White Paper Machinery Equipment for North America www.eaton.eu

Electrical equipment of industrial machinery exported to North America

Learning from the good, and bad, experience of others

White Paper Dipl.-Ing. Wolfgang Esser Electrical equipment of industrial machinery exported to North America Learning from the good, and bad, experience of others

Clarifications to Topics Seite Table 1 Table 2

Machinery for export to North America 4

Certification choices for electrical equipment Point 6, Point 7 4

Knowledge and application of standards 5

Source references 6

Dealing with inspection issues 6

Using the right codes and standards Point 1, Point 2 Point 1 7

The most common and serious offenses 8

• Unevaluated products Point 2, Point 3 8 • Unauthorized modifications of certified equipment, Point 3, Point 7 9 triggering a re-evaluation process • Power supplies Point 7 9

• Application related errors 9

– Miniature Circuit Breakers Point 4 9

– Manual Motor Controllers Point 5 9

• Use of IP... environmental ratings per IEC/EN standards Point 6 9

• Wiring materials Point 3, Point 4 10

• Wiring/Cable installations Point 3, Point 4 10

Feeder and Branch Circuits Point 2, Point 10 12

Branch Circuit Protective Devices Point 3 Point 2, Point 10, Point 11 15

Appropriate power distribution networks and nominal voltage ratings Point 3 Point 3 17 Distinctive aspects of North American motor currents and voltage Point 3, Point 4 19 ratings High fault ratings Point 3 Point 3 20

Enclosures and environmental ratings Point 2, Point 4 Point 6 21

Grounding issues Point 3, Point 4 Point 12 23

Errors on nameplate ratings, warning markings and documentation Point 4 Point 8 24

Traceability of materials certification Point 2 Point 9 24

Short Circuit Current Rating (SCCR) Point 5 25

Summary 26

Bibliography 27

2 Notable differences in the rules governing the export of IEC based electrical equipment and machinery to North America

1. – Use of North American based electrical codes and product equipment standards, – attention to additional regional and locally enforced regulations which may apply.

2. – Use of equipment certified by NRTLs, Components must be certified to the applicable product standards and applied properly per the electrical codes.

3. – Certified components must be selected, sized, combined and applied per the locally enforced codes and standards, – Component combinations, e.g. motor starters, must be tested and submitted as complete assemblies by the manufac- turer in order to achieve certified high fault short circuit ratings, – Any application limitations related to the equipment must be taken into consideration during the planning stages, – Certified components and combinations cannot be physically altered or changed in any form, – Applicable wiring and installation requirements outlined in locally enforced electrical codes must be strictly followed.

4. – Local market practices and conventions peculiar to North America, which can in some cases markedly differ from cus- tomary IEC practices, must be taken into consideration.

5. – The overall short circuit current rating (SCCR) of industrial control panels must be determined and be part of the control panel nameplate ratings.

6. – The need to establish whether the electrical assembly is best certified initially by a NRTL, and at which location. – If applicable, obtain NRTL certification for the manufacturing facility.

7. – The machine and its associated electrical equipment will be inspected locally by the AHJ- Authority Having Jurisdiction – who ultimately will approve, or reject, the assembly, – necessary changes can often only be carried out by locally based North American contractors, – Changes to an assembly would likely result in a re-evaluation and re-labeling by a NRTL for approval by the AHJ.

Codes = National Electrical Code (NEC), USA, Canadian Electrical Code (CEC), Canada NRTL = Nationally Recognized Testing Laboratories, e.g. UL, CSA, ETL Intertek High Fault Ratings = optimized test results, e.g. to achieve higher SCCR values

Table 1: The procedures governing the design, construction and installation of electrical equipment for machinery destined for export to North America can be markedly different from those which apply in countries predominantly served by IEC standards. The major differ- ences can be generally summed up by the 7 points indicated above. Refer to UL508A, Table SA1.1 for further information on applicable standards.

12 Red Flags. Errors that are most commonly caught by inspectors from European based NRTLs.

1. Designing to the wrong standards

2. Improperly sized electrical clearances in the feeder circuit

3. Improper selection and sizing of components

4. Use of UL 1077 type supplementary protectors instead of proper branch circuit protective devices

5. Use of UL 508 type manual motor controllers instead of proper branch circuit protective devices

6. Environmental rating issues with enclosures 7. Power supplies (Recognized Components instead of Listed Components, industrial devices rather than Class 2 certified equipment) 8. Errors in nameplates, wiring diagrams and warning markings

9. Traceability of certification not possible (e.g. for wiring materials)

10. Improper selection of protective devices for adjustable speed drives

11. Transformer protection not meeting code requirements

12. Grounding/Earthing issues Source: UL Deutschland, ETL Intertek Deutschland

Table 2: Errors that are often caught by NRTL inspectors when evaluating „Industrial Control Panels for Machinery” designed to meet the North American UL 508A und NFPA 79 standards. AHJs are regularly confronted with machinery related inst allation violations out- side the panel as well, or with missing or insufficient environmental ratings on door mounted components and enclosures. If a panel isn’t evaluated first by a NRTL, then a good portion of the above mentioned errors are likely to be flagged by the AHJ.

3 Electrical equipment of industrial machinery exported to North America Learning from the good, and bad, experience of others

Machinery for export to North this paper is thus to enable exporters used by Europeans even though America to get a jump on eliminating potential “approval” is technically not the right setbacks right from the start. word when referring to the certification The volume of industrial machinery process (Table 1, Point 6). There exported to North America (mostly A North Americanized version of a are many good reasons for certifying the US and Canada) from Germany, machine and control panel6 from various equipment in the country of origin. Europe and the rest of the IEC world1 is machinery manufacturers involved in Potential errors can be more easily quite considerable. The positive trend the export trade will tend to vary from and economically remedied directly has been especially noticeable in the make to make, and reflect either a at the producer’s manufacturing area of innovative and technologically lack of knowledge of the specialized location. It’s often not possible, or sophisticated machinery originating out requirements of that market or an even allowed, for manufacturers to of Germany. unwillingness, or lack of capability, in carry out the work themselves at taking the necessary steps to bring the end-user’s site in North America. Whereas electrical assemblies in the their equipment in conformity with Their employees may only be able to majority of countries around the world locally applicable codes and standards. supervise, and the work may need to are primarily governed by IEC standards, Space saving component designs be carried out by local contractors and the prevalent codes and standards in and technologically modern solutions, field technicians (aspects of the NFPA North America (NEC2, CEC3, UL 508A4, combined with European advances in the 70E Standard may also come into play8) NFPA795), to which electrical equipment field of functional safety, are important (Table 1, Point 7, -Changes-). Another must comply, are still markedly different reasons why German and European alternative for producers is to have from the IEC standards in many respects. made machinery equipment designs are their own assembly facilities certified Market conventions [1] and customer in such demand in North America. by a NRTL as a manufacturing location sensibilities in North America also with listing privileges. This would add remain distinct and divergent in many The electrical equipment portion of flexibility to their planning schedules. ways from those encountered in the IEC industrial machinery alone features The manufacturer in this case, after a world. Unfortunately, these habits and a particularly large value added and period of auditing and training, would customs are largely undocumented and differentiation potential. A significant be empowered to affix a NRTL label must often be laboriously extracted from percentage of exported machinery is or listing to the electrical assembly. It passages in codes and standards that fully automated. Many of our clients are can also be motivational for personnel are difficult for foreigners to decipher. internationally renowned as technological to work in a certified manufacturing The fact that the documentation is leaders in their field and, accordingly, location since the certification process solely formulated in English, or rather, in demand for their products globally is is associated to an additional level of Americanized English, can be a further high. Still, in spite of the state-of-the-art personal commitment and responsibility handicap to non-native speakers from technology incorporated, the equipment on their part. Certified manufacturing foreign countries. This author has made must still be made to conform to the locations are bound by contract to regular a point of repeatedly describing these design and installation requirements and periodical auditing conducted by field peculiar market habits and customs of relevant North American codes and inspectors from the NRTL’s Follow-up- in many other technical papers under standards. There really is no exception Service department, who are tasked with the general topic of export[2] in order to this rule. Adhering to local market and verifying that the manufacturing process to better familiarize readers with these equipment application conventions will at is being performed in accordance with concepts . Being confronted with least simplify the export process. the provisions of the certification, and unexpected market differences through in full compliance with the product costly mistakes and/or red-tagging is Certification choices for electrical standards. not the most efficient and appropriate equipment way to go about the export business. When the need arises to certify It makes good sense for this reason to The possibility exists for machine electrical equipment for export, the best closely study and analyze the errors that manufacturers to submit to third party way to proceed is often determined exporters often make when dealing with certification from certification agencies by the scope of the project, as well the specialized requirements of the North (NRTL7) right at their manufacturing as the extent of the demand on the American market. The primary goal of locations in order to get their assemblies manufacturer. In cases where the export “approved”, a term that is commonly portion is relatively small, it often pays to sub-contract the work to more seasoned panel builders who possess the 1 IEC = International Electrotechnical Commission 2 NEC = National Electrical Code = NFPA 70 6 Machinery assemblies refers to a group 3 CEC = Canadian Electrical Code of machines which have a functional 4 UL 508A = Standard for Industrial Control Panels interdependence 5 NFPA 79 = Electrical Standard for Industrial 7 NRTL = Nationally Recognized Testing 8 NFPA 70E = Standard for Electrical Safety in the Machinery Laboratories Workplace

4 knowledge and experience to re-engineer control assembly will be approved by In Canada, equipment that is deemed and adapt IEC layouts in order to make the local AHJ in the US or the provincial lacking in compliance with Canadian them compliant with North American inspection services in Canada, but it goes safety regulations may even be flagged requirements. Eaton can provide a long way in verifying its compliance by customs officials. That makes it names of clients who can competently with relevant codes and standards to the very difficult to resolve the dispute undertake such projects. This method local authorities. As a final alternative, locally. The equipment is likely to get can also be useful, at least pertaining to the electrical assembly of industrial sent back to the sender and country of an initial batch of machines, as a means machinery can be submitted to a field origin, resulting in significant delays and to stave off internal training costs for certification and labeling evaluation financial losses, and possibly impact a engineering personnel, which would contracted locally to a NRTL in North supplier’s image in the market place. eventually become necessary in the America, ideally scheduled before the event of a significant rise in the export approval inspection by the AHJ. Knowledge and application of content of the business. On the other standards hand, manufacturers who are concerned In cases where it’s difficult to determine with prematurely exposing proprietary the conformity requirements of This author is frequently contacted by information on their equipment to the specialized machinery or assemblies phone and asked to provide information market place may conclude that handling with local codes and standards, it on the extent of differentiation between everything in-house is the better option can be especially useful to establish IEC and North American based electrical to pursue. The technology usually contact with the AHJ or approval equipment designed for industrial determines the level of automation authorities in North America during machinery. Obviously, safe for very involved, and to a certain extent, the the planning stages of the project in specific questions, this is not a topic extremely fast turnout of a wide range order to arrive at mutually acceptable which can be easily or satisfactorily of new products. Because of inherent solutions to potentially problematic covered in an individual phone call. secrecy aspects to the technology, many issues. A meeting with an AHJ in the Table 1 is an attempt at summarizing the machinery panel doors at industrial trade US to go over the details can save time experiences of the author on this topic, shows purposely remain closed. It’s safe and money down the road, and likely gathered through the many seminars he to say that the pratice is not meant solely positively influence the outcome of an conducted on export related themes, to minimize electrical hazards. approval evaluation. The caveat is, of as well as in consulting sessions with course, that one knows ahead of time a broad spectrum of clients. Table 1 There are yet other exporting the location of the end-user and where can serve as a chart or checklist to this manufacturers who willfully forego the machinery will be installed. If so, effect. There are also many technical any actions at their production facility another good reason to contact the papers on specific export related topics geared towards the conformity of AHJ is to establish whether any of the available from Eaton [2] to interested their equipment with relevant North requirements found in national editions readers. The text that follows will American codes and standards. They of relevant codes and standards are provide examples to better illustrate the prefer to wait and see what transpires, supplemented by locally applicable and individual points mentioned in Tables if anything, at the installation site once enforced rules. Also, states in the US 1 and 2, along with commentary on the equipment is delivered. This method do not uniformly adopt and enable the frequently encountered pitfalls. Mistakes can also be successful, especially if the newest editions of the national electrical that are especially critical involve exporting firm has had experience and code. Advanced contacts with local those that would require component previous success in this regard. As a authorities in the case of serially or replacements or exchanges for which rule however, newly installed electrical mass produced machinery, on the other there is insufficient room in the panel equipment for machinery will need to hand, is essentially ruled out since the to accommodate. Whereas technical be locally approved by the Authority final destination of the equipment will papers are usually written to describe Having Jurisdiction – AHJ (Table 1, largely remain unknown. However, we how solutions and procedures can best Point 7 -AHJ-). The term AHJ is used to know from experience that complex be applied, this paper will focus more on refer either to individual field inspectors machinery is likely to be associated with following the correct path based on the or to the local departments of towns orders dealing with specific customers difficult experiences and misfortunes of and jurisdictions which are tasked with in mind, and with an established end-use others, who were perhaps not as careful the approval of electrical installations in location. and diligent in their approach as they their districts. The AHJ is mostly, but should have been. not always, a specialist in the electrical Local AHJs can request a field evaluation field. In Canada the field inspections of from a NRTL whenever electrical North American standards will, on electrical assemblies are in large part assemblies show no evidence of occasion, be dismissed too lightly by carried out by provincial authorities, such certification from a NRTL, and where designers. Conscious efforts are even as the Electrical Safety Authority in the they may suspect lack of conformity made to purposely avoid them. There province of Ontario, who mostly work in with local codes and may otherwise is sometimes a sense on the part of close co-ordination with CSA regulatory be reluctant or unwilling to carry out manufacturers that this approach is services to insure compliance with the the approval of the equipment on their validated simply because problems provisions of the Canadian Electrical own. A certification mark from a NRTL haven’t been encountered, or that one’s Code. These inspectors often have ties is particularly advantageous, since it position as a market leader is strong to the Canadian Hydro electrical utility alleviates a good portion of the AHJ’s enough to circumvent normal rules. This grids so that one can expect a high burden of responsibility in this respect. view can change quickly if a manufacturer degree of competency on their part. The AHJs are likely to approve a control supplies equipment to a new location certification work on electrical equipment panel that is properly listed and labeled and is suddenly faced with an AHJ that carried out by the NRTL’s is still not a by a NRTL without performing any doesn’t like what he sees, and doesn’t 100% guarantee that the machine or its additional checking of the assembly. really care whose name is on the

5 nameplate. The examples provided here, shouldn’t be the only criterium for practitioners, master tradespersons, and which have occurred over and over manufacturers to go by. A design technicians, engineers and NRTL again during the equipment inspections, engineer or team involved in export specialists involved in the export will hopefully drive home the inherent projects should always be keenly aware business. These discussions reveal limitations of this risky and questionable of the responsibilities they shoulder, and that not all problems can be resolved approach. Eaton can’t emphasize strongly implement solutions accordingly. solely with input from technical experts. enough how important and crucial it is for Teamwork amongst the varied groups manufacturers to follow and comply fully Source references within an organization is the real essence with the requirements of the relevant needed to make the export of complex North American codes and standards Certification agencies like Underwriters equipment such as industrial machinery for their exported equipment. And Eaton Laboratories (UL)9 Germany and ETL a truly successful endeavor. Information goes to great lengths to help you achieve Intertek10 Germany keep statistics on to and from sales personnel, support this goal. the errors most commonly encountered from the purchasing and commercial during their equipment evaluation end, and in some cases from the legal Designers of control panels for industrial process. Additional NRTLs are also department, can all be vital in this pursuit. machinery should have as a minimum planning to accumulate similar data. Close co-operation with the marketing in their possession the latest versions Table 2 summarizes the 12 most department is key, and the need for all to of the UL 508A and NFPA 79 standards frequently encountered errors compiled establish an excellent working relationship (Figure 1). Copies of the current edition from the agencies’ own lists of 10 with the machinery design team is also a of the National Electrical Code (NEC) common mistakes along with the must. All these fundamentals have to be for the USA and the Canadian Electrical author’s own results based on his in place in order to successfully build and Code (CEC) for Canada should also experience on the subject matter. The design machinery that is both safe and be part of their library. The electrical problems and errors encountered with suitable for global usage. Codes are referenced often in Table 1. local AHJs in North America by clients Unfortunately, only a small number undergoing inspections, and confided to Dealing with inspection issues of firms elect to keep copies of the the author, have also been covered in electrical codes as in-house resources. this paper. Often times a simple inquiry It’s best to remain calm whenever Navigating through the English language made during the design engineering dealing with problems that may arise documentation is admittedly a challenge, phase, or a closer evaluation of the during inspections. Overly emotional but can be greatly helped by attending code requirements, would have been responses and engaging in blame games export related seminars. Discussing sufficient in avoiding the problems. are never helpful. If there is any red- difficult aspects of the subject matter tagging involved it will be formalized with colleagues can also be very helpful, When mentioning „others“, i.e. those in a written process, which will then if the opportunities exist to do so. One from whom we wish to learn based make it possible to clearly ascertain should also seek application guidance on their mistakes as well as from their the reasons behind the stand-off. If from suppliers, whose products are positive experiences, the author is the issue pertains to the questionable purchased for export purposes. That’s referring to the many discussions and application of a particular component it’s a good way for clients to identify with exchanges he has had with over 1000 recommended to contact the supplier whom they should be partnering for of that product to solicit their comments export related business. The export and input. A supplier will often need to business can indeed provide compelling get involved and confirm the problem, 9 UL = Underwriters Laboratories = reasons to switch and embrace more http://www.ul.com/global/deu/pages/ because components really are helpful suppliers. Discounted pricing 10 ETL Intertek = www.intertek.de frequently misapplied. Additional supplier provided information can also turn out to be particularly useful, especially when it leads to a quick resolution of Industrial Machinery the issue. The supplier can sometimes NEC (NFPA 70) NEC Art. 670 NFPA 79 provide key additional documentation Requirements for the eletrical and elect- Leading electrical standard that can be crucial to an inspector in ronical equipment of Industrial Machinery for Industrial Mechinery his evaluation of the equipment. Many Electrical design requirements for machinery control panels firms undertake additional measures to facilitate inspections, such as Design of Industrial Control Panels per UL 508A incorporating product certification file numbers right into the parts list. Other Part 1: Part 2: companies prefer to provide separate General Use Panels Specific Use Panels binders containing product certification information as part of their overall Art. 65 … 67 in UL 508A and …. …. Industrial NFPA 79 documentation for the equipment. Machinery Eaton’s Online Catalog provides key certification information on its products IndustrialIndustrial only in NFPA 79 Applications: …. …. MachineryMachinery on each component selection page (Figure 2). The AHJ always has the last word with respect to the approval of Figure 1: The dominant standards in North America dealing with electrical equipment for electrical equipment at the installation industrial machinery. The National Electrical Code references both the UL 508A standard for industrial control panels and NFPA79 standard for industrial machinery in the body of site and any problems that may have its text. The NFPA 79 standard in North America is comparable in scope to the IEC/EN 60 arisen during the inspection process. The 204-1 standard. withholding of approval on the part of

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Figure 2: A sample page from the European edition of the online catalog showing how North American relevant information for components is displayed. Section a provides the most important product certification information of the equipment featured on the page. This gives clients the opportunity to incorporate key certification details into their own technical documentation as they are going through the component selection process.

the inspector and the lack of resolution owner’s due diligence in creating a safe based standards, but this was not meant to the issues at hand effectively prevent environment for his employees in the as a slight to corresponding Canadian the flow of power to the equipment workplace and is another good reason standards. Rather, it was primarily due for at the installation site, and can directly to justify the inspection process. It brevity reasons, since US based standards expose the end-user/owner to potential also provides the owner with excellent tend to have shorter reference names insurance and liability concerns. In North grounds to defray any resultant costs of and, generally speaking, are more widely America the owner of an establishment approval and inspection problems directly recognized globally. Relevant standards or plant is directly responsible for back to the supplier without much of an are usually broken down into those insuring the safety of the employees argument. specific to products and of more interest at the workplace and all employees to component manufacturers (e.g. UL have the right to contact OSHA11 if they Using the right codes and standards 489/CSA C22.2 No. 5-09, UL 508 /CSA perceive or detect any safety related C22.2 No. 14-05, UL 1077/CSA C22.2 issue in their work environment. OSHA The National Electrical Code (NEC) in the No. 235-04 (R2009) etc…) and those that has thousands of inspectors working in USA and the Canadian Electrical Code lean more towards installers, contractors the field tasked with investigating such (CEC) in Canada can be thought of, for all and panel builders (e.g. UL 508A and cases. It is in the end-user/owner’s best intents and purposes, as de facto legally NFPA 79). Component manufacturers interest to require full compliance of binding documents. They each essentially must also keep abreast of installation applicable codes and standards for the provide a legal and technical foundation based standards, since they can directly machinery from a supplier. The AHJ’s on which electrical equipment, such as impact the development of component or provincial authority’s approval of the is required for industrial machinery, can accessories, such as mounting and equipment is also a verification of the be properly installed and operated. Both wiring aids, that facilitate compliance the US and Canada possess their own with these standards, as well as enable standards making organizations. The manufacturers to provide valuable codes and standards of each respective application assistance to their clients. 11 OSHA = U.S. Department of Labor, Occupational country are heavily harmonized, but not Safety & Health Administration, also: Occupational Safety & Health Act. OSHA also always identical in every respect. The Two main standards in the US dealing accredits each NRTL. paper does make references mostly to US primarily with the design and installation

7 of industrial machinery equipment are MCB = Miniature Circuit Breakers UL 508A and NFPA 79. Canada does not MCCB = (Miniature) Molded Case Circuit Breaker really have any current and comparable standards to those two in terms of scope. Similar requirements exist, but MCCB for MCB for they are integrated into existing, more Feeder and Branch Circuit Protection Supplementary Protection broadly defined standards. Having an electrical assembly compliant with the USA: UL 489 USA: UL 1077 requirements of UL 508A and NFPA79 Canada: CSA C22.2 No. 5-09 Canada: CSA C22.2 No. 235 thus makes sense in Canada as well, Large electrical spacings Small electrical spacings since both countries share many of the LISTED Component Í Recognized Component Í same regulatory practices. The scope of machinery is not defined exactly in the IEC / EN 60 898 same manner in North America as it is in the IEC world. For example, pumps Caution! and compressors in the EU fall under Main distribution An improper component system the machinery directive, whereas they selection in this area counts are not strictly considered machines in as one of the 10 most

North America. It’s always advisable, incoming side Industrial control panel frequently made errors Feeder Circuits flagged by inspection therefore, to establish ahead of time if Large creepage and clearance Main switch distances the equipment at hand is subject to the Busbar system authorities. Branch Circuit provisions of the industrial machinery Protective Device Branch Circuits standards, or is perhaps better covered small creepage and clearance distances Load side under a different standard. The requirements for industrial machinery in North America, as per NFPA 79 and Part Figure 3: The right side of the figure shows a Type FAZ…, IEC miniature circuit breaker that is commonly used as a load circuit protective device in the IEC world. In North 2 of UL 508A Section 2, are amongst the America these devices are certified per UL 1077/CSA C22.2 No. 235-04 (R2009) as most stringent, so that any equipment supplementary protectors and can be applied in branch or load circuits for supplementary in compliance with those standards protection only. The device on the left side of the figure (FAZ..-..-NA) has been could be deemed to safely meet all the constructionally modified in its termination area to accommodate the larger electrical clearances. These devices are certified as molded case circuit breakers per UL 489/CSA requirements encountered in general C22.2 No. 5-09 and are thus suitable, like any other molded case circuit breaker, as a industrial applications. As an example, branch circuit protective device for all loads as defined per the electrical codes. there is a standard now being formulated for the control of wind power and it is currently based to a large extent, both in Europe as well as in North America, SA1.1 from the UL508A standard, in a CCN using UL’s on-line certification on the same requirements being applied and is fairly comprehensive in this directory (http://database.ul.com/cgibin/ to industrial machinery. Examples of regard. The 508A standard committee XYV/template/LISEXT/1FRAME/index. equipment that fall under the provisions panel is also fully aware of the need to html) will yield a listing of suppliers for of industrial machinery can be found accommodate additional component equipment certified under that control under paragraphs 1.2 and 65.1 of categories (e.g. some important ones number. the UL 508A standard, as well under from Europe) into Table SA1.1. As a rule, Annex C of NFPA 79. Industrial control EU style declarations of conformity from The most common and serious panels for machinery falling under Part component manufacturers don’t carry a offenses 2 of UL 508A are also subject to the lot of weight in North America. Rather, constructional requirements specified the North American safety system is The obvious mistake when designing in the general (Part 1) portion of the based primarily on third party certification electrical equipment for industrial standard. of electrical equipment provided by machinery is not taking into consideration NRTLs. The certification is associated the requirements of the UL 508A Points 1 and 2 of Table 1 and Point 1 of with a mark from the certification agency, and NFPA 79 standards. It can’t be Table 2 deal primarily with the product usually appearing on the product itself. emphasized enough for designers to standards for a number of components. Smaller scale component manufacturers avail themselves of these standards and Many designers are under the impression outside North America are often engineer their assemblies accordingly. that every product which carries a unfamiliar with component certification, The standards also contain valuable North American certification mark is or simply can’t afford to go through the information on how to properly size key automatically suitable for use in electrical process. These firms have a tendency components in North American power assemblies for industrial machinery. to promote the view that unevaluated and control circuits. That assumption is false. A power components don’t necessarily present supply that is certified as informational any acceptance problems in North • Unevaluated equipment technology equipment is not necessarily America. Are you prepared to live with suitable for industrial machinery that kind of advice? Components can The selection and sizing of power applications. Some components are always be procured locally in North circuit components per IEC methods, even evaluated to multiple standards America in case of need. As mentioned, or solely in conformity with IEC [3]. Information on the appropriate Table SA1.1 of the UL 508A standard standards (i.e. products without any standards for components pertaining to provides information on various NA certification), will generally not be industrial machinery, including category groupings and their corresponding acceptable in North America. Control code numbers, is provided in Table category control numbers (CCNs). Keying circuit components in secondary

8 auxiliary circuits (Low-voltage limited- the use of equipment not certified to and loads, and which extend beyond energy circuits) which are unevaluated the proper standards can often present enclosure walls, must be protected can be allowed under certain defined problems. The requirements for Class by BCPDs. Supplementary protectors conditions. UL Germany und ETL 2 certified equipment and proper that are suitable for DC circuits must Intertek Germany make use of a „100 separation of circuits are frequently not also be marked with appropriate DC Watt“ rule-of-thumb in this cases followed. The selection of transformers ratings. There is in the meantime a which usually refers to applications and power supplies should be done in constructional variant of this protective under low voltage conditions (24V, < accordance with the proper standard device which incorporates larger 30V) and a maximum current of 4A. for the application and it’s always electrical clearances on its field The conditions of acceptability for best, and least complicated, to use terminations. These devices have the unevaluated components in UL listed Listed equipment over Recognized Eaton type designation FAZ..-..-NA and control panels are defined in Appendix components whenever possible. are certified as true molded case circuit B of the UL 508A standard, and (Table 2, Point 7). Supplementary breakers per UL 489/CSA C22.2- No. generally relegate these components protectors are often used on the 5-09 (Figure 3). A number of certified to Class 2 defined circuits. There are secondaries of power supplies to protect accessories such as bus connectors no exceptions for components in the individual circuits. However, not all and wiring aids are also offered for power circuit, and those that have a power supplies can deliver short circuit this line. protective function will get especially currents in those secondaries that are scrutinized to make sure that they sufficiently high to trip a protective • Manual motor controllers carry the right NRTL certification marks device. Besides the lack of adequate and ratings to verify their suitability per protection, that also means that a faulted As indicated in Table 2, Point 5, IEC the NEC/CEC electrical codes (Table 1, circuit cannot be annunciated via an style motor protective switches are Points 2 and 3). auxiliary contact of the protective switch. certified as manual motor controllers That in turn can complicate efforts to per the UL 508 standard and are • Unauthorized modifications of troubleshoot circuits. thus unsuitable as branch circuit certified equipment, triggering a protective devices in North American re-evaluation process • Application related errors power circuits. As described later this particular certification can be It should be strongly emphasized • Miniature circuit breakers expanded (UL 508 Type E, Manual that certified equipment may not be Self-Protected Combination Motor altered in the field, nor undergo any A recurring, and serious problem, is the Controller) so that a modified controller unauthorized modification in end- use of overcurrent protective devices, (larger spacing terminal on its supply use products. To do so is a violation mostly in load circuits, which do not side and padlockable knob) can provide of the agreement under which the carry the proper certification in North the branch circuit protective function product was certified, and carries America as a branch circuit protective to individual motor branch circuits. An consequences. An example of that device (BCPDs, to be described later). additional and typical mistake on the would be to cut the supply chord Internationally rated miniature circuit part of IEC based designers, which of a certified piece of equipment breakers, in compliance with IEC/ is very often made, is to use these and connect the exposed wires to a EN 60898, are normally certified in Type E controllers for the branch set of terminals. (Table 1, Point 3, North America solely as Supplementary circuit protection of non-motor loads. -Manipulation-). The goal is to select Protectors per UL 1077/CSA C22.2 The Eaton controller type PKZM4 is industrial equipment which has the No. 235-04 (R2009). As such, these available in the meantime as a variant proper certification and, in accordance devices typically fulfill only an additional (PKZM4-..-CB) that is certified as a with the manufacturer’s instructions, or secondary protective function molded case circuit breaker per the can be installed into an industrial in North American power circuits UL 489 and CSA C22.2- No. 5-09 control enclosure and/or panel. (There (Table 2, Point 4). In addition, they are product standards, and constructionally are, however, some inspectors that certified as recognized components features the larger creepage and are more tolerant than others when only, which are typically amongst the clearance distances on its field it comes to the practice of modifying most misapplied of products in North terminations (Figure 4). That product chord equipped components in American assemblies. The improper can thus be more universally applied order to fit an industrial application). application of IEC style miniature per the electrical codes as a feeder The replacement of products in a circuit breakers is a well known and branch circuit protective device for high fault rated certified assembly problem to most NRTL and AHJ field a number of different loads and also with non-identical components (i.e. inspectors. The mistake made in the features a high short circuit current different type or make) would also IEC world is to apply these in North interrupting rating (SCCR). fall under the header of product American power circuits as branch modifications that are not permitted. circuit protective devices, which is • Use of IP... environmental ratings Any changes or modifications to a one of the most commonly flagged per IEC/EN standards listed and labeled assembly can also problems in export assemblies. The trigger a re-evaluation process by proper way to use supplementary Another source of problems is the a field inspector. (Table 1, Point 7, protectors is to apply them in circuits use of IEC based standards that are -Re-evaluation of an assembly). where the electrical codes do not not recognized by the North American mandate the use of BCPDs, e.g. in electrical codes. For example, the • Power supplies the secondaries of control circuit IP codes defined in IEC/EN 60 529, transformers, or in circuits tapped from which references varying degrees of Transformers and power supplies the load of a BCPD. Branch circuit protection against ingress of liquids belong to a product grouping in which conductors for low voltage circuits and solid particles, have no relevance

9 Application as Type E/F only with additional per UL 489 BK50/3 terminal Molded Case PKZM4-..-CB UL 508 Circuit Breaker Large electrical New! clearances Rated currents: 16, 25, 32 A

SCCR: 65 kA / 480Y/277 V 22 kA / 600Y/347 V

Molded case circuit breaker for the North American market PKZM4-..-CB

PKZM4 Only 55mm wide! Large electrical plus circuit breaker certification clearances

Figure 4: The manual motor controller Type PKZM4, certified per UL 508/CSA C22.2 No. 14-05, constructionally modified to feature larger electrical clearances on its terminations, was additionally evaluated and certified as a molded case circuit breaker per UL 489/CSA C22.2 No. 5-09. The PKZM4-..-CB circuit breaker can be applied as a branch circuit protective device, whereas its manual motor controller equivalent cannot.

in North America (Table 2, Point 6). be used as a suitable replacement. IEC, reduction and conversion factors It is essential that North American The present situation is somewhat applicable to conductors provided by environmental type ratings be used, unclear. Various cable manufacturers the electrical codes which must be and that they ideally be certified by UL/ are advising that it’s not always factored in to all applications. It’s also CSA, e.g. UL/CSA Type 4X (Table 3), technologically possible to replace a good idea to plan for ample reserve rather than specified as NEMA ratings, highly specialized AWM conductors space and not push cable loading to such as NEMA 4X. The difference with MTW equivalents. There are maximum values which might invite between NEMA ratings12 and UL/ also signs that the present limitations discussions later on about potentially CSA ratings is that the former is a self- imposed in the NFPA 79 standard unacceptable temperature rises in the certified manufacturer rating, whereas will be reversed or scaled back quite panel or machine. Also seek the advice UL/CSA ratings are third party, NRTL a bit in the next edition to reflect that of your cable supplier in this regard. certified ratings which are sought and fact. At this time it’s best to consult Representatives of NRTL certification preferred by AHJs and field electrical your cable suppliers on the matter in agencies in Germany recommend, inspection services. order to find out the latest status. It’s whenever possible, to attach external also worthwhile, depending on the cabling directly to the machinery, • Wiring materials application, to carefully consider the including the cable troughs linking need for particular characteristics when individual machines. It’s a good idea The use of improper wiring materials selecting cables, such as oil resistance, to avoid any wiring installation on the (Table 1, Point 3, -Wiring- and thickness of insulation, cable tray use building or structure itself, since it Installation guidelines-) for any given and suitability for exposed runs. It’s could potentially involve compliance application occurs as frequently as important to clearly describe to your with various additional chapters of the the use of incorrect standards. The cable supplier the exact application you NEC or CEC. The goal would be to NFPA 79 standard, in its 2007 edition, are facing in order to obtain precise have only the supply conductors to the heavily restricted the use of popular information on the suitability of the machine control panel be installed in AWM (Recognized Appliance Wiring products you are considering. Clarify conduit. Anyone interested in finding Material) conductors, certified to the temperature rating for which out more about North American UL 758. MTW-wire (Listed Machine the cable or conductor is certified. installation practices would be wise to Tool Wire), certified to UL 1063, can The ampacity tables in the electrical consult the handbook version of the code for conductors are provided at current edition of the NEC [4]. One will an ambient temperature of 30 °C. instantly recognize the need to work Certified industrial control equipment with a North American contractor or 12 NEMA = National Electrical Manufacturers is normally rated up to 40 °C. There partner in this respect, since market Association = http://www.nema.org/ are, however, in similar fashion to practices and conventions, including

10 North American Application Rough North American Application Rough environmental Type equivalency to IP environmental Type equivalency to IP ratings ratings ** ratings ratings ** per IEC/EN per IEC/EN 60529, DIN 40050 60529, DIN 40050 UL/CSA Type 1 Incidental Indoor use IP20 UL/CSA Type 4 X Indoor or IP66 contact with enclosed Watertight, raintight, Outdoor use * equipment; falling dirt dusttight, corrosion resistant UL/CSA Type 2 Driptight Indoor use IP22 UL/CSA Type 5 Indoor use IP53 Driptight, dusttight UL/CSA Type 3 Outdoor use IP55 UL/CSA Type 6 Indoor or IP67 Dusttight, raintight, Raintight, watertight, Outdoor use * degree of protection temporarily against rain, snow and sleet submersible UL/CSA Type 3 R Outdoor use IP24 UL/CSA Type 12 Indoor use IP54 Rainproof, degree of Common industrial protection against rain, rating, driptight, snow and sleet dusttight UL/CSA Type 3 S Outdoor use IP55 UL/CSA Type 13 Indoor use IP54 Dusttight, raintight, proof driptight, dusttight, against snow and sleet oiltight UL/CSA 3X, 3RX, 3SX Outdoor use IP55 Same as 3,3R and 3S, but with corrosion resistance UL/CSA Type 4 Indoor or IP66 Watertight, raintight, Outdoor use * dusttight general purpose water-tight drip-tight submersible dust-tight ice resistant rain-tight sleet resistant rain-proof corrosion resistant weather-proof oil-tight * Take note of manufacturer markings and instructions! ** IP ratings are not allowed as substitutes for Type Ratings in North America!

Table 3: The IP ratings referenced in the table represent a rough comparison only. A precise comparison is not possible since tests and evaluation criteria between both standards are markedly different. UL/CSA certified Type ratings are now replacing equivalent NEMA Types. UL/CSA Types are more meaningful to AHJs and field inspectors since the markings represent third party verification from a NRTL. The North American reference standards are the NEC (NFPA70), CEC, UL 50, UL 50E, CSA-C22.2 No. 94-M91 (2006), NEMA 250 -2008.

selection of the appropriate materials, have more copper per cross-section from the main power circuit and may can be markedly different from the IEC and have thicker insulation that IEC be feeding Class 2 type circuits, or world. equivalents, something that needs those that are used in interlocking to be taken into consideration when circuitry originating from outside the • Wiring/Cable installations planning available panel space. The panel and may remain live when the packing density of components and supply circuit disconnecting means Cable trays and channels outside the cabling inside many IEC based control is in the OFF position. All conductors enclosure, as well as certified wiring panels tends to be relatively high occupying the same cable channel ducts inside the panel, shouldn’t be versus typical North American layouts. must have an insulation rating in loaded at any more than 50% of their North American control panels are accordance with the maximum voltage capacity. This is an area that is very normally laid out to accommodate present in the group. The insulation often flagged by inspectors and little more room for wiring, and are usually rating of network cabeling, which can leeway is granted when these limits larger due to the use of power circuit sometimes be 150V only, is often not are exceeded. Cable channels that are components that typically occupy taken into consideration in this respect. too small for the demand are a difficult more volume than IEC based designs. The use of certified wiring materials, problem to solve since inevitably The Authority Having Jurisdiction and of typical North American color more room needs to be freed up is normally used to seeing roomier schemes for wire insulation, is strictly inside the panel to accommodate the panels, and that same standard will be enforced. The use of different color conductors installed. North American expected when evaluating imported coding schemes in the IEC world is conductors (AWG-sizes13) usually assemblies. Additional wiring and one of the major impediments towards cabling installation errors include the realization of a true world market the lack of proper identification and machine. The NFPA 79 electrical separation between circuits of different standard for industrial machinery 13 AWG = American Wire Gauge potential, e.g. those that are tapped requires that conductors be identified

11 defined by the branch circuit protective Main distribution Incoming terminals are still part of the devices (BCPD’s) in the circuit, which system feeder circuit will be described later. Table 4 provides or The Branch Circuit ends at the branch definitions for the circuits in line with the circuit protective device (seen from the load side) NEC.

Components suitable for feeder incoming side Industrial control panel circuits are constructionally equipped with larger electrical clearances, as Feeder Circuits Main switch Large creepage and clearance shown in Table 5, on their power or distances Busbar system terminations. The larger clearances Busbar system must also be present between power Branch Circuit and control circuit termination areas Protective Device Branch Circuit of the component. Components in the Protective Device Incoming terminals branch circuit are allowed to have the are still part of the feeder circuit The Branch Circuit ends smaller, more IEC like, industrial control ➡ at the Branch Circuit spacings as per Table 6. Naturally, Branch Circuits protective Device BCPD small creepage and clearance ➡ (viewed from the local side) distances feeder style components with the larger Load side clearances are allowed in the branch circuit. Figure 6 shows what is meant by creepage and clearance distances Figure 5: Clarification of the terms „Feeder Circuit“ and „Branch Circuit“ with respect to electrical clearances. The lack of compliance with this boundary line often leads to errors and how the spacings from Tables 5 which are difficult to resolve. and 6 are to be applied. The spacings shown are minimums and lower values are not permitted. Component manufacturers need to insure for at their terminations and provides under Point 2 of Table 2. It’s best to use certification purposes that the spacings various options for manufacturers to these terms exactly as they appear in the present in their constructional designs accomplish the task. The requirement North American electrical codes since fulfill the requirements of the respective often causes hardship because failure they really don’t relate to anything else product standards. A panel builder would to do so usually gets flagged, and is that is similar in international standards. be responsible to insure that spacings difficult and time consuming to remedy Furthermore, familiarity with the terms between live parts and live parts to once a panel is completed. will facilitate the dialogue with any North ground for components, accessories American based individual involved and mounting hardware would be Feeder and Branch Circuits in a project, including local electrical maintained in accordance with the contractors and field inspectors. Figure 5 installation standard. The blow-out area A more detailed description of „Branch shows how these terms are applied. of protective devices like circuit breakers Circuits“ and „Feeder Circuits“, terms The major difficulty in comprehension is an aspect that is often overlooked that are not readily understood in the IEC resides in identifying the proper by panel designers. Those oversights world, is required in order to better grasp boundaries between both power circuit are typically difficult to remedy once the significance of the errors highlighted forms. The boundary is essentially a panel layout has been finalized and implemented. This problem is not directly related to minimum creepage and clearance requirements, but is voltage Exemple: dependent. It is thus critical that the manufacturer’s installation instructions f x mm be followed at all times in this regard, including the provision of any additional accessories or covers that may be indicated and deemed necessary to comply with all the requirements for a proper installation of the equipment. Parts like barriers and covers that are There are additional detailed requirements to follow! designed per IEC standards to provide protection against shock hazards spacing over surface, creepage distance often have the additional role in North American installations of maintaining proper clearances between live parts and spacing through air, clearance, air gap grounded surfaces on components and within the electrical assembly. There are live parts usually additional instructions pertaining to these accessories which are meant to be supplied to the user as well as be part of the overall documentation Figure 6: Voltage dependent creepage and clearance distances hinder the likelihood of package associated to the machinery. electrical tracking over surfaces of insulating material and flash-overs through air. North Manufacturers will want to insure, also American spacings requirements are greater than those encountered in IEC standards. for liability reasons, that all the necessary

12 information related to their product or NEC Definitions assembly is at the disposal of the end- user. Required electrical clearances Feeder Circuits in North American installations must All circuit conductors and elements between the service equipment, the be physically measured and are not source of a separately derived system, or other power supply source and the permitted to be verified alternatively through impulse testing, as is allowed final branch-circuit overcurrent protective device. (BCOPDs). per IEC/EN standards. The housings and Branch Circuits surfaces of power and control gear are often ribbed and appear jagged, since The circuit conductors and elements between the final overcurrent the use of grooves and ridges is often protective device protecting the circuit and the connected loads. necessary to constructionally comply with the spacings requirements of the Table 4: Not the exact verbiage found under the definitions of feeder and branch circuits appearing in the NEC, but the essential ideas behind them. The term „Overcurrent“ in product standards. Eaton circuit breakers North America encompasses any current in excess of the rated current of equipment, and molded case switches can all be including overload, short circuit and ground fault currents. These definitions do not reverse fed. That is something that an include any restrictions or parameters based on voltage. They thus apply equally for low AHJ will pay attention to, since devices voltage circuits. that can’t be reverse fed will be marked accordingly with the word “LINE” on their supply side. Clearance and creepage distances in feeder circuits ≤ 125 V 126 – 250 V 251 – 600 V The boundary between branch and Through Air 12,7 mm 19,1 mm 25,4 mm feeder circuits is best visualized starting from the load side, back towards the Over Surface 19,1 mm 31,8 mm 50,8 mm energy source (Figure 5). The first Between live parts and 12,7 mm 12,7 mm 25,4 mm protective device encountered, which grounded metal parts assumes the overcurrent protective function for the branch circuit ➡ (conductors, components, load) and Table 5: Minimum clearance and creepage distances in feeder circuits, e.g. for typical has the proper certification to do so, North American voltage levels of 480 und 600 V, as well as for slash voltage ratings of is the branch circuit protective device. 480Y/277 V or 600Y/347 V. Additional protective devices can be mounted between the BCPD and the Clearance and creepage distances in branch circuits load. That would be the case for example in a group installation arrangement, ≤ 125 V 126 – 250 V 251 – 600 V in which the BCPD functions as the Through Air 3,2 mm 6,41 mm 9,5 mm back-up protective device for a group of manual motor controllers (Figure 7). The Over Surface 6,4 mm 9,5 mm 12,7 mm motor controllers (in this case without Between live parts and 12,7 mm 12,7 mm 12,7 mm the need for the larger spacing terminal grounded metal parts on their supply side) are positioned in between the load and the BCPD, and ➡ fulfill a protective function as well. Table 6: Minimum clearance and creepage distances i e.g. for typical North American Design engineers at times will mark voltage levels of 480 und 600 V, as well as for slash voltage ratings of 480Y/277 V or the boundary between feeder and 600Y/347 V. branch with dotted lines on their wiring diagrams in order to better validate their component choices and facilitate codes with respect to the 1/3rd 1/10th want to use these as protective devices subsequent discussions with field rules. The need for closer co-ordination for power transformers, as is typically inspectors and/or customers, should of conductor protection in group done in the IEC world. There’s a simple the issue arise at a later date. The installations is alleviated by the use of North American explanation for that. author fields many questions on these modern UL 508 Type E, manual self- They call these devices combination boundaries and on BCPDs in general. protected combination motor controllers, motor controllers because that’s what There is great potential for error in this and/or UL 508 Type F, combination they do: switch, protect and control area. motor controllers (Figure 8) [5]. Motor motors. controllers that are so certified fulfill It’s very important in branch circuits, the overcurrent protective functions A relatively new change in the UL particularly those in group installations for individual motor branch circuits and standard for power conversion with manual motor controllers that can be installed up to their maximum equipment, UL 508C, allows incorporate tapped circuits, to insure short circuit rating without the need for manufacturers to specify UL 508 Type E that all segments, from the main switch, additional back-up protection. It’s worth controllers as the short circuit protective BCPD and on down to the individual noting however, that UL 508 Type E and device for adjustable speed drives. The loads, are adequately protected. The F controllers are suitable as protective stipulation is that the type and make of proper co-ordination of protective and switching devices for individual the Type E controller needs to be marked elements in group installations is motor circuits only. Typical mistakes on the converter. (Table 2, Point 10). especially critical in order to comply with occur when designers want to use the The same marking requirement exists the wiring provisions of the electrical same products for non-motor loads, or for other types of protective devices

13 that manufacturers may use for the short circuit test, such as semiconductor Feeder Circuit Feeder Circuit fuses and instantaneous-trip circuit breakers. It is, however, not necessary for either inverse time circuit breaker BCPD A grouping of controllers or standard fuse markings to appear on has 1 BCPD only drives, assuming that they pass the short circuit test with both, at the full ratings required by the standard. Otherwise the drives would need to be marked with the current rating of the inverse time breaker BCPD and/or the class and ampere rating of the fuse used for the test. These markings are necessary to meet the intent of the electrical codes. 1 Branch Circuit 1 Branch Circuit A general statement can be made that industrial control devices certified to UL 508/CSA C22.2 No. 14-05 (smaller electrical clearances), like contactors Figure 7: Branch Circuit Protective Devices in the above diagram are installed ahead a for example, are not allowed in feeder group of PKE-… or PKZM0-.., motor starters and DILM magnetic contactors. The BCPD circuits (Table 2, Point 2). This also and motor starter components on the right side of the figure are mounted on a busbar applies to Supplementary Protectors system. The manual motor controllers require the branch circuit overcurrent protective device because their capabilities based on their certification include the motor switching per UL 1077/ CSA C22.2 No. 235-04 and overload protective function only [4]. The type of power distribution network in this (R2009). The technical committee panel case has no impact with respect to the controller ratings. Yellow background = Feeder for the UL 508A standard is discussing circuit, green background = Branch Circuit. at this time under which conditions

UL 508 Type F Combination Motor Controller

Disconnect, Short circuit, controller and motor overload protection in one combination. = minimal coordination requirements

Group Protection / Group Installation

Protective device Differently sized for the group (BCPD) conductors! Motor inrush currents! Co-ordination UL 508 Type F combination motor PKZM requirements! controllers can be used up to their The protective device maximum SCCR without back-up assumes the disconnect The PKZM0 assumes protection. and overcurrent protection MMM the overload protection for the group of control- for the motor and lers and conductors. conductor = BCPD for the group = Circuit Breaker or Fuse only 1 Branch Circuit, since The PKZM will also trip only 1 BCPD present under short circuit conditions!

Figure 8: UL 508 Type F combination motor controllers allow for a much simpler layout with minimal sizing requirements. The need to co-ordinate reduced cross-sections as in group arrangements is eliminated. The short circuit and overload protective functions are accomplished by the same device. Component co-ordination requirements are much less demanding.

14 Suitability of various protective devices as Branch Circuit Protective Devices (BCPD) For the following equipment/load types Type of BCPD General Drives Motors Trans- Lighting Heating Equipment Power con- formers loads loads protection. version assemblies, equipment conductor protection x x (x) x x x Molded case circuit breakers plus contac- (Inverse Time Circuit Breakers) tor and over- per UL 489, CSA C22.2 No. 5-09 load relay xxxx x x Motor protective circuit breakers mostly with per UL 489, CSA C22.2 No. 5-09 additional with additional calibration contactor per UL 508, CSA C22.2 No. 14-05 ***) ***) ***) ***) ***) ***) Supplementary Protectors per UL 1077, CSA C22.2 No. 235-04 x x (x) x x x Fuses plus contac- per UL 248, CSA C22.2 No. 248 tor and over- load relay ***) ***) ***) ***) ***) ***) Manual motor controllers – (x)*) x – – – UL 508 Type E Self-Protected Starter = Combination Motor Controllers BCPD ––x– – – UL 508 Type F Starter = Combination Motor Controllers BCPD – – (x)**) – – – Manual motor controllers with individual back-up protective device – – (x)**) – – – Manual motor controllers in Group installations

(x) Conditional Usage *) The drives are tested and marked with the model number and manufacturer of the Type E controller. **) The protective device (circuit breaker or fuse) is the BCPD and the manual motor controller provides the motor overload protection. ***) Not suitable as a BCPD under any circumstances! Table 7: Inverse time circuit breakers and fuses can be universally applied as BCPDs. IEC-Manual motor controllers can be additionally evaluated and certified to fulfill the BCPD function in individual motor circuits. A Type E controller cannot be combined with any motor controller, but must be tested with specific controllers and marked accordingly as a Type F combination motor controller. The use of fuses may require the specification of the class of fuse used. The interrupting rating of a BCPD, or the short circuit current rating of a combination motor controller, must be sufficiently high enough for the application. It would have to be as high as the interrupting rating of the feeder current limiting protective device in a 508A control panel, if the interrupting rating of the feeder device is to be used as the panel’s overall SCCR value, since the lower let-through values of current limiting protective devices have no influence on downstream ratings of protective devices in 508A assemblies at this time.

industrial components, contactors in short circuit current rating (SCCR). As to the illustration (Table 1, Point 3, particular, could be used in the feeder a clarification to Table 2, Point 2 it’s -Application restrictions-) (Figure 10). circuit, since these devices are finding worth noting that only listed inverse time Common mistakes involve the use of more and more usage in functional safety circuit breakers certified to UL 489 and Type E controllers as protective devices circuits. As power switches they are also standard fuses certified to UL 248 are for power transformers or heating loads deemed to be well suited for safe and universally applicable as BCPD’s for all (Table 2, Error 11). Both these loads reliable isolation of energy sources under loads (Figure 9 and 10) (Table 7) and can be protected by circuit breakers and potentially hazardous conditions. marked with short circuit interrupting fuses exclusively. Type E and Type F ratings. This sets them apart from controllers are still relatively new to the Branch Circuit Protective Devices specialty components which, if they are North American landscape. They have to be used as short circuit protective mostly found their way into the market The application and significance of devices for certain types of loads and via imported machinery. However, their BCPD’s have been touched upon in controllers, such as drives for example, appeal is growing fast amongst North the preceding sections. Branch Circuit need to be identified by type and make American end-users and OEMs who Protective Devices provide overcurrent on the equipment (Table 2, Point 10). recognize their performance, as well protection for all circuits from their The use of UL 508 Type E controllers in as their space saving features, and are nominal current rating up to their this regard is subject to the limitations eager to take advantage of the new interrupting rating, which is to say their highlighted in the accompanying text technology. North American standards

15 ? = All load types: e.g. NEC or CEC before they can certify it for Heaters usage. Ideally, new technology would Transformers also be described in electrical assembly Lighting cd e Drives standards like UL 508A and NFPA 79 for RU +DXSWYHUWHLOHU Capacitors applications such as industrial machinery. It’s a complex and time consuming endeavor, especially considering that the (LQVSHLVHVHLWH? ? M 0DFKLQHU\FRQWURO cycle period for changes in the electrical c Circuit breakers, always large spacings codes runs typically in 3 year intervals. Fuses, always large spacings The picture is further complicated by dRU (LQVSHLVHVFKDOWHU )HHGHU&LUFXLWV e UL 508 Type E, large spacings on conflicting interests on the part of /DUJHHOHFWULFDOFOHDUDQFHV supply side only, for individual motors or manufacturers and trade groups who drives only. do not always pursue the same agenda when promoting changes to the codes. /// %XVEDUV\VWHP The use of fuses as BCPDs is more %UDQFK&LUFXLW3URWHFWLYH'HYLFHV prevalent in North America than in the IEC world, where people tend to %UDQFK&LUFXLWV prefer fuseless based panel engineering 6PDOOHOHFWULFDOFOHDUDQFHV designs. The use of North American /RDGVLGH fuses in an IEC design based panel runs counter to the stated goal of having a layout for machinery that is Figure 9: The type of load needs to be considered when applying UL 489/CSA C22.2 truly global and uniform. IEC fuses are No. 5-09 circuit breakers, UL 248/CSA C22.2 No. 248 fuses and UL 508 Type E und Type not acceptable in North America as F controllers as protective devices. Circuit breakers and fuses can be universally applied, protective devices and the amount of but may require additional components in motor circuits. Type E controllers can only be used to protect motors and drives in individual motor branch circuits. space they take up in a panel generally tends to be smaller, which would make a change to larger North American bases more problematic. Table 8 provides an organizations are thus faced with ever practices in the IEC world. An ongoing overview of available fuses on the North increasing pressure to incorporate many problem for new technology is that it American market. When selecting fuses of the IEC based component designs takes time for it to make its way into the as protective devices for components it’s and philosophies into the electrical product and installation standards, and important to consider, if applicable, the codes. One can remain hopeful that the especially the electrical codes, which is class and rating of fuse that was used allowance of these specialty controllers the ultimate step towards legitimizing to certify the equipment to make sure as protective devices for motor loads is its application. Certification agencies the correct choice of fuse can be made. the first step towards expanding their must always determine that a product Testing could involve the use of ratings functionality more in line with current does not violate the requirements of the and class designations which would need

Circuit breakers can be universally applied as branch UL 508 Type E und F controllers provide the branch circuit circuit protective devices for various loads. protective function for individual motor branch circuits only.

FAZ…-NA PKZM4…-CB NZM…-NA UL 508 Type E *) UL 508 Type F *)

Nearly always suitable as BCPDs Limitations as BCPDs

Figure 10: It’s important to differentiate between branch circuit protective devices that are universally applicable, and those which can fulfill the branch circuit protective function only in specific applications, e.g. for motors only. Component short circuit testing and certi- fication markings ultimately determine the type of branch circuit protective device which can be used, e.g. not all types of devices are suitable for drives, and some protective devices would require additional markings on components. *) In Canada, use of the large spacing BK../3-PKZ..-E terminal for Type E controllers is not required. Type E controllers at this time must all be equipped with padlockable knobs, whether open or enclosed, in both the USA and Canada.

16 Table 8: Standard North American feeder and branch circuit fuses certified per UL 248-.. and CSA C22.2 No. 248-.. including class designations, ratings and areas of application.

to be indicated on the component in switching duties. The Eaton controllers to the more restrictive provisions of the the form of a marking and which would have been additionally evaluated for group installation rules. need to be relied upon for replacement group installations, which would enable purposes. The personnel safety an arrangement of multiple controllers Appropriate power distribution provisions of the NFPA 70E standard under one back-up branch circuit networks and nominal voltage ratings with respect to fuse replacements need protective device, subject to the wiring to be followed closely in this regard. and co-ordination requirements of the As mentioned in Table 1, Point 3, As mentioned, the product standard electrical codes for such installations [5] -Limitations-, as well as Point 3 of requires several markings when using (i.e. protection for tapped circuits (e.g. Table 2, improper equipment selection fuses to denote the class and type and 1/3rd rule), consideration of the starting with respect to the power distribution fuse suitable for replacement purposes, conditions for the motors involved, network configuration is a very common if applicable. These markings normally summation of full load currents and error on the part of exporters. Many of appear in the form of labels adjacent to applicable correction factors, ideally an the more compactly designed protective the fuse bases. arrangement that involves motors of devices from the IEC world are rated relatively similar sizes, etc…). in North America for applications in UL 508 Type E self-protected solidly grounded distribution systems combination motor controllers and The PKZM… and PKE manual motor only [6] (Table 10). In Germany this Type F combination motor controllers controllers have additionally been is the most common form of power are typically rated for use in solidly evaluated as Tap Conductor Protectors. distribution network. Solidly grounded grounded distribution networks A certification as tap conductor protector distribution systems in North America only (the voltage rating needs to be allows the controllers to be used per are identified with a “slash voltage” particularly considered in this regard). the 1/10th rule provisions of the NEC rating. Examples of the way these The application of these devices in under group installations. It is also worth systems are referenced in standards ungrounded systems, or in many delta noting that tap conductor protectors and technical documentation would be configured networks, would most likely (Table 9) are mostly applicable in solidly 480Y/277VAC or 600Y/347VAC. The require an additional and suitably rated grounded systems only. The use of presence of a single protective device back-up protective device such as a Type F combination motor controllers so rated in a control panel would require breaker or fuse. The back-up protective for individual motor branch circuits can the voltage rating appearing on the device would provide the function of also be a very useful option to consider panel’s nameplate to reflect that system overcurrent protection and isolation for for these applications since, like Type E accordingly. As per Figure 12, protective the branch circuit, and the controllers controllers, they don’t require additional devices with this rating are tested by a would assume motor overload and back-up protection and are not subject NRTL under configurations C and E at

17 Advantages and drawbacks of various motor starter configurations achieved with IEC/ EN manual motor controllers, in applications per North American electrical standards

Grouping of manual Individual motor branch Individual motor branch Grouping of manual motor motor controllers circuits with circuits with branch circuit controllers listed for group additionally listed as tap UL 508 Type E- und protective device installations conductor protectors Type F-motor starters

Fulfills the role of the Protective device required Protective device required Protective device required BCPD 3 branch circuit protective device

Advantage: Advantage: Drawback: Drawback: Application in grounded and Application in grounded and Application in solidly Application in solidly ungrounded networks ungrounded networks grounded networks only grounded networks only

Drawback: Advantage: Advantage: Advantage: protentially many protective lesser amount of protective lesser amount of protective No protective device devices repuired devices repuired devices repuired required 1

Advantage: Advantage: Drawback: Advantage: Conductor sizing 1 and Conductor sizing 1 Conductor sizing 1 and Conductor sizing1 per protection per the 1/10 rule per individual motor rules protection per the 1/3 rule individual motor rules and BCPD 2

Advantage: Advantage: Drawback: Advantage: no complex group no complex group installation group building group building installation provisions to provisions to follw more difficult less difficult follow

Drawback: Advantage: 1 Motor circuit conductors are additional groupings likely to lessen the number always sized at motor full load necessary of groupings necessary 2 BCPD = Branch Circuit Protective currents (per tables) x 1.25. Device

Table 9: The advantages and limitations of various IEC based manual motor controllers with respect to their scope of application.

the reduced voltage level between phase This can be a difficult situation for machinery with relatively smaller power and ground. The set-up is used to verify exporters of mass produced machinery requirements and involves the use of that no dangerous arc-overs occur during who have no way of knowing ahead of an additional power transformer whose various portions of certification testing. time which type of power distribution secondary can be configured to form Any such arc-over causing the connected network will be present at the final a solidly grounded voltage network fuse to blow would constitute a test end-use location of their equipment. to accommodate the equipment. In failure. It is possible for devices to have There are then 2 possible scenarios to other words, create your own solidly full, phase-to-phase/phase-to-ground contemplate as solutions. One would grounded energy distribution system. ratings at lower voltages, e.g. 480V, and be to forego as a rule the selection of Design layouts for larger machinery, still be slash rated, e.g. 600Y/347VAC any equipment that is dependent on which usually feature individual power at higher voltage ratings. In that case, a solidly grounded power distribution transformers, can be made to insure the device would be suitable in solidly network. The drawback would be that that the secondary of the transformer grounded systems only at that higher it would entail the likely use of larger is configured with a solidly grounded voltage. The voltage markings on the and more numerous (additional back-up connection. Machinery that is exported to device would then be referred to as 480 protective devices) components, and Canada, as a rule, is often equipped with VAC and 600Y/347VAC . Please note thus a more expensive machine. Another step down transformers in order to get that a slash rating alone of 600Y/347VAC consequence of this option, which can around the requirements of a full 600V does not adequately cover applications be rather disappointing, is that the final rating for the equipment. The machinery in full 480V systems. Only a fully 600V layout would be in even greater contrast is then operated with 400V or 480V, rated protective device would be able to to comparable IEC based designs, and simply because there is a lack of fully be cover applications in straight, or full, would make it harder to pursue the oft rated 600V gear, or the 600V equipment 480V systems [6]. stated goal of achieving a more universal may not be sufficiently rated to handle design for the machinery. The other the breaking capacity requirements. option is one that lends itself well for It’s a good way to solve two problems

18 Switching and protective devices which are rated at their maximum voltage ratings in solidly grounded power distribution systems only. Product type Eaton model number Maximum Voltage rating Application Grounded or Above that, solidly Please refer to Table 7 ungrounded grounded system system, rating of Phase-Phase bzw. Phase/N Inverse Time Molded Case NZM1-…-NA 240 V 480Y/277 V e.g. BCPD, Main Disconnect Circuit Breaker NZM2-…-NA *) 480 V 600Y/347 V switch PKZM4-…-CB 240 V 600Y/347 V z. B. BCPD FAZ...-NA 240 V 480Y/277 V FAZ…-RT dependent on device rated current

Molded Case Switches NS1-…-NA 240 V 480Y/277 V e.g. Main Disconnect switch NS2-…-NA 480 V 600Y/347 V UL 508 Type E PKZM0 + AK-PKZ0 + 240 V 480Y/277 V Manual Combination Motor Self-Protected Combination BK25/3-PKZ0-E 600Y/347 V Controller, Motor Controller PKZM4 + AK-PKZ0 + dependent on device BCPD for individual motors BK50/3-PKZ4-E rated current as Type E PKE + AK-PKZ0 BCPD for drives when tested + BK25/3-PKZ0-E and marked UL 508 Type F Combination PKZM0 + AK-PKZ0 240 V 480Y/277 V Combination Motor Motor Controller + BK25/3-PKZ0-E 600Y/347 V Controller + bestimmtes DILM dependent on device PKZM4 + AK-PKZ0 rated current + BK50/3-PKZ4-E + bestimmtes DILM MSC-DE-...-SP Supplementary Protectors FAZ… 240 V 480Y/277 V For supplementary dependent on device protection only, not as a rated current substitute for BCPD *) NZM.2-ME..-NA suitable up to 480 V

Table 10: Compact and modern IEC based switching and protective devices which are suitable for solidly grounded power distribution systems only at their maximum rated voltage. These networks are the most predominant in IEC countries. The table shows devices so rated in Eaton‘s current catalog offering. The device’s nominal rated current is also a determining factor. Slash voltage rated distribution systems and markings on equipment such as 480Y/277 V or 600Y/347 V are very important criteria in determining the suitability of these components in actual applications.

at once. Some manufacturers require 460V for example will be connected to 230, 460 and 575 V. These differing the end-user to furnish a transformer a nominal voltage rating source of 480V voltage values are, however, a source on-site. The wise course of action is (Table 11). The simple explanation given of confusion amongst many export certainly to describe ahead of time in to the author is that the full magnitude planners. Eaton provides voltage pairings, clear details the exact ratings of the of the nominal rated source voltage e.g. 480 and 460V, 600 and 575V, under equipment being offered, and to specify will never reach the motor. In Canada, the selection guidelines for contactors whether additional equipment would be an analogous situation exists whereby and motor starters in its product catalogs needed on site. If possible, information motors with typical nameplate voltage to minimize confusion for designers in on equipment rated for solidly grounded ratings of 575V will be connected to this regard. Refer also to [7]. Standard supply networks only should be indicated 600V sources. A general statement induction motors in North America are in catalogs or product brochures supplied can be made that the higher voltage typically HP rated at the lower utilization with the machinery. rating, i.e. 240, 480, 600 V, represents levels, and not the nominal voltage the nominal rated voltage to which the ratings of 120, 208, 240, 480, and 600 V. Distinctive aspects of North American electrical equipment for machinery motor currents and voltage ratings should be based on, and is the value Another distinctive aspect involves the which should appear on the control sizing of motor conductors. The rated A peculiarity in North America, which panel’s nameplate rating label, assuming nameplate current of a motor is not nearly always becomes a source of the equipment isn’t slash voltage rated. used as a basis for sizing, but rather, the confusion in the IEC world, revolves Incidentally, slash voltage ratings are values that appear in the electrical code around the use of motor specific voltage based only on nominal voltage values tables, such as Table 430-250 of the ratings both in the USA and Canada. A of 120, 208, 240, 480, and 600 V and NEC, which is the basis for Table 50.1 of motor with a nameplate voltage rating of not the utilization ratings of 115, 200, UL 508A. The conductors are then sized

19 for higher fault ratings, for example The most important application restrictions of IEC based as part of a combination motor starter equipment certified to North American standards with fuses or circuit breakers as the protective device in the combination. Per application: Case by case basis, per technical ratings: The components which make up IEC-Manual motor controllers • pa. reduction in voltage ratings these tested and certified assemblies • pa. application in solidly grounded networks only • only with additional back-up cannot subsequently be exchanged or • pa. reduction in nominal rated currents protection interchanged in the field, as is more • pa. reduction in conductor ampacities • Group installation is possible commonly practiced in the IEC world. • or certification as UL 508 Type E High fault ratings for motor starter Combination motor controller Per the type of circuit, in Feeder Circuits: combinations are usually established • or certification as UL 508 Type F • No 508 type indsutrial control components at standardized values per the product Combination motor controller • Exception: Incoming supply parts of UL 508 Type standard, such as 50, 65 and 100kA. • Used for motor protection only E und Type F combination motor controllers Eaton provides basic information on IEC-Miniature circuit breakers • No supplementary protectors fault ratings in the online catalog, e.g. • Used as Supplementary • Bus bar systems with larger electrical clearan- motor contactors, in association with Protectors only ces only. fuses and circuit breakers, as well as • Terminals with larger electrical clearances only. Combination motor starters high fault ratings, also in association with • mostly 3 components: fuses and circuit breakers. Combination Circuit breaker, contactor, motor starter tables made up fuses overload relay pa. = partial or circuit breakers, together with a contactor and a separately mounted Figure 11: Examples of restrictions applicable to IEC based equipment in North America overload relay are also provided. Three relative to IEC standards and international market conventions and practices. component motor starter combinations with circuit breakers are typical in North America. A circuit breaker is not normally calibrated to provide motor overload protection, which explains the need for the additional motor overload relay. Eaton Full Voltages offers an interesting alternative in this e.g. 480 V or 600 V: regard consisting of a fully listed inverse time circuit breaker (Motor Protective Circuits A and B Circuit Breaker) NZM.2.-ME…-NA, Phase / Phase additionally evaluated and certified to provide the motor overload protective function in motor branch circuits. This represents a relatively new concept in North America [8]. The breaker, together with a magnetic motor contactor, allows Slash Voltages the construction of a two component combination motor starter more typical e.g. 480 Y / 277 V or of IEC based designs. This variant of 600 Y / 347 V: circuit breaker is fully listed per UL 489 Circuits C and E as an inverse time circuit breaker, but Phase / N additionally meets the motor overload calibration requirements of UL 508. Eaton can thus supply 2 component combination starter solutions with a high SCCR rating of 65kA @ 480Y/277VAC Figure 12: Test circuit configurations for full voltage (Phase-Phase) and slash voltage values for motor full load currents of up (Phase-Neutral) ratings. A blown fuse during testing is indicative of a failed test. to 200A.

Contactors are normally short-circuit tested per the product standard with at a factor of 1.25 times the table values. Sizing the conductors with this in mind fuses and circuit breakers that can be Additional factors may impact conductor ahead of time will help avoid the need to rated up to 400% of the contactor’s sizing, such as cable ratings, installation, exchange conductors later on in the field. full load current ratings, a value which conduit sizes, ambient temperature etc… is based on a contactor’s application A formulaic conversion to HP should High Fault Ratings primarily in motor circuits per the also be made whenever applying motors electrical codes. However, the need to that are rated in kW only. Even though a Power circuit components that are establish ever higher SCCR values for non-standard HP value is likely to result, certified per the industrial control component usage in control panels has which cannot be referenced in any code standard [1, 3] must undergo basic short meant that component tests are being table, most field inspectors would then circuit testing to establish a standard increasingly conducted with closer find it acceptable to base the motor fault or SCCR rating (e.g. SCCR = 5 or matched protective devices. The newly conductor sizing on the next larger size 10kA, depending on the component). introduced PKZM4-..-CB molded case standard HP rating found in the table. The component can then be submitted circuit breaker from Eaton is proving to

20 Nominal- Service Utilization Motor NEMA Voltage Voltage Voltage Nameplate Requirements Voltage Rated voltage Range B Range A Motor voltage Tolerance ® ➝ - 5 %, + 5 % - 13 %, + 6 % - 10 %, + 4 %rating - 10 %, + 10 % 120 V 114 – 126 V 104,4 – 127,2 V 108 – 124,8 V 115 V 103,5 – 126,5 V 208 V 197,6 – 218,4 V 181 – 220,5 V 187,2 – 216,3 V 200 V 180 – 220 V 240 V 228 – 218,4 V 208,9 – 254,4 V 216 – 249,6 V 230 V 207 – 253 V 277 V 263,2 – 290,9 V 241 – 293,6 V 249,3 – 288 V - 480 V 456 – 504 V 417,6 – 508,8 V 432 – 499,2 V 460 V 414 – 506 V 600 V 570 – 630 V 522 – 636 V 540 – 624 V 575 V 517,5 – 632,5 Band width 10 % 19 % 14 % 20 %

Table 11: Nominal and utilization voltage ratings differ in North America. Motors are usually rated at utilization voltage levels, such as 460V or 575V.

be a viable alternative to fuses in this rule out the possibility of mixing and one that has been ideally third party regard, since it has by design excellent matching components from other certified by a NRTL for the particular short circuit protective capabilities and makes and brands to achieve the environment into which the equipment has already yielded impressive results same results. Individual component is installed, e.g. UL/CSA Type 4X, Type when tested in combination with small manufacturers have no commercial 12 etc… An environmental rating must contactors to establish high fault ratings. interest in certifying combinations of still be established even if there is no products with components of other free standing enclosure associated to The nameplate rating labels of UL 508 brands, particularly when they also the equipment, such as when the control Type E self-protected controllers will manufacture their own. And without equipment is mounted in a cavity of the typically provide the model numbers any contractual agreements between machinery itself. If an enclosure does of motor contactors with which they manufacturers, there’s no way to not show any marked environmental were tested in order to establish Type determine if or when a product would be rating it is simply assigned a Type 1 F combination motor controller ratings. altered sufficiently to affect the results rating, which is more or less equivalent These ratings will reflect SCCR values, of previously conducted testing. This to an IP20 rating in the IEC world. and at which voltage the values are important fact is alluded to in Table 1 The UL 508A standard for industrial applicable. These will be slash rated under Point 3, -Combinations-, and also control panels provides important voltages in the majority of cases. UL 508 referred to in Table 2 under Point 3. constructional guidelines with respect Type E and Type F- Motor controllers High Fault Ratings for components and to maintaining and assigning the proper are usually offered only with high fault combinations can be an important criteria environmental ratings to a finished ratings. In 2012 Eaton expanded their in the ability to establish a high overall control panel assembly, particularly for Type E and F series of controllers by SCCR value for industrial machinery more challenging situations such as introducing the new PKE manual motor control panels per UL 508A and NFPA when cut-outs are required in a door, and controller, which featured a solid state 79. It’s necessary to make sure that the provisions of the standard should be based trip system [3]. The Canadian all the combination starter tests were strictly followed in this regard. It would based CSA standards do not yet officially certified in order for them to be useful for be nearly impossible to verify a higher recognize a Type F combination motor that purpose. Eaton provides its clients environmental rating for a completed controller. However, UL based Type with optimal combination possibilities machine assembly at the installation site F ratings indicated on controllers for to choose from. Newly established and once its rating were deemed to be Type these combinations have been readily certified combinations are continually 1 for lack of better information. Third accepted in Canada without any field being introduced to supplement the party certified environmental ratings inspection problems. Type E Controllers present listings in our printed edition such as UL/CSA Type… (Table 3) are are not required by CSA in Canada to of the online catalog since we consider much more desirable than similar NEMA be equipped with the large spacing these assemblies to be an essential and ratings, and are increasingly required BK../3-PKZ..-E incoming supply terminal permanent part of our product offering. by field AHJs. UL/CSA type ratings are (which, unfortunately, represents a subject to testing and certification by deviation between both countries in this Enclosures and environmental ratings NRTLs, whereas NEMA ratings are self- regard). A padlockable knob for open certified by a manufacturer. The actual mounted Type E devices has always Errors associated to the use of certified testing requirements, however, in both been a clear requirement in Canada. It enclosures in panels, as referenced in UL/CSA and NEMA standards (NEMA was recently confirmed that the same Table 2, Point 6, are mostly related 250), are the same. It’s crucial that all requirement exists in the UL standard for to the determination of the proper openings into the enclosures are closed US based applications and is referenced environmental rating of the overall panel by equipment, e.g. control and signaling in paragraph 76.4 of the UL 508 product once the empty enclosure has been devices, observation windows etc…, standard. fitted with equipment and accessories. that is certified with the same, or better, It’s also important that enclosures environmental rating than the enclosure The afore-mentioned combination be marked with a North American in order to maintain the overall integrity starter testing and markings required environmental type rating officially of the rating assigned. Cable entry by the product standard effectively recognized by the electrical codes, and locations and provisions are also part of

21

Figure 13: Eaton door mounted rotary and supplementary handle kits comply with all the requirements of the UL 508A and NFPA 79 standards with respect to the operating handles of supply circuit disconnecting switches for industrial machinery, including a deliberate action design incorporated into the supplementary handle to meet the enclosure interlocking provisions of the standards.

the evaluation to ultimately determine and electrically interlock them with an in order to perform certain necessary the environmental rating of the assembly undervoltage or shunt trip accessory tasks, like troubleshooting for example, in its end-use application. to trip the main disconnect switch under live conditions. The requirements open. It was thus possible to freely outlined in the safety standard NFPA Enclosure related errors also include open any panel door, since it led to an 70E [9] for work to be performed under missing, or insufficient, door interlocking automatic shutdown of the power to energized conditions are to be strictly provisions for electrical assemblies, in the equipment. However, an abrupt followed in this regard. The interlocking particular, control panels for industrial removal of power is not without its share function must automatically re-activate machinery. Door interlocking is often of potential hazards, especially if critical itself to cancel the override once all accomplished mechanically in North processes that have been initiated are doors have been re-closed. Not all door American enclosures (Table 1, Point 4). detrimentally impacted by the sudden interlocking schemes that one comes Electrical interlocking, or a combination interruption, and cannot resume to their across in the market place meets all the of both mechanical and electrical full completion once power is restored. requirements. interlocking, is also permitted. The basic In addition, a total loss of power can rule to follow in the case of industrial make it more difficult to troubleshoot the The requirements also stipulate that machinery panels per UL 508A and NFPA source of the problem. Tripping open the the supply circuit disconnecting means, 79 is to provide a design that insures main disconnect switch to cut off power independent of the door position, must that all panel doors will be closed and could also introduce a more dangerous remain accessible and be operable interlocked before the supply circuit condition if the risk assessment for the without the use of a tool, and must be disconnecting means can be turned machinery has established the need for padlockable in the OFF position. Eaton ON and the contents energized. This Stop category levels that first require fulfills this requirement with a main requirement applies for both single door the controlled removal of power before disconnect switch kit that includes and multi-door panels. Doors can be allowing the main disconnect switch to a secondary, supplementary handle opened only when the main supply circuit open. Thus, there is a need to conduct a which mounts directly onto the switch disconnecting means has been turned risk assessment for each machine design housing. This supplementary handle OFF or is in the open position. The same in this regard. The idea is to eventually provides a positional indication of the applies if there is an additional supply establish a circuit with overall Emergency main contacts, a padlocking feature, circuit disconnecting means feeding the Switching Off provisions in order to and a proper means with which the panel from another source. In single door create a condition in which all power to switch can be operated when the panels, the mechanical door interlocking the equipment can be removed safely. panel door is open (Figure 13). These requirement can be accomplished using supplementary handles also include the built-in interlock feature of Eaton door Qualified persons are enabled to a “deliberate action” design feature mounted handles for their disconnect temporarily override the door interlocking to fulfill a safety requirement of the switches. It was common practice years provisions of the supply circuit NFPA 79 and UL 508A industrial ago to install limit switches in doors disconnect while it is in the ON position machinery standards that is geared

22 towards preventing inadvertent closing Tag Out provisions and markings per will be terminated more often directly of the disconnecting means while NFPA 70E requirements). Certain onto the power component whereas the enclosure door is open. In order machines may have cavities external in IEC based assemblies, the use of to engage the switch mechanism the to the control panel which are used to terminal blocks for both power and handle must first be turned towards house additional electrical components. control connections is more prevalent. the ON position about 15 to 20°, It’s likely that the need to access these North American layouts will, therefore, depending on the frame size, and then machinery mounted components will generally require more free space to be deliberately pushed down and turned be rare, so it’s recommended to close accommodate this practice. simultaneously in order to complete off the door or opening of this cavity the operation [10]. The inspectors are with screws, so that its cover doesn’t Grounding issues increasingly monitoring this situation have to be interlocked or require any very closely to insure that the deliberate special monitoring. A warning symbol Proper grounding concerns (Table 2, action requirement of the standard is should also be affixed to the cover if it’s Point 12) are very rarely an issue for met. They are also actively asking for not readily apparent from the outside European based industrial machinery the exchange and replacement of main that electrical components are mounted and its associated electrical control disconnect switches which they deem inside. equipment. Grounding related issues inadequate in fulfilling the requirement. also occupy the last spot in the table The deliberate action requirement, as There is an additional aspect which is statistically for errors encountered in spelled out in the standards, deals more sometimes overlooked in enclosures. North American assemblies. Although specifically with enclosure interlocking Individually enclosed components and machinery manufacturers and panel requirements, but it also directly combinations need to be tested in builders supply their equipment usually impacts all door mounted rotary handle their respective enclosures. Enclosure completely assembled and wired, it’s operators of IEC based disconnect volumes, which are established through still difficult to determine whether switches which separate from the product testing, represent minimum grounding related problems develop switch body when the enclosure door is values which an installer or panel builder because the equipment is somehow open! Thus the need for the elaborate must abide by when planning a layout lacking in this regard, or if there are design features of the Eaton NFPA 79 for an industrial control panel. Larger grounding incompatibility issues with the supply circuit disconnecting switch enclosures are also better at absorbing supply source at the installation site. In operator kit. internal pressures released from short any case, the grounding requirements circuits inside the panel, and are able to of US based installations is thoroughly There are applications, usually involving more effectively dissipate temperature covered by NEC Article 250 and must be very large machines, in which the rises from energized components. The followed. These requirements are fully power supply source is furnished enclosure volumes established through compatible with those that are outlined directly by the end-user, sometimes short-circuit and temperature rise testing in sections 15, 16 and 17 of the UL 508A in specially enclosed electrical rooms of combination motor starters, whether standard and in Chapter 8 of NFPA 79 for that are not accessible to non-qualified individually enclosed or in MCC (Motor industrial control panels and the electrical personnel. The machinery manufacturer Control Center) units, must thus be equipment associated to industrial in this case is often asked to supply the followed and considered as absolute machinery. machinery control portion, housed in minimum values. Individually enclosed an industrial control panel, but without components and combinations are not The use of conduits (primarily rigid its own supply circuit disconnecting always available from European based but also flexible metal conduits, as means. The machinery control portion manufacturers as complete type tested well as non-metallic conduit, also rigid will also usually involve the supply assemblies. The main reason is often and flexible in design) is the most of „intelligent“ loads equipped with tied to low demand for those specific popular and accepted means in North adjustable speed drives and/or servos, types, and the desire of customers to America of enclosing and protecting as well as the necessary software to have more flexibility in determining how conductors that are used to distribute run them. There is always a greater best to utilize available enclosure types the electrical energy throughout a plant need in these applications to insure and sizes to house components. Another or industrial manufacturing location. that communication channels between common mistake is to improperly Individual conductors, more so than the supplier of the highly automated size conductor cross-sections for the multi-conductor jacketed assemblies, are machinery and the end-user, as well as application and end up with smaller pulled through these conduits to their with the AHJ, are well established. It’s wire than what the components were final termination point. The NEC allows also recommended to supply enclosures tested with per the requirements of the the use of rigid and flexible metal conduit that allow access only to qualified product standard. Conductors do more as the equipment grounding conductor persons. That can be easily achieved than just conduct the electric current; under certain defined conditions. with the provision of customized safety they also draw heat away from the However, the use of separately run locks with special keys for personnel electrical components to which they are equipment grounding conductors is to use when accessing the enclosure, connected. Enclosure layouts should a more frequently utilized method in rather than standardized enclosure also leave ample room to make sure modern installations. The conduits must locking systems that allow entry with that requirements for minimum cable establish and/or maintain continuity of commonly available keys or tools. bending radii are followed. Tables are ground throughout the installation and Another worthwhile consideration may provided in the electrical codes (NEC/ with the enclosures onto which they be to provide functionally safe circuitry CEC) to this effect, and it is an aspect are terminated (Table 1, Point 4). The in the control portion which would that is always closely monitored by the use of non-metallic enclosures in certain allow electrical actuation of the main approval authorities. Market conventions situations makes it especially imperative disconnecting means from within the differ somewhat in this respect. In North that proper ground continuity, ideally panel (in association with Lock Out/ America, generally speaking, field wiring through the presence of a separate

23 equipment grounding conductor, is established in order to insure proper Example of a warning label bonding of all incoming and outgoing conduits as well as non-conducting metal parts within the enclosures. The 1. Warning signalling word convention in North America is for 2. Type of danger conduits to be primarily terminated, for both incoming and outgoing conductors, 3. Consequence of the hazard on the top side of the electrical housing or enclosure (Table 1, Point 3, 4. Measures to undertake in order to reduce the hazardous condition -Installation guidelines-) One way to eliminate the need for conduits in the vicinity of the machine assembly, and as advised by the NRTLs in Germany, The warning needs to include all 4 is to make provisions for all machinery points, not just 1 and 2! associated wiring to be properly attached and secured to the machine itself, rather than on the building or structure. Figure 14: Example of a warning label per ANSI Z535.4.

Errors on nameplate ratings, warning markings and documentation regard. The possibility that unqualified manuals and would be an excellent NRTLs summarize these errors as or insufficiently trained personnel would reference source to have on hand and indicated in Table 2, Point 8. The find themselves in a position of servicing follow in this regard. nameplate of an industrial control panel and maintaining the machinery can never must include the manufacturer of the be entirely ruled out. This can potentially Based on feedback from seminar panel and, if applicable, a distinct marker increase the need for additional warning participants, and in separate discussions identifying the exact manufacturing markings to be placed on the equipment. with many other clients, it would seem site in case the manufacturer has Warning markings must be placed in the that the use of IEC wiring symbols, multiple assembly facilities. If a machine direct vicinity of the potentially hazardous rather than traditional North American manufacturer hires an outside panel condition. The best and most prudent ANSI based symbols, is gaining in builder to build the control panel, then thing to do is to follow North American acceptance throughout North America. the panel builder’s name or identifier practices with respect to the application While encouraging, the author still must appear on the nameplate. of warning markings, and solely use recommends the provision of a cross- Ultimately, the location responsible markings that are in accordance with reference comparison chart showing for building the panel must be readily the ANSI Z535.4-200714 standard [11]. both IEC and ANSI symbols as part of identifiable. Most panel builders prefer Figure 14 shows an example of a the machinery assembly documentation to both engineer and assemble the panel warning marking that is in accordance (Figure 15). That approach has proven for that very reason. The name of the with North American requirements itself to be very useful. The Eaton machine manufacturer, or that of the and expectations for such markings. A wiring manual, which is available and panel builder, can additionally appear quick internet search will yield catalog can be downloaded free of charge from on the control panel’s nameplate. Each information from many North American the internet as a pdf file, includes a machine must have a dedicated wiring suppliers of warning labels which can be comparison chart that can be copied for diagram set. used as a selection guide for the type of this purpose15. English must be used in markings to be used, rather than waste all documentation for the US market. In In certain defined instances the time creating new and original designs Canada, depending on the region and standards will require the placement that run the risk of not being properly circumstance, documentation in both of warning markings to alert users of recognized or understood. Machinery French and English will be required. In potentially hazardous and dangerous designers are wise to bend to North the southern US states there is increased conditions. A good example would be American practices and conventions demand for machinery documentation when an industrial machinery control in this regard, even if these markings in both English and Spanish. North panel has more than one supply can seem superfluous in view of the Americans, as a rule, prefer the presence source and main disconnecting means machinery’s inherent safety design. It’s of at least some text over the exclusive (Note: a supply circuit disconnecting also good practice, keeping in mind the use of pictograms, as is commonly done means cannot be a transfer switch). product liability concerns, to replicate in Europe. The standard prescribes letter height the same warning markings relating to guidelines for these markings and in potentially hazardous conditions in all Traceability of materials certification some cases the exact language to be appropriate sections of the machinery used. Warning markings are especially documentation and servicing manuals. Back when wiring material was not yet required whenever residual risks from The ANSI Z535.6-2006 standard [12] marked with information such as cross- a hazardous condition cannot be totally deals with the provision of safety related section, manufacturer, certification marks eliminated. The machine manufacturer markings in handbooks and servicing etc...,one had to make sure to retain all is ultimately responsible for determining packaging and carton markings to verify all the potential residual hazards that are associated to the machinery and not open himself up to product liability issues 14 ANSI = American National Standards Institute, through lack of due diligence in this http://www.ansi.org/ 15 http://www.wiringmanual.com

24 Eaton Wiring Manual 06/11 Eaton Wiring Manual 06/11 Export to World Markets and North America Export to World Markets and North America Electrical circuit symbols, Europe – North America Electrical circuit symbols, Europe – North America

Description IEC (DIN EN) NEMA ICS/ANSI/IEEE Description IEC (DIN EN) NEMA ICS/ANSI/IEEE

Electromechanical operating or or × N/O contact, delayed when or device with On-delay closing T.C. 07-15-08 x device code letter 07-05-02 07-05-01 ˅ table, page 9-17 N/C contact, delayed when or Electromechanical device with or or × reclosing T.C. Off-delay 07-05-03 07-05-04 07-15-07 x device code letter Control devices ˅ table, page 9-17 Push-button (not stay-put) Electromechanical device with or or × PB On- and Off-delay 07-15-09 x device code letter 07-07-02 ˅ table, page 9-17 Spring-return switches with PB Electromechanical device of a N/C contact, manually operated thermal relay or by pushing, e.g. push-button 07-15-21 Spring-return switches with PB Contacts N/O and N/C contacts, manually operated by pushing 9 N/O contact or or 9 Spring-return switches with PB

07-02-01 07-02-02 latching position and one N/O contact, manually operated by N/C contact or pushing

07-02-03 Spring-return switches with latching position and one N/C Changeover contact with or contact, manually operated by interruption striking (e.g. mushroom button) 07-02-04 Position switches (N/O LS Early-make N/O contact of a TC or TDC contacts)

contact assembly Limit switches (N/O contacts) 07-08-01 07-04-01 Position switches (N/C LS Late-break N/C contact of a T0 or TD0 contacts) contact assembly Limit switches (N/C contacts) 07-08-02 07-04-03 Spring-return switches with LS N/O contacts, mechanically operated, N/O contacts closed

9-30 9-31

Figure 15: Excerpt of a comparison between IEC and ANSI electrical symbols. Source: Chapter 9, Eaton Wiring Manual 2011, “Automation and Power Distribution. http://www.wiringmanual.com

the data, and thus the problems alluded to in Table 2, Point 9 had much greater significance. Today, any material which lacks thesee key markings will be subject to close scrutiny. Plastic materials are especially critical with respect to their flammability ratings. Errors can be easily made, for example, when choosing the right kind of material for observation windows in panels, or any kind of cover plates for electrical components, or when putting together panel bus bar systems from loose parts. It’s not just a matter of Back-up-Protection per IEC-Practices Application of current limiting getting the technical features right. The back-up protective devices proper use and application of materials in this regard must be sanctioned by the standard, and verifiable by the inspection authorities accordingly for evaluation Figure 16: The figure on the left shows an example of back-up protection per IEC purposes. practices. The presence of the Q1 or F2 protective device increases the overall short circuit rating of outgoing switches Q2 through Q4 up to a desired value established and verified through testing. Manufacturers routinely include technical data on permissible Short Circuit Current Rating (SCCR) component combinations in their product catalogs to this effect. The principle would be referred to as “Series Ratings” in North America. The right side of the figure shows The determination of an overall short a current limiting upstream protective device, either Q5 or F2. Per IEC practices the circuit current rating per Table 1, sizing of protective devices Q6 through Q8 relative to their short circuit rating would Point 5, is now one of the key aspects be established in accordance with the let-through values of the upstream devices. to consider in the design of industrial This allows the possibility for more compact and economical components with lower short circuit ratings to be installed downstream. Both these principles are currently control panels. The resultant value must not permitted as a means to establish overall short circuit current ratings for industrial be part of the data appearing on the control panels per the UL 508A standard, although the electrical codes do permit the control panel’s nameplate. The inference practice under defined conditions for other types of applications.

25 from Table 2 is that the NRTLs, up is not a sanctioned practice in North Summary: to this point anyway, do not consider American industrial control panels. Thus, this requirement to be overly prone for the short circuit rating of all protective Both the positive experiences and errors, since it doesn’t even show up devices in a panel must have a SCCR that unfortunate mishaps of others can as a problem issue in the tabulation. is at least equal to, or greater than, the enlighten us in determining the most That is perhaps due to the degree of overall short circuit rating that is assigned effective way to avoid costly and time uncertainty which still prevails this topic. to the panel. This conservative approach consuming export related errors. The There are constant efforts under way to can make the application of certain paper attempted to highlight the most update Supplement SB of the UL 508A product lines of protective devices much commonly made mistakes and provide in this regard, which is the predominant more difficult, or eliminate their usage advice on how to avoid them. The document used in North America to altogether. statistics demonstrate that the fall-out establish SCCR values for control panels. from these mistakes should not be A practical goal would be, for example, Machinery manufacturers and panel under-estimated, and that purposely at least in the case of large machinery, builders, at least in Germany, strive to avoiding North American standards is to establish values more in line with do the right thing and are very much unwise since all of these errors are likely the true relationship which exists in the interested in fully complying with the to be flagged by field inspectors and field between the current rating of the SCCR requirements outlined in the North AHJs. The negative consequences of machinery and the overall short circuit American standards. But there remains having to remedy any of these mistakes rating that is to be realistically expected. much uncertainty on how best to achieve after the fact will become immediately If a piece of machinery is large enough to this. clear to a project engineer. In extreme require its own power transformer then it cases it could mean a completely stands to reason that the available short Let’s keep in mind too that the reliability re-designed panel. Proper adherence circuit current of that power transformer of machinery designed to IEC standards to the requirements of North American will likely be high. Thus, the SCCR has proven itself the world over. What codes and standards will help you avoid associated to the machinery assembly is produced in the IEC world can’t these major mistakes, and greatly should also be correspondingly high. The be all bad. It’s also difficult to obtain improve your chances of designing and author published a more extensive paper informational self-help guides or building a control panel assembly that on this topic some time ago [13]. At the assistance manuals from North America will be approved by North American time of this writing the situation is such which specifically address this particular AHJs. Familiarity with the standards that many machinery and panel builders requirement of the standard. In spite would also increase the odds of more are mostly assigning overall values of of this it is strongly recommended that quickly obtaining NRTL certification for 10kA to their panels and assemblies. machinery and panel builders be clear in your manufacturing facility should this Some NRTL field inspectors purposely specifying as part of their product offer option become more feasible in your avoid providing specific details on the to potential clients a SCCR rating for the business plan. topic whereas others advise the use of North American equipment they would a 5kA minimum SCCR value to avoid the be supplying, since it is now a firmly The complexity involved in designing need for closer checking. There have also established requirement of the electrical „North American“ machinery is nearly been important discussions on the effect codes. There are always external always greater than its IEC equivalent. of wire ferrules on component SCCR measures which can be implemented on The broader the involvement in this values, and the initial plan had been to site to reduce the available fault current business, the greater the need to access limit ferrule equipped terminations to at the incoming terminals of a control proper training and support material on 10kA ceilings, which would have made it panel and satisfy requirements. the subject, and to have on hand current very difficult to achieve an overall panel and relevant standards to follow. The value greater than that rating. The topic The basic principle in establishing an additional outlay of resources should has in the meantime been thoroughly overall SCCR value for a control panel be readily documented in order to more discussed amongst UL and 508A revolves around the need to evaluate accurately gauge and calculate the committee panel members and the ruling all the components and combinations ultimate costs from machine to machine. is, rightfully, that the use of ferrules does which make up the power circuit, and not have any negative or limiting impact singling out those with the lowest SCCR Validity: December 2014 on the SCCR of a component. values. The standard then allows the possibility of raising the ratings of lesser The contents of this paper reflect rated, passive power circuit components editions of relevant North American The UL 508A standard is also more through the use of power transformers, codes & standards valid as of this date. restrictive than the IEC when it comes or through the use of a current limiting Binding technical information on Eaton to fully utilizing the benefits of current protective device such as a circuit equipment mentioned throughout limitation technology in control panels. breaker or fuse in the feeder circuit the paper can be found in the most Specifically, there are limitations imposed which would lower overall let-through recent versions of product catalogs and when evaluating component ratings values downstream from the device. documentation. The suitability of the based on lower let-through values and in The lowest SCCR value determined recommendations provided in the paper the use of series connected protective from this evaluation establishes the should be checked against the specific devices with current limiting capabilities. overall short circuit rating (SCCR) of the requirements of each application. A series rating, i.e. one based on the panel. This value must then appear on ability of a protective device to raise the control panel nameplate to meet the the overall rating of a lesser rated requirements of both the standard and downstream protective device (such the electrical codes. as FAZ…-NA) when used in a series connected arrangement (Figure 16),

26 Acknowledgment: [6] Wolfgang Esser [13] Wolfgang Esser „Exportrelevante Spannungs- „SCCR – Overall Panel Short Circuit The author gratefully acknowledges angaben und Netzformen in Current Rating – gemäß NEC und the technical support of the following Nordamerika“ UL Standards“ individual in the preparation of this paper: VER4300-965de VER 0211-956D

Mr. Andre R. Fortin, BA Phys. „Export relevant voltage „SCCR – Overall Panel Short Circuit information and mains forms in Current Rating – per NEC and …… North America“ UL Standards“ VER4300-965en VER0211-959GB, References: Eaton Industries GmbH, Bonn, 2010 Article No. 110102 Moeller GmbH, Bonn, 2007 [1] „Schaltgeräte und Schaltanlagen für [7] Wolfgang Esser den Weltmarkt und für den Export „Leistungsschilder richtig nutzen nach Nordamerika“ – erfolgreich nach Nordamerika VKF0211-563D exportieren“ VER4300-962de „Components and Systems suitable for World Markets and Export to „Be more successful in exports North America“ to North America – With the use VKF0211-563GB of properly certified and marked Eaton Industries GmbH, Bonn, 2010 equipment” VER4300-962en [2] Wolfgang Esser Eaton Industries GmbH, Bonn, 2010 weitere Veröffentlichungen: www.eaton.eu/veroeffentlichungen [8] Wolfgang Esser www.eaton.eu/publications „2-Komponenten-Motorstarter für den Einsatz in Nordamerika“ [3] Wolfgang Esser VER1200+2100-967de „Leichtere Produktauswahl für den Export nach Nordamerika“ „2-Component Combination Motor VER0211-969de Controller solutions for North America” „Product selection for North VER1200+2100-967en American exports made easy“ Eaton Industries GmbH, Bonn, 2010 VER0211-969en Eaton Industries GmbH, Bonn, 2010 [9] NFPA 70E, Standard for Electrical Safety in the Workplace, 2009 [4] Mark W. Earley, Jeffrey S. Sargent “National Electrical Code Handbook [10] Wolfgang Esser Twelfth Edition „Hauptschalter mit Drehgriffen International Electrical Code Series konform mit NFPA 79 und UL 508A National Fire Protection Association, einsetzen.“ Quincy, Massachusetts VER1230-966de

[5] Wolfgang Esser „Supply circuit disconnecting „Besondere Bedingungen für den means with rotary handles in Einsatz von Motorschutzschaltern compliance with NFPA 79 and und Motorstartern in Nordamerika“ UL 508A” VER1210+1280-928D VER1230-966en Eaton Industries GmbH, Bonn, 2010 „Special considerations governing the application of Manual Motor [11] ANSI Z535.4-2007, “American Controllers and Motor Starters in National Standard for Product North America“ Safety Signs and Labels” VER1210+1280-928GB, Eaton Industries GmbH, Bonn, 2010 [12] ANSI Z535.6-2006, “American National Standard For Product Safety Information In Product Manuals, Instructions, And Other Collateral Materials”

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Eaton Industries GmbH Hein-Moeller-Str. 7–11 D-53115 Bonn Germany Moeller series is a registered trademark © 2015 by Eaton Corporation of Eaton Corporation All rights reserved All other trademarks are property of their Printed in Germany 03/15 respective owners. Publication No.: WP027007EN ip March 2015 SmartWire-DT® is a registered trademark Article No.: 180528 of Eaton Corporation.