NEMA Standards Publication ICS 20-2009 (R2015)

Informational Guide to Electrical Industrial Topics

Published by

National Electrical Manufacturers Association

th
1300 North 17 Street, Suite 900
Rosslyn, Virginia 22209

www.nema.org

© 2009 National Electrical Manufacturers Association. All rights, including translation into other
languages, reserved under the Universal Copyright Convention, the Berne Convention for the Protection
of Literary and Artistic Works, and the International and Pan American copyright conventions.
 NOTICE AND DISCLAIMER

The information in this publication was considered technically sound by the consensus of persons
engaged in the development and approval of the document at the time it was developed. Consensus
does not necessarily mean that there is unanimous agreement among every person participating in the
development of this document.

NEMA standards and guideline publications, of which the document contained herein is one, are
developed through a voluntary consensus standards development process. This process brings together
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publication. While NEMA administers the process and establishes rules to promote fairness in the
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CONTENTS

Foreword............................................................................................................................................................... ii
Section 1 Comparison of UL 50/UL 50E to IEC 60529 Enclosure Type Ratings ............................... 1
Section 2 Guide to IEC Utilization Categories and UL Ratings for Motor Controllers ........................ 5
Section 3 Motors Design IEC vs. NEMA ............................................................................................. 8
Section 4 Wire Sizing in Accordance with IEC Standards ................................................................ 12
Section 5 Application Considerations for UL Combination Starters.................................................. 13
Section 6 NEC 430 Part IX, and Section 430-109 Motor Circuit Switch vs. Motor Disconnects ...... 17
Section 7 Understanding Protection Requirements of the National Electrical Code ........................ 21
Section 8 Feeder and Branch Circuits .............................................................................................. 29

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FOREWORD

As a result of increased activity in the field of harmonization, primarily involving North American and IEC
based standards for electrical equipment, new topics and terminology continue to surface that are
increasingly confronting the public and users at large, but which may not be clearly understood.

This informational guide was created to provide additional background information on various key topics
of interest related to the application and proper usage of electrical equipment in the global marketplace.

The topics in this document do not contain all the details and variations of all the mentioned equipment.
However, Standard and Code references have been included in the different sections with the intent that
users reference them as necessary.

In addition, we recommend that you contact the product manufacturer for any product-specific questions
that are not covered in this informational guideline. Referenced Standards are intended to be those of the
latest revision or latest edition.

NEMA publications are subject to periodic review. Any comments or proposed revisions to this guide
should be submitted to:

Senior Technical Director, Operations

National Electrical Manufacturers Association
1300 North 17th Street, Suite 900
Rosslyn, Virginia 22209

This Standards Publication was developed by the Industrial Automation Control Products and Systems
Section. Section approval of the standard does not necessarily imply that all section members voted for its
approval or participated in its development. At the time it was approved, the Group/Section was composed of
the following members:

ABB Inc. Eaton Electric

Carlo Gavazzi Automation Components Omron Electronics LLC
Cooper Bussmann Phoenix Contact, Inc.
Cummins, Inc. Post Glover Resistors, Inc.
Eaton Electrical, Inc. Reliance Controls Corporation
Electro Switch Corporation Rockwell Automation
Emerson Electric Co. Russelectric, Inc.
Everlite Hybrid Industries Inc. SEW-Eurodrive, Inc.
GE Siemens Industry, Inc.
Hubbell Incorporated Square D Company
Joslyn Clark Controls, Inc. Torna Tech Inc.
L-3 Communications, Power Paragon Toshiba International Corporation
Master Control Systems, Inc. Tyco Electronics/AMP
Metron, Inc. WAGO Corporation
Mitsubishi Electric Automation, Inc. Yaskawa Electric America, Inc.

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Section 1
COMPARISON OF UL 50/UL 50E TO IEC 60529 ENCLOSURE TYPE RATINGS

UL 50/UL 50E type ratings account for intended indoor and outdoor environmental conditions such as
dripping water, dust, hose-directed oil and water, rain, ice formation, and enclosure material ability to
withstand rusting and UV exposure.

UL 50/UL 50E has construction and performance requirements relative to enclosure construction that are
not contained in IEC 60529 such as metal type, thicknesses, door/cover applicability, hinge design,
knockouts, gasket material, corrosion protection methods.

UL type enclosure ratings are applicable to enclosures and enclosed type products only.

UL does not equate Type Ratings to IP ratings. Appendix A of NEMA 250 does have a table equating
NEMA Type Ratings to IP Ratings. There are also numerous other publications and internet sites that
provide comparisons between Type Ratings and IP ratings.

The IEC designation consists of the letters IP followed by two numerals. The first characteristic numeral
indicates the degree of protection provided by the enclosure with respect to persons and solid foreign
objects entering the enclosure. The second characteristic numeral indicates the degree of protection
provided by the enclosure with respect to the harmful ingress of water.

Additional suffix letters may be specified to denote a higher degree of protection against access to
hazardous parts than what is specified by the first numeral. Supplementary letters may also be specified
to denote protection under specific conditions (e.g., specified weather conditions, high voltage apparatus).

IP codes are applicable to both open type and enclosed type products.

IEC 60529 Ingress Protection IP codes account for protection against ingress of objects (e.g., dust, wire,
finger, fist) and water (e.g., sprinkler, hose) and optionally may account for protection against impact to
the enclosure.

IEC 60529 does not specify degrees of protection against damage of equipment, risk of explosions, or
conditions such as moisture (produced for example by condensation) or corrosive vapors.

IEC requirements for enclosure construction are typically contained in the product standards.

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UL 50 enclosure type ratings are designated by number as noted in the following table.

Table 1-1
UL 50 ENCLOSURE TYPE RATINGS

1 Indoor use primarily to provide a degree of protection against limited amounts of falling dirt.

2 Indoor use primarily to provide a degree of protection against limited amounts of falling
water and dirt.
3 Outdoor use primarily to provide a degree of protection against rain, sleet, wind blown dust
and damage from external ice formation.
3R Outdoor use primarily to provide a degree of protection against rain, sleet, and damage
from external ice formation.
3S Outdoor use primarily to provide a degree of protection against rain, sleet, windblown dust
and to provide for operation of external mechanisms when ice laden.
4 Indoor or outdoor use primarily to provide a degree of protection against windblown dust
and rain, splashing water, hose-directed water and damage from external ice formation.
4X Indoor or outdoor use primarily to provide a degree of protection against corrosion,
windblown dust and rain, splashing water, hose-directed water, and damage from external
ice formation.
5 Indoor use primarily to provide a degree of protection against settling airborne dust, falling
dirt, and dripping noncorrosive liquids.
6 Indoor or outdoor use primarily to provide a degree of protection against hose-directed
water, and the entry of water during occasional temporary submersion at a limited depth
and damage from external ice formation.
6P Indoor or outdoor use primarily to provide a degree of protection against hose-directed
water, the entry of water during prolonged submersion at a limited depth and damage from
external ice formation.
12, 12K Indoor use primarily to provide a degree of protection against circulating dust, falling dirt,
and dripping noncorrosive liquids.
13 Indoor use primarily to provide a degree of protection against dust, spraying of water, oil,
and noncorrosive coolant.

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IP code ratings are designated as follows:

IP X X X
First Index—Foreign Bodies Protection, Solids
Protection against
Index Protection against solid objects (foreign bodies)
hazardous parts
0 No special protection
Back of hand
1 50 mm sphere shall not Large foreign bodies, diam. >50 mm
fully penetrate
Finger
2 12.5 mm sphere shall not Medium-sized foreign bodies, diam. >12 mm
fully penetrate
Tools
3 2.5 mm sphere shall not Small foreign bodies, diam. >2.5 mm
penetrate at all
Wires
4 1.0 mm probe shall not Granular foreign bodies, diam. >1 mm
penetrate at all
Wires
Dust-protected; dust deposits are permitted, but their volume must
5 1.0 mm probe shall not
not affect the function of the unit or impair safety
penetrate at all
Wires
6 1.0 mm probe shall not Dust-tight
penetrate at all

Second Index—Water Protection, Liquids

Index Protection against water Protection from condition

0 No special protection
1 Water dripping/falling vertically Condensation/Light rain

2 Water sprayed at an angle (up to 15º from the vertical) Light rain with wind

3 Spray water (any direction up to 60º from the vertical) Heavy rainstorm

4 Spray water from all directions, (limited ingress permitted) Splashing

Low pressure water jets from all directions, (limited ingress
5 Hose down, residential
permitted)
Hose down, commercial.
6 High pressure jets from all directions, (limited ingress permitted)

7 Temporary immersion, 15 cm to 1m Temporary Immersion

8 Permanent Immersion, under pressure Continuous immersion

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Third Index—Additional Protection from Hazardous Parts

Index Protection against impact Equivalent mass impact
A Back of hand Large foreign bodies, diam. >50 mm

B Finger Medium-sized foreign bodies, diam. >12.5 mm

C Tools with a thickness >2.5 mm Small foreign bodies, diam. >2.5 mm

D Wires with a thickness >1 mm Granular foreign bodies, diam. >1 mm

Fourth Index—Supplementary Protection

Index Significance

H High-voltage apparatus

M Protection against ingress of water when moveable parts of equipment are in motion

S Protection against ingress of water when moveable parts of equipment are stationary
Protection against specified weather conditions provided with additional protective features or
W
processes

Reference Documents:

 UL 50E Enclosures for Electrical Equipment, Environmental Considerations

 CSA C22.2 No. 94-1 Enclosures for Electrical Equipment, Non-Environmental Considerations
 NEMA 250 Enclosures for Electrical Equipment (1000 V Maximum)
 IEC 60529 Degrees of protection provided by enclosures (IP Code)

Note—This is a guide, and standards continuously change; always refer to the latest revision of the applicable standards for current
requirements.

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Section 2
GUIDE TO IEC UTILIZATION CATEGORIES AND UL RATINGS FOR MOTOR
CONTROLLERS

Summary:
The purpose of this section is to compare the utilization categories in IEC to Underwriters’ Laboratories
application ratings and definite purpose ratings for motor controllers in order to:

 Facilitate harmonization (possible adoption of utilization categories by UL)

 Provide a tool to do one test to obtain ratings under IEC and UL.

Typical methods to perform one set of tests to obtain multiple ratings are called “umbrella” tests. This
involves picking the worst case test parameters and conditions and combining them into one set of tests.
While this reduces the number of tests, very often the combined worst case conditions are more severe
than the test device can withstand.

In some cases, there are minor differences that can easily be accounted for. In other cases, there are
differences in test parameters that can be accounted for in an “umbrella” test. Lastly, there are categories
that have significant differences that, while “umbrella” tests can be designed to cover, may be too severe
when all worst cases are combined.

The three tables below compare utilization categories to ratings for motor controllers and attempt to point
out considerations for “umbrella” testing. This guide does not address IEC utilization categories for other
equipment considered.

Reference Documents:
IEC 60947-1 Low-voltage switchgear and controlgear—Part 1: General rules

IEC 60947-4-1 Low-voltage switchgear and controlgear—Part 4-1: Contactors and motor-starters—
Electromechanical contactors and motor-starters

CANENA 60947-1 Low-voltage switchgear and controlgear—Part 1: General rules

CANENA 60947-4-1 Low-voltage switchgear and controlgear—Part 4-1: Contactors and motor-starters—
Electromechanical contactors and motor-starters
th
UL 508 Industrial Control Equipment, 17 Edition

Note—This is a guide, and standards continuously change; always refer to the latest revision of the applicable standards for current
requirements.

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Table 2-1
UTILIZATION CATEGORIES THAT ARE ESSENTIALLY EQUIVALENT TO UL RATINGS

IEC Utilization IEC Utilization UL Rating Description Consideration for

Category Category Description Umbrella Testing
Non- or slightly
AC-1 General Use Use worst case off time
inductive loads
Electric discharge
AC-5a Inductive Ballast Use worst case off time
lamps
Use worst case off time,
AC-5b Incandescent lamps Tungsten (Incandescent) IEC requires lamp load;
no synthetic loads
Use worst case off time
Non- or slightly
DC-1 DC non-inductive and polarity reversal for
inductive loads
IEC
Use worst case off time,
DC-6 Incandescent lamps DC Incandescent Lamps for IEC polarity reversal,
and lamp load
To be
Elevator Ratings Elevator Ratings Essentially the same
determined

Where the categories are essentially equivalent, performing one set of tests will cover both ratings under
the conditions noted.

Table 2-2
UTILIZATION CATEGORIES THAT SOMEWHAT ALIGN WITH UL RATINGS AND MAY BE COVERED
WITH UMBRELLA TESTS

IEC Utilization IEC Utilization UL Rating Description Consideration for

Category Category Description Umbrella Testing
Use commercially
AC-6b Capacitor banks Capacitive switching
available capacitors
Hermetic refrigerant
Use worst case off time,
AC-8a compressor—manual Hermetic compressor
worst case power factor
reset
Hermetic refrigerant Covered if LRA used,
Compressor—auto reset
AC-8b compressor—auto worst case PF and on/off
(recycle)
reset times used

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Table 2-3
UTILIZATION CATEGORIES THAT DO NOT ALIGN WITH UL RATINGS

IEC Utilization IEC Utilization UL Rating Description Consideration for

Category Category Description Umbrella Testing
Slip-ring motors:
AC-2 No equivalent rating N/A
starting, switching off
Squirrel-cage motors:
AC-3 starting, switching off
during running Across-the-line motor Significant test
Squirrel-cage motors: starting differences exist
AC-4 starting, plugging,
inching

AC-6a Transformers No equivalent rating N/A

Shunt motors, starting, Across-the-line Significant test

DC-3
plugging, inching DC motor starting differences exist
Series motors, starting,
DC-5 No equivalent rating N/A
plugging, inching

Motor starting utilization categories AC-2, AC-3, and AC-4 are specific motor applications. UL has an
across-the-line motor starting rating that covers a variety of applications. These do not line up well,
though tests can be designed to cover an IEC category and a UL rating.

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Section 3
MOTORS DESIGN IEC VS. NEMA

Summary:
This guide provides a brief comparison between the AC 3-phase motor design according to the IEC
60034 series standard and the NEMA MG 1 standard. The comparison in this guide is limited to the
Asynchronous motor type (3-phase Induction Squirrel Cage), which is the most widely in the industry
worldwide and in North America.

3.1 IEC Cooling

The IEC has a two-digit IC Code for the motor method of cooling (IC, International Cooling). They are
defined in standard IEC 60034-6 [4]. The most common open and enclosed NEMA types are also
described in the NEMA publication MG 2 [2]. Common types appear below:

IEC Cooling method: NEMA Cooling method:

IC 01 for open motors ODP guarded Open type
IC 40 for enclosed non ventilated TENV Totally Enclosed Non Ventilated
IC 41 enclosed fan cooled TEFC Totally Enclosed Fan Cooled
IC 48 enclosed for use in air stream TEAO Totally Enclosed Air Over

3.2 IEC Motor Enclosure Type

The IEC IP system (Ingress Protection) as defined in IEC 60529 is used. The first digit indicates the
protection against the solid and the second numeral is for protection against the liquid. A table of the
common type of motor enclosures is shown, (not an equivalency comparison):

IEC Ingress Protection, IP Code NEMA motor enclosure:

IP 00 not protected solid or liquid
IP 20 finger-proof
IP 12 dripping water at 15 deg.
IP 13 rain sprayed at 60 deg.
IP 55 dust-tight & water jet
IP 68 continuous immersion
Open type
Open type guarded, against contact by a 12 mm probe
ODP Open type, Drip-proof
WP Weather-proof
TE Totally Enclosed
Submersible motor, e.g., pump

3.3 IEC Motors Design Types

The IEC Design Types are in relation to the full-load torque versus the synchronous speed. The electrical
performance characteristics of IEC Design N (normal) is for normal locked rotor torque and Design H
(high) is for high locked rotor torque. The suffix Y may be used for star-delta wounded motors, e.g.,
design NY or HY (for motors provided with the six wire of the windings available).

A comparison table of the NEMA design A, B, C, and D and IEC designs H and N is shown below.

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IEC AC Motor Torque Types NEMA Motor Torque Types

IEC Design N, normal locked rotor torque
and high locked rotor current
IEC Design H, High locked rotor current
And high locked rotor current.
NEMA Design B, Normal locked rotor torque
and normal locked rotor current.
NEMA Design C, High locked rotor torque, normal
locked rotor current.
NEMA Design D, High locked rotor torque and high slip.
NEMA Design A, Normal locked rotor torque, and high
locked rotor current.

The below figure from NEMA MG 2 shows the curve of Percent Full load torque versus Percent Motor
synchronous speed for NEMA design A, B, C, and D.

Figure 3-1
FIGURE FROM NEMA MG 2

3.4 IEC Motors Duty Cycle

In the industry most users refer to duty cycle in one of two terms: continuous or intermittent. IEC 60034-1
breaks it into eight ratings [3]:

S1 Continuous duty. The motor works at constant load for enough time to reach temperature
equilibrium.

S2 Short-time-duty. The motor works at constant load, but not long enough to reach temperature
equilibrium, and rest periods are long enough for the motor to reach ambient temperature.

S3 Intermittent periodic duty. Sequential, identical run and rest cycle with constant load.
Temperature equilibrium is never reached. Starting current has little effect on temperature rise.

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S4 Intermittent periodic duty with starting. Sequential, identical start, run and rest cycles with
constant load. Temperature equilibrium is never reached, but starting current affects
temperature rise.

S5 Intermittent periodic duty with electric braking. Sequential, identical cycles of starting, running at
constant load, electric braking, and rest. Temperature equilibrium is not reached.

S6 Continuous operation with intermittent load. Sequential, identical cycles of running with constant
load and running with no load. No rest period.

S7 Continuous operation with electric braking. Sequential, identical cycles of starting, running at
constant load, and electric braking. No rest period.

S8 Continuous operation with periodic changes in load and speed. Sequential, identical duty cycles
of start, run at constant load and given speed, then run at other constant loads and speeds. No
rest.

3.5 Kilowatt Output with Horsepower Equivalents

IEC uses kilowatts mechanical output and NEMA uses horsepower. Similar to NEMA, IEC assigns
comparable power ratings to standard frame sizes. The IEC standard motor frame sizes appear in IEC
60072-1 [6]. A comparison of the Full Load Motor Amperes, FLA, for AC induction motor, four pole, 3 ph,
(400 v - 50 Hz, 1500 rpm), and (460 v - 60 Hz, 1800 rpm) is shown below.

FLA at 400 vac- kW kW HP (746 w) FLA at 460 vac

50Hz Primary Series Secondary 60 Hz, (NEC
Series 430-250)
…….. ……… ……. …..
1.1 0.37 1/2 1.1
1.5 0.55 3/4 1.6
1.9 0.75 1 2.1
2.5 1.1 1.5 3.0
3.4 1.5 2 3.4
1.8
4.8 2.2 3 4.8
3
6.3 3.7 5 7.6
8.1 4
11 5.5 7.5 11
6.3
14.8 7.5 10 14
9
21 11 15 21
13
28.5 15 20 27
……… …….. …….. …….

References:
[1] Motors and Generators, NEMA Standards Publication NEMA MG 1-2006.

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[2] Guide for selection, installation, and use of electric motors and generators, NEMA Standards
Publication NEMA MG 2.

[3] Rotating electrical machines—Part 1: Rating and performance, IEC 60034-1.

[4] Rotating electrical machines—Part 6: Methods of cooling (IC Codes), IEC 60034-6.

[5] Rotating electrical machines—Part 12: Starting performance of single-speed three-phase cage
induction motors, IEC 60034-12.

[6] Dimensions and Output Series for Rotating electrical machines—Part I: Frame number 56 to 400 IEC
60072-1.

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Section 4
WIRE SIZING IN ACCORDANCE WITH IEC STANDARDS

Generally speaking, the selection process for conductor cross-sections and ampacity per IEC standards
is fairly straightforward and is covered by the following formula:

Ie ≤ In ≤ Iz,

in which each term is defined to be:

Ie = Load Current; In = Rated Current of protective device; Iz = Conductor Ampacity

Thus, the conductor ampacity is always selected to be equal to or greater than both the rating of the
protective device and the load operating current. In addition, it is necessary to consider the type of
protective device in the circuit at hand, since it may also ultimately impact the final ampacity and cross
section of the conductor selected to service the load.

The following parameters are applicable for the selection of the protective device in relation to the
conductor ampacity:

I2 ≤ 1.45 Iz

whereby I2 is the rated tripping current of the protective device as determined by tests from the respective
product standard. Thus, the tripping current of the protective device in the circuit must never exceed
145% of the conductor’s ampacity.

Similar to the NEC, ampacity tables in IEC installation standards provide wire ampacities as a function of
many variables, including wire insulation type and cross-section, type of installation (either enclosed in
walls or in free air), and whether conductors are of the single or multi-core variety. Conductor cross-
2
sections in IEC standards are typically provided in mm .

Adjustable protective devices meeting the 145% tripping criteria are usually set to the rated load or
conductor ampacity from the tables. Fixed protective devices, whose rated current In does not exactly
match the conductor ampacity table values, must either be selected at the next lower available rated
current, or may require an increase in the conductor cross-section and ampacity values to ensure
compliance with the aforementioned formulae.

Summary:
Sizing of conductors per IEC standards follows a somewhat different set of criteria from what we are
accustomed to in North America. Adherence to the guidelines outlined above will ensure that the basic
conductor selection process per IEC standards has been met for the majority of applications. As in all
cases, careful consideration of the load type and current is necessary in the end to ensure proper
selection of conductors and associated electrical equipment for all circuits.

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Section 5
APPLICATION CONSIDERATIONS FOR UL COMBINATION STARTERS

Combination starters are the most common type of packaged motor controllers. They are called
combination because of their construction and combined functions. The National Electrical Code® (NEC)
defines the required functions of combination starters. Underwriters Laboratories, Inc. (UL) specifies the
tests and verifications that the components must pass before they can be listed as suitable for use for
those functions.

Figure 5-1
REQUIRED FUNCTIONS OF COMBINATION STARTERS

Figure 5-1 depicts the four component functions that comprise a complete motor branch circuit as defined
by the NEC.

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UL currently recognizes six different styles of combination starters that meet the requirements of a motor
branch circuit. This data bulletin discusses the six types of UL recognized combination starters, with an
emphasis on UL 508 Type E and Type F classifications. The topics discussed in this paper are:

 Types of combination starter constructions

 Self-protected designation and implications
 Coordination considerations
 Motor control panel design implications

UL 508 is the UL safety standard for industrial control equipment. Part IV defines the component
functions, construction, testing, and performance requirements of six styles of combination starters. Each
of the six styles meets the requirements of NEC Article 430 for the motor disconnecting means, the motor
branch-circuit short-circuit and ground fault protection, the motor controller, and the motor overload (OL)
protection. Each provides adequate protection against fire or personal injury under fault conditions. The
UL 508 type designations are differentiated by the actual components used to protect the motor branch
circuit as illustrated in Table 5-1.

Table 5-1
UL COMBINATION STARTER TYPE DESIGNATIONS

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5.1 UL Combination Starters Types A through D

UL 508 Types A through D combination starters use either a listed disconnect switch and fuses or a listed
circuit breaker as the disconnect means and for short circuit protection. Each type uses a separate UL
508 listed motor controller and overload relay. These starters are evaluated by UL under the same set of
short circuit performance tests. Each type clears faults without causing a fire or posing an electrical shock
hazard to personnel. Each type is allowed to sustain damage that is contained within enclosures and may
require the repair or replacement of devices after performing their protective function.

5.2 UL Combination Starter Type E

This product is an integrated device that performs all the required functions of a combination starter. It
may be manual-only, or it may also incorporate a magnetic or solid state motor controller.

5.3 UL Combination Starter Type F

This product is the combination of a Type E combination motor controller plus a separate motor controller.
It is evaluated under the same short circuit tests as Types A through D, but it is not considered self-
protected.

5.4 Type E Marking Requirements

A UL 508 Type E self-protected combination starter must be marked “Self-Protected Combination Motor
Controller.” UL 508 does allow combinations of devices to be used in a Type E combination starter as
long as they pass the performance testing required for the self-protected designation. The most common
arrangement on the market today is a manual Type E self-protected combination motor starter used with
a contactor. This arrangement can be assembled and shipped as a single unit by the manufacturer or as
separate components. However, the assembled unit or separate components must be suitably marked.

 An assembled unit must be marked as a “Self-Protected Combination Motor Controller”.

 The manual self-protected combination starter must be marked “Self-Protected Combination

Motor Controller when used with [the load side component's manufacturer and part number]” or
“Self-Protected Combination Motor Controller when used with Motor Controllers Marked For Use
With This Component” when it is intended to be listed as part of a Type F Combination Motor
Controller.

 The motor controllers must be marked “Suitable For Use On Load Side Of [manufacturer and part
number] Manual Self-Protected Combination Motor Controller” when the manual Type E starter
makes reference to the marked motor controllers rather than marking the controllers on the
Manual Self-Protected Combination Motor Controller.

If no reference is made to a self-protected combination motor controller or combination motor controller,

then the assembly is simply a UL 508 motor controller and motor overload relay. A UL Listed short-circuit
protective device and disconnect must also be used with those components to meet the NEC
requirements for a motor branch circuit.

5.5 Coordination Considerations

NEC requires panel builders to list the short-circuit current rating of their motor control panels. This
requirement is designed to help users properly coordinate their motor control equipment with their
distribution system in the event of a fault. In the past, a UL 508A panel did not carry a short-circuit current
rating. The motor control panel and enclosure combination must limit the damage after interrupting the
short circuit as follows:

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A. No expulsion of any debris, fire, or molten metal from the enclosure

B. Enclosure door/cover must remain closed and must be possible to open
C. Enclosure must remain intact with little to no cracks or openings
D. No damage to any conductor or terminal connector
E. No conductor can be pulled out of its terminal connector
F. No breakage or cracking of insulating bases of mounted parts to the extent that they fall off the
panel or expose live parts

The requirement to list the short-circuit current rating means that panel designers must consider the panel
as one coordinated unit. They must use the lowest rated device as their panel's short-circuit current rating
unless the devices were tested together for a higher coordinated rating. UL 508A, Supplement SB
provides the requirements for determining the overall short-circuit current rating of the Industrial Control
Panel.

5.6 Motor Control Panel Design Implications

5.6.1 Group Motor Considerations
Article 430.53 (C) and (D) of the NEC allow a single short-circuit protective device to be used for more
than one motor circuit under certain specific conditions. Panel builders use this article to decrease the
size and cost of the motor control panel. However, they first have to make sure that the components used
are marked and listed for such use. The components suitable for use in motor group installations can be
marked in one of two ways.

1. The motor controller and motor overload relay are both listed as suitable for group installation. An
inverse time circuit breaker or a fuse may be used as the short-circuit protective device. The
panel designer must then ensure that the short-circuit protective device selected (fuses or inverse
time circuit breaker) is not larger than allowed by Article 430.40 for the smallest overload relay
used in the circuit. Once these conditions are met, the panel designer can downsize the
conductor from the short-circuit protective device to the individual motor controller/overload relay
to 1/3 the size of the branch circuit conductor feeding the short-circuit protective device. The
designer must limit the motor circuit conductor length from the short circuit protective device to
the motor controller/overload relay to 25 feet or less.

2. The motor controller is listed as suitable for tap conductor protection in group installations. This
category allows the designer to downsize the conductor from the short-circuit protective device to
the individual motor controller to 1/10 the size of the branch circuit conductor feeding the short-
circuit protective device. The designer must limit the motor circuit conductor length from the short-
circuit protective device to the motor controller to 10 feet or less. In both cases, the feeder taps
cannot be less than 125% of the connected motor FLA rating.

Using UL 508 Type E self-protected combination starters or Type F combination starters in a similar
manner instead of UL 508 motor controllers and overload relays Listed for group installation simplifies
multiple motor applications for panel designers. Each circuit is then considered a motor branch circuit.
The feeder tap conductors can be downsized per Article 430.28. This allows the same flexibility in
conductor sizing as offered in Article 430.53 (D) without the component marking and overload relay to
short-circuit protective device verification requirements. The UL 508A panel does not need a main short
circuit protective device in these applications. The upstream short-circuit protective device feeding it
protects the panel. The designer only has to consider the enclosure/panel disconnect requirements from
the NEC or local codes.

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Section 6
NEC 430 PART IX, AND SECTION 430-109 MOTOR CIRCUIT SWITCH VS. MOTOR
DISCONNECTS

What are the important differences between: NEC 430 Part IX (Motor Circuit Switch), and Section 430-
109 (Motor Disconnects)?

6.1 Background
It can be said that, over the course of the last decade or so, a good deal of confusion had spread across
many sectors of the industry as to what exactly constituted a proper Motor Circuit Disconnecting Means
per the intent of Article 430, particularly as it related to manual switches carrying HP ratings, which by
design, and seemingly by definition, could be deemed suitable for that purpose.

Much of the problem was due to confusion between manually operated switches, listed as manual motor
controllers under UL 508, and devices listed as disconnecting means under UL 98. Generally speaking,
this was due largely in part to a growing number of compact IEC style disconnect switches in the U.S.
marketplace being applied under earlier editions of the NEC, which back then did not adequately define
the acceptability of such products as a motor disconnecting means under the guidelines of Section
430.109.

Traditionally, these aforementioned IEC style disconnect switches had been evaluated by certification
agencies, such as UL and CSA, primarily as Manual Motor Controllers. As such, these products never did
truly fulfill the definition of a Disconnecting Means per the intent of Section 430.109, even though they
were being applied in this manner.

The 1999 Edition of the NEC sought to remedy this situation by introducing additional categories under
430.109 to better differentiate between these two types of HP rated products, and help provide
clarifications with respect to their proper application.

A nationally recognized testing laboratory, UL in this case, established additional testing methods to verify
the use of such controllers as a disconnecting means in motor circuits, and put in place a requirement
that they carry a marking to this effect per the newly introduced NEC guidelines.

The situation today with respect to the NEC can thus be summarized as follows:
NEC 430 Part IX, and Section 430-109, Motor Circuit Switch vs. Motor Disconnects, NEC 430.109:
 This section of Article 430 defines the types of products that are deemed to be acceptable for use
as a Disconnecting Means in motor circuits.

The NEC defines Disconnecting Means in the following way:

"A device, or group of devices, or other means whereby the conductors of a circuit can be
disconnected from their source of supply."

Currently, the two types of products at issue here can be found under the following headings in Section
430.109:

 430.109 (A)(1): "Motor Circuit Switch"

o The NEC describes a "Motor Circuit Switch" under that section as a listed motor-circuit
switch rated in horsepower.

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 430.109 (A)(6): "Manual Motor Controller"

o The NEC describes this further as a listed manual motor controller additionally marked
"Suitable as Motor Disconnect."

A more detailed description of each product is necessary in order to better explain their proper application
per the intent of the NEC.

NEC 430 Part IX, and Section 430-109, Motor Circuit Switch vs. Motor Disconnects, 430.109(A)(1)-
"Motor Circuit Switch"
 These products are defined in NEC 100 as follows:
o A switch rated in HP that is capable of interrupting the maximum operating overload
current of a motor of the same HP rating as the switch at the rated voltage.
o In the industry, these products are known under the following UL product categories and
product category codes (Source: UL White Book 2007):
 Open Type Switches (WHTY)
 Enclosed Switches (WIAX)
 Dead-Front Switches (WHKS)
 Pullout Switches (WGEU)
 The products that fall under those categories, and are intended to be used as the disconnecting
means in motor circuits per the intent of NEC 430, are marked in the following way:
o "Motor-Circuit Switch" or "Motor-Circuit Pullout Switch," per their respective category.
o Up to 100 HP, these switches can fulfill both the disconnect and controller functions.
o Above 100 HP, they are restricted as a Disconnecting Means only.
o These products feature a construction that permits their use both in feeder and branch
circuits per the NEC.
o They would be UL listed to the following standards:
 UL 98 (Enclosed and Dead-Front Switches");
 UL Subject 98A (Outline of Investigation for Open Type Switches); and
 UL 1429 (Pullout Switches).
o They are also covered in NEMA standards:
 KS 1 Enclosed and Miscellaneous Distribution Equipment Switches (600 Volts
Maximum
 KS 2 Distribution Equipment Switch Application and Maintenance Guide, A
User’s Reference
 ICS 2, Part 8 Disconnect Devices for Use in Industrial Control Equipment

NEC 430 Part IX, and Section 430-109, Motor Circuit Switch vs. Motor Disconnects, 430.109 (A)(6):
"Manual Motor Controller"
 These products are not defined in the NEC under that particular heading. However, they are
known under the following UL product category and product category code (Source: UL White
Book 2007):
o Motor Controllers, Manual (NLRV) are described as manually operated devices intended
for across-the-line starting of motors.
 Manual Motor Controllers in this category can additionally be investigated for use
as a motor disconnect switch per UL Industrial Control Standards (UL 508 and
UL 60947) and if so, are marked "Suitable as Motor Disconnect." Per the intent of
the NEC, and unlike the previously described Motor Circuit Switches, these
devices are intended to be installed solely on the load side of the motor branch
circuit overcurrent protective device. Important distinctions to this rule exist, but
they are very specific:

1. Manual Motor Controllers additionally marked "Suitable as Motor Disconnect" are permitted on
the line side of Power Electronic Devices that come equipped with fuses, provided that suitable

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branch circuit protection is provided on the line side of the manual motor controller. In this case,
the fuses provided within the Power Electronic Devices are considered as supplementary fuses.
2. Manual Motor Controllers additionally marked "Suitable as Motor Disconnect" are permitted as
the branch circuit disconnecting means for stationary motors rated 2 HP or less, and 300 V or
less.

The Electrical Standard for Industrial Machinery, NFPA 79, also allows the use of Manual Motor
Controllers marked "Suitable as Motor Disconnect" as a means to disconnect electrical equipment and
enable work to be performed when the equipment is de-energized and isolated.

In this case, however, the same application guideline would apply as per NEC 430-109, namely that the
device would need to be installed on the load side of the final branch circuit overcurrent protective in the
circuit.

Such manual motor controllers would also not be considered suitable as the Supply Circuit Disconnecting
Means per the NFPA 79 standard.

NEC 430 Part IX, and Section 430-109, Motor Circuit Switch vs. Motor Disconnects, 430-1 Graphical
presentation

430-1 Graphical presentation Disconnecting Means per NEC 430

Part IX, for motor circuits up to
600 Volts, Nominal

430.109(A)(1)-
"Motor Circuit Switch"

430.109(A)(6):
"Manual Motor Controller"
additionally marked
"Suitable as Motor Disconnect"

Figure 6-1
GRAPHICAL PRESENTATION OF MOTOR CIRCUIT SWITCH VS. MOTOR DISCONNECTS

NEC 430 Part IX, and Section 430-109, Motor Circuit Switch vs. Motor Disconnects

Summary:
Requirements for the Disconnecting Means used in motor circuits are covered under NEC 430, Part IX.

"Motor Circuit Switches" and "Manual Motor Controllers" additionally marked "Suitable as Motor
Disconnect" represent categories of listed HP rated devices that are both suitable for this application, but
under a different set of guidelines, as described in Section 430-109 of the NEC.

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Product markings and UL classification categories are important tools for field inspectors and users alike
to use as a means to identify these devices in the industrial sector, and also verify their proper application
in feeder and/or motor branch circuits per the requirements of the NEC.

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Section 7
UNDERSTANDING PROTECTION REQUIREMENTS OF THE NATIONAL
ELECTRICAL CODE

7.1 Feeder Circuit Versus Branch Circuit Protection

In the United States, the electrical supply system to motor circuits is divided into two distinct parts, the
Feeder Circuit and the Branch Circuit. The National Electrical Code defines a Feeder Circuit as “All circuit
conductors between the service equipment, the source of a separately derived system, or other power
supply source and the final branch-circuit overcurrent device.” The Branch Circuit is defined as “The
circuit conductors between the final overcurrent device protecting the circuit and the outlet(s).” In the case
of Motor Branch Circuits, the “outlet(s)” are the motor(s). What is important to note here is that in both
cases, the protection is for the circuit conductors.

The National Electrical Code has specific rules that apply to the protection of conductors in the Feeder
Circuit, and in the Branch Circuit, and in Group Motor Applications within the Branch Circuit. The purpose
of this discussion is to explain those requirements, as they relate to motor circuits, and to demonstrate
how the latest changes in the National Electrical Code affect the use of Industrial Control products.

7.2 Motor Circuit Applications: Feeder Circuit Ending in a Branch-Circuit Protective Device
(Fuse, Circuit Breaker or Self-Protected Combination Starter
Motor applications require that each motor circuit be protected by a Branch Circuit Protective Device
(BCPD). The line-side of the BCPD is in the “Feeder Circuit,” and the NEC has a set of rules that
determine how to size the Feeder Conductors, the Feeder Tap Conductors, and the Feeder Circuit
protective device (FCPD), in order to protect the conductors between the FCPD and the BCPD.

7.3 Feeder Circuit Protection Sizing

The Feeder Circuit Protection (either a fuse or circuit breaker) protects both the Feeder Conductors and
the Feeder Tap Conductors. Since it must be large enough allow the largest motor on the circuit to start, it
is sized at 400% of the largest motor FLA PLUS the currents drawn on all other loads on the circuit

The Feeder Conductors must be sized to carry 125% of the largest motor FLA, PLUS the current drawn
by other loads on the circuit. There is no limit to the length of the Feeder Conductors.

7.4 Feeder Tap Conductors

The Feeder Tap Conductors are subdivisions of the Feeder Circuit Conductors that feed individual
Branch Circuits. There are three basic situations that affect the calculations. The length and ampacity of
the Feeder Tap Conductors, ampacity of the Feeder Conductors, and size of the FCPD are all inter-

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related, and can vary depending upon the installation. All calculations require that the Feeder Circuit
terminate in a Branch Circuit Protective Device (BCPD). Devices Listed as Self-Protected Combination
Starters qualify as Branch Circuit Protective Devices for motor applications. The sizing of the feeder tap
conductors in relation to the feeder conductors can vary depending upon the length of the tap conductors.

7.5 Calculations Involving the Feeder Tap Conductor, Feeder Conductors, and Feeder Circuit
Protective Device
1. In the first example, the length of the Feeder Tap Conductor is greater than 25 ft. Under this
condition, the ampacity of the Feeder Tap Conductor must be at least as great as that of the
Feeder Conductor.

2. In the second example, the length of the Feeder Tap Conductor is LESS THAN 25 ft, but
GREATER THAN 10 ft. In this situation, the ampacity of the Feeder Conductor must be NO
MORE THAN 3 times as much as that of the Feeder Tap Conductor. Stating this in another way,
the Feeder Tap Conductors must have an ampacity of AT LEAST 1/3 that of the Feeder
Conductor.

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3. In the third example, the Feeder Tap Conductor is LESS THAN 10 ft long. Here, the size
(ampacity) of the Feeder Tap Conductor is related to the Feeder Circuit Protective Device (FCPD)
rather than the Feeder Conductor ampacity. The size of the FCPD is permitted to be rated a
MAXIMUM of 10 times the ampacity of the Feeder Tap Conductor.

7.6 Motor circuit applications: Branch Circuit requirements for individual motor applications
The requirements for sizing of the Branch Circuit Protective Device and Branch Circuit Conductors are
fairly straightforward for individual motor applications on branch circuits

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7.7 Motor Circuit Applications: Branch Circuit Requirements for Motor Group Applications
The requirements for sizing the Branch Circuit Protective Device, Branch Circuit Conductors, and Motor
Tap Conductors for Motor Group Applications are very much like the requirements for sizing components
in the Feeder Circuit. However, there are some differences between the requirements for circuits that end
in a manual motor controller marked “suitable for tap conductor protection in group applications”
(hereafter abbreviated “GTCP” for convenience) versus circuits which end in a controller not marked in
this way.

First, we’ll address the applications where the circuit does NOT end in the GTCP. The Branch Circuit
Protection is sized in much the same way as the Feeder Circuit Protection is sized in the Feeder Circuit.
The BCPD is permitted to be sized at 400% of the largest motor of the Group, plus the sum of all other
loads in the Group.

The Branch Circuit Conductors must be sized to carry 125% of the largest motor FLA, PLUS the current
drawn by other loads on the circuit. There is no limit to the length of the Branch Circuit Conductors.

7.8 Calculations Involving the Motor Tap Conductor, Branch Circuit Conductors, and Branch
Circuit Protective Device (Manual Motor Controller not Suitable for Tap Conductor Protection)
The Motor Tap Conductors are subdivisions of the Branch Circuit Conductors that feed individual motor
Circuits (or other loads.) The length and ampacity of the Motor Tap Conductors, ampacity of the Branch

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Circuit Conductors, and size of the BCPD are all inter-related, and can vary depending upon the
installation. Protection must also be provided for the Conductors to the motor, from the Controller.

1. In the first example, the length of the Motor Tap Conductor is greater than 25 ft. The length is
measured from the tap point to the motor overload protective device. Under this condition, the
ampacity of the Motor Tap Conductor AND the Conductors to the Motor must be at least as great
as that of the Branch Circuit Conductor.

2. In the second example, the length of the Motor Tap Conductor is LESS THAN 25 ft. The 25 ft
length is measured from the tap point to the Motor Overload Protective Device. In this situation,
the ampacity of the Branch Circuit Conductor must be NO MORE THAN 3 times as much as that
of the Motor Tap Conductor. Stating this in another way, the Motor Tap Conductors must have an
ampacity of AT LEAST 1/3 that of the Branch Circuit Conductor. The ampacity requirement
applies to all the tap conductors between the branch circuit conductor and the motor.

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7.9 Calculations Involving the Motor Tap Conductor, Branch Circuit Conductors, and Branch
Circuit Protective Device (Manual Motor Controller Suitable for Tap Conductor Protection)
This brings us to the group application circuit in which the motor tap conductor terminates in a Manual
Motor Controller marked “suitable for tap conductor protection in group applications” (GTCP). Because
the GTCP has been tested and listed for this special application, the calculations for conductor and BCPD
sizing in group applications are different than for circuits which do not use GTCPs.

1. In the first example for this product, the length of the Motor Tap Conductor is greater than 25 ft.
Under this condition, the ampacity of the Motor Tap Conductor must be at least as great as that of
the Branch Circuit Conductor. The measurement is made from the tap point to the GTCP.
However, because the GTPC has been tested and listed to provide protection for the conductors
to the motor, the conductors between the GTCP and the motor must only be sized at 125% of the
motor FLA.

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2. In the second example, the length of the Motor Tap Conductor is LESS THAN 25 ft, but
GREATER THAN 10 ft. Again, the measurement is made from the tap point to the GTCP. In this
situation, the ampacity of the Branch Circuit Conductor must be NO MORE THAN 3 times as
much as that of the Motor Tap Conductor. Stating this in another way, the Motor Tap Conductors
must have an ampacity of AT LEAST 1/3 that of the Branch Circuit Conductor.

3. In the third example, the Motor Tap Conductor is LESS THAN 10 ft. long. Once again, the
measurement is made from the tap point to the GTCP. Here, the size (ampacity) of the Motor Tap
Conductor is related to the Branch Circuit Protective Device (BCPD) rather than the Branch
Circuit Conductor ampacity. The size of the BCPD is permitted to be rated a MAXIMUM of 10
times the ampacity of the Motor Tap Conductor.

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Section 8
FEEDER AND BRANCH CIRCUITS
Important NEC definitions

Fig. 1: Typical feeder and branch circuits (Source: NFPA 70 Handbook)

Fig. 2: Typical feeder and motor branch circuits in industrial applications (Source: UL 508A, Safety
Standard for Industrial Control Panels).

Feeder Circuit

NEC Article 100 defines a feeder as follows:

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"All circuit conductors between the service equipment, the source of a separately derived
system, or other power supply source and the final branch-circuit overcurrent device."

As a general rule, the feeder circuit conductors are those that are fed from a service disconnecting
means, and are used to supply power to a branch-circuit overcurrent protective device, or to a
panelboard, control panel or other engineered system which contains branch-circuit overcurrent
protective devices.
The minimum feeder-circuit conductor size is based on an ampacity rating not less than the sum of the
noncontinuous load plus 125% of the continuous load, unless the entire assembly, including feeder
overcurrent protective devices, is listed for continuous operation at 100% of its ampere rating.

The general requirements for feeders are covered in Article 215 of NFPA 70 (NEC).

Branch Circuit

NEC Article 100 defines a branch circuit as follows:

"The circuit conductors between the final overcurrent protective device protecting the circuit and the
outlet(s)."

A branch circuit thus begins at the load end of its overcurrent protective device and terminates at the last
outlet. An outlet is defined as a point on the wiring system at which current is taken to supply utilization
equipment, and includes receptacles, lighting and generally any type of equipment that utilizes electric
energy, such as appliances, motors, and/or other loads.

The NEC defines various types of branch circuits, such as Motor, Appliance, General-Purpose, Individual
and Multi-Wire, all of which fall under the above general definition.

Important considerations regarding branch-circuits include:

 As a general rule, the rating of a branch circuit is determined by the maximum rating or setting of
the overcurrent protective device, and not by the ampacity of the branch circuit conductors.
 The continuous load supplied by a branch circuit should not exceed 80% of the branch-circuit
rating, unless the assembled equipment, including overcurrent protective devices, is listed for
continuous operation at 100% of its ampere rating. (This is a similar rule to the one applicable to
feeders.)
 The general requirements for branch circuits can be found in Article 210 of NFPA 70 (NEC).
Branch circuits for motor loads have special considerations, which are covered in Article 430.

The NEC should be consulted for more detailed descriptions and definitions of branch circuit types based
on the particular application under consideration, and to determine if any conductor adjustment or
correction factors need to be taken into account for proper sizing of branch circuit conductors.

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