NEMA ICS 7.

1-2022

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

© 2022 by the 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.

The National Electrical Manufacturers Association (NEMA) standards and guideline publications, of which
the document contained herein is one, are developed through a voluntary consensus standards
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have an interest in the topic covered by this publication. While NEMA administers the process and
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of the statement.

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CONTENTS

Foreword ................................................................................................................................................. iii

Section 1 GENERAL ............................................................................................................................... 1
1.1 Scope ...................................................................................................................................... 1
1.2 Definitions ............................................................................................................................... 1
1.3 Referenced Standards ............................................................................................................ 1
Section 2 CONSTRUCTION REQUIREMENTS ..................................................................................... 3
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 ........................................................................................................................ 3
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 Overcurrent (Short-Circuit) Protection ....................................................................... 4
2.4.6 Power Transformer .................................................................................................... 4
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 ................................................................................................................. 5
2.8 Internal Conductors ................................................................................................................ 6
2.9 Wiring Methods and Practices ................................................................................................ 6
2.10 Grounded Circuits and Equipment Grounding ....................................................................... 6
2.10.1 Enclosure Lighting Circuits and Convenience Outlets .............................................. 6
2.10.2 Grounding .................................................................................................................. 6

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2.11 Setup and Service Requirements for Energized Equipment .................................................. 6

2.11.1 Movable Assemblies ................................................................................................. 6
2.11.2 Nonelectrical Apparatus ............................................................................................ 6
Section 3 TESTS ..................................................................................................................................... 7
3.1 Control Equipment and Systems ............................................................................................ 7
Section 4 GUIDE FOR SAFETY IN THE APPLICATION OF ADJUSTABLE-SPEED DRIVE
SYSTEMS ............................................................................................................................... 8
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.............................................................................................................. 13
4.2.1 Installation of Motors ............................................................................................... 13
4.2.2 Installation of Control Equipment ............................................................................ 13
4.3 Safety in Operation ............................................................................................................... 14
4.4 Safety in Maintenance .......................................................................................................... 15

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Foreword

In the preparation of this technical 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 overloads, 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, installation, 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 a hazardous condition
can occur, compliance with this publication does not by itself ensure 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 Electrical 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 technical publication are given on page 1. The book consists of the
following sections:

• Section 1—Defines the scope of the standard, lists the referenced standards, and defines terms.
• Section 2—Defines construction details that contribute to safety. It is intended to assist the
electrical manufacturer in designing and building equipment with features that will reduce hazards
and also to assist the user and the manufacturer of the driven equipment in the selection of
electrical equipment that has been designed and built to include features that contribute to safety.
• Section 3—Sets forth test requirements.
• Section 4—Intended 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 means to reduce them.

NEMA ICS 7.1-2022 supplements NEMA ICS 7-2020 Industrial Control and Systems: Adjustable-Speed
Drives.

The purpose of this technical 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.

NEMA technical 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.

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Comments will be welcomed. Proposed revisions to this technical publication should be submitted to:

NEMA Technical and Industry Affairs Department

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

This technical 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.—Cary, NC
CARLO GAVAZZI, INC.—Buffalo Grove, IL
Cummins, Inc.—Minneapolis, MN
Danfoss VLT Drives—Loves Park, IL
Delta Products Corporation—Research Triangle Park, NC
Eaton—Menomonee Falls, WI
Electro Switch Corporation—Weymouth, MA
Elliott Control Company, Ltd.—Willis, TX
Emerson Electric Co.—Saint Louis, MO
Fuji Electric Corporation—Edison, NJ
Generac Power Systems, Inc.—Waukesha, WI
Hubbell Incorporated—Shelton, CT
Hypertherm Incorporated—Hanover, NH
Legrand North America—New London, CT
Master Controls Systems, Inc.—Lake Bluff, IL
Mitsubishi Electric Automation, Inc.—Vernon Hills, IL
Nidec Motor Corporation—Saint Louis, MO
Phoenix Contact, Inc.—Middletown, PA
Post Glover Resistors, Inc.—Erlanger, KY
Reliance Controls Corporation—Racine, WI
Rockwell Automation—Milwaukee, WI
Schneider Electric—Andover, MA
SEW-Eurodrive, Inc.—Lyman, SC
Siemens Industry, Inc.—Norcross, GA
TE Connectivity—Harrisburg, PA
TECO-Westinghouse Motor Company—Round Rock, TX
Toshiba International Corporation—Houston, TX
Turntide Technologies—Sunnyvale, CA
WAGO Corporation—Germantown, WI
Weidmuller Inc.—Richmond, VA
WorldWide Electric Corporation—Rochester, NY
Yaskawa 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 that 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 DC drive systems connected to line voltages up to 1.5 kVAC or DC,
50 Hz or 60 Hz, and AC drive systems with converter input voltages up to 1.5 kV, 50 Hz or 60 Hz, and
output voltages up to 1.5 kV.

These standards are intended for industrial equipment that will be installed in accordance with the
National Electrical Code and the manufacturer’s instructions. They are not considered adequate for
industrial equipment intended for use in locations that 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 craft
e. Equipment for household use
f. Equipment built to military specifications that 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 for 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. All electric vehicles
l. Passenger elevators or movable walkways or lifts
m. Marine equipment
n. Grid interactive inverters to connect distributed generation to the electrical grid
o. Traction drives

1.2 Definitions

Refer to ICS 7, Part 1, for equipment definitions.

1.3 Referenced Standards

This standard incorporates by reference provisions from other publications. These normative references
are cited at the appropriate places in the text, and the publications are listed below. For undated
references, the latest edition of the publication referred to applies (including amendments).

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NEMA ICS 1 Industrial Control and Systems: General Requirements

NEMA ICS 1.1 Safety Guidelines for the Application, Installation, and Maintenance of Solid State
Control

NEMA ICS 1.3 Preventive Maintenance of Industrial Control and Systems Equipment

NEMA ICS 7 Industrial Control and Systems: Adjustable-Speed Drives

NEMA ICS 19 Diagrams, Device Designations, and Symbols for Industrial Control and Systems

NEMA MG 1 Motors and Generators

NEMA MG 2 Safety Standard and Guide for Selection, Installation, and Use of Electric Motors
and Generators

IEC 60417 Graphical symbols for use on equipment

IEC 61800-5-2 Adjustable speed electrical power drive systems - Part 5-2: Safety requirements -
Functional

NFPA 70 National Electrical Code

NFPA 70B Recommended Practice for Electrical Equipment Maintenance

NFPA 70E Standard for Electrical Safety in the Workplace

NFPA 79 Electrical Standard for Industrial Machinery

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

UL 61800-5-2 Adjustable Speed Electrical Power Drive Systems - Part 5-2: Safety
Requirements - Functional

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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 NEMA MG 1.

2.1.2 Device Identification

Shall be in accordance with UL 61800-5-1.

2.1.3 Basic Drive Module / Complete Drive Module (BDM / CDM) (Controller) Nameplate

Shall be in accordance with UL 61800-5-1.

2.2 Operating and Maintenance Data

Warning labels and instruction documents shall be in accordance with 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 IEC 60417 or NEMA ICS 19.

2.3 Supply Circuit Disconnecting Devices

2.3.1 General

The requirements of Section 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 the other function(s) shall also be met.

2.3.2 Type

The disconnecting device shall be a switch or circuit breaker that clearly indicates whether it is open or
closed. Switches and circuit breakers that are normally power operated shall include means for manual
opening. The disconnecting devices may also have a tripped position that 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 necessary in order to comply with NFPA 70
National Electrical Code.

2.3.3 Rating

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

Consideration shall also be given to the short-circuit withstand rating and to the ability of the
disconnecting device to interrupt current during an overload condition.

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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 National Electrical Code, and NFPA 79 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 National Electrical Code, 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 UL 61800-5-1 and NFPA 70 National
Electrical Code.

2.3.7 Isolation

Isolation requirements shall be in accordance with NFPA 70 National Electrical Code and UL 61800-5-1.

2.4 Protection

2.4.1 Interrupting Capacity

Devices that are intended to break short-circuit current shall have an interrupting capacity at nominal
circuit voltage at least equal to maximum available short-circuit current that is available at the line
terminals of the devices. Devices that are intended to interrupt current at other than short-circuit levels
shall have an interrupting capacity at nominal circuit voltage at least equal to the current that must be
interrupted.

Refer also to UL 61800-5-1.

2.4.2 Control Circuit

Control circuit overcurrent protection shall be in accordance with NFPA 70 National Electrical Code and in
compliance with manufacturer’s instructions.

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 the requirements of UL 61800-5-1 and
NFPA 70 National Electrical Code Article 430.

2.4.5 Overcurrent (Short-Circuit) Protection

Short-circuit protection shall be in accordance with NFPA 70 National Electrical Code Article 430 and UL
61800-5-1.

2.4.6 Power Transformer

A transformer internal to the drive shall be protected in accordance with UL 61800-5-1.

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A transformer external to the drive shall be protected in accordance with NFPA 70 National Electrical
Code Article 450.

2.4.7 Draining of Stored Charge

Capacitor discharge shall be in compliance with 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 in 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

Control circuits internal to the drive shall be protected in accordance with UL 61800-5-1.

Control circuits external to the drive shall be protected in accordance with NFPA 70 National Electrical
Code.

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 through 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.

2.5.2.3 Safety Interlock

Safety interlock circuits shall have surge protection installed. Refer to NFPA 70 National Electrical Code
Article 670.

2.6 Control Devices

2.6.1 AC Motor Starters

When operated, AC motor starters shall simultaneously 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 in such a way that in normal operation
the contactor does not make or break the load current, it shall comply with UL 61800-5-1.

2.7 Control Enclosures

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

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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 conditions of use. Internal conductors shall be in accordance
with UL 61800-5-1.

2.9 Wiring Methods and Practices

Wiring methods and practices shall be in accordance with UL 61800-5-1 and either NFPA 70 National
Electrical Code or NFPA 79 as appropriate.

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 NFPA 70 National Electrical Code Article 250 and UL 61800-5-1.

2.11 Setup 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. Refer to Section 4.

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. Refer to Section 4.

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Section 3
TESTS

3.1 Control Equipment and Systems

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

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Section 4
GUIDE FOR SAFETY IN THE APPLICATION 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.
NEMA 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 Section 6.2 of NEMA MG 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 designed? 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 that access to the isolated areas is limited only to qualified personnel.
Qualified personnel are those who are familiar with the construction and operation and maintenance of
the equipment and the hazards involved.

4.1.2.1.1 Application in Places Regularly Open to the Public

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

a. Motors as described in Section 6.6.2 of NEMA MG 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.

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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 Section 6.6.3 of NEMA MG 2

b. Enclosed control and power conversion equipment that requires a tool or key to open
c. Enclosed control and power conversion equipment with door interlocks that prevent the opening
of enclosure doors unless power is disconnected or that 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 Sections 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 startup 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 that 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.

4.1.2.2 Incoming Line Equipment

For drives supplied without the disconnecting devices described in Section 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.

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 Section 4.4. Disconnects should be specified in accordance with
the type, rating, and specific application of requirements given in Articles 430.101 through 430.113 and
430.128 of the National Electrical Code.

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 than 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 Table 430.52 and discussed in Articles 430.51 through 430.58 of the
National Electrical Code.

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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. The 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 Article 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
manufacturer’s recommendation for the drive and be coordinated with the short-circuit current rating of
the supply and the provision for earthing of the system.

4.1.2.5 Power Supply Considerations

Some supply systems, such as “floating,” unearthed, “IT,” impedance grounded, Delta or Corner earthed
Delta, and “high-leg Delta,” may not be suitable for a specific drive. Reference should be made to the
manufacturer’s 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 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.

All equipment, including each drive, must be provided with properly sized power connections for safe
operation, per NFPA 70 National Electrical Code and NFPA 79.

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 Electrical Code and NFPA 79.

4.1.2.7 User-Accessible Low Voltage Circuits

User-accessible signals and power sources such as communication circuits that 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,
that is connected to PELV circuits. Details of this requirement are provided in NFPA 79 Article 6.4.

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

a. Limit switches to prevent overtravel 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 that prevent the opening of enclosure doors unless power is disconnected or that
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 hazard.
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 satisfactory for use with a particular
application, that method may be used. Otherwise, it is necessary to specify stopping 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 Article 9.2 when specifying control requirements for stopping.

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 are 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 providing a holding torque; 2) power is blocked from

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the motor with holding torque applied by an auxiliary device; 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
Sections 4.3 and 4.4.

Some machinery requires that the operator periodically contact parts of the machine that 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 that 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, the use of a “safe
stop 1” or “safe torque off” capability that complies with the requirements of UL 61800-5-2 or IEC 61800-
5-2 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 type. 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.

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 controller. 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 concerning load characteristics and accuracy requirements should be furnished.

4.1.3.6 Speed Limitation

Adjustable-speed drives should be prevented from operating at speeds that 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 limit the speed. In other cases, it may be
necessary for the drive to provide a “safely limited speed” function that complies with the requirements for
functional safety according to UL 61800-5-2 or IEC 61800-5-2. 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 that 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

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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 increases greatly with
speed
b. When alternating-current motors operate from a fixed-frequency supply

Article 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
Where the reflected inertia of the load at the motor shaft is larger than the 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 or 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 backup circuitry.
e. Redundant systems
Where the application requires exceptional reliability for the protection of life, health, property, or
perishable products, the use of backup 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 Article 9.

4.2 Safety in Installation

4.2.1 Installation of Motors

Recommendations concerning installation of motors are provided in NEMA 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.

4.2.2.2 Codes and Standards Requirements

Installation of controllers and drive systems should be made in conformance with NFPA 70 National
Electrical Code; regulations of the Occupational Safety and Health Administration or other national,

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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.

4.2.2.3 Lighting

Adequate lighting should be available for troubleshooting and maintenance of the equipment.

4.2.2.4 Flooring

Flooring shall be of significant strength to support the equipment installed.

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

4.2.2.5 Locking Means

Lockout and tagout procedures shall follow NFPA 70E.

4.2.2.6 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 practice must be followed to maintain
good service continuity, prevent apparatus damage, and provide expected performance.

4.2.2.7 Installation Workmanship

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

4.2.2.8 Environmental Considerations

Ensure environmental conditions comply with the manufacturer’s recommendations.

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 in Part 11 provides guidance regarding lockout-tagout procedures to control such risks.

Recommendations concerning the operation of motors are provided in NEMA 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 that 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

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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 that are actually needed by the operator, as for example, speed
setting, tension adjusting means, etc., should be accessible to them. Access 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.
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 written manual for use by
supervisors in training new personnel should be considered.

Ensure environmental conditions comply with the manufacturer’s recommendations.

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 Article 11 provides guidance regarding lockout-tagout procedures to control such
risks.

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

© 2022 National Electrical Manufacturers Association