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Extra-low voltage

Extra-low voltage (ELV) is an supply voltage level defined as a nominal voltage not exceeding 50 V () or 120 V (ripple-free) between any two points of an electrical or between any point and . This classification, part of the broader low-voltage band, is established to minimize the risk of electric shock in electrical systems, as these levels are considered safe for human contact under normal conditions without additional protective measures like or grounding. The definition originates from international standards such as IEC 60364-4-41, which specifies protection against electric shock, and IEC 61140, focusing on common aspects of electrical safety. ELV systems are widely applied in environments where electrical hazards are heightened, such as swimming pools, outdoor portable appliances, medical devices, and industrial settings requiring touch-safe power distribution. Within ELV, specialized categories include safety extra-low voltage (SELV), which ensures the voltage remains below ELV limits even under single-fault conditions and is electrically separated from higher-voltage circuits to prevent hazardous transfer. Another variant is protected extra-low voltage (PELV), similar to SELV but allowing a protective connection while maintaining separation from hazardous voltages. These distinctions enhance safety in applications like battery-powered tools, systems, and control circuits, where compliance reduces the need for extensive barriers or interlocks. The adoption of ELV standards promotes global harmonization in electrical installations, with bodies like the (IEC) providing the foundational guidelines, while national codes such as the UK's align closely for wiring regulations. In practice, ELV enables efficient power delivery for low-risk devices, including , security systems, and interfaces, balancing safety with functionality in modern infrastructure.

Introduction

Definition and Voltage Limits

Extra-low voltage (ELV) is defined as a nominal voltage not exceeding 50 V alternating current (AC) root mean square (RMS) or 120 V direct current (DC) ripple-free between conductors or to earth or any conductor and earth. This threshold establishes ELV as a category within electrical systems designed to minimize shock hazards. The distinction between AC and DC limits arises from differences in physiological impact; AC at power frequencies (50–60 Hz) is more hazardous due to its ability to induce rhythmic muscle contractions and disrupt cardiac rhythm at lower currents than DC. The 50 V AC RMS threshold is derived from human body models in IEC 60479-1, where it limits prospective touch currents to levels with low probability of ventricular fibrillation when sustained, based on human body models in IEC 60479-1, assuming a minimum internal body resistance of about 500 Ω and external skin resistance of 1,000–1,500 Ω under dry conditions (yielding ~20–50 mA, above let-go but below typical VF thresholds for short durations). For DC, the 120 V ripple-free limit accommodates higher tolerance (~2–4 times AC for VF risk), as steady DC currents cause less tetanic contraction and fibrillation risk, with thresholds based on body current limits in IEC 60479-1 to avoid fibrillation (yielding ~50–100 mA under dry conditions, below typical DC VF onset). Ripple-free DC specifies a direct voltage where the alternating ripple component is negligible, conventionally defined as an r.m.s. ripple voltage not more than 10 % of the DC component, with the maximum peak value not exceeding 140 V for safety considerations. Voltage measurements follow standardized methods: RMS for AC, calculated as the square root of the mean of the squared instantaneous values over one period to reflect heating effect; for DC, the steady-state arithmetic mean value, though peak values are assessed for fault-induced transients or pulsed DC. These measurements apply under normal operating conditions, with ELV limits verified in both normal and single-fault scenarios to account for potential increases in voltage during insulation failures or overloads. ELV is differentiated from , defined by IEC as nominal voltages exceeding ELV limits but not surpassing 1,000 V RMS or 1,500 V ripple-free. In contrast to informal or context-specific terms like ultra-low voltage—often used in for levels below 5–12 V without standardized thresholds—ELV represents a formal safety band emphasizing reduced .

Safety Principles and Benefits

The safety of extra-low voltage (ELV) systems stems from the physiological effects of electrical on the , where the risk of injury is primarily determined by the magnitude and duration of flow rather than voltage alone. Human electropathology identifies key thresholds for (AC) at power frequencies: perception occurs at approximately 0.2–1 mA, causing a faint tingle; the let-go threshold, beyond which voluntary muscle release from the current source becomes difficult, is typically 6–16 mA (varying by and conditions) for adults; and risk increases above 60 mA for exposures exceeding 0.5 seconds. These thresholds are established by international standards based on empirical , ensuring that ELV limits to levels with low risk of in most scenarios, thereby minimizing involuntary and cardiac risks even if contact is sustained. The human body's to flow, predominantly at interface, further underpins ELV safety. Dry typically exhibits a of 1000-2000 ohms between points such as hand-to-hand, limiting for ELV applications well below harmful levels even under normal conditions. In adverse scenarios like wet hands or broken , where can drop to 500 ohms or lower, ELV still restricts to under 100 for voltages up to 50 V in conservative models, preventing high probability of fibrillation thresholds. This physiological buffering allows ELV to prioritize safety in environments where higher voltages would pose immediate dangers, such as conductive or damp settings. Benefits of ELV include significantly reduced risks of electric shock, thermal burns, and ignition, particularly in hazardous locations like wet areas or near conductive materials, where traditional low-voltage systems might fail. By limiting energy transfer, ELV enables simplified requirements and, in isolated systems, eliminates the need for protective grounding, lowering installation complexity and maintenance costs without compromising protection. These advantages are evident in applications like portable tools in outdoor or settings, where fault currents remain non-lethal even during direct contact. From an engineering perspective, ELV principles rely on from higher-voltage sources to prevent fault propagation, ensuring that any single insulation failure does not expose users to dangerous potentials. For instance, in scenarios involving or minor abrasions that reduce skin resistance, the inherent voltage ceiling maintains below typical fibrillation thresholds, allowing potential self-rescue or low lethality. This design philosophy evolved from early 20th-century experiments, notably Charles Dalziel's 1940s studies on AC fibrillation s, which quantified safe let-go levels at 9 mA for 50% of adult males and informed modern thresholds like the 5 mA safety limit for general populations.

Types

Safety Extra-Low Voltage (SELV)

Safety Extra-Low Voltage (SELV) refers to an electrical system in which the voltage cannot exceed extra-low voltage limits—typically 50 V AC or 120 V —under both normal operating conditions and single-fault conditions, with full electrical separation from higher voltage supplies through double or reinforced and no reliance on protective earthing. This separation ensures that even if a fault occurs, such as a to a higher , the SELV remains at safe voltage levels, providing the highest degree of protection against electric in areas where direct human contact is likely. SELV systems require isolation devices, such as transformers compliant with IEC 61558-1, which incorporate or reinforced insulation to achieve protective separation equivalent to two layers of basic . These requirements mandate that the SELV circuit be fully from hazardous live parts and , preventing any conductive path that could introduce higher voltages. Compliance ensures the system withstands single faults without exceeding ELV thresholds, prioritizing over operational continuity. Unique applications of SELV include medical electrical equipment, where isolation protects patients from shock during direct contact, as specified in safety standards for such devices. It is also employed in toys powered by transformers meeting IEC 61558-2-7, ensuring child-safe operation without risk of hazardous voltages. Additionally, SELV powers handheld tools and equipment in wet environments, such as swimming pools, to mitigate risks in conductive conditions. Testing for SELV involves dielectric strength verification, such as applying 1500 V across to confirm it withstands potential breakdowns without failure. Creepage and clearance distances between conductors are measured and must meet minimum values per IEC 60664-1 to prevent arcing or tracking under or . These tests ensure the insulation integrity required for safe operation.

Protected Extra-Low Voltage (PELV)

Protected Extra-Low Voltage (PELV) is defined as an electrical system in which the voltage does not exceed extra-low voltage (ELV) limits under both normal operating conditions and single-fault conditions, providing protection against electric shock through basic combined with a protective earthing . This ensures that, in the event of a fault such as failure, the touch voltage remains within safe ELV thresholds, typically not exceeding 50 V RMS or 120 V ripple-free, aligning with the same voltage caps as Safety Extra-Low Voltage (SELV) systems. The requirements for PELV systems emphasize single-fault protection via the protective earth connection, which diverts fault currents safely to ground, preventing hazardous voltages from appearing on accessible parts. This protection is typically implemented using devices such as residual current devices (RCDs) or fuses to clear faults quickly, ensuring the system returns to a safe state. Additionally, PELV wiring must be physically segregated from higher-voltage circuits to avoid inadvertent connections that could introduce dangerous potentials. In contrast to SELV, which achieves safety through complete electrical separation and double or reinforced without reliance on ing, PELV permits a single layer of between live s and provided the protective is connected, thereby lowering and costs while still ensuring equivalent in grounded environments. This makes PELV particularly suitable and often mandatory for industrial control applications where protective ing infrastructure is already in place. Common examples of PELV applications include low-voltage lighting circuits in industrial settings and control panels for machinery, where compliance with IEC 60204-1 ensures safe operation by integrating protective earthing with ELV limits.

Functional Extra-Low Voltage (FELV)

Functional extra-low voltage (FELV) refers to an electrical circuit in which the voltage does not exceed extra-low voltage limits—typically 50 V AC or 120 V DC ripple-free—used primarily for operational or functional purposes rather than for inherent safety, and featuring simple separation from higher low-voltage circuits. Unlike safety extra-low voltage (SELV) or protected extra-low voltage (PELV), FELV circuits do not provide full isolation or reinforced insulation from hazardous voltages and may be connected to protective earthing. This simple separation typically involves a single layer of basic insulation, allowing potential connection to higher voltages under fault conditions without qualifying as a safety-isolated system. FELV systems require additional protective measures to mitigate risks, particularly where user access is possible, such as physical barriers, enclosures, or warning labels to prevent direct contact with live parts. Live parts must be separated from other circuits by at least simple or protective insulation, with voltage limited to ELV levels under normal no-fault conditions; however, under single-fault or earth-fault scenarios, voltages at accessible parts may exceed ELV limits; therefore, supplementary protections like fuses or overcurrent devices are required to prevent hazardous contact. If the voltage exceeds safer thresholds (e.g., 25 V AC in dry conditions or 12 V AC/30 V DC in wet conditions), direct contact protection via IP2X/IPXXB enclosures or insulation tested to 500 V AC for 1 minute is mandatory. Plugs and sockets in FELV systems must not be interchangeable with those of SELV, PELV, or higher-voltage supplies in the same installation to avoid accidental cross-connection. FELV circuits find application in scenarios where low voltage supports efficient or control without prioritizing , such as in machine control systems for industrial automation. They are also employed in audio/visual systems, setups, and internal low-voltage interfaces within computer and telecommunication equipment, where functional performance drives the voltage choice and enclosures provide secondary protection. Due to their limited separation from higher voltages, FELV circuits are not suitable for direct human contact or accessible applications without robust enclosures or barriers, as fault conditions could elevate voltages beyond safe ELV levels. In equipment, compliance follows standards like IEC 60950-1 (now superseded by IEC 62368-1), emphasizing supplementary safeguards rather than standalone safety.

Reduced Low Voltage (RLV)

Reduced Low Voltage (RLV) is a UK-specific system under BS 7671, adapting low-voltage principles with a nominal line-to-line voltage that does not exceed 110 V AC (exceeding standard ELV limits) and the nominal line-to-earth voltage limited to 63.5 V AC, thereby reducing the risk of electric shock in hazardous environments. This configuration typically involves a single-phase center-tapped supply operating at 55-0-55 V AC (55 V line-to-earth) or a three-phase star-connected system without a neutral conductor (63.5 V line-to-earth), where the midpoint or star point is earthed to limit touch voltages accordingly. RLV serves as a practical adaptation of extra-low voltage principles, allowing higher voltages than standard SELV or PELV systems when necessary for powering equipment, while still prioritizing safety through reduced exposure to live parts. Key requirements for RLV systems include double or reinforced insulation, or equivalent barriers and enclosures, for basic protection against direct contact, in accordance with Regulation 411.8.2 of BS 7671. There is no provision for an earthed neutral; instead, all live conductors must be protected by double-pole (single-phase) or triple-pole (three-phase) devices, with fault protection achieved via automatic disconnection using devices within 5 seconds or devices (RCDs). These systems are specifically tailored for environments where standard extra-low voltage supplies are insufficient for operational needs, such as in and , and must comply with additional standards like BS 7375 for distribution units. RLV finds unique applications in powering portable hand tools and temporary lighting on construction sites, as well as in underground settings like rail trackside equipment and cleaning sockets, where the reduced touch voltage minimizes shock hazards for unskilled workers. Regulation 704.410.3.10 of strongly recommends RLV for socket-outlets up to 32 A supplying hand-held tools and for portable or local lighting up to 2 kW, often in conjunction with 30 mA RCDs for added . This approach ensures reliable power delivery in damp or confined spaces without the need for full electrical separation. The concept of RLV originated in the late , following recommendations in the 1949 Annual Report of HM Chief Inspector of Factories, which advocated its use on building and sites to enhance amid rising . It was formally introduced in the for hazardous locations, including atmospheres in mines, differing from IEC standards that emphasize stricter extra-low voltage limits without this elevated regional variant. Since its adoption, RLV systems have recorded no fatalities from electric shock in compliant installations, underscoring their effectiveness in high-risk applications.

Applications

Stand-Alone Power Systems

Stand-alone power systems utilize extra-low voltage (ELV) to deliver safe, efficient in off-grid environments, where panels and batteries generate (DC) power typically at 12 V or 24 V for applications such as , water pumps, and small appliances in remote areas. These systems often employ DC ELV directly from batteries to power low-risk loads, while inverters convert the output to (AC) ELV below 50 V rms when needed for compatible devices. Common implementations include rural homesteads with DC bus configurations ranging from 100 Wp to 1 kWp, ensuring operation within ELV limits of less than 120 V DC or 50 V AC as defined by standards like AS/NZS 3000. Design considerations in these systems emphasize voltage management and protection against to maintain ELV . Lead-acid or lithium-ion , often configured in 12 V or 24 V banks, store energy for 1–3 days of , with sizing based on daily load needs (e.g., 12 kWh for 3,000 Wh consumption). Charge controllers, such as (MPPT) types, regulate input from solar arrays to prevent voltage spikes exceeding ELV thresholds, achieving efficiencies of 95%–99%. Inverters must match voltage and handle surges up to 1,000 W for loads like pumps, using single-insulated cables for ELV sections to simplify wiring while adhering to standards like IEC 62109. ELV stand-alone systems offer advantages including inherent protection from grid faults, as they operate independently, and simplified wiring due to lower voltage requirements that reduce risks and installation complexity for competent users. Examples include recreational vehicles (RVs) and , where 12 V systems power lights and pumps efficiently without extensive . These setups promote in off-grid homes, eliminating blackouts and minimizing utility costs. Challenges arise from energy storage limitations, as battery capacity dictates system reliability, often requiring efficient ELV-compatible loads to avoid depletion during low solar periods. Maintenance of batteries, lasting 5–15 years, and sensitivity to inconsistent voltage from partial charges can lead to inverter inefficiencies or equipment failure if not monitored. Surge protection and proper sizing are essential to handle variable loads without exceeding ELV boundaries.

Fixed Installations and Appliances

In fixed installations, extra-low voltage (ELV) systems are commonly employed in residential and commercial buildings for applications requiring enhanced safety, such as doorbells operating at 12-24 V, HVAC controls, and systems including intercoms and controls. These systems are segregated from higher-voltage wiring to prevent and ensure safety, typically using dedicated conduits or raceways insulated for the highest voltage present, as required for safety extra-low voltage (SELV) circuits. In mixed-voltage environments, this segregation minimizes risks of fault propagation, with ELV circuits often routed separately from mains power to avoid . ELV appliances integrated into fixed setups include LED lighting systems powered at 12-24 DC, battery chargers for devices like electric toothbrushes, and certain kitchen appliances such as under-cabinet lights or control circuits in blenders operating below 50 AC. Compliance is ensured through markings like UL for Class 2 power supplies (limiting output to 60 W at 12 DC or 96 W at 24 DC to reduce fire and shock hazards) and for general product safety under directives covering voltages below 50 AC. These appliances prioritize low-energy operation and are designed for seamless integration without requiring guarding, as their voltage levels pose minimal shock risk. Integration of ELV in fixed installations often involves isolating transformers that step down mains voltage (e.g., 120/240 ) to 12-24 V levels, providing galvanic separation via high-insulation windings or earthed screens to maintain protective extra-low voltage (PELV) standards suitable for general fixed setups. Fault protection in these mixed-voltage environments relies on double or reinforced in transformers, ground-fault detection modules to interrupt currents exceeding safe limits, and avoidance of earthing live ELV conductors to prevent hazardous touch voltages during faults. Since the 2010s, the adoption of ELV has surged in smart homes due to the proliferation of (IoT) devices, such as connected thermostats, smart doorbells, and wireless sensors operating at 5-24 V, enabling safer, more efficient automation without extensive rewiring. This trend, driven by over 12 billion connected devices globally by 2022 and reaching nearly 20 billion as of 2025, has integrated ELV into for energy savings and , contrasting with traditional higher-voltage systems.

Regulations and Standards

International Standards (IEC)

The (IEC) establishes the foundational global standards for extra-low voltage (ELV) systems, emphasizing protection against electric shock through defined voltage limits, separation techniques, and installation requirements. Central to this framework is IEC 61140, which provides common aspects for protection against electric shock in installations and equipment, including the delineation of ELV as voltages not exceeding 50 V AC or 120 V DC ripple-free to minimize physiological effects on humans and . This standard originated concepts like safety extra-low voltage (SELV) and reinforced insulation to prevent hazardous contact, serving as the basis for worldwide ELV definitions. IEC 60364 series addresses low-voltage electrical installations, incorporating ELV provisions in parts such as -4-41 for protection against electric shock and recent extensions like -7-716 for ELV DC distribution in balanced IT cables. The series was updated with -1:2025 (Edition 6.0), reinforcing fundamental principles for ELV safety. These standards mandate basic protection via barriers or enclosures and fault protection through automatic disconnection or equipotential bonding to ensure ELV circuits remain isolated from higher voltages. Complementing this, IEC 61558 covers the safety of transformers and power supply units used in ELV applications, requiring safety isolating transformers to maintain SELV output under fault conditions, with insulation levels tested for . Requirements in these standards focus on separation—such as or reinforced insulation—and fault tolerance, where ELV systems must withstand single faults without exceeding safe voltage limits, including testing protocols for impulse withstand voltage to simulate overvoltages. For instance, transformers under IEC 61558 undergo creepage and clearance measurements to prevent , ensuring reliability in ELV power supplies. The evolution of IEC ELV standards traces back to IEC Publication 479 (first edition 1974, later renumbered as IEC 60479-1), which analyzed current effects on the to establish risk-based voltage thresholds, transitioning to modern approaches in IEC 61140's third edition (2001, amended 2004) that integrated hazard analysis over prescriptive rules. Subsequent updates, including the fourth edition of IEC 61140 in 2016 and 2020s amendments in for DC systems, incorporate risk assessment for emerging applications like low-voltage DC microgrids, enhancing amid integration. IEC standards exert significant global influence, harmonized within the (ISO) and adopted as the baseline in over 170 countries through national electrotechnical committees, facilitating uniform testing and for ELV equipment worldwide. This adoption promotes in stand-alone power systems and fixed installations, with protocols like those in IEC 61140 influencing impulse withstand testing to verify ELV resilience against transients.

European Union Directives

The Low Voltage Directive (2014/35/EU) establishes essential health and safety requirements for electrical equipment placed on the market, applying specifically to equipment operating at nominal voltages between 50 V and 1,000 V for (AC) or between 75 V and 1,500 V for (DC). Extra-low voltage (ELV) systems, defined as those below 50 V AC or 120 V DC ripple-free, fall outside this scope and are thus exempt from the directive's conformity assessment obligations, though they may still need to comply with related harmonized standards for safety. Manufacturers of equipment within the directive's voltage range must conduct a , prepare technical documentation, and declare conformity before affixing the to ensure safe integration with ELV components where applicable. ELV concepts, particularly safety extra-low voltage (SELV) and protected extra-low voltage (PELV), are integrated into the (2006/42/EC), which requires machinery designers to eliminate or reduce electrical hazards, including those from low-voltage systems, by referencing harmonized standards like EN 60204-1 for protective measures against electric shock. These standards specify SELV and PELV as safe ELV implementations with voltage limits up to 50 V AC or 120 V DC, ensuring separation from higher voltage circuits in machinery to prevent indirect contact risks. Post-Brexit adjustments in the 2020s have maintained these EU requirements for member states while the adopted parallel UKCA marking, but ELV safety principles remain aligned with IEC-based harmonized standards within the EU framework. Enforcement of these directives involves notified bodies for certain high-risk assessments, though the Low Voltage Directive primarily relies on manufacturer self-declaration; non-compliance can result in market withdrawal, product recalls, or administrative fines varying by , often reaching thousands of euros, with the serving as the visible indicator of . Market surveillance authorities in each EU country monitor compliance, and harmonized standards under the directives provide presumption of when applied to ELV elements. In the Construction Products Regulation (EU) No 305/2011, ELV wiring and cables for power, control, and communication systems are regulated as construction products, requiring a declaration of for essential characteristics like reaction to and electrical to ensure safe in buildings. This includes harmonized standards for low-voltage cabling that support ELV applications, with mandatory for and through systems like AVCP ( and of constancy of ).

National Regulations

In the , low-voltage power-limited circuits operating at less than 50 volts, similar to ELV systems, are regulated under the (NEC), specifically through Article 725 in the 2023 edition for Class 1, Class 2, and Class 3 remote-control, signaling, and power-limited circuits to mitigate shock and fire risks in low-power applications such as thermostats and security systems, which consolidated requirements from the former Article 720. Class 2 circuits, for instance, are limited to 30 volts and 100 VA to ensure inherent safety without additional protection. Underwriters Laboratories (UL) standards, such as UL 62368-1 for audio/video and equipment, further certify such devices for compliance, emphasizing low-energy limits in device design and installation. Australia and New Zealand adopt AS/NZS 3000:2018, the Wiring Rules, which includes Section 7.5 dedicated to extra-low voltage electrical installations, aligning closely with for voltages not exceeding 50 V AC or 120 V ripple-free, while incorporating local requirements such as enhanced protection in bushfire-prone areas to prevent ignition from electrical faults. These rules mandate separation of ELV circuits from higher voltage systems and specific testing protocols, with amendments up to 2024 addressing environmental resilience in high-risk zones. In , NBR 5410:2004 (with amendments through 2021) governs low-voltage electrical installations up to 1000 V, adopting principles for ELV systems while incorporating adjustments for tropical climates, such as elevated temperature ratings for insulation and conductors to account for humidity and heat. The National Electric Energy Agency (ANEEL) provides oversight through resolutions like Normative Resolution 482/2012, ensuring ELV compliance in and building installations via mandatory inspections and grid interconnection rules. The United Kingdom's :2018 (18th Edition, with Amendment 2:2022) outlines requirements for ELV and reduced (RLV) systems, defining RLV as nominal line-to-line voltages up to 110 V and line-to-earth up to 63.5 V, with Regulation 411.8 mandating fault protection via RCDs and disconnection times not exceeding 5 seconds. Post-Brexit, the standard maintains alignment with CENELEC harmonized documents but introduces national deviations, such as stricter detection in domestic ELV circuits, without full EU directive enforcement. National regulations exhibit diversity in ELV approaches: the prioritizes energy limitations (e.g., power caps in Class 2 circuits) for safety in limited-energy systems, contrasting with IEC-influenced standards in /New Zealand, , and the , which emphasize voltage thresholds and environmental adaptations, as updated in the 2023 edition and equivalent national codes through 2025. This reflects varying priorities, with the focusing on circuit power to reduce hazard potential, while others integrate voltage-based isolation with local climatic or regulatory nuances.

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