_N 

1500 1520 1540 1560 1580 1600

Voltage (Vdc)

-40

0

40

80

120

160

{SOV2} V(P) - V(Batt -) 

{SOV2} V(S) - V(Batt -) 

{SOV2} V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-75

Figure C-70 Intermediate-Scale Test #9 ground voltage monitoring circuit indication

C.2.11 Intermediate-Scale Test #10

Table C-41 Intermediate-Scale Test #10 parameters.

Cable Type for SOV-1 Kerite 9c, 12AWG, without zinc wrap

SOV-1 Position Position C

Cable Fill Type Bundle Tray A, Cable 1

Cable Type for SOV-2 Kerite, 10c, 12AWG, with zinc wrap

SOV-2 Position Position B

Cable Fill Type Specialized Tray C, Cable 3

Battery Voltage (Pre-test) 121.96 Vdc

Battery Voltage (Post-test) 122.21 Vdc

Time (seconds)

0 500 1000 1500 2000 2500 3000 3500

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-76

Table C-42 Intermediate-Scale Test #10 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

2298-2463 SOV-2 – Voltage Increase from 1.06V to 38V on Solenoid

2458-2463 SOV-2 – False Indication Red Light ON [5s duration]

2458-2463 HS SOV-2 – Conductor R (5s duration)

2465 Positive Fuse Clear – SOV-2

2502 Negative Fuse Clear – SOV-2

3328-3370 SOV-1 – Voltage Increase from 4V to 26.5V on Solenoid

3354-3370 SOV-1 – False Indication Red Light ON [16s duration]

3354-3370 HS SOV-1 – Conductor R (16s duration)

3646 Positive Fuse Clear – SOV-1

3960 Fire Off

Figure C-71 Intermediate-Scale Test #10 temperature profile

Time (s)

0 1000 2000 3000 4000

Temperature (C)

0

200

400

600

800

1000

1200

1400

1600

1st SOV-2 Failure (2502s - 523C)

B Position - Tray - Middle

B Position - Kerite 10c wo

C Position - 3' 

C Position - Middle

C Position - 7' 

C Position - Kerite 12c wo - 3'

C Position - Kerite 12c wo - 5' 

Plot 1 Upper specification

1st SOV-1 Failure (3646s - 412C)

Thermocouples

Failing
C-77

Figure C-72 Intermediate-Scale Test #10 SOV-1 and SOV-2 current/voltage plots

Time (Seconds)

3000 3200 3400 3600 3800

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

SOV-1_CT35_1_P 

SOV-1_CT35_2_S1 

SOV-1_CT35_3_G 

SOV-1_CT35_4_S2 

SOV-1_CT35_5_N 

3000 3200 3400 3600 3800

Voltage (Vdc)

-40

0

40

80

120

160

{SOV1} V(P) - V(Batt -) 

{SOV1} V(S) - V(Batt -) 

{SOV1} V(N) - V(Batt -) 

Time (Seconds)

2400 2450 2500 2550 2600

Current (Amps)

-2

0

2

4

6

8

SOV-2_CT35_1_P 

SOV-2_CT35_2_S1 

SOV-2_CT35_3_G 

SOV-2_CT35_4_S2 

SOV-2_CT35_5_N 

2400 2450 2500 2550 2600

Voltage (Vdc)

-40

0

40

80

120

160

{SOV2} V(P) - V(Batt -) 

{SOV2} V(S) - V(Batt -) 

{SOV2} V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit

G = 6.3304A at 3360s S1 = 3.4143A at 3370s

7.0188A at 2500s

6.3257A at 2463s
C-78

Figure C-73 Intermediate-Scale Test #10 ground voltage monitoring circuit indication

C.2.12 Intermediate-Scale Test #11

Table C-43 Intermediate-Scale Test #11 parameters.

Cable Type for SOV-1 EPR/CPE, 7c, 12AWG

SOV-1 Position Position B

Cable Fill Type Fill Tray A, Cable 2

Cable Type for SOV-2 EPR/CPE, 7c, 12AWG

SOV-2 Position Position D

Cable Fill Type Bundle Tray I, Cable 2

Battery Voltage (Pre-test) 122.93 Vdc

Battery Voltage (Post-test) 123.14 Vdc

Time (seconds)

0 1000 2000 3000 4000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-79

Table C-44 Intermediate-Scale Test #11 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1569 Negative Fuse Clear – SOV-1

2858 -2915 SA SOV-2 – Conductor S2 (57s duration)

2912-2917 SOV-2 – False Indication Red Light ON [5s duration]

2912-2915 HS SOV-2 – Conductor R (3s duration)

2917 Negative Fuse Clear – SOV-2

4500 Fire Off

Figure C-74 Intermediate-Scale Test #11 temperature profile

Time (seconds)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

1st SOV-1 Failure (1569s - 542C)

B Position - Middle

D Position - 3'

D Position - Middle

D Position - 7'

Plot 1 1st Failure

1st SOV-2 Failure (2858s - 660C)
C-80

Figure C-75 Intermediate-Scale Test #11 SOV-1 and SOV-2 current/voltage plots

Time (Seconds)

1000 1200 1400 1600 1800

Current (Amps)

-0.08

-0.06

-0.04

-0.02

0.00

0.02

0.04

0.06

SOV-1_CT35_1_P 

SOV-1_CT35_2_S1 

SOV-1_CT35_3_G 

SOV-1_CT35_4_S2 

SOV-1_CT35_5_N 

1000 1200 1400 1600 1800

Voltage (Vdc)

-80

-40

0

40

80

120

160

{SOV1} V(P) - V(Batt -) 

{SOV1} V(S) - V(Batt -) 

{SOV1} V(N) - V(Batt -) 

Time (Seconds)

2800 2900 3000 3100 3200 3300 3400

Current (Amps)

-1

0

1

2

3

4

SOV-2_CT35_1_P 

SOV-2_CT35_2_S1 

SOV-2_CT35_3_G 

SOV-2_CT35_4_S2 

SOV-2_CT35_5_N 

2800 2900 3000 3100 3200 3300 3400

Voltage (Vdc)

-80

-40

0

40

80

120

160

{SOV2} V(P) - V(Batt -) 

{SOV2} V(S) - V(Batt -) 

{SOV2} V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-81

Figure C-76 Intermediate-Scale Test #11 ground voltage monitoring circuit indication

C.2.13 Intermediate-Scale Test #12

Table C-45 Intermediate-Scale Test #12 parameters.

Cable Type for SOV-1 EPR/CPE, 7c, 12AWG

SOV-1 Position Position D

Cable Fill Type Bundle Tray A, Cable 2

Cable Type for SOV-2 EPR/CPE, 7c, 12AWG

SOV-2 Position Position B

Cable Fill Type Fill Tray C, Cable 2

Battery Voltage (Pre-test) 122.31 Vdc

Battery Voltage (Post-test) 122.86 Vdc

Time (seconds)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
C-82

Table C-46 Intermediate-Scale Test #12 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

2316 Negative Fuse Clear – SOV-2, Red Light Shorting to Solenoid

2540 Positive Fuse Clear – SOV-2

2540-3141 SOV-1 – Positive and Negative Voltages Reflecting Shorting Behavior 

from Large Coil

3075 Positive Fuse Clear – SOV-1

3141 Negative Fuse Clear – SOV-1

3894 Fire Off

Figure C-77 Intermediate-Scale Test #12 temperature profile

Time (seconds)

0 1000 2000 3000 4000

Temperature (C)

0

200

400

600

800

1000

1st SOV-2 Failure (2314s - 479C)

B Position - Middle

D Position - 3'

D Position - Middle

D Position - 7'

Plot 1 1st Failure

1st SOV-1 Failure (3131s - 649C)
C-83

Figure C-78 Intermediate-Scale Test #12 SOV-1 and SOV-2 current/voltage plots

Time (Seconds)

3000 3050 3100 3150 3200

Current (Amps)

-8

-6

-4

-2

0

2

4

6

8

SOV-1_CT35_1_P 

SOV-1_CT35_2_S1 

SOV-1_CT35_3_G 

SOV-1_CT35_4_S2 

SOV-1_CT35_5_N 

3000 3050 3100 3150 3200

Voltage (Vdc)

-80

-40

0

40

80

120

160

{SOV1} V(P) - V(Batt -) 

{SOV1} V(S) - V(Batt -) 

{SOV1} V(N) - V(Batt -) 

Time (Seconds)

2200 2300 2400 2500 2600

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

SOV-2_CT35_1_P 

SOV-2_CT35_2_S1 

SOV-2_CT35_3_G 

SOV-2_CT35_4_S2 

SOV-2_CT35_5_N 

2200 2300 2400 2500 2600

Voltage (Vdc)

-40

0

40

80

120

160

{SOV2} V(P) - V(Batt -) 

{SOV2} V(S) - V(Batt -) 

{SOV2} V(N) - V(Batt -) 

SOV-1 Circuit

SOV-2 Circuit
C-84

Figure C-79 Intermediate-Scale Test #12 ground voltage monitoring circuit indication

Time (seconds)

0 1000 2000 3000 4000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 

Appendix D. 1-inch Solenoid-Operated 

Valve (SOV) and Large Coil Circuits
D-1

D.1 Small-Scale Results

The purpose of this section is to provide the paired circuit analysis for each test in the smalland intermediate-scale experiments. Every test has a nominal summary of the specific

experimental parameters, sequence of events, and data supporting the sequential events. It 

should be noted that circuit grounding observations were included for Penlight since only two 

circuits were tested and ground faults were, in general, simple and easily identifiable. In the 

intermediate-scale experiments, however, the number of commonly grounded circuits and wide 

berth of failure times overcomplicates detailed observations. As such, the intermediate-scale 

ground behavior was not described in as much detail as the Penlight tests.

The results from the Penlight tests are presented below. The data is presented in numerical as 

opposed to chronological order.

D.1.1 Test #5

This test evaluated a thermoset (TS) cable located in a cable tray. Post-test inspection of the 

fuses found the negative 25-A fuse on the large coil operational while all other fuses had 

cleared. The Red Indicating Lamp was functional during this test.

Table D-1 Penlight Test #5 parameters.

Test Date July 22, 2009

# Current Transducer turns CT500 = 1 CT35 = 1

Cable Type XLPE/CSPE, 7c, 12AWG LG Coil, 1” Valve, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 470 °C

Battery Voltage 123.2 Vdc (Pre-test) 123.4 Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

LG TC 1”
D-2

Table D-2 Penlight Test #5 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

591-631 False Indication – 1” valve – Red lamp ON

591-649 HS 1” Valve – Conductor R (40s longest duration)

597 Cable Ignition

610-618 False Indication – Lg Coil – Red lamp ON

610-618 HS Lg Coil – Conductor R (8s duration)

616-618 SA Lg Coil – Cable S (2s duration)

634-648 False Indication – 1” valve – Red lamp ON

636-653 HS 1” Valve – Conductor G (5s longest duration)

636-654 SA 1” Valve – Cable S (5s longest duration)

643-648 False Indication – 1” valve – Green lamp ON

648-650 False Indication – 1” valve – Red lamp ON

650-654 False Indication – 1” valve – Green lamp ON

654 Positive Fuse Clear – Lg Coil

656 Negative Fuse Clear – 1” Valve (10A)

1257 Penlight off

Figure D-1 Penlight Test #5 temperature profile

Time (seconds)

0 200 400 600 800 1000 1200 1400

Temperature (C)

0

100

200

300

400

500

600

700

1st Failure (591 s - 464C)

Penlight 

Cable 1 

Cable 2 
D-3

Figure D-2 Penlight Test #5 ground monitoring circuit voltages

Time (seconds)

0 200 400 600 800 1000 1200

Voltage (Vdc)

-100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 
D-4

Figure D-3 Penlight Test #5 1-inch SOV and large coil modified voltage/current plots

580 600 620 640 660 680

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(G) - V(Batt -) 

V(S) - V(Batt -) 

V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

580 600 620 640 660 680

Current (Amps)

-1

0

1

2

3

4

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

580 600 620 640 660 680

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

V(P) - V(Batt -) 

V(G) - V(Batt -) 

V(S) - V(Batt -) 

V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

580 600 620 640 660 680

Current (Amps)

-0.5

0.0

0.5

1.0

1.5

2.0

2.5

P - Positive

G - Green Lamp

S - Coil

N2 - Negative
D-5

Figure D-4 Penlight Test #5 1-inch SOV and large coil indicating lamps modified 

voltage/current

1" Valve Circuit - Lamps

Time (seconds)

580 600 620 640 660 680

Current (Amps)

-1

0

1

2

3

4

P - Positive

G - Green Lamp

R - Red Lamp

N1 - Negative

N2 - Negative

580 600 620 640 660 680

Voltage (Vdc)

-40

0

40

80

120

160

V(R) - V(Batt -) 

V(G) - V(Batt -) 

Lg Coil Circuit - Lamps

Time (seconds)

580 600 620 640 660 680

Current (Amps)

-0.4

0.0

0.4

0.8

1.2

1.6

2.0

P - Positive

G - Green Lamp

N1 - Negative

N2 - Negative

580 600 620 640 660 680

Voltage (Vdc)

-40

0

40

80

120

160

V(R) - V(Batt -) 

V(G) - V(Batt -) 
D-6

D.1.2 Test #6

Test 6 evaluated TS cables located in a cable tray. For the 1-in. valve, the normally open (NO) 

contact controlling the indication “R” lamp had failed shut in past testing, which caused it to be 

closed at the start of this test. As such, the Red Indicating lamp acted as a positive source 

conductor. The normally closed (NC) contact was also closed at the beginning; however, the 

data shows that it did function properly. It momentarily opened when the spurious actuation 

occurred on the 1-inch valve circuit. Post-test evaluation of the fuses indicated that both 

positive fuses for both circuits were operational, while the negative fuses for both circuits had 

cleared.

Table D-3 Penlight Test #6 parameters.

Test Date July 22, 2009

# Current Transducer turns CT500 = 1 CT35 = 1

Cable Type XLPE/CSPE, 7c, 12AWG 1” Valve, Lg Coil, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 470 °C

Battery Voltage 123.4 Vdc (Pre-test) 123.5 Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table D-4 Penlight Test #6 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

598 SA 1” Valve – Cable S (<1s duration)

600 Cable Ignition

610 Negative Fuse Clear – 1” valve (10A)

676 Battery Positive shorts to ground

677 Negative Fuse Clear – Lg Coil (25A)

1320 Penlight off

1” TC LG
D-7

Figure D-5 Penlight Test #6 temperature profile

Time (seconds)

0 200 400 600 800 1000 1200 1400

Temperature (C)

0

100

200

300

400

500

600

700

1st Failure (597s - 459C)

Penlight 

Cable 1 

Cable 2 
D-8

Figure D-6 Penlight Test #6 ground monitoring circuit voltages

Time (seconds)

0 200 400 600 800 1000 1200 1400

Voltage (Vdc)

-150

-100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 
D-9

Figure D-7 Penlight Test #6 1-inch SOV and large coil modified voltage/current plots

580 600 620 640 660 680 700

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(G) - V(Batt -) 

V(S) - V(Batt -) 

V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

580 600 620 640 660 680 700

Current (Amps)

-0.5

0.0

0.5

1.0

1.5

2.0

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

580 600 620 640 660 680 700

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

V(P) - V(Batt -) 

V(G) - V(Batt -) 

V(S) - V(Batt -) 

V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

580 600 620 640 660 680 700

Current (Amps)

-0.10

-0.05

0.00

0.05

0.10

0.15

0.20

0.25

P - Positive

G - Green Lamp

S - Coil

N2 - Negative
D-10

Figure D-8 Penlight Test #6 1-inch SOV and large coil indicating lamps modified 

voltage/current

1" Valve Circuit - Lamps

Time (seconds)

580 600 620 640 660 680 700

Current (Amps)

-0.5

0.0

0.5

1.0

1.5

2.0

P - Positive

G - Green Lamp

R - Red Lamp

N1 - Negative

N2 - Negative

580 600 620 640 660 680 700

Voltage (Vdc)

0

40

80

120

160

V(R) - V(Batt -) 

V(G) - V(Batt -) 

Lg Coil Circuit - Lamps

Time (seconds)

580 600 620 640 660 680 700

Current (Amps)

-0.10

-0.05

0.00

0.05

0.10

0.15

0.20

0.25

P - Positive

G - Green Lamp

N1 - Negative

N2 - Negative

580 600 620 640 660 680 700

Voltage (Vdc)

-40

0

40

80

120

160

V(R) - V(Batt -) 

V(G) - V(Batt -) 
D-11

D.1.3 Test #11

This test evaluated the performance of a thermoplastic (TP) cable located in a cable tray. Of 

interest in the tests were the interactions between the two cables. At 1089 seconds, a source 

conductor in the 1-inch valve cable energized a target conductor in the large coil cable, thus 

causing an intercable spurious actuation. This intercable interaction is aided by the cable tray 

conductivity. Post-test evaluation of the fuses indicated that both negative fuses had cleared 

while both positive fuses remained operational. The Red Indicating lamp was functional during 

this test.

Table D-5 Penlight Test #11 parameters.

Test Date July 22, 2009

# Current Transducer turns CT500 = 1 CT35 = 1

Cable Type PE/PVC, 7c,12 AWG Lg Coil, 1” Valve , TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 325 °C

Battery Voltage 123.3 Vdc (Pre-test) 123.4 Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

1” TC LG
D-12

Table D-6 Penlight Test #11 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

1087-1141 Battery Positive shorts to ground

1089-1104 False Indication – 1” Valve – Red lamp ON

1089-1141 SA Lg Coil – Cable S (52s duration) – Inter-cable

1093-1129 HS 1” Valve – Conductor R (19s longest duration)

1108-1834 HS 1” Valve – Conductor G (367s longest duration)

1108-2260 SA 1” Valve – Cable S (796s longest duration)

1109 False Indication – 1” Valve – Green lamp ON

1110-1130 False Indication – 1” Valve – Red lamp ON

1130-1141 False Indication – 1” Valve – Green lamp ON

1142-1455 Battery Negative shorts to ground

1142-1455 False Indication – 1” Valve – Green lamp OFF

1456-1464 False Indication – 1” Valve – Red lamp ON

1456-2456 SA Lg Coil – Cable S (996s longest duration)

1456 HS 1” Valve – Conductor R (<1s duration)

1464-1835 False Indication – 1” Valve – Green lamp ON

1464-2457 Battery Positive shorts to ground

1464-2260 SA 1” Valve – Cable S(796s duration)

1534 HS Lg Coil – Conductor R (<1s duration)

1534-2457 False Indication – 1” Valve – Red lamp ON

1930-2262 False Indication – 1” Valve – Green lamp ON

1931-2260 HS 1” Valve – Conductor G (329s duration)

2261 Negative Fuse Clear – 1” Valve (10A)

2457 Negative Fuse Clear – Lg Coil (25A)

2495 Cable Ignition

2795 Penlight off
D-13

Figure D-9 Penlight Test #11 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

100

200

300

400

500

600

700

1st Failure (1089s - 264C)

Penlight 

Cable 1 

Cable 2 
D-14

Figure D-10 Penlight Test #11 ground monitoring circuit voltages

Time (seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

-100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 
D-15

Figure D-11 Penlight Test #11 1-inch SOV and large coil modified voltage/current plots

1000 1200 1400 1600 1800 2000 2200 2400 2600

Voltage (Vdc)

-80

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(G) - V(Batt -) 

V(S) - V(Batt -) 

V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

1000 1200 1400 1600 1800 2000 2200 2400 2600

Current (Amps)

-1

0

1

2

3

4

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

1000 1200 1400 1600 1800 2000 2200 2400 2600

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

V(P) - V(Batt -) 

V(G) - V(Batt -) 

V(S) - V(Batt -) 

V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

1000 1200 1400 1600 1800 2000 2200 2400 2600

Current (Amps)

-1

0

1

2

3

4

5

P - Positive

G - Green Lamp

S - Coil

N2 - Negative
D-16

Figure D-12 Penlight Test #11 1-inch SOV and large coil indicating lamps modified 

voltage/current

1" Valve Circuit - Lamps

Time (seconds)

1000 1200 1400 1600 1800 2000 2200 2400 2600

Current (Amps)

-1

0

1

2

3

4

5

P - Positive

G - Green Lamp

R - Red Lamp

N1 - Negative

N2 - Negative

1000 1200 1400 1600 1800 2000 2200 2400 2600

Voltage (Vdc)

-40

0

40

80

120

160

V(R) - V(Batt -) 

V(G) - V(Batt -) 

Lg Coil Circuit - Lamps

Time (seconds)

1000 1200 1400 1600 1800 2000 2200 2400 2600

Current (Amps)

-1

0

1

2

3

4

5

P - Positive

G - Green Lamp

N1 - Negative

N2 - Negative

1000 1200 1400 1600 1800 2000 2200 2400 2600

Voltage (Vdc)

-40

0

40

80

120

160

V(R) - V(Batt -) 

V(G) - V(Batt -) 
D-17

D.1.4 Test #36

Test# 26 evaluated TS cables located in a cable tray with both indicating lights on. The NO

contact controlling the indication “R” lamp had fused shut in past testing, which caused it to be 

closed at the start of this test. The NC contact was also closed at the beginning; however, the 

data shows that it did function properly by opening when the spurious actuation occurred on the 

1-inch valve circuit. Post-test evaluation of the fuses indicated that the large coil positive fuse 

remained operational, while all other fuses had cleared. Through the open end of the conduit, 

flames which would extinguish then reignite were observed.

Table D-7 Penlight Test #36 parameters.

Test Date August 11, 2009

# Current Transducer turns CT500 = 2 CT35 = 5

Cable Type XLPE/CSPE, 7c,12 AWG 1” Valve, Lg Coil, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 525 °C

Battery Voltage 123.3 Vdc (Pre-test) 123.6 Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table D-8 Penlight Test #36 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

1391 Flash fire which ignites then self-extinguished multiple times

1611-1623 SA 1” Valve – Cable S (12s duration)

1624 Negative Fuse Clear – 1” Valve (10A)

1743 Negative Fuse Clear – Lg Coil (25A)

3230 Penlight off

1” TC LG
D-18

Figure D-13 Penlight Test #36 temperature profile

Figure D-14 Penlight Test #36 ground monitoring circuit voltages

Time (seconds)

0 500 1000 1500 2000 2500 3000 3500

Temperature (C)

0

100

200

300

400

500

600

1st Failure (1611s - 475C)

Penlight 

Cable 1 

Cable 2 

Time (seconds)

0 500 1000 1500 2000 2500 3000 3500

Voltage (Vdc)

-150

-100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 
D-19

Figure D-15 Penlight Test #36 1-inch SOV and large coil modified voltage/current plots

1500 1550 1600 1650 1700 1750 1800

Voltage (Vdc)

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(G) - V(Batt -) 

V(S) - V(Batt -) 

V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

1500 1550 1600 1650 1700 1750 1800

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

1500 1550 1600 1650 1700 1750 1800

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

V(P) - V(Batt -) 

V(G) - V(Batt -) 

V(S) - V(Batt -) 

V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

1500 1550 1600 1650 1700 1750 1800

Current (Amps)

-0.03

-0.02

-0.01

0.00

0.01

0.02

0.03

0.04

P - Positive

G - Green Lamp

S - Coil

N2 - Negative
D-20

Figure D-16 Penlight Test #36 1-inch SOV and large coil indicating lamps modified 

voltage/current

1" Valve Circuit - Lamps

Time (seconds)

1500 1550 1600 1650 1700 1750 1800

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

P - Positive

G - Green Lamp

R - Red Lamp

N1 - Negative

N2 - Negative

1500 1550 1600 1650 1700 1750 1800

Voltage (Vdc)

0

40

80

120

160

V(R) - V(Batt -) 

V(G) - V(Batt -) 

Lg Coil Circuit - Lamps

Time (seconds)

1500 1550 1600 1650 1700 1750 1800

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

0.10

P - Positive

G - Green Lamp

N1 - Negative

N2 - Negative

1500 1550 1600 1650 1700 1750 1800

Voltage (Vdc)

-40

0

40

80

120

160

V(R) - V(Batt -) 

V(G) - V(Batt -) 
D-21

D.1.5 Test #40

The TP cables located in a rigid steel conduit were evaluated. Post-test inspection of the fuses 

found that all positive fuses had cleared and all negative fuses had remained operational. 

There is also evidence of an intercable interaction, involving a source conductor in the large coil 

circuit and a target conductor (coil) in the 1-inch valve circuit that supplies the coil with sufficient 

voltage and current; the interaction causes three separate spurious actuations of 2- or 3-second 

durations each.

Table D-9 Penlight Test #40 parameters.

Test Date August 12, 2009

# Current Transducer turns CT500 = 2 CT35 = 5

Cable Type PE/PVC, 7c, 12AWG 1” Valve, Lg Coil, TC

Cable Fill 3 cables

Raceway Configuration Conduit

Penlight Setpoint Various

Battery Voltage 123.3 Vdc (Pre-test) 123.3 Vdc (Post-test)

Thermocouple Channels TC Top=Ch3 TC Bottom=Ch4

TC Cable = Ch5

Table D-10 Penlight Test #40 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

3345 Penlight increased to 475 °C

3985 Penlight increased to 500 °C

4063-4166 Battery Positive shorts to ground

4063-4166 SA Lg Coil – Cable S (66s longest duration)

4068-4166 False Indication – Lg Coil – Red lamp ON

4068-4166 HS Lg Coil – Conductor R (98s duration)

4167-4312 Battery Negative shorts to ground

4167 Fuse Clear – 1” Valve (10A)

4280 Penlight off

4314-4329 HS Lg Coil – Conductor R (15s duration)

4314-4329 SA Lg Coil – Cable S(15s duration)

4316-4329 SA 1” Valve – Cable S (9s longest duration)

4317-4329 False Indication – Lg Coil – Red lamp ON

4330-4330 Battery negative shorts to ground

4330 Positive Fuse Clear – Lg coil (25A)

TC LG

1”
D-22

Figure D-17 Penlight Test #40 temperature profile

Time (seconds)

0 1000 2000 3000 4000 5000 6000

Voltage (Vdc)

-150

-100

-50

0

50

100

150

VTU_1 

VTU_2 

VT7_1 

Figure D-18 Penlight Test #40 ground monitoring circuit voltages

Time (seconds)

0 1000 2000 3000 4000 5000

Temperature (C)

0

100

200

300

400

500

600

1st Failure (4063s - 445C)

Penlight 

Cable 1 

Cable 2 
D-23

Figure D-19 Penlight Test #40 1-inch SOV and large coil modified voltage/current plots

3800 3900 4000 4100 4200 4300 4400

Voltage (Vdc)

-80

-40

0

40

80

120

160

V(P) - V(Batt -) 

V(G) - V(Batt -) 

V(S) - V(Batt -) 

V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

3800 3900 4000 4100 4200 4300 4400

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

3800 3900 4000 4100 4200 4300 4400

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

V(P) - V(Batt -) 

V(G) - V(Batt -) 

V(S) - V(Batt -) 

V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

3800 3900 4000 4100 4200 4300 4400

Current (Amps)

-1

0

1

2

3

4

5

P - Positive

G - Green Lamp

S - Coil

N2 - Negative
D-24

Figure D-20 Penlight Test #40 1-inch SOV and large coil indicating lamps modified 

voltage/current

1" Valve Circuit - Lamps

Time (seconds)

3800 3900 4000 4100 4200 4300 4400

Current (Amps)

-1

0

1

2

3

4

P - Positive

G - Green Lamp

R - Red Lamp

N1 - Negative

N2 - Negative

3800 3900 4000 4100 4200 4300 4400

Voltage (Vdc)

-40

0

40

80

120

160

V(R) - V(Batt -) 

V(G) - V(Batt -) 

Lg Coil Circuit - Lamps

Time (seconds)

3800 3900 4000 4100 4200 4300 4400

Current (Amps)

-1

0

1

2

3

4

5

P - Positive

G - Green Lamp

N1 - Negative

N2 - Negative

3800 3900 4000 4100 4200 4300 4400

Voltage (Vdc)

-40

0

40

80

120

160

V(R) - V(Batt -) 

V(G) - V(Batt -) 
D-25

D.2 Intermediate-Scale Results

The results from the intermediate-scale tests are presented below. Similar to the previous 

section, the data is presented in numerical as opposed to chronological order.

D.2.1 Intermediate-Scale Test Prelim #1

The 1-in. valve and large coil circuits did not fail during this test. When looking at the data, there 

is a pronounced drift which was due to the magnetism effects from the dc battery bank. A full 

description of the drift may be found in the Current Transducer section of the main body.

Table D-11 Intermediate-Scale Test Prelim #1 test parameters.

Cable Type for 1-inch Valve XLPE/CSPE, 7c, 12AWG

1-inch Valve Position Position E

Cable Fill Type Fill Tray H, Cable 1

Cable Type for Large Coil XLPE/CSPE, 7c, 12AWG

Large Coil Position Position E

Cable Fill Type Fill Tray H, Cable 2

Battery Voltage (Pre-test) 122.82Vdc

Battery Voltage (Post-test) 123.13 Vdc

Table D-12 Intermediate-Scale Test Prelim #1 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1361 Fire Off, Circuits did not fail, maximum temperature was 

approximately 380 °C.
D-26

Figure D-21 Intermediate-Scale Test Prelim #1 temperature profile

Time (seconds)

0 1000 2000 3000 4000 5000 6000

Temperature (C)

0

100

200

300

400

500

Fire Time vs E Position - 3' 

Fire Time vs E Position - Middle 

Fire Time vs E Position - 7' 
D-27

Figure D-22 Intermediate-Scale Test Prelim #1 1-inch SOV and large coil current/voltage 

plots

0 1000 2000 3000 4000 5000 6000

Voltage (Vdc)

0

20

40

60

80

100

120

140

{1"Valve} V(P) - V(Batt -) 

{1"Valve} V(G) - V(Batt -) 

{1"Valve} V(S) - V(Batt -) 

{1"Valve} V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

0 1000 2000 3000 4000 5000 6000

Current (Amps)

-0.04

-0.02

0.00

0.02

0.04

0.06

1"Coil_CT35_1_P 

1"Coil_CT35_2_G 

1"Coil_CT35_5_S 

1"Coil_CT35_4_N2 

0 1000 2000 3000 4000 5000 6000

Voltage (Vdc)

0

20

40

60

80

100

120

140

{LgCoil} V(P) - V(Batt -) 

{LgCoil} V(G) - V(Batt -) 

{LgCoil} V(S) - V(Batt -) 

{LgCoil} V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

0 1000 2000 3000 4000 5000 6000

Current (Amps)

-0.020

-0.015

-0.010

-0.005

0.000

0.005

0.010

0.015

P - Positive

G - Green Lamp

S - Coil

N2 - Negative
D-28

Figure D-23 Intermediate-Scale Test Prelim #1 ground voltage monitoring circuit 

indication

D.2.2 Intermediate-Scale Test #1

Table D-13 Intermediate-Scale Test #1 parameters.

Cable Type for 1-inch Valve XLPE/CSPE, 7c, 12AWG

1-inch Valve Position Position B

Cable Fill Type Fill Tray D, Cable 1

Cable Type for Large Coil XLPE/CSPE, 7c, 12AWG

Large Coil Position Position B

Cable Fill Type Fill Tray D, Cable 2

Battery Voltage (Pre-test) 123.31 Vdc

Battery Voltage (Post-test) 120.72 Vdc

Time (seconds)

0 1000 2000 3000 4000 5000 6000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
D-29

Table D-14 Intermediate-Scale Test #1 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1358-1391 HS 1” Valve – Conductor G (30s longest duration)

1358-1391 SA 1” Valve – Cable S (30s longest duration)

1367-1465 HS Lg Coil – Conductor R (69s duration)

1367-1377 Large Coil – False Indication Red Light ON [10s duration]

1384 Large Coil – False Indication Red Light ON [1s duration]

1396-1439 Large Coil – False Indication Red Light ON [43s duration]

1446-1465 SA Lg Coil – Cable S (12s longest duration)

2889 Positive Fuse Clear – 1” Valve

2889 Positive Fuse Clear – Lg Coil

3128 Negative Fuse Clear – 1” Valve

4380 Fire Off

Figure D-24 Intermediate-Scale Test #1 temperature profile

Time (seconds)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

1000

1200

1400

1st 1" SOV Failure (1361s - 414C)

B Position - Tray - Middle 

Plot 1 1st Failure ( s - C)

1st Lg Coil Failure (1449s - 371C)
D-30

Figure D-25 Intermediate-Scale Test #1 1-inch SOV and large coil current/voltage plots

1200 1300 1400 1500 1600

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{1"Valve} V(P) - V(Batt -) 

{1"Valve} V(G) - V(Batt -) 

{1"Valve} V(S) - V(Batt -) 

{1"Valve} V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

1200 1300 1400 1500 1600

Current (Amps)

-1

0

1

2

3

4

1"Coil_CT35_1_P 

1"Coil_CT35_2_G 

1"Coil_CT35_5_S 

1"Coil_CT35_4_N2 

1300 1350 1400 1450 1500

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{LgCoil} V(P) - V(Batt -) 

{LgCoil} V(G) - V(Batt -) 

{LgCoil} V(S) - V(Batt -) 

{LgCoil} V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

1300 1350 1400 1450 1500

Current (Amps)

-1

0

1

2

3

4

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

5.556A at 1391s
D-31

Figure D-26 Intermediate-Scale Test #1 ground voltage monitoring circuit indication

D.2.3 Intermediate-Scale Test #2

Table D-15 Intermediate-Scale Test #2 parameters.

Cable Type for 1-inch Valve XLPE/CSPE, 7c, 12AWG

1-inch Valve Position Position C

Cable Fill Type Bundle Tray A, Cable 3

Cable Type for Large Coil XLPE/CSPE, 7c, 12AWG

Large Coil Position Position C

Cable Fill Type Bundle Tray A, Cable 4

Battery Voltage (Pre-test) 121.77 Vdc

Battery Voltage (Post-test) 122.97 Vdc

Time (seconds)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
D-32

Table D-16 Intermediate-Scale Test #2 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

4492 Negative Fuse Clear – Lg Coil

Note: Negative current remains at approximately 0.1A

6060 Fire Off

Figure D-27 Intermediate-Scale Test #2 temperature profile

Time (seconds)

0 1000 2000 3000 4000 5000 6000 7000

Temperature (C)

0

100

200

300

400

500

1st 1" SOV Failure (3975s - 352C)

C Position - 3' 

C Position - Middle 

C Position - 7' 

Plot 1 1st Failure ( s - C)

1st Lg Coil Failure (4492s - 311C)
D-33

Figure D-28 Intermediate-Scale Test #2 1-inch SOV and large coil current/voltage plots

3500 3600 3700 3800 3900 4000 4100

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{1"Valve} V(P) - V(Batt -) 

{1"Valve} V(G) - V(Batt -) 

{1"Valve} V(S) - V(Batt -) 

{1"Valve} V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

3500 3600 3700 3800 3900 4000 4100

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

0.10

0.12

1"Coil_CT35_1_P 

1"Coil_CT35_2_G 

1"Coil_CT35_5_S 

1"Coil_CT35_4_N2 

4000 4500 5000 5500 6000

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{LgCoil} V(P) - V(Batt -) 

{LgCoil} V(G) - V(Batt -) 

{LgCoil} V(S) - V(Batt -) 

{LgCoil} V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

4000 4500 5000 5500 6000

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

0.25

0.30

P - Positive

G - Green Lamp

S - Coil

N2 - Negative
D-34

Figure D-29 Intermediate-Scale Test #2 ground voltage monitoring circuit indication

D.2.4 Intermediate-Scale Test #3

Table D-17 Intermediate-Scale Test #3 parameters.

Cable Type for 1-inch Valve XLPE/CSPE, 7c, 12AWG

1-inch Valve Position Position D

Cable Fill Type Bundle Tray B, Cable 3

Cable Type for Large Coil XLPE/CSPE, 7c, 12AWG

Large Coil Position Position D

Cable Fill Type Bundle Tray B, Cable 4

Battery Voltage (Pre-test) 121.59 Vdc

Battery Voltage (Post-test) 121.55 Vdc

Time (seconds)

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
D-35

Table D-18 Intermediate-Scale Test #3 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

2156-2167 HS Lg Coil – Conductor R (11s duration)

2156-2178 Large Coil – False Indication Red Light ON [22s duration]

2169 Negative Fuse Clear – Lg Coil

2183-2221 Large Coil – False Indication Red Light ON [38s duration]

2186-2228 HS 1” Valve – Conductor G (35s longest duration)

2186-2228 SA 1” Valve – Cable S (35s longest duration)

2226-2286 Large Coil – False Indication Red Light ON [60s duration]

2229 Negative Fuse Clear – 1” Valve

2288 Positive Fuse Clear – Lg Coil

3370 Fire Off

Figure D-30 Intermediate-Scale Test #3 temperature profile

Time (seconds)

0 1000 2000 3000 4000

Temperature (C)

0

200

400

600

800

1st 1" SOV Failure (2188s - 556C)

D Position - 3' 

D Position - Middle 

D Position - 7' 

Plot 1 1st Failure ( s - C)

1st Lg Coil Failure (2288s - 560C)
D-36

Figure D-31 Intermediate-Scale Test #3 1-inch SOV and large coil current/voltage plots

2100 2150 2200 2250 2300

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{1"Valve} V(P) - V(Batt -) 

{1"Valve} V(G) - V(Batt -) 

{1"Valve} V(S) - V(Batt -) 

{1"Valve} V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

2100 2150 2200 2250 2300

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1"Coil_CT35_1_P 

1"Coil_CT35_2_G 

1"Coil_CT35_5_S 

1"Coil_CT35_4_N2 

2100 2150 2200 2250 2300

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{LgCoil} V(P) - V(Batt -) 

{LgCoil} V(G) - V(Batt -) 

{LgCoil} V(S) - V(Batt -) 

{LgCoil} V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

2100 2150 2200 2250 2300

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

0.5

P - Positive

G - Green Lamp

S - Coil

N2 - Negative
D-37

Figure D-32 Intermediate-Scale Test #3 ground voltage monitoring circuit indication

D.2.5 Intermediate-Scale Test #4

Table D-19 Intermediate-Scale Test #4 parameters.

Cable Type for 1-inch Valve XLPE/CSPE, 7c, 12AWG

1-inch Valve Position Position A

Cable Fill Type Fill Tray A, Cable 4

Cable Type for Large Coil XLPE/CSPE, 7c, 12AWG

Large Coil Position Position A

Cable Fill Type Fill Tray A, Cable 3

Battery Voltage (Pre-test) 121.83 Vdc

Battery Voltage (Post-test) 122.74 Vdc

Time (seconds)

0 1000 2000 3000 4000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
D-38

Table D-20 Intermediate-Scale Test #4 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1533-1671 1-inch valve – False Indication Green Light OFF [138s duration]

1650-1673 Large Coil – Voltage Increase from 10V to 46V on Red Light [23s 

duration]

1671 HS 1” Valve – Conductor G (<1s duration)

1671-1673 SA 1” Valve – Cable S (2s duration)

1675 Positive Fuse Clear – Lg Coil

5305 Negative Fuse Clear – 1” Valve

5307 Negative Fuse Clear – Lg Coil

6720 Fire Off

Figure D-33 Intermediate-Scale Test #4 temperature profile

Time (seconds)

0 2000 4000 6000 8000

Temperature (C)

0

200

400

600

800

1st 1" SOV Failure (1671s - 468C)

A Position - Middle 

Plot 1 1st Failure ( s - C)

1st Large Coil Failure (1675s - 458C)
D-39

Figure D-34 Intermediate-Scale Test #4 1-inch SOV and large coil current/voltage plots

1400 1450 1500 1550 1600 1650 1700

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{1"Valve} V(P) - V(Batt -) 

{1"Valve} V(G) - V(Batt -) 

{1"Valve} V(S) - V(Batt -) 

{1"Valve} V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

1400 1450 1500 1550 1600 1650 1700

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1"Coil_CT35_1_P 

1"Coil_CT35_2_G 

1"Coil_CT35_5_S 

1"Coil_CT35_4_N2 

1600 1620 1640 1660 1680 1700

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{LgCoil} V(P) - V(Batt -) 

{LgCoil} V(G) - V(Batt -) 

{LgCoil} V(S) - V(Batt -) 

{LgCoil} V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

1600 1620 1640 1660 1680 1700

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

3.9A at 1529s 5.5A at 1586s

5.2A at 1669s

G: Transducer Saturation at 1670s

G: 6.3A at 1673s

N2: 6.0A at 1673s
D-40

Figure D-35 Intermediate-Scale Test #4 ground voltage monitoring circuit indication

D.2.6 Intermediate-Scale Test #5

Table D-21 Intermediate-Scale Test #5 parameters.

Cable Type for 1-inch Valve PE/PVC, 7c, 12AWG

1-inch Valve Position Position B

Cable Fill Type Fill Tray D, Cable 1

Cable Type for Large Coil PE/PVC, 7c, 12AWG

Large Coil Position Position B

Cable Fill Type Fill Tray D, Cable 2

Battery Voltage (Pre-test) 124.02 Vdc

Battery Voltage (Post-test) 122.74 Vdc

Time (seconds)

0 2000 4000 6000 8000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
D-41

Table D-22 Intermediate-Scale Test #5 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

534-655 1-inch Valve – Current Increase on Positive and Negative 2 [121s 

duration]

655 Negative Fuse Clear – 1” Valve

819-908 SA Lg Coil – Cable S (89s duration) (3.5A) 

897-908 HS Lg Coil – Conductor R (11s duration)

897-908

908

Large Coil – False Indication Red Light ON [11s duration]

1-inch Valve – Positive Fuse Clears

910 Positive Fuse Clear – Lg Coil

1339 Negative Fuse Clear – Lg Coil

2640 Fire Off

Figure D-36 Intermediate-Scale Test #5 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

200

400

600

800

1000

1st 1" SOV Failure (655s - 217C)

B Position - Tray - Middle 

Plot 1 1st Failure ( s - C)

1st Large Coil Failure (819s - 229C)
D-42

500 600 700 800 900 1000

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{1"Valve} V(P) - V(Batt -) 

{1"Valve} V(G) - V(Batt -) 

{1"Valve} V(S) - V(Batt -) 

{1"Valve} V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

500 600 700 800 900 1000

Current (Amps)

-0.10

-0.05

0.00

0.05

0.10

0.15

0.20

1"Coil_CT35_1_P 

1"Coil_CT35_2_G 

1"Coil_CT35_5_S 

1"Coil_CT35_4_N2 

750 800 850 900 950 1000

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{LgCoil} V(P) - V(Batt -) 

{LgCoil} V(G) - V(Batt -) 

{LgCoil} V(S) - V(Batt -) 

{LgCoil} V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

750 800 850 900 950 1000

Current (Amps)

-1

0

1

2

3

4

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

Figure D-37 Intermediate-Scale Test #5 1-inch SOV and large coil current/voltage plots
D-43

Figure D-38 Intermediate-Scale Test #5 ground voltage monitoring circuit indication

D.2.7 Intermediate-Scale Test #6

The field notes indicate that both fuses cleared for the 1-in. valve circuit; however, only the 

negative fuse clear was captured in the data.

Table D-23 Intermediate-Scale Test #6 parameters.

Cable Type for 1-inch Valve PE/PVC, 7c, 12AWG

1-inch Valve Position Position C

Cable Fill Type Bundled Tray B, Cable 1

Cable Type for Large Coil PE/PVC, 7c, 12AWG

Large Coil Position Position C

Cable Fill Type Bundled Tray B, Cable 2

Battery Voltage (Pre-test) 123.56 Vdc

Battery Voltage (Post-test) 123.04 Vdc

Time (seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
D-44

Table D-24 Intermediate-Scale Test #6 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1194-1315 Large Coil – Voltage Increase and Stabilization on Positive 

to Approximately 0.035A

1317 Negative Fuse Clear – Lg Coil 

1548-1637 SA 1” Valve – Cable S (89s duration) (0.75A) 

1548-1637 HS 1” Valve – Conductor G (89s duration)

1720 Negative Fuse Clear – 1” Valve

2640 Fire Off

Figure D-39 Intermediate-Scale Test #6 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

100

200

300

400

500

1st Lg Coil Failure (1317s - 333C)

C Position - 3' 

Plot 1 1st Failure ( s - C)

1st 1" SOV Failure (1548s - 337C)
D-45

Figure D-40 Intermediate-Scale Test #6 1-inch SOV and large coil current/voltage plots

1300 1400 1500 1600 1700 1800

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{1"Valve} V(P) - V(Batt -) 

{1"Valve} V(G) - V(Batt -) 

{1"Valve} V(S) - V(Batt -) 

{1"Valve} V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

1300 1400 1500 1600 1700 1800

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1"Coil_CT35_1_P 

1"Coil_CT35_2_G 

1"Coil_CT35_5_S 

1"Coil_CT35_4_N2 

1000 1100 1200 1300 1400 1500

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{LgCoil} V(P) - V(Batt -) 

{LgCoil} V(G) - V(Batt -) 

{LgCoil} V(S) - V(Batt -) 

{LgCoil} V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

1000 1100 1200 1300 1400 1500

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

P - Positive

G - Green Lamp

S - Coil

N2 - Negative
D-46

Figure D-41 Intermediate-Scale Test #6 ground voltage monitoring circuit indication

D.2.8 Intermediate-Scale Test #7

Table D-25 Intermediate-Scale Test #7 parameters.

Cable Type for 1-inch Valve PE/PVC, 7c, 12AWG

1-inch Valve Position Position B, Cable 1

Cable Fill Type Conduit

Cable Type for Large Coil PE/PVC, 7c, 12AWG

Large Coil Position Position B, Cable 1

Cable Fill Type Conduit

Battery Voltage (Pre-test) 121.98 Vdc

Battery Voltage (Post-test) 122.83 Vdc

Time (seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
D-47

Table D-26 Intermediate-Scale Test #7 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1426 Negative Fuse Clear – Lg Coil 

1691-1762 1-inch Valve – False Indication Red Light ON [72s duration]

1713 1-inch Valve – Current Increase to Approximately 0.78A on 

Positive

1713-1758 SA 1” Valve – Cable S (45s duration) (0.76A) 

1713-1758 HS 1” Valve – Conductor G (45s duration)

1760 Negative Fuse Clear – 1” Valve

2400 Fire Off, Large Coil – Positive Fuse Did Not Clear, 1-inch Valve –

Positive Fuse Did Not Clear

Figure D-42 Intermediate-Scale Test #7 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

100

200

300

400

500

600

1st Lg Coil Failure (1426s - 475C)

B Position - Conduit - 3' 

Plot 1 1st Failure ( s - C)

1st 1" SOV Failure (1713s - 488C)
D-48

Figure D-43 Intermediate-Scale Test #7 1-inch SOV and large coil current/voltage plots

1600 1650 1700 1750 1800

Voltage (Vdc)

-40

-20

0

20

40

60

80

100

120

140

{1"Valve} V(P) - V(Batt -) 

{1"Valve} V(G) - V(Batt -) 

{1"Valve} V(S) - V(Batt -) 

{1"Valve} V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

1600 1650 1700 1750 1800

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1"Coil_CT35_1_P 

1"Coil_CT35_2_G 

1"Coil_CT35_5_S 

1"Coil_CT35_4_N2 

1000 1100 1200 1300 1400 1500

Voltage (Vdc)

-40

-20

0

20

40

60

80

100

120

140

{LgCoil} V(P) - V(Batt -) 

{LgCoil} V(G) - V(Batt -) 

{LgCoil} V(S) - V(Batt -) 

{LgCoil} V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

1000 1100 1200 1300 1400 1500

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

P - Positive

G - Green Lamp

S - Coil

N2 - Negative
D-49

Figure D-44 Intermediate-Scale Test #7 ground voltage monitoring circuit indication

D.2.9 Intermediate-Scale Test #8

The field notes indicate that both fuses cleared for the 1-in. valve circuit; however, only the 

negative fuse clear was captured in the data.

Table D-27 Intermediate-Scale Test #8 parameters.

Cable Type for 1-inch Valve PE/PVC, 7c, 12AWG

1-inch Valve Position Position A

Cable Fill Type Fill Tray A, Cable 3

Cable Type for Large Coil PE/PVC, 7c, 12AWG

Large Coil Position Position A

Cable Fill Type Fill Tray A, Cable 4

Battery Voltage (Pre-test) 121.78 Vdc

Battery Voltage (Post-test) 122.56 Vdc

Time (seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
D-50

Table D-28 Intermediate-Scale Test #8 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

898 Negative Fuse Clear – 1” Valve 

940-1063 HS Lg Coil – Conductor G (123s duration)

940-1063 SA Lg Coil – Cable S (123s duration)

941-1060 Large Coil – False Indication Red Light ON [119s duration]

943-1060 Large Coil – Current Increase on Green to Approximately 3.6A

1064 Negative Fuse Clear – Lg Coil

1064 1-inch Valve – Current Increase on Green to Approximately 2.05A

1064 1-inch Valve – Current Decrease on Positive to Approximately -

1.24A

1102-1135 Large Coil – Current Increase on Green to Transducer Saturation

2495 Fire Off, Large Coil – Positive Fuse Did Not Clear

Figure D-45 Intermediate-Scale Test #8 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

200

400

600

800

1000

1st Lg Coil Failure (943s - 795C)

A Position - Middle 

Plot 1 1st Failure ( s - C)

1st 1" SOV Failure (1137s - 794C)
D-51

Figure D-46 Intermediate-Scale Test #8 1-inch SOV and large coil current/voltage plots

600 700 800 900 1000 1100 1200

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{1"Valve} V(P) - V(Batt -) 

{1"Valve} V(G) - V(Batt -) 

{1"Valve} V(S) - V(Batt -) 

{1"Valve} V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

600 700 800 900 1000 1100 1200

Current (Amps)

-1.5

-1.0

-0.5

0.0

0.5

1.0

1"Coil_CT35_1_P 

1"Coil_CT35_2_G 

1"Coil_CT35_5_S 

1"Coil_CT35_4_N2 

600 700 800 900 1000 1100 1200

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{LgCoil} V(P) - V(Batt -) 

{LgCoil} V(G) - V(Batt -) 

{LgCoil} V(S) - V(Batt -) 

{LgCoil} V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

600 700 800 900 1000 1100 1200

Current (Amps)

-2

0

2

4

6

8

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

2.0537A at 1064s
D-52

Figure D-47 Intermediate-Scale Test #8 ground voltage monitoring circuit indication

D.2.10 Intermediate-Scale Test #9

Table D-29 Intermediate-Scale Test #9 parameters.

Cable Type for 1-inch Valve Armored, 8c, 12AWG

1-inch Valve Position Position B

Cable Fill Type Specialized Tray B, Cable 1

Cable Type for Large Coil Armored, 8c, 12AWG

Large Coil Position Position B

Cable Fill Type Specialized Tray B, Cable 2

Battery Voltage (Pre-test) 122.15 Vdc

Battery Voltage (Post-test) 122.41 Vdc

Time (seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
D-53

Table D-30 Intermediate-Scale Test #9 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

628-638 1-inch Valve – False Indication Red Light ON [10s duration]

628-637 SA 1” Valve – Cable S (10s duration) (0.74A) 

638 Negative Fuse Clear – 1” Valve

729-759 HS Lg Coil – Conductor R (30s duration)

731-747 Large Coil – False Indication Red Light ON [16s duration]

750-760 Large Coil – False Indication Red Light ON [10s duration]

752-759 SA Lg Coil – Cable S (7s duration)

778 Negative Fuse Clear – Lg Coil

1605 Positive Fuse Clear – Lg Coil

3300 Fire Off

Figure D-48 Intermediate-Scale Test #9 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500 3000 3500

Temperature (C)

0

200

400

600

800

Large Coil Failure (765s - 451C)

B Position - Tray - Middle 

1-inch Valve Failure (628s - 313C)

B Position - Armored 

Large Coil Failure (765s - 451C)
D-54

Figure D-49 Intermediate-Scale Test #9 1-inch SOV and large coil current/voltage plots

600 650 700 750 800

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{1"Valve} V(P) - V(Batt -) 

{1"Valve} V(G) - V(Batt -) 

{1"Valve} V(S) - V(Batt -) 

{1"Valve} V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

600 650 700 750 800

Current (Amps)

-0.5

0.0

0.5

1.0

1.5

2.0

1"Coil_CT35_1_P 

1"Coil_CT35_2_G 

1"Coil_CT35_5_S 

1"Coil_CT35_4_N2 

600 650 700 750 800

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{LgCoil} V(P) - V(Batt -) 

{LgCoil} V(G) - V(Batt -) 

{LgCoil} V(S) - V(Batt -) 

{LgCoil} V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

600 650 700 750 800

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

3.7A at 759s
D-55

Figure D-50 Intermediate-Scale Test #9 ground voltage monitoring circuit indication

D.2.11 Intermediate-Scale Test #10

Table D-31 Intermediate-Scale Test #10 parameters.

Cable Type for 1-inch Valve Kerite, 7c, 12AWG, with zinc wrap

1-inch Valve Position Position D

Cable Fill Type Bundled Tray A, Cable 1

Cable Type for Large Coil Kerite, 9c, 12AWG, without zinc wrap

Large Coil Position Position D

Cable Fill Type Bundled Tray A, Cable 1

Battery Voltage (Pre-test) 121.96 Vdc

Battery Voltage (Post-test) 122.21 Vdc

Time (seconds)

0 500 1000 1500 2000 2500 3000 3500

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
D-56

Table D-32 Intermediate-Scale Test #10 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

2502-2544 1-inch Valve – False Indication Red Light ON [42s duration]

2735 Large Coil – Current Increase to Approximately 2.65A for the 

Remainder of the Test

2635-2642 SA 1” Valve – Conductor G (7s duration) (0.79A) 

2635-2642 HS 1” Valve – Cable S (7s duration)

2635-2644 1-inch Valve – False Indication Red Light ON [9s duration]

2644 Negative Fuse Clear – 1” Valve

2767-2795 Large Coil – Voltage Increase to Approximately 47V

2823-2835 HS Lg Coil – Conductor R (12s duration)

2890 Negative Fuse Clear – Lg Coil

3124 Positive Fuse Clear – Lg Coil

3960 Fire Off

Figure D-51 Intermediate-Scale Test #10 temperature profile

Time (seconds)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

D Position - Middle 

1-inch Valve SA (2635s - 417C)

D Position - Kerite 7c w - 5' 

D Position - Kerite 9c wo - 5' 

Large Coil Fuse Clear (2890s - 494C)
D-57

Figure D-52 Intermediate-Scale Test #10 1-inch SOV and large coil current/voltage plots

1800 2000 2200 2400 2600 2800

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{1"Valve} V(P) - V(Batt -) 

{1"Valve} V(G) - V(Batt -) 

{1"Valve} V(S) - V(Batt -) 

{1"Valve} V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

1800 2000 2200 2400 2600 2800

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1"Coil_CT35_1_P 

1"Coil_CT35_2_G 

1"Coil_CT35_5_S 

1"Coil_CT35_4_N2 

2000 2200 2400 2600 2800 3000

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

160

{LgCoil} V(P) - V(Batt -) 

{LgCoil} V(G) - V(Batt -) 

{LgCoil} V(S) - V(Batt -) 

{LgCoil} V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

2000 2200 2400 2600 2800 3000

Current (Amps)

-0.5

0.0

0.5

1.0

1.5

2.0

2.5

3.0

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

6.8932A at 2498s
D-58

Figure D-53 Intermediate-Scale Test #10 ground voltage monitoring circuit indication

D.2.12 Intermediate-Scale Test #11

The field notes indicate that both fuses cleared for the 1-in. valve circuit; however, only the 

negative fuse clear was captured in the data.

Table D-33 Intermediate-Scale Test #11 parameters.

Cable Type for 1-inch Valve EPR/CPE, 7c, 12AWG

1-inch Valve Position Position B

Cable Fill Type Fill Tray A, Cable 3

Cable Type for Large Coil EPR/CPE, 7c, 12AWG

Large Coil Position Position B

Cable Fill Type Fill Tray A, Cable 4

Battery Voltage (Pre-test) 122.93 Vdc

Battery Voltage (Post-test) 123.14 Vdc

Time (seconds)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
D-59

Table D-34 Intermediate-Scale Test #11 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated, 1-inch Valve – Red light conductor reading 60V, 

most likely due to effects from previous test

0-1436 HS Lg Coil – Conductor R (979 longest duration)

1183-1197 Large Coil – False Indication Red Light ON [14s duration]

1250-1304 Large Coil – False Indication Red Light ON [54s duration]

1307-1349 HS 1” Valve – Conductor G (23s longest duration)

1307-1349 SA 1” Valve – Cable S (23s longest duration)

1307-1327 1-inch Valve – False Indication Red Light ON [20s duration]

1321-1323 Large Coil – False Indication Red Light ON [2s duration]

1340-1342 1-inch Valve – False Indication Red Light ON [2s duration]

1251 Positive Fuse Clear – Lg Coil

1427 Negative Fuse Clear – 1” Valve

1430-1434 Large Coil – Current Increase to Transducer Saturation on 

Positive Conductor

1432-1434 SA Lg Coil – Cable S (2s duration) (2.6A)

1432 Large Coil – False Indication Red Light ON [1s duration]

1437 Negative Fuse Clear – Lg Coil 

4500 Fire Off, Large Coil – Positive Fuse Did Not Clear

Figure D-54 Intermediate-Scale Test #11 temperature profile

Time (seconds)

0 1000 2000 3000 4000 5000

Temperature (C)

0

100

200

300

400

500

600

700

B Position - Middle 

1st 1" SOV Failure (1310s - 512C)

1st Lg Coil Failure (1432s - 523C)
D-60

Figure D-55 Intermediate-Scale Test #11 1-Inch SOV and large coil current/voltage plots

1200 1250 1300 1350 1400 1450 1500

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

{1"Valve} V(P) - V(Batt -) 

{1"Valve} V(G) - V(Batt -) 

{1"Valve} V(S) - V(Batt -) 

{1"Valve} V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

1200 1250 1300 1350 1400 1450 1500

Current (Amps)

-1.0

-0.5

0.0

0.5

1.0

1.5

2.0

1"Coil_CT35_1_P 

1"Coil_CT35_2_G 

1"Coil_CT35_5_S 

1"Coil_CT35_4_N2 

1100 1200 1300 1400 1500

Voltage (Vdc)

-40

-20

0

20

40

60

80

100

120

140

{LgCoil} V(P) - V(Batt -) 

{LgCoil} V(G) - V(Batt -) 

{LgCoil} V(S) - V(Batt -) 

{LgCoil} V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

1100 1200 1300 1400 1500

Current (Amps)

-2

0

2

4

6

8

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

N2: 4.5A at 1337s G: 5.2A at 1339s
D-61

Figure D-56 Intermediate-Scale Test #11 ground voltage monitoring circuit indication

D.2.13 Intermediate-Scale Test #12

Table D-35 Intermediate-Scale Test #12 parameters.

Cable Type for 1-inch Valve EPR/CPE, 7c, 12AWG

1-inch Valve Position Position D

Cable Fill Type Bundle Tray A, Cable 3

Cable Type for Large Coil EPR/CPE, 7c, 12AWG

Large Coil Position Position D

Cable Fill Type Bundle Tray A, Cable 4

Battery Voltage (Pre-test) 122.31 Vdc

Battery Voltage (Post-test) 122.86 Vdc

Time (seconds)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
D-62

Table D-36 Intermediate-Scale Test #12 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated, 1-inch Valve – Red light conductor reading 60V, most 

likely due to effects from previous test

2746-2797 SA Lg Coil – Cable S (51s duration) (3.4A)

2901-2939 1-inch Valve – Current Increase on Red Light (3.627A) [38s duration]

2889 Positive Fuse Clear – 1” Valve

2889 Positive Fuse Clear – Lg Coil

3128 Negative Fuse Clear – 1” Valve

3131-3136 Large Coil – False Indication Red Light ON [5s duration]

3143 Large Coil – False Indication Red Light ON [1s duration]

3147-3154 Large Coil – False Indication Red Light ON [7s duration]

3894 Fire Off, Large Coil – Negative Fuse Did Not Clear

Figure D-57 Intermediate-Scale Test #12 temperature profile

Time (seconds)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

D Position - 3' 

1st Lg Coil Failure (2746s - 683C)

1st 1" SOV Failure (3032s - 667C)
D-63

Figure D-58 Intermediate-Scale Test #12 1-inch SOV and large coil current/voltage plots

2400 2600 2800 3000 3200

Voltage (Vdc)

-60

-40

-20

0

20

40

60

80

100

120

140

160

{1"Valve} V(P) - V(Batt -) 

{1"Valve} V(G) - V(Batt -) 

{1"Valve} V(S) - V(Batt -) 

{1"Valve} V(N2) - V(Batt -) 

1-inch Valve Circuit

Time (seconds)

2400 2600 2800 3000 3200

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1"Coil_CT35_1_P 

1"Coil_CT35_2_G 

1"Coil_CT35_5_S 

1"Coil_CT35_4_N2 

2600 2700 2800 2900 3000 3100 3200

Voltage (Vdc)

-20

0

20

40

60

80

100

120

140

160

{LgCoil} V(P) - V(Batt -) 

{LgCoil} V(G) - V(Batt -) 

{LgCoil} V(S) - V(Batt -) 

{LgCoil} V(N2) - V(Batt -) 

Lg Coil Circuit

Time (seconds)

2600 2700 2800 2900 3000 3100 3200

Current (Amps)

-2

0

2

4

6

8

P - Positive

G - Green Lamp

S - Coil

N2 - Negative

P: 3.3A at 3128s

G: 1.6A at 3128s
D-64

Figure D-59 Intermediate-Scale Test #12 ground voltage monitoring circuit indication

Time (seconds)

0 1000 2000 3000 4000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 

Appendix E. Switchgear Circuits
E-1

E.1 Small-Scale Results

The purpose of this section is to provide the paired circuit analysis for each test in the smalland intermediate-scale experiments. Every test has a nominal summary of the specific 

experimental parameters, sequence of events, and data supporting the sequential events. It 

should be noted that circuit grounding observations were included for Penlight since only two 

circuits were tested and ground faults were, in general, simple and easily identifiable. In the 

intermediate-scale experiments, however, the number of commonly grounded circuits and wide 

berth of failure times overcomplicates detailed observations. As such, the intermediate-scale 

ground behavior was not described in as much detail as the Penlight tests.

The results from the Penlight tests are presented below. The data is presented in numerical as 

opposed to chronological order. All of the Penlight tests were conducted with the 15-kV 

breaker.

E.1.1 Penlight Test #3

Table E-1 Penlight Test #3 parameters.

Test Date July 21, 2009

# Current Transducer turns CT500 = 1 CT35 = 1

Cable Type XLPE/CSPE, 7c, 12AWG Close, Trip, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 470 °C

Battery Voltage 123.9Vdc (Pre-test) 

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table E-2 Penlight Test #3 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

301 Cable Ignition

626-666 False Indication Red lamp ON

 (voltage loss to 26Vdc)

666-698 False Indication Green Lamp OFF

 (voltage 110-121Vdc)

667-686 HS Trip Coil (19s duration)

700 Fuse Clear – Trip circuit (35A)

719 SA – Breaker Closes

721-731 HS Conductor C1 (10s duration)

733-734 HS Conductor C1 (1s duration)

735 Fuse Clear – Positive and Negative

912 Penlight off

TC Trip Close
E-2

Figure E-1 Penlight Test #3 temperature profile

Time (seconds)

0 200 400 600 800 1000

Temperature (C)

0

100

200

300

400

500

600

700

1st Failure (579s - 476C)

Penlight 

Cable 1 

Cable 2 
E-3

Figure E-2 Penlight Test #3 switchgear close and trip coil modified voltage/current plots

Time (seconds)

500 550 600 650 700 750 800

Current (Amps)

-10

0

10

20

30

40

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

500 550 600 650 700 750 800

Voltage (Volts)

-40

0

40

80

120

160

PT - Positive

T - Trip Coil

N2 - Negative

Trip Circuit

Close Circuit

Time (seconds)

500 550 600 650 700 750 800

Current (Amps)

-0.5

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

PC - Positive

N1 - Negative

500 550 600 650 700 750 800

Voltage (Volts)

-40

0

40

80

120

160

PC - Positive

C1 - Close Coil

N1 - Negative
E-4

Figure E-3 Penlight Test #3 ground monitoring circuit voltages

Figure E-4 Penlight Test #3 switchgear indicating lamps modified voltage/current

Time (seconds)

0 200 400 600 800 1000

Voltage (Volts) -100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 

Time (seconds)

500 550 600 650 700 750 800

Voltage (Vdc)

-40

0

40

80

120

160

R - Red Lamp

G - Green Lamp

500 550 600 650 700 750 800

Current (Amps)

-0.16

-0.12

-0.08

-0.04

0.00

0.04

R - Red Lamp

G - Green Lamp
E-5

Three cables (one energized on the close circuit side, one energized on the trip circuit side, and 

one monitoring thermal data) were used in Test 3. The Close and Trip circuit cables were 

paired together and run adjacent to the thermal cable. The close circuit was fused at 15 A and 

the trip circuit was fused at 35 A. Recall that both the positive and negative sides of the battery 

power feed are fused for a total of four fuses. The Penlight was set to an exposure temperature 

of 470 °C. During this test the breaker was operated in a “normally open” condition and did 

experience spurious closure followed by fuse blow failures. In other words, the breaker did 

close and remained closed on loss of circuit power. Post-test analysis showed that three of the 

four fuses blew open. Only the 35-A negative-side fuse on the trip circuit survived the 

experiment. There was also significant arcing associated with the cables and some conductors 

did fail to open circuit due to the arcing (see photos). 

Figure E-5 Post-test investigation of the burned cables
E-6

Figure E-6 Upper-most cable displays conductor arcing and breakage

Figure E-7 Closeup of the beads of molten copper from Test 3 with a section of 

conductor missing. The missing section was found lying on the Penlight 

heating shroud below the cable tray.
E-7

E.1.2 Penlight Test #4

This test evaluated thermoset (TS) cables located in a cable tray. Post-test measurements 

indicate that the positive fuses on close circuit had cleared while all other fuses were 

operational. Therefore, the trip circuit did not blow any fuses during the test. Test #4 resulted in 

four spurious actuations. The anti-pump circuit did not prohibit the breaker from reclosing, 

because voltage is lost on the close coil and resets the anti-pump circuit. Post-test inspection of 

the fuses indicated that only the positive 15-A fuse blew with both 35-A and negative 15-A fuses 

still operational.

Table E-3 Penlight Test #4 parameters.

Test Date July 30, 2009

# Current Transducer Turns CT500 = 2 CT35 = 5

Cable Type XLPE/CSPE, 7c, 12AWG Close, Trip, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 470 °C

Battery Voltage 123.Vdc (Pre-test) N/A (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table E-4 Penlight Test #4 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

299 Cable Ignition

550-597 False Indication Red lamp ON

568-640 Cable thermocouples providing abnormal results, perhaps due to 

the arcing behavior

568-581 HS Conductor G (13s duration)

577-581 False Indication Green lamp OFF

589-590 HS Trip Coil (1s duration)

593 HS Trip Coil (<1s duration)

597-696 HS Trip Coil (99s duration)

598-625 False Indication Green lamp OFF

623-638 Positive Battery Lead Shorts to Ground

625 SA – Breaker Closes

625-626 False Indication Red lamp OFF

626 SA – Breaker trips

626-632 False Indication Green lamp OFF

628 Positive Fuse Clear Close

Trip TC Close
E-8

Table E-5 Penlight Test #4 sequence of events (continued).

Time (seconds) Event/Observation

633 SA – Breaker trips

635-700 False Indication Green lamp OFF

639-1638 Battery Negative shorts to ground

697 SA – Breaker trips

701-1440 False Indication Red lamp ON

711 HS – Trip Coil (<1s duration)

713 HS – Trip Coil (<1s duration)

719-731 HS – Trip Coil (12s duration)

820 HS – Trip Coil (<1s duration)

1387-1534 Multiple HS to Conductor G (4s longest duration)

1441-1637 False Indication Green lamp OFF

1638 Penlight off

Figure E-8 Penlight Test #4 temperature profile

Time (seconds)

0 200 400 600 800 1000 1200 1400 1600 1800

Temperature (C)

0

200

400

600

800

1000

1200

1400 1st Failure (568s - 429C)

Penlight 

Cable 1 

Cable 2 
E-9

Figure E-9 Penlight Test #4 ground monitoring circuit voltages

Time (seconds)

0 200 400 600 800 1000 1200 1400 1600 1800

Voltage (Volts) -150

-100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 
E-10

Figure E-10 Penlight Test #4 switchgear close and trip coil modified voltage/current 

plots

Time (seconds)

400 600 800 1000 1200 1400 1600

Current (Amps)

0

2

4

6

8

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

Trip Circuit

Time (seconds)

400 600 800 1000 1200 1400 1600

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

400 600 800 1000 1200 1400 1600

Voltage (Volts)

-40

0

40

80

120

160

PT - Positive

T - Trip Coil

N2 - Negative

Trip Circuit

Close Circuit

Time (seconds)

500 550 600 650 700

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

PC - Positive

N1 - Negative

500 550 600 650 700

Voltage (Volts)

-40

0

40

80

120

160

PC - Positive

C1 - Close Coil

N1 - Negative

Peak 2.02 A Peak 3.685 Amps
E-11

Figure E-11 Penlight Test #4 switchgear indicating lamps modified voltage/current

Time (seconds)

400 600 800 1000 1200 1400 1600

Voltage (Vdc)

-40

0

40

80

120

160

R - Red Lamp

G - Green Lamp

400 600 800 1000 1200 1400 1600

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

R - Red Lamp

G - Green Lamp
E-12

E.1.3 Penlight Test #10

This test evaluated thermoplastic (TP) cables located in a cable tray. No spurious actuations 

were observed during Test 10; however a hot short on the trip coil did occur. Therefore, had the 

breaker been in the closed position a spurious actuation would have occurred at 899 seconds. 

Post-test measurements indicate that all fuses had cleared. A review of the data indicates that 

the negative fuse of the close coil circuit cleared at 911 seconds, while the remaining three 

fuses cleared at 2378 seconds.

Table E-6 Penlight Test #10 parameters.

Test Date July 21, 2009

# Current Transducer Turns CT500 = 1 CT35 = 1

Cable Type PE/PVC, 7c, 12AWG Close, Trip, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 325 °C

Battery Voltage 123.6Vdc (Pre-test) N/A (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table E-7 Penlight Test #10 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

899-1055 HS Trip Coil (156s duration)

911-2377 Battery Positive Shorts to Ground

911 Negative Fuse Clear – Close Circuit (15A)

911-2465 False Indication Green Lamp OFF

1033-1260 False Indication Red Lamp ON

1056-1069 HS Conductor G (13s duration)

1069-1109 HS Trip Coil (40s duration)

1110-1177 HS Conductor G (67s duration)

1178-1184 HS Trip Coil (6s duration)

1185 HS Conductor G (<1s duration)

1186 HS Trip Coil (<1s duration)

1187-1235 HS Conductor G (48s duration)

1236 HS Trip Coil (<1s duration)

1237-1238 HS Conductor G (1s duration)

1239-1243 HS Trip Coil (4s duration)

1244-1245 HS Conductor G (1s duration)

1246-1566 HS Trip Coil (320s duration)

1567-1625 False Indication Red Lamp Flickering

Trip TC Close
E-13

Table E-8 Penlight Test #10 sequence of events (continued).

Time (seconds) Event/Observation

1567-1577 HS Conductor G (110s duration)

1578-1581 HS Trip Coil (3s duration)

1582-1591 HS Conductor G (9s duration)

1592-1607 HS Trip Coil (15s duration)

1608-1623 HS Conductor G (15s duration)

1625 HS Trip Coil (<1s duration)

1626-2221 False Indication Red Lamp ON

1626-1665 HS Conductor G (39s duration)

1666-1668 HS Trip Coil (2s duration)

1670-1673 HS Trip Conductor (3s duration)

1674-1692 HS Conductor G (18s duration)

1693 HS Trip Coil (<1s duration)

1694-1746 HS Conductor G (52s duration)

1747 HS Trip Coil (<1s duration)

1748-1752 HS Conductor G (4s duration)

1753 HS Trip Coil (<1s duration)

1754-1759 HS Conductor G (5s duration)

1760 HS Trip Coil (<1s duration)

1761-1762 HS Conductor G (1s duration)

1762-2158 HS Trip Coil (396s duration)

2159-2163 HS Conductor G (4s duration)

2164-2183 HS Trip Coil (19s duration)

2184-2198 HS Conductor G (14s duration)

2199 HS Trip Coil (<1s duration)

2200-2212 HS Conductor G (12s duration)

2213 HS Trip Coil (<1s duration)

2214 HS Conductor G (<1s duration)

2215 HS Trip Coil (<1s duration)

2216-2221 HS Conductor G (5s duration)

2222-2266 HS Trip Coil (44s duration)

2285 Cable Ignition

2378 Positive Fuse Clear – Trip Circuit (35A)

2465 Penlight off
E-14

Figure E-12 Penlight Test #10 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500

Temperature (C)

0

100

200

300

400

500

600

700

1st Failure (899s - 254C)

Penlight 

Cable 1 

Cable 2 
E-15

Figure E-13 Penlight Test #10 switchgear close and trip coil modified voltage/current 

plots

Time (seconds)

800 1000 1200 1400 1600 1800 2000 2200 2400

Current (Amps)

0

10

20

30

40

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

Trip Circuit

Time (seconds)

800 1000 1200 1400 1600 1800 2000 2200 2400

Current (Amps)

-0.2

-0.1

0.0

0.1

0.2

0.3

0.4

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

800 1000 1200 1400 1600 1800 2000 2200 2400

Voltage (Volts)

-80

-40

0

40

80

120

160

PT - Positive

T - Trip Coil

N2 - Negative

Trip Circuit

Close Circuit

Time (seconds)

800 1000 1200 1400 1600 1800 2000 2200 2400

Current (Amps)

-0.15

-0.10

-0.05

0.00

0.05

0.10

0.15

0.20

PC - Positive

N1 - Negative

800 1000 1200 1400 1600 1800 2000 2200 2400

Voltage (Volts)

-40

0

40

80

120

160

PC - Positive

C1 - Close Coil

N1 - Negative
E-16

Figure E-14 Penlight Test #10 ground monitoring circuit voltages

Figure E-15 Penlight Test #10 switchgear indicating lamps modified voltage/current

Time (seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Volts) -150

-100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 

Time (seconds)

0 500 1000 1500 2000 2500

Voltage (Vdc)

-40

0

40

80

120

160

R - Red Lamp

G - Green Lamp

0 500 1000 1500 2000 2500

Current (Amps)

-0.15

-0.10

-0.05

0.00

0.05

0.10

R - Red Lamp

G - Green Lamp
E-17

The setup for Test 10 was identical to Test 3 except for use of the TP cable instead of TS. The 

Penlight was set to an exposure temperature of 325 °C. In this case, the breaker did not 

experience spurious actuation. However, only the 15-A fuses on the close circuit cleared,

leaving the 35-A fuses on the trip side intake through to the end of the exposure. Post-test 

examination demonstrated that both of the 35-A fuses remained intact, and review of the data 

showed that both the positive and negative conductors remained energized throughout the test. 

It should be noted that the TP cables ignited upon arcing, and that arcing was witnessed 

throughout the test and even past the time that Penlight heating was shut down. This test is 

interesting because, as seen from the photos, the conductors suffered severe damage from 

arcing and large sections of the conductor fell away from the cable ends as a result. All of the 

insulation in the central section of the cable (about 2 feet in length) burned away, and yet the 

35-A side of the circuit was never de-energized via fuse blow failures. The conductors were left 

open-circuited but remained energized.

Figure E-16 Post-test investigation of Test 10
E-18

Figure E-17 Damaged cable from electrical arcing 

Figure E-18 Copper beading from the arcing conductors located on the shroud to 

Penlight
E-19

Figure E-19 Conductors sections that fell away from the cables due to arcing damage

Figure E-20 Conductor sections from previous figure
E-20

Figure E-21 Closeup of the cable tray placed on the specimen preparation table

Figure E-22 Closeup of the conductors post-test
E-21

Figure E-23 Conductors from the two energized cables welded onto the cable tray

Figure E-24 Closeup of the conductors welded onto rung of the cable tray
E-22

Figure E-25 Hole in a rung of the cable tray with welded conductor attached

Figure E-26 Closeup of one hole in a rung of the cable tray
E-23

Figure E-27 Closeup of another hole with the welded conductor

E.1.4 Penlight Test #21

This test evaluated armored cable with TS-insulated conductors and TP jacketing located in a 

cable tray. Post-test measurements indicate that the negative fuses on both circuits 

(Trip/Close) had cleared while the positive fuses did not.

Test 21 resulted in no spurious actuations or hot shorts. The first cable failure observed was 

dual indication at 716 seconds. A large fault in both cables caused both 15-A and 35-A fuses 

on the negative side to clear. The positive 15-A and 35-A fuses remained operational. 

Table E-9 Penlight Test #21 parameters.

Test Date September 28, 2009

# Current Transducer Turns CT500 = 2 CT35 = 5

Cable Type Armored, 8c, 12AWG Close, Trip, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 470 °C

Battery Voltage 123.6Vdc (Pre-test) N/A (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Trip TC Close
E-24

Table E-10 Penlight Test #21 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

717-963 False Indication Red Lamp ON

758-963 Battery Negative Shorts to Ground

905 Cable Ignition

962 SA – Breaker closes

963 Fuse Clear – Both Close and Trip Circuits

963-1245 Battery Positive Shorts to Ground

1245 Penlight off

1500 Cable Flame Out

Figure E-28 Penlight Test #21 temperature profile

Time (seconds)

0 200 400 600 800 1000 1200 1400

Temperature (C)

0

100

200

300

400

500

600

700

1st Failure (716s - 340C beneath - 440C surface)

Penlight 

Beneath Armor 1 

Beneath Armor 2 

TC Cable 
E-25

Figure E-29 Penlight Test #21 switchgear close and trip coil modified voltage/current 

plots

Time (seconds)

600 700 800 900 1000

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

600 700 800 900 1000

Voltage (Volts)

-40

0

40

80

120

160

PT - Positive

T - Trip Coil

N2 - Negative

Trip Circuit

Close Circuit

Time (seconds)

600 700 800 900 1000

Current (Amps)

0.00

0.04

0.08

0.12

0.16

PC - Positive

N1 - Negative

600 700 800 900 1000

Voltage (Volts)

-40

0

40

80

120

160

PC - Positive

C1 - Close Coil

N1 - Negative

Transducer

saturation
E-26

Figure E-30 Penlight Test #21 ground monitoring circuit voltages

Figure E-31 Penlight Test #21 switchgear indicating lamps modified voltage/current

Time (seconds)

0 200 400 600 800 1000 1200 1400

Voltage (Volts) -150

-100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 

Time (seconds)

600 700 800 900 1000

Voltage (Vdc)

-40

0

40

80

120

160

R - Red Lamp

G - Green Lamp

600 700 800 900 1000

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

0.10

R - Red Lamp

G - Green Lamp
E-27

E.1.5 Penlight Test #24

This test evaluated TS cable located in a cable tray. Post-test measurements indicate that the 

negative fuses on both circuits (Trip/Close) and the positive fuse on the trip circuit had cleared.

No spurious actuations were observed during Test 24. However, a hot short on the trip coil did 

occur. Therefore, had the breaker been in the closed position a spurious actuation would have 

occurred at 2,103 seconds.

Table E-11 Penlight Test #24 parameters.

Test Date July 29, 2009

# Current Transducer Turns CT500 = 2 CT35 = 5

Cable Type EPR/CPE, 7c, 12AWG Close, Trip, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 470 °C

Battery Voltage 123.Vdc (Pre-test) N/A (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table E-12 Penlight Test #24 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

2103-2126 HS Trip Coil (23s duration)

2103-2137 False Indication Green lamp OFF

2114 Cable Ignition

2127-2137 HS Conductor G (10s duration)

2139 HS Trip Coil (<1s duration)

2139-2205 False Indication Red lamp ON

2144-2146 HS Conductor G (2s duration)

2193 Positive and Negative Fuse Clear – Close Circuit (15A)

2206-2251 Multiple HS Conductor G (20s longest duration)

2227 HS Trip Coil (<1s duration)

2230-2232 HS Trip Coil (2s duration)

2248-2281 False Indication both Red lamp ON

2288-2504 Battery Negative shorts to ground

2284 Positive Fuse Clear – Trip Circuit (35A)

2504 Penlight off

Trip TC Close
E-28

Figure E-32 Penlight Test #24 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500

Temperature (C)

0

200

400

600

800

1st Failure (2103s - 361C)

Penlight 

Cable 1 

Cable 2 
E-29

Figure E-33 Penlight Test #24 switchgear close and trip coil modified voltage/current 

plots

Time (seconds)

2000 2050 2100 2150 2200 2250 2300

Current (Amps)

-2

0

2

4

6

8

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

2000 2050 2100 2150 2200 2250 2300

Voltage (Volts)

-40

0

40

80

120

160

PT - Positive

T - Trip Coil

N2 - Negative

Trip Circuit

Close Circuit

Time (seconds)

2000 2050 2100 2150 2200 2250 2300

Current (Amps)

-0.02

-0.01

0.00

0.01

0.02

0.03

0.04

PC - Positive

N1 - Negative

2000 2050 2100 2150 2200 2250 2300

Voltage (Volts)

-40

0

40

80

120

160

PC - Positive

C1 - Close Coil

N1 - Negative
E-30

Figure E-34 Penlight Test #24 ground monitoring circuit voltages

Figure E-35 Penlight Test #24 switchgear indicating lamps modified voltage/current

Time (seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Volts) -150

-100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 

Time (seconds)

2000 2050 2100 2150 2200 2250 2300

Voltage (Vdc)

-40

0

40

80

120

160

R - Red Lamp

G - Green Lamp

2000 2050 2100 2150 2200 2250 2300

Current (Amps)

-0.04

-0.02

0.00

0.02

0.04

0.06

0.08

R - Red Lamp

G - Green Lamp
E-31

E.1.6 Penlight Test #29

This test evaluated TP cable located in a cable tray. Post-test measurements indicate that all 

fuses had cleared. Test 29 was videographed, and as such, the front insulation cover was 

removed from the penlight apparatus such that the camera could observe and record the arcing 

of this test. This video is enclosed on the DVD found on the back over of this report. A single 

spurious actuation was observed in this test when the Close coil was spuriously energized and 

the breaker closed at 3,530 seconds. Since the fuse to the trip circuit had cleared before this 

spurious actuation, there were no additional opportunities for a spurious actuation.

Table E-13 Penlight Test #29 parameters.

Test Date July 29, 2009

# Current Transducer Turns CT500 = 2 CT35 = 5

Cable Type Tefzel, 7c, 12AWG Close, Trip, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint Various

Battery Voltage 123.2 Vdc (Pre-test) 123.3Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table E-14 Penlight Test #29 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

3421-3440 HS Trip Coil (19s duration)

3441-3440 False Indication Green lamp OFF

3445 HS Trip Coil (<1s duration)

3448-3484 Battery Negative shorts to ground

3451-3483 False Indication Red lamp ON

3456 HS Trip Coil (<1s duration)

3465-3476 False Indication Green lamp OFF

3466 HS Trip Coil (<1s duration)

3485-3488 HS Trip Coil (3s duration)

3485-3530 False indication Green lamp OFF

3489 Negative Fuse Clear – Trip Circuit (35A)

3530 SA – Breaker Closes

3530-4926 HS Conductor C1 (1396s duration)

False Indication Red Lamp OFF

4927 Positive and Negative Fuse Clear – Close Circuit (15A)

5820 Penlight off

Trip TC Close
E-32

Figure E-36 Penlight Test #29 temperature profile

Time (seconds)

0 1000 2000 3000 4000 5000 6000

Temperature (C)

0

100

200

300

400

500

600

1st Failure (3421s - 303C)

Penlight 

Cable 1 

Cable 2 
E-33

Figure E-37 Penlight Test #29 switchgear close and trip coil modified voltage/current 

plots

Time (seconds)

3300 3350 3400 3450 3500 3550 3600

Current (Amps)

0

2

4

6

8

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

Trip Circuit

Time (seconds)

3300 3350 3400 3450 3500 3550 3600

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

3300 3350 3400 3450 3500 3550 3600

Voltage (Volts)

-40

0

40

80

120

160

PT - Positive

T - Trip Coil

N2 - Negative

Trip Circuit

Close Circuit

Time (seconds)

3200 3400 3600 3800 4000 4200 4400 4600 4800 5000

Current (Amps)

-0.10

-0.05

0.00

0.05

0.10

0.15

0.20

PC - Positive

N1 - Negative

3200 3400 3600 3800 4000 4200 4400 4600 4800 5000

Voltage (Volts)

-40

0

40

80

120

160

PC - Positive

C1 - Close Coil

N1 - Negative

Peak 1.93 Amps
E-34

Figure E-38 Penlight Test #29 ground monitoring circuit voltages

Figure E-39 Penlight Test #29 switchgear indicating lamps modified voltage/current

Time (seconds)

0 1000 2000 3000 4000 5000 6000

Voltage (Volts) -150

-100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 

Time (seconds)

3300 3350 3400 3450 3500 3550 3600

Voltage (Vdc)

-40

0

40

80

120

160

R - Red Lamp

G - Green Lamp

3300 3350 3400 3450 3500 3550 3600

Current (Amps)

-0.04

-0.02

0.00

0.02

0.04

0.06

0.08

R - Red Lamp

G - Green Lamp
E-35

During this test, video was used to capture the arcing behavior of the cables. The photo below 

is a still shot from the video.

Figure E-40 Penlight Test #29 temperature profile

E.1.7 Penlight Test #32

This test evaluated TP cable located in a cable tray. Post-test measurements indicate that the 

negative fuse on the Trip circuit was operational with all other fuses cleared.

Table E-15 Penlight Test #32 parameters.

Test Date September 24, 2009

# Current Transducer Turns CT500 = 2 CT35 = 5

Cable Type PVC/PVC, 7c, 12AWG Close, Trip, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 325 °C

Battery Voltage 122.9 Vdc (Pre-test) 122.5Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Trip TC Close
E-36

Table E-16 Penlight Test #32 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

607 SA – Breaker Closes

607-619 HS Conductor G (12s duration)

607-620 Breaker Remains Closed

607-620 False Indication Red lamp OFF

608 Negative Fuse Clear – Close Circuit

608-633 Battery Positive shorts to ground

620 SA – Breaker trips

620-622 HS Trip Coil (Breaker remains Open)

621-631 HS Trip Coil (10s duration)

624-631 HS Trip Coil (Breaker remains Open)

620-633 False Indication Red lamp ON

624-633 False Indication Green lamp OFF

633-990 Battery Negative shorts to ground

634 Positive Fuse Clear – Trip Circuit

634 Positive Fuse Clear – Close Circuit

810 Cable Ignition

990 Penlight off

Figure E-41 Penlight Test #32 temperature profile

Time (seconds)

0 200 400 600 800 1000

Temperature (C)

0

100

200

300

400

1st Failure (607s - 223C)

Penlight 

Cable 1 

Cable 2 
E-37

Figure E-42 Penlight Test #32 switchgear close and trip coil modified voltage/current 

plots

Time (seconds)

580 600 620 640 660

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

580 600 620 640 660

Voltage (Volts)

-80

-40

0

40

80

120

160

PT - Positive

T - Trip Coil

N2 - Negative

Trip Circuit

Close Circuit

Time (seconds)

580 600 620 640 660

Current (Amps)

0.0

0.1

0.2

0.3

PC - Positive

N1 - Negative

580 600 620 640 660

Voltage (Volts)

-40

0

40

80

120

160

PC - Positive

C1 - Close Coil

N1 - Negative

Peak ~2.2 Amps
E-38

Figure E-43 Penlight Test #32 ground monitoring circuit voltages

Figure E-44 Penlight Test #32 switchgear indicating lamps modified voltage/current

Time (seconds)

0 200 400 600 800 1000

Voltage (Volts) -150

-100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 

Time (seconds)

580 600 620 640 660

Voltage (Vdc)

-40

0

40

80

120

160

R - Red Lamp

G - Green Lamp

580 600 620 640 660

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

R - Red Lamp

G - Green Lamp
E-39

E.1.8 Penlight Test #35

This test evaluated thermoplastic (TP) cable located in a cable tray. Post-test measurements 

indicate that the positive fuse on both circuits (Trip/Close) were operational with all negative 

fuses cleared.

Table E-17 Penlight Test #35 parameters.

Test Date September 25, 2009

# Current Transducer Turns CT500 = 2 CT35 = 5

Cable Type XLPE/CSPE, 7c, 12AWG Close, Trip, TC

Cable Fill 3 cables

Raceway Configuration Conduit (2.5 in. dia.)

Penlight Setpoint 525 °C

Battery Voltage 125.7 Vdc (Pre-test) 124.4 Vdc (Post-test)

Thermocouple Channels Conduit Top=Ch3 Conduit Bottom=Ch4

TC Cable – Ch5

Table E-18 Penlight Test #35 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

1693 SA – Breaker Closes

1692-1779 HS Close Coil (Breaker Remains Closed)

1692-1736 False Indication Red lamp OFF

1693-1738 HS Conductor G (45s duration)

1694-1779 HS Conductor C1 (85s duration)

1739 Negative Fuse Clear – Trip Circuit (35A)

1738-1980 Positive Battery Lead Shorts to Ground

1739-1980 Battery Positive shorts to ground

1739-1980 False Indication Red lamp OFF

1780 Negative Fuse Clear – Close Circuit (15A)

1980 Penlight off

TC

Close Trip
E-40

Figure E-45 Penlight Test #35 temperature profile

Time (seconds)

0 500 1000 1500 2000

Temperature (C)

0

100

200

300

400

500

600

1st Failure (1692s - 498C Conduit - 405C Cable)

Penlight 

Conduit Top 

Conduit Bottom 

TC Cable 
E-41

Figure E-46 Penlight Test #35 switchgear close and trip coil modified voltage/current 

plots

Time (seconds)

1660 1680 1700 1720 1740 1760 1780 1800

Current (Amps)

-0.1

0.0

0.1

0.2

0.3

0.4

0.5

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

1660 1680 1700 1720 1740 1760 1780 1800

Voltage (Volts)

-40

0

40

80

120

160

PT - Positive

T - Trip Coil

N2 - Negative

Trip Circuit

Close Circuit

Time (seconds)

1660 1680 1700 1720 1740 1760 1780 1800

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

PC - Positive

N1 - Negative

1660 1680 1700 1720 1740 1760 1780 1800

Voltage (Volts)

-40

0

40

80

120

160

PC - Positive

C1 - Close Coil

N1 - Negative

Peak ~1.8 Amps

Transducer

saturation
E-42

Figure E-47 Penlight Test #35 ground monitoring circuit voltages

Figure E-48 Penlight Test #35 switchgear indicating lamps modified voltage/current

Time (seconds)

0 500 1000 1500 2000 2500

Voltage (Volts) -150

-100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 

Time (seconds)

1660 1680 1700 1720 1740 1760 1780 1800

Voltage (Vdc)

-40

0

40

80

120

160

R - Red Lamp

G - Green Lamp

1660 1680 1700 1720 1740 1760 1780 1800

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

R - Red Lamp

G - Green Lamp
E-43

E.1.9 Penlight Test #39

This test evaluated TP cable located in a conduit. Post-test measurements indicate that the all 

fuses on the close circuit were cleared while all fuses on the trip circuit were operational.

Table E-19 Penlight Test #39 parameters.

Test Date September 24, 2009

# Current Transducer Turns CT500 = 2 CT35 = 5

Cable Type PE/PVC, 7c, 12AWG Close, Trip, TC

Cable Fill 3 cables

Raceway Configuration Conduit (2.5 in. dia.)

Penlight Setpoint 470 °C

Battery Voltage 122.8 Vdc (Pre-test) 122.9 Vdc (Post-test)

Thermocouple Channels Conduit Top=Ch3 Conduit Bottom=Ch4

TC Cable – Ch5

Table E-20 Penlight Test #39 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

1171-4400 False Indication Green lamp OFF

1171-1677 HS Conductor G (506s duration)

1667-3520 Sporadic short to ground on Battery Positive and Negative

1678-1686 HS Trip Coil (8s duration)

1680-3386 HS Trip Coil with large variations in voltage (Breaker remains Open)

1687 HS Conductor G (<1s duration)

1688-1824 HS Trip Coil (136s duration)

1825-1829 HS Conductor G (4s duration)

1830-2074 Multiple HS Trip Coil (205s longest duration)

2026-3596 Multiple HS Conductor G (252s longest duration)

2027-4174 Multiple HS Trip Coil (597s longest duration)

3147-3155 False Indication Red lamp ON (not full voltage, i.e., lamp dim)

3270 Penlight increased to 500 °C

3387-3520 False Indication Red lamp ON

3520-3615 Increasing voltage on Close Coil up to 37.4Vdc

3617 Negative Fuse Clear – Close Circuit (15A)

3521-4175 Battery Positive shorts to ground

4175 Positive Fuse Clear – Trip Circuit

4175 Positive Fuse Clear – Close Circuit

4400 Penlight off

TC

Close

Trip
E-44

Figure E-49 Penlight Test #39 temperature profile

While conducting this test, the Penlight control system experienced a fault that required 

restarting the system. It took approximately one minute from the time of the failure to the time of 

the restart of Penlight. As shown in Figure E-34, the ambient temperatures at the start of the 

test are above normal due to the short heating period before the actual start of the tests. 

Therefore, the test continued immediately after the Penlight failure and the apparatus was not 

allowed to cool down. However, because of the quick turnaround, and the low ambient 

temperatures at the beginning of the test this should not have any significance to the failures 

identified in this test.

Time (seconds)

0 1000 2000 3000 4000 5000

Temperature (C)

0

100

200

300

400

500

600

1st Failure (1171s - Conduit 416C - Cable 348C)

Penlight 

Conduit Top 

Conduit Bottom 

TC Cable 
E-45

Figure E-50 Penlight Test #39 switchgear close and trip coil modified voltage/current 

plots

Time (seconds)

1500 2000 2500 3000 3500 4000 4500

Current (Amps)

-1

0

1

2

3

4

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

1500 2000 2500 3000 3500 4000 4500

Voltage (Volts)

-80

-40

0

40

80

120

160

200

PT - Positive

T - Trip Coil

N2 - Negative

Trip Circuit

Close Circuit

Time (seconds)

3200 3400 3600 3800 4000 4200 4400

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

PC - Positive

N1 - Negative

3200 3400 3600 3800 4000 4200 4400

Voltage (Volts)

-80

-40

0

40

80

120

160

200

PC - Positive

C1 - Close Coil

N1 - Negative

Peak ~1.44 Amps

Transducer

saturation
E-46

Figure E-51 Penlight Test #39 ground monitoring circuit voltages

Figure E-52 Penlight Test #39 switchgear indicating lamps modified voltage/current

Time (seconds)

0 1000 2000 3000 4000 5000

Voltage (Volts) -150

-100

-50

0

50

100

150

200

VT7_1 

VTU_1 

VTU_2 

Time (seconds)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-40

0

40

80

120

160

200

R - Red Lamp

G - Green Lamp

0 1000 2000 3000 4000 5000

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

R - Red Lamp

G - Green Lamp
E-47

E.1.10 Penlight Test #42

This test evaluated TS cable located in a cable tray. Post-test measurements indicate that the 

positive fuse on the trip circuit remained operational while all other fuses had cleared.

Table E-21 Penlight Test #42 parameters.

Test Date September 25, 2009

# Current Transducer Turns CT500 = 2 CT35 = 5

Cable Type XLPE/CSPE, 7c, 12AWG Close, Trip, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint Various

Battery Voltage 124.3 Vdc (Pre-test) 123.5 Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table E-22 Penlight Test #42 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

5400 Penlight increased to 455 °C

6000 Penlight increased to 480 °C

6038-6120 False Indication Green lamp OFF

6040 HS Conductor G (<1s duration)

6041-6100 HS Trip Coil (59s duration)

6100-6120 False Indication Red lamp ON

6101-6146 Multiple HS Conductor G (18s longest duration)

6120 SA – Breaker Closes

6120-6136 HS Close Coil (Breaker remains Closed)

6136-6162 Multiple HS Conductor Trip Coil (5s longest duration)

6137 Fuse Clear – Close circuit (15A)

6137-6143 False Indication Green lamp OFF

6144-6156 False Indication Red lamp ON

6157-6330 False Indication Green lamp OFF

6163 Fuse Clear – Trip circuit (35A)

6330 Penlight off

Trip TC Close
E-48

Figure E-53 Penlight Test #42 temperature profile

Time (seconds)

0 2000 4000 6000 8000

Temperature (C)

0

200

400

600

800

1st Failure (6038s - 411C)

Penlight 

Cable 1 

Cable 2 
E-49

Figure E-54 Penlight Test #42 switchgear close and trip coil modified voltage/current 

plots

Time (seconds)

6000 6050 6100 6150 6200 6250 6300

Current (Amps)

0

2

4

6

8

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

Trip Circuit

Time (seconds)

6000 6050 6100 6150 6200 6250 6300

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

6000 6050 6100 6150 6200 6250 6300

Voltage (Volts)

-40

0

40

80

120

160

PT - Positive

T - Trip Coil

N2 - Negative

Trip Circuit

Close Circuit

Time (seconds)

6000 6050 6100 6150 6200 6250 6300

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

PC - Positive

N1 - Negative

6000 6050 6100 6150 6200 6250 6300

Voltage (Volts)

-40

0

40

80

120

160

PC - Positive

C1 - Close Coil

N1 - Negative

Peak ~1.78 Amps
E-50

Figure E-55 Penlight Test #42 ground monitoring circuit voltages

Figure E-56 Penlight Test #42 switchgear indicating lamps modified voltage/current

Time (seconds)

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Volts) -150

-100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 

Time (seconds)

6000 6050 6100 6150 6200 6250 6300

Voltage (Vdc)

-40

0

40

80

120

160

R - Red Lamp

G - Green Lamp

6000 6050 6100 6150 6200 6250 6300

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

R - Red Lamp

G - Green Lamp
E-51

E.1.11 Penlight Test #JPN-1

Test cables were supplied by Japan Nuclear Safety Organization (JNES). Cable construction 

consisted of a six-conductor control cable with 14 AWG conductors and a spirally wound copper 

shield. In this test, the shield was not grounded. In addition, only the close circuit of the breaker 

control was tested. Therefore, the results do not include information on the trip circuit. The test 

was shut down soon after the spurious actuation caused the breaker to close and the fuse did 

not clear before termination of the test.

Table E-23 Penlight Test #JPN-1 parameters.

Test Date September 15, 2009

# Current Transducer Turns CT500 = 2 CT35 = 5

Cable Type JNES supplied Cable Close, Trip, TC

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 325 °C

Battery Voltage 123.1 Vdc (Pre-test) 123.0 Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table E-24 Penlight Test #JPN-1 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

1760 Penlight Increased to 350 °C

1977 SA – Breaker Closes

1977-2041 HS Conductor C1 (64s duration)

2042 Positive Fuse Clear – Close Circuit

2040 Penlight off

TC Close
E-52

Figure E-57 Penlight Test #JPN-1 temperature profile

Figure E-58 Penlight Test #JPN-1 switchgear close coil modified voltage/current plots

Time (seconds)

0 500 1000 1500 2000

Temperature (C)

0

100

200

300

400

1st Failure (1977s - 294C)

Penlight 

TC Cable Far 

TC Cable Top 

TC Cable Near 

Close Circuit

Time (seconds)

1800 1850 1900 1950 2000

Current (Amps)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

PC - Positive

N1 - Negative

1800 1850 1900 1950 2000

Voltage (Volts)

-40

0

40

80

120

160

PC - Positive

C1 - Close Coil

N1 - Negative
E-53

Figure E-59 Penlight Test #JPN-1 ground monitoring circuit voltages

E.1.12 Penlight Test #JPN-2

Test cables were supplied by JNES. Cable construction consisted of a six-conductor control 

cable with 14 AWG conductors and a spirally wound copper shield.

Table E-25 Penlight Test #JPN-2 parameters.

Test Date September 16, 2009

# Current Transducer Turns CT500 = 2 CT35 = 5

Cable Type JNES supplied Cable Close, Trip, TC1, TC2

Cable Fill 3 cables

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 350 °C

Battery Voltage Vdc (Pre-test) Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Time (seconds)

0 500 1000 1500 2000 2500

Voltage (Volts) -100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 

TC1 Close TC2 Trip
E-54

Table E-26 Penlight Test #JPN-2 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

978-1361 Voltage loss on Trip circuit “R” conductor (~100Vdc)

1322-1456 Battery Negative shorts to Ground

1362-1456 False Indication Red lamp ON

 This is an Inter-cable hot short between Trip cable “R” conductor and 

Close cable “N1” conductor

1457 Negative Fuse Clear – Close Circuit

1457-2071 Battery Positive shorts to Ground

1457-2071 HS Trip Coil (614s duration)

2072-2120 False Indication Red lamp ON

2072-2111 Battery Negative shorts to Ground

2112-2430 Battery Positive shorts to Ground

2114-2118 HS Conductor G (4s duration)

2120-2431 HS Trip Coil (311s duration)

2121-2430 False Indication Red lamp ON

2430 Penlight off

Figure E-60 Penlight Test #JPN-2 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500

Temperature (C)

0

100

200

300

400

500

600

1st Failure (978s - 280C)

Penlight 

Cable 1 

Cable 2 
E-55

Figure E-61 Penlight Test #JPN-2 switchgear close and trip coil modified 

voltage/current plots

Time (seconds)

1200 1400 1600 1800 2000 2200 2400

Current (Amps)

0

2

4

6

8

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

Trip Circuit

Time (seconds)

1200 1400 1600 1800 2000 2200 2400

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

PT - Positive

G - Green Lamp

R - Red Lamp

N2 - Negative

1200 1400 1600 1800 2000 2200 2400

Voltage (Volts)

-40

0

40

80

120

160

PT - Positive

T - Trip Coil

N2 - Negative

Trip Circuit

Close Circuit

Time (seconds)

1200 1400 1600 1800 2000 2200 2400

Current (Amps)

-0.05

0.00

0.05

0.10

0.15

0.20

PC - Positive

N1 - Negative

1200 1400 1600 1800 2000 2200 2400

Voltage (Volts)

-40

0

40

80

120

160

PC - Positive

C1 - Close Coil

N1 - Negative
E-56

Figure E-62 Penlight Test #JPN-2 ground monitoring circuit voltages

Figure E-63 Penlight Test #JPN-2 switchgear indicating lamps modified voltage/current

Time (seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Volts) -150

-100

-50

0

50

100

150

VT7_1 

VTU_1 

VTU_2 

Time (seconds)

800 1000 1200 1400 1600 1800 2000 2200 2400

Voltage (Vdc)

-40

0

40

80

120

160

R - Red Lamp

G - Green Lamp

800 1000 1200 1400 1600 1800 2000 2200 2400

Current (Amps)

0.00

0.05

0.10

0.15

0.20

R - Red Lamp

G - Green Lamp
E-57

This test yielded interesting arcing results similar to previous tests; however, this cable sample 

contained a copper wrap beneath the jacketing material. The copper wrap was grounded to the 

cable tray.

Figure E-64 Penlight Test #JPN-2 post-test investigation of the cable sample

Figure E-65 Penlight Test #JPN-2 post-test investigation of the cable sample
E-58

E.2 Intermediate-Scale Results

The results from the intermediate-scale tests are presented below. Similar to the previous 

section, the data is presented in numerical as opposed to chronological order. In this section, it 

should be noted that Intermediate-Scale Tests Prelim Test #1, #4, and #8 used the original 15-

kV breaker. All other intermediate-scale experiments were conducted using the 4.16-kV 

breaker described in Appendix A.

E.2.1 Intermediate-Scale Prelim Test #1

It should be noted that “North Top” was the nomenclature for the thermocouple used to monitor 

the air temperature for this test. This was subsequently changed to be more specific for the 

other tests.

Table E-27 Intermediate-Scale Prelim Test #1 parameters.

Switchgear Type Square D 15KV DSE Breaker

Cable Type for SWGR-C XLPE/CSPE, 7C, 12AWG

SWGR-C Position Position B

Cable Fill Type Fill Tray H, Circuit 1

Cable Type for SWGR-T XLPE/CSPE, 7C, 12AWG

SWGR-T Position Position B

Cable Fill Type Fill Tray H, Circuit 2

Battery Voltage (Pre-test) 122.8 Vdc

Battery Voltage (Post-test) 123.1 Vdc

Table E-28 Intermediate-Scale Prelim Test #1 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated {Breaker is OPEN}

442-466 HS Conductor R (24s duration)

468 HS Conductor G (<1s duration)

470-477 HS Trip Coil (7s duration)

479-482 HS Conductor R (3s duration)

484-506 HS Trip Coil (22s duration)

506 Positive Fuse Clear Close

506-520 HS Conductor R (14s duration)

508 SA Breaker Closes

508-515 HS Conductor G (7s duration)

521-526 HS Conductor (5s duration)
E-59

Table E-29 Intermediate-Scale Prelim Test #1 sequence of events (continued).

Time (seconds) Event/Observation

528-530 HS Trip Coil (2s duration)

532 HS Conductor G (<1s duration)

534-537 HS Conductor R (3s duration)

540 Negative Fuse Clear – Trip

542 Negative Fuse Clear – Close

5100 Fire Off

Figure E-66 Intermediate-Scale Prelim Test #1 temperature profile

Time (seconds)

0 1000 2000 3000 4000 5000 6000

Temperature (C)

0

200

400

600

800

1000

1st Failure (502s - 677C)

Fire Time vs north top 

Plot 1 1st Failure (s - C)
E-60

Figure E-67 Intermediate-Scale Prelim Test #1 switchgear current/voltage plots

Time (seconds)

400 450 500 550 600

Current (Amps)

-2

0

2

4

6

8

SWGR-b_CT35_1_PT 

SWGR-b_CT35_4_N2 

400 450 500 550 600

Voltage (Volts)

-40

0

40

80

120

160

SWGR-a_CT35_1_PC 

SWGR-T V(T) - V(Batt -) 

SWGR-T V(N2) - V(Batt -) 

Trip Circuit

Close Circuit

Time (seconds)

400 450 500 550 600

Current (Amps)

-0.2

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

SWGR-a_CT35_1_PC 

SWGR-a_CT35_2_N1 

400 450 500 550 600

Voltage (Volts)

-40

0

40

80

120

160

SWGR-C V(PC) - V(Batt -) 

SWGR-C V(C1) - V(Batt -) 

SWGR-C V(N1) - V(Batt -) 
E-61

Figure E-68 Intermediate-Scale Prelim Test #1 ground voltage monitoring circuit 

indication

E.2.2 Intermediate-Scale Test #1

Table E-30 Intermediate-Scale Test #1 parameters.

Switchgear Type GE VB1 5KVAC

Cable Type for SWGR-C

XLPE/CSPE, 7C, 

12AWG

SWGR-C Position Position D

Cable Fill Type Bundled Tray B

Cable Type for SWGR-T

XLPE/CSPE, 7C, 

12AWG

SWGR-T Position Position D

Cable Fill Type Bundled Tray B

Battery Voltage (Pre-test) 123.3 Vdc

Battery Voltage (Post-test) 120.7 Vdc

Time (seconds)

400 450 500 550 600

Voltage (Volts) -150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
E-62

Table E-31 Intermediate-Scale Test #1 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated {Breaker is OPEN}

1361-1374 HS Trip Coil (13s duration)

1396 Battery positive shorted to ground

1396-1869 HS Trip Coil (473s duration)

2196 Negative Fuse Clear – Close

2247-2263 HS Conductor R (16s duration)

2265-2986 Multiple HS Trip Coil (470s longest duration)

2267-3057 Multiple HS Conductor R (24s longest duration)

2269 HS Conductor G (<1s duration)

2272 HS Conductor G (<1s duration)

2290-2972 Multiple HS Conductor G (3s longest duration)

3006-4040 Multiple HS Trip Coil (265s longest duration)

3937-4337 Multiple HS Conductor G (4s longest duration)

3939-4156 Multiple HS Conductor R (90s longest duration)

4121-4156 Multiple HS Trip Coil (63s longest duration)

4380 Fire Off

Figure E-69 Intermediate-Scale Test #1 temperature profile

Time (seconds)

0 1000 2000 3000 4000 5000

Temperature (C)

0

100

200

300

400

500

600

700

1st SWGR Failure (2196s - 525C)

D Position - 3' 

D Position - Middle 

D Position - 7' 

Plot 1 1st Failure (s - C)
E-63

Figure E-70 Intermediate-Scale Test #1 switchgear current/voltage plots

Time (seconds)

1000 2000 3000 4000 5000

Current (Amps)

-2

0

2

4

6

8

Positive Lead

Green Lamp

Red Lamp

Negative Lead

1000 2000 3000 4000 5000

Voltage (Volts)

-80

-40

0

40

80

120

160

200

Positive Lead

Trip Coil Lead

Green Lamp

Red Lamp

Negative Lead

Trip Circuit

Close Circuit

Time (seconds)

2000 2200 2400 2600 2800 3000

Current (Amps)

-2

0

2

4

6

8

Positive Lead

Negative Lead

2000 2200 2400 2600 2800 3000

Voltage (Volts)

-40

0

40

80

120

160

Positive Lead

Close Coil Lead

Negative Lead
E-64

Figure E-71 Intermediate-Scale Test #1 ground voltage monitoring circuit indication

E.2.3 Intermediate-Scale Test #3

Table E-32 Intermediate-Scale Test #3 parameters.

Switchgear Type GE VB1 5KVAC

Cable Type for SWGR-C XLPE/CSPE, 7C, 12AWG

SWGR-C Position Position B

Cable Fill Type Conduit

Cable Type for SWGR-T XLPE/CSPE, 7C, 12AWG

SWGR-T Position Position B

Cable Fill Type Conduit

Battery Voltage (Pre-test) 121.6 Vdc

Battery Voltage (Post-test) 121.6 Vdc

Time (seconds)

0 1000 2000 3000 4000 5000

Voltage (Volts) -150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
E-65

Table E-33 Intermediate-Scale Test #3 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated {Breaker is OPEN}

1232-1359 HS Conductor R (27s duration)

1232-1363 SWGR-T: R voltage decreases then recovers

1363 HS Trip Coil (<1s duration)

1365-1372 HS Conductor R (7s duration)

1375-1406 HS Trip Coil (31s duration)

1408-1418 HS Conductor R (10s duration)

1420-1677 HS Trip Coil (257s duration)

1460 SA – Breaker Closes

1460-1468 HS Conductor C1 (8s duration)

1679-3276 Multiple HS Conductor R (354s longest duration)

1685-3045 Multiple HS Trip Coil (94s duration)

2255-2629 HS Conductor G (374s duration)

2645-3200 Multiple HS Conductor G (347s duration)

3370 Fire Off

Figure E-72 Intermediate-Scale Test #3 temperature profile

Time (seconds)

0 1000 2000 3000 4000

Temperature (C)

0

100

200

300

400

500

600

1st SWGR Failure (1460s - 456C)

B Position -Conduit - 3' 

B Position -Conduit - Middle 

B Position -Conduit - 7' 

Plot 1 1st Failure (s - C)
E-66

Figure E-73 Intermediate-Scale Test #3 switchgear current/voltage plots

Time (seconds)

0 1000 2000 3000 4000

Current (Amps)

-2

0

2

4

6

8

SWGR-T PT

SWGR-T G 

SWGR-T R 

SWGR-T N2 

0 1000 2000 3000 4000

Voltage (Volts)

-40

0

40

80

120

160

SWGR-T V(PT) - V(Batt -) 

SWGR-T V(T) - V(Batt -) 

SWGR-T V(G) - V(Batt -) 

SWGR-T V(R) - V(Batt -) 

SWGR-T V(N2) - V(Batt -) 

Trip Circuit

Close Circuit

Time (seconds)

0 1000 2000 3000 4000

Current (Amps)

0

1

2

3

4

5

6

7

SWGR-C PC 

SWGR-C N1 

0 1000 2000 3000 4000

Voltage (Volts)

-40

0

40

80

120

160

SWGR-C V(PC) - V(Batt -) 

SWGR-C V(C1) - V(Batt -) 

SWGR-C V(N1) - V(Batt -) 
E-67

Figure E-74 Intermediate-Scale Test #3 ground voltage monitoring circuit indication

E.2.4 Intermediate-Scale Test #4

Table E-34 Intermediate-Scale Test #4 parameters.

Switchgear Type Square D 15KV DSE Breaker

Cable Type for SWGR-C XLPE/CSPE, 7C, 12AWG

SWGR-C Position Position E

Cable Fill Type Bundled Tray I

Cable Type for SWGR-T XLPE/CSPE, 7C, 12AWG

SWGR-T Position Position E

Cable Fill Type Bundled Tray I

Battery Voltage (Pre-test) 121.8 Vdc

Battery Voltage (Post-test) 122.7 Vdc

Time (seconds)

0 1000 2000 3000 4000

Voltage (Volts) -150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
E-68

Table E-35 Intermediate-Scale Test #4 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated {Breaker is OPEN}

3580-5262 SWGR-T: Hot short – Voltage on T slowly increases

4682-5184 SWGR-T: Hot short – Voltage on R slowly increases

4768 Positive Fuse Clear – Close

5179-5227 HS Trip Coil (48s duration)

5179-5228 SWGR-T: False indication – Red light ON [44s duration]

5230-5321 Multiple HS Conductor R (12s longest duration)

5237-5241 HS Trip Coil (4s duration)

5258-5485 Multiple HS Trip Coil (40s longest duration)

5345-5756 Multiple HS Conductor R (269s longest duration)

5410-5417 HS Conductor G (7s duration)

5723 Negative Fuse Clear – Close

5758-6149 HS Trip Coil (391s duration)

6108-6720 Multiple HS Conductor R (569s longest duration)

6160-6720 HS Trip Coil (60s duration)

6720 Fire Off

Figure E-75 Intermediate-Scale Test #4 temperature profile

Time (seconds)

0 2000 4000 6000 8000

Temperature (C)

0

200

400

600

800

1000

1200

1400

1600

1st SWGR Failure (4766s - 363C)

E Position - 3' 

E Position - Middle 

E Position - 7' 

Plot 1 1st Failure (s - C)

E-Middle Thermocouple

Fails
E-69

Figure E-76 Intermediate-Scale Test #4 switchgear current/voltage plots

Time (seconds)

0 2000 4000 6000 8000

Current (Amps)

-2

0

2

4

6

8

SWGR-T PT 

SWGR-T G 

SWGR-T R 

SWGR-T N2 

0 2000 4000 6000 8000

Voltage (Volts)

-80

-40

0

40

80

120

160

SWGR-T V(PT) - V(Batt -) 

SWGR-T V(T) - V(Batt -) 

SWGR-T V(G) - V(Batt -) 

SWGR-T V(R) - V(Batt -) 

SWGR-T V(N2) - V(Batt -) 

Trip Circuit

Close Circuit

Time (seconds)

0 2000 4000 6000 8000

Current (Amps)

-2

0

2

4

6

8

SWGR-C PC 

SWGR-C N1 

0 2000 4000 6000 8000

Voltage (Volts)

-40

0

40

80

120

160

SWGR-C V(PC) - V(Batt -) 

SWGR-C V(C1) - V(Batt -) 

SWGR-C V(N1) - V(Batt -) 
E-70

Figure E-77 Intermediate-Scale Test #4 ground voltage monitoring circuit indication

E.2.5 Intermediate-Scale Test #5

Table E-36 Intermediate-Scale Test #5 parameters.

Switchgear Type GE VB1 5KVAC

Cable Type for SWGR-C PE/PVC, 7C, 12AWG

SWGR-C Position Position D

Cable Fill Type Bundled Tray B

Cable Type for SWGR-T PE/PVC, 7C, 12AWG

SWGR-T Position Position D

Cable Fill Type Bundled Tray B

Battery Voltage (Pre-test) 124.0 Vdc

Battery Voltage (Post-test) 122.7 Vdc

Time (seconds)

0 2000 4000 6000 8000

Voltage (Volts) -150

-100

-50

0

50

100

150

Fire Time (s) vs Ground_VT7_1 

Fire Time (s) vs Ground_VTU_1 

Fire Time (s) vs Ground_VTU_2 
E-71

Table E-37 Intermediate-Scale Test #5 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated {Breaker is OPEN}

546-908 HS Trip Coil (362s duration)

546-910 Positive shorts to ground

910-1596 Negative shorts to ground

1339-1353 HS Conductor G (14s duration)

1339-1359 SWGR-T: Loss of indication – Green light is OFF

1357 HS Conductor G (<1s duration)

1371-1432 SWGR-T: Erroneous indication – Green and Red lights both ON

1372-1504 HS Conductor R (132s duration)

1424 SA – Breaker Close

1424-1428 HS Conductor C1 (4s duration)

1429 Positive Fuse Clear – Close

1462 HS Conductor G (<1s duration)

1589-1594 HS Conductor G (5s duration)

1596-2641 HS Trip Coil (1045s duration)

1597 Negative Fuse Clear – Close

2640 Fire Off

Figure E-78 Intermediate-Scale Test #5 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

200

400

600

800

1st SWGR Failure (1424s - 539C)

D Position - 3' 

D Position - Middle 

D Position - 7' 

Plot 1 1st Failure (s - C)
E-72

Figure E-79 Intermediate-Scale Test #5 switchgear current/voltage plots

Time (seconds)

800 1000 1200 1400 1600 1800 2000

Current (Amps)

-2

0

2

4

6

8

SWGR-bT PT 

SWGR-T G 

SWGR-T R 

SWGR-T N2 

800 1000 1200 1400 1600 1800 2000

Voltage (Volts)

-40

0

40

80

120

160

SWGR-T V(PT) - V(Batt -) 

SWGR-T V(T) - V(Batt -) 

SWGR-T V(G) - V(Batt -) 

SWGR-T V(R) - V(Batt -) 

SWGR-T V(N2) - V(Batt -) 

Trip Circuit

Close Circuit

Time (seconds)

800 1000 1200 1400 1600 1800 2000

Current (Amps)

-0.02

0.00

0.02

0.04

0.06

0.08

0.10

FSWGR-C PC 

SWGR-C N1 

800 1000 1200 1400 1600 1800 2000

Voltage (Volts)

-40

0

40

80

120

160

SWGR-C V(PC) - V(Batt -) 

SWGR-C V(C1) - V(Batt -) 

SWGR-C V(N1) - V(Batt -) 
E-73

Figure E-80 Intermediate-Scale Test #5 ground voltage monitoring circuit indication

E.2.6 Intermediate-Scale Test #6

Table E-38 Intermediate-Scale Test #6 parameters.

Switchgear Type GE VB1 5KVAC

Cable Type for SWGR-C PE/PVC, 7C, 12AWG

SWGR-C Position Position B

Cable Fill Type Conduit

Cable Type for SWGR-T PE/PVC, 7C, 12AWG

SWGR-T Position Position B

Cable Fill Type Conduit

Battery Voltage (Pre-test) 123.6 Vdc

Battery Voltage (Post-test) 123.0 Vdc

Time (seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Volts) -150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
E-74

Table E-39 Intermediate-Scale Test #6 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated {Breaker is CLOSED}

158-166 HS Conductor C1 (8s duration)

170-243 HS Conductor C1 (73s duration)

251-277 HS Conductor C1 (26s duration)

285 HS Conductor C1 (<1s duration)

336-849 HS Conductor C1 (513s duration)

338-1168 Positive shorts to ground

850 SA – Breaker trip

850-1166 HS Trip Coil (316s duration)

1168-1538 Negative shorts to ground {low quality}

1182-1187 HS Conductor R (5s duration)

1292-1303 HS Conductor R (11s duration)

1325-1503 HS Conductor R (178s duration)

1515-1517 HS Conductor R (2s duration)

1538-1564 HS Trip Coil (26s duration)

1538-1566 Positive shorts to ground

1546-1564 HS Conductor C1 (18s duration)

1566 Negative shorts to ground

1603 SA – Breaker Close

1605 SA – Breaker Trip

1701 HS Conductor R (<1s duration)

1701 Negative Fuse Clear – Close

1721-1725 HS Conductor R (4s duration)

1727 Negative Fuse Clear – Trip

2460 Fire Off
E-75

Figure E-81 Intermediate-Scale Test #6 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

100

200

300

400

500

600

1st SWGR Failure (850s - 431C)

Conduit - 3' 

Conduit - Middle 

Conduit - 7' 

Plot 1 1st Failure (s - C)
E-76

Figure E-82 Intermediate-Scale Test #6 switchgear current/voltage plots

Time (seconds)

800 1000 1200 1400 1600 1800 2000

Current (Amps)

-2

0

2

4

6

8

SWGR-T PT 

SWGR-T G 

SWGR-T R 

SWGR-T N2 

800 1000 1200 1400 1600 1800 2000

Voltage (Volts)

-40

0

40

80

120

160

SWGR-T V(PT) - V(Batt -) 

SWGR-T V(T) - V(Batt -) 

SWGR-T V(G) - V(Batt -) 

SWGR-T V(R) - V(Batt -) 

SWGR-T V(N2) - V(Batt -) 

Trip Circuit

Close Circuit

Time (seconds)

800 1000 1200 1400 1600 1800 2000

Current (Amps)

-1

0

1

2

3

4

5

SWGR-C PC 

SWGR-C N1 

800 1000 1200 1400 1600 1800 2000

Voltage (Volts)

-40

0

40

80

120

160

SWGR-C V(PC) - V(Batt -) 

SWGR-C V(C1) - V(Batt -) 

SWGR-C V(N1) - V(Batt -) 
E-77

Figure E-83 Intermediate-Scale Test #6 ground voltage monitoring circuit indication

E.2.7 Intermediate-Scale Test #7

Table E-40 Intermediate-Scale Test #7 parameters.

Switchgear Type GE VB1 5KVAC

Cable Type for SWGR-C PE/PVC, 7C, 12AWG

SWGR-C Position Position D

Cable Fill Type Bundled Tray B

Cable Type for SWGR-T PE/PVC, 7C, 12AWG

SWGR-T Position Position D

Cable Fill Type Bundled Tray B

Battery Voltage (Pre-test) 122.0 Vdc

Battery Voltage (Post-test) 122.8 Vdc

Time (seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Volts) -150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
E-78

Table E-41 Intermediate-Scale Test #7 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated {Breaker is CLOSED}

185-202 HS Conductor C1 (17s duration)

302 Positive shorts to ground

302-1093 HS Conductor C1 (791s duration)

1095 SA – Breaker trip

1095-1352 HS Trip Coil (257s duration)

1102-1285 HS Conductor C1 (183s duration)

1273 SWGR-T: Erroneous Indication – R shorts to N2; Red and Green Lamps 

are ON

1286 Negative Fuse Clear – Close

1348-1388 SWGR-T: PT shorts to N2 – high-current event [40s duration]

1353-1386 HS Conductor G (33s duration)

1388 Negative Fuse Clear – Trip

2400 Fire Off

Figure E-84 Intermediate-Scale Test #7 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

200

400

600

800

1000

1st SWGR Failure (1095s - 678C)

D Position - 3' 

D Position - Middle 

D Position - 7' 

Plot 1 1st Failure (s - C)
E-79

Figure E-85 Intermediate-Scale Test #7 switchgear current/voltage plots

Time (seconds)

0 500 1000 1500 2000 2500 3000

Current (Amps)

-2

0

2

4

6

8

SWGR-T PT 

SWGR-T G 

SWGR-T R 

SWGR-T N2 

0 500 1000 1500 2000 2500 3000

Voltage (Volts)

-40

0

40

80

120

160

SWGR-T V(PT) - V(Batt -) 

SWGR-T V(T) - V(Batt -) 

SWGR-T V(G) - V(Batt -) 

SWGR-T V(R) - V(Batt -) 

SWGR-T V(N2) - V(Batt -) 

Trip Circuit

Close Circuit

Time (seconds)

0 500 1000 1500 2000 2500 3000

Current (Amps)

0.00

0.02

0.04

0.06

0.08

0.10

SWGR-C PC 

SWGR-C N1 

0 500 1000 1500 2000 2500 3000

Voltage (Volts)

-40

0

40

80

120

160

SWGR-C V(PC) - V(Batt -) 

SWGR-C V(C1) - V(Batt -) 

SWGR-C V(N1) - V(Batt -) 
E-80

Figure E-86 Intermediate-Scale Test #7 ground voltage monitoring circuit indication

E.2.8 Intermediate-Scale Test #8

Table E-42 Intermediate-Scale Test #8 parameters.

Switchgear Type Square D 15KV DSE Breaker

Cable Type for SWGR-C PE/PVC, 7C, 12AWG

SWGR-C Position Position C

Cable Fill Type Bundled Tray A

Cable Type for SWGR-T PE/PVC, 7C, 12AWG

SWGR-T Position Position C

Cable Fill Type Bundled Tray A

Battery Voltage (Pre-test) 121.8 Vdc

Battery Voltage (Post-test) 122.6 Vdc

Time (seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Volts) -150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
E-81

Table E-43 Intermediate-Scale Test #8 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated {Breaker is OPEN}

711-900 Negative shorts to ground

900 Positive shorts to ground

901-938 HS Trip Coil (37s duration)

943-1101 HS Trip Coil (158s duration)

1102-1135 HS Conductor G (33s duration)

1137-1248 HS Trip Coil (111s duration)

1252 Smoke coming from SWGR – Circuit power isolated at DC breakers

1252 Negative Fuse Clear – Close

1252 Positive Fuse Clear – Trip

2495 Fire Off

Figure E-87 Intermediate-Scale Test #8 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

100

200

300

400

500

600

1st SWGR Failure (1102s - 303C)

C Position - 3' 

C Position - Middle 

C Position - 7' 

Plot 1 1st Failure (s - C)

SWGR Circuit Isolated (1252s)
E-82

Figure E-88 Intermediate-Scale Test #8 switchgear current/voltage plots

Time (seconds)

600 800 1000 1200 1400

Current (Amps)

-2

0

2

4

6

8

SWGR-T PT 

SWGR-T G 

SWGR-T R 

SWGR-T N2 

600 800 1000 1200 1400

Voltage (Volts)

-40

0

40

80

120

160

SWGR-T V(PT) - V(Batt -) 

SWGR-T V(T) - V(Batt -) 

SWGR-T V(G) - V(Batt -) 

SWGR-T V(R) - V(Batt -) 

SWGR-T V(N2) - V(Batt -) 

Trip Circuit

Close Circuit

Time (seconds)

600 800 1000 1200 1400

Current (Amps)

-0.015

-0.010

-0.005

0.000

0.005

0.010

0.015

0.020

0.025

SWGR-C PC 

SWGR-C N1 

600 800 1000 1200 1400

Voltage (Volts)

-40

0

40

80

120

160

SWGR-C V(PC) - V(Batt -) 

SWGR-C V(C1) - V(Batt -) 

SWGR-C V(N1) - V(Batt -) 

Current Transducers

Saturated
E-83

Figure E-89 Intermediate-Scale Test #8 ground voltage monitoring circuit indication

Intermediate-Scale Test #8 resulted in internal damage to the 15-kV circuit breaker. In 

summary, the findings indicate that the root cause of the high-current event and resulting 

damage appear to be the result of PT shorting to N2 through conductor G. The current running 

through the breaker from G to N2 through the 16-gage internal panel wires caused those wires 

to overheat, generating smoke, and ultimately melting the copper conductors, thus cutting off 

the current flow path.

Even though the investigation revealed that the connections made to the circuit breaker panel 

from the cables under test were reversed, circuit analysis of the event indicates that that was 

not a contributing cause. Damage to the same internal wires would have occurred given the 

same sequence of PT-G-N2 shorting, even if the connections had been correctly made. More 

information is available in Appendix A.4.2.

Time (seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Volts) -150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
E-84

E.2.9 Intermediate-Scale Test #9

Table E-44 Intermediate-Scale Test #9 parameters.

Switchgear Type GE VB1 5KVAC

Cable Type for SWGR-C Armored Cable, 8C, 12AWG

SWGR-C Position Position D

Cable Fill Type Tray

Cable Type for SWGR-T Armored Cable, 8C, 12AWG

SWGR-T Position Position D

Cable Fill Type Tray

Battery Voltage (Pre-test) 122.1 Vdc

Battery Voltage (Post-test) 122.4 Vdc

Table E-45 Intermediate-Scale Test #9 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated {Breaker is CLOSED}

623-759 HS Conductor C1 (136s duration)

623-1602 Positive shorts to ground

765-778 Brief period (13s) where Negative shorts to ground

778-1506 HS Conductor C1 (728s duration)

1586-1600 HS Conductor C1 (14s duration)

1602-2422 Negative shorts to ground

1604 SA – Breaker Trip

1628 SA – Breaker Close

1640 SWGR-T: Erroneous Indication – G shorts to ground; Red and Green 

Lamps are ON

1704 SA – Breaker Trip

1918 SA – Breaker Close

2413-2417 HS Conductor R (4s duration)

2420 HS Conductor R (<1s duration)

2422 Positive shorts to ground

2422-3302 HS Trip Coil (880s duration)

3300 Fire Off
E-85

Figure E-90 Intermediate-Scale Test #9 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500 3000 3500

Temperature (C)

0

200

400

600

800

1st SWGR Failure (1920s - 601C)

D Position - 3' 

D Position - Middle 

D Position - 7' 

Plot 1 1st Failure (s - C)
E-86

Figure E-91 Intermediate-Scale Test #9 switchgear current/voltage plots

Time (seconds)

0 500 1000 1500 2000 2500 3000 3500

Current (Amps)

-2

0

2

4

6

8

SWGR-T PT 

SWGR-T G 

SWGR-T R 

SWGR-T N2 

0 500 1000 1500 2000 2500 3000 3500

Voltage (Volts)

-40

0

40

80

120

160

200

SWGR-T V(PT) - V(Batt -) 

SWGR-T V(T) - V(Batt -) 

SWGR-T V(G) - V(Batt -) 

SWGR-T V(R) - V(Batt -) 

SWGR-T V(N2) - V(Batt -) 

Trip Circuit

Close Circuit

Time (seconds)

0 500 1000 1500 2000 2500 3000 3500

Current (Amps)

-2

0

2

4

6

8

SWGR-C PC 

SWGR-C N1 

0 500 1000 1500 2000 2500 3000 3500

Voltage (Volts)

-40

0

40

80

120

160

SWGR-C V(PC) - V(Batt -) 

SWGR-C V(C1) - V(Batt -) 

SWGR-C V(N1) - V(Batt -) 
E-87

Figure E-92 Intermediate-Scale Test #9 ground voltage monitoring circuit indication

E.2.10 Intermediate-Scale Test #10

It should be noted that the trip and close SWGR circuits were conducted within the same cable.

Table E-46 Intermediate-Scale Test #10 parameters.

Switchgear Type GE VB1 5KVC

Cable Type for SWGR-C Kerite, 15C, with zinc wrap

SWGR-C Position Position B

Cable Fill Type Fill Tray 

Cable Type for SWGR-T Kerite, 15C, with zinc wrap

SWGR-T Position Position B

Cable Fill Type Fill Tray 

Battery Voltage (Pre-test) 122.0 Vdc

Battery Voltage (Post-test) 122.2 Vdc

Time (seconds)

0 500 1000 1500 2000 2500 3000 3500

Voltage (Volts) -150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
E-88

Table E-47 Intermediate-Scale Test #10 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated {Breaker is CLOSED, jumper installed between 

C1 and PC}

657-968 Negative going to ground potential

968-2484 Negative shorted to ground 

2644-3090 SWGR-T: Voltage on G decreasing slowly

3099-3279 Multiple HS Conductor G (5s longest duration)

3099-3282 Multiple HS Conductor R (17s longest duration)

3108 SA – Breaker Trip

3177 Positive Fuse Clear – Close

3960 Fire Off

The circuit breaker was tested starting in the closed position. The jumper installed between C1 

and PC was to keep the anti-pump relay in the closing circuit energized throughout the test. 

Also, both SWGR circuits (Close and Trip) were contained within the single 15-conductor 

Kerite®test cable during this exposure run.

Figure E-93 Intermediate-Scale Test #10 temperature profile

Time (seconds)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

1000

1200

1400

1st SWGR Failure (3108s - 338C)

B Position - Tray - Middle 

B Position - Kerite 15c w 

Plot 1 1st Failure (s - C)

Tray thermocouple

begins to fail
E-89

Figure E-94 Intermediate-Scale Test #10 switchgear current/voltage plots

Time (seconds)

2600 2800 3000 3200 3400 3600 3800 4000

Current (Amps)

-2

0

2

4

6

8

SWGR-T PT 

SWGR-T G 

SWGR-T R 

SWGR-T N2 

2600 2800 3000 3200 3400 3600 3800 4000

Voltage (Volts)

-40

0

40

80

120

160

SWGR-T V(PT) - V(Batt -) 

SWGR-T V(T) - V(Batt -) 

SWGR-T V(G) - V(Batt -) 

SWGR-T V(R) - V(Batt -) 

SWGR-T V(N2) - V(Batt -) 

Trip Circuit

Close Circuit

Time (seconds)

2600 2800 3000 3200 3400 3600 3800 4000

Current (Amps)

-2

0

2

4

6

8

SWGR-C PC 

SWGR-C N1 

2600 2800 3000 3200 3400 3600 3800 4000

Voltage (Volts)

-40

0

40

80

120

160

SWGR-C V(PC) - V(Batt -) 

SWGR-C V(C1) - V(Batt -) 

SWGR-C V(N1) - V(Batt -) 
E-90

Figure E-95 Intermediate-Scale Test #10 ground voltage monitoring circuit indication

E.2.11 Intermediate-Scale Contingency Test #1

This is the first of two supplemental or “contingency” tests run in the intermediate-scale test cell. 

In both contingency tests, only cables serving the SWGR circuits were exposed to the fire 

conditions. Like the initial conditions of Intermediate-Scale Test #10, the breaker was put into 

the closed position before the test and a jumper was installed between C1 and PC in the Close 

circuit. This was the starting point during both contingency tests.

Table E-48 Intermediate-Scale Contingency Test #1 parameters.

Switchgear Type GE VB1 5KVAC

Cable Type for SWGR-C XLPO, 7C, 12AWG

SWGR-C Position Position B

Cable Fill Type Fill Tray H

Cable Type for SWGR-T XLPO, 7C, 12AWG

SWGR-T Position Position B

Cable Fill Type Fill Tray H

Battery Voltage (Pre-test) 125.0 Vdc

Battery Voltage (Post-test) 121.7 Vdc

Time (seconds)

0 1000 2000 3000 4000 5000

Voltage (Volts) -150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
E-91

Table E-49 Intermediate-Scale Contingency Test #1 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated {Breaker is CLOSED; jumper installed between C1 and 

PC}

378-420 SWGR-T: Voltage on G decreasing 

394-398 HS Conductor G (4s duration)

394-416 Multiple HS Conductor R (6s duration)

408-498 Multiple HS Conductor G (1s longest duration)

410 SA – Breaker Trip

410-423 Negative shorted to ground

412-497 Multiple HS Trip Coil (80s longest duration)

423 Positive shorted to ground

423 Negative Fuse Clear – Close

499-1021 Multiple HS Trip Coil (241s longest duration)

741-985 Multiple HS Conductor G (3s longest duration)

823-970 Multiple HS Conductor R (3s longest duration)

1020 Fire Off

Figure E-96 Intermediate-Scale Contingency Test #1 temperature profile

Time (seconds)

0 200 400 600 800 1000 1200

Temperature (C)

0

50

100

150

200

1st SWGR Failure (406s - 136C)

B Position - Middle 

Plot 1 1st Failure (s - C)
E-92

Figure E-97 Intermediate-Scale Contingency Test #1 switchgear current/voltage plots

Time (seconds)

400 600 800 1000

Current (Amps)

-2

0

2

4

6

8

SWGR-T PT 

SWGR-T G 

SWGR-T R 

SWGR-T N2 

400 600 800 1000

Voltage (Volts)

-40

0

40

80

120

160

SWGR-T V(PT) - V(Batt -) 

SWGR-T V(T) - V(Batt -) 

SWGR-T V(G) - V(Batt -) 

SWGR-T V(R) - V(Batt -) 

SWGR-T V(N2) - V(Batt -) 

Trip Circuit

Close Circuit

Time (seconds)

400 600 800 1000

Current (Amps)

-2

0

2

4

6

8

SWGR-C PC 

SWGR-C N1 

400 600 800 1000

Voltage (Volts)

-40

0

40

80

120

160

SWGR-C V(PC) - V(Batt -) 

SWGR-C V(C1) - V(Batt -) 

SWGR-C V(N1) - V(Batt -) 
E-93

Figure E-98 Intermediate-Scale Contingency Test #1 ground voltage monitoring circuit 

indication

E.2.12 Intermediate-Scale Contingency Test #2

Table E-50 Intermediate-Scale Contingency Test #2 parameters.

Switchgear Type GE VB1 5KVAC

Cable Type for SWGR-C Tefzel

SWGR-C Position Position B

Cable Fill Type Fill Tray H

Cable Type for SWGR-T Tefzel

SWGR-T Position Position B

Cable Fill Type Fill Tray H

Battery Voltage (Pre-test) 122.7 Vdc

Battery Voltage (Post-test) 122.4 Vdc

Time (seconds)

0 200 400 600 800 1000 1200

Voltage (Volts) -150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
E-94

Table E-51 Intermediate-Scale Contingency Test #2 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated {Breaker is CLOSED; jumper installed between C1 

and PC}

332 Positive shorts to ground

332-333 HS Conductor G (1s duration)

334-336 HS Trip Coil (2s duration)

334 SA – Breaker Trip

337 Negative Fuse Clear – Trip

354 SA – Breaker Closes

354-457 HS Conductor C1 (103s duration)

458 Negative Fuse Clear – Close

1006 Fire Off

Figure E-99 Intermediate-Scale Contingency Test #2 temperature profile

Time (seconds)

0 200 400 600 800 1000 1200

Temperature (C)

0

20

40

60

80

100

120

140

160

1st SWGR Failure (337s - 96C)

B Position - Middle 

Plot 1 1st Failure (s - C)
E-95

Figure E-100 Intermediate-Scale Contingency Test #2 switchgear current/voltage plots

Time (seconds)

300 350 400 450 500

Current (Amps)

-2

0

2

4

6

8

SWGR-T PT 

SWGR-T G 

SWGR-T R 

SWGR-T N2 

300 350 400 450 500

Voltage (Volts)

-40

0

40

80

120

160

SWGR-T V(PT) - V(Batt -) 

SWGR-T V(T) - V(Batt -) 

SWGR-T V(G) - V(Batt -) 

SWGR-T V(R) - V(Batt -) 

SWGR-T V(N2) - V(Batt -) 

Trip Circuit

Close Circuit

Time (seconds)

300 350 400 450 500

Current (Amps)

-0.04

-0.02

0.00

0.02

0.04

0.06

SWGR-C PC 

SWGR-C N1 

300 350 400 450 500

Voltage (Volts)

-40

0

40

80

120

160

SWGR-C V(PC) - V(Batt -) 

SWGR-C V(C1) - V(Batt -) 

SWGR-C V(N1) - V(Batt -) 
E-96

Figure E-101 Intermediate-Scale Contingency Test #2 ground voltage monitoring circuit 

indication

Time (seconds)

0 200 400 600 800 1000 1200

Voltage (Volts) -150

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 

Appendix F. Intercable Configuration Circuit
F-1

F.1 Small-Scale Results

The purpose of this section is to provide the paired circuit analysis for each test in the smalland intermediate-scale experiments. Every test has a nominal summary of the specific 

experimental parameters, sequence of events, and data supporting the sequential events. It 

should be noted that circuit grounding observations were included for Penlight since only two 

circuits were tested and ground faults were, in general, simple and easily identifiable. In the 

intermediate-scale experiments, however, the number of commonly grounded circuits and wide 

berth of failure times overcomplicates detailed observations. Therefore, the intermediate-scale 

ground behavior was not described in as much detail as the Penlight tests.

The results from the Penlight tests are presented below. The data is presented in numerical as 

opposed to chronological order. It should be noted that throughout the penlight tests, the 

bundle of five cables was placed on a non-conductive piece of fiberglass insulation to isolate the 

cables from the tray. 

F.1.1 Penlight Test #45

A post-test inspection of the fuses indicated that fuse S2- remained operational with all other 

fuses clearing.

Table F-1 Penlight Test #45 parameters.

Test Date October 9, 2009

Cable Type XLPE/CSPE, 7c, 12AWG

Cable Fill 5 cables S1+, S2+, T, S1-, S2-

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 460 °C

Battery Voltage 123.2Vdc (Pre-test) 122.8Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table F-2 Penlight Test #45 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

867 Cable Ignition

1550 Beginning of cable to cable interaction

Positive voltage is induced on all conductors indicating that 

Either S1+ or S2+ is interacting with cable.

Since individual target (T) conductors remain at the identical voltage to one 

another, it would indicate that the target cable failed internally prior to any 

intercable interactions.

2200 Penlight off

T

S1-

S1+

S2+

S2-
F-2

Figure F-1 Penlight Test #45 temperature profile

Figure F-2 Penlight Test #45 ground monitoring circuit voltages

Time (seconds)

0 500 1000 1500 2000 2500

Temperature (C)

0

100

200

300

400

500

Penlight 

Time(seconds)

0 500 1000 1500 2000 2500

Voltage (Vdc)

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
F-3

Figure F-3 Penlight Test #45 intercable modified voltage plots

F.1.2 Penlight Test #46

A post-test inspection of the fuses indicated that S2 – remained operational with all other fuses 

clearing.

Table F-3 Penlight Test #46 parameters.

Test Date October 8, 2009

Cable Type EPR/CPE, 7c, 12AWG

Cable Fill 5 cables S1+, S2+, T, S1-, S2-

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 470 °C

Battery Voltage 123.24 Vdc (Pre-test) N/A (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Time (seconds)

1400 1600 1800 2000 2200

Voltage (Vdc)

-40

0

40

80

120

160

T1-V(Batt-) 

T2-V(Batt-) 

T3-V(Batt-) 

T4-V(Batt-) 

T5-V(Batt-) 

T6-V(Batt-) 

T7-V(Batt-) 

T

S1-

S1+

S2+

S2-
F-4

Table F-4 Penlight Test #46 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

930 Cable Ignition

1000-1263 Beginning of cable to cable interaction. Negative voltage is induced on 

conductors T2-T7 (outer ring) indicating that either S1- or S2- is 

interacting with target cable. Since individual target (T) conductors T2-

T7 remain at the identical voltage to one another, it would indicate that 

the target cable failed internally prior to any intercable interactions. 

This also indicates that the T1 conductor had not yet failed to the rest 

of the conductors. (263s duration)

1264-1316 Positive voltage is inducted on conductors T2-T7 (outer ring)

Indicating that either S1+ or S2+ is interacting with target cable. (52s 

duration)

1316-1440 Negative voltage is induced on all conductors T1-T7. (124s duration)

1440 Penlight off

Figure F-4 Penlight Test #46 temperature profile

Time (seconds)

0 200 400 600 800 1000 1200 1400 1600

Temperature (C)

0

100

200

300

400

500

Penlight 
F-5

Figure F-5 Penlight Test #46 ground monitoring circuit voltages

Figure F-6 Penlight Test #46 intercable modified voltage plots

Time(seconds)

1000 1100 1200 1300 1400

Voltage (Vdc)

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 

Time (seconds)

1000 1100 1200 1300 1400

Voltage (Vdc)

0

40

80

120

T1-V(Batt-) 

T2-V(Batt-) 

T3-V(Batt-) 

T4-V(Batt-) 

T5-V(Batt-) 

T6-V(Batt-) 

T7-V(Batt-) 
F-6

F.1.3 Penlight Test #47

A post-test inspection of the fuses indicated that S1+ and S2- remained operational with the 

other two fuses (S2+ and S1-) clearing.

Table F-5 Penlight Test #47 parameters.

Test Date October 8, 2009

Cable Type PE/PVC, 7c, 12AWG

Cable Fill 5 cables S1+, S2+, T, S1-, S2-

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 350 °C

Battery Voltage 123.3 Vdc (Pre-test) N/A (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Table F-6 Penlight Test #47 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

1800 Penlight increased to 375 °C

2240 Beginning of intercable interactions

4350-6575 Cable interaction from both source cables (positive and negative).

Conductor T5 shorts to positive (S1+ or S2+) source cable.

Conductor T2 shorts to negative (S1- or S2-) source cable.

(2225s duration)

7200 Penlight increased to 390 °C

7800 Penlight increased to 405 °C

8640 Penlight off

T

S1-

S1+

S2+

S2-
F-7

Figure F-7 Penlight Test #47 temperature profile

Figure F-8 Penlight Test #47 ground monitoring circuit voltages

Time (seconds)

0 2000 4000 6000 8000 10000

Temperature (C)

50

100

150

200

250

300

350

400

450

Penlight 

Time(seconds)

0 2000 4000 6000 8000 10000

Voltage (Vdc)

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
F-8

Figure F-9 Penlight Test #47 intercable modified voltage plots

F.1.4 Penlight Test #48

A post-test inspection of the fuse indicated that S1+ remained operational with all other fuses 

(S2+, S1-, and S2-) clearing.

Table F-7 Penlight Test #48 parameters.

Test Date October 8, 2009

Cable Type PVC/PVC, 7c, 12AWG

Cable Fill 5 cables S1+, S2+, T, S1-, S2-

Raceway Configuration Cable Tray (12” wide)

Penlight Setpoint 400 °C

Battery Voltage Vdc (Pre-test) Vdc (Post-test)

Thermocouple Channels TC1=Ch3 TC2=Ch4

Time (seconds)

2000 3000 4000 5000 6000 7000 8000

Voltage (Vdc)

40

50

60

70

80

T1-V(Batt-) 

T2-V(Batt-) 

T3-V(Batt-) 

T4-V(Batt-) 

T5-V(Batt-) 

T6-V(Batt-) 

T7-V(Batt-) 

T

S1-

S1+

S2+

S2-
F-9

Table F-8 Penlight Test #48 sequence of events.

Time (seconds) Event/Observation

0 Penlight on

550 Beginning of intercable interactions with negative source cable (S1- or 

S2-). Conductors T2-T7 have shorted together prior to the intercable

interactions. Conductor T1 has not yet fully shorted to the exterior ring of 

conductors until 843s.

2804 Penlight off

Figure F-10 Penlight Test #48 temperature profile

Time (seconds)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

100

200

300

400

500

Penlight 
F-10

Figure F-11 Penlight Test #48 ground monitoring circuit voltages

Figure F-12 Penlight Test #48 intercable modified voltage plots

Time(seconds)

0 500 1000 1500 2000 2500 3000 3500

Voltage (Vdc)

-100

-50

0

50

100

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 

Time (seconds)

600 800 1000 1200 1400

Voltage (Vdc)

-40

0

40

80

120

160

T1-V(Batt-) 

T2-V(Batt-) 

T3-V(Batt-) 

T4-V(Batt-) 

T5-V(Batt-) 

T6-V(Batt-) 

T7-V(Batt-) 
F-11

F.2 Intermediate-Scale Results

The results from the intermediate-scale tests are presented below. Similar to the previous 

section, the data is presented in numerical as opposed to chronological order. The one main 

difference between the small- and intermediate-scale experiments was the use of the fiberglass 

board to isolate the cable bundle from the tray. During the intermediate-scale experiments, the 

fiberglass board was not used. The specific test configuration should be observed in the test 

parameters.

F.2.1 Intermediate-Scale Test Prelim #1

Table F-9 Intermediate-Scale Test Prelim #1 parameters.

Cable Type for Intercable Configuration XLPE/CSPE, 7c, 12AWG

Intercable Configuration Position Position D

Cable Fill Type Bundled Tray K

Battery Voltage (Pre-test) 122.82Vdc

Battery Voltage (Post-test) 123.13 Vdc

Table F-10 Intermediate-Scale Test Prelim #1 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

5100 Fire Off, fuses for the source cables were still functional, 

no intercable interactions detected.
F-12

Figure F-13 Intermediate-Scale Test Prelim #1 temperature profile

Temperature

Time (s)

0 1000 2000 3000 4000 5000 6000

Temperature (C)

0

200

400

600

800

D Position - 3' 

D Position - Middle 

D Position - 7' 
F-13

Figure F-14 Intermediate-Scale Test Prelim #1 intercable source voltage plots

Positive Sources

Time (s)

0 1000 2000 3000 4000 5000 6000

Voltage (Vdc)

-150

0

150

Ground_VTU_2 

Int-Cab_VTU-S1+a 

Int-Cab_VTU-S1+b 

Int-Cab_VTU-S2+a 

Int-Cab_VTU-S2+b 

Negative Sources

Time (s)

0 1000 2000 3000 4000 5000 6000

Voltage (Vdc)

-150

0

150

Ground_VTU_1 

Int-Cab_VTU-S1-a 

Int-Cab_VTU-S1-b 

Int-Cab_VTU-S2-a 

Int-Cab_VTU-S2-b 
F-14

Figure F-15 Intermediate-Scale Test Prelim #1 intercable target conductor voltage plot

Time (s)

0 1000 2000 3000 4000 5000 6000

Voltage (Vdc)

-150

0

150

Int-Cab_VT7-T1 

Int-Cab_VT7-T2 

Int-Cab_VT7-T3 

Int-Cab_VT7-T4 

Int-Cab_VT7-T5 

Int-Cab_VT7-T6 

Int-Cab_VT7-T7 
F-15

Figure F-16 Intermediate-Scale Test Prelim #1 ground voltage monitoring circuit 

indication

F.2.2 Intermediate-Scale Test #1

Table F-11 Intermediate-Scale Test #1 parameters.

Cable Type for Intercable Configuration XLPE/CSPE, 7c, 12AWG

Intercable Configuration Position Position C

Cable Fill Type Bundled Tray F

Battery Voltage (Pre-test) 123.31 Vdc

Battery Voltage (Post-test) 120.72 Vdc

Time (seconds)

0 1000 2000 3000 4000 5000 6000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
F-16

Table F-12 Intermediate-Scale Test #1 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

2520-2934 Negative source interaction with target cable. At 

this time, the outer ring of conductors have shorted 

together; however, the inner conductor has not yet 

failed to the others. The target cable drops to 

approximately -25V. (414s duration)

2934-2936 Positive source interaction with the target conductors. 

The outer ring on the target cable experiences 

approximately 7V. (2s duration)

2936-2965 Negative source interaction with target cable. At this 

time, the target cable drops to approximately -26V. (29s 

duration)

2965 All the conductors in the target cable have shorted 

together, as indicated by the identical voltage reading.

2965-3988 The target cable experiences positive and negative 

interaction ranging from -26 to 15V. (23s duration)

4030 Source 1, negative fuse clears

4341 Source 1, positive fuse clears

4380 Fire Off

Figure F-17 Intermediate-Scale Test #1 temperature profile

Temperature

Time (s)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

1000

1200

1400

C Position - 3' 

C Position - Middle 

C Position - 7' 

1st Failure (2520s - 383C)
F-17

Figure F-18 Intermediate Scale Test #1 intercable source voltage plots

Positive Sources

Time (s)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VTU_2 

Int-Cab_VTU-S1+a 

Int-Cab_VTU-S1+b 

Int-Cab_VTU-S2+a 

Int-Cab_VTU-S2+b 

Negative Sources

Time (s)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VTU_1 

Int-Cab_VTU-S1-a 

Int-Cab_VTU-S1-b 

Int-Cab_VTU-S2-a 

Int-Cab_VTU-S2-b 
F-18

Figure F-19 Intermediate Scale Test #1 intercable target conductor voltage plots

Figure F-20 Intermediate-Scale Test #1 ground voltage monitoring circuit indication

Time (s)

2400 2600 2800 3000 3200 3400 3600 3800 4000 4200

Voltage (Vdc)

-80

0

80

Int-Cab_VT7-T1 

Int-Cab_VT7-T2 

Int-Cab_VT7-T3 

Int-Cab_VT7-T4 

Int-Cab_VT7-T5 

Int-Cab_VT7-T6 

Int-Cab_VT7-T7 

Time(seconds)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
F-19

F.2.3 Intermediate-Scale Test #2

Table F-13 Intermediate-Scale Test #2 parameters.

Cable Type for Intercable Configuration XLPE/CSPE, 7c, 12AWG

Intercable Configuration Position Position D

Cable Fill Type Bundle Tray E

Battery Voltage (Pre-test) 121.77 Vdc

Battery Voltage (Post-test) 122.97 Vdc

Table F-14 Intermediate-Scale Test #2 sequence of events

Time (seconds) Event/Observation

0 Fire Initiated

1110 Source 1 and Source 2, negative fuses clear

3017 Source 2, positive fuse clears

2562-3113 During this time range, the target cable interacts with a 

positive source cable and ranges from 1 - 6V. The 

target cable failed internally before shorting to the 

positive source. (551s duration)

3202 Source 1, positive fuse clears

6060 Fire Off

Figure F-21 Intermediate-Scale Test #2 temperature profile

Temperature

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Temperature (C)

0

200

400

600

800

D Position - 3' 

D Position - Middle 

D Position - 7' 

1st Failure (1110s - 375C)
F-20

Figure F-22 Intermediate-Scale Test #2 intercable source voltage plots

Positive Sources

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vdc)

-150

0

150

Ground_VTU_2 

Int-Cab_VTU-S1+a 

Int-Cab_VTU-S1+b 

Int-Cab_VTU-S2+a 

Int-Cab_VTU-S2+b 

Negative Sources

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vdc)

-150

0

150

Ground_VTU_1 

Int-Cab_VTU-S1-a 

Int-Cab_VTU-S1-b 

Int-Cab_VTU-S2-a 

Int-Cab_VTU-S2-b 
F-21

Figure F-23 Intermediate-Scale Test #2 intercable target conductor voltage plots

Figure F-24 Intermediate-Scale Test #2 ground voltage monitoring circuit indication

Time (s)

2400 2600 2800 3000 3200

Voltage (Vdc)

-80

0

80

Int-Cab_VT7-T1 

Int-Cab_VT7-T2 

nt-Cab_VT7-T3 

Int-Cab_VT7-T4 

Int-Cab_VT7-T5 

Int-Cab_VT7-T6 

Int-Cab_VT7-T7 

Time(seconds)

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
F-22

F.2.4 Intermediate-Scale Test #3

Table F-15 Intermediate-Scale Test #3 parameters.

Cable Type for Intercable Configuration XLPE/CSPE, 7c, 12AWG

Intercable Configuration Position Position A

Cable Fill Type Fill Tray F

Battery Voltage (Pre-test) 121.59 Vdc

Battery Voltage (Post-test) 121.55 Vdc

Table F-16 Intermediate-Scale Test #3 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

461-499 The target cable begins to short with the positive 

source cables. During this time, the voltage increases 

from 1V to 3V. (38s duration)

499-543 The target cable continues to short with the positive source 

cables. During this time, the outer ring ranged from 17V to 

104V, though T5 conductor declined to 8V approximately 9 

seconds before the other conductors. The inner most 

conductor (T1) did not short to the outer ring and as such 

ranged from 14 to 85V during this period. (54s duration)

543 The target cable does not interact with the source cables 

for the remainder of the test indicating a fuse clear.

546 Source 2, positive fuse clears

1168 Source 1, positive fuse clears

1168 Source 1 and Source 2, negative fuses clear

3370 Fire Off
F-23

Figure F-25 Intermediate-Scale Test #3 temperature profile

Temperature

Time (s)

0 1000 2000 3000 4000

Temperature (C)

0

200

400

600

800

A Position - Middle 

1st Failure (461s - 490C)
F-24

Figure F-26 Intermediate-Scale Test #3 intercable source voltage plots

Positive Sources

Time (s)

0 1000 2000 3000 4000

Voltage (Vdc)

-150

0

150

Ground_VTU_2 

Int-Cab_VTU-S1+a 

Int-Cab_VTU-S1+b 

Int-Cab_VTU-S2+a 

Int-Cab_VTU-S2+b 

Negative Sources

Time (s)

0 1000 2000 3000 4000

Voltage (Vdc)

-150

0

150

Ground_VTU_1 

Int-Cab_VTU-S1-a 

Int-Cab_VTU-S1-b 

Int-Cab_VTU-S2-a 

Int-Cab_VTU-S2-b 
F-25

Figure F-27 Intermediate-Scale Test #3 intercable target conductor voltage plots

Figure F-28 Intermediate-Scale Test #3 ground voltage monitoring circuit indication

Time (s)

350 400 450 500 550 600 650

Voltage (Vdc)

-150

0

150

Int-Cab_VT7-T1 

Int-Cab_VT7-T2 

Int-Cab_VT7-T3 

Int-Cab_VT7-T4 

Int-Cab_VT7-T5 

Int-Cab_VT7-T6 

Int-Cab_VT7-T7 

Time(seconds)

0 1000 2000 3000 4000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
F-26

F.2.5 Intermediate-Scale Test #4

Table F-17 Intermediate-Scale Test #4 parameters.

Cable Type for Intercable Configuration XLPE/CSPE, 7c, 12AWG

Intercable Configuration Position Position B

Cable Fill Type Fill Tray G

Battery Voltage (Pre-test) 121.83 Vdc

Battery Voltage (Post-test) 122.74 Vdc

Table F-18 Intermediate-Scale Test #4 sequence of events

Time (seconds) Event/Observation

0 Fire Initiated

1675 Source 1 and Source 2, negative fuses clear

3815-3923 Voltage increase of approximately 1V (118s duration)

4517 Source 2, positive fuse clears

4796 Source 1, positive fuse clears

6720 Fire Off

Figure F-29 Intermediate-Scale Test #4 temperature profile

Temperature

Time (s)

0 2000 4000 6000 8000

Temperature (C)

0

200

400

600

800

1000

B Position - Middle 

1st Failure (1675s - 229C)
F-27

Figure F-30 Intermediate-Scale Test #4 intercable source voltage plots

Positive Sources

Time (s)

0 2000 4000 6000 8000

Voltage (Vdc)

-150

0

150

Ground_VTU_2 

Int-Cab_VTU-S1+a 

Int-Cab_VTU-S1+b 

Int-Cab_VTU-S2+a 

Int-Cab_VTU-S2+b 

Negative Sources

Time (s)

0 2000 4000 6000 8000

Voltage (Vdc)

-150

0

150

Ground_VTU_1 

Int-Cab_VTU-S1-a 

Int-Cab_VTU-S1-b 

Int-Cab_VTU-S2-a 

Int-Cab_VTU-S2-b 
F-28

Figure F-31 Intermediate-Scale Test #4 intercable target conductor voltage plots

Figure F-32 Intermediate-Scale Test #4 ground voltage monitoring circuit indication

Time (s)

0 2000 4000 6000 8000

Voltage (Vdc)

-150

0

150

Int-Cab_VT7-T1 

Int-Cab_VT7-T2 

Int-Cab_VT7-T3 

Int-Cab_VT7-T4 

Int-Cab_VT7-T5 

Int-Cab_VT7-T6 

Int-Cab_VT7-T7 

Time(seconds)

0 2000 4000 6000 8000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
F-29

F.2.6 Intermediate-Scale Test #5

Table F-19 Intermediate-Scale Test #5 parameters.

Cable Type for Intercable Configuration PE/PVC, 7c, 12AWG

Intercable Configuration Position Position C

Cable Fill Type Bundled Tray F

Battery Voltage (Pre-test) 124.02 Vdc

Battery Voltage (Post-test) 122.74 Vdc

Table F-20 Intermediate-Scale Test #5 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1760 Source 1, negative fuse clears

2026 Source 2, negative fuse clears

2055 Source 1 and Source 2, positive fuses clear

2640 Fire Off, source conductors did not interact with the target cable

Figure F-33 Intermediate-Scale Test #5 temperature profile

Temperature

Time (s)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

100

200

300

400

500

600

C Position - 3' 

C Position - Middle 

C Position - 7' 

1st Failure (1760s - 373C)
F-30

Figure F-34 Intermediate-Scale Test #5 intercable source voltage plots

Positive Sources

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VTU_2 

Int-Cab_VTU-S1+a 

Int-Cab_VTU-S1+b 

Int-Cab_VTU-S2+a 

Int-Cab_VTU-S2+b 

Negative Sources

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VTU_1 

Int-Cab_VTU-S1-a 

Int-Cab_VTU-S1-b 

Int-Cab_VTU-S2-a 

Int-Cab_VTU-S2-b 
F-31

Figure F-35 Intermediate-Scale Test #5 intercable target conductor voltage plots

Figure F-36 Intermediate-Scale Test #5 ground voltage monitoring circuit indication

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Int-Cab_VT7-T1 

Int-Cab_VT7-T2 

Int-Cab_VT7-T3 

Int-Cab_VT7-T4 

Int-Cab_VT7-T5 

Int-Cab_VT7-T6 

Int-Cab_VT7-T7 

Time(seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
F-32

F.2.7 Intermediate-Scale Test #6

Table F-21 Intermediate-Scale Test #6 parameters.

Cable Type for Intercable Configuration PE/PVC, 7c, 12AWG

Intercable Configuration Position Position D

Cable Fill Type Bundled Tray F

Battery Voltage (Pre-test) 123.56 Vdc

Battery Voltage (Post-test) 123.04 Vdc

Table F-22 Intermediate-Scale Test #6 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

336 Source 1 and Source 2, positive fuses clear

828 Source 1, negative fuse clears

2020 Source 2, negative fuse clears

2460 Fire Off, source conductors did not interact with the target cable

Figure F-37 Intermediate-Scale Test #6 temperature profile.

Temperature

Time (s)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

200

400

600

800

1000

D Position - 3' 

D Position - Middle 

D Position - 7' 

1st Failure (336s - 244C)
F-33

Figure F-38 Intermediate-Scale Test #6 intercable source voltage plots

Positive Sources

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VTU_2 

Int-Cab_VTU-S1+a 

Int-Cab_VTU-S1+b 

Int-Cab_VTU-S2+a 

Int-Cab_VTU-S2+b 

Negative Sources

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VTU_1 

Int-Cab_VTU-S1-a 

Int-Cab_VTU-S1-b 

Int-Cab_VTU-S2-a 

Int-Cab_VTU-S2-b 
F-34

Figure F-39 Intermediate-Scale Test #6 intercable target conductor voltage plots

Figure F-40 Intermediate-Scale Test #6 ground voltage monitoring circuit indication

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Int-Cab_VT7-T1 

Int-Cab_VT7-T2 

Int-Cab_VT7-T3 

Int-Cab_VT7-T4 

Int-Cab_VT7-T5 

Int-Cab_VT7-T6 

Int-Cab_VT7-T7 

Time(seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
F-35

F.2.8 Intermediate-Scale Test #7

Table F-23 Intermediate-Scale Test #7 parameters.

Cable Type for Intercable Configuration PE/PVC, 7c, 12AWG

Intercable Configuration Position Position A

Cable Fill Type Fill Tray F

Battery Voltage (Pre-test) 121.98 Vdc

Battery Voltage (Post-test) 122.83 Vdc

Table F-24 Intermediate-Scale Test #7 sequence of events

Time (seconds) Event/Observation

0 Fire Initiated

448 Source 1 and Source 2, positive fuses clear

449 Source 1, negative fuse clears

788 Source 2, negative fuse clears

2400 Fire Off, source conductors did not interact with the target cable

Figure F-41 Intermediate-Scale Test #7 temperature profile

Temperature

Time (s)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

200

400

600

800

1000

A Position - Middle 

1st Failure (448s - 700C)
F-36

Figure F-42 Intermediate-Scale Test #7 intercable source voltage plots

Positive Sources

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VTU_2 

Int-Cab_VTU-S1+a 

Int-Cab_VTU-S1+b 

Int-Cab_VTU-S2+a 

Int-Cab_VTU-S2+b 

Negative Sources

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VTU_1 

Int-Cab_VTU-S1-a 

Int-Cab_VTU-S1-b 

Int-Cab_VTU-S2-a 

Int-Cab_VTU-S2-b 
F-37

Figure F-43 Intermediate-Scale Test #7 intercable target conductor voltage plots

Figure F-44 Intermediate-Scale Test #7 ground voltage monitoring circuit indication

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-80

0

80

Int-Cab_VT7-T1 

Int-Cab_VT7-T2 

Int-Cab_VT7-T3 

Int-Cab_VT7-T4 

Int-Cab_VT7-T5 

Int-Cab_VT7-T6 

Int-Cab_VT7-T7 

Time(seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
F-38

F.2.9 Intermediate-Scale Test #8

Table F-25 Intermediate-Scale Test #8 parameters.

Cable Type for Intercable Configuration PE/PVC, 7c, 12AWG

Intercable Configuration Position Position B

Cable Fill Type Fill Tray G

Battery Voltage (Pre-test) 121.78 Vdc

Battery Voltage (Post-test) 122.56 Vdc

Table F-26 Intermediate-Scale Test #8 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1481-1736 The outer ring of conductors on the target cable 

have shorted to a negative source. Since the center 

conductor remains at a nominal 0V, it may be 

assumed that the center conductor has not yet 

interacted with the outer ring. (255s duration)

1637-1736 The inner conductor of the target cable begins to detect 

a negative voltage. (99s duration)

1736-2491 The target cable shorts together and is interacting with 

the negative source. The target cable records a -112V 

before clearing to a nominal zero. (755s duration)

2493 Source 1 and Source 2, negative fuses clear

2495 Fire Off, Source 1 and Source 2 positive fuses did not 

clear
F-39

Figure F-45 Intermediate-Scale Test #8 temperature profile

Temperature

Time (s)

0 500 1000 1500 2000 2500 3000

Temperature (C)

0

200

400

600

800

1000

B Position - Middle 

1st Failure (1481s - 450C)
F-40

Figure F-46 Intermediate-Scale Test #8 intercable source voltage plots

Positive Sources

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VTU_2 

Int-Cab_VTU-S1+a 

Int-Cab_VTU-S1+b 

Int-Cab_VTU-S2+a 

Int-Cab_VTU-S2+b 

Negative Sources

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VTU_1 

Int-Cab_VTU-S1-a 

Int-Cab_VTU-S1-b 

Int-Cab_VTU-S2-a 

Int-Cab_VTU-S2-b 
F-41

Figure F-47 Intermediate-Scale Test #8 intercable target conductor voltage plots

Figure F-48 Intermediate-Scale Test #8 ground voltage monitoring circuit indication

Time (s)

1400 1600 1800 2000 2200 2400 2600

Voltage (Vdc)

-150

0

150

Int-Cab_VT7-T1 

Int-Cab_VT7-T2 

Int-Cab_VT7-T3 

Int-Cab_VT7-T4 

Int-Cab_VT7-T5 

Int-Cab_VT7-T6 

Int-Cab_VT7-T7 

Time(seconds)

0 500 1000 1500 2000 2500 3000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
F-42

F.2.10 Intermediate-Scale Test #9

Table F-27 Intermediate-Scale Test #9 parameters.

Cable Type for Intercable Configuration EPR/CPE, 7c, 12AWG

Intercable Configuration Position Position C

Cable Fill Type Bundled Tray F

Battery Voltage (Pre-test) 122.15 Vdc

Battery Voltage (Post-test) 122.41 Vdc

Table F-28 Intermediate-Scale Test #9 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1602-2382 A positive source cable interacts with the target 

cable. The outer ring of the target cable has shorted 

together; however, the center conductor has not yet 

shorted to the outer most conductors. The outer 

conductors reach 9V while the inner conductor 

reaches 6V. (780s duration)

2382-2422 During this time range, the target cable fluctuates 

between positive and negative source interactions. (40s 

duration)

2422-2941 The target cable shorts to a negative source and 

receives approximately -20V. (519s duration)

2680-2941 The target cable's center conductor shorts to its outer 

ring. (261s duration)

2782 Source 2, negative fuse clear.

2941 Source 1, negative fuse clear.

3300 Fire Off, the positive fuses did not clear.
F-43

Figure F-49 Intermediate-Scale Test #9 temperature profile

Temperature

Time (s)

0 500 1000 1500 2000 2500 3000 3500

Temperature (C)

0

100

200

300

400

500

600

C Position - 3' 

C Position - Middle 

C Position - 7' 

1st Failure (1602s - 298C)
F-44

Figure F-50 Intermediate-Scale Test #9 intercable source voltage plots

Positive Sources

Time (s)

0 500 1000 1500 2000 2500 3000 3500

Voltage (Vdc)

-150

0

150

Ground_VTU_2 

Int-Cab_VTU-S1+a 

Int-Cab_VTU-S1+b 

Int-Cab_VTU-S2+a 

Int-Cab_VTU-S2+b 

Negative Sources

Time (s)

0 500 1000 1500 2000 2500 3000 3500

Voltage (Vdc)

-150

0

150

Ground_VTU_1 

Int-Cab_VTU-S1-a 

Int-Cab_VTU-S1-b 

Int-Cab_VTU-S2-a 

Int-Cab_VTU-S2-b 
F-45

Figure F-51 Intermediate-Scale Test #9 intercable target conductor voltage plots

Figure F-52 Intermediate-Scale Test #9 ground voltage monitoring circuit indication

Time (s)

1600 1800 2000 2200 2400 2600 2800 3000

Voltage (Vdc)

-80

0

80

Int-Cab_VT7-T1 

Int-Cab_VT7-T2 

Int-Cab_VT7-T3 

Int-Cab_VT7-T4 

Int-Cab_VT7-T5 

Int-Cab_VT7-T6 

Int-Cab_VT7-T7 

Time(seconds)

0 500 1000 1500 2000 2500 3000 3500

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
F-46

F.2.11 Intermediate-Scale Test #10

Table F-29 Intermediate-Scale Test #10 parameters.

Cable Type for Intercable Configuration EPR/CPE, 7c, 12AWG

Intercable Configuration Position Position A

Cable Fill Type Fill Tray E

Battery Voltage (Pre-test) 121.96 Vdc

Battery Voltage (Post-test) 122.21 Vdc

Table F-30 Intermediate-Scale Test #10 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

514-758 The outer ring of the target cable shorts to a negative 

source cable. The center conductor did not completely 

short to the outer ring during this time, as indicated by 

the different target cable voltages. During this period, the 

outer ring reached approximately -38V while the inner 

conductor reached -9V. (244s duration)

657 Source 1, positive fuse clear

758-823 The entire target cable shorted together and interacted with a 

positive source cable. The target nearly reaches 15V before 

dropping to a nominal 0V. (65s duration)

823 Source 2, positive fuse clear

2482 Source 1 and Source 2, negative fuses clear

3960 Fire Off
F-47

Figure F-53 Intermediate-Scale Test #10 temperature profile

The estimated cable temperature at the time of first failure was derived from an average of the 

thermocouple reading after it recovered function during the last five seconds of the shorting 

event (753 – 758 seconds).

Temperature

Time (s)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

 Position - Middle 

Anomalous Thermocople 1st Failure (514s - 642C)

Behavior (495 - 753 seconds)
F-48

Figure F-54 Intermediate-Scale Test #10 intercable source voltage plots

Positive Sources

Time (s)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VTU_2 

Int-Cab_VTU-S1+a 

Int-Cab_VTU-S1+b 

Int-Cab_VTU-S2+a 

Int-Cab_VTU-S2+b 

Negative Sources

Time (s)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VTU_1 

Int-Cab_VTU-S1-a 

Int-Cab_VTU-S1-b 

Int-Cab_VTU-S2-a 

Int-Cab_VTU-S2-b 
F-49

Figure F-55 Intermediate-Scale Test #10 intercable target conductor voltage plots

Figure F-56 Intermediate-Scale Test #10 ground voltage monitoring circuit indication

Time (s)

400 500 600 700 800 900

Voltage (Vdc)

-80

0

80

Int-Cab_VT7-T1 

Int-Cab_VT7-T2 

Int-Cab_VT7-T3 

Int-Cab_VT7-T4 

Int-Cab_VT7-T5 

Int-Cab_VT7-T6 

Int-Cab_VT7-T7 

Time(seconds)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
F-50

F.2.12 Intermediate-Scale Test #11

Table F-31 Intermediate-Scale Test #11 parameters

Cable Type for Intercable Configuration EPR/CPE, 7c, 12AWG

Intercable Configuration Position Position C

Cable Fill Type Bundled Tray H

Battery Voltage (Pre-test) 122.93 Vdc

Battery Voltage (Post-test) 123.14 Vdc

Table F-32 Intermediate-Scale Test #11 sequence of events

Time (seconds) Event/Observation

0 Fire Initiated

3184-4460 The outer ring of the target cable shorts to a 

negative source cable; however, the inner conductor 

does not yet short to the outer ring. The voltage 

drops to approximately -37V. The inner conductor 

gets to approximately -35V. (1276s duration)

4460-4500 The inner conductor shorts to the outer ring of target 

conductors. At the conclusion of the test, the target 

cable reaches -37V. (40s duration)

4500 Fire Off, positive and negative fuses for both sources did 

not clear
F-51

Figure F-57 Intermediate-Scale Test #11 temperature profile

Temperature

Time (s)

0 1000 2000 3000 4000 5000

Temperature (C)

0

100

200

300

400

500

600

C Position - 3' 

C Position - Middle 

C Position - 7' 

1st Failure (3184s - 462C)
F-52

Figure F-58 Intermediate-Scale Test #11 intercable source voltage plots

Positive Sources

Time (s)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VTU_2 

Int-Cab_VTU-S1+a 

Int-Cab_VTU-S1+b 

Int-Cab_VTU-S2+a 

Int-Cab_VTU-S2+b 

Negative Sources

Time (s)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VTU_1 

Int-Cab_VTU-S1-a 

Int-Cab_VTU-S1-b 

Int-Cab_VTU-S2-a 

Int-Cab_VTU-S2-b 
F-53

Figure F-59 Intermediate-Scale Test #11 intercable target conductor voltage plots

Figure F-60 Intermediate-Scale Test #11 ground voltage monitoring circuit indication

Time (s)

3000 3200 3400 3600 3800 4000 4200 4400 4600

Voltage (Vdc)

-80

0

80

Int-Cab_VT7-T1 

Int-Cab_VT7-T2 

Int-Cab_VT7-T3 

Int-Cab_VT7-T4 

Int-Cab_VT7-T5 

Int-Cab_VT7-T6 

Int-Cab_VT7-T7 

Time(seconds)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 
F-54

F.2.13 Intermediate-Scale Test #12

Table F-33 Intermediate-Scale Test #12 parameters.

Cable Type for Intercable Configuration EPR/CPE, 7c, 12AWG

Intercable Configuration Position Position A

Cable Fill Type Fill Tray G

Battery Voltage (Pre-test) 122.31 Vdc

Battery Voltage (Post-test) 122.86 Vdc

Table F-34 Intermediate-Scale Test #12 sequence of events.

Time (seconds) Event/Observation

0 Fire Initiated

1222-1225 Positive source starting to short to target cable; 

approximately 1.5V during this range. (3s duration)

1223 Source 1, negative fuse clear

1227-1398 Negative source starting to short to target cable; 

between 1 and 2.5V during this range. (171s duration)

1703 Source 1 and Source 2, Positive fuses clear

1703 Source 2, negative fuse clear

3894 Fire Off

Figure F-61 Intermediate-Scale Test #12 temperature profile

Temperature

Time (s)

0 1000 2000 3000 4000 5000

Temperature (C)

0

200

400

600

800

1000

A Position - Middle 

1st Failure (1222s - 467C)
F-55

Figure F-62 Intermediate-Scale Test #12 intercable source voltage plots

Positive Sources

Time (s)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VTU_2 

Int-Cab_VTU-S1+a 

Int-Cab_VTU-S1+b 

Int-Cab_VTU-S2+a 

Int-Cab_VTU-S2+b 

Negative Sources

Time (s)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VTU_1 

Int-Cab_VTU-S1-a 

Int-Cab_VTU-S1-b 

Int-Cab_VTU-S2-a 

Int-Cab_VTU-S2-b 
F-56

Figure F-63 Intermediate-Scale Test #12 intercable target conductor voltage plots

Figure F-64 Intermediate-Scale Test #12 ground voltage monitoring circuit indication

Time (s)

1100 1200 1300 1400 1500 1600 1700

Voltage (Vdc)

-80

0

80

Int-Cab_VT7-T1 

Int-Cab_VT7-T2 

Int-Cab_VT7-T3 

Int-Cab_VT7-T4 

Int-Cab_VT7-T5 

Int-Cab_VT7-T6 

Int-Cab_VT7-T7 

Time(seconds)

0 1000 2000 3000 4000 5000

Voltage (Vdc)

-150

0

150

Ground_VT7_1 

Ground_VTU_1 

Ground_VTU_2 

Appendix G. AC Surrogate Circuit Diagnostic Units
G-2

G.1 Penlight Preliminary Test 1

The purpose of this section is to provide the circuit analysis for each test in the small- and 

intermediate-scale experiments. Every test has a nominal summary of the specific sequence of 

events and data supporting the sequential events.

Table G-1 Penlight Test Preliminary 1, summary of circuit faulting behavior for all 

tested circuits.

Summary of Circuit Faulting Behavior for all Tested Circuits

Circuit 1 The XLPE/CSPE cables were heated at a Penlight setting of 470 °C. 

Initial voltage leakages were detected on V3 as early as 436 s, when it 

steadily increased from 1 – 19 V over the span of 88 s. Other 

conductors, namely the Passive Target (V4), were also experiencing 

voltage increase. From 514 – 550 s, the voltage on V4 increased from 

1 – 10 V. During this time span, the voltage and current on Active 

Target 6 started to increase steadily until spurious actuation 

approximately 13 s later. Active Target 6 spuriously actuated at 550 s 

into the test and continued for 9 s. During this time span, Active Target 

hot shorted to a source conductor. Once the spurious actuation cleared 

on Active Target 6, Active Target 5 actuated and continued to do so 

until the fuse cleared 32 s later at a test time of 591 s.

Circuit 2 The XLPE/CSPE cables were heated at a Penlight setting of 470 °C. 

Initial voltage leakages were detected on V3 as early as 427 s, when it 

steadily increased from 1 – 20 V over the span of 103 seconds. Its 

voltage then fluctuated between 7 and 32 V. A spurious actuation on 

Active Target 6 occurred approximately 563 s into the test. The 

component operation persisted for 40 s. During this time, Active Target 

5 experienced a hot short that continued until the spurious actuation on 

Target 6 cleared, upon which Target 5 actuated. This actuation held for 

1 s before the fuse cleared at 604 s into the test.

Circuit 3 Circuit 3 was not used in this test.

Circuit 4 Circuit 4 was not used in this test.
G-3

G.1.1 SCDU 1

Table G-2 Penlight Test Preliminary 1, SCDU 1, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

436-524 Voltage 

increase on V3

During this time period, the voltage increased on V3 

from 1 – 19 V.

514-550 Voltage 

increase on V4

The voltage increased from 1 – 10 V during this range.

524-535 Voltage 

decrease on V3

The voltage on V3 decreases to approximately 9 V.

533 Voltage 

increase on 

Active Target 6

The voltage steadily increases on Target 6 until a 

subsequent spurious actuation.

535-560 Voltage on V3 

increases

During this range, the voltage on V3 increases from 9 –

100 V.

537-550 Voltage 

leakage into 

Active Target 6

Voltage increases steadily on Active Target 6 until it hot 

shorts 13 s later.

539 Current 

increase on 

Active Target 6

The current steadily increases on Target 6 until a 

subsequent spurious actuation.

550-559 Spurious 

actuation on 

Active Target 6

A spurious actuation on Active Target 6 occurs initially 

at 100 V and 0.32 A. The actuation persists for 9 

seconds before clearing.

550-559 Hot short on 

Active Target 5

The voltage on Active Target 5 increases to a nominal 

100 V.

559-591 Spurious 

actuation on 

Active Target 5

Upon the clearing of the spurious actuation on Active 

Target 6, Active Target 5 actuates and continuously 

operates until the fuse clears 32 s later. The initial 

voltage and current were 105V and 0.226 A, 

respectively.

591 Fuse clear on 

SCDU 1

The fuse clears on SCDU 1 and the conductors decline 

to a nominal 0 V.
G-4

Summary Observations

The XLPE/CSPE cables were heated at a Penlight setting of 470 °C. Initial voltage 

leakages were detected on V3 as early as 436 s when it steadily increased from 1 – 19 V 

over the span of 88 s. Other conductors, namely the Passive Target (V4), were also 

experiencing voltage increase. From 514 – 550 s, the voltage on V4 increased from 1 – 10

V. During this time span, the voltage and current on Active Target 6 started to increase 

steadily until spurious actuation approximately 13 s later. Active Target 6 spuriously 

actuated at 550 s into the test and continued for 9 s. During this time span, Active Target 

hot shorted to a source conductor. Once the spurious actuation cleared on Active Target 6, 

Active Target 5 actuated and continued to do so until the fuse cleared 32 s later at a test 

time of 591 s.

Figure G-1 Penlight Test Preliminary 1, SCDU 1, source and target voltage response

Time (s)

0 200 400 600 800 1000 1200

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-5

Figure G-2 Penlight Test Preliminary 1, SCDU 1, source and target voltage response, 

limited time span

Figure G-3 Penlight Test Preliminary 1, SCDU 1, overlay of key voltages and key 

currents

Time (s)

500 520 540 560 580 600 620 640

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 
G-6

Figure G-4 Penlight Test Preliminary 1, SCDU 1, overlay of key voltages and key 

currents, limited time span

Figure G-5 Penlight Test Preliminary 1, SCDU 1, all measured voltages

Time (s)

500 520 540 560 580 600 620 640

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 

Time (s)

0 200 400 600 800 1000 1200

Voltage (Vc)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 
G-7

Figure G-6 Penlight Test Preliminary 1, SCDU 1, all measured voltages, limited time span

Figure G-7 Penlight Test Preliminary 1, SCDU 1, all measured currents

Time (s)

500 520 540 560 580 600 620 640

Voltage (Vc)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0

1

2

3

4

5

6

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-8

Figure G-8 Penlight Test Preliminary 1, SCDU 1, all measured currents, limited time span

Time (s)

500 520 540 560 580 600 620 640

Current (A)

0

1

2

3

4

5

6

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-9

G.1.2 SCDU 2

Table G-3 Penlight Test Preliminary 1, SCDU 2, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

427-530 Voltage increase 

on V3

The voltage on V3 increases from 1 – 20 V during 

this time span.

530-563 Voltage on V3 is 

fluctuating

The voltage on V3 fluctuates from 7 – 32 V.

563-603 Spurious 

actuation on 

Active Target 6

A spurious actuation occurs on Active Target 6 at 

108 V and 0.171 A. This persisted for 40 s before 

clearing.

563-598 Hot short on 

Active Target 5

The voltage on Active Target 5 tops 100 V during 

this time range. The hot short subsequently clears 

after 35 seconds; however, it occurs again 2 s later.

600-603 Hot short on 

Active Target 5

The voltage increases again to approximately 100 V.

603-604 Spurious 

actuation on 

Active Target 5

A spurious actuation occurs on Active Target 5 at 88

V and 0.25 A. This persisted for approximately 1 s 

before clearing.

604 Fuse clear The fuse on SCDU 2 clears.

Summary Observations

The XLPE/CSPE cables were heated at a Penlight setting of 470 °C. Initial voltage 

leakages were detected on V3 as early as 427 s when it steadily increased from 1 – 20 V 

over the span of 103 s. Its voltage then fluctuated between 7 and 32 V. A spurious 

actuation on Active Target 6 occurred approximately 563 s into the test. The component 

operation persisted for 40 s. During this time, Active Target 5 experienced a hot short that 

continued until the spurious actuation on Target 6 cleared, upon which Target 5 actuated. 

This actuation held for 1 s before the fuse cleared.
G-10

Figure G-9 Penlight Test Preliminary 1, SCDU 2, source and target voltage response

Figure G-10 Penlight Test Preliminary 1, SCDU 2, source and target voltage response, 

limited time span

Time (s)

0 200 400 600 800 1000 1200

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

400 450 500 550 600 650

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-11

Figure G-11 Penlight Test Preliminary 1, SCDU 2, overlay of key voltages and key 

currents

Figure G-12 Penlight Test Preliminary 1, SCDU 2, overlay of key voltages and key 

currents, limited time span

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 

Time (s)

400 450 500 550 600 650

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 
G-12

Figure G-13 Penlight Test Preliminary 1, SCDU 2, all measured voltages

Figure G-14 Penlight Test Preliminary 1, SCDU 2, all measured voltages, limited time 

span

Time (s)

0 200 400 600 800 1000 1200

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 

Time (s)

400 450 500 550 600 650

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 
G-13

Figure G-15 Penlight Test Preliminary 1, SCDU 2, all measured currents

Figure G-16 Penlight Test Preliminary 1, SCDU 2, all measured currents, limited time 

span

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0

1

2

3

4

5

6

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 

Time (s)

400 450 500 550 600 650

Current (A)

0

1

2

3

4

5

6

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-14

G.2 Penlight Preliminary Test 2

Table G-4 Penlight Test Preliminary 2, summary of circuit faulting behavior for all 

tested circuits.

Summary of Circuit Faulting Behavior for all Tested Circuits

Circuit 1 Initial voltage leakage was detected on Passive Target 4 at 736 s into 

the test. The voltage on Passive Target 4 would eventually get to 12

V at 1186 s. At 1123 s, the voltage on Active Target 6 began 

increasing from 1 V until the spurious actuation at 1186 s. The 

activation voltage and current was 86 V and 0.392 A, respectively. 

The fuse cleared at approximately 1250 s into the test.

Circuit 2 Initial voltage increase was observed on the Passive Target 4 

conductor at 740 s into the test and continued until the spurious 

actuation of Active Target 6. The spurious actuation occurred at 1226

s into the test. While operating, a hot short occurred on Active Target 

5 bring its nominal voltage to 80 V briefly before increasing to 125 V. 

This persisted until the fuse cleared. At 1254 s into the test, a hot 

short was also detected on the Passive Target 4 conductor. This 

short continued for 11 s before clearing. The equipment operation 

continued for 54 s until the fuse cleared. 

Circuit 3 Circuit 3 was not used in this test.

Circuit 4 Circuit 4 was not used in this test.

G.2.1 SCDU 1

Table G-5 Penlight Test Preliminary 2, SCDU 1, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

736-1186 Voltage increase 

detected on 

Passive Target 4

The voltage increases from 1 – 12 V during this time 

span.

1123-1186 Voltage increase 

detected on 

Active Target 6

During this data range, the voltage on Active Target 

6 increases from approximately 1 V to actuation at 

86 V and 0.392 A.

1186-1250 Spurious 

actuation on 

Target 6

Active Target experiences a spurious actuation at 

86 V and 0.392 A. The duration of the operation 

was 64 s before a subsequent fuse clear.

1250 Fuse clear The fuse on SCDU 1 clears.

Summary Observations

Initial voltage leakage was detected on Passive Target 4 at 736 s into the test. The 

voltage on Passive Target 4 would eventually get to 12 V at 1186 s. At 1123 s, the 
G-15

voltage on Active Target 6 began increasing from 1 V until the spurious actuation at 

1186 s. The activation voltage and current was 86 V and 0.392 A, respectively. The 

fuse cleared at approximately 1250 s into the test.

Figure G-17 Penlight Test Preliminary 2, SCDU 1, source and target voltage response

Time (s)

0 200 400 600 800 1000 1200 1400

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-16

Figure G-18 Penlight Test Preliminary 2, SCDU 1, source and target voltage response, 

limited time span

Figure G-19 Penlight Test Preliminary 2, SCDU 1, overlay of key voltages and key 

currents

Time (s)

600 800 1000 1200 1400

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 200 400 600 800 1000 1200 1400

Current (A)

0

1

2

3

4 Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 
G-17

Figure G-20 Penlight Test Preliminary 2, SCDU 1, overlay of key voltages and key 

currents, limited time span

Figure G-21 Penlight Test Preliminary 2, SCDU 1, all measured voltages

Time (s)

600 800 1000 1200 1400

Current (A)

0

1

2

3

4 Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 

Time (s)

0 200 400 600 800 1000 1200 1400

Voltage (Vc)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 
G-18

Figure G-22 Penlight Test Preliminary 2, SCDU 1, all measured voltages, limited time 

span

Figure G-23 Penlight Test Preliminary 2, SCDU 1, all measured currents

Time (s)

600 800 1000 1200 1400

Voltage (Vc)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 

Time (s)

0 200 400 600 800 1000 1200 1400

Current (A)

0

1

2

3

4

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-19

Figure G-24 Penlight Test Preliminary 2, SCDU 1, all measured currents, limited time 

span

Time (s)

600 800 1000 1200 1400

Current (A)

0

1

2

3

4

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-20

G.2.2 SCDU 2

Table G-6 Penlight Test Preliminary 2, SCDU 2, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

740-1226 Voltage increase 

on V4

The voltage on V4 increases from 1 – 10 V 

during this time range.

1226-1280 Spurious 

actuation on 

Active Target 6

Active Target 6 actuates with a voltage of 112 V 

and current of 0.256 A.

1226-1280 Hot short on 

Active Target 5

Active Target 5 experiences a hot short that 

increases the voltage to a nominal 80 V before 

settling in at a nominal 125 V.

1254-1265 Hot short on 

Passive Target 4

The Passive Target experiences a hot short that 

drives its voltage to 125 V.

1280 Fuse clear The fuse clears on SCDU 2.

Summary Observations

Initial voltage increase was observed on the Passive Target 4 conductor at 740 s into 

the test and continued until the spurious actuation of Active Target 6. The spurious 

actuation occurred at 1226 s into the test. While operating, a hot short occurred on 

Active Target 5 bring its nominal voltage to 80 V briefly before increasing to 125 V. 

This persisted until the fuse cleared. At 1254 s into the test, a hot short was also 

detected on the Passive Target 4 conductor. This short continued for 11 s before 

clearing. The equipment operation continued for 54 s until the fuse cleared. 
G-21

Figure G-25 Penlight Test Preliminary 2, SCDU 2, source and target voltage response

Figure G-26 Penlight Test Preliminary 2, SCDU 2, source and target voltage response, 

limited time span

Time (s)

0 200 400 600 800 1000 1200 1400

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

800 900 1000 1100 1200 1300 1400

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-22

Figure G-27 Penlight Test Preliminary 2, SCDU 2, overlay of key voltages and key 

currents

Figure G-28 Penlight Test Preliminary 2, SCDU 2, overlay of key voltages and key 

currents, limited time span

Time (s)

0 200 400 600 800 1000 1200 1400

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 

Time (s)

1000 1100 1200 1300 1400 1500

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 
G-23

Figure G-29 Penlight Test Preliminary 2, SCDU 2, all measured voltages

Figure G-30 Penlight Test Preliminary 2, SCDU 2, all measured voltages, limited time 

span

Time (s)

0 200 400 600 800 1000 1200 1400

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 

Time (s)

700 800 900 1000 1100 1200 1300

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 
G-24

Figure G-31 Penlight Test Preliminary 2, SCDU 2, all measured currents

Figure G-32 Penlight Test Preliminary 2, SCDU 2, all measured currents, limited time 

span

Time (s)

0 200 400 600 800 1000 1200 1400

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 

Time (s)

800 1000 1200 1400

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-25

G.3 Penlight Preliminary Test 3

Table G-7 Penlight Test Preliminary 3, summary of circuit faulting behavior for all 

tested circuits.

Summary of Circuit Faulting Behavior for all Tested Circuits

Circuit 1 A hot short on V3 was detected at 863 s and continued until the fuse 

cleared 23 s later.

Circuit 2 The fuse on SCDU 2 clears. No spurious actuations or hot shorts 

were detected.

Circuit 3 Circuit 3 was not used in this test.

Circuit 4 Circuit 4 was not used in this test.

G.3.1 SCDU 1

Table G-8 Penlight Test Preliminary 3, SCDU 1, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

863-886 Hot short 

detected on V3

At this time, the voltage increases from a nominal 0

V to 127 V and continues until the fuse clears 23 s 

later.

886 Fuse clear The fuse on SCDU 1 clears.

Summary Observations

A hot short on V3 was detected at 863 s and continued until the fuse cleared 23 s 

later.
G-26

Figure G-33 Penlight Test Preliminary 3, SCDU 1, source and target voltage response

Figure G-34 Penlight Test Preliminary 3, SCDU 1, overlay of key voltages and key 

currents

Time (s)

0 200 400 600 800 1000 1200

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

800 900 1000 1100 1200

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-27

Figure G-35 Penlight Test Preliminary 3, SCDU 1, all measured voltages

Figure G-36 Penlight Test Preliminary 3, SCDU 1, all measured voltages, limited time 

span

Time (s)

0 200 400 600 800 1000 1200

Voltage (Vc)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 

Time (s)

850 860 870 880 890 900

Voltage (Vc)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 
G-28

Figure G-37 Penlight Test Preliminary 3, SCDU 1, all measured currents

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-29

G.3.2 SCDU 2

Table G-9 Penlight Test Preliminary 3, SCDU 2, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

912 Fuse clear The fuse on SCDU 2 clears. No spurious 

actuations or hot shorts were detected.

Summary Observations

The fuse on SCDU 2 clears. No spurious actuations or hot shorts were detected.

Figure G-38 Penlight Test Preliminary 3, SCDU 2, source and target voltage response

Time (s)

0 200 400 600 800 1000 1200

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-30

Figure G-39 Penlight Test Preliminary 3, SCDU 2, overlay of key voltages and key 

currents

Figure G-40 Penlight Test Preliminary 3, SCDU 2, all measured voltages

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0

1

2

3

4 Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 

Time (s)

0 200 400 600 800 1000 1200

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 
G-31

Figure G-41 Penlight Test Preliminary 3, SCDU 2, all measured currents

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-32

G.4 Penlight Preliminary Test 4

Table G-10 Penlight Test Preliminary 4, summary of circuit faulting behavior for all 

tested circuits.

Summary of Circuit Faulting Behavior for all Tested Circuits

Circuit 1 Both actuators experience hot shorts. Initially, target T6 actuated and 

T5 was locked out. The hot short on T6 then dropped out, allowing 

T5 to actuate. The hot short to T6 later re-formed, but T6 was locked 

out by the continuing spurious actuation on T5. Overall, the hot 

short/spurious actuation signals persisted for 292 s.

Circuit 2 This circuit experienced a spurious actuation to T5 that persisted for 

approximately 27 seconds before a fuse-blow occurred.

Circuit 3 Circuit 3 was not used in this test.

Circuit 4 Circuit 4 was not used in this test.

G.4.1 SCDU 1

Table G-11 Penlight Test Preliminary 4, SCDU 1, summary of observed faulting 

behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

878 Spurious 

actuation T6, 

hot short on 

T5

Hot short impact both T5 and T6, but T6 locks in first 

which engages electrical interlock on T5. (T5 sees 

voltage but no current flow. T6 sees both voltage and 

current flow)

918 T6 drops out 

allowing T5 to 

lock in

With drop-out of HS to T6, T5 locks in and T6 is now 

locked out by electrical interlock

984 HS to T6 - no 

actuation

T6 sees return of hot short but remains locked out by 

T5.

1170 Fuse blow

Summary Observations

Both actuators experience hot shorts. Initially, target T6 actuated and T5 was locked 

out. The hot short on T6 then dropped out, allowing T5 to actuate. The hot short to 

T6 later re-formed, but T6 was locked out by the continuing spurious actuation on T5. 

Overall, the hot short/spurious actuation signals persisted for 292 s.
G-33

Figure G-42 Penlight Test Preliminary 4, SCDU 2, source and target voltage response

Figure G-43 Penlight Test Preliminary 4, SCDU 1, source and target voltage response, 

limited time span

Time (s)

0 200 400 600 800 1000 1200

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

800 900 1000 1100 1200

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-34

Figure G-44 Penlight Test Preliminary 4, SCDU 1, overlay of key voltages and key 

currents

Figure G-45 Penlight Test Preliminary 4, SCDU 1, overlay of key voltages and key 

currents, limited time span

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 

Time (s)

800 900 1000 1100 1200

Current (A)

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 
G-35

Figure G-46 Penlight Test Preliminary 4, SCDU 1, all measured voltages

Figure G-47 Penlight Test Preliminary 4, SCDU 1, all measured voltages, limited time 

span

Time (s)

0 200 400 600 800 1000 1200

Voltage (Vc)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 

Time (s)

800 900 1000 1100 1200

Voltage (Vc)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 
G-36

Figure G-48 Penlight Test Preliminary 4, SCDU 1, all measured currents

Figure G-49 Penlight Test Preliminary 4, SCDU 1, all measured currents, limited time 

span

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 

Time (s)

800 900 1000 1100 1200

Current (A)

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-37

G.4.2 SCDU 2

Table G-12 Penlight Test Preliminary 4, SCDU 2, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

845 Spurious 

actuation on 

Target 5

872 Short to ground The circuit shorted to ground as the fuse tripped. 

No components were activated.

Summary Observations

This circuit experienced a spurious actuation to T5 that persisted for approximately 27 

seconds before a fuse-blow occurred.

Figure G-50 Penlight Test Preliminary 4, SCDU 2, source and target voltage response

Time (s)

0 200 400 600 800 1000 1200

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-38

Figure G-51 Penlight Test Preliminary 4, SCDU 2, source and target voltage response, 

limited time span

Figure G-52 Penlight Test Preliminary 4, SCDU 2, overlay of key voltages and key 

currents

Time (s)

800 820 840 860 880 900

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 
G-39

Figure G-53 Penlight Test Preliminary 4, SCDU 2, overlay of key voltages and key 

currents, limited time span

Figure G-54 Penlight Test Preliminary 4, SCDU 2, all measured voltages

Time (s)

800 820 840 860 880 900

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 

Time (s)

0 200 400 600 800 1000 1200

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 
G-40

Figure G-55 Penlight Test Preliminary 4, SCDU 2, all measured voltages, limited time 

span

Figure G-56 Penlight Test Preliminary 4, SCDU 2, all measured currents

Time (s)

800 820 840 860 880 900

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-41

Figure G-57 Penlight Test Preliminary 4, SCDU 2, all measured currents, limited time 

span

Time (s)

800 820 840 860 880 900

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-42

G.5 Penlight Test 13, Qualification

Table G-13 Penlight Test 13, qualification, summary of circuit faulting behavior for all 

tested circuits.

Summary of Circuit Faulting Behavior for all Tested Circuits

Circuit 1 Target 6 was actuated approximately 56 minutes into the test. The 

conductor remained energized for the duration of the experiment, 

approximately 24 minutes.

Circuit 2 Circuit 2 was not used in this test.

Circuit 3 Circuit 3 was not used in this test.

Circuit 4 Circuit 4 was not used in this test.

G.5.1 SCDU 1

Table G-14 Penlight Test 13, qualification, SCDU 1, summary of observed faulting 

behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

2275 Slight 

increase in 

voltage 

noticed

A very slight increase in voltage (approximately 2 V) 

was detected at this time and persisted for about 10 

minutes. This correlated with the increase in 

temperature from 300 °C to 325 °C.

3360 Target 

conductor 6 

was actuated

Target 6 was actuated and maintained actuation for 

the duration of the experiment, which was about 24 

minutes. The voltage read was approximately 125 V.

Summary Observations

The Penlight temperature was set to a nominal 300 °C for approximately 35 minutes. 

About 20 minutes into the test and at around 200 °C on the cable thermocouples, 

popping of the cable jacket was heard and liquid was later seen bubbling out of the 

temperature monitoring cable. After 35 minutes, Penlight was increased to 325 °C. 

Blistering and swelling of the cable jacket was noticed at cable temperatures around 

250 °C. After 12 minutes at a Penlight temperature of 325 °C, it was increased to 

350 °C. About 9 minutes later, Target 6 was actuated. No flame occurred throughout 

the test.
G-43

Figure G-58 Penlight Test 13, qualification, SCDU 1, source and target voltage 

response to temperature conditions

Figure G-59 Penlight Test 13, qualification, SCDU 1, source and target voltage 

response

Time (s)

0 1000 2000 3000 4000 5000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

50

100

150

200

250

300

350

400

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Top TC 

Side TC 

Exposure Temperature 

Time (s)

0 1000 2000 3000 4000 5000 6000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-44

Figure G-60 Penlight Test 13, qualification, SCDU 1, overlay of key voltages and key 

currents

Figure G-61 Penlight Test 13, qualification, SCDU 1, all measured voltages

Time (s)

0 1000 2000 3000 4000 5000 6000

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 

Time (s)

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 
G-45

Figure G-62 Penlight Test 13, qualification, SCDU 1, all measured currents

Time (s)

0 1000 2000 3000 4000 5000 6000

Current (A)

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-46

G.6 Penlight Test 13

Table G-15 Penlight Test 13, summary of circuit faulting behavior for all tested circuits.

Summary of Circuit Faulting Behavior for all Tested Circuits

Circuit 1 Circuit 1 experienced slight voltage increases on Target 5 and 6 about 

19 minutes into the experiment. These stabilized to approximately 1.5

V until cable ignition. Target 6 actuated at approximately 4575 s and 

cleared the fuse moments later.

Circuit 2 Circuit 2 experienced voltage increased on Target 5 and 6 about 20 

minutes into the test. The maximum voltages reached during this 

increased activity were approximately 4 V and 12 V on Target 5 and 6, 

respectively. This activity leveled off after about 25 minutes to about 3

V on Target 5 and 8 V on Target 6. The stabilized voltages began to 

increase once the cables ignited at about 73 minutes into the test. 

Target 6 did not actuate; however, it experienced 85 V before the fuse 

cleared.

Circuit 3 Circuit 3 was not used in this test.

Circuit 4 Circuit 4 was not used in this test.

G.6.1 SCDU 1

Table G-16 Penlight Test 13, SCDU 1, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

1150 Slight 

increase in 

voltage to 

Target 5

At this approximate time, the cable temperature 

reached about 280 °C. The voltage on Target 5 

increased to just over 2.5 V and remained around 2 V 

until the circuit failure

4575 Target 6 

actuated

Ignition occurred approximately 150 s before Target 6 

actuated. The duration was rather brief since the 

fuse tripped just after actuation.

Summary Observations

The Penlight temperature was set to a nominal 350 °C for approximately 32 minutes. 

Smoke was observed about 10 minutes into the test, and at around 200 °C on the 

cable thermocouples popping of the cable jacket was heard and liquid was later seen 

bubbling out of the temperature monitoring cables. Slight voltage increases were 

detected at approximately 1150 s and 280 °C. After 32 minutes, Penlight was 

increased to 375 °C. After 13 minutes, Penlight was increased to 400 °C. About 10 

minutes later, Penlight was again increased to 425 °C. Ignition occurred about a 

minute and a half later. Target 6 actuated two and a half minutes after the final 

temperature increase and lasted only moments before tripping the fuse.
G-47

Figure G-63 Penlight Test 13, SCDU 1, source and target voltage response to 

temperature conditions

Figure G-64 Penlight Test 13, SCDU 1, source and target voltage response

Time (s)

0 1000 2000 3000 4000 5000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

200

400

600

800

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Top TC for 5c

Side TC for 5c

Exposure Temperature 

Time (s)

0 1000 2000 3000 4000 5000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-48

Figure G-65 Penlight Test 13, SCDU 1, overlay of key voltages and key currents

Figure G-66 Penlight Test 13, SCDU 1, all measured voltages

Time (s)

0 1000 2000 3000 4000 5000

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 

Time (s)

0 1000 2000 3000 4000 5000

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 
G-49

Figure G-67 Penlight Test 13, SCDU 1, all measured currents

Time (s)

0 1000 2000 3000 4000 5000

Current (A)

0

1

2

3

4

5

6

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-50

G.6.2 SCDU 2

Table G-17 Penlight Test 13, SCDU 2, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

1260 Increasing 

voltage occurs on 

Target 5 and 

Target 6

Increased voltages were being detected on 

both Target 5 and Target 6 when the cable 

temperatures were approximately 260 °C. 

Target 5 hovered at 4 V while Target 6 reached 

just beyond 12 V.

2790 Voltages stabilize 

on both Target 5 

and Target 6

The voltage increase on Target 5 stabilized at 

around 2.5 V until 4450 s. Target 6 stabilized at 

approximately 5.7 V until roughly the same time 

as Target 5.

4450 After stabilizing, 

both Target 5 and 

6 experienced an 

increase in 

voltages

At this approximate time, the cables within 

Penlight ignited. Voltages steadily increased on 

both Target 5 and 6 until the ultimate failure at 

4590 s. Target 5 edged to around 3 V while 

Target 6 reached 8 V.

4590 Target 6 

experienced a 

voltage increase 

and subsequently 

tripped the 3-A 

fuse.

Upon ignition, the cable experienced 

degradation, which ultimately leads to shorting 

behavior that tripped the fuse. Though Target 6 

did not actuate, there was an increase in 

voltage to approximately 85 V.

Summary Observations

The Penlight temperature was set to a nominal 350 °C for approximately 32 minutes. 

Smoke was observed about 10 minutes into the test, and at around 200 °C on the 

cable thermocouples popping of the cable jacket was heard and liquid was later seen 

bubbling out of the temperature monitoring cables. Just over 20 minutes into the 

test, voltages increased on both Target 5 and Target 6 to about 4 V and 12 V, 

respectively. These voltages stabilized after about 25 minutes. Penlight was 

increased to 375 °C after 32 minutes. Waiting 13 minutes, Penlight was increased to 

400 °C. About 10 minutes later, Penlight was again increased to 425 °C. Ignition 

occurred about a minute and a half later and voltages began to increase once again. 

Both Target 5 and 6 did not actuate before the fuse was tripped; however, voltages 

on Target 6 increased to 85 V.
G-51

Figure G-68 Penlight Test 13, SCDU 2, source and target voltage response to 

temperature conditions

Figure G-69 Penlight Test 13, SCDU 2, source and target voltage response

Time (s)

0 1000 2000 3000 4000 5000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

600

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Top TC for 10c

Side TC for 10c

Exposure Temperature 

Time (s)

0 1000 2000 3000 4000 5000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-52

Figure G-70 Penlight Test 13, SCDU 2, overlay of key voltages and key currents

Figure G-71 Penlight Test 13, SCDU 2, all measured voltages

Time (s)

0 1000 2000 3000 4000 5000

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 

Time (s)

0 1000 2000 3000 4000 5000

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 
G-53

Figure G-72 Penlight Test 13, SCDU 2, all measured currents

Time (s)

0 1000 2000 3000 4000 5000

Current (A)

0

1

2

3

4

5

6

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-54

G.7 Penlight Test 14

Table G-18 Penlight Test 14, summary of circuit faulting behavior for all tested circuits.

Summary of Circuit Faulting Behavior for all Tested Circuits

Circuit 1 Circuit 1 was the 5c Kerite®cable. Penlight was originally set to 

450 °C and ignition occurred approximately 10 minutes into the test. 

At this time, the temperature on the 5c and 10c Kerite® was noted at 

294 °C and 229 °C, respectively. About 5 1⁄2 minutes later, Circuit 1 

failed.

Circuit 2 Circuit 2 was the 10c Kerite®cable. Penlight was originally set to 

450 °C and ignition occurred approximately 10 minutes into the test. 

At this time, the temperature on the 5c and 10c Kerite® was noted at 

294 °C and 229 °C, respectively. As the cable temperature 

increased, voltage increases were noticed. About 51⁄2 minutes later, 

Circuit 2 failed.

Circuit 3 Circuit 3 was not used in this test.

Circuit 4 Circuit 4 was not used in this test.

G.7.1 SCDU 1

Table G-19 Penlight Test 14, SCDU 1, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

964 The circuit 

shorted to 

ground

At this time, the voltage shorted out. No 

components were activated.

Summary Observations

Penlight was originally set to 450 °C and ignition occurred approximately 10 minutes 

into the test. At this time, the temperature on the 5c and 10c Kerite® was noted at 

294 °C and 229 °C, respectively. About 51⁄2 minutes later, Circuit 1 failed.
G-55

Figure G-73 Penlight Test 14, SCDU 1, source and target voltage response to 

temperature conditions

Figure G-74 Penlight Test 14, SCDU 1, source and target voltage response

Time (s)

0 250 500 750 1000 1250 1500

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

600

700

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Top TC for 5c 

Side TC for 5c

Exposure Temperature Time (s)

0 250 500 750 1000 1250 1500

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-56

Figure G-75 Penlight Test 14, SCDU 1, overlay of key voltages and key currents

Figure G-76 Penlight Test 14, SCDU 1, all measured voltages

Time (s)

0 250 500 750 1000 1250 1500

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 

Time (s)

0 250 500 750 1000 1250 1500

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 
G-57

Figure G-77 Penlight Test 14, SCDU 1, all measured currents

Time (s)

0 250 500 750 1000 1250 1500

Current (A)

0

1

2

3

4

5

6

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-58

G.7.2 SCDU 2

Table G-20 Penlight Test 14, SCDU 1, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

760 Voltage increase 

on Target 6

At this time, the voltage steadily increased to 

approximately 4 V. The voltage decreased to 

about 2 V over the span of about 3 minutes.

964 Short to ground The circuit shorted to ground as the fuse 

tripped. No components were activated.

Summary Observations

Penlight was originally set to 450 °C and ignition occurred approximately 10 minutes 

into the test. At this time, the temperature on the 5c and 10c Kerite® was noted at 

294 °C and 229 °C, respectively. As the cable temperature increased, voltage 

increases were noticed. About 5 1⁄2 minutes later, Circuit 2 failed.

Figure G-78 Penlight Test 14, SCDU 2, source and target voltage response to 

temperature conditions

Time (s)

0 250 500 750 1000 1250 1500

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

600

700

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Top TC for 10c

Side TC for 10c

Exposure Temperature 
G-59

Figure G-79 Penlight Test 14, SCDU 2, source and target voltage response

Figure G-80 Penlight Test 14, SCDU 2, overlay of key voltages and key currents

Time (s)

0 250 500 750 1000 1250 1500

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 250 500 750 1000 1250 1500

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 
G-60

Figure G-81 Penlight Test 14, SCDU 2, all measured voltages

Figure G-82 Penlight Test 14, SCDU 2, all measured currents

Time (s)

0 250 500 750 1000 1250 1500

Voltage (Vdc)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 

Time (s)

0 250 500 750 1000 1250 1500

Current (A)

0

1

2

3

4

5

6

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-61

G.8 Penlight Test 15

This test was being conducted to replicate the heating pattern of Test 13, Qualification. The test 

was terminated before electrical failure occurred, but was done so intentionally to conduct posttest analysis. A more detailed description of the test findings may be found in the Kerite 

Quicklook Report (SAND2010-4936).

Table G-21 Penlight Test 15, summary of circuit faulting behavior for all tested circuits.

Summary of Circuit Faulting Behavior for all Tested Circuits

Circuit 1 The 5c Kerite® was used for Circuit 1. Penlight was initially set to 

300 °C for about 37 minutes. The temperature was then increased to 

325 °C. About 2 minutes after the increase, bubbling liquid was 

noticed from the end of the thermally monitored cable. Around this 

time, voltages were increasing to approximately 2 V on Target 6. 

Twelve minutes later, the temperature was again increased, this time 

to 350 °C. The temperature was increased to 375 °C 15 minutes 

later. After about 16 minutes, the temperature was increased to 

400 °C where it remained for the duration of the test (approximately 

16 more minutes). Cable temperatures hit 350 °C, but never ignited. 

The test ran about 1 hour and 40 minutes.

Circuit 2 The 10c Kerite® was used for Circuit 2. Penlight was initially set to 

300 °C for about 37 minutes. The temperature was then increased to 

325 °C. About 61⁄2 minutes after the increase, bubbling liquid was 

noticed from the end of the thermally monitored cable. Around this 

time, voltages were increasing to approximately 2 V on Target 6. 

Twelve minutes later, the temperature was again increased, this time 

to 350 °C. The temperature was increased to 375 °C 15 minutes 

later. After about 16 minutes, the temperature was increased to 

400 °C, where it remained for the duration of the test (approximately 

16 more minutes). Cable temperatures hit 350 °C, but never ignited. 

The test ran about 1 hour and 40 minutes.

Circuit 3 Circuit 3 was not used in this test.

Circuit 4 Circuit 4 was not used in this test. 
G-62

G.8.1 SCDU 1

Table G-22 Penlight Test 15, SCDU 1, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

2360 Slight 

increase in 

voltage on 

Target 6.

This test was to replicate Test 13. The voltage 

increase occurred when the Penlight control 

temperature was increased from 300 °C to 325 °C. It 

reached approximately 2 V.

Summary Observations

Penlight was initially set to 300 °C for about 37 minutes. The temperature was then 

increased to 325 °C. About 2 minutes after the increase, bubbling liquid was noticed 

from the end of the thermally monitored cable. Around this time, voltages were 

increasing to approximately 2 V on Target 6. Twelve minutes later, the temperature 

was again increased, this time to 350 °C. The temperature was increased to 375 °C 

15 minutes later. After about 16 minutes, the temperature was increased to 400 °C, 

where it remained for the duration of the test (approximately 16 more minutes). Cable 

temperatures hit 350 °C, but never ignited. The test ran about 1 hour and 40 minutes.

Figure G-83 Penlight Test 15, SCDU 1, source and target voltage response to 

temperature conditions

Time (s)

0 2000 4000 6000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

600

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Top TC for 5c

Side TC for 5c

Exposure Temperature 
G-63

Figure G-84 Penlight Test 15, SCDU 1, source and target voltage response

Figure G-85 Penlight Test 15, SCDU 1, overlay of key voltages and key currents

Time (s)

0 2000 4000 6000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 1000 2000 3000 4000 5000

Current (A)

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 
G-64

Figure G-86 Penlight Test 15, SCDU 1, all measured voltages

Figure G-87 Penlight Test 15, SCDU 1, all measured currents

Time (s)

0 2000 4000 6000

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 

Time (s)

0 1000 2000 3000 4000 5000

Current (A)

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-65

G.8.2 SCDU 2

Table G-23 Penlight Test 15, SCDU 2, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

2344 Voltage increase 

on Target 5 and 

Target 6

At this time, the temperature was increased 

from 300 °C to 325 °C. Target 5 experienced 

an increase of 12 V while Target 6 experienced 

about 4 V.

4650 Targets 5 and 6 

stabilize

Targets 5 and 6 stabilize to about 7 V and 3 V, 

respectively, for the duration of the test.

Summary Observations

Penlight was initially set to 300 °C for about 37 minutes. The temperature was then 

increased to 325 °C. About 61⁄2 minutes after the increase, bubbling liquid was 

noticed from the end of the thermally monitored cable. Around this time, voltages 

were increasing to approximately 2 V on Target 6. Twelve minutes later, the 

temperature was again increased, this time to 350 °C. The temperature was 

increased to 375 °C 15 minutes later. After about 16 minutes, the temperature was 

increased to 400 °C, where it remained for the duration of the test (approximately 16 

more minutes). Cable temperatures hit 350 °C, but never ignited. The test ran about 

1 hour and 40 minutes.

Figure G-88 Penlight Test 15, SCDU 2, source and target voltage response to 

temperature conditions

Time (s)

0 2000 4000 6000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Top TC for 10c

Side TC for 10c

Exposure Temperature 
G-66

Figure G-89 Penlight Test 15, SCDU 2, source and target voltage response

Figure G-90 Penlight Test 15, SCDU 2, overlay of key voltages and key currents

Time (s)

0 2000 4000 6000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 2000 4000 6000

Current (A)

-1.4

-1.2

-1.0

-0.8

-0.6

-0.4

-0.2

0.0

0.2

0.4

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 
G-67

Figure G-91 Penlight Test 15, SCDU 2, all measured voltages

Figure G-92 Penlight Test 15, SCDU 2, all measured currents

Time (s)

0 2000 4000 6000

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 

Time (s)

0 2000 4000 6000

Current (A)

0.00

0.05

0.10

0.15

0.20

0.25

0.30

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-68

G.9 Penlight Test 16

Table G-24 Penlight Test 16, summary of circuit faulting behavior for all tested circuits.

Summary of Circuit Faulting Behavior for all Tested Circuits

Circuit 1 The 10c Kerite® was used for Circuit 1. The temperature was set to 

470 °C for this test. Popping and crackling was heard 5 minutes into 

Test 16. Ignition occurred 5 minutes into the test, and about 3

minutes later voltage increases were noticed on Target 6. The 

voltages hovered around 2 V until the ultimate short to ground. A 

short to ground was observed nearly 14 minutes from Penlight 

activation. There were no spurious operations noticed during the 

experiment.

Circuit 2 The 5c Kerite® was used for Circuit 2. The temperature was set to 

470 °C for this test. Popping and crackling was heard 5 minutes into 

Test 16. Ignition occurred 5 minutes into the test. At short to ground 

was observed about 121⁄2 minutes from Penlight activation. There 

were no spurious operations noticed during the experiment.

Circuit 3 Circuit 3 was not used in this test.

Circuit 4 Circuit 4 was not used in this test.

G.9.1 SCDU 1

Table G-25 Penlight Test 16, SCDU 1, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

630 Slight increase 

in voltage on 

Target 6

The temperature was set to 470 °C for this test. 

Popping and crackling was heard 5 minutes into Test 

16. Ignition occurred 5 minutes into the test, and 

about 3 minutes later voltage increases were noticed 

on Target 6. The voltages hovered around 2 V until 

the ultimate short to ground.

834 Short to 

ground

At this time, there was a short to ground and the fuse 

has blown.

Summary Observations

The temperature was set to 470 °C for this test. Popping and crackling was heard 5

minutes into Test 16. Ignition occurred 5 minutes into the test, and about 3 minutes 

later voltage increases were noticed on Target 6. The voltages hovered around 2 V 

until the ultimate short to ground. A short to ground was observed nearly 14 minutes 

from Penlight activation. There were no spurious operations noticed during the 

experiment.
G-69

Figure G-93 Penlight Test 16, SCDU 1, source and target voltage response to 

temperature conditions

Figure G-94 Penlight Test 16, SCDU 1, source and target voltage response

Time (s)

0 200 400 600 800 1000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

600

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Top TC for 10c

Side TC for 10c 

Exposure Temperature 

Time (s)

0 200 400 600 800 1000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-70

Figure G-95 Penlight Test 16, SCDU 1, overlay of key voltages and key currents

Figure G-96 Penlight Test 16, SCDU 1, all measured voltages

Time (s)

0 200 400 600 800 1000

Current (A)

-2

-1

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 

Time (s)

0 200 400 600 800 1000

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 
G-71

Figure G-97 Penlight Test 16, SCDU 1, all measured currents

G.9.2 SCDU 2

Table G-26 Penlight Test 16, SCDU 2, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

750 Short to ground There were no indications of voltage increase 

on the Targets of Circuit 2. Ultimately, the 

circuit failed at 750 s.

Summary Observations

The temperature was set to 470 °C for this test. Popping and crackling was heard 5

minutes into Test 16. Ignition occurred 5 minutes into the test. A short to ground 

was observed about 121⁄2 minutes from Penlight activation. There were no spurious 

operations noticed during the experiment.

Time (s)

0 200 400 600 800 1000

Current (A)

0

1

2

3

4

5

6

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-72

Figure G-98 Penlight Test 16, SCDU 2, source and target voltage response to 

temperature conditions

Figure G-99 Penlight Test 16, SCDU 2, source and target voltage response

Time (s)

0 200 400 600 800 1000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

600

700

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Top TC for 5c 

Side TC for 5c

Exposure Temperature 

Time (s)

0 200 400 600 800 1000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-73

Figure G-100 Penlight Test 16, SCDU 2, overlay of key voltages and key currents

Figure G-101 Penlight Test 16, SCDU 2, all measured voltages

Time (s)

0 200 400 600 800 1000

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 

Time (s)

0 200 400 600 800 1000

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 
G-74

Figure G-102 Penlight Test 16, SCDU 2, all measured currents

Time (s)

0 200 400 600 800 1000

Current (A)

0

1

2

3

4

5

6

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-75

G.10 Penlight Test 17, Qualification

Table G-27 Penlight Test 17, Qualification, summary of circuit faulting behavior for all 

tested circuits.

Summary of Circuit Faulting Behavior for all Tested Circuits

Circuit 1 The 3c Kerite® FR-III was used for Circuit 1. The initial temperature 

was set to 375 °C for 20 minutes, at which it was increased to 

400 °C. Ten minutes later, the temperature was increased to 

435 °C. Nine minutes later, the temperature was increased to 

470 °C. Bubbling was observed; however, the cable did not ignite. 

After 47 minutes, the circuit failed to ground. 

Circuit 2 Circuit 2 was not used in this test.

Circuit 3 Circuit 3 was not used in this test.

Circuit 4 Circuit 4 was not used in this test.

G.10.1 SCDU 1

Table G-28 Penlight Test 17, Qualification, SCDU 1, summary of observed faulting 

behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

2769 Short to 

ground

At this time, the circuit voltage shorted to ground

Summary Observations

The initial temperature was set to 375 °C for 20 minutes, at which it was increased to 

400 °C. Ten minutes later, the temperature was increased to 435 °C. Nine minutes 

later, the temperature was increased to 470 °C. Bubbling was observed; however, 

the cable did not ignite. After 47 minutes, the circuit failed to ground. 
G-76

Figure G-103 Penlight Test 17, Qualification, SCDU 1, source and target voltage 

response to temperature conditions

Figure G-104 Penlight Test 17, Qualification, SCDU 1, source and target voltage 

response

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

600

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Top TC 

Side TC 

Exposure Temperature 

Time (s)

0 500 1000 1500 2000 2500 3000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-77

Figure G-105 Penlight Test 17, Qualification, SCDU 1, overlay of key voltages and key 

currents

Figure G-106 Penlight Test 17, Qualification, SCDU 1, all measured voltages

Time (s)

0 500 1000 1500 2000 2500 3000

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 
G-78

Figure G-107 Penlight Test 17, Qualification, SCDU 1, all measured currents

Time (s)

0 500 1000 1500 2000 2500 3000

Current (A)

0

1

2

3

4

5

6

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-79

G.11 Penlight Test 17

Table G-29 Penlight Test 17, summary of circuit faulting behavior for all tested circuits.

Summary of Circuit Faulting Behavior for all Tested Circuits

Circuit 1 The Kerite® FR-III, 3c, 6 AWG was used for Circuit 1. The initial 

Penlight temperature was set to 430 °C. Swelling of the cable jacket 

was observed approximately 8 minutes into the test. Smoldering of 

the cable jacket was noticed about 12 minutes after Penlight was 

turned on. Ignition of the cables occurred 29 minutes after Penlight 

was turned on. Two minutes later, Targets 5 and 6 spuriously 

operated. This activity occurred until a fuse trip approximately 11⁄2 

minutes later.

Circuit 2 The Kerite® FR-III, 3c, 6 AWG was used for Circuit 2. The initial 

Penlight temperature was set 430 °C. Swelling of the cable jacket 

was observed approximately 8 minutes into the test. Smoldering of 

the cable jacket was noticed about 12 minutes after Penlight was 

turned on. Ignition of the cables occurred 29 minutes after Penlight 

was turned on. About 30 minutes into the test, Circuit 2 began 

experiencing voltage degradation until the fuse tripped about 2 

minutes later.

Circuit 3 Circuit 3 was not used in this test.

Circuit 4 Circuit 4 was not used in this test.

G.11.1 SCDU 1

Table G-30 Penlight Test 17, SCDU 1, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

1764 Shorting 

behavior 

initiates

At this time, shorting behavior was observed 

between Target 5 and Target 6 for over 1 minute. 

1848 Fuse trip The activity on Targets 5 and 6 ceased as the fuse 

for Circuit 1 tripped.

Summary Observations

The initial Penlight temperature was set 430 °C. Swelling of the cable jacket was 

observed approximately 8 minutes into the test. Smoldering of the cable jacket was 

noticed about 12 minutes after Penlight was turned on. Ignition of the cables 

occurred 29 minutes after Penlight was turned on. Two minutes later, Targets 5 and 

6 spuriously operated. This activity occurred until a fuse trip approximately 11⁄2

minutes later.
G-80

Figure G-108 Penlight Test 17, SCDU 1, source and target voltage response to 

temperature conditions

Figure G-109 Penlight Test 17, SCDU 1, source and target voltage response

Time (s)

0 500 1000 1500 2000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

200

400

600

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Circuit 1 TC for 3c

Time (s)

0 500 1000 1500 2000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-81

Figure G-110 Penlight Test 17, SCDU 1, source and target voltage response, limited 

time span

Figure G-111 Penlight Test 17, SCDU 1, overlay of key voltages and key currents

Time (s)

1700 1750 1800 1850 1900

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 500 1000 1500 2000

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 
G-82

Figure G-112 Penlight Test 17, SCDU 1, overlay of key voltages and key currents, 

limited time span

Figure G-113 Penlight Test 17, SCDU 1, all measured voltages

Time (s)

1700 1750 1800 1850 1900

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 

Time (s)

0 500 1000 1500 2000

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 
G-83

Figure G-114 Penlight Test 17, SCDU 1, all measured voltages, limited time span

Figure G-115 Penlight Test 17, SCDU 1, all measured currents

Time (s)

1700 1750 1800 1850 1900

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 

Time (s)

0 500 1000 1500 2000

Current (A)

0

1

2

3

4

5

6

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-84

Figure G-116 Penlight Test 17, SCDU 1, all measured currents, limited time span

G.11.2 SCDU 2

Table G-31 Penlight Test 17, SCDU 2, summary of observed faulting behavior

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

1785 Voltage 

degradation on 

the source 

conductor

At this time, the voltage on the source 

conductor began to degrade. This degradation 

lasted approximately 115 s before the fuse 

tripped.

1900 Fuse trip At this time, the fuse tripped for Circuit 2.

Summary Observations

The initial Penlight temperature was set 430 °C. Swelling of the cable jacket was

observed approximately 8 minutes into the test. Smoldering of the cable jacket was 

noticed about 12 minutes after Penlight was turned on. Ignition of the cables 

occurred 29 minutes after Penlight was turned on. About 30 minutes into the test, 

Circuit 2 began experiencing voltage degradation until the fuse tripped about 2 

minutes later.

Time (s)

1700 1750 1800 1850 1900

Current (A)

0

1

2

3

4

5

6

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-85

Figure G-117 Penlight Test 17, SCDU 2, source and target voltage response to 

temperature conditions

Figure G-118 Penlight Test 17, SCDU 2, source and target voltage response

Time (s)

0 500 1000 1500 2000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

600

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Circuit 2 TC for 3c

Exposure Temperature

Time (s)

0 500 1000 1500 2000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-86

Figure G-119 Penlight Test 17, SCDU 2, overlay of key voltages and key currents

Time (s)

0 500 1000 1500 2000

Current (A)

0

1

2

3

4

5

6 Voltage (Vdc)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 
G-87

Figure G-120 Penlight Test 17, SCDU 2, all measured voltages

Figure G-121 Penlight Test 17, SCDU 2, all measured currents

Time (s)

0 500 1000 1500 2000

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 

Time (s)

0 500 1000 1500 2000

Current (A)

0

1

2

3

4

5

6

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-88

G.12 Penlight Test 18

Table G-32 Penlight Test 18, summary of circuit faulting behavior for all tested circuits.

Summary of Circuit Faulting Behavior for all Tested Circuits

Circuit 1 The circuit used Kerite® FR-III, 3c, 6 AWG. The circuit did not fail. 

The initial Penlight temperature was set to 420 °C and increased to 

450 °C after 42 minutes. Ignition occurred 53 minutes after the 

temperature increase. Ignition most likely occurred as a result of 

shorting in Circuit 2. After the Penlight test, the conductors were 

observed to be spread apart and away from the cable tray, which 

may have allowed the cable to continuously operate.

Circuit 2 The circuit used Kerite® FR-III, 3c, 6 AWG. At this time, the fuse 

cleared. The initial Penlight temperature was set to 420 °C and 

increased to 450 °C after 42 minutes. Ignition occurred 53 minutes 

after the temperature increase. 

Circuit 3 Circuit 3 was not used in this test.

Circuit 4 Circuit 4 was not used in this test.
G-89

G.12.1 SCDU 1

Table G-33 Penlight Test 18, SCDU 1, summary of observed faulting behavior

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

5807 Fuse cleared The circuit used Kerite® FR-III, 3c, 6 AWG. At this 

time, the fuse cleared. The initial Penlight 

temperature was set to 420 °C and increased to 

450 °C after 42 minutes. Ignition occurred 53 

minutes after the temperature increase.

Figure G-122 Penlight Test 18, SCDU 1, source and target voltage response to 

temperature conditions

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

600

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Circuit 1 TC for 3c

Exposure Temperature
G-90

Figure G-123 Penlight Test 18, SCDU 1, source and target voltage response

Figure G-124 Penlight Test 18, SCDU 1, overlay of key voltages and key currents

Time (s)

0 2000 4000 6000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 2000 4000 6000

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 
G-91

Figure G-125 Penlight Test 18, SCDU 1, all measured voltages

Figure G-126 Penlight Test 18, SCDU 1, all measured currents

Time (s)

0 2000 4000 6000

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 

Time (s)

0 2000 4000 6000

Current (A)

0

1

2

3

4

5

6

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-92

G.12.2 SCDU 2

Table G-34 Penlight Test 18, SCDU 2, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

5665 Target 6 

actuated

The circuit used Kerite® FR-III, 3c, 6A WG. The 

initial Penlight temperature was set to 420 °C and 

increased to 450 °C after 42 minutes. Ignition 

occurred 53 minutes after the temperature 

increase. Ignition most likely occurred as a result 

of shorting in Circuit 2. Target 6 was actuated and 

Target 5 displayed signs of voltage increase.

5700 Fuse trip The fuse tripped and source voltage dropped to 

zero.

Summary Observations

The circuit used Kerite® FR-III, 3c, 6 AWG. The initial Penlight temperature was set 

to 420 °C and increased to 450 °C after 42 minutes. Ignition occurred 53 minutes 

after the temperature increase. Ignition most likely occurred as a result of shorting in 

Circuit 2. Target 6 was actuated and Target 5 displayed signs of voltage increase. 

The fuse tripped and the source voltage dropped to zero about a half minutes after 

actuation.

Figure G-127 Penlight Test 18, SCDU 2, source and target voltage response to 

temperature conditions

Time (s)

0 2000 4000 6000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

600

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Circuit 2 TC for 3c

Exposure Temperature
G-93

Figure G-128 Penlight Test 18, SCDU 2, source and target voltage response

Figure G-129 Penlight Test 18, SCDU 2, overlay of key voltages and key currents

Time (s)

0 2000 4000 6000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 2000 4000 6000

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 
G-94

Figure G-130 Penlight Test 18, SCDU 2, all measured voltages

Figure G-131 Penlight Test 18, SCDU 2, all measured currents

Time (s)

0 2000 4000 6000

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 

Time (s)

0 2000 4000 6000

Current (A)

0

1

2

3

4

5

6

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-95

G.13 Penlight Test 19

Table G-35 Penlight Test 19, summary of circuit faulting behavior for all tested circuits

Summary of Circuit Faulting Behavior for all Tested Circuits

Circuit 1 Penlight was originally set to 470 °C. At 586 s into the test, the fuse on 

SCDU 1 cleared. No spurious actuations were detected.

Circuit 2 Penlight was originally set to 470 °C. At 585 s into the test, the fuse on 

SCDU 2 cleared. No spurious actuations were detected.

Circuit 3 Circuit 3 was not used in this test.

Circuit 4 Circuit 4 was not used in this test.

G.13.1 SCDU 1

Table G-36 Penlight Test 19, SCDU 1, summary of observed faulting behavior

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

586 Fuse clear The fuse on the SCDU 1 circuit clears and no spurious 

actuations were detected.

Summary Observations

Penlight was originally set to 470 °C. At 586 s into the test, the fuse on SCDU 1 cleared. No 

spurious actuations were detected.
G-96

Figure G-132 Penlight Test 19, SCDU 1, source and target voltage response to 

temperature conditions

Figure G-133 Penlight Test 19, SCDU 1, source and target voltage response

Time (s)

0 200 400 600 800

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

600

700

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Cable 1

Cable 2

Exposure Temperature 

Time (s)

0 200 400 600 800

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-97

Figure G-134 Penlight Test 19, SCDU 1, overlay of key voltages and key currents

Figure G-135 Penlight Test 19, SCDU 1, all measured voltages

Time (s)

0 200 400 600 800

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 

Time (s)

0 200 400 600 800

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 
G-98

Figure G-136 Penlight Test 19, SCDU 1, all measured currents

G.13.2 SCDU 2

Table G-37 Penlight Test 19, SCDU 2, summary of observed faulting behavior

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

585 Fuse clear The fuse on the SCDU 2 circuit clears and no 

spurious actuations were detected.

Summary Observations

Penlight was originally set to 470 °C. At 585 s into the test, the fuse on SCDU 2 

cleared. No spurious actuations were detected.

Time (s)

0 200 400 600 800

Current (A)

0

1

2

3

4

5

6

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-99

Figure G-137 Penlight Test 19, SCDU 2, source and target voltage response to 

temperature conditions

Figure G-138 Penlight Test 19, SCDU 2, source and target voltage response

Time (s)

0 200 400 600 800

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

600

700

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Cable 1

Cable 2

Exposure Temperature 

Time (s)

0 200 400 600 800

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-100

Figure G-139 Penlight Test 19, SCDU 2, overlay of key voltages and key currents

Figure G-140 Penlight Test 19, SCDU 2, all measured voltages

Time (s)

0 200 400 600 800

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 

Time (s)

0 200 400 600 800

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 
G-101

Figure G-141 Penlight Test 19, SCDU 2, all measured currents

Time (s)

0 200 400 600 800

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-102

G.14 Intermediate-Scale Test JPN 1

G.14.1 SCDU 1

Figure G-142 Intermediate-Scale Test JPN-1, SCDU 1, source and target voltage 

response to temperature conditions

Time (s)

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

0

20

40

60

80

100

120

140

160

180

Temperature (°C)

0

50

100

150

200

250

300

350

400

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

North Top

North Mid
G-103

Figure G-143 Intermediate-Scale Test JPN-1, SCDU 1, source and target voltage 

response

Figure G-144 Intermediate-Scale Test JPN-1, SCDU 1, overlay of key voltages and key 

currents

Time (s)

0 1000 2000 3000 4000 5000 6000

Votlage (Vac)

0

20

40

60

80

100

120

140

160

180

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 1000 2000 3000 4000 5000 6000

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

Voltage (Vac)

0

20

40

60

80

100

120

140

160

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 
G-104

Figure G-145 Intermediate-Scale Test JPN-1, SCDU 1, all measured voltages

Figure G-146 Intermediate-Scale Test JPN-1, SCDU 1, all measured currents

Time (s)

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

0

20

40

60

80

100

120

140

160

180

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 

Time (s)

0 1000 2000 3000 4000 5000 6000

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-105

Table G-38 Intermediate-Scale Test JPN-1, SCDU 1, summary of observed faulting 

behavior.

Time 

(seconds) Event Discussion

NA SCDU #1 did 

not 

experience 

failure

The circuit did not fail. As with Circuit 2 and Circuit 3, 

voltage and temperature declines were observed at 

154 s and 858 s. There was an increase in voltage at 

2120 s, which was also observed to a greater extent 

in Circuit 2 and Circuit 3. At approximately 3640 s, 

voltages on Target 4 and Target 5 reached a peak of 

4 V; however, they steadily declined to the initial 

voltages.

G.14.2 SCDU 2

Figure G-147 Intermediate-Scale Test JPN-1, SCDU 2, source and target voltage 

response to temperature conditions

Time (s)

0 1000 2000 3000 4000

Voltage (Vac)

0

50

100

150

200

250

300

350

Temperature (°C)

0

200

400

600

800

1000

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Center Top

Center Mid
G-106

Figure G-148 Intermediate-Scale Test JPN-1, SCDU 2, source and target voltage 

response

Figure G-149 Intermediate-Scale Test JPN-1, SCDU 2, source and target voltage 

response, limited time span

Time (s)

0 1000 2000 3000 4000 5000

Votlage (Vac)

0

50

100

150

200

250

300

350

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

2050 2100 2150 2200 2250

Votlage (Vac)

0

50

100

150

200

250

300

350

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-107

Figure G-150 Intermediate-Scale Test JPN-1, SCDU 2, overlay of key voltages and key 

currents

Figure G-151 Intermediate-Scale Test JPN-1, SCDU 2, overlay of key voltages and key 

currents, limited time span

Time (s)

0 1000 2000 3000 4000 5000 6000

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

50

100

150

200

250

300

350

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 

Time (s)

2050 2100 2150 2200 2250

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

50

100

150

200

250

300

350

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 
G-108

Figure G-152 Intermediate-Scale Test JPN-1, SCDU 2, all measured voltages

Figure G-153 Intermediate-Scale Test JPN-1, SCDU 2, all measured voltages, limited 

time span

Time (s)

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

0

50

100

150

200

250

300

350

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 

Time (s)

2050 2100 2150 2200 2250

Voltage (Vac)

0

50

100

150

200

250

300

350

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 
G-109

Figure G-154 Intermediate-Scale Test JPN-1, SCDU 2, all measured currents

Figure G-155 Intermediate-Scale Test JPN-1, SCDU 2, all measured currents, limited 

time span

Time (s)

0 1000 2000 3000 4000 5000 6000

Current (A)

0

1

2

3

4

5

6

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 

Time (s)

2050 2100 2150 2200 2250

Current (A)

0

1

2

3

4

5

6

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-110

Table G-39 Intermediate-Scale Test JPN-1, SCDU 2, summary of observed faulting 

behavior.

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

2100 Voltage increase 

on Target 4

Circuit 2 begins to experience an increase in 

voltage on the target conductors, namely Target 

4. Up until the spurious actuation, Target 4 

periodically experiences nominal 120 V shorting 

activity.

2120 Electrical 

anomaly

At this time, there was a dramatic increase in 

voltage that far exceeded reasonable 

expectations. This may have been caused by a 

disturbance in monitoring equipment.

2156 Spurious 

actuation

The Target 6 conductor spuriously actuates.

2171 Spurious 

actuation clears

The spurious operation is restored; however, 

voltage is still present on Target 4.

2185 Fuse clears The fuse tripped and source voltage dropped to 

zero.

Summary Observations

As with Circuit 1 and Circuit 3, voltage and temperature declines were observed at 

154 s and 858 s. A voltage increase was detected on Target 4 and the conductor 

experienced full line voltage periodically until the fuse subsequently cleared a 11⁄2 

minutes later. There was an increase in voltage at 2120 s, which was also observed 

in Circuit 1 and Circuit 3; however, was associated with a disturbance in monitoring 

equipment. Target 6 spuriously operated for approximately 15 s before clearing. 

Target 4 continued to see voltages of 9 V until the fuse cleared 15 s later.
G-111

G.14.3 SCDU 3

Figure G-156 Intermediate-Scale Test JPN-1, SCDU 3, source and target voltage 

response to temperature conditions

It should be noted that “South Mid” and “South Top” was the nomenclature for the 

thermocouples used to monitor the air temperature for this test. This was subsequently 

changed to be more specific for the other tests.

Time (s)

0 1000 2000 3000 4000

Voltage (Vac)

0

20

40

60

80

100

120

140

160

Temperature (°C)

0

200

400

600

800

1000

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Center Top

Center Mid
G-112

Figure G-157 Intermediate-Scale Test JPN-1, SCDU 3, source and target voltage 

response

Figure G-158 Intermediate-Scale Test JPN-1, SCDU 3, overlay of key voltages and key 

currents

Time (s)

0 1000 2000 3000 4000 5000

Votlage (Vac)

0

20

40

60

80

100

120

140

160

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 1000 2000 3000 4000 5000 6000

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

160

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 
G-113

Figure G-159 Intermediate-Scale Test JPN-1, SCDU 3, all measured voltages

Figure G-160 Intermediate-Scale Test JPN-1, SCDU 3, all measured currents

Time (s)

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

0

20

40

60

80

100

120

140

160

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 

Time (s)

0 1000 2000 3000 4000 5000 6000

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-114

Table G-40 Intermediate-Scale Test JPN-1, SCDU 3, summary of observed faulting 

behavior.

Summary of Observed Faulting Behavior for Circuit #3

Time 

(seconds) Event Discussion

1840 Slight voltage 

increase begins 

on Target 4

The voltage on Target 4 increases to 

approximately 5 V. 

2015 Fuse clears The fuse cleared for SCDU 3.

2120 Electrical 

anomaly

At this time, there was an increase in voltage that 

indicated an electric anomaly. Since the fuse 

had already cleared, no electricity should have 

been detected and recorded. This may have 

been caused by a disturbance in the monitoring 

equipment.

Summary Observations

As with Circuit 1 and Circuit 2, voltage and temperature declines were observed at 

154 s and 858 s. A slight voltage increase was detected and reached a maximum of 5

V before the fuse ultimately cleared 2015 s into the test. There was an increase in 

voltage at 2120 s, which was also observed to a greater extent in Circuit 2 and Circuit 

3. Since the fuse was cleared in SCDU 3 at this time, it indicates that the monitoring 

equipment recorded an anomalous data point for each of the circuits.

G.15 Intermediate-Scale Test Prelim 1

G.15.1 SCDU 1

Not Used

G.15.2 SCDU 2

Not Used
G-115

G.15.3 SCDU 3

Figure G-161 Intermediate-Scale Test Preliminary 1, SCDU 3, source and target voltage 

response to temperature conditions

Time (s)

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

0

20

40

60

80

100

120

140

160

Temperature (°C)

0

100

200

300

400

500

600

700

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Air Temp - 3'

Air Temp - 5'

Air Temp - 7'
G-116

Figure G-162 Intermediate-Scale Test Preliminary 1, SCDU 3, source and target voltage 

response

Figure G-163 Intermediate-Scale Test Preliminary 1, SCDU 3, overlay of key voltages 

and key currents

Time (s)

0 1000 2000 3000 4000 5000 6000

Votlage (Vac)

0

20

40

60

80

100

120

140

160

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 1000 2000 3000 4000 5000 6000

Current (A)

0.00

0.05

0.10

0.15

0.20

0.25

0.30

Voltage (Vac)

0

20

40

60

80

100

120

140

C3 A1 

C3 A2 

C3 A7 

C3 V2 

C3 V5 

C3 V6 
G-117

Figure G-164 Intermediate-Scale Test Preliminary 1, SCDU 3, all measured voltages

Table G-41 Intermediate-Scale Test Preliminary 1, SCDU 3, summary of observed 

faulting behavior.

Time (s)

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

0

20

40

60

80

100

120

140

160

C3 V1 

C3 V2 

C3 V3 

C3 V4 

C3 V5 

C3 V6 

C3 V7 

C3 V8 

Time (s)

0 1000 2000 3000 4000 5000 6000

Current (A)

0.00

0.05

0.10

0.15

0.20

0.25

0.30

C3 A1 

C3 A2 

C3 A3 

C3 A4 

C3 A5 

C3 A6 

C3 A7 

C3 A8 
G-118

Summary of Observed Faulting Behavior for Circuit #3

Time 

(seconds) Event Discussion

1626-2471 Voltage increase 

begins on 

Conductor 3

The voltage is approximately 8 V on 

Conductor 3 at this time. Over the following 

14 minutes, the voltage would increase to 

about 56 V.

2043-2418 Voltage increase 

begins on Target 4

The voltage is approximately 2 V on Target 4

at this time. Over the following 61⁄2 minutes, 

the voltage would increase to about 20 V.

2418 Voltage stabilizes 

on Target 4

The voltage stabilizes around 20 V. By the 

end of the test, the voltage on Target 4 

reaches 27 V.

2471-3544 Voltage on 

Conductor 3 

reaches 

approximately 56 V, 

then steadily 

declines

The voltage on Conductor 3 reaches 

approximately 56 V before steadily declining 

over nearly 18 minutes to about 50 V. At 

3544 s, the voltage drops to a nominal 0 V.

3715-3735, 

3752-3754, 

3756-3774

Voltage on 

Conductor 3 jumps 

from 0 V to 

approximately 50 V 

before again 

dropping to 0 V

During these time periods, the voltage on 

Conductor 3 started at a nominal 0 V and 

then sharply increased to 50 V before 

subsequently dropping out.

5100 Test concluded The voltage on Target 4 reaches a maximum 

of 27 V, however, the fuses did not clear 

before the conclusion of the test. The 

maximum current was on Conductor 2, a 

source conductor, and it reached 

approximately 0.27 A by the conclusion of the 

experiment.

Summary Observations

SCDU 3 and 4 were co-located in a cable tray in Position C of the intermediate-scale 

structure. A random fill tray was placed in Position A to help provide the hot gas 

layer. Initial voltage leakage could be detected as early as 1626 s when Conductor 3 

experienced a gradual voltage increase until reaching a maximum of 56 V at 2471 s. 

At 3544 s, the voltage on Conductor 3 dropped to a nominal 0 V. There was another 

voltage increase monitored on the Target 4 conductor that started around 2043 s and 

reached a plateau of 20 V at 2418 s. By the conclusion of the experiment at 5100s, 

the voltage on Target 4 reached 27 V. After three instances of voltage increase on 

Conductor 3, circuit failure was not observed during the test, and this was verified by 

post-test fuse inspection.
G-119

G.15.4 SCDU 4

Figure G-165 Intermediate-Scale Test Preliminary 1, SCDU 4, source and target voltage 

response to temperature conditions

Figure G-166 Intermediate-Scale Test Preliminary 1, SCDU 4, source and target voltage 

response

Time (s)

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Air Temp - 3'

Air Temp - 5'

Air Temp - 7'

Time (s)

0 1000 2000 3000 4000 5000 6000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-120

Figure G-167 Intermediate-Scale Test Preliminary 1, SCDU 4, overlay of key voltages 

and key currents

Figure G-168 Intermediate-Scale Test Preliminary 1, SCDU 4, all measured voltages

Time (s)

0 1000 2000 3000 4000 5000 6000

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

Voltage (Vac)

0

20

40

60

80

100

120

140

C4 A1 

C4 A2 

C4 A7 

C4 V2 

C4 V5 

C4 V6 

Time (s)

0 1000 2000 3000 4000 5000 6000

Voltage (Vac)

0

20

40

60

80

100

120

140

C3 V1 

C3 V2 

C3 V3 

C3 V4 

C3 V5 

C3 V6 

C3 V7 

C3 V8 
G-121

Figure G-169 Intermediate-Scale Test Preliminary 1, SCDU 4, all measured currents

Time (s)

0 1000 2000 3000 4000 5000

Current (A)

0.00

0.05

0.10

0.15

0.20

0.25

0.30

C3 A1 

C3 A2 

C3 A3 

C3 A4 

C3 A5 

C3 A6 

C3 A7 

C3 A8 
G-122

Table G-42 Intermediate-Scale Test Preliminary 1, SCDU 4, summary of observed 

faulting behavior.

Summary of Observed Faulting Behavior for Circuit #4

1552-2431 Voltage increase 

begins on 

Conductor 3

The voltage is approximately 4 V on Conductor 3 

at this time. Voltage would increase to about 54

V before steadily declining for the remainder of 

the test.

2170-2384 Voltage increase 

begins on Target 4

The voltage is approximately 2 V on Target 4 at 

this time. During this time period, the voltage 

would increase to about 20 V. Although most of 

the voltage increase occurs during this time 

range, by the end of the test the voltage on 

Target 4 reaches 26 V.

2384-5100 Voltage stabilizes 

on Target 4

The voltage stabilizes around 20 V. There is a 

gradual increase throughout the remainder of the 

test and Target 4 finishes the test at 

approximately 26 V.

2431-5100 Voltage on 

Conductor 3 

steadily declines

The voltage on Conductor 3 reaches 

approximately 54 V before steadily declining over 

the remainder of the test to about 41 V.

5100 Test concluded The voltage on Conductor 3 and Target 4 

finished at 42 V and 26 V, respectively; however, 

the fuse did not clear before the conclusion of 

the test. The maximum current was on 

Conductor 1, a source conductor, and it reached 

approximately 0.25 A by the conclusion of the 

experiment.

Summary Observations

SCDU 3 and 4 were co-located in a cable tray in Position C of the intermediate-scale 

structure. A random fill tray was placed in Position A to help provide the hot gas layer. 

Initial voltage leakage could be detected as early as 1552 s when Conductor 3 

experienced a gradual voltage increase until reaching a maximum of 54 V at 2431 s. 

There was another voltage increase monitored on the Target 4 conductor that started 

around 2170 s and reached a plateau of 20 V at 2384 s. By the conclusion of the 

experiment at 5100 s, the voltage on Conductor 3 and Target 4 reached 41 V and 27

V, respectively. Circuit failure was not observed during the test, and this was verified 

by post-test fuse inspection.
G-123

G.16 Intermediate-Scale Test Prelim 2

G.16.1 SCDU 1

Figure G-170 Intermediate-Scale Test Preliminary 2, SCDU 1, source and target voltage 

response to temperature conditions

Time (s)

0 300 600 900 1200 1500

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

200

400

600

800

1000

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Position D - 7'

Position D - Middle

Position D - 3'
G-124

Figure G-171 Intermediate-Scale Test Preliminary 2, SCDU 1, source and target voltage 

response

Figure G-172 Intermediate-Scale Test Preliminary 2, SCDU 1, overlay of key voltages 

and key currents

Time (s)

0 250 500 750 1000 1250 1500

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 250 500 750 1000 1250 1500

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 
G-125

Figure G-173 Intermediate-Scale Test Preliminary 2, SCDU 1, all measured voltages

Figure G-174 Intermediate-Scale Test Preliminary 2, SCDU 1, all measured currents

Time (s)

0 250 500 750 1000 1250 1500

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 

Time (s)

0 250 500 750 1000 1250 1500

Current (A)

0

1

2

3

4

5

6

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-126

Table G-43 Intermediate-Scale Test Preliminary 2, SCDU 1, summary of observed 

faulting behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

567 Voltage drop 

and current 

increase on 

Conductor 2

At this time, the voltage dropped from approximately 

130 V to 84 V and a current increase to 5.32 A was 

observed at the same instant.

571 Fuse clear The fuse cleared and there were no spurious 

actuations.

Summary Observations

SCDU 1 and SCDU 2 were co-located in Position D in the intermediate-scale 

structure. A bundle of cables was located directly below in Position B. The circuit 

ultimately resulted in a fuse clear at 571 s and there were no spurious actuations.
G-127

G.16.2 SCDU 2

Figure G-175 Intermediate-Scale Test Preliminary 2, SCDU 2, source and target voltage 

response to temperature conditions

Figure G-176 Intermediate-Scale Test Preliminary 2, SCDU 2, source and target voltage 

response

Time (s)

0 250 500 750 1000 1250 1500

Voltage (Vac)

0

20

40

60

80

100

120

140

160

Temperature (°C)

0

200

400

600

800

1000

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Position D - 7'

Position D - Middle

Position D - 3'

Time (s)

0 250 500 750 1000 1250 1500

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-128

Figure G-177 Intermediate-Scale Test Preliminary 2, SCDU 2, overlay of key voltages 

and key currents

Figure G-178 Intermediate-Scale Test Preliminary 2, SCDU 2, all measured voltages

Time (s)

0 250 500 750 1000 1250 1500

Current (A)

0

1

2

3

4 Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 

Time (s)

0 250 500 750 1000 1250 1500

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 
G-129

Figure G-179 Intermediate-Scale Test Preliminary 2, SCDU 2, all measured currents

Table G-44 Intermediate-Scale Test Preliminary 2, SCDU 2, summary of observed 

faulting behavior.

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

576 Voltage drop and 

current increase 

on Conductor 2

At this time, the voltage dropped from 

approximately 130 V to 102 V and a current 

increase to 3.38 A was observed at the same 

instant.

577 Fuse clear The fuse cleared and there were no spurious 

actuations.

Summary Observations

SCDU 1 and SCDU 2 were co-located in Position D in the intermediate-scale 

structure. A bundle of cables was located directly below in Position B. The circuit 

ultimately resulted in a fuse clear at 577 s and there were no spurious actuations.

Time (s)

0 250 500 750 1000 1250 1500

Current (A)

0

1

2

3

4

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-130

G.16.3 SCDU 3

Not Used

G.16.4 SCDU 4

Not Used

G.17 Intermediate-Scale Test 4

G.17.1 SCDU 1

Figure G-180 Intermediate-Scale Test 4, SCDU 1, source and target voltage response to 

temperature conditions

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

200

400

600

800

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

D Position - 7'

D Position - Middle

D Position - 3'
G-131

Figure G-181 Intermediate-Scale Test 4, SCDU 1, source and target voltage response

Figure G-182 Intermediate-Scale Test 4, SCDU 1, source and target voltage response, 

limited time span

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

4000 4100 4200 4300 4400 4500 4600

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-132

Figure G-183 Intermediate-Scale Test 4, SCDU 1, overlay of key voltages and key 

currents

Figure G-184 Intermediate-Scale Test 4, SCDU 1, overlay of key voltages and key 

currents, limited time span

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Current (A)

0

1

2

3

4

5 Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 

Time (s)

4200 4300 4400 4500 4600

Current (A)

0

1

2

3

4

5 Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 
G-133

Figure G-185 Intermediate-Scale Test 4, SCDU 1, all measured voltages

Figure G-186 Intermediate-Scale Test 4, SCDU 1, all measured voltages, limited time 

span

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 

Time (s)

4000 4100 4200 4300 4400 4500 4600

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 
G-134

Figure G-187 Intermediate-Scale Test 4, SCDU 1, all measured currents

Figure G-188 Intermediate-Scale Test 4, SCDU 1, all measured currents, limited time 

span

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Current (A)

0

1

2

3

4

5

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 

Time (s)

4200 4250 4300 4350 4400 4450 4500

Current (A)

0

1

2

3

4

5

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-135

Table G-45 Intermediate-Scale Test 4, SCDU 1, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

3986-4196 Voltage 

increase on 

Passive 

Target

The voltage on the Passive Target increased from 8 –

27 V during this time span.

4196-4372 Voltage 

stabilization 

on Passive 

Target

The voltage on the Passive Target stabilized between 

27 – 30 V during this time span.

4369-4381 Voltage 

increase on 

V5 Active 

Target

The voltage on the Circuit Path 5 Active Target 

increased from 2 – 40 V during this time span.

4372-4381 Voltage 

stabilization 

on Passive 

Target

The voltage on the Passive Target stabilized between 

23 – 27 V during this time span.

4381-4425 Spurious 

actuation on 

Active Target, 

Green Light

There was a spurious actuation on V5, the Active 

Target attached to the Green Indication Light. 

Current increased to 0.53 A before stabilizing at 

nominally 0.18 A.

4425-4429 Spurious 

actuation on 

Active Target, 

Orange Light

There was a spurious actuation on V6, the Active 

Target attached to the Orange Indication Light. 

Current increased to 0.40 A before stabilizing at 

nominally 0.145 A.

4930 Fuse Clear The fuse clears on SCDU 1.

Summary Observations

The SCDU cables were co-located in Position D of the intermediate-scale structure. 

Initial signs of degradation were observed at approximately 3986 s. At this point, the 

voltage on the Passive Target began to steadily increase from 8 V to 27 V before 

stabilizing between 27 – 30 V. The voltage on the Active Target (V5) increased from 2 

– 40 V over a 12-s span until spurious operation. Spurious actuation on V5 persisted 

for 44 s before the other Active Target (V6) operated. The Orange Indication Lamp 

continued for 4 s before the fuse cleared at 4930 s.
G-136

G.17.2 SCDU 2

Figure G-189 Intermediate-Scale Test 4, SCDU 2, source and target voltage response to 

temperature conditions

Figure G-190 Intermediate-Scale Test 4, SCDU 2, source and target voltage response

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

200

400

600

800

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

D Position - 7'

D Position - Middle

D Position - 3'

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-137

Figure G-191 Intermediate-Scale Test 4, SCDU 2, source and target voltage response, 

limited time span

Figure G-192 Intermediate-Scale Test 4, SCDU 2, overlay of key voltages and key 

currents

Time (s)

3900 3950 4000 4050 4100

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 
G-138

Figure G-193 Intermediate-Scale Test 4, SCDU 2, overlay of key voltages and key 

currents, limited time span

Figure G-194 Intermediate-Scale Test 4, SCDU 2, all measured voltages

Time (s)

3900 3950 4000 4050 4100 4150 4200

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 
G-139

Figure G-195 Intermediate-Scale Test 4, SCDU 2, all measured voltages, limited time 

span

Figure G-196 Intermediate-Scale Test 4, SCDU 2, all measured currents

Time (s)

3900 3950 4000 4050 4100 4150 4200

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Current (A)

0

1

2

3

4

5

6

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-140

Figure G-197 Intermediate-Scale Test 4, SCDU 2, all measured currents, limited time 

span

Table G-46 Intermediate-Scale Test 4, SCDU 2, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

4002-4015 Current and 

voltage increase 

on Target 6

There was an increase in voltage and current on 

Target 6.

4014-4016 Voltage increase 

on V3, a spare 

conductor

The voltage increased from 16 – 71 V in this time 

range.

4015-4063 Spurious 

actuation on 

Target 6

The voltage and current on Active Target 6 

increased to 121 V and 0.21 A, respectively. 

4015-4063 Hot short on 

Active Target 5 

Voltage increase was detected and persisted 

until the fuse clearing.

4063 Fuse clear The fuse cleared on SCDU 2.

Time (s)

3900 3950 4000 4050 4100 4150 4200

Current (A)

0

1

2

3

4

5

6

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-141

Summary Observations

The SCDU cables were co-located in Position D of the intermediate-scale structure. 

Initial signs of degradation were observed at approximately 4002 s. At this point, the 

voltage and current on the Active Target 6 began to steadily increase from 1 V to 54 V 

before actuating at 4015 s. The device activated for 48 s before the fuse cleared at 

4063 s. At 4014 s, the voltage on the spare conductor increased from 16 – 71 V in 

approximately 2 s. A hot short was also detected on Active Target 5 around the same 

time, although it never engaged.

G.17.3 SCDU 3

Figure G-198 Intermediate-Scale Test 4, SCDU 3, source and target voltage response to 

temperature conditions

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

600

700

800

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

D Position - 7'

D Position - Middle

D Positoin - 3'
G-142

Figure G-199 Intermediate-Scale Test 4, SCDU 3, source and target voltage response

Figure G-200 Intermediate-Scale Test 4, SCDU 3, source and target voltage response, 

limited time span

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

4200 4300 4400 4500 4600 4700 4800

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-143

Figure G-201 Intermediate-Scale Test 4, SCDU 3, overlay of key voltages and key 

currents

Figure G-202 Intermediate-Scale Test 4, SCDU 3, overlay of key voltages and key 

currents, limited time span

Time (s)

0 2000 4000 6000

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C3 A1 

C3 A2 

C3 A7 

C3 V2 

C3 V5 

C3 V6 

Time (s)

4400 4500 4600 4700 4800

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C3 A1 

C3 A2 

C3 A7 

C3 V2 

C3 V5 

C3 V6 
G-144

Figure G-203 Intermediate-Scale Test 4, SCDU 3, all measured voltages

Figure G-204 Intermediate-Scale Test 4, SCDU 3, all measured voltages, limited time 

span

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vac)

0

20

40

60

80

100

120

140

C3 V1 

C3 V2 

C3 V3 

C3 V4 

C3 V5 

C3 V6 

C3 V7 

C3 V8 

Time (s)

4200 4300 4400 4500 4600 4700 4800

Voltage (Vac)

0

20

40

60

80

100

120

140

C3 V1 

C3 V2 

C3 V3 

C3 V4 

C3 V5 

C3 V6 

C3 V7 

C3 V8 
G-145

Figure G-205 Intermediate-Scale Test 4, SCDU 3, all measured currents

Figure G-206 Intermediate-Scale Test 4, SCDU 3, all measured currents, limited time 

span

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Current (A)

0

1

2

3

4

5

6

C3 A1 

C3 A2 

C3 A3 

C3 A4 

C3 A5 

C3 A6 

C3 A7 

C3 A8 

Time (s)

4500 4550 4600 4650 4700

Current (A)

0

1

2

3

4

5

6

C3 A1 

C3 A2 

C3 A3 

C3 A4 

C3 A5 

C3 A6 

C3 A7 

C3 A8 
G-146

Table G-47 Intermediate-Scale Test 4, SCDU 3, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #3

Time 

(seconds) Event Discussion

4233-4585 Gradual voltage 

increase on 

Passive Target 4

At 4233 s, the voltage on Target 4 is 

approximately 7 V. Over the time span, the 

voltage increases to about 29 V.

4578-4580 Voltage increase 

on Active Target 6

The voltage increases from approximately 1 V 

to about 12 V during this range.

4580-4588 Voltage and current 

increase on Active 

Target 6

The voltage fluctuates from as low as 9 V to as 

high as 41 V during this range.

4585-4606 Voltage fluctuation 

on Target 4

Over 21 s, the voltage on Target 4 fluctuates 

from as low as 21 V to as high as 82 V. This is 

consistent with activity in other conductors.

4586-4606 Hot short on Active 

Target 5

Active Target 5 displays similar voltage 

fluctuations to the other conductors, but not 

high enough to cause actuation.

4588-4602 Active Target 6 

locking in and out

During this period of time, the contacts are 

experiencing sufficient voltage and current to 

cause the actuation of the component, but not 

continuously. The Target conductor engages,

then disengages rapidly and repeatedly.

4602-4606 Spurious Actuation 

on Target 6

Target 6 actuates and holds for 4 s before the 

fuse clears.

4606 Fuse clear The fuse cleared on SCDU 3.

Summary Observations

The SCDU cables were co-located in Position D of the intermediate-scale structure. 

Initial signs of degradation were observed at approximately 4233 s. At this point, the 

voltage and current on the Passive Target began to steadily increase from 7 V to 29 V 

before stabilizing between 27 – 29 V. The voltage on the Active Target (V6) increased 

from 1 – 12 V over a 12-s span beginning at 4578 s. From approximately 4580 – 4606

s, voltage fluctuations were observed on Targets 4, 5, and 6. From 4588 – 4602 s, 

Target 6 rapidly and repeatedly engaged and disengaged until a spurious actuation 

persisted for 4 s before the fuse cleared at 4606 s.
G-147

G.17.4 SCDU 4

Figure G-207 Intermediate-Scale Test 4, SCDU 4, source and target voltage response to 

temperature conditions

Figure G-208 Intermediate-Scale Test 4, SCDU 4, source and target voltage response

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

200

400

600

800

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

D Position - 7'

D Position - Middle

D Position - 3'

Time (s)

0 2000 4000 6000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-148

Figure G-209 Intermediate-Scale Test 4, SCDU 4, source and target voltage response, 

limited time span

Figure G-210 Intermediate-Scale Test 4, SCDU 4, overlay of key voltages and key 

currents

Time (s)

4200 4300 4400 4500 4600 4700 4800

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Current (A)

0

1

2

3

4

5 Voltage (Vac)

0

20

40

60

80

100

120

140

C4 A1 

C4 A2 

C4 A7 

C4 V2 

C4 V5 

C4 V6 
G-149

Figure G-211 Intermediate-Scale Test 4, SCDU 4, overlay of key voltages and key 

currents, limited time span

Figure G-212 Intermediate-Scale Test 4, SCDU 4, all measured voltages

Time (s)

4200 4300 4400 4500 4600 4700 4800

Current (A)

0

1

2

3

4

5 Voltage (Vac)

0

20

40

60

80

100

120

140

C4 A1 

C4 A2 

C4 A7 

C4 V2 

C4 V5 

C4 V6 

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Voltage (Vac)

0

20

40

60

80

100

120

140

C3 V1 

C3 V2 

C3 V3 

C3 V4 

C3 V5 

C3 V6 

C3 V7 

C3 V8 
G-150

Figure G-213 Intermediate-Scale Test 4, SCDU 4, all measured voltages, limited time 

span

Figure G-214 Intermediate-Scale Test 4, SCDU 4, all measured currents

Time (s)

4000 4200 4400 4600 4800 5000

Voltage (Vac)

0

20

40

60

80

100

120

140

C3 V1 

C3 V2 

C3 V3 

C3 V4 

C3 V5 

C3 V6 

C3 V7 

C3 V8 

Time (s)

0 1000 2000 3000 4000 5000 6000 7000

Current (A)

0

1

2

3

4

5

C3 A1 

C3 A2 

C3 A3 

C3 A4 

C3 A5 

C3 A6 

C3 A7 

C3 A8 
G-151

Figure G-215 Intermediate-Scale Test 4, SCDU 4, all measured currents, limited time 

span

Time (s)

4300 4350 4400 4450 4500

Current (A)

0

1

2

3

4

5

C3 A1 

C3 A2 

C3 A3 

C3 A4 

C3 A5 

C3 A6 

C3 A7 

C3 A8 
G-152

Table G-48 Intermediate-Scale Test 4, SCDU 4, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #4

Time 

(seconds) Event Discussion

4097-4386 Voltage increase on 

Passive Target 4

The voltage during this time range increases from 4 –

20 V.

4386-4538 Voltage stabilizes 

on Target 4

The voltage remains in a range from 20 – 27 V

4538-4606 Voltage drops on 

Target 4

Target 4 voltage decreases from 20 V to 2 V.

4590-4606 Voltage and current 

increase on Active 

Target 5

Over this range, the voltage on Active Target 5 

increased from 2 – 34 V.

4606-4617 Voltage increase on 

Active Target 6

Target 6 voltage increases from 1 – 29 V during this 

range.

4606-4647 Active Target 5 

spuriously actuates

Target 5 actuates with an exposure to 84 V and 0.17

A. The duration lasts for 41 s.

4606-4672 Voltage fluctuation 

on Target 4

The voltage on Target 4 fluctuates from 

approximately 4 – 118 V.

4619-4627 Hot short on Target 

6

A hot short on Target 6 causes a voltage increase to 

approximately 117 V.

4627-4647 Voltage fluctuation 

on Target 6

The voltage on Target 6 fluctuates from 

approximately 4 – 119 V.

4647-4652 Spurious actuation 

clears

Target 5 is no longer engaged.

4652-4672 Active Target 5 and 

6 locking in and out

During this period of time, the contacts are 

experiencing sufficient voltage and current to cause 

the actuation of the component, but not continuously. 

The two Target conductors engage, then disengage 

rapidly and repeatedly, causing the Green and 

Orange indication lights to operate.

4672 Fuse clear The fuse clears on SCDU 4.

Summary Observations

The SCDU cables were co-located in Position D of the intermediate-scale structure. 

Initial signs of degradation were observed at approximately 4097 s. At this point, the 

voltage and current on the Passive Target began to steadily increase from 4 V to 20 V 

before stabilizing between 20 – 27 V. Starting at 4590 s, there is a voltage increase from 

2 – 34 V detected on Target 5 before the device actuates at 4606 s. The actuation 

persists for 41 s before clearing. While actuated, Target 6 experience a hot short taking 

its voltage up to approximately 117 V. After the actuation on Target 5 clears, engaging 

and disengaging of both Targets 5 and 6 occurred until the fuse cleared at 4672 s.
G-153

G.18 Intermediate-Scale Test 8

G.18.1 SCDU 1

Figure G-216 Intermediate-Scale Test 8, SCDU 1, source and target voltage response to 

temperature conditions

Figure G-217 Intermediate-Scale Test 8, SCDU 1, source and target voltage response

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

200

400

600

800

1000

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

D Position - 7'

D Position - Middle

D Position - 3'

Time (s)

0 500 1000 1500 2000 2500 3000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-154

Figure G-218 Intermediate-Scale Test 8, SCDU 1, source and target voltage response, 

limited time span

Figure G-219 Intermediate-Scale Test 8, SCDU 1, overlay of key voltages and key 

currents

Time (s)

900 1000 1100 1200 1300 1400

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 500 1000 1500 2000 2500 3000

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 
G-155

Figure G-220 Intermediate-Scale Test 8, SCDU 1, overlay of key voltages and key 

currents, limited time span

Figure G-221 Intermediate-Scale Test 8, SCDU 1, all measured voltages

Time (s)

900 1000 1100 1200 1300 1400

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vc)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 
G-156

Figure G-222 Intermediate-Scale Test 8, SCDU 1, all measured voltages, limited time 

span

Figure G-223 Intermediate-Scale Test 8, SCDU 1, all measured currents

Time (s)

900 1000 1100 1200 1300 1400

Voltage (Vc)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 

Time (s)

0 500 1000 1500 2000 2500 3000

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-157

Figure G-224 Intermediate-Scale Test 8, SCDU 1, all measured currents, limited time 

span

Table G-49 Intermediate-Scale Test 8, SCDU 1, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

967 Hot short on 

Conductor 3

Conductor 3 experienced a hot short that persisted 

for the remainder of the test.

1174-1276 Spurious 

actuation of 

Target 6

Target 6 experiences a spurious actuation that lasted 

for 102 s until the fuse cleared. The voltage and 

current was 123 V and 0.157 A, respectively.

1174-1204 Voltage 

increase on 

Target 5

There is a voltage increase of approximately 17 V 

until the Target 5 hot shorts at 1204 s.

1204-1259 Hot short on 

Target 5

A hot short, which bring the Target 5 voltage to 

approximately 125 V, continues for 55 s. After 

clearing, the voltage dropped back to a range of 17 –

20 V until the fuse cleared.

1276 Fuse clear The fuse for SCDU 1 clears.

Time (s)

900 1000 1100 1200 1300 1400

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-158

Summary Observations

The cables for the SCDU circuits are co-located within the same bundled tray in 

Position D of the intermediate-scale structure. The first noted failure occurred 967 s 

into the test when a hot short occurred on Conductor 3, bringing it to approximately 

125 V. A spurious actuation occurred on Target 6 at 1174 s and continued for 102 s. 

The voltages and currents at this time were 123 V and 0.157 A, respectively. A hot 

short that brings Target 5 up to 125 V was detected from 1204 – 1259 s. The fuse 

cleared at 1276 s.

G.18.2 SCDU 2

Figure G-225 Intermediate-Scale Test 8, SCDU 2, source and target voltage response to 

temperature conditions

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

200

400

600

800

1000

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

D Position - 7'

D Position - Middle

D Position - 3'
G-159

Figure G-226 Intermediate-Scale Test 8, SCDU 2, source and target voltage response

Figure G-227 Intermediate-Scale Test 8, SCDU 2, overlay of key voltages and key 

currents

Time (s)

0 500 1000 1500 2000 2500 3000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 500 1000 1500 2000 2500 3000

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 
G-160

Figure G-228 Intermediate-Scale Test 8, SCDU 2, all measured voltages

Figure G-229 Intermediate-Scale Test 8, SCDU 2, all measured currents

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 

Time (s)

0 500 1000 1500 2000 2500 3000

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-161

Table G-50 Intermediate-Scale Test 8, SCDU 2, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

2035 Fuse clear At this time, the fuse cleared. There were no 

spurious actuations or significant voltage or 

current increases.

Summary Observations

The cables for the SCDU circuits are co-located within the same bundled tray in 

Position D of the intermediate-scale structure. There were no spurious actuations or 

hot shorts during the test. The fuse cleared at 2035 s into the test.

G.18.3 SCDU 3

Figure G-230 Intermediate-Scale Test 8, SCDU 3, source and target voltage response to 

temperature conditions

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

100

200

300

400

500

600

700

800

900

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

D Position - 7'

D Position - Middle 

D Position - 3'
G-162

Figure G-231 Intermediate-Scale Test 8, SCDU 3, source and target voltage response

Figure G-232 Intermediate-Scale Test 8, SCDU 3, overlay of key voltages and key 

currents

Time (s)

0 500 1000 1500 2000 2500 3000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 500 1000 1500 2000 2500 3000

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C3 A1 

C3 A2 

C3 A7 

C3 V2 

C3 V5 

C3 V6 
G-163

Figure G-233 Intermediate-Scale Test 8, SCDU 3, all measured voltages

Figure G-234 Intermediate-Scale Test 8, SCDU 3, all measured currents

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

0

20

40

60

80

100

120

140

C3 V1 

C3 V2 

C3 V3 

C3 V4 

C3 V5 

C3 V6 

C3 V7 

C3 V8 

Time (s)

0 500 1000 1500 2000 2500 3000

Current (A)

0

1

2

3

4

5

6

C3 A1 

C3 A2 

C3 A3 

C3 A4 

C3 A5 

C3 A6 

C3 A7 

C3 A8 
G-164

Table G-51 Intermediate-Scale Test 8, SCDU 3, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #3

Time 

(seconds) Event Discussion

515 SCDU 3 fuse 

clear

The fuse cleared on SCDU 3. Up to this point in the 

test, there were no spurious actuations of hot 

shorting behavior observed.

1494-1522 Intercable 

interaction on 

Conductor 3

During this time range, a voltage increase to 

approximately 128 V was detected. It is likely that 

the interaction occurred with SCDU 4, the cable 

directly to the side of SCDU 3.

1528-1732 Intercable 

interaction on 

Conductor 3

During this time range, a voltage increase to 

approximately 128 V was detected. It is likely that 

the interaction occurred with SCDU 4, the cable 

directly to the side of SCDU 3.

1732 SCDU 4 fuse 

clear

The fuse cleared on SCDU 4 and the electrical 

activity observed on Conductor 3 was concluded.

Summary Observations

The cables for the SCDU circuits are co-located within the same bundled tray in 

Position D of the intermediate-scale structure. The fuse for SCDU 3 cleared at 515 s 

and up to this point there were no observations spurious actuations or hot short 

activity. At 1494 s, a hot short was observed on Conductor 3 and persisted for 28 s 

before dropping out. It was subsequently engage at 1528 s and continue for 204 s. At 

1732 s into the test, the fuse for SCDU 4 cleared and the electrical activity ceased on 

Conductor 3 of SCDU 3.
G-165

G.18.4 SCDU 4

Figure G-235 Intermediate-Scale Test 8, SCDU 4, source and target voltage response to 

temperature conditions

Figure G-236 Intermediate-Scale Test 8, SCDU 4, source and target voltage response

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

200

400

600

800

1000

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

D Position - 7'

D Position - Middle

D Position - 3'

Time (s)

0 500 1000 1500 2000 2500 3000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-166

Figure G-237 Intermediate-Scale Test 8, SCDU 4, overlay of key voltages and key 

currents

Figure G-238 Intermediate-Scale Test 8, SCDU 4, overlay of key voltages and key 

currents, limited time span

Time (s)

0 500 1000 1500 2000 2500 3000

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

Voltage (Vac)

0

20

40

60

80

100

120

140

C4 A1 

C4 A2 

C4 A7 

C4 V2 

C4 V5 

C4 V6 

Time (s)

1100 1150 1200 1250 1300

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

Voltage (Vac)

0

20

40

60

80

100

120

140

C4 A1 

C4 A2 

C4 A7 

C4 V2 

C4 V5 

C4 V6 
G-167

Figure G-239 Intermediate-Scale Test 8, SCDU 4, all measured voltages

Figure G-240 Intermediate-Scale Test 8, SCDU 4, all measured currents

Time (s)

0 500 1000 1500 2000 2500 3000

Voltage (Vac)

0

20

40

60

80

100

120

140

C3 V1 

C3 V2 

C3 V3 

C3 V4 

C3 V5 

C3 V6 

C3 V7 

C3 V8 

Time (s)

0 500 1000 1500 2000 2500 3000

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

C3 A1 

C3 A2 

C3 A3 

C3 A4 

C3 A5 

C3 A6 

C3 A7 

C3 A8 
G-168

Figure G-241 Intermediate-Scale Test 8, SCDU 4, all measured currents, limited time 

span

Table G-52 Intermediate-Scale Test 8, SCDU 4, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #4

Time 

(seconds) Event Discussion

1732 Fuse clear The fuse clears in SCDU 4.

Summary Observations

The cables for the SCDU circuits are co-located within the same bundled tray in 

Position D of the intermediate-scale structure. A source cable shorted to SCDU 3 at 

1494 s and persisted until 1522 s. Another intercable interaction, which persisted for 

204 s, was observed on Conductor 3 until the fuse cleared on SCDU 4 at 1732 s into 

the test.

Time (s)

1100 1150 1200 1250 1300

Current (A)

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

C3 A1 

C3 A2 

C3 A3 

C3 A4 

C3 A5 

C3 A6 

C3 A7 

C3 A8 
G-169

G.19 Intermediate-Scale Test 11

G.19.1 SCDU 1

Figure G-242 Intermediate-Scale Test 11, SCDU 1, source and target voltage response 

to temperature conditions

Time (s)

0 200 400 600 800 1000 1200

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

200

400

600

800

1000

1200

1400

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

A Position - Middle
G-170

Figure G-243 Intermediate-Scale Test 11, SCDU 1, source and target voltage response

Figure G-244 Intermediate-Scale Test 11, SCDU 1, source and target voltage response, 

limited time span

Time (s)

0 200 400 600 800 1000 1200

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

800 850 900 950 1000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-171

Figure G-245 Intermediate-Scale Test 11, SCDU 1, overlay of key voltages and key 

currents

Figure G-246 Intermediate-Scale Test 11, SCDU 1, overlay of key voltages and key 

currents, limited time span

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 

Time (s)

800 850 900 950 1000

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 
G-172

Figure G-247 Intermediate-Scale Test 11, SCDU 1, all measured voltages

Figure G-248 Intermediate-Scale Test 11, SCDU 1, all measured voltages, limited time 

span

Time (s)

0 200 400 600 800 1000 1200

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 

Time (s)

800 850 900 950 1000

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 
G-173

Figure G-249 Intermediate-Scale Test 11, SCDU 1, all measured currents

Figure G-250 Intermediate-Scale Test 11, SCDU 1, all measured currents, limited time 

span

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 

Time (s)

800 850 900 950 1000

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-174

Table G-53 Intermediate-Scale Test 11, SCDU 1, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

868-900 Voltage 

increase on 

Passive 

Target 4

The voltage on Passive Target 4 increased from 1 V 

to as high as 18 V over this time span.

895-900 Spurious 

actuation on 

Target 6

There was a 5-s spurious actuation on Target 6 

before the fuse cleared.

900 Fuse clear At this time, the fuse cleared on SCDU 1.

Summary Observations

The three SCDU circuit cables were co-located in Position A. Initial failure was 

detected at 868 s as the voltage began to steadily increase on the Passive Target. 

The voltage initially started at 1 V and reached as high as 18 V before the fuse 

cleared. A spurious actuation was detected on Target 6 for 5 s before the fuse 

cleared at 900 s.
G-175

G.19.2 SCDU 2

Figure G-251 Intermediate-Scale Test 11, SCDU 2, source and target voltage response 

to temperature conditions

Figure G-252 Intermediate-Scale Test 11, SCDU 2, source and target voltage response

Time (s)

0 200 400 600 800 1000 1200

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

200

400

600

800

1000

1200

1400

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

A Position - Middle

Time (s)

0 200 400 600 800 1000 1200

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-176

Figure G-253 Intermediate-Scale Test 11, SCDU 2, source and target voltage response, 

limited time span

Figure G-254 Intermediate-Scale Test 11, SCDU 2, overlay of key voltages and key 

currents

Time (s)

800 850 900 950 1000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0

1

2

3

4 Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 
G-177

Figure G-255 Intermediate-Scale Test 11, SCDU 2, overlay of key voltages and key 

currents, limited time span

Figure G-256 Intermediate-Scale Test 11, SCDU 2, all measured voltages

Time (s)

800 850 900 950 1000

Current (A)

0

1

2

3

4 Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 

Time (s)

0 200 400 600 800 1000 1200

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 
G-178

Figure G-257 Intermediate-Scale Test 11, SCDU 2, all measured voltages, limited time 

span

Figure G-258 Intermediate-Scale Test 11, SCDU 2, all measured currents

Time (s)

800 850 900 950 1000

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0

1

2

3

4

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-179

Figure G-259 Intermediate-Scale Test 11, SCDU 2, all measured currents, limited time 

span

Time (s)

800 850 900 950 1000

Current (A)

0

1

2

3

4

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-180

Table G-54 Intermediate-Scale Test 11, SCDU 2, summary of observed faulting 

behavior.

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

743-869 Voltage increase 

observed on 

Conductor 3

The voltage on Conductor 3 increases from 5 V 

to 10 V during this time span.

869-881 Voltage increase 

observed on 

Conductor 3

There is a voltage increase on Conductor 3 from 

10 V to 23 V during this time span.

881-910 Voltage increase 

observed on 

Conductor 3

The voltage on Conductor 3 varied from 1 V to 

as high as 107 V during this time span.

878-892 Voltage increase 

observed on 

Passive Target 4

The Passive Target 4 conductor experiences 

voltage fluctuation from 2 V to 85 V before 

stabilizing back to a nominal 1 V.

889-900 Voltage increase 

observed on 

Active Target 5

The Active Target 5 conductor experiences 

voltage fluctuation from 1 V to 23 V before 

stabilizing back to a nominal 1 V.

904-910 Voltage increase 

observed on 

Active Target 6

The Active Target 6 conductor experiences 

voltage fluctuation from 1 V to 23 V before 

stabilizing back to a nominal 1 V.

921 Fuse clear The fuse on SCDU 2 clears.

Summary Observations

The three SCDU circuit cables were co-located in Position A. Initial voltage leakage 

was observed on Conductor 3, primarily from 743 – 869 s, where the voltage 

increased from 5 to 10 V. The voltage subsequently increased at a greater rate 

starting at 869 s, when it increased from 10 – 23 V over a 12-s period. The next 29 s 

carried voltage fluctuations from as low as 1 V to as high as 107 V. Passive Target 4 

would also experience large voltage fluctuations (from 2 – 85 V) from 878 – 892 s. 

Voltage fluctuations from 1 – 23 V were detected on Active Target 5 over an 11-s span 

beginning at 889 s. On Active Target 6, voltage fluctuations from 1 – 23 V were 

observed from 904 – 910 s. At 921 s, the fuse cleared on SCDU 2.
G-181

G.19.3 SCDU 3

Figure G-260 Intermediate-Scale Test 11, SCDU 3, source and target voltage response 

to temperature conditions

Figure G-261 Intermediate-Scale Test 11, SCDU 3, source and target voltage response

Time (s)

0 200 400 600 800 1000 1200

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

200

400

600

800

1000

1200

1400

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

A Position - Middle

Time (s)

0 200 400 600 800 1000 1200

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-182

Figure G-262 Intermediate-Scale Test 11, SCDU 3, overlay of key voltages and key 

currents

Figure G-263 Intermediate-Scale Test 11, SCDU 3, all measured voltages

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C3 A1 

C3 A2 

C3 A7 

C3 V2 

C3 V5 

C3 V6 

Time (s)

0 200 400 600 800 1000 1200

Voltage (Vac)

0

20

40

60

80

100

120

140

C3 V1 

C3 V2 

C3 V3 

C3 V4 

C3 V5 

C3 V6 

C3 V7 

C3 V8 
G-183

Figure G-264 Intermediate-Scale Test 11, SCDU 3, all measured currents

Table G-55 Intermediate-Scale Test 11, SCDU 3, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #3

Time 

(seconds) Event Discussion

811 Fuse clear At this time, the fuse cleared on SCDU 3. There 

were no spurious actuations or hot short 

behavior observed on this circuit.

Summary Observations

The three SCDU circuit cables were co-located in Position A. At 811 s, the fuse 

cleared on SCDU 3. There were no spurious actuations or hot short behavior on this 

circuit.

G.19.4 SCDU 4

Not Used.

Time (s)

0 200 400 600 800 1000 1200

Current (A)

0

1

2

3

4

5

6

C3 A1 

C3 A2 

C3 A3 

C3 A4 

C3 A5 

C3 A6 

C3 A7 

C3 A8 
G-184

G.20 Intermediate-Scale Test 12

G.20.1 SCDU 1

Figure G-265 Intermediate-Scale Test 12, SCDU 1, source and target voltage response 

to temperature conditions

Time (s)

0 1000 2000 3000 4000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

200

400

600

800

1000

1200

1400

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

C Position - 7'

C Position - Middle

C Posiion - 3'
G-185

Figure G-266 Intermediate-Scale Test 12, SCDU 1, source and target voltage response

Figure G-267 Intermediate-Scale Test 12, SCDU 1, source and target voltage response, 

limited time span

Time (s)

0 1000 2000 3000 4000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

3200 3400 3600 3800

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-186

Figure G-268 Intermediate-Scale Test 12, SCDU 1, overlay of key voltages and key 

currents

Figure G-269 Intermediate-Scale Test 12, SCDU 1, overlay of key voltages and key 

currents, limited time span

Time (s)

0 1000 2000 3000 4000

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 

Time (s)

3200 3400 3600 3800

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 A1 

C1 A2 

C1 A7 

C1 V2 

C1 V5 

C1 V6 
G-187

Figure G-270 Intermediate-Scale Test 12, SCDU 1, all measured voltages

Figure G-271 Intermediate-Scale Test 12, SCDU 1, all measured voltages, limited time 

span

Time (s)

0 1000 2000 3000 4000

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 

Time (s)

3200 3400 3600 3800

Voltage (Vac)

0

20

40

60

80

100

120

140

C1 V1 

C1 V2 

C1 V3 

C1 V4 

C1 V5 

C1 V6 

C1 V7 

C1 V8 
G-188

Figure G-272 Intermediate-Scale Test 12, SCDU 1, all measured currents

Figure G-273 Intermediate-Scale Test 12, SCDU 1, all measured currents, limited time 

span

Time (s)

0 1000 2000 3000 4000

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 

Time (s)

3200 3400 3600 3800

Current (A)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

C1 A1 

C1 A2 

C1 A3 

C1 A4 

C1 A5 

C1 A6 

C1 A7 

C1 A8 
G-189

Table G-56 Intermediate-Scale Test 12, SCDU 1, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #1

Time 

(seconds) Event Discussion

3268-3795 Voltage increase 

detected on 

Passive Target 4

The voltage on Passive Target 4 increased from 

1 - 10 V during this time range.

3795-3857 Spurious 

actuation of Active 

Target 6

A spurious operation occurred on Active Target 6 at 

120 V and 0.208 A. The actuation continued for 62 s 

until the fuse cleared.

3795-3857 Hot short on 

Active Target 5

There was a hot short detected on Active Target 5 

that carried approximately 111 V. This shorting 

behavior continued until the fuse cleared at 3857 s 

into the test.

3795-3828 Voltage increase 

detected on 

Passive Target 4

During this time range, a voltage increase from 

10 - 50 V was detected.

3829-3857 Hot short on 

Passive Target 4

The voltage on Passive Target 4 increased to 

approximately 122 V until the fuse cleared.

3857 Fuse clear The fuse on SCDU 1 cleared.

Summary Observations

Three SCDU circuit cables were tested in Position C in the intermediate-scale structure. 

Initial failure was detected at 3268 s. Voltage began to increase from 1 – 10 V on the 

Passive Target 4. At 3795 s, Target 6 actuated and continued for 62 s when the fuse 

cleared. During the same period of time, Target 5 experienced a hot short that carried 

approximately 111 V. Passive Target 4 had a voltage increase from 10 – 50 V until hot 

shorting at 3829 s. This hot short persisted until the fuse cleared at 3829 s.
G-190

G.20.2 SCDU 2

Figure G-274 Intermediate-Scale Test 12, SCDU 2, source and target voltage response 

to temperature conditions

Figure G-275 Intermediate-Scale Test 12, SCDU 2, source and target voltage response

Time (s)

0 1000 2000 3000 4000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

200

400

600

800

1000

1200

1400

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

C Position - 7'

C Position - Middle

C Position - 3'

Time (s)

0 1000 2000 3000 4000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-191

Figure G-276 Intermediate-Scale Test 12, SCDU 2, overlay of key voltages and key 

currents

Figure G-277 Intermediate-Scale Test 12, SCDU 2, all measured voltages

Time (s)

0 1000 2000 3000 4000

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C2 A1 

C2 A2 

C2 A7 

C2 V2 

C2 V5 

C2 V6 

Time (s)

0 1000 2000 3000 4000

Voltage (Vac)

0

20

40

60

80

100

120

140

C2 V1 

C2 V2 

C2 V3 

C2 V4 

C2 V5 

C2 V6 

C2 V7 

C2 V8 
G-192

Figure G-278 Intermediate-Scale Test 12, SCDU 2, all measured currents

Table G-57 Intermediate-Scale Test 12, SCDU 2, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #2

Time 

(seconds) Event Discussion

3185-3541 Voltage increase 

on Target 4

During this time span, the voltage increased from 

1 – 5 V.

3541 Fuse clear The fuse cleared on SCDU 2.

Summary Observations

Three SCDU circuit cables were tested in Position C in the intermediate-scale 

structure. A voltage increase from 1 – 5 V was recorded initially at 3185 s and 

continued for 56 s. At 3541 s, the fuse on SCDU 2 clears.

Time (s)

0 1000 2000 3000 4000

Current (A)

0

1

2

3

4

5

6

C2 A1 

C2 A2 

C2 A3 

C2 A4 

C2 A5 

C2 A6 

C2 A7 

C2 A8 
G-193

G.20.3 SCDU 3

Figure G-279 Intermediate-Scale Test 12, SCDU 3, source and target voltage response 

to temperature conditions

Figure G-280 Intermediate-Scale Test 12, SCDU 3, source and target voltage response

Time (s)

0 1000 2000 3000 4000

Voltage (Vac)

0

20

40

60

80

100

120

140

Temperature (°C)

0

200

400

600

800

1000

1200

1400

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

C Position - 7'

C Position - Middle

C Position - 3'

Time (s)

0 1000 2000 3000 4000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6
G-194

Figure G-281 Intermediate-Scale Test 12, SCDU 3, source and target voltage response, 

limited time span

Figure G-282 Intermediate-Scale Test 12, SCDU 3, overlay of key voltages and key 

currents

Time (s)

2800 2850 2900 2950 3000

Votlage (Vac)

0

20

40

60

80

100

120

140

Source Conductor 1

Target Conductor 4

Target Conductor 5

Target Conductor 6

Time (s)

0 1000 2000 3000 4000

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C3 A1 

C3 A2 

C3 A7 

C3 V2 

C3 V5 

C3 V6 
G-195

Figure G-283 Intermediate-Scale Test 12, SCDU 3, overlay of key voltages and key 

currents, limited time span

Figure G-284 Intermediate-Scale Test 12, SCDU 3, all measured voltages

Time (s)

2800 2850 2900 2950 3000

Current (A)

0

1

2

3

4

5

6 Voltage (Vac)

0

20

40

60

80

100

120

140

C3 A1 

C3 A2 

C3 A7 

C3 V2 

C3 V5 

C3 V6 

Time (s)

0 1000 2000 3000 4000

Voltage (Vac)

0

50

100

150

200

250

300

350

C3 V1 

C3 V2 

C3 V3 

C3 V4 

C3 V5 

C3 V6 

C3 V7 

C3 V8 
G-196

Figure G-285 Intermediate-Scale Test 12, SCDU 3, all measured voltages, limited time 

span

Figure G-286 Intermediate-Scale Test 12, SCDU 3, all measured currents

Time (s)

2800 2850 2900 2950 3000

Voltage (Vac)

0

50

100

150

200

250

300

350

C3 V1 

C3 V2 

C3 V3 

C3 V4 

C3 V5 

C3 V6 

C3 V7 

C3 V8 

Time (s)

0 1000 2000 3000 4000

Current (A)

0

1

2

3

4

5

6

C3 A1 

C3 A2 

C3 A3 

C3 A4 

C3 A5 

C3 A6 

C3 A7 

C3 A8 
G-197

Figure G-287 Intermediate-Scale Test 12, SCDU 3, all measured currents, limited time 

span

Table G-58 Intermediate-Scale Test 12, SCDU 3, summary of observed faulting behavior.

Summary of Observed Faulting Behavior for Circuit #3

Time 

(seconds) Event Discussion

2716-2923 Voltage increase 

on Passive 

Target 4

The voltage increased from 1 – 5 V until the fuse 

cleared. 

2923 Fuse clear The fuse for SCDU 3 cleared.

Summary Observations

Three SCDU circuit cables were tested in Position C in the intermediate-scale 

structure. A voltage increase from 1 – 5 V was recorded initially at 2716 s and 

continued for 207 s. At 2923 s, the fuse on SCDU 3 cleared.

G.20.4 SCDU 4

Not Used.

Time (s)

2800 2850 2900 2950 3000

Current (A)

0

1

2

3

4

5

6

C3 A1 

C3 A2 

C3 A3 

C3 A4 

C3 A5 

C3 A6 

C3 A7 

C3 A8 

BIBLIOGRAPHIC DATA SHEET

(See instructions on the reverse)

NRC FORM 335

(12-2010)

NRCMD 3.7

U.S. NUCLEAR REGULATORY COMMISSION 1. REPORT NUMBER

 (Assigned by NRC, Add Vol., Supp., Rev.,

 and Addendum Numbers, if any.)

NUREG/CR-7100

SAND2012-0323P

3. DATE REPORT PUBLISHED

MONTH

April

YEAR

2012

4. FIN OR GRANT NUMBER

USNRC JCN N6579

2. TITLE AND SUBTITLE

Direct Current Electrical Shorting in Response to Exposure Fire (DESIREE-Fire): Test Results

5. AUTHOR(S)

S.P.Nowlen, J.W.Brown, T.J. Olivier, F.J.Wyant

6. TYPE OF REPORT

Technical

7. PERIOD COVERED (Inclusive Dates)

2/26-2010 - 1/30/2012

8. PERFORMING ORGANIZATION - NAME AND ADDRESS (If NRC, provide Division, Office or Region, U.S. Nuclear Regulatory Commission, and mailing address; if contractor,

Sandia National Laboratories

9. SPONSORING ORGANIZATION - NAME AND ADDRESS (If NRC, type "Same as above"; if contractor, provide NRC Division, Office or Region, U.S. Nuclear Regulatory Commission, 

Division of Risk Analysis

provide name and mailing address.)

and mailing address.)

10. SUPPLEMENTARY NOTES

G. Taylor, NRC Project Manager

11. ABSTRACT (200 words or less)

 This report presents the results of a series of fire tests performed to assess cable failure modes and effects behavior for

direct current (dc)-powered control circuits. The project, known as the Direct Current Electrical Shorting in Response to

Exposure Fire (DESIREE-Fire) test project, was sponsored by the U.S. Nuclear Regulatory Commission Office of Nuclear

Regulatory Research. The tests were performed by and at Sandia National Laboratories in Albuquerque, NM. The program was

conducted with the collaboration of the Electric Power Research Institute (EPRI) and its member utilities. EPRI representatives

participated in all phases of program planning, execution, data analysis, and data reporting by providing both peer review and

in-kind material support.

 The test program involved a series of both small- and intermediate-scale fire tests. Each test exposed one or more electrical

control cables commonly used in the existing fleet of U.S. nuclear power plants (NPPs) to fire exposure conditions. Each test

cable was connected to one of several circuit simulator units designed to mimic the behavior of typical NPP components. The

simulated dc-powered control circuits included motor-operated valves, solenoid-operated valves of various sizes, and a medium

voltage circuit breaker unit. Cable electrical performance is monitored throughout each test to determine both the timing and

mode of circuit faulting behavior. This report focused on a factual reporting of the test program and test data. Insights regarding

dc-powered control circuit cable failure modes and effects are to be addressed separately via a Phenomena Identification and

Ranking Table (PIRT) exercises to qualitatively rank fire-induced electrical circuit phenomena and an expert elicitation to provide

quantitative numerical estimates to the likelihood of various fire-induced circuit failure configurations. One PIRT panel focused

on electrical behavior and the second on implications for probabilistic risk assessment.

12. KEY WORDS/DESCRIPTORS (List words or phrases that will assist researchers in locating the report.)

Electric cables, cables, fire, cable failure, fire risk, fire PRA, fire PSA, post-fire safe shutdown, spurious

actuaiton, spurious operation, hot short 14. SECURITY CLASSIFICATION

13. AVAILABILITY STATEMENT

unlimited

(This Page)

unclassified

(This Report)

unclassified

15. NUMBER OF PAGES

16. PRICE

NRC FORM 335 (12-2010)

Risk and Reliability Analysis Dept. 6761

P.O. Box 5800

Albuquerque, NM 87185-0748

Office of Nuclear Regulatory Research

U.S. Nuclear Regulatory Commission

Washington, DC 20555-0001