Nema Ics 3.1 2019 Watermarked

NEMA Standards Publication ICS 3.
1-2019
Guide for the Application, Handling, Storage, Installation, and Maintenance

of Medium-Voltage AC Contactors, Controllers, and Control Centers
Published by
National Electrical Manufacturers Association

1300 North 17th Street, Suite 900
Rosslyn, Virginia 22209
www.nema.org
© 2019 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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NEMA ICS 3.1-2019
Page i
CONTENTS
Figures iii
Foreword iv
1 SCOPE ................................................................................................................................ 1
2 SELECTION AND APPLICATION ..................................................................................... 2
2.1 Ratings and Characteristics ................................................................................................ 2
2.2 Selection of Ratings and Characteristics for Service Conditions ........................................ 2
2.3 Control of Motor Loads ....................................................................................................... 5
2.4 Additional Considerations for Synchronous Motors ............................................................ 8
2.5 Control of Non-Motor Loads .............................................................................................. 10
2.6 Coordination with Power Systems .................................................................................... 12
3 ORDERING INFORMATION ............................................................................................ 15
3.1 Application Ratings ........................................................................................................... 15
4 GENERAL INFORMATION AFTER RECEIVING ............................................................ 17
4.1 Precautions ....................................................................................................................... 17
4.2 Recommended Procedure ................................................................................................ 17
4.3 References ........................................................................................................................ 17
4.4 Qualified Person................................................................................................................ 17
4.5 Manufacturers Instructions ................................................................................................ 17
4.6 Conditions during Transport, Storage, and Installation..................................................... 18
4.7 Precautions ....................................................................................................................... 18
5 HANDLING ....................................................................................................................... 19
5.1 General ............................................................................................................................. 19
5.2 Unpacking/Packing ........................................................................................................... 19
5.3 Moving ............................................................................................................................... 19
6 STORAGE ........................................................................................................................ 22
6.1 Controllers for Indoor Installation ...................................................................................... 22
6.2 Controllers for Outdoor Installation ................................................................................... 22
6.3 Routine Inspection ............................................................................................................ 22
7 INSTALLATION ................................................................................................................ 23
7.1 General ............................................................................................................................. 23
7.2 Site Preparation ................................................................................................................ 23
7.3 Physical Clearance Considerations .................................................................................. 23
7.4 Normal Service Conditions ............................................................................................... 23
7.5 Special Service Conditions ............................................................................................... 23
7.6 Assembly ........................................................................................................................... 24
8 CONDUCTORS ................................................................................................................ 25
8.1 Connections: ..................................................................................................................... 25
8.2 Physical Considerations .................................................................................................... 25
8.3 Electrical Considerations .................................................................................................. 25
8.4 Bus Interconnection Links ................................................................................................. 25
© 2019 National Electrical Manufacturers Association.

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8.5 Cleanup during Installation ............................................................................................... 25

9 GROUNDING .................................................................................................................... 26
9.1 General ............................................................................................................................. 26
9.2 Controller Used as Service Entrance Equipment for a System with a Neutral ................. 26
9.3 Controller Used as Service Entrance Equipment for a System without a Neutral ............ 26
9.4 Controller Used as a Main Section for a Separately Derived System .............................. 27
9.5 Controllers not Used as Service Entrance Equipment nor as a Main Section
for a Separately Derived System ...................................................................................... 27
10 INSPECTION PRIOR TO INITIAL ENERGIZATION........................................................ 28
10.1 Remove Shorting Jumpers ............................................................................................... 28
10.2 Remove Temporary Shipping Blocking............................................................................. 28
10.3 Bus Bracing Integrity ......................................................................................................... 28
10.4 Connections ...................................................................................................................... 28
10.5 Possible Damage .............................................................................................................. 28
10.6 Operating Mechanisms ..................................................................................................... 29
10.7 Ground-Fault Protection System....................................................................................... 29
10.8 Adjustable Current and Voltage Trip Mechanisms ........................................................... 29
10.9 Overload Relays................................................................................................................ 29
10.10 Removable Permanent Parts and Barriers ....................................................................... 29
10.11 Cleaning ............................................................................................................................ 29
10.12 Electrical Insulation Test ................................................................................................... 29
10.13 Enclosure .......................................................................................................................... 29
11 INITIAL ENERGIZATION OF EQUIPMENT ..................................................................... 30
11.1 Manufacturers Instruction ................................................................................................. 30
11.2 General ............................................................................................................................. 30
11.3 Contactors and Switches .................................................................................................. 30
11.4 Loads ................................................................................................................................ 30
11.5 Energization Sequence ..................................................................................................... 30
11.6 Individual Loads after Disconnect Device Closure ........................................................... 30
11.7 Records ............................................................................................................................. 30
11.8 Spare parts........................................................................................................................ 30
12 MAINTENANCE AND USE .............................................................................................. 31
12.1 Fundamentals ................................................................................................................... 31
12.2 Safety Precautions ............................................................................................................ 32
12.3 General Guidelines ........................................................................................................... 32
12.4 Specific Guidelines............................................................................................................ 34
12.5 Maintenance of Controllers After a Fault Condition .......................................................... 36
12.6 Controller Failures ............................................................................................................. 37

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Figures
Figure 1 Time vs. Prospective Current.............................................................................................. 4

Figure 2 Full-Voltage Starting............................................................................................................ 5
Figure 3 Reduced-Voltage Reactor or Resistor Starting................................................................... 6
Figure 4 Reduced-Voltage Auto-Transformer Starting ..................................................................... 7
Figure 5 Part-Winding Starting .......................................................................................................... 8
Figure 6 Lifting with Eye-Bolts or Lifting Plates ............................................................................... 20
Figure 7 Lifting with Integral Lift Angle ............................................................................................ 21

NEMA ICS 3.1-2019
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Foreword
This publication is a guide containing practical information to the application, handling, storage,
installation, and maintenance of AC general-purpose medium-voltage contactors and Class E controllers.
It was prepared by the Medium Voltage Controllers Technical Subcommittee of the NEMA Industrial
Automation Control Products and Systems Section. It was approved in accordance with the bylaws of
NEMA.
This guide was developed in response to the many questions from the user public and has been
developed from the experience of the member companies working with their customers and users. It
provides information that will be useful to architects, electrical engineers, electrical contractors,
maintenance engineers, and others who are responsible for the installation of this equipment.
NEMA publications are subject to periodic review. Any comments or proposed revisions to this guide
should be submitted to:
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.—Cary, NC
ASCO Power Technologies—Florham Park, NJ
Carlo Gavazzi, Inc.—Buffalo Grove, IL
Cummins, Inc.—Minneapolis, MN
Danfoss Drives—Chambersburg, PA
Delta Electronics (Americas) Ltd.—Research Triangle Park, NC
E+I Engineering US Corporation—Anderson, SC
Eaton—Milwaukee, WI
Electro Switch Corporation—Weymouth, MA
Elliott Control Company, Ltd.—Willis, TX
Franklin Control Systems—Hillsboro, OR
Fuji Electric Corporation of America—Roanoke, VA
Generac Power Systems—Waukesha, WI
Hubbell Industrial Controls, Inc.—Archdale, NC
Joslyn Clark Controls, Inc.—Elizabethtown, NC
Master Controls Systems, Inc.—Lake Bluff, IL
Mitsubishi Electric Automation, Inc.—Vernon Hills, IL
NORD Gear Corporation—Waunakee, WI
Omron Electronics LLC—Schaumburg, IL
Phoenix Contact, Inc.—Middletown, PA
Post Glover Resistors, Inc.—Erlanger, KY
Reliance Controls Corporation—Racine, WI
Rockwell Automation—Milwaukee, WI
Schneider Electric—Lexington, KY
SEW-Eurodrive, Inc.—Lyman, SC
Siemens Industry, Inc.—Norcross, GA
Software Motor Corporation—Sunnyvale, CA

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TE Connectivity—Harrisburg, PA
Toshiba International Corporation USA—Houston, TX
WAGO Corporation—Germantown, WI
Weidmuller Inc.—Richmond, VA
Yaskawa America, Inc. Drives and Motor Division—Waukegan, IL

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NEMA ICS 3.1-2019
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1 Scope
This guide applies to the installation and maintenance of AC medium-voltage contactors, and Class E
controllers rated 1,501-15,000 volts, installed in accordance with the National Electrical Code® (NEC®),
NFPA 70 and the manufacturer’s instructions. The requirements in the CANENA-developed UL 347 and
NEMA SG 10-2008 apply. These instructions are not considered appropriate to industrial control
equipment intended for use in locations designated as hazardous (classified) in the National Electrical
Code.
This guide is not intended to replace the manufacturer’s instructions and does not purport to cover all
possible circumstances arising from the application, handling, storage, and installation of this equipment.
Any problems or questions should be discussed with the manufacturer.

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2 Selection and Application
A controller, suitable for a given duty in service, is best selected by considering the individual rated values
required by load conditions and fault conditions.
2.1 RATINGS AND CHARACTERISTICS

The rated characteristics defined in this clause are further discussed in UL 347 in the clause number
shown.
a. rated voltage (Ur): 4.1

b. rated insulation level (Ud) (power-frequency withstand test voltage), (Up) (impulse test voltage):
4.2
c. rated frequency (fr): 4.3
d. rated short-time withstand current (Ik): 4.5
e. rated peak withstand current (Ip): 4.6.1
f. rated duration of short circuit (tk): 4.7
g. rated supply voltage of operating devices, and of auxiliary and control circuits (Ua): 4.8
h. rated supply frequency of closing and opening devices and of control circuits: 4.9
i. rated making and breaking capacities: 4.103
j. mechanical endurance: 4.105
k. rated continuous (thermal) current (Ith): 4.4.101
l. coordination with medium-voltage fuses: 4.107
m. starting autotransformer or reactor characteristics: 4.109
n. use at high altitudes: 2.2.1
2.2 SELECTION OF RATINGS AND CHARACTERISTICS FOR SERVICE CONDITIONS

2.2.1 Selection of Rated Voltage
The rated voltage of the controller should be chosen so as to be at least equal to the highest voltage of
the system at the point where it is to be installed.
The rated voltage should be selected from the Standard values provided in UL 347.
2.2.2 Insulation Coordination

In selecting the rated voltage, the corresponding insulation levels specified in clause 4.2 and table 1 of
UL 347 should also be taken into account. The values in Table 1 apply to both indoor and outdoor
equipment.
2.2.3 Rated Frequency

Rated frequencies are 50 or 60 Hz, and the manufacturer should be consulted if a controller is to be used
at any frequency other than rated frequency.
2.2.4 Rated Short-Time Withstand Current

The rated short-time withstand current is the highest prospective rms short-circuit current to which the
controller may be connected. It establishes the breaking capacity of the controller, under the conditions of
use and behavior prescribed in this Standard in a circuit having a power-frequency recovery voltage
corresponding to the rated voltage of the controller.

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E1 controller rated breaking capacities are limited by the contactor breaking ratings. E2 controllers
incorporate current-limiting fuses, and their breaking capacity is largely determined by that of the medium
voltage fuses used in the controller.
An equipment assembly that incorporates multiple circuit-breakers and/or controllers will have a breaking
capacity that is limited to the lowest-rated controller or breaker in the assembly.
The breaking capacity of a controller, breaker, or assembly must be equal to or greater than the
maximum expected fault current level of the point in the distribution system at which the controller is to be
located. The conductors used to connect the equipment to the distribution system must also be capable
of withstanding this short circuit current.
2.2.5 Rated Continuous (Thermal) Current

The rated continuous (thermal) current of a controller is assigned by the controller manufacturer on the
basis of information gained from temperature-rise tests and will depend on the type and ratings of the
contactor and the fuses. The thermal capability of the controller may have to be reduced where the
ambient temperature in service exceeds the prescribed ambient temperature.
Note:The rated continuous (thermal) current of a controller is generally less than, but should not
be in excess of, the rated continuous current of the fuses as assigned by the fuse manufacturer.
2.2.6 Local Atmospheric and Climatic Conditions

The equipment specification should state whether the equipment is to be of indoor or outdoor type, and
shall also specify the environmental conditions at the installation site. The installation of the equipment
shall be in accordance with the manufacturers’ installation instructions for those environmental conditions.
2.2.7 Use at High Altitudes

The normal service conditions specified in UL 347 provide for controllers intended for use at altitudes not
exceeding 1,000 m (3,300 ft).
UL 347 also recognizes installations up to 3,000 m (9,900 ft) however the manufacturer must be
consulted regarding installations at altitudes higher than 1,000 m (3,300 ft) as variations in design, current
and insulation level derating, and/or special adjustments might be required.
2.2.8 Coordination with Medium-Voltage Current-Limiting Fuses

The object of this part of the guide, taken in conjunction with the applicable guide for fuses, IEEE
C37.48.1, is to specify criteria for the selection of a combination of contactor and medium-voltage fuses
that will ensure safe operation, using the parameter values established by tests in accordance with this
Standard.
The test duties specified in this Standard cover most users' requirements.
Use of fuses other than those recommended by the controller manufacturer is subject to agreement
between the manufacturer and user.
2.2.9 Take-Over Current (Crossover Current)

The value of the take-over current (also referred to as crossover current) of a controller is dependent
upon both the contactor opening time (including relay time) and the time-current characteristic of the fuse.
As its name implies, it is the value of overcurrent above which the fuses take over the function of current
interruption from the overload relay and contactor.
From a practical standpoint, the maximum take-over current for a given application is determined as
follows.

NEMA ICS 3.1-2009
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Superimpose upon the total clearing time time-current characteristic of the fuse (see Figure 1) a time
equal to the minimum opening time, or minimum response time if operated by an overcurrent relay and/or
time delay device. The associated current is the value of the take-over current, and shall not be greater
than the rated take-over current which is the current determined by the fuse manufacturer and used on
the make and break capability test. (See 6.102 of UL 347).
Time Fuse
Contactor
Maximum break time (increased by the maximum

relay operating time if operated by external
over-current relays)
Maximum opening time, or minimum

response time if operated by an over-
current relay and/or time delay device
Maximum take-over current
Minimum take-over current
Maximum operating time for maximum

rated current
Minimum pre-arcing time
Prospective current
IEC 1375/99
Figure 1
TIME VS. PROSPECTIVE CURRENT
2.2.10 Fuse Operation

The three fuses fitted in a given controller shall be all of the same type and current rating; otherwise, the
performance of the controller could be adversely affected.
It is vital for the correct operation of the controller that the fuses are inserted with the strikers (if
applicable) correctly located.
When a controller has operated as a result of a three-phase fault, it is possible for

a. only two out of the three fuses to have operated;
b. all three fuses to have operated, but for only one out of the three strikers to have ejected.
Such conditions can occur under three-phase service conditions and are not considered abnormal.
Where a controller has opened without any obvious signs of a fault on the system, examination of the
operated fuse or fuses may give an indication as to the type of fault current and its approximate value.

NEMA ICS 3.1-2019
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It is advisable to discard and replace all three fuses when the fuse(s) in one or two poles of a controller
has (have) operated.
After an event that causes clearing of medium voltage fuses, the entire controller should be inspected
before being returned to service.
2.3 CONTROL OF MOTOR LOADS

Typical methods of starting AC motors are shown in Figures 2 through 5. An "X" in the contactor
sequence chart indicates closed contacts. For additional information on controllers for synchronous
motors, see clause 2.4.
The starting current values for the various methods of motor starting shown in Figures 2 through 5 may
be determined as discussed in 2.3.1 – 2.3.4
2.3.1 Full-Voltage Starting (Figure 2)

The starting current is equal to the locked-rotor current at full voltage.
Figure 2
FULL-VOLTAGE STARTING
(DC Field is Applicable Only to Synchronous Motors)
2.3.2 Resistor or Reactor Reduced-Voltage Starting (Figure 3)

The starting current is determined from the sum of the impedances of the starting reactor or resistor and
of the motor under locked-rotor conditions.

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Figure 3
Reduced-Voltage Reactor Or Resistor Starting

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2.3.3 Autotransformer Reduced-Voltage Starting (Figure 4)
Figure 4
REDUCED-VOLTAGE AUTO-TRANSFORMER STARTING
The starting current drawn from the line is:
I × p 2 + 0.25 I m
The starting current taken by the motor is:
I×p
The autotransformer neutral current is:
(I × p ) − (I × p 2 + 0.25I m )
where:
I = Locked-rotor amperes at full voltage
p = Transformer tap used (fraction of full voltage)
Im = Rated full-load current of the motor. The term 0.25 I is introduced to allow for auto-
m
transformer magnetizing current
Note—Power factor correction capacitors should not be directly connected on the load side of the autotransformer (see 2.5.3 l).

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2.3.4 Part-Winding Starting (Figure 5)

The starting current is the locked-rotor current of the motor connected for starting.
Figure 5
PART-WINDING STARTING
(DC Field is Applicable Only To Synchronous Motors)
2.4 ADDITIONAL CONSIDERATIONS FOR SYNCHRONOUS MOTORS

A synchronous motor is a motor designed to operate at a constant speed that is determined by the
number of poles and the frequency of the alternating current supplying the stator of the motor.
Synchronous motors do not rely on rotor slip to induce a voltage on the rotor. Instead, a DC current is
injected into the motor field windings so that once accelerated to full speed; the motor is synchronized.
2.4.1 Types of Synchronous Motors

Synchronous motors are either of the brush or brushless type. The brushless type feeds DC into the field
winding of the motor without the use of brushes. Brush type exciters feed DC into the field winding of the
motor via brushes and slip rings.
2.4.2 Means of Excitation
a. Static field exciter: a solid-state DC rectifier that supplies DC excitation to the field windings of
a brush-type synchronous motor. The exciter is usually connected to the three-phase supply
voltage, stepped down to low voltage then rectified to DC.
b. Motor generator exciter: a motor-generator set connected to a rectifier that supplies DC

excitation to the field windings of a brush-type synchronous motor. The motor-generator is often
fed by a low-voltage supply but can also be connected to medium voltage.
c. Brushless exciter: An alternator-rectifier exciter that is mounted directly to the rotor of a

brushless synchronous motor. The rotating exciter provides a direct connection to the
synchronous motor field winding, thus eliminating the need for field brushes. However, the
brushless exciter still requires a small excitation, usually less than 15 A.

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2.4.3 Construction
2.4.3.1 General
Each synchronous motor controller should include the following components:
a. Unless integral to the machine (such as in most brushless synchronous motors), a means that
automatically applies field excitation at the proper time.
b. In the case of a brushless-type synchronous motor, an ammeter.
c. Field discharge resistor—Unless integral to the machine (such as in brushless synchronous

motors), a field discharge resistor is needed. This is a resistor that is connected to the field
windings during acceleration. This resistor creates a closed circuit for the field winding. During
acceleration, there is an induced voltage through the field winding circuit that aids in the
acceleration of the motor. It is crucial that the user supplies the controller manufacturer with
accurate requirements for the field discharge resistor. If the resistance is excessive, the
induced voltage may reach levels that can damage the insulation of the field winding and the
controller field circuit. It is also necessary to know the induced current at zero speed of the
motor and the acceleration time so that the field discharge resistor is sized to handle the
current for the specified acceleration time to prevent damage to the resistor through
overheating.
2.4.3.2 Protection Means

Unless integral to the machine, protective functions for synchronous motor controllers should provide:
a. Means to automatically remove field excitation in event of pull-out
b. When required by the particular application, field loss protection shall be included to disconnect
the motor from the line in the event of excitation failure. Field loss protection is recommended
for motors provided with controllers arranged for re-synchronizing when pull-out conditions are
encountered
c. Means to protect the field against excessive induced voltage during normal operation out of
synchronism
d. Means to protect the squirrel-cage windings during operation out of synchronism

e. Means to automatically disconnect the motor from the line in case of pull-out, when required by
the particular application
f. Three motor running overcurrent (overload) protective units unless the motor, the motor control
apparatus and the branch circuit conductors are otherwise adequately protected
g. Instantaneous undervoltage protection. When required by the particular application, time-delay

undervoltage protection shall be included in lieu of instantaneous undervoltage protection
h. When required by the particular application, the DC control bus supplying field excitation shall
have a suitable two-pole disconnect means and short-circuit protection. Field discharge means
shall be permanently connected across the load side of this protective device and
disconnecting means
2.4.3.3 Additional Features

When required by the application, additional features may include the following:
a. An exciter field rheostat
b. Means to re-synchronize in the event of pull-out

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2.5 CONTROL OF NON-MOTOR LOADS

2.5.1 Transformer Loads
The rating and protective devices for the controller should be selected to address the following special
considerations:
a. Phase unbalanced loads—Transformers with single-phase loads may be operated with
significant unbalanced loads. The selection of current transformers and protective relaying
should be evaluated based on potentially unbalanced loads for these situations.
b. Magnetizing inrush current—The controller and specifically the selected power fuse must be
capable of carrying, without damage, the inrush current of the transformer.
c. Transformer damage protection—Unless provided by secondary protection, the controller must

provide overcurrent protection to prevent I2t from reaching the transformer damage curve.
d. Transformer overloads—There are transformers that are capable of being operated above their
nameplate kVA rating for significant periods of time.
C37.91 (IEEE Guide for Protecting Power Transformers) should be used for guidance on transformer
applications.
2.5.2 Capacitor Loads

Control of capacitors requires special considerations, to include:
Controller continuous current ratings should be selected based on the actual capacitance current they are
required to interrupt, including the following effects:
a. Voltage Factor. The nameplate reactive power rating of the capacitor bank, in kVar, is to be
multiplied by the ratio of the maximum service voltage to the capacitor bank nameplate voltage
when calculating the capacitance current at the applied voltage. This factor can be as large as
1.1 since capacitors can be operated continuously up to 10% above the capacitor rated
voltage.
b. Capacitor Tolerance. The manufacturing tolerance in capacitance is −0 to +10% with a more

frequent average of −0 to +5%. A multiplier in the range of 1.05 to 1.10 should be used to
adjust the nominal current to the value allowed by tolerance in capacitance.
c. Harmonic Component. Capacitor banks provide a low-impedance path for the flow of harmonic
currents. When capacitor banks are ungrounded, no path is provided for zero-sequence
harmonics (third, sixth, ninth, etc.), and the multiplier for harmonic currents is less. A multiplier
of 1.1 is generally used for a grounded neutral bank and 1.05 for an ungrounded neutral.
Section 460.24 of the 2017 NEC® requires that switching devices be capable of carrying continuously
135% of the rated capacitor current.
2.5.3 Power Factor Correction Capacitors

a. Avoid oversizing capacitors—When power factor correction capacitors are connected to and
switched along with individual motor loads, it is important not to oversize the capacitors. These
capacitors are either connected at the motor terminals or are connected to the load side of the
main contactor in a medium-voltage controller. If capacitor kVar is too large for a particular
motor, overvoltages can occur, as high as 175% in some tests. These excessive voltages can
damage motor insulation, capacitors, or fuses. Motor manufacturer’s data will usually stipulate
the maximum power factor correction capacitor rating that should be connected to a motor. If
this data is not available, it is common practice to size capacitors to correct the full load motor
power factor to a maximum of .95 lagging. In no case should a capacitor be connected that

NEMA ICS 3.1-2019
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causes the power factor to reach unity for any loading of the motor. For further information, see
IEEE Std 1036-2010, clause 11.1.2.
b. Resonance—Power factor capacitors can drastically change the frequency response of an

industrial power system. If the circuit resonance created by the capacitors corresponds to
harmonic frequencies of nonlinear loads at the facility, they will cause significant voltage
distortion. It may be necessary to reduce the amount of capacitance or add filtering to the
power system so that the harmonic resonance does not occur.
c. Harmonics—Power systems with significant harmonic content can lead to failure of capacitors
and capacitor fuses due to the heating effects of the additional harmonic current. Capacitor
fuse failures caused by harmonics are typified by fuse rupturing from failures of low current
interruption during running conditions, not make or break. It is recommended to reduce the
harmonic content of the installation to eliminate this condition.
d. Back-to-back capacitor switching—Excessive inrush currents can be seen at the terminals of a

power factor correction capacitors energized on a circuit that contains multiple power factor
correction capacitors already energized. The inrush current increases as the connected kVar is
increased in relation to the system impedance and especially when the impedance between the
capacitors is low. It may be necessary to add series reactors to the capacitors to limit the inrush
current in more severe cases. For more information, see IEEE C37.012.
e. Make and break capability—Inrush currents, especially in back-to-back capacitor connections,

should be evaluated with respect to the make and break capabilities of the controller. Switching
capacitors may also lead to pre-strike and re-strike conditions that affect the make and break
capability of the controller. For more information, see IEEE C37.012.
f. Pre-strike/re-strike—It may be advisable to add surge suppressing devices to mitigate the

negative effects of voltage transients caused by pre-strike and re-strike during switching.
g. Rated voltage versus system voltage—The kVar of a given capacitor is based on its rated
voltage. Applying a capacitor at system voltages below its rated voltage will reduce the actual
kVars the capacitor can supply to the system. A capacitor should not be applied in continuous
duty on a system voltage above its voltage rating.
h. To limit switching overvoltages and overcurrents, do not energize capacitor banks within five
minutes after their de-energization.
i. To eliminate overvoltages caused by ferroresonance (more likely to occur in ungrounded or

high impedance ground systems), avoid single-phasing a capacitor bank connected to a
transformer. See IEEE Standards Dictionary Online.
j. Discharge of power capacitors—Safe discharge of power capacitors should be ensured.

Medium-voltage power capacitors, complying with IEEE 18, are supplied with internally
mounted discharge resistors that dissipate capacitor voltage down to 50 V within 5 min.
Capacitors without internally mounted discharge resistors must be supplied with external
discharge resistors. See NFPA 70, section 460.28.
k. Short-circuiting and grounding—Capacitors should be short-circuited and grounded before

servicing controllers. When shorting and grounding capacitors, the interconnection of units
within the bank, the discharge resistors, and the type of fusing should be taken into account.
l. Capacitor connection for reduced voltage controllers—power factor correction capacitors

should not be directly connected on the load side of the autotransformer or reactor of a reduced
voltage starter. Such a connection can lead to damage to the autotransformer or reactor
windings and can also generate significant voltage transients. Power factor correction

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capacitors should only be connected on the line side of the reactor or autotransformer or be
connected via an additional contactor after the controller has transitioned to full voltage.
m. Do NOT connect power-factor correction capacitors or surge capacitors to the load (motor)
circuit of a solid-state controller (SSRVS), either at the controller itself or at the motor-terminal
box. During starting, the load-side capacitors will appear as a short circuit across the silicon-
controlled rectifiers (SCR) of the SSRVS, which will cause a high di/dt, and will damage the
SCRs. Capacitors, if used, must be connected to the line side of the SSRVS unit.
Note: Occasionally, when a motor controlled by an autotransformer starter is being stopped, a

significant noise may be emitted from the autotransformer. In such situations, it has been noted that
maintaining the run contactor closed for the deceleration period alleviates the condition.
2.6 COORDINATION WITH POWER SYSTEMS

2.6.1 Considerations
In applying medium-voltage equipment, consideration should be given by the user to coordination with the
power system and upstream and downstream equipment, including, but not limited to:
a. The range of system voltage to which the equipment will be connected;
b. Maximum available fault current of the system at the point of installation of the controller;
c. Nature and location of intentional electric system grounding, particularly the maximum ground-
fault current;
d. The anticipated connected load, i.e., motor starting and full-load currents, motor acceleration
time, and motor starting method (full-voltage or reduced-voltage);
e. Upstream and downstream protection devices and settings;
f. Lightning and switching surges.
2.6.2 Voltage Coordination with Upstream Devices

The rated supply voltage of the controller shall be coordinated with the voltage of the system to which it is
connected.
2.6.3 Current Coordination with Upstream and Downstream Devices

The controller, as installed, shall have a fault interrupting rating at least as high as the available fault
capacity of the system to which it is connected. For power system integrity, the overcurrent protection
characteristics of the controller should coordinate with the upstream and downstream equipment.
2.6.4 Ground-Fault Current Coordination

On an intentionally grounded electric power system, ground fault protection should be considered. A
ground fault relay within the controller should coordinate with upstream relays.
2.6.5 Insulation Coordination

Securing adequate insulation surge voltage protection depends upon a combination of good design
practices with the selection of appropriate surge voltage protective devices. Manufacturers are permitted
to assign one of two levels of rated lightning impulse withstand voltage.
Incoming surge voltages should be evaluated considering waveform variations and reflections. For
approximating a worst-case peak voltage, multiply the lightning impulse protection level (LPL) of the
surge arrester by 260%.

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For a proper protective margin, the lightning impulse withstand test voltage from Table 1 of UL 347
should be at least 20% more than the calculated worst case of incoming overvoltage.
The following are example calculations for approximating a worst-case of incoming overvoltage with
resultant multipliers leading to the selection of the appropriate rated lightning impulse withstand voltage
for the equipment. These examples assume that surge protection for the equipment is provided by surge
arresters remote from this equipment so that the effects of voltage reflection of the incoming wave must
be considered.
Example 1: 4.16 kV Grounded System

Required
Equipment
Rated
Arrester Lightning
Type of Duty Cycle Arrester Arrester Impulse
Surge Rating 1) MCOV 1) LPL 2) LPL X 1.2 3) LPL X 2.6 4) Withstand
Arrester kV, rms kV, rms kV, crest kV, crest kV, crest Voltage
Col 1 Col 2 Col 3 Col 4 Col 5 Col 6 Col 7
Station 3.0 2.55 8.6 10.3 22.4 45 kV
Intermediate 3.0 2.55 12.5 15.0 32.5 45 kV
Distribution 3.0 2.55 10.9 13.1 28.3 45 kV
1. Surge arrester duty cycle rating is often referred to as the rated voltage of the arrester. MCOV
is the maximum continuous operating voltage of the arrester.
2. Typical data for selected arrester. Lightning Impulse Protective Level (LPL) is the higher of the
discharge voltages established by tests using 8/20 μs discharge current impulses or gap
sparkover (for arresters with a gap) voltages. For this example, the discharge voltage at 10kA
has been used.
3. Protective Margin of 20% (see IEEE C62.22) is recommended for insulation coordination.
4. 260% allowance for arrester location remote from medium-voltage controller, to allow for
reflections, wave shape variations, etc.
Example 2: 4.16 kV Ungrounded System

Required
Equipment
Rated
Arrester Arrester Lightning
Type of Duty Cycle MCOV 1) Arrester Impulse
Surge Rating 1) LPL 2) LPL X 1.2 3) LPL X 2.6 4) Withstand
Arrester kV, rms kV, rms kV, crest kV, crest kV, crest Voltage
Col 1 Col 2 Col 3 Col 4 Col 5 Col 6 Col 7
Station 6.0 5.1 15.2 18.2 39.5 45 kV
Intermediate 6.0 5.1 16.2 19.4 42.1 45 kV
Distribution 6.0 5.1 22.0 26.4 57.2 60 kV
1. Surge arrester duty cycle rating is often referred to as the rated voltage of the arrester. MCOV
is the maximum continuous operating voltage of the arrester.
2. Typical data for selected arrester. Lightning Impulse Protective Level (LPL) is the higher of the
discharge voltages established by tests using 8/20 μs discharge current impulses or gap

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sparkover (for arresters with a gap) voltages. For this example, the discharge voltage at 10kA
has been used.
3. Protective Margin of 20% (see IEEE C62.22) is recommended for insulation coordination.
4. 260% allowance for arrester location remote from medium-voltage controller, to allow for
reflections, wave shape variations, etc.
The examples cited are for application at standard altitude (1000 m or below). If the application is at a
higher altitude, refer to IEEE C37.100.1, IEEE Standard of Common Requirements for High Voltage
Power Switchgear Rated Above 1000 V, for information on derating.
For more information on the application of surge arresters to safeguard electric power equipment against
the hazards of abnormally high-voltage surges of various origins, see the applicable Standards and
application guides for surge arresters. (Reference IEEE C62.22, IEEE Guide for the Application of Metal-
Oxide Surge Arresters for Alternating-Current Systems.)

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3 Ordering Information
3.1 APPLICATION RATINGS

When inquiring for or ordering a contactor, controller, or control center, the following particulars should be
provided to the supplier.
3.1.1 Particulars of System

a. rated supply voltage;
b. rated supply frequency;
c. number of phases;
d. details of system grounding (solidly grounded wye, high or low resistance grounded wye or
delta, or ungrounded wye or delta);
e. system short circuit capacity at the point of connection to the equipment.
3.1.2 Motor Data

a. Basic Motor Data (all motors)
a. Rated voltage
b. Horsepower
c. Full load current
d. Service factor (normally 1.0 or 1.15)
e. Locked rotor current
f. Acceleration time
g. Full Voltage or Reduced Voltage
h. Non-Reversing or Reversing
i. Squirrel cage, Synchronous, or Wound Rotor
b. For non-solid state reduced-voltage controllers

1. Type (autotransformer or reactor)
2. Desired tap setting for autotransformer or reactor
3. Acceleration time at reduced voltage
4. Medium or heavy duty autotransformer or reactor (see clause 4.204 of UL 347)
5. Thermal sensors desired for autotransformer/reactor coils
c. For solid-state reduced-voltage controllers

1. Acceleration time at reduced voltage
2. Medium or other duty (see clause 4.204 of UL 347)
3. Expected cable capacitance
d. Synchronous
1. Brush type or brushless
2. Power factor (1.0 or 0.8 leading)
3. Excitation source for brush type (specify one)
a. Manufacturer supplied static exciter
b. Customer supplied static exciter
c. Customer supplied MG set/shaft-mounted generator
4. Excitation voltage (nominally 95 Vdc for brushless and 125 or 250 Vdc for brush type)
5. Excitation current (maximum-cold and normal-hot)
6. Maximum time on squirrel cage winding
7. Discharge resistor size (ohms, amperes, and time) for brush type
8. Induced field current for brush type

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9. Exciter field current for brushless type

10. Exciter field voltage for brushless type
e. Two Speed
1. Two winding
2. Single winding
3.1.3 Transformer Load Data

a. Transformer type (dry-type, cast coil, liquid-filled)
b. Rated voltage
c. kVA Rating (self-cooled and maximum fan-cooled, if applicable)
d. Overload requirements
e. Phase
f. Impedance
g. Primary, secondary winding connection
3.1.4 Capacitor Bank

a. Bank kVAR
b. Recommended minimum bank fuse size
3.1.5 Branch Feeder

a. Branch continuous current
b. Maximum current (from transformer or motor inrush)
c. Recommended minimum branch fuse size
3.1.6 Transfer Switch (UL 1008A)

a. Sources—1 utility/1 generator, 2 utilities
b. Continuous current of each source
c. Maximum current for each source
3.1.7 Special Service Conditions

A. Minimum and maximum ambient temperatures (if outside the range of 0–40 °C).
B. Altitude of installation if above 1000 m.
C. Special conditions likely to exist or arise; for example, unusual exposure to water vapor, moisture,
fumes, explosive gases, excessive dust, or salt air.
D. If the equipment may be exposed in service to abnormal shocks or vibrations (such as from
seismic activity).
E. If its support may be capable of assuming a sloping position either permanently or temporarily (for
example, devices fitted aboard ships).
F. If the equipment may be mounted on a moving device.

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4 General Information After Receiving
4.1 PRECAUTIONS
There is a hazard of electric shock whenever working on or near electrical equipment. All power supplying
the equipment should be turned off before starting work and disconnecting means should be locked out
and/or tagged out in accordance with NFPA 70E, Chapter 1. Where it is not feasible to de-energize the
system, the following precautions should be taken:
a. Persons working near exposed parts that are or may be energized should be instructed and
should use practices (including appropriate apparel, equipment, and tools) in accordance with
NFPA 70E, Chapter 1.
b. Persons working on exposed parts that are or may be energized should be qualified persons
who have been trained to work on energized circuits.
c. All applicable local and national safety requirements and procedures should be followed,
including the requirements of OSHA, and of NFPA 70E article 130.2(B) concerning an
Energized Electrical Work Permit.
4.2 RECOMMENDED PROCEDURE

The operation of controllers is dependent upon handling, installation, operation, and maintenance by
qualified personnel. Failure to follow fundamental installation and maintenance recommendations could
lead to personal injury and damage to the controller and other property.
4.3 REFERENCES
References to the National Electrical Code®, shown as NFPA 70 (NEC), refer to NFPA Publication No.
70. Although not specifically referenced, the National Electrical Safety Code®, ANSI C2, is also
applicable.
Reference to the manufacturer, unless otherwise specified, means the controller manufacturer.
4.4 QUALIFIED PERSON

OSHA 29 CFR Part 1910.399 defines a qualified person as “One familiar with the construction and
operation of the equipment and the hazards involved.” NFPA 70E Article 100 defines a qualified person
as “one who has skills and knowledge related to the construction and operation of the electrical
equipment and installations and has received safety training on the hazards involved.”
NFPA 70E Article 110 also provides the following definition:
“Qualified Person. A qualified person shall be trained and knowledgeable in the construction and
operation of equipment or a specific work method and be trained to identify and avoid the electrical
hazards that might be present with respect to that equipment or work method.
(a) Such persons shall also be familiar with the proper use of the special precautionary techniques,
applicable electrical policies and procedures, PPE, insulating and shielding materials, and insulated tools
and test equipment. A person can be considered qualified with respect to certain equipment and methods
but still be unqualified for others.”
4.5 MANUFACTURER INSTRUCTIONS

It is essential that the transport, storage, and installation of the controller, as well as the operation and
maintenance in service, be performed in accordance with instructions given by the manufacturer.

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Consequently, the manufacturer should provide instructions for the transport, storage, installation,
operation, and maintenance of the controller.
The instructions for the transport and storage should be given at a convenient time before delivery, and
the instructions for the installation, operation, and maintenance should be given by the time of delivery at
the latest.
4.6 CONDITIONS DURING TRANSPORT, STORAGE, AND INSTALLATION

A special agreement should be made between the manufacturer and user if the service conditions of
temperature and humidity defined in the order cannot be guaranteed during transport, storage, and
installation. Special precautions may be essential for the protection of insulation during transport, storage,
and installation, and prior to energizing, to prevent moisture absorption due, for instance, to rain, snow, or
condensation. Vibrations during transport shall be considered. Appropriate instructions should be given.
4.7 PRECAUTIONS
All maintenance shall be performed by trained, qualified personnel, using safety practices and protective
equipment applicable to systems over 1000 V.

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5 Handling
5.1 GENERAL
The manufacturer's handling instructions for the specific equipment should be followed. The controller
should be handled with care, to avoid damage to components and to the frame or its finish.
The following guidelines are provided to help during handling:
5.1.1 Upright Position

The controller should be kept in an upright position unless otherwise specifically permitted by the
manufacturer. If it is received in the horizontal position, the carrier should be notified of possible damage,
and the controller should be restored to the vertical position as soon as practical.
5.1.2 Handling Equipment Capability

Medium-voltage controllers can be extremely heavy. Equipment used in the handling of controllers should
be capable of handling the weight. This capability should be confirmed prior to starting any handling
operations with the controller.
5.2 UNPACKING/PACKING
5.2.1 Initial Inspection
When the controller is received, it should be unpacked sufficiently to inspect for concealed damage and to
determine that the shipment is complete and correct.
5.2.2 Storage before Installation

If the controller is to be stored for any length of time prior to installation, the packing should be restored
for protection during that period. Where conditions permit, the packing should be left intact until the
controller is at the final installation position. If the packing is removed, the top and openings of the
equipment should be covered during the construction period to protect it against dust and debris. See the
Storage section below for additional storage guidelines.
5.2.3 Shipping Skids

The controller should remain secured to the shipping skid to prevent distortion of the frame and to
minimize tipping during handling.
5.2.4 Unpacking and Lifting

Required information for unpacking and lifting safely, including details of any special lifting and positioning
devices that are necessary, should be given.
5.3 MOVING
Extreme care should be exercised during any movement and placement operations to prevent dropping
or unintentional rolling or tipping.
5.3.1 Rod and Pipe Rollers

Rod or pipe rollers, with the aid of pinch bars, provide a simple method of moving the controller on a level
floor. The load should be steadied to prevent tipping.

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5.3.2 Forklift
A forklift truck may offer a more convenient method of handling the controller. A safety strap should be
used when handling a controller with a forklift. The forks should be inserted under the shipping skid. The
metal transom of the controller enclosure may not be capable of supporting the concentrated load on the
forks. The ends of the forks should not enter the bottom of an open-bottom enclosure.
5.3.3 Overhead Hoisting

Where it is necessary to move the controller between elevations, overhead hoisting may be required.
Lifting plates and eye-bolts (Figure 6) or channels, angles, or bars with lift holes (Figure 7) may be
provided as a permanent or removable part of the controller. Some controllers may not be suitable for
overhead lifting and may require that specialized lifting equipment be used. If the equipment is suitable
for overhead lifting, the following guidelines apply:
a. Spreaders (Figure 6) should be used to provide the vertical lift on eye-bolts required to avoid
eye-bolt failure.
b. The rigging lengths should be selected or adjusted to compensate for any unequal distribution
of load and to maintain the controller in an upright position. Some controller interiors may
contain heavy equipment, such as transformers mounted within, that could make the center of
gravity be considerably off mechanical center.
c. The angle between the lifting cables and vertical should not be allowed to exceed 45 degrees.
d. Ropes or cables should not pass through the lift holes in bars, angles, or channels. Slings with
safety hooks or shackles, of adequate load rating, should be used.
Figure 6
Lifting With Eye-Bolts Or Lifting Plates

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The height of the lift

point above the lifting angle
should be at least ½ of ‘A’ (the
distance between lifting holes).
This corresponds to a
maximum angle of 45 degrees
as shown
Figure 7
Lifting with Integral Lift Angle

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6 Storage
6.1 CONTROLLERS FOR INDOOR INSTALLATION

A controller intended for indoor installation that is not installed and energized immediately should be
stored in a clean, dry space where a uniform temperature prevents condensation.
6.1.1 Indoor Storage

Preferably, a controller intended for indoor installation should be stored in a heated building with
adequate air circulation and protection from dirt and water. The controller should be stored where it is not
subject to mechanical damage, especially during building construction.
6.1.2 Outdoor Storage

A controller intended for indoor installation that is to be stored outdoors should be securely covered for
protection from weather conditions and dirt. Temporary electrical heating should be installed to prevent
condensation. The installer should consult with the controller manufacturer regarding the proper sizing of
heaters. All loose packing or flammable materials should be removed before energizing space heaters.
6.2 CONTROLLERS FOR OUTDOOR INSTALLATION

A non-energized outdoor controller should be kept dry internally by installing temporary heating, or by
energizing self-contained space heaters provided by the manufacturer if ordered. If conduit or throat
connections are not installed promptly, their openings (and any other openings) should be covered to
prevent direct entry of rain, etc.
6.3 ROUTINE INSPECTION

Routine scheduled inspections should be performed if the controller is stored for an extended period. This
is to check for condensation, dampness, corrosion, vermin, and adequacy of space heating.

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7 Installation
7.1 GENERAL
The manufacturer's instructions for the specific controller should be located and followed.
The fault capability of the power system at the point of installation should not exceed the short-circuit
rating of the controller.
Refer to the Handling section above for handling guidelines during moving and installation.
7.2 SITE PREPARATION

It is recommended that site preparation be completed before the controller is unpacked, so that possible
problems—such as headroom, conduit location, cable tray locations, ventilation, etc.—can be solved,
ensuring a safe installation, in compliance with the building plans and codes.
The intended mounting surface should be level so that the controller is not distorted when bolted into
place. The overhead should be checked for plumbing condensation, sprinklers, or similar possible
sources of trouble, and corrective steps should be taken where necessary.
Adequate grounding connections should be established in accordance with the manufacturer's

recommendations and applicable code requirements.
7.3 PHYSICAL CLEARANCE CONSIDERATIONS

The following items are offered for guidance only. Additional clearances may be required by the
applicable installation codes, the design of the equipment, or the manufacturer’s requirements.
7.3.1 Rear Access Required

If rear access is required to work on de-energized parts, a minimum 30-inch clearance (77 cm), or as
specified by the manufacturer, should be provided. In all cases, the workspace shall permit at least a 90-
degree opening of doors or hinged panels, except where greater working space is required by NEC
110.34.
7.3.2 Rear Access Not Required

Where rear access is not required, the clearance between the rear of the controller and a wall should be
at least 0.5 inches (1.3 cm) for indoor equipment and 6 inches (16 cm) for outdoor equipment.
7.3.3 Front Access Working Space

A minimum working space should be allowed in front of the controller of 36 inches (92 cm) for 2500 volts
to ground maximum and 48 inches (122 cm) for maximum 7200 volts to ground. These minimums should
be increased if it is necessary to accommodate movement around open enclosure doors or to comply
with applicable codes.
7.4 NORMAL SERVICE CONDITIONS

See clause 2.1 of UL 347 for normal service conditions.
7.5 SPECIAL SERVICE CONDITIONS

See clause 2.2 of UL 347 for special service conditions.

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Unless the controller has been specified and designed for unusual service conditions, it should not be
exposed to abnormal ambient temperatures, abnormal altitudes, corrosive or explosive fumes, dust,
vapors, dripping or standing water, abnormal vibration or seismic conditions, shock, tilting, or other
unusual operating conditions.
7.5.1 Locations Near Heat Source

If the controller includes or is located near significant heat-generating components, such as large power
resistors, sufficient ventilation should be provided to maintain an ambient air temperature around the
enclosure within the normal service conditions (maximum 40°C ambient or as indicated on the assembly
rating label) as established in clause 2.1 of UL 347.
7.5.2 Damp Locations

If the location for installation is damp, space heaters may be required. If provided by the manufacturer,
they should be connected as specified by the manufacturer.
7.6 ASSEMBLY
When controllers are shipped not fully assembled, care must be taken to follow the drawings and
instructions provided to correctly assemble the controllers on site. If there is a need to disassemble
assembled controllers on site, to install them, the manufacturer should be consulted before and after to
verify that the disassembly and reassembly are done correctly.
7.6.1 Mounting
Site plans for mounting of controllers and other devices should be made using and following the
instructions and drawings provided by the equipment manufacturers.
7.6.2 These instructions should also indicate:
a. the total mass of the apparatus inclusive of extinguishing or insulating fluids;
b. the mass of extinguishing or insulating fluids;
c. the mass of the heaviest part of the apparatus to be lifted separately if it exceeds 100 kg (220
lb).

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8 Conductors
8.1 CONNECTIONS:
Instructions should include information on:
a. connection of conductors, comprising the necessary advice to prevent overheating and
unnecessary strain on the switchgear and controlgear and to provide adequate clearance
distances;
b. connection of auxiliary circuits;
c. connection of liquid or gas systems, if any, including size and arrangement of piping;
d. connection for grounding.
8.2 PHYSICAL CONSIDERATIONS

Cable and wire bundles that enter the control enclosure should be routed to avoid interference with
moving parts of the controller.
Minimum recommended bending radius for each particular cable should be observed.
Power cables should be supported to withstand short-circuit forces, particularly when such cables span
over 18 inches (46 cm) between supports.
8.3 ELECTRICAL CONSIDERATIONS

Power cables should be adequate to carry the load current shown on the ratings nameplate and should
have an adequate voltage rating. Care should be taken not to select cable sizes that are larger than can
be accommodated by the equipment.
Cables should be dressed and terminated as appropriate for the voltage class and manufacturer's
recommendations.
Adequate electrical clearance between energized parts and to ground should be allowed.
8.4 BUS INTERCONNECTION LINKS

If power buses or ground buses are supplied with links for interconnection between sections, they should
be installed as specified by the manufacturer. All-access covers that are temporarily removed during
installation should be replaced.
Note: Covers that may be supplied only for protection during shipment should not be replaced.
8.5 CLEANUP DURING INSTALLATION

All debris and tools should be removed from each compartment as installation of cabling and conductors
is completed.

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9 Grounding
9.1 GENERAL
Grounding of the controller should be carefully executed to make certain that the actual ground is that
which was intendeded. Special attention should be paid to protection for operating personnel, to
protection of equipment itself (e.g., ground-fault relays), and to protection of sensitive transducers or
control devices that are electronic in nature.
All cable shields shall be connected to the ground bus or ground terminal of the controller in accordance
with the applicable installation codes and manufacturer instructions.
9.2 CONTROLLER USED AS SERVICE ENTRANCE EQUIPMENT FOR A SYSTEM WITH A

NEUTRAL
9.2.1 Grounding Electrode Conductor
A grounding electrode conductor, sized in accordance with applicable installation codes, should be run
from the grounding electrode to the controller ground bus or ground terminal designated by the
manufacturer. The connection of the grounding electrode conductor shall be made in the vertical section
of the equipment where the supply conductors are terminated.
9.2.2 Main Bonding Jumper

A main bonding jumper, sized in accordance with applicable installation codes, is required. If not installed
by the manufacturer, the main bonding jumper must be provided by the installer. This bonding jumper
must electrically connect the incoming grounded circuit conductor to the grounding electrode conductor.
Typically, the main bonding jumper is connected between the neutral bus or terminal and the ground bus.
The main bonding jumper shall be installed in the vertical section of the equipment where the supply
conductors are terminated.
9.2.3 Ground Interconnection

Proper connection of the grounding electrode conductor and main bonding jumper will effectively connect
together the grounding electrode, the controller frame, all outgoing equipment grounding conductors, and
the system ground.
9.2.4 Terminations of Grounding Conductors

No connection should be made to ground on the load side of any sensor used for ground fault protection.
Connections for all equipment grounding conductors shall be made on the ground bus.
9.2.5 Dual-Fed with Ground-Fault Protection

Where the controller or system is dual-fed (double-ended) and has ground-fault protection, special
precautions are necessary to accomplish proper grounding and bonding. The applicable installation
codes and manufacturer's instructions shall be followed.
9.3 CONTROLLER USED AS SERVICE ENTRANCE EQUIPMENT FOR ASYSTEM WITHOUT A

NEUTRAL
9.3.1 Grounding Electrode Conductor
A grounding electrode conductor, sized in accordance with applicable installation codes, should be run
from the grounding electrode to the controller ground bus.

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9.3.2 Ground Interconnection

Proper connection of the grounding electrode conductor and main bonding jumper will effectively connect
together the grounding electrode, the controller frame, all outgoing equipment grounding conductors, and
the system ground.
9.4 CONTROLLER USED AS A MAIN SECTION FOR A SEPARATELY DERIVED SYSTEM

For a separately derived system, the grounding electrode conductor connection and the main bonding
jumper may be provided at the transformer or generator that supplies the system or may be included in
the controller.
When either the grounding electrode conductor connection, or the main bonding jumper, or both, are
located within the controller, they shall meet the requirements of section 9.2 or 9.3 as appropriate.
9.5 CONTROLLERS NOT USED AS SERVICE ENTRANCE EQUIPMENT NOR AS A MAIN

SECTION FOR A SEPARATELY DERIVED SYSTEM
9.5.1 Grounding Conductors
The controller frame and any ground bus should be grounded by means of equipment grounding
conductors, sized in accordance with applicable installation codes. The equipment grounding conductors
shall be run with the main supply conductors.
9.5.2 Grounded Circuit Conductors

When provided, grounded circuit conductors shall not be bonded to ground within the controller.

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10 Inspection Prior To Initial Energization
Prior to energizing the controller for the first time, it should be inspected. The following should be
regarded as starting points for developing a comprehensive start-up plan.
In all circumstances, the manufacturer's instructions should be the primary guide.
10.1 REMOVE SHORTING JUMPERS

Shorting jumpers should be removed from the secondary of current transformers once their load is
connected. A current transformer should not be operated with its secondary circuit open.
10.2 REMOVE TEMPORARY SHIPPING BLOCKING

All blocks or other temporary holding means used for shipment should be removed from all component
devices in the controller.
10.3 BUS BRACING INTEGRITY

The integrity of all bus bracing should be checked.
10.4 CONNECTIONS
10.4.1 Phase Sequence
Each load should be connected to its intended controller, and phase sequence should be checked.
10.4.2 Wiring Diagram Agreement

All circuits should be compared for agreement with the wiring diagrams that accompany the controller.
10.4.3 Wiring Clearances

Field wiring should be checked for adequate clearance and physically secured to withstand the effects of
fault current.
10.4.4 Ground
All grounding connections should be checked. If there is no ground bus, the sections of the controller that
are shipped separately should be connected in such a way as to ensure a continuous grounding path.
10.5 POSSIBLE DAMAGE

10.5.1 Internal Devices
All internal devices should be checked for damage. All necessary repairs or replacements should be
made.
10.5.2 Enclosure
The enclosure should be checked to see that it has not been damaged so as to reduce electrical
spacings.
10.5.3 Warning Signs

Any warning signs should not be removed, covered over, or obscured by paint.

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10.6 OPERATING MECHANISMS

10.6.1 Manually Operated Mechanisms
All switches and other operating mechanisms should be manually exercised to make certain that they are
properly aligned and operate freely. Operating mechanisms, such as interlocks, key switches, etc., should
be checked for function as intended for the protection of personnel and equipment.
10.6.2 Electrically Operated Mechanisms

With all loads disconnected from power, all electrically operated switches, contactors, and other
mechanisms should be exercised to determine that the devices operate properly. An auxiliary source of
control power may be necessary to provide power to the electrical operators. If so, caution is required.
10.7 GROUND-FAULT PROTECTION SYSTEM

The ground-fault protection system (if furnished) should be tested in accordance with the manufacturer's
instructions.
10.8 ADJUSTABLE CURRENT AND VOLTAGE TRIP MECHANISMS

The setting of any adjustable current and voltage trip mechanisms should be verified to the proper values.
Damage from faults can be reduced if the devices used for short-circuit and ground-fault protection are
set or chosen to operate at values as close to normal as feasible while allowing for expected transients.
10.9 OVERLOAD RELAYS

Overload relays should be installed, selected, and adjusted for the full-load current shown on the
nameplate of each motor or load rating and the control manufacturer's instructions. Power circuit fuses
should be in accordance with the application requirements. Make sure that fuses are completely inserted
in their holders.
10.10 REMOVABLE PERMANENT PARTS AND BARRIERS

To prevent possible damage to equipment or injury to personnel, all parts and barriers that may have
been removed during wiring and installation should be checked that they have been properly reinstalled.
10.11 CLEANING
Before closing the enclosure, all-metal chips, scrap wire, and other debris from the controller should be
removed. If there is an appreciable accumulation of dust or dirt, the controller should be cleaned by using
a brush, vacuum cleaner, or clean, lint-free rags. Compressed air should not be used because it will
redistribute contaminants on other surfaces.
10.12 ELECTRICAL INSULATION TEST

An electrical insulation test should be performed to make sure that the controller and field wiring are free
from short-circuits and grounds. This should be done phase-to-ground, phase-to-phase, and
phase-to-neutral (if applicable) with the switches or contactors opened. Disconnect any devices that have
limited dielectric strength and are not designed for this test. A transformer, coil, or similar device normally
connected between lines of opposite polarity shall be disconnected from one side of the line during tests
between terminals of opposite polarity.
10.13 ENCLOSURE
Care should be exercised that when covers are installed, doors closed, etc., no wires are pinched, and all
enclosure parts are properly aligned and tightened.

NEMA ICS 3.1-2009
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11 Initial Energization of Equipment
11.1 MANUFACTURER INSTRUCTIONS

Review and verify that any and all instructions from manufacturers regarding the installation, operation,
interlocking, and energization are understood and have been followed prior to energization.
11.2 GENERAL
Energizing a controller for the first time or after maintenance presents additional hazards if problems such
as damaged equipment, incorrect assembly, or improper installation practices have not been detected in
the inspection process.
Safety procedures in accordance with manufacturer’s instructions, local and national safety codes, and
practices typically taught and followed by professionals trained in medium-voltage equipment must be
followed. Therefore, only qualified personnel should energize the equipment.
For further information, see NEMA SG 10, Guide to OSHA and NFPA 70E Safety Regulations When
Servicing and Maintaining Medium-Voltage Switchgear and Circuit Breakers Rated Above 1000 Volts.
11.3 CONTACTORS AND SWITCHES

All contactors and switches should be in the off position before energizing the bus.
11.4 LOADS
There should be no load on the controller when it is energized unless the manufacturer specifies
otherwise. All of the downstream loads, including those such as distribution equipment and other devices
that are remote from the controller, should be turned off.
11.5 ENERGIZATION SEQUENCE

The equipment should be energized in sequence by starting at the source end of the system and working
toward the load end: first the main devices, then the feeder devices, and then the branch circuit devices.
With barriers (if applicable) in place and unit doors closed and latched, the devices should be turned on
with firm positive motion. Protective devices and switches that are not quick-acting should not be "teased"
into the closed or open position.
11.6 INDIVIDUAL LOADS AFTER DISCONNECT DEVICE CLOSURE

After all disconnect devices have been closed, loads may be energized. The motor rotation should be
checked with the motor uncoupled from its load.
11.7 RECORDS
Instruction leaflets and diagrams should be collected and filed and readily available for use. Any changes
made to the circuit diagrams should be recorded. Inspection and test results should be recorded. All of
the above should be incorporated in the documentation as specified in 12.1.3.
11.8 SPARE PARTS

A supply of spare parts, fuses, etc. should be established.

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12 Maintenance and Use
12.1 FUNDAMENTALS
12.1.1 Planning
A well-planned and executed preventive maintenance program is essential to the satisfactory operation of
medium-voltage control equipment. A program should be established at the time the equipment is
installed. At that time, any manufacturer’s instructional literature should be reviewed and retained in a
location readily accessible for reference during maintenance of the equipment.
Persons performing maintenance shall be qualified persons (see 4.4).
For further information, see NEMA’s SG 10 Guide to OSHA and NFPA 70E Safety Regulations When
Servicing and Maintaining Medium-Voltage Switchgear and Circuit Breakers Rated Above 1000 Volts.
The user should record the following information:

a. the serial number and the type of the equipment;
b. the date when the equipment is put in service;
c. the results of all measurements and tests, including diagnostic tests, carried out during the life
of the equipment;
d. dates and extent of the maintenance work carried out;
e. the history of service, periodical records of the operation counters and other indications (e.g.,
fault operations);
f. references to any failure report.
An entry should be made into a log each time preventive maintenance is performed. The entry should
indicate the date maintenance was performed; observations; description of any repairs or modifications
and reasons for them; and identity of the person(s) who performed the maintenance.
In case of failure and defects, the user should make a failure report (See Clause 12.6.1) and should
inform the manufacturer by stating the special circumstances and measures taken. Depending upon the
nature of the failure, an analysis of the failure should be made in collaboration with the manufacturer.
12.1.2 Scheduling
A schedule should be established for routine preventive maintenance of the equipment at intervals
selected on the basis of severity of duty and environment. The schedule should be adjusted if later
experience indicates the need.
12.1.3 Documentation
A specific checklist of routine preventive maintenance requirements for each equipment item is
recommended, as well as a logbook to record the maintenance history.
12.1.4 Renewal Parts

A supply of renewal parts recommended by the equipment manufacturer should be kept available.

NEMA ICS 3.1-2009
Page 32
12.2 SAFETY PRECAUTIONS

12.2.1 Work Practices
For the safety of maintenance personnel as well as others who might be exposed to hazards associated
with maintenance activities, the safety-related work practices of NFPA 70E, Chapter 2, should always be
followed when working on electrical equipment. Maintenance personnel should be trained in the safety
practices, procedures, and requirements that pertain to their respective job assignments.
12.2.2 De-Energization for Maintenance or Service

If maintenance or service is to be performed, circuit parts and equipment that can endanger personnel
should be de-energized and locked out or tagged out in accordance with all local and national safety
requirements. If more than one incoming power source exists (e.g., a separate control circuit), make sure
that all sources are de-energized. All sources of electrical power must be disconnected using a
disconnecting device that provides positive isolation from electrical power. Any stored energy, electrical
or mechanical must also be discharged.
12.2.3 Working on Energized Equipment

Persons should not be permitted to work on electric circuit parts or equipment that have not been de-
energized and locked out or tagged out unless they are qualified and trained to use all appropriate safe
work practices, procedures, and protective equipment in accordance with the requirements specified in
NFPA 70E, Article 110. No work should be permitted on energized electrical equipment in any hazardous
(classified) location as defined in the National Electrical Code, NFPA 70.
12.2.3.1 Grounding of the Equipment

Live parts to which an employee can be exposed shall be put into an electrically safe work condition
before an employee works on or near them, in accordance with NFPA 70E Article 110. The requirements
of OSHA and of NFPA 70E Section 130.2(B) concerning an Energized Electrical Work Permit should be
followed.
12.2.4 Hazards of Controlled Equipment

Maintenance activities, particularly shutdown and the return to service of equipment or processes, must
be coordinated with operations management to avoid hazardous conditions. Access to any machinery or
process equipment that is controlled by the electrical equipment undergoing maintenance should be
prohibited unless all means of activating the machinery or process have been locked out or blocked,
including release or restraint of all stored energy, such as the electrical charge in capacitors, pressure in
fluid or gas systems, and stored mechanical energy in springs and elevated parts.
12.3 GENERAL GUIDELINES

12.3.1 Opening Enclosures
Control equipment should be kept clean and dry. If moisture condensation occurs inside an enclosure,
corrective action, such as the installation of a space heater, should be taken. Refer to the manufacturer
for the recommended heater size for the controller.
Before opening the door or cover of a cabinet or enclosure, comply with Clause 12.2, Safety Precautions.
Foreign material, dirt, hardware, or debris should be removed from the outside top surfaces to avoid the
risk of anything falling onto the equipment. Methods used in cleaning the outside of cabinets or
enclosures should be chosen with consideration for the enclosure’s Type designations as described in UL
50E, to avoid the risk of contaminating the enclosed equipment.
Enclosure doors, access plates, and covers are intended to remain closed during normal operation.
Evidence that equipment has been operated with the enclosure door open or cover removed is usually an
indication of a problem that should be diagnosed and corrected.

NEMA ICS 3.1-2019
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12.3.2 Inspection
Upon opening the cabinet or enclosure, control equipment should be inspected for any dust, dirt, moisture
or evidence of moisture, or other contamination. If any is found, the cause must be eliminated. This could
indicate an incorrectly selected, deteriorated, or damaged enclosure; unsealed enclosure openings;
internal condensation; condensate from an unsealed conduit; or improper operating procedures (e.g.,
operating with enclosure door or cover open).
A general inspection of mechanical integrity should be made, i.e., loose, broken, missing, or badly worn
parts. The intended movement of mechanical parts, such as armatures and contacts of electromechanical
contactors, isolating switches, switching device mechanisms, and mechanical interlocks should be
checked for freedom of motion and functional operation. For example, does a mechanical interlock
actually provide the intended function?
Ventilation passages should be kept open. If equipment depends on auxiliary cooling or heating, the
temperature control system should be checked and repaired, if necessary, to ensure proper functioning.
Filters should be cleaned or replaced, if necessary, based on inspection or the time interval
recommended by the manufacturer.
12.3.3 Cleaning
Corroded or damaged parts should be replaced. Dirty, wet, or contaminated parts of control equipment
should also be replaced unless they can be cleaned effectively by vacuuming or wiping with a dry cloth or
soft brush. Use care to avoid damaging delicate parts. Compressed air is not recommended for cleaning
because it may displace dirt, dust, or debris into other parts or equipment, or damage delicate parts.
Liquid cleaners, including spray cleaners, are not recommended unless specified by the equipment
manufacturer, because of the risk of residues causing damage or interfering with electrical or mechanical
functions. The inside of the cabinet or enclosure should also be cleaned, including removal of any
hardware or debris, so that any new or unusual wear or loss of parts occurring after the inspection may
be more readily detected during subsequent maintenance.
12.3.4 Servicing
Any broken, deformed, or badly worn parts or assemblies should be replaced with manufacturer
recommended renewal parts. Any loose fasteners should be retightened securely (to manufacturer-
recommended torque if specified). Lubricate mechanisms only if recommended by the manufacturer,
using only the recommended type and amount of lubricant. Remove any surplus lubricant to avoid risk of
establishing a tracking path across insulating surfaces, and of excess lubricant migrating into areas that
should not be lubricated.
If dust or dirt has accumulated on heat sinks and/or components that generate heat, it should be removed
carefully by vacuuming, wiping, or brushing, since such accumulation can reduce heat dissipation
capability and lead to premature failures.
12.3.5 Diagnosis
Maintenance should always aim to determine and correct the cause of any problems, not just the
symptoms.
12.3.6 Repair
If the equipment condition indicates the need for adjustment, repair, or replacement, the manufacturer’s
instruction manual should be followed carefully. Diagnostic information within such a manual should be
used to identify the probable source of the problem and to formulate a repair plan. The level of field repair
recommended by the manufacturer should be followed; if more extensive repair is needed, the item
should be replaced and/or returned to the manufacturer.

NEMA ICS 3.1-2009
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12.3.7 Replacement Parts

Some apparently equivalent replacement parts from sources other than the original equipment
manufacturer may not be suitable because the original equipment manufacturer may have required the
original part to meet unique specifications, performance, or test requirements (e.g., burn-in). Therefore,
replacement parts meeting the specifications of the original equipment manufacturer should be used.
Care should be taken to avoid the use of parts that are no longer compatible with changes in the
equipment; revision levels should be verified. All parts contained in a replacement kit should be changed.
Do not use parts that have deteriorated in storage.
12.3.8 Disposal of Parts

Government regulations and/or safe practice dictate that some types of parts that may be removed during
maintenance require special handling and disposal. Examples are lithium storage batteries, and
capacitors or transformers filled with polychlorinated biphenyl (PCB) electrolyte. Follow manufacturer’s
instructions and any applicable government regulations.
12.3.9 Fault Conditions

Fault conditions can cause extensive damage to the controller. The opening of one or more medium-
voltage power circuit fuses indicates a fault condition in excess of operating overload. Where evidence of
a fault is found, before restoring power, any damaged item(s) should be repaired or replaced. Refer to
Clause 12.5 for further information.
12.3.10 Functional Check

After inspection, maintenance, or repair operations, the equipment should be tested for proper functioning
before it is returned to service. During such tests, personnel should be protected against hazards in the
event of a malfunction. A change in magnitude or frequency of vibration or noise indicates a need for
attention; for example, a noisy AC magnet solenoid. (See Clause 12.4.5.)
12.4 SPECIFIC GUIDELINES

12.4.1 Disassembly/Reassembly
Disassembly/reassembly of a mechanism shall be performed only by qualified personnel. The
manufacturer’s instructions should be followed for disassembly, reassembly, and any required adjustment
or lubrication. Upon reassembly, the mechanism should be checked for freedom of motion and functional
operation. Alignment should be checked by operating the mechanism, and all interlock operations should
be verified.
12.4.2 Terminals and Connections

Loose electrical connections can cause overheating that can lead to equipment malfunction or failure.
Loose bonding or grounding can compromise safety and/or function. Terminal screws, lugs, bus
connections, bonding, and grounding connections should be checked for tightness and retightened
securely (to manufacturer’s specifications) as required. Fuse clips should be checked for signs of
overheating, looseness or inadequate spring pressure, and replaced if necessary. Any parts or wiring
found to be damaged by overheating should be replaced, using parts supplied or recommended by the
manufacturer. Evidence of overheating may include discolored conductors, terminals or parts; or melted,
charred, or burned insulation.
CAUTION: Do not remove plating on aluminum or copper parts in joints or terminations.
12.4.3 Conductors
Examine insulation on conductors for overheating or chafing against metal edges that could progress into
an insulation failure. Any damaged conductors should be replaced. Replacement conductors should be
re-routed, braced, or shielded if needed to avoid similar damage in future operation. Temporary wiring
should be removed or replaced by permanent wiring.

NEMA ICS 3.1-2019
Page 35
12.4.4 Vacuum Interrupters

Vacuum interrupters (bottles) in a vacuum contactor should be checked for vacuum integrity periodically
by performing a dielectric test across the open contacts in accordance with the manufacturer's
recommendations. Contact wear allowance (overtravel) and contact spring pressures (if required) should
be checked against the manufacturer's recommendation in the specific instruction literature.
12.4.5 AC Magnet Solenoids

A noisy solenoid in a relay or contactor having an AC magnet indicates failure to seat properly or a
broken or loose shading coil. The cause should be determined and corrected to avoid overheating and
coil damage. If a coil exhibits evidence of overheating (cracked, melted, or burned insulation), it must be
replaced, after the cause of overheating has been detected and corrected. This could include the AC
magnet symptoms described above, or any binding that keeps the magnet from seating properly when
energized, or overvoltage or undervoltage conditions. If melted coil insulation has flowed onto other parts,
they should be cleaned or replaced.
12.4.6 Solid-State Devices

Solid-state devices require periodic visual inspection. Printed circuit boards should be inspected to
determine that they are fully inserted into the edge board connectors. Board locking tabs should also be
engaged. Unplugging and re-plugging of connectors to verify seating is not recommended, as this will
shorten the useful life of most types of connectors used with solid-state devices. Dust or dirt, if found,
should be cleaned from boards and components. Solvents should not be used on printed circuit boards.
Necessary replacements should be made only at the printed circuit board or plug-in component level
unless otherwise recommended by the equipment manufacturer. Special care is needed to avoid damage
when servicing equipment that contains electrostatic-sensitive components. Manufacturer’s
recommendations should be followed for removal, handling, packaging, shipping, and/or replacement of
such components or modules.
Use only test equipment and test instructions specified by the manufacturer of the solid-state equipment
to avoid damage to the solid-state equipment or the test equipment or unintended actuation of other
equipment controlled by the solid-state equipment.
12.4.7 Protective Devices

The rating and setting of protective devices for each particular application, such as fuses, switching
devices, and overload relays, should be checked to verify that they are proper. Adjustment, repair, or
replacement should be performed as necessary, in accordance with any applicable instructions of the
manufacturer. For replacement purposes, use only fuse types and ratings specified by the equipment
manufacturer. Never attempt to defeat rejection mechanisms, which are provided to guard against the
installation of the wrong type of fuses.
12.4.8 Indicating Devices

All indicating lamps, mechanical flags, and similar auxiliaries should be checked and repaired or replaced
if required.
12.4.9 Labels and Nameplates

Labels and nameplates should be checked to verify that they are securely attached and legible. Clean or
replace any that are damaged, loose, missing, or deteriorated to the extent that legibility is compromised.
Do not modify or remove any listing mark or label for any third-party organization

NEMA ICS 3.1-2009
Page 36
12.5 MAINTENANCE OF CONTROLLERS AFTER A FAULT CONDITION

12.5.1 Introduction
In a motor branch circuit that has been properly installed, coordinated, and in-service prior to the fault, the
opening of the medium-voltage power circuit fuse(s) indicates a fault condition in excess of operating
overload. After the opening of any medium-voltage power circuit fuse(s), the controller should be
inspected for damage in accordance with manufacturer's instructions and the procedures below. The fault
condition should be corrected and the necessary repairs or replacements made before re-energizing the
branch circuit.
12.5.2 Procedures
It is recommended that the following general procedures be observed by qualified personnel in the
inspection and repair of the controller involved in the fault. Manufacturer’s service instructions should also
be consulted for additional details. The following procedures are to be followed in order to return to
service a motor controller that has been subjected to a short circuit or a ground fault. These procedures
are not intended to cover other elements of the branch circuit, such as wiring, motors, and transformers,
which may also require attention.
DANGER: all inspections and tests are to be made on controllers and equipment which are de-energized,
disconnected, locked out, and tagged so that accidental contact cannot be made with live parts and so
that all plant safety procedures will be observed.
12.5.2.1 Enclosure
Where substantial damage to the enclosure, such as deformation, displacement of parts, or burning has
occurred, replace the entire controller.
12.5.2.2 Isolation Switch

Verify that the external operating handle is capable of opening the switch. If the handle fails to open the
switch or if visual inspection after opening indicates deterioration beyond normal wear and tear, such as
overheating, contact blade or jaw pitting, insulation breakage, or charring, replace the switch.
12.5.2.3 Medium-Voltage Power Circuit Fuses and Fuse Holders

Even if only one fuse has opened, all three fuses should be replaced as they may have internal damage.
Medium-voltage fuses, although robust in external appearance, have fuse elements of relatively fragile
construction. Fuses should, therefore, be kept in their protective packaging until ready for installation and
should be handled with the same degree of care as a relay, meter, or other similar item. Where
deterioration of fuse holders or their insulating mounts has occurred, replace them.
12.5.2.4 Terminals, Buses, Stabs and Internal Conductors

Where there are indications of arcing damage or overheating, or both, such as discoloration and melting
of insulation, replace the damaged parts.
12.5.2.5 Vacuum Contactor

If the contact gap of the vacuum interrupters (bottles) is outside the manufacturer’s specified tolerance,
there is a loss of adequate contact wear allowance (wipe), or if the vacuum interrupters fail a vacuum
integrity test, the interrupters require replacement. Follow the manufacturer’s instructions for replacement
of vacuum interrupters and for adjusting and checking the contact gap and wipe. If deterioration extends
beyond the vacuum interrupters, such as heat damage, displacement of metal, binding, or evidence of
insulation damage, replace the entire contactor.
12.5.2.6 Overload Relays

If burnout of the current element of an overload relay has occurred or if there is obvious damage, replace
the complete overload relay. If there is no visual indication of damage that would require replacement of

NEMA ICS 3.1-2019
Page 37
the overload relay, trip the relay electrically or mechanically to verify the proper functioning of the
overload relay contact(s). If there is no visual indication of damage that would require replacement of an
overload relay with solid-state output, check the overload relay output to verify performance within the
minimum and maximum current ratings.
12.5.2.7 Return to Service

Before returning the controller to service, check for the tightness of electrical connections and for the
absence of short circuits, ground faults, and leakage current.
Close and secure all equipment enclosures before the branch circuit is energized.
12.6 CONTROLLER FAILURES

12.6.1 Failure Report
The purpose of making a failure report is to standardize the recording of controller failures.
12.6.1.1 Objectives of a Failure Report

The objectives of a failure report are:
a. to describe the failure using a common terminology;

b. to provide data for the user statistics;
c. to provide meaningful feedback to the manufacturer.
12.6.1.2 Items to Include in the Failure Report

A failure report should include:
a. Identification of the controller that failed:
b. Substation name;
c. Identification of the controller (manufacturer, type, serial number, ratings);
d. Location (indoor, outdoor);
e. Enclosure type;
f. Operating mechanism, if applicable (latched or non-latched);
g. History of the controller:
1. date of commissioning of the equipment;
2. date of failure/defect;
3. total number of operating cycles, if applicable;
4. date of last maintenance;
5. details of any changes made to the equipment since manufacture;
6. total number of operating cycles since last maintenance;
7. condition of the controller when the failure/defect was discovered (in service,
maintenance, etc.).
8. identification of the sub-assembly/component responsible for the primary failure/defect
9. medium-voltage stressed components;
10. electrical control and auxiliary circuits;
11. operating mechanism, if applicable;
12. other components.
h. Stresses presumed contributing to the failure/defect
1. environmental conditions (temperature, wind, rain, snow, ice, pollution, lightning, etc.);
2. classification of the failure/defect;
3. major failure;
4. minor failure;
5. defect.
i. Origin and cause of the failure/defect
1. origin (mechanical, electrical, tightness if applicable);
2. cause (design, manufacture, inadequate instructions, incorrect mounting, incorrect
maintenance, stresses beyond those specified, etc.).

NEMA ICS 3.1-2009
Page 38
j. Consequences of the failure or defect

1. controller down-time;
2. time consumption for repair;
3. labor cost;
4. spare parts cost.
k. A failure report may include the following information:
1. drawings, sketches;
2. photographs of defective components;
3. single-line station diagram;
4. operation and timing sequences;
5. records or plots;
6. references to maintenance or operating manuals.
l. Actual operations taking place at the time of the failure, and preceding the failure, including
actions of persons in the vicinity of the equipment as well as operation of the equipment.
m. Oscillography from protective relays on the circuit involved with the failure, and from the next
upstream device(s), in addition to event logs from both.

NEMA ICS 3.1-2019
Page 39
Bibliography
ANSI/IEEE C2 National Electrical Safety Code
IEEE 18 Standard for Shunt Power Capacitors
IEEE C37.012 Application Guide for Capacitance Current Switching for AC High-Voltage Circuit Breakers
IEEE C37.48.1 Guide for the Operation, Classification, Application, and Coordination of Current-Limiting
Fuses with Rated Voltages 1−38 kV
IEEE C37.91 Guide for Protecting Power Transformers
IEEE C37.100.1 Standard of Common Requirements for High Voltage Power Switchgear Rated Above
1000 V
IEEE C62.22 IEEE Guide for the Application of Metal-Oxide Surge Arresters for Alternating-Current
Systems
IEEE 1036 Guide for Application of Shunt Power Capacitors
IEEE Standards Dictionary Online
NEMA SG 10 Guide to OSHA and NFPA 70E Safety Regulations when Servicing and Maintaining
Medium-Voltage Switchgear and Circuit Breakers Rated Above 1000 V
NFPA 70 National Electrical Code®
NFPA 70E Standard for Electrical Safety in the Workplace
OSHA 29 CFR 1910 Occupational Safety and Health Standards
UL 50E Enclosures for Electrical Equipment, Environmental Considerations
UL 347 Medium-Voltage AC Contactors, Controllers, and Control Centers
UL 1008A Transfer Switch Equipment, Over 1000 Volts
Note: IEEE Standards Dictionary Online subscription is available at:

http://www.ieee.org/portal/innovate/products/standard/standards_dictionary.html

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NEMA Standards Publication ICS 3.

Guide for the Application, Handling, Storage, Installation, and Maintenance

National Electrical Manufacturers Association

© 2019 National Electrical Manufacturers Association.

8.5 Cleanup during Installation ............................................................................................... 25

© 2019 National Electrical Manufacturers Association.

Figure 1 Time vs. Prospective Current.............................................................................................. 4

© 2019 National Electrical Manufacturers Association.

Technical Director, Operations

© 2019 National Electrical Manufacturers Association.

© 2019 National Electrical Manufacturers Association.

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© 2019 National Electrical Manufacturers Association.

© 2019 National Electrical Manufacturers Association.

2 Selection and Application

2.1 RATINGS AND CHARACTERISTICS

a. rated voltage (Ur): 4.1

2.2 SELECTION OF RATINGS AND CHARACTERISTICS FOR SERVICE CONDITIONS

2.2.2 Insulation Coordination

2.2.3 Rated Frequency

2.2.4 Rated Short-Time Withstand Current

© 2019 National Electrical Manufacturers Association.

2.2.5 Rated Continuous (Thermal) Current

2.2.6 Local Atmospheric and Climatic Conditions

2.2.7 Use at High Altitudes

2.2.8 Coordination with Medium-Voltage Current-Limiting Fuses

2.2.9 Take-Over Current (Crossover Current)

© 2019 National Electrical Manufacturers Association.

Maximum break time (increased by the maximum

Maximum opening time, or minimum

Maximum operating time for maximum

Minimum pre-arcing time

2.2.10 Fuse Operation

When a controller has operated as a result of a three-phase fault, it is possible for

© 2019 National Electrical Manufacturers Association.

2.3 CONTROL OF MOTOR LOADS

2.3.1 Full-Voltage Starting (Figure 2)

2.3.2 Resistor or Reactor Reduced-Voltage Starting (Figure 3)

© 2019 National Electrical Manufacturers Association.

© 2019 National Electrical Manufacturers Association.

2.3.3 Autotransformer Reduced-Voltage Starting (Figure 4)

The starting current drawn from the line is:

The starting current taken by the motor is:

The autotransformer neutral current is:

© 2019 National Electrical Manufacturers Association.

2.3.4 Part-Winding Starting (Figure 5)

2.4 ADDITIONAL CONSIDERATIONS FOR SYNCHRONOUS MOTORS

2.4.1 Types of Synchronous Motors

2.4.2 Means of Excitation

b. Motor generator exciter: a motor-generator set connected to a rectifier that supplies DC

c. Brushless exciter: An alternator-rectifier exciter that is mounted directly to the rotor of a

© 2019 National Electrical Manufacturers Association.

b. In the case of a brushless-type synchronous motor, an ammeter.

c. Field discharge resistor—Unless integral to the machine (such as in brushless synchronous

2.4.3.2 Protection Means

a. Means to automatically remove field excitation in event of pull-out

d. Means to protect the squirrel-cage windings during operation out of synchronism

g. Instantaneous undervoltage protection. When required by the particular application, time-delay

2.4.3.3 Additional Features

© 2019 National Electrical Manufacturers Association.

2.5 CONTROL OF NON-MOTOR LOADS

c. Transformer damage protection—Unless provided by secondary protection, the controller must

2.5.2 Capacitor Loads