NEMA ICS 7.

1-2014

Safety Standards for Construction and Guide for Selection, Installation, and
Operation of Adjustable-Speed Drive Systems

Published by:

National Electrical Manufacturers Association

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

www.nema.org

2014 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.
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TABLE OF CONTENTS
Page

Foreword .............................................................................................................iii
Section 1 GENERAL
1.1 Scope ................................................................................................................. 1
1.2 Definitions .......................................................................................................... 1
1.3 Referenced Standards ........................................................................................ 2
Section 2 CONSTRUCTION REQUIREMENTS
2.1 Adjustable Speed Drive System Rating and Identification Plates .......................... 3
2.1.1 Motor Nameplates .................................................................................. 3
2.1.2 Device Identification ............................................................................... 3
2.1.3 Basic Drive Module / Complete Drive Module (BDM / CDM)
(Controller) Nameplate .......................................................................... 3
2.2 Operating and Maintenance Data ........................................................................ 3
2.3 Supply Circuit Disconnecting Devices ................................................................. 3
2.3.1 General .................................................................................................. 3
2.3.2 Type ...................................................................................................... 3
2.3.3 Rating .................................................................................................... 4
2.3.4 Supply Conductors to be Disconnected ................................................... 4
2.3.5 Mounting ................................................................................................ 4
2.3.6 Operating Handle ................................................................................... 4
2.3.7 Isolation ................................................................................................. 4
2.4 Protection ............................................................................................................ 4
2.4.1 Interrupting Capacity ............................................................................... 4
2.4.2 Control Circuit ......................................................................................... 4
2.4.3 Undervoltage (Low-Voltage) Protection .................................................... 4
2.4.4 Motor Overload ....................................................................................... 4
2.4.5 Supply-circuit Overcurrent (Short-Circuit) Protection ................................ 5
2.4.6 Power Transformer ................................................................................. 5
2.4.7 Draining of Stored Charge ....................................................................... 5
2.4.8 Short-Circuit Considerations for Equipment ............................................. 5
2.5 Control Circuits .................................................................................................... 5
2.5.1 General ................................................................................................... 5
2.5.2 Interlocking ............................................................................................. 5
2.6 Control Devices .................................................................................................... 5
2.6.1 AC Motor Starters .................................................................................... 5
2.6.2 Contactors ............................................................................................... 5
2.7 Control Enclosures ................................................................................................ 6
2.8 Internal Conductors ................................................................................................ 6
2.9 Wiring Methods and Practices ................................................................................. 6
2.10 Grounded Circuits and Equipment Grounding ......................................................... 6

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2.10.1 Enclosure Lighting Circuits and Convenience Outlets .............................. 6

2.10.2 Grounding .............................................................................................. 6
2.11 Set-up and Service Requirements for Energized Equipment .................................. 6
2.11.1 Movable Assemblies ............................................................................... 6
2.11.2 Nonelectrical apparatus .......................................................................... 6
Section 3 TESTS
3.1 Control Equipment and Systems .......................................................................... 7
Section 4 GUIDE FOR SAFETY IN APPLICATION OF ADJUSTABLE-SPEED DRIVE
SYSTEMS
4.1 Safety in Application ............................................................................................ 8
4.1.1 Factors to be Considered ........................................................................ 8
4.1.2 Electrical and Thermal Safety .................................................................. 8
4.1.3 Control Safety ....................................................................................... 11
4.2 Safety in Installation .......................................................................................... 14
4.2.1 Installation of Motors ............................................................................. 14
4.2.2 Installation of Control Equipment ........................................................... 14
4.3 Safety in Operation ............................................................................................ 15
4.4 Safety in Maintenance ....................................................................................... 16

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Foreword

In the preparation of this standards publication, input of users and other interested parties has
been sought and evaluated.

It is general knowledge that the misuse of electricity is potentially hazardous and may create risks
to personnel and property. In addition to shocks or burns from direct contact with live parts , the
risks may also include: 1) fire resulting from over loads, faulty wiring, or faulty equipment and 2)
injuries resulting from erratic machine operation. The degree of hazard can be greatly reduced by
proper design, construction, selection, installatio n, and use, but hazards cannot be completely
eliminated. The reduction of hazard should be the joint responsibility of the user and the
manufacturers of: 1) the driven equipment 2) the motor or motors and 3) the electrical equipment
for supplying and controlling the power for the motor or motors.

Since any electrical equipment can be installed or operated in such a manner that hazardous
condition can occur, compliance with this publication does not by itself assure a safe installation.
However, when equipment complying with this publication is properly selected with respect to the
driven load and environment and is installed in accordance with the National Electric Code, the
potential hazards to persons and property will be reduced.

The importance of communication between manufacturer and user cannot be overemphasized.

The chances for preventing hazardous incidents and limiting their consequences are greatly
improved when both user and manufacturer are correctly and fully informed with respect to the
intended use and all environmental and operating conditions.

The purpose and scope of this Standards Publication are given on page 1. The book consists of
the following clauses:

Clause 1Defines the scope of the standard, lists the referenced standards, and d efines
terms.
Clause 2Defines construction details which contribute to safety. It is intended to assist the
electrical manufacturer to design and build equipment with features which will reduce hazards
and also to assist the user and the manufacturer of t he driven equipment in the selection of
electrical equipment which has been designed and built to include features that contribute to
safety.
Clause 3Sets forth test requirements.
Clause 4Intended to guide the user and the manufacturer of the driven equipment in the
proper selection, installation, and operation of adjustable -speed drive systems. Since the
reduction of hazards depends greatly on how equipment is selected, installed and used, this
section points out possible hazards and suggests ways and me ans to reduce them.

ICS 7.1-2014 supplements NEMA ICS 7-2014 Industrial Control and Systems: Adjustable Speed
Drives.

The purpose of this standards publication is to define the construction and test requirements for
adjustable-speed drive systems and to provide recommendations for their selection, installation,
and operation in such a manner as to provide for the practical safeguarding of persons.

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NEMA standards publications are subject to periodic review. They are revised frequently to reflect
user input and to meet changing conditions and technical progress. Users should secure the latest
editions.

Comments will be welcomed. Proposed revisions to this standards publication should be

submitted to:

Senior Technical Director, Operations

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

This standards publication was approved by the NEMA Industrial Automation Control Products and
Systems Section. Section approval of this standard, however, does not necessarily imply that all
section members voted for its approval or participated in its development. At the time this
standard was approved, the Industrial Automation Control Products and Systems Section
consisted of the following members:

ABB Inc.Raleigh, NC
Bluffton Motor Works-Bluffton, IN
CARLO GAVAZZI, INC.Buffalo Grove, IL
Cummins, Inc.Minneapolis, MN
Danfoss VLT Drives-Milwaukee, WI
Delta Products Corporation-Research Triangle Park, NC
EatonMilwaukee, WI
Electro Switch CorporationWeymouth, MA
Elliott Control Company, Ltd.-Willis, TX
Emerson Electric Co.Saint Louis, MO
GEFairfield, CT
Generac Power Systems, Inc.-Waukesha, WI
Hubbell IncorporatedShelton, CT
Hypertherm Incorporated- Hanover, NH
Joslyn Clark Controls, Inc.Lancaster, SC
L-3 Communications/SPD TechnologiesAnaheim, CA
Master Controls Systems, Inc.Lake Bluff, IL
Mitsubishi Electric Automation, Inc.Vernon Hills, IL
Nidec Motor Corporation-Saint Louis, MO
Omron Electronics LLCHoffman Estates, IL
Phoenix Contact, Inc.Middletown, PA
Post Glover Resistors, Inc.Erlanger, KY
Reliance Controls CorporationRacine, WI
Rockwell AutomationMilwaukee, WI
Russelectric, Inc.Hinngham, MA
Schneider ElectricPalatine, IL
SEW-Eurodrive, Inc.Lyman, SC
Siemens Industry, Inc.Norcross, GA
TE Connectivity, Harrisburg, MA
TIAX LLC-Lexington, KY
Tornatech Inc.Saint-Laurent, Canada
Toshiba International CorporationHouston, TX
Vacon, Inc.-Milwaukee, WI
WAGO CorporationGermantown, WI
WEG Electric Corp.-Duluth, GA
Yaskawa Electric America, Inc.Waukegan, IL

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Section 1
GENERAL

1.1 SCOPE

These standards apply to all industrial equipment electrical components and wiring which are
parts of the electrical drive system, commencing at the point of connection of input power to these
components. They apply to open or enclosed electrical equipment for use on circuits which
operate from an alternating-current supply voltage of 600 volts or less.

These standards are intended for industrial equipment which will be installed in accordance with
the National Electrical Code and the manufacturers instructions. They are not considered
adequate for industrial equipment intended for use in locations which are designated as
hazardous in the National Electrical Code.

These standards are generally applicable, but there may be situations where a conflict with other
safety measures or operational requirements will necessitate that these standards be modified.

Excluded from this publication are:

a. Portions, subassemblies, or parts of motors or controllers to be used in the manufacture

of more complete controllers or drive systems
b. Main propulsion equipment for railroad and transit locomotive cars
c. Automotive equipment
d. Equipment for airborne or aerospace craf t
e. Equipment for household use
f. Equipment built to military specifications which conflict with or override the provisions of
this publication
g. Additional specific features required for use under unusual service conditions, in locations
involving hazardous atmospheres and hazardous projects
h. Systems for processes using electricity for purposes other than supplying and controlling
electric motors
i. Drive systems rated less than 1/4 horsepower
j. Drive systems for portable tools
k. Industrial electric trucks
l. Passenger elevators or moveable walkways or lifts
m. Marine equipment

1.2 DEFINITIONS

Refer to ICS 7, Part 1 for equipment definitions.

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1.3 REFERENCED STANDARDS

In this publication, reference is made, in part or in full, to the following standards listed below.
Copies are available from the indicated sources.

National Electrical Manufacturers Association

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

ICS 1-2000 (R2005) Industrial Control and Systems

General Requirements

ICS 1.1-1984 (R2003) Safety Guidelines for the Application, Installation and Maintenance of Solid-State
Control

ICS 1.3-1986 (R2001) Preventive Maintenance of Industrial Control and Systems Equipment

ICS 2-2000 (R2005) Industrial Control and Systems

Controllers Contactors and Overload Relays

ICS 7-2014 Industrial Control and Systems

Adjustable Speed Drives

ICS 4-2005 Industrial Control and Systems

Terminal Blocks

ICS 6-1993 (R2001) Industrial Controls and Systems

Enclosures

MG 1-2011 Motors and Generators

MG 2-2014 Safety Standards for Construction and Guide for Selection, Installation and Use of
Electric Motors and Generators

National Fire Protection Association

Batterymarch Park
Quincy, MA 02269

NFPA 70-2005 National Electrical Code

NFPA 70E-2004 Standard for Electrical Safety Requirements for Employee Workplaces

NFPA 79-2002 Electrical Standard for Industrial Machinery

Underwriters Laboratories Inc.

333 Pfingsten Rd.
Northbrook, IL 60062

UL 508C Standard for Power Conversion Equipment

UL 61800-5-1 Standard for Adjustable Speed Electrical Power Drive Systems: Part 5-1: Safety
Requirements Electrical, Thermal and Energy

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Section 2
CONSTRUCTION REQUIREMENTS

2.1 ADJUSTABLE SPEED DRIVE SYSTEM RATING

AND IDENTIFICATION PLATES

2.1.1 Motor Nameplates

Motors, both alternating-current and direct-current, shall be identified in accordance with MG 1.

2.1.2 Device Identification

Shall be in accordance with either UL 508C or UL 61800-5-1.

2.1.3 Basic Drive Module / Complete Drive Module (BDM / CDM) (Controller)
Nameplate
Shall be in accordance with either UL 508C or UL 61800-5-1.

2.2 OPERATING AND MAINTENANCE DATA

Warning labels and instruction documents shall be in accordance with either UL 508C or
UL 61800-5-1.

Documents should be of such a size and quality as to be clearly legible. The format and symbols
for diagrams should be in accordance with ICS 19.

2.3 SUPPLY CIRCUIT DISCONNECTING DEVICES

2.3.1 General

The requirements of clause 2.3 apply to the disconnecting means required by NFPA 70 National
Electrical Code, Article 430 if the devices used are supplied as a part of the control equipment.

If a device used for or as part of the disconnecting means is also used for any other function(s),
such as overcurrent protection, the requirements of t he other function(s) shall also be met.

2.3.2 Type

The disconnecting device shall be a switch or circuit breaker which clearly indicates whether it is
open or closed. Switches and circuit breakers which are normally power operated shall include
means for manual opening. The disconnecting devices may also have a tripped position which
shall be identified when this differs from the manually opened position.

If the main power disconnecting device is mounted in a control equipment enclosure, the
indication shall be visible outside of the enclosure.

Provisions for locking the disconnecting device may be necess ary in order to comply with the
NFPA 70.

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2.3.3 Rating

The ampacity of the disconnecting means shall be not less than 115 percent of the maximum
continuous current required for all equipment which may be in operation at the same time under
normal conditions. Refer to NFPA 70 Article 430.

The load interrupting capacity of the disconnecting device shall be not less than the maximum
operating overload current of the drive system.

2.3.4 Supply Conductors to be Disconnected

Disconnection of supply conductors, including remotely energized control and signal conductors,
shall be in accordance with NFPA 70, and NPFA 79 Chapter 5 if the PDS is part of an industrial
machine.

2.3.5 Mounting

Provision of main power disconnecting means and multiple disconnecting devices shall be in
accordance with NFPA 70, and NFPA 79 if the PDS is part of an industrial machine.

2.3.6 Operating Handle

Handle height and locking provisions shall be in accordance with NFPA 70 , Article 430.

2.3.7 Isolation

Isolation requirements shall be in accordance with NFPA 70 and either UL 508C or UL 61800-5-1.

2.4 PROTECTION

2.4.1 Interrupting Capacity

Devices which are intended to break short-circuit current shall have an interrupting capacity
sufficient for the voltage used and for the current that must be interrupted when the control
equipment or drive system is connected to a power supply having the capacity to apply maximum
voltage and maximum available short-circuit current within the limits specified for the equipment.
Refer also to UL 508C or UL 61800-5-1.

2.4.2 Control Circuit

Control circuit overcurrent protection shall be in accordance with UL 508C or UL 61800-5-1.

2.4.3 Undervoltage (Low-Voltage) Protection

Undervoltage protection shall be in accordance with NFPA 79.

2.4.4 Motor Overload

Motor overload protection shall be provided in accordance with NFPA 70, Article 430.

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2.4.5 Overcurrent (Short-Circuit) Protection

Short-circuit protection shall be in accordance with NFPA 70, Article 430 and either UL 508C or
UL 61800-5-1.

2.4.6 Power Transformer

A transformer shall be protected in accordance with NFPA 70, Article 450 and either UL 508C or
UL 61800-5-1.

2.4.7 Draining of Stored Charge

Capacitor discharge shall be in compliance with UL 508C or UL 61800 -5-1.

2.4.8 Short-Circuit Considerations for Equipment

Under normal operating conditions a power converter (controller) shall not create a hazard i n the
event of a short-circuit at any point within the power converter (controller) when it is connected to
a power source as specified on the nameplate and protected as specified in the installation
manual.

2.5 CONTROL CIRCUITS

2.5.1 General

Requirements for control circuits, except those noted in 2.5.2 shall be in accordance with
NFPA 79.

2.5.2 Interlocking

2.5.2.1 Plugging Circuits

All plugging switches or zero speed switches that are used to control the application or removal of
power in order that moving parts may be slowed down, stopped, or reversed shall be provided with
features incorporated in the control circuit to prevent the reapplication of power after the
completion of the plugging operation and to prevent the application of power th rough any manual
movement of the plugging switch shaft, or of the motor or equipment.

2.5.2.2 Bypass and Isolation Interlocked

All bypass and isolation circuits shall be protected from simultaneous energization unless
specifically designed by the manufacturer for simultaneous energization.

2.6 CONTROL DEVICES

2.6.1 AC Motor Starters

When operated, AC motor starters shall switch all of the power conductors leading to their
associated motors.

2.6.2 Contactors

Where a contactor having the coil circuit interlocked or sequenced such that in normal operation
the contactor does not make or break load current shall comply with UL 508C or UL 61800 -5-1.

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2.7 CONTROL ENCLOSURES

Enclosures shall be in accordance with UL 508C or UL 61800 -5-1.

2.8 INTERNAL CONDUCTORS

The internal conductors shall be protected from mechanical damage during assembly and
installation. The insulation, conductors and routing of all internal conductors shall be suitable for
the electrical, mechanical, thermal and environmental c onditions of use. Internal conductors shall
be in accordance with UL 508C or UL 61800-5-1.

2.9 WIRING METHODS AND PRACTICES

Wiring methods and practices shall be in accordance with NFPA 70 or NFPA 79 as appropriate,
and either UL 508C or UL 61800-5-1.

2.10 GROUNDED CIRCUITS AND EQUIPMENT GROUNDING

2.10.1 Enclosure Lighting Circuits and Convenience Outlets

Enclosure lighting circuits and convenience outlets shall be in accordance with NFPA 79.

2.10.2 Grounding

Grounding shall be in accordance with the NFPA 70 Article 250 and either UL 508C or
UL 61800-5-1.

2.11 SET-UP AND SERVICE REQUIREMENTS FOR ENERGIZED EQUIPMENT

2.11.1 Movable Assemblies

If a portion of the equipment carries more than 50 volts and can be moved into a position outside
of the volume occupied by the closed enclosure or into an aisle, the assembly shall include
guarding for circuits above 50 volts except where the short -circuit current for these voltages is
limited to less than 5 milliamperes.

2.11.2 Nonelectrical Apparatus

Nonelectrical apparatus shall not be located in the same compartment with electrical control
equipment unless the devices and their air, water, or hydraulic fluid supply lines are essential to
the operation of the electrical components. Nonelectrical apparatus shall not require servicing
while the electrical apparatus is energized.

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Section 3
TESTS

3.1 CONTROL EQUIPMENT AND SYSTEMS

Adjustable speed drives shall comply with the test requirements in UL 508C or UL 61800 -5-1.
Industrial control equipment and systems shall be capable of withstanding the high -potential tests
described in ICS 1, clause 8.

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Section 4
GUIDE FOR SAFETY IN THE APPLICATION OF
OF ADJUSTABLE-SPEED DRIVE SYSTEMS

4.1 SAFETY IN APPLICATION

4.1.1 Factors to be Considered

The applications for adjustable-speed drive systems are so numerous that exceptions can be cited
to almost every recommendation for safe application. Among the many factors that should be
considered in application are the following:

a. Electrical, thermal, and mechanical safety

b. Control safety
c. Functional safety including high-availability where the application requires exceptional
reliability for the protection of life and health, property, or perishable products.

Many adjustable speed drive systems make use of solid state devices in the power and control
circuits. ICS 1.1 should also be considered in the application and installation of adjustable speed
drives when solid state devices are involved.

4.1.2 Electrical and Thermal Safety

4.1.2.1 Protection Using Enclosures

Recommendations for motor enclosures are given in MG 2, clause 6.2. The required degree of
enclosure for motor controllers and drive systems should be established by the user or the
manufacturer of the driven equipment, considering the following:

a. Will the equipment be installed in:

1) Places regularly open to the public
2) Places frequented only by persons employed on the premises
3) Places accessible only to qualified personnel
b. Will the equipment be attended by an operator when it is in use
c. Does the enclosure discourage inappropriate use or approaches to the equipment
d. Is it possible to encounter hazard in the installed equipment if it is approached or serviced
in a manner other than the manner for which it was design ed? If so, are the hazards of
such actions visibly obvious to the personnel operating, servicing, and generally having
access to the equipment.

The following recommendations for the selection of enclosures are given as a guide. In addition, it
may be appropriate to make the equipment inaccessible by fencing, by isolation in a room by
additional enclosures, or by other means so access to the isolated areas is limited only to qualified
personnel. Qualified personnel are those who are familiar with the constr uction and operation and
maintenance of the equipment and the hazards involved.

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4.1.2.1.1 Application in Places Regularly Open to the Public

For those applications in places which are regularly open to the public and which cannot be
isolated from the public, only the following equipment should be used:

a. Motors as described in MG 2, clause 6.6.2.

b. Enclosed control and power conversion equipment with provision for locking or
padlocking doors. Consideration should be given to protection against finger access and
ingress of foreign objects and liquids typical for the installation site. See also NFPA 70
National Electrical Code, Article 110.

4.1.2.1.2 Application in Places Restricted to Persons Employed on the Premises

Many years of experience in industrial plants, light commercial installations, and other areas
where access to the equipment is normally restricted to persons employed on the premises have
established that the following equipment has a successful and satisfactory safety record:

a. Motors as described in MG 2, clause 6.6.3.

b. Enclosed control and power conversion equipment which requires a tool or key to open
c. Enclosed control and power conversion equipment with door interlocks which prevent the
opening of enclosure doors unless power is disconnected or which cause power to be
disconnected if doors are opened.
Consideration should be given to protection against finger access and ingress of foreign objects
and liquids typical for the installation site. See also NFPA 70 National Electrical Code, Article 110.

4.1.2.1.3 Application in Places Accessible Only to Qualified Personnel

Enclosures described in 4.1.2.1.1 and 4.1.2.1.2 may be used in places accessible only to
electrically qualified personnel. In addition, many years of experience in power plants and in other
applications where equipment is accessible only to qualified personnel have established that open
equipment has an acceptable safety record.

4.1.2.1.4 Protection inside enclosures

Occasionally during start up and maintenance, qualified personnel may require access to
energized equipment inside enclosures. Consideration should be given to protecting personnel
from shock hazards inside enclosures by using appropriately-designed components or providing
barriers which prevent accidental contact. Reference NFPA 79 for detailed requirements. Work
performed on energized equipment within enclosures must also consider the hazard of explosion
(arc blast) or arc flash as well as the hazard of electric shock. This is addressed in NFPA 70E ,
Annex K.

4.1.2.2 Incoming Line Equipment

For drives supplied without the disconnecting devices described in clause 2.3, external
disconnecting device(s) may be required in accordance with National Electrical Code,
Article 430, Parts VI, IX and X.

Disconnection is not required solely for remotely energized control and signal conductors in
locations where access is limited to qualified persons.

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For the protection of maintenance personnel, provisions may be needed for locking the
disconnecting or isolation means in the open position. Locking requirements, such as lock size or
number of locks to be used, should be user specified. See also clause 4.4. Disconnects should be
specified in accordance with the type, rating, and specific application of require ments given in the
National Electrical Code, paragraphs 430.101 through 430.113 and 430.128.

Certain types of drives such as ac adjustable-speed drives and drives with high harmonic content
can have a maximum continuous current at reduced speed higher th an the full-load current at
rated speeds. For such applications, the maximum continuous current should be used as a basis
for selection of equipment rating.

The required interruption capacity of incoming line equipment, particularly with respect to the
available fault current of the supply to which the power converter (controller) is to be connected,
should be coordinated between manufacturer and user. Application information on ratings or
protective settings of the protective devices is given in National Electrical Code, table 430.52
and discussed in paragraphs 430.51 through 430.5.

4.1.2.3 Isolation

Provision should be made in the design and installation of drive systems for electrical isolation
(disconnection) to permit work to be performed upon equipment. T he overall system supply
disconnecting device may provide this capability. However, when work must be performed upon
separately operable portions of a system at times when some portions remain under power ,
isolation (disconnection) means must be provided for the equipment of each portion.

The following requirements apply to any power isolating switch that is furnished to isolate a portion
of the electrical equipment of a drive system and that is not any part of the supply circuit
disconnecting means required by the National Electrical Code, Article 430, Parts VI, IX, and X.
Other requirements can be found in NFPA 79, Clause 5.5.
a. A warning label shall be placed adjacent to the operating handle stating that it does not
disconnect power from the equipment.
b. Where the isolating means is not intended to interrupt load current, a warning label shall
state DO NOT OPEN UNDER LOAD. This warning may be combined with the warning in
a. above.

4.1.2.4 Overcurrent Protection

Overcurrent protection must be provided to protect the supply conductors and drive system
against overcurrent in the event of short circuits or ground faults. Overcurrent protection must
conform to the published recommendations of the drive manufacturer as well as the requirements
of the National Electrical Code, Article 430, Parts IV, V, and VI. The overcurrent protection must
conform to the manufacturers recommendation for the drive and be coordinated with the short
circuit current rating of the supply and the provision for earthing of the syste m.

4.1.2.5 Power Supply Considerations

Some supply systems, such as floating, unearthed, IT, impedance grounded, Delta or Corner
earthed Delta, high-leg Delta, may not be suitable for a specific drive. Reference should be
made to the manufacturers installation instructions.

Unless appropriately rated, drives powered from floating or IT supply systems (which are not
referenced to earth potential) may result in excessive voltage between internal power circuits of
the drive and chassis. In some circumstances, this condition can cause a dangerous failure of the

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drive insulation system and some components. In order to avoid this condition, supply systems
should be referenced to earth either through a solid or impedance connection.

4.1.2.6 Earthing of System Components

All equipment, including each drive, must be provided with properly-sized protective earth (ground)
connections for safe operation, per NFPA 70 National Electric Code and NFPA 79.

4.1.2.7 User-Accessible Low Voltage Circuits

User-accessible signals and power sources such as communication circuits which connect the
drive system to other equipment such as PLCs must satisfy the requirements for PELV (Protective
Extra Low Voltage). This requirement applies to all equipment , both within the drive system and
external to the drive system, which is connected to PELV circuits. Details of this requirement are
provided in NFPA 79 Clause 6.4.

4.1.2.8 Thermal Safety for Braking Systems

When dynamic braking is used and the brake resistors are mounted external to the drive
enclosure(s), burn and fire hazards must be considered depending upon design and application
circumstances.

4.1.3 Control Safety

4.1.3.1 Automatic Restart

Automatic restart or run on power up should not be used for applications in which unexpected
starting of a machine may be hazardous to persons or property.

4.1.3.2 Interlocking

Electrical or mechanical interlocking or both is frequently used to assure a desired sequence or

prevent incorrect or dangerous operation. The following are examples of types of interlocking
which, when required, should be specified for adjustable -speed drive systems:

a. Limit switches to prevent over-travel of machine elements or interference with machine

movements.
b. Non-repeat control interlocking. The cycle does not repeat if the start button is held in the
closed position. It is necessary for the operator to release the start button and to push it
again to start a new cycle.
c. Door interlocks which prevent the opening of enclosure doors unl ess power is
disconnected or which cause power to be disconnected if doors are opened.
d. Interlocks to prevent the application of one polarity until the other polarity has been
disconnected, in cases where such simultaneous application would present a haz ard.
e. Interlocks to cause brakes to be set following a stop command.

4.1.3.3 Stop Functions

A variety of machine stopping functions are used in conjunction with adjustable-speed drives.
When experience has shown that a particular stopping method is sa tisfactory for use with a
particular application, that method may be used. Otherwise, it is necessary to specify stopping

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performance in terms of time or distance and to provide information concerning inertia and speed -
torque characteristics of the load.

The control requirements for initiating and maintaining certain stop modes are also important and
can be application-specific. In addition to the following information, the user should consider the
requirements found in NFPA 79, Clause 9.2 when specifying control requirements for stop.

Any specific requirements for stopping performance, such as may be required by a certain
industry, should be specified. In the absence of a specific requirement and where necessary to
avoid injury to personnel or damage to a machine, the motor should be stopped as quickly as
practical.

For emergency stop functions, reliability considerations may require a particular stopping method.
For example, a springset friction brake, properly maintained, is usually more reliable than a
method that depends upon the availability of adequate electric power supply. For some
applications, redundant stopping means may be necessary.

Where there is more than one mode of system operation, the modes for which each run/stop
device and protective function is to be effective should be specified.

4.1.3.4 Zero Speed Holding Torque Methods

After a Stop Function has been executed, the driven shaft speed may be addressed in any of the
following methods: 1) power is blocked from the motor without prov iding a holding torque 2) power
is blocked from the motor with holding torque applied by auxiliary device; or 3) power is applied to
the motor by the drive controller to achieve a holding torque , or, 4) power is applied to the motor
by the drive controller to achieve a holding torque and/or a holding torque is applied by an
auxiliary device. The typical drive provides method 1) Methods 2), 3) , and 4) require additional
specification for devices or drive controller functions.

4.1.3.5 Exposure to Moving Parts

Operating and maintenance personnel should not be exposed to the moving parts of a machine.
See also Clauses 4.3 and 4.4.

Some machinery requires that the operator periodically contact parts of the machine which have
been stopped but normally move. Examples of such operations include, but are not limited to,
loading and unloading of reels, spools or spindles, tool changing, and threading. In addition to the
applicable industry and government standards, which may apply to mechanical or electrical
guarding requirements of such applications, the zero speed requirements of the drive system must
also be considered.

When the output of a drive must be electronically inhibited to prevent a motion hazard, t he use of
a safe stop 1 or safe torque off capability which has been evaluated (and possibly certified by a
third party) for functional safety is recommended. Some applications may require that torque-
producing power to the motor be blocked by electromechanical isolation devices such as
contactors or switches. These isolation devices may be either mechanically or electrically
sequenced. The isolation devices may be located between the motor and the output of the
controller or between the input line and the controller depending upon the drive controller ty pe.
Where isolation is required by the application, this should be specified, and complete information
concerning the type, expected sequencing, and location in the power circuit of the isolation device
should be furnished.

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If a zero speed command (see 4.1.3.4) must be used (for example, during holding or position
keeping operation), the maintaining of zero speed condition during normal operation is dependent
upon the drift or accuracy of the signal source as well as the characteristics of the drive contro ller.
These factors must be carefully considered when determining the suitability of this method for
achieving and maintaining zero speed. Where zero speed regulation is required by the application,
this should be specified, and complete information concer ning load characteristics and accuracy
requirements should be furnished.

4.1.3.6 Speed Limitation

Adjustable-speed drives should be prevented from operating at speeds which could cause injury to
personnel or damage to the driving or driven machinery.

In many cases, the nature of the machine, the system, or the load will inherently prevent
excessive speed. When the machine is always under the manual control of a qualified operator, it
may be satisfactory to depend upon the machine operator to safely limi t the speed. In other cases,
it may be necessary for the drive to provide a safely limited speed function which has been
evaluated for functional safety. Alternatively, the machine designer may use additional equipment,
such as brakes, relays, or mechanical speed-limit devices to provide a safe limitation of system
speed.

Particular attention should be given to the following situations which may require provisions for
safe speed limiting:
a. An overhauling load
b. Machine loading or adjustment requiring the speed to be held below the maximum rated
speed of the drive equipment
c. A direct-current motor operating with weakened field excitation
d. A possible loss of load on a series-wound motor, or on motors connected in series, or on
a motor controlled by a torque regulator

Speed-limiting devices are seldom necessary for situations such as the following, in which the
inherent characteristics of the motor tend to limit speed:
a. When the motor drives a fan or other load for which the required torque increas es greatly
with speed
b. When alternating-current motors operate from a fixed-frequency supply

Section 430-89 in the National Electrical Code should be considered when determining the need
for speed-limiting devices.

4.1.3.7 Additional Control Safety Considerations

The applications for adjustable-speed drive systems are so numerous that exceptions can be cited
to almost every recommendation for safe application. Among the many factors that must be
considered are the following:

a. Overhauling loads:
Where the load is capable of delivering torque to the drive motor, as in hoists, non -
reversing non-inverting adjustable-speed drives may not be satisfactory.
b. High inertia loads:

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Where the reflected inertia of the load at the motor shaft is larger than t he motor rotor
inertia, additional consideration should be given to the rating and design of the drive,
such as the selection of the dynamic braking resistors.
c. Loss of conductor:
Where connections between the power source, power converter (controller) and motor
are made through sliding contacts, plug connectors or in any way in which continuity may
be lost, resulting in loss of control of the motor, specific precautions may be necessary to
prevent motor overspeed.
d. Overtravel protection:
Where reversing or stopping of the drive is required at the end of travel, it may be
desirable to provide back-up circuitry.
e. Redundant systems:
Where the application requires exceptional reliability for the protection of life, health,
property, or perishable products, the use of back-up equipment may be necessary.

4.1.3.8 Additional Guidance

Additional guidance on control safety applicable to drive systems can be found in NFPA 79 ,
chapter 9.

4.2 SAFETY IN INSTALLATION

4.2.1 Installation of Motors

Recommendations concerning installation of motors are provided in MG 2.

4.2.2 Installation of Control Equipment

4.2.2.1 Lifting

When lifting or moving equipment, the manufacturer's recommendations should be followed.

4.2.2.3 Codes and standards requirements

Installation of controllers and drive systems should be made in conformance with the NFPA 70
National Electrical Code, regulations of the Occupational Safety and Health Administration or
other national, regional, or industry codes and standards, or all of the above. Where appropriate,
consideration should also be given to the requirements of NFPA 79 Electrical Standard for
Industrial Machinery.

4.2.2.4 Lighting

Adequate lighting should be available for trouble-shooting and maintenance of the equipment.

4.2.2.5 Flooring

A noncombustible insulating floor or mat should be provided in the area immediately surrounding
the electrical system where maintenance is required.

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4.2.2.6 Locking Means

Lockout and tagout procedures will follow NFPA 70E.

4.2.2.7 Interconnecting Wiring

Where signal circuits such as those from speed-setting potentiometers and transducer outputs are
remotely located from the power converter (controller), the manufacturer's recommendations
concerning the isolation and wiring of signal circuits should be followed.

Since non-sinusoidal currents and voltages are generally present on the power conductors (both
input and output) of the drive, particular care should also be exercised in selection, segregation,
and installation of power conductors associated with the power converter and motor of the same
and adjacent drives. Other power conductors associated with a drive installation may also require
special consideration.The manufacturer's recommendations concerning acceptable wiring p ractice
must be followed to maintain good service continuity, prevent apparatus damage, and provide
expected performance.

4.2.2.8 Installation Workmanship

A safe and reliable installation requires careful attention to the installation of conduit and oth er
raceways, wire pullings, connections, etc., to avoid damage to conductor insulation and nicked
wire terminations, and to assure continuity of the conduit and equipment enclosure grounding
system. Unskilled workmen may be unaware of the requirements or h azards involved. It is
recommended that only qualified personnel be employed for installing electrical equipment.

4.3 SAFETY IN OPERATION

In some types of operations, persons exposed to moving parts of machinery may be subjected to
significant risks of injury by inadvertent startup of the machinery. Reference should be made to
NFPA 70E, which provides guidance regarding lockout -tagout procedures to control such risks.

Recommendations concerning the operation of motors are provided in MG 2.

Regardless of the care exercised in the design and manufacture of an adjustable -speed drive or in
the selection and rating of components, there are hazards which can be encountered if such
equipment is improperly operated.

It is sometimes possible to misadjust the equipment and thus produce unsatisfactory or unsafe
operation. The manufacturer's instructions should always be used as a guide for functional
adjustments. Personnel who are to have access to these adjustments (setup and operating
people) should be familiar with both the drive manufacturer's instructions and the machinery being
driven.

Only those operational adjustments which are actually needed by the operator, as for example,
speed setting, tension adjusting means, etc., should be accessible to him. Acces s to other
controls should be restricted to prevent unauthorized changes in operating characteristics.

Examples of improper (and perhaps unsafe) operation include:

a. Setting the speed too high or too low for the specific application
b. Changing the cycle or sequence of the machine beyond those conditions for which the
drive was originally designed
c. Changing the load being driven beyond the limits for which the equipment was intended

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d. Substituting an improperly rated motor or other components

e. Attempting to bypass design functions, for example, attempting to jog at rates higher than
the preset rate by using the start and stop function. The operator of the drive equipment
should be properly trained in the operation of the equipment. Provision of a writ ten
manual for use by supervisors in training new personnel should be considered.

4.4 SAFETY IN MAINTENANCE

In some types of maintenance activities, persons exposed to moving parts of machinery may be
subjected to significant risks of injury by inadvertent startup of the machinery. Reference should
be made to NFPA 70E, which in Part 11 provides guidance regarding lockout -tagout procedures to
control such risks.

Recommendations concerning safety in maintenance can be found in ICS 1.3 and in NFPA 70B.

2014 National Electrical Manufacturers Association