ARC FLASH LABELING

This guide describes best practices for arc flash labeling . The intent is to provide arc flash labeling that delivers proper safety warnings and
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maximizes communication throughout the facility. If you need further assistance after reviewing this best practice guide, please contact one of
our knowledgeable customer service representatives at 1-800-788-5572.

1 TOOLS
Learn what labeling tools are required for arc ash labeling
and about other tools which will aid in compliance.

2 DEFINITIONS
Learn what an arc ash is and what potential hazards it
may pose on employees and bystanders.
What is an Arc Flash?
Definitions of Terms

4 EVALUATION - FACILITY INSPECTION

Find out what needs to be evaluated in a facility.

2 Why is it important to know what an arc ash is? 5 LABEL CREATION

Learn what is required on labels, when to use a Danger
label over a Warning label and how to print arc ash labels.
What information should be included on an Arc Flash Label?
DANGER vs. WARNING Labels
Arc Flash Label (Sign) and Tag Design
Needed Equipment and Supplies
Label Creation Steps

10 LABEL PLACEMENT
Proper placement of arc ash labels will increase worker
safety and improve overall workow.
Labels Should Be Placed
Removing Old Labels

11 LABEL MAINTENANCE
Learn how to extend the life of arc ash labels.

12 ARC FLASH INFORMATION GUIDE

When should a DANGER label be used? A brief overview of the data which is required on arc ash

5 When should a WARNING label be used? labels for NFPA 70E compliance.

This guide is published by Graphic Products, the manufacturer of DuraLabel printers and supplies. We are a leading international manufactur-
er of industrial-quality printers and label supplies for facility identification. We specialize in providing support solutions for OSHA and ANSI com-
pliance and offer more than 50 application-specific supplies for the most extreme indoor and outdoor conditions. Due to our large inventory,
we can ship same day and our technical support is free-of-charge for as long as you are a customer, guaranteed. Contact us for a free catalog.

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DISCLAIMER: This guide is for general purposes only. It is not a substitute for review of applicable standard. We have
attempted to make this guide as complete and accurate as possible. However, you are responsible for meeting all code requirements, for
providing arc flash labeling throughout your facility, and for having complete, correct and proper arc flash labeling. We provide no
guarantees, nor warranties as to the correctness, accuracy or applicability of the information in this guide. We disclaim all liability
associated with the use of the information provided in this guide.

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 LABELING TOOLS: DuraLabel provides the necessary labeling tools to print arc ash labels on demand and at a low cost.

TOOLS
The recommended tools and equipment involved with Arc Flash labeling projects include:
Technical or safety information regarding equipment to be labeled
Computer with Windows 2000 Operating System or above
Use a laptop or the DuraLabel Mobile Print Station 150 XL if portability is needed
Word processing software or DuraLabel DuraSuite Labeling Software
DuraLabel PRO 300 library of symbols, templates and examples
DuraLabel PRO 300 series printer2 (http://www.DuraLabel.com)
DuraLabel PRO 300 battery (optional, for portability)
DuraLabel PRO 300 arc flash label supplies (select the supplies
best suited for your labeling requirements)
4" x 6" Die-cut labels with preprinted DANGER header
4" x 6" Die-cut labels with preprinted WARNING header
Continuous two-color vinyl
DuraLabel PRO 300 black thermal transfer ribbon
Specialty supplies
4" x 6" Die-cut labels with preprinted Danger header (Spanish)
4" x 6" Die-cut labels with preprinted Warning header (Spanish or French)
6.8" x 10.5" Die-cut labels with preprinted Danger & Warning headers (DL7 & DL9 only)
8.8" x 12.8" Die-cut labels with preprinted Danger & Warning headers (DL9 only)
Supplies and equipment to clean and prepare surfaces for labeling
Putty knife or wire brush

2
Although other industrial quality printers may be used, the DuraLabel PRO 300 is a popular thermal transfer printer proven to make
effective, long-lasting arc flash labels. The descriptions given in this guide use the DuraLabel PRO 300.

1 1-800-788-5572 www.DuraLabel.com
 ARC FLASH?: Understanding what an arc ash is will heighten the awareness and importance of required PPE when working on or near equipment.

DEFINITIONS
What is an Arc Flash?
An arc ash is a rapid, explosive discharge of electrical
energy that usually results from a short circuit fault. Metal
vaporized by the 5,000+ degree temperatures of an arc ash
produces a high temperature plasma. A blast shock wave
propels unvaporized metal as high velocity shrapnel. An
arc ash can occur in as little as 1/1000 of a second. It is
unexpected, violent and deadly.
The potential for an injury can be reduced using various
techniques such as remote breaker racking, remote door
openers/closers, precautions when working on equipment
and proper personal protective equipment (PPE). A key
element in any arc ash safety program is the use of
labels and signs to provide warnings about arc ash and
information about safety requirements.

For more information about arc flash: http://www.LabelPrinters.org

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DEFINITIONS
Definitions of Terms (from NFPA 70E, 2009 Edition)
The following terms are frequently found on arc ash labels and signs.
Flash Protection Boundary This is the distance from
an arc source within which a person could receive a
second degree burn if an electrical arc ash were to
occur.
Limited Approach Boundary This is the distance
from an exposed energized electrical conductor or
circuit part within which a shock hazard exists.
Restricted Approach Boundary This is the distance
from an exposed energized electrical conductor
or circuit within which there is an increased risk
of shock, due to electrical arc over combined with
inadvertent movement.
Prohibited Approach Boundary This is the distance
from an exposed energized electrical conductor or
circuit part within which work is considered to be the
same as making contact with the electrical conductor
or circuit part.
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Arc-Rated FR is arc-rated flame-resistance.
3 1-800-788-5572
Incident Energy The amount of energy impressed on a
surface, a certain distance from the source, generated
during an electrical arc event. One of the units used
to measure incident energy is calories per centimeter
squared (cal/cm2).
Personal Protection Equipment (PPE) All parts of
the body inside the Arc Flash Protection Boundary
shall be protected. Arc-Rated FR4 clothing and other
personal protective equipment (PPE) shall be used by
the employee based on the incident energy exposure
associated with the specic task and Hazard/Risk
category numbers 0 through 4. Recognizing that
incident energy increases as the distance from the arc
ash decreases, additional PPE shall be used for any
parts of the body that are closer than the distance at
which the incident energy was determined.
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 FACILITY INSPECTIONS: Stay compliant with todays standards and inspect facilities regularly to assist in arc ash safety.

EVALUATION FACILITY INSPECTION

Conduct an inspection of your facility to determine the need for new and replacement arc ash labels.
When evaluating your facility, look for and/or pay attention to:
Existing labels
Are they still legible? (Damaged, deteriorated, etc)
Are they accurate? (Proper calculations, boundaries, PPE, etc) Also be sure to note the date of
Equipment without labels your last arc ash analysis. NFPA
New equipment
70E Article 130.3 states you must
re-evaluate an arc ash analysis
Does the new equipment pose an arc flash danger?
at least every five years.
Have boundaries been calculated?
If this re-evaluation shows a change,
Areas where maintenance has been performed your labels need to be updated.
Traffic areas
Areas from which people should be excluded due to arc flash hazard

Table 1
Methods Advantages Limitations
There are currently several IEEE 1584 Most recent and Hasnt been available for long in the
calculation methods being Equations comprehensive workplace; some doubts about accuracy
used to determine arc ash NFPA 70E Easy to use Tables must be applied within their
boundaries. Each method Articles & Tables Quick PPE reference specified ranges
has its own strengths and
FLUX.exe Easy to use Applies only to open-air, single-phase arcs
weaknesses.
Common Inaccurate when multiple correction factors
are added

The focus of these standards is calculating the radiated heat
or incident energy, falling on a surface, produced by an
arcing fault. Although no single method can fully calculate
arc ash hazards, it is recommended that IEEE 1584 be
used as the primary arc-ash calculation method, especially
for determining ash protection boundaries. IEEE 1584,
Guide For Performing Arc-Flash Hazard Calculations,
provides the equations and methods used to calculate the
incident energy level a worker could be exposed to in
cal/cm2. If IEEE 1584 calculated exposure levels are not
available, then use other methods.
Tables 130.7 (C)(9) and 130.7 (C)(10) from NFPA
Article 70E are the most common references for
determining exposure levels and required PPE. However,
these tables are based on assumptions using engineering
principles about electrical systems. Each table includes
notes to determine whether the electrical system falls
within the engineering principles used to create the
tables. At the minimum, equipment should display arc
ash labeling when the system operates at 50 volts or
more.

NOTE: Arc flash calculation is not an exact science. Always use caution and multiple methods to verify results.

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 ARC FLASH LABELS: The DuraLabel PRO 300 & 9000 are great printers for customizing Arc Flash labels on demand and at a low price.

LABEL CREATION
NFPA 70E standards require the arc ash label to display the incident energy or required level of PPE. NFPA 70E recommends including
as much information as possible. Thorough information concerning the level of the arc ash hazard allows qualied persons to know
what level of precaution and type of personal protective equipment (PPE) is necessary when working on or near the equipment.

What Information Should Be Included On An Arc Flash Label?

The label should clearly show there is a serious hazard.
Use a DANGER or a WARNING label with the appropriate
signal word (Danger or Warning) in the header. The
label should also identify the hazard as being both an arc
ash and a shock hazard. Article 110.16 of The National
Electrical Code (NEC) states that labeling must warn about
both arc ash and shock hazards. The label also needs to
clearly state the incident energy or required level of PPE.
Although labeling is important, the best way to prevent
electrical injuries is to de-energize the equipment and
use Lockout/Tagout (LOTO). Identifying the available
upstream lockable point on the label helps enforce LOTO.
By identifying the rst disconnect feeding the equipment,
LOTO is reinforced and workers are reminded to use
LOTO procedures.

DANGER vs. WARNING Labels

When should a label with a DANGER header be used and when should a label with a WARNING header be used? The
rule of thumb is that a warning header should be used when the incident energy is 40 cal/cm2 or less. If the incident energy
is greater than 40 cal/cm2, then a danger label should be used.

The ANSI Z535.4-2007 standard provides the following
denitions for signal words:
4.14.1 DANGER: Indicates a hazardous situation which,
if not avoided, will result in death or serious injury. This
signal word is to be limited to the most extreme situations.
4.14.2 WARNING: Indicates a hazardous situation which, if
not avoided, could result in death or serious injury.
If the ANSI Z535.4-2007 standard, sections 4.14.1 & 4.14.2,
is strictly interpreted, then danger labels should never be
used for arc ash because arc ash incidents cannot be said
to always cause death. However, because arc ash injuries
are so severe the 40 cal/cm2 standard has been adopted
by many facilities. Whichever approach is used in your
facility, what is important is that it be used consistently
throughout your facility and preferably throughout your
organization.

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 LABEL CREATION

Arc Flash Label (Sign) and Tag Design

ANSI Z535 is a standard many national code-enforcing government agencies and standard-setting non-prot organizations
defer to for industrial label and tag design standards.

The NFPA defers arc ash sign design standards to ANSI
Z535 (NFPA 2009-70E130.7(E)). According to these
ANSI standards, a Danger or Warning sign should be
used to identify arc ash hazards since it will or could
present a life threatening injury. Danger signs are reserved
for hazards which will have a probability of death or
serious injury if the accident occurs and Warning signs are
reserved for hazards which could have a probability of
death or serious injury if the accident occurs. As explained
earlier in this document, a lethal arc ash hazard will
typically release energy greater than 40 cal/cm2 and
therefore should be identied with a Danger sign.
ANSI requires the use of a three panel design to identify
Danger and Warning signs. These are the Signal Word
Panel, the Safety Alert Panel and the Message Panel.

Signal Word Panel Safety Alert Symbol Panel

The Signal Word Panel provides a red background for a
white Danger Signal Word or an orange background for a
black Warning Signal Word. This panel always goes at the
top of a label or tag to help direct a readers attention to the
signal word.
A Safety Alert Symbol Panel (exclamation point
surrounded by a triangle) should be used to help alert
readers to potential personal injury hazards. This panel
should always precede the Warning or Danger Signal
Word. The color of the exclamation point should always
match the background color of the Signal Word Panel. For
Danger labels, the triangle used in the Safety Alert Symbol
is all white with no border. Warning labels use an all black
triangle with no border.

The position of the Safety Alert Symbol must be aligned

with the base of the safety word. The height of the symbol
should be equal to or exceed the letter height of the
associated signal word. Both the Safety Alert Symbol and
Safety Alert Symbol Signal Word Panel
Signal Word should then be centered.

Message Panel
A Message Panel must be included on Danger and Warning labels and tags to provide a separate area for hazard
information to be printed. This separation helps eliminate reader confusion and directs attention to the Safety Alert
Symbol and Safety Signal Word from a distance.
The background color of a message panel may be white or Message Panel is used, message information must be printed
black (ANSI Z535.4-20076.2.1, ANSI Z535.4-2007B3.3.10). in white lettering for both Danger and Warning labels and
According to ANSI, this choice should be based on which tags. Black lettering is required for white panels used with
message panel color will be more legible. Lighting, text Warning signs. Red or black lettering may be used on white
size, text amount and contrast with surrounding surfaces panels for Danger signs. Generally, a white message panel
should all play a role in color consideration. If a black will provide the best legibility in most conditions.

NON-COMPLIANT ARC FLASH LABEL DESIGN: COMPLIANT ARC FLASH LABEL DESIGNS:

Since a message panel is required,

all red Danger signs and tags and all
orange Warning signs and tags are
no longer compliant with NFPA and
ANSI standards. These ve examples are
acceptable label designs
An example of an old-style all orange for Danger & Warning
Warning arc ash label which is now arc ash labels.
non-compliant.

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7 1-800-788-5572 www.DuraLabel.com
 LABEL CREATION

Needed Equipment and Supplies

Options to obtain needed arc ash labels are: If only a small number of labels are needed, they can be ordered online at
www.GraphicProducts.com/cls. If more than a few labels are needed, it is more economical to use a DuraLabel PRO 300
printer and DuraLabel PRO 300 supplies.

DuraLabel PRO 300 offers an Arc Flash Package
providing commonly used arc ash labeling materials.
The DuraLabel Arc Flash Package includes:
DuraLabel PRO 300 Printer and software package
2" Orange 3.0 mil Premium Vinyl Tape
4" x 6" DANGER Arc Flash Die-Cuts (5 rolls)
4" x 6" WARNING Arc Flash Die-Cuts (5 rolls)
4.3" Black Standard Resin Ribbon (2 rolls)
Specialty supplies that can be added:
4" x 6" DANGER Arc Flash Die-Cuts
4" x 6" WARNING Arc Flash Die-Cuts
Spanish 4" x 6" DANGER Arc Flash Die-Cuts
Spanish 4" x 6" WARNING Arc Flash Die-Cuts
French 4" x 6" WARNING Arc Flash Die-Cuts
Two-Color Orange Striped Vinyl
In addition to the sizes above, the following are available for
larger DuraLabel printers
6.8" x 10.5" DANGER Arc Flash Die-Cuts (DL7 & DL9 only)
6.8" x 10.5" WARNING Arc Flash Die-Cuts (DL7 & DL9 only)
8.8" x 12.8" DANGER Arc Flash Die-Cuts (DL9 only)
8.8" x 12.8" WARNING Arc Flash Die-Cuts (DL9 only)

This is the standard Arc Flash package.

However this package can be customized.
Call 1-800-788-5572 for details.

6.8" x 10.5"
Label

4" x 6"
Label

LARGE ARC FLASH LABELS: Use large labels when visibility from a distance is needed to keep
workers at a safe distance when entering a room or servicing equipment.

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LABEL CREATION

Label Creation Steps (with the DuraLabel PRO 300)

Two options are available with the DuraLabel PRO 300.
The DuraSuite Labeling Software, included with the
DuraLabel PRO 300, provides a database for storing and
tracking arc ash labels, and it directly prints on the 4"
x 6" die-cut DuraLabel PRO 300 arc ash labels. The
DuraLabel PRO 300 can also print arc ash labels using
continuous two-color vinyl tapes.
When using continuous vinyl tapes, design the required
labels with a familiar word processing program, such as
Microsoft Word or OpenOfce.org Document. The CD
included with the DuraLabel PRO 300 comes with pre-
made MS Word templates and examples. The DuraLabel
PRO 300 printer can print on continuous vinyl supplies and
die-cut labels up to 4" wide.

Material Loading
1. Load the DuraLabel PRO 300 printer with DuraLabel,
continuous white with orange or red header vinyl, or die-
cut labels with pre-printed headers. (If loaded with die-
cut labels, set the gap sensor following the instructions
in the DuraLabel PRO 300 manual).
2. Load the DuraLabel PRO 300 printer with DuraLabel
PRO 300 black ribbon.

Label Creation Using Die-Cut Labels

1. Open the DuraSuite Labeling Software.
2. Select the Arc Flash module.
3. Enter data fields.
4. Select number of labels to be printed. DuraSuite Software: Quickly and easily print arc ash labels
using Duralabels comprehensive arc ash software.
5. Print the label(s).

Label Creation Using Continuous Vinyl

1. Open word processor.
2. Load the DuraLabel PRO 300 Arc Flash Template.
This will format the page to the appropriate size.
3. Modify the template to include information that is
specific to this label such as boundary distance,
energy, and necessary PPE.
4. Print the label(s).
DuraLabel Striped Vinyl: Two-Color striped vinyl comes in various
widths. Custom sizes are available. Call 1-800-788-5572.

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 LOCATION OF LABELS: It is critical labels are placed appropriately to be seen from normal approach and applied correctly for longevity.

LABEL PLACEMENT
Labels Should Be Placed:
On or close to the appropriate system or equipment.
To be visible from the point of normal approach.

Removing Old Labels

Many labels can be removed by scraping them off with a
putty knife. However, with strong labels such as DuraLabel
vinyl tapes, this can be a labor intensive process. Heating
the label with a heat gun will speed this process.

For some applications a powered wire brush can be used

to quickly remove labels. The use of this type of tool must
take into consideration the type of surface the label is LABEL PLACEMENT: Labels should be placed on or close to the
appropriate system or equipment.
applied to and whether that surface will be damaged.

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 LABEL MAINTENANCE: Equipment with missing labels or labels deteriorated beyond legibility, can contribute to serious injury or death.

LABEL MAINTENANCE
Labels should be properly maintained to ensure legibility and readability. Under normal conditions labels will last ve to seven years.
Environmental conditions can result in a shorter, or a longer life.

Labels should be inspected on a periodic basis and replaced
if they are missing or have deteriorated beyond legibility.
Accumulation of debris, grease, oil, or other materials
should be cleaned off.
Labels are only useful if they are visible. DuraLabel PRO
300 supplies are chemical resistant, therefore solvents and
cleaning agents may be used when necessary to clean off
dirt, grime, oil, etc If cleaning is not possible and the
label is not readable, replace the existing label.
Set up a schedule to reevaluate your facility. Refer to the
section Evaluation Facility Inspection on page 4 of this guide
for help.

2011 Graphic Products, Inc. All Rights Reserved.

The DuraLabel PRO 300 is an economical high-

speed thermal transfer printer that quickly and
efciently prints arc ash labels you need!
Call 1-800-788-5572 or visit DuraLabel.com

Die-cut Warning Labels

Die-cut vinyl labels are
preprinted with an orange
WARNING header. Our
proprietary software also works
with these labels. Heading also
available in Spanish or French.

White with Orange Header

This 4" wide continuous vinyl
supply comes preprinted with Die-cut Danger Labels
an orange header. The word Die-cut vinyl labels are
Warning and the warning preprinted with a red
symbol are printed in the DANGER header. We
header at the same time the have developed
rest of your customized proprietary software to
information is printed in make printing on these
the white section. labels a breeze. Heading also
available in Spanish or French.

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The following Arc Flash Guide is offered by Graphic Products to aid in properly labeling arc flash warning & danger labels.

ARC FLASH INFORMATION GUIDE

DATA REQUIRED TO BE ON ARC FLASH WARNING LABELS
2009 edition of NFPA 70E requires the label to display the incident energy or required level of PPE

The required PPE is specified by the Flash Hazard Category

on the label shown to the right. Each Flash Hazard Category
has specific required PPE associated with that category.

Flash Protection Boundary

This boundary is the closest anyone may approach without the use of
PPE. The available short circuit current, predicted fault duration and the
voltage are all needed to determine the flash protection boundary. This
boundary is the distance from the arc source where there is an incident
energy level of 5.0 J/cm2. According to NFPA 70E, there are three ways
this boundary can be calculated:

Analysis based on Article 130.3 (A)

Analysis based on NFPA 70E Annex D
Analysis based on IEEE 1584
PPE Required
The Personal Protective Equipment required is dependent on
the incident energy at every point a person may perform work on

Limited Approach Boundary
This boundary may only be crossed by a qualified person. An
unqualified person, wearing appropriate personal protective clothing
may cross if accompanied by a qualified person. Becoming qualified
requires training on the specific hazards of the equipment, as well as
general training on the hazards of working on energized equipment.
Proper application of PPE must be a part of this training. Annex C.1.1
and C.1.2.2
energized equipment. An electrical engineer or other qualified person
should perform the calculations that determine the incident energy.
The appropriate PPE should cover all parts of the body that may
be exposed to an arc flash. This could include boots, gloves, flame
resistant clothing, safety glasses, etc. Hearing protection and leather
gloves are required for all hazard risk categories. (Table 130.7 (C)(10))
The 2009 edition of NFPA 70E, Article 130.3 (C) requires a label that
displays either this information or the incident energy.

Restricted Approach Boundary Available Short-Circuit Current

This boundary may only be crossed by a qualified person that has
a documented plan approved by authorized management and uses
adequate shock prevention equipment and techniques. Annex C.1.2.3
Prohibited Approach Boundary
This boundary may only be crossed by a qualified person that has
the same level of protection required for direct contact with live parts.
Annex C.1.2.4
This is the maximum current available at given points in a system.
It is determined by short-circuit studies. This information is then
used to perform a short-circuit analysis. The resulting data is used to
determine the bolted three-phase short-circuit current which allows
for the calculation of the arcing fault current.
Incident Energy (in J/cm 2 or in cal/cm2)
This is the energy per unit area on a surface located at the normal
working distance from the potential arc source. The incident energy is
measured in units of Joules or calories per square centimeter. Second

Determining Boundaries
The limited, restricted and prohibited approach boundaries are
determined using NFPA Table 130.2 (C) Approach Boundaries to
Energized Electrical Conductors or Circuit Parts for Shock Protection.
degree burns occur at an energy level of approximately 5.0 J/cm2.
NFPA 70E Article 130.3 (C) requires either the incident energy or the
required PPE to be shown on the label.
Voltage Shock Hazard
The voltage shock hazard is based on the voltage of a system. It is used
to determine the glove rating when working on that system. NFPA 70E
has a table for glove ratings based on the voltage shock hazard.

NFPA 70E Article 130.3 states that an arc flash hazard analysis must be reviewed every 5 years
or whenever a major modification or renovation occurs. 1/11

This guide is for general information purposes only. It is not a substitute for review of applicable standards. 2011 Graphic Products, Inc.
Bring It On!
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Many of our 50+ DuraLabel specialty supplies were first developed
to solve a unique challenge for one of our customers.

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