SA08302002E - Control Panel Design Guide

Control panel design guide
UL 508A control panel design guide

The easy-to-design guide for selection of electrical control components in control panels used in industrial machinery applications
This guide is provided to assist with the design of control panels per ULT 508A, specifically for use in industrial machinery applications. This guide is designed to cover the most common applications of electrical control products per UL 508A, but is by no means an exhaustive guide, and does not cover all uses and applications associated with UL 508A regulations. This guide is not intended to be used in lieu of UL 508A or other regulatory standards. Always consult all pertinent actual regulatory standards and local standard representatives to ensure full compliance.
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Designing the panel

Feeder Main Multi-Load Panel 4
Feeder Main
See Page 4
Feeder Main Feeder

Main See Page 4
Feeder Main
Group Motor 6
Single Motor Panel Individual Circuit for Motor Load

Branch Protection Branch Branch Protection Protection Branch Branch Protection Protection Branch Branch Protection Protection Branch Protection Branch Protection Branch Protection
Heater or Lighting Lead OR Power Transformer or Power Circuit Supply Wiring

M L M
14
Controller
Controller Controller
Transformer or Power Controller Supply M
Transformer or Power Supply M L M
Controller
Transformer or Power Controller Supply M Overload Protection L M
16
Overload Protection
Overload Overload Protection Protection
Overload Protection
L M
Overload Protection
Accessories 19
Group MotorMultiple Motors Protected Motors Protected Individual CircuitIndividual Circuit Heater or Group MotorMultiple for Motor Load for Motor Load Lighting Load by a Single Set of FusesSingle Set of Fuses or Breaker by a or Breaker
See Page 6 See Page 6 See Page 8 See Page See Page 8 14
Control Heater or Circuit Lighting Load

See Page See Page 14 20
Control Circuit
See Page 20
Single Motor Load

See Page 31
Control Single Motor Circuit Load

See Page See Page 31 20
Control Circuit
See Page 20 Circuit
Control
20
Single Motorload
31
Sizing the feeder

The feeder amp rating is sized based on the sum of the amp rating of the largest branch protective device plus the fullload currents of the other loads. In this example, the 125A circuit breaker is the largest short-circuit protective device. This value is added to the full load currents of the other loads in the circuit (motors, heater, and the primary of the transformer). The overcurrent feeder amp rating should not exceed the conductor ampacity rating on the loadside. For conductor ampacity ratings, see Table 28.1 on Page 18.
Circuit Breaker 50A Circuit Breaker 125A Circuit Breaker 25A Fuses 6A Circuit Breaker 175A
Reference Section 32.3.1 a
Overload Protection
Overload Protection
Overload Protection
Controller
Controller
Controller
Controller
Controller
Overload Protection
Motor Load 3.4 FLA
Motor Load 7.6 FLA
Motor Load 14 FLA
Motor Load 65 FLA
Heater Load 20A
Transformer Load (Primary Side) 1.95A
Example Multi-Load Panel
125A + 3.4A + 7.6A + 14A + 20A + 2A = 172A Use closest size, 175A
Breaker and Fused Disconnect Selection

Molded Case Circuit Breaker Rotary Fusible Disconnect (Fuses not Included)
EG Frame
Target Ampacity Breaker Frame
NEMA 1/12/3R Rotary Handle Mechanism, 12 Shaft for EG EGHMVD12B

25 kA 480V 65 kA 240V
JG Frame
25 kA 480V 35 kA 240V
EMA 1/12/3R Rotary Handle Mechanism, 12 Shaft for JG JGHMVD12B

35 kA 480V 65 kA 240V
LG Frame
NNEMA 1/12/3R Rotary Handle Mechanism, 12 Shaft for LG LGHMVD12B

100 kA @ 600V with Class J 200 kA 600V with Class J
18 kA 480V 25 kA 240V
65 kA 480V 65 kA 480V 100 kA 480V 100 kA 240V 100 kA 240V 200 kA 240V
1 3 6 10 15 20 25 30 35 40 45 50 60 70 80 90 100 110 125 150 175 200 225 250 300 350 400 450 500 600
EG EG EG EG EG EG EG EG EG EG EG EG EG EG EG EG EG EG EG JG JG JG JG JG LG LG LG LG LG LG
EGB3015FFG EGB3015FFG EGB3015FFG EGB3015FFG EGB3015FFG EGB3020FFG EGB3025FFG EGB3030FFG EGB3035FFG EGB3040FFG EGB3045FFG EGB3050FFG EGB3060FFG EGB3070FFG EGB3080FFG EGB3090FFG EGB3100FFG EGB3125FFG EGB3125FFG
JGE3150FAG JGE3175FAG JGE3200FAG JGE3225FAG JGE3250FAG
EGE3015FFG EGE3015FFG EGE3015FFG EGE3015FFG EGE3015FFG EGE3020FFG EGE3025FFG EGE3030FFG EGE3035FFG EGE3040FFG EGE3045FFG EGE3050FFG EGE3060FFG EGE3070FFG EGE3080FFG EGE3090FFG EGE3100FFG EGE3125FFG EGE3125FFG
JGS3150FAG JGS3175FAG JGS3200FAG JGS3225FAG JGS3250FAG LGE3300FAG LGE3350FAG LGE3400FAG LGE3500FAG LGE3500FAG LGE3600FAG
EGH3015FFG EGH3015FFG EGH3015FFG EGH3015FFG EGH3015FFG EGH3020FFG EGH3025FFG EGH3030FFG EGH3035FFG EGH3040FFG EGH3045FFG EGH3050FFG EGH3060FFG EGH3070FFG EGH3080FFG EGH3090FFG EGH3100FFG EGH3125FFG EGH3125FFG
JGH3150FAG JGH3175FAG JGH3200FAG JGH3225FAG JGH3250FAG LGH3300FAG LGH3350FAG LGH3400FAG LGH3500FAG LGH3500FAG LGH3600FAG
EGC3015FFG EGC3015FFG EGC3015FFG EGC3015FFG EGC3015FFG EGC3020FFG EGC3025FFG EGC3030FFG EGC3035FFG EGC3040FFG EGC3045FFG EGC3050FFG EGC3060FFG EGC3070FFG EGC3080FFG EGC3090FFG EGC3100FFG EGC3125FFG EGC3125FFG JGC3150FAG JGC3175FAG JGC3200FAG JGC3225FAG JGC3250FAG LGU3300FAG LGU3350FAG LGU3400FAG LGU3500FAG LGU3500FAG LGU3600FAG
Base R4H3030FJ NEMA 1, 3R, 12 handle PHB1N12F 12" shaft SF320PH5X5 Fuse type Class J Integrated lugs #14#10
Base R9J3030FJ NEMA 4X handle PHB1N4XF 12" shaft SF320PH10X10 Fuse type Class J Terminal lugs #10#6
Base R9K3060FJ NEMA 4X handle PHB2N4XF 12" shaft SF320PH10X10 Fuse type Class J Integrated lugs #10#6
Base R9K3100FJ NEMA 4X handle PHB2N4XF 12" shaft SF320PH10X10 Fuse type Class J Terminal lugs #121 Base R9K3200FJ NEMA 4X handle PHB2N4XF 12" shaft SF320PH10X10 Fuse type Class J Terminal lugs #63/0
Base R9K3400FJ NEMA 4X handle PHB2N4XF 12" shaft SF320PH10X10 Fuse type Class J Terminal lugs #2600 kcmil
Base R9K3600FJ NEMA 4X handle PHB3N4XF 12" shaft SF320PH12X12 Fuse type Class J Terminal lugs 2x #22x 600 kcmil
Group motor design

The following rules apply to manual motor controllers for motor loads only: A single set of fuses or breaker can be used if the following conditions are met:
Branch Protection
Reference Section 31.4.1 c
1. All power circuit devices are rated for group motor use as indicated on the component, heater tables or instruction publication. 2. The following tap rule (31.4.3) is met: a. The conductors to the individual loads are not less than 1/10 the ampacity of the branch circuit protection for each circuit provided with a manual motor controller (MMC) marked Suitable as tap conductor protection in group installations. Also, the conductors on the load side of the MMC shall not have an ampacity less than 125% of the motor FLA. 3. The branch circuit protection is sized by the sum of the following: a. If the branch protection is a breaker, 250% of the largest motor FLA, plus the sum of the remaining motor loads, b. If the branch protection is a time delay fuse, 175% of the largest motor FLA, plus the sum of the remaining motor loads, or c. If the branch protection is a CC fuse, 300% of the largest motor FLA, plus the sum of the remaining motor loads. 4. The branch circuit protection must not exceed the amp rating as specified in the group installation marking of the power circuit components and the type specified.
XT Manual Motor Controller (XTSC)
Controller
Controller
Controller
Overload Protection
Overload Protection
Overload Protection
Group MotorMultiple Motors Protected by a Single Set of Fuses or Breaker
Note: UL 508 Type F combination motor controllers (XTFC) are self-protected and do not limit the upstream protective devices.
6
Manual Motor Controllers Short-Circuit Ratings for UL/CSAT Group Installations

XTSC and XTSR Manual Motor Controllers (MMC) / Starter Combinations Group Installation, UL/CSA Assembled Controller Non-Reversing Reversing FLA Adjustment Range/Overload ReleaseIr (Amps) Maximum rms Symmetrical Short-Circuit Ratings (kA) 240V 480V 600V Maximum Upstream Protective Device (Amps) Maximum Fuse 600V Maximum Circuit Breaker 600V
XTSC and XTSR Frame B MMP + Frame B Contactor XTSCP16BBA XTSCP25BBA XTSCP40BBA XTSCP63BBA XTSC001BBA XTSC1P6BBA XTSCAP5BBA XTSC004BBA XTSC6P3BBA XTSC010BBA XTSC012BBA XTSC016BBA XTSC016BCA XTSC020BCA XTSC025BCA XTSC032BCA XTSC016DCA XTSC025DCA XTSC032DCA XTSC040DDA XTSC050DDA XTSC058DDA XTSC063DDA XTSRP16BBA XTSRP16BBA XTSRP40BBA XTSRP63BBA XTSR001BBA XTSR1P6BBA XTSR2P5BBA XTSR004BBA XTSR6P3BBA XTSR010BBA XTSR012BBA XTSR016BCA XTSR020BCA XTSR025BCA XTSR032BCA XTSR016DCA XTSR025DCA XTSR032DCA XTSR040DDA XTSR050DDA XTSR058DDA XTSR063DDA 0.10.16 0.160.25 0.250.4 0.40.63 0.631 11.6 1.62.5 2.54 46.3 6.310 812 1016 1016 1620 20-25 2532 1016 1625 2532 32-40 4050 5058 5563 50 50 50 50 50 50 50 50 50 22 10 10 10 10 10 5 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 22 10 10 10 10 10 5 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 22 10 10 10 10 10 5 10 10 10 10 10 600 600 600 600 600 600 600 600 600 150 150 150 150 150 150 150 600 600 600 600 600 600 600 600 600 600 600 600 600 600 125 125 125 125 125 125 125 600 600 600 600 600
XTSC and XTSR Frame B MMP + Frame C Contactor
XTSC and XTSR Frame D MMP + Frame C Contactor
XTSC and XTSR Frame D MMP + Frame D Contactor
Note: Products are shown with a 120 Vac coil. For other coil voltages, replace the "A" suffix with the corresponding letter from the following table.
Coil Voltage Suffix
120 Vac 24 Vdc 24 Vac 240 Vac
A TD T B
Refer to Page 5 for breaker part numbers and to Page 19 for fuse base part numbers.
7
Individual circuit for motor load

There are several ways to build a branch circuit for a motor load. Each method provides short-circuit protection, motor overload protection, and the ability to start and stop the motor. Some additionally provide a means to disconnect the branch circuit for maintenance and safety purposes. UL 508 Type F Combination Motor Controllers (CMCs) (manual motor protector + contactor + line-side adapter) provide the most efficient means to build a branch circuit for a motor. CMCs are designed for motor loads such that they do not need to be oversized (as breakers and fuses are) to prevent tripping during motor startup. CMCs not only take up less space, but also install more quickly. For selection of motor branch circuits for 240V, refer to Pages 10 and 11.
Individual Circuit for Motor Load
Reference Sections 31.3, 33.2, 34.2, 66.8
Branch Protection
Controller
Overload Protection
For selection of motor branch circuits for 480V, refer to Pages 12 and 13.
Motor Branch Circuit Types

Motor Branch Devices Fuse and Starter Breaker and Starter Motor Circuit Protector and Starter Combination Motor Controller (Type F)
Fuses Short-circuit protection
Breaker Motor disconnect Short-circuit protection
MCP Motor disconnect Short-circuit protection
CMC Motor disconnect Short-circuit and motor overload protection Motor controller
Contactor Motor controller Overload relay Motor overload protection
Branch circuit functions Disconnect function Short-circuit protection Motor controller Motor overload protection Installation Installation effort Line-side commoning links Usability Controller options Resetability after short circuit Protection Sizing protective devices Disconnect (separate) Fuse block/fuses Contactor Overload relay High Not available Remote Replacement fuses necessary Fuses are sized up to 300% of the FLA to prevent nuisance tripping during startup. Because the fuses are oversized for the motor FLA, an overload relay is also needed. No, unless provided in a separate disconnect Low Moderate Breaker Breaker Contactor Overload relay Moderate Not available Remote Reset breaker switch Breakers are sized up to 250% of the FLA to prevent nuisance tripping during startup. Because the breaker is oversized for the motor FLA, an overload relay is also needed. Yes, with breaker accessory Moderate Moderate
Quantity Frame B
Motor circuit protector Motor circuit protector Contactor Overload relay Moderate Not available Remote Reset MCP switch MCPs are sized up to 800 to 1100% of the FLA to prevent nuisance tripping during startup. Because the MCP provides no thermal protection, an overload relay is needed. Yes, with MCP accessory Moderate Moderate
C D
Manual motor protector Manual motor protector Contactor Manual motor protector Low Yes Manual or remote Reset CMC switch CMCs are sized according to the motor FLA to provide overload protection. The CMC includes short circuit that is designed to mimic the motor inrush (14 times FLA). Included in MMP Low Low
F G
Safety Padlockable provision Cost Component price Panel space (and cost)
Components used to build a reversing contactor For reversing applications, the contactors should have mechanical and electrical interlocks. For Frame B, use contactors with a built-in NC auxiliary (ending in B01A instead of B10A).
2 2 1 1
Contactor Mechanical interlock Reversing link kit
XTCE...B01 XTCEXMLB XTCEXRLB
XTCE...C01 XTCEXFAC20 XTCEXMLC XTCERLC
XTCE...D00 XTCEXFBG11 XTCEXMLD XTCEXRLD
XTCE...F00 XTCEXFBG11 XTCEXMLG XTCEXRLG
XTCE...G00 XTCEXFBG11 XTCEXMLG XTCEXRLG
Auxiliary contact (front) XTCEXFAC20
Branch Motor Selection for 230 Vac

HP (230V) FLA Minimum Wire Size (AWG) 1/2 2.2 14 3/4 3.2 14 1 4.2 14 1-1/2 6 14 2 6.8 14 3 9.6 14 5 15.2 12 7-1/2 22 10
Fuse amperage Fuse type Contactor Auxiliary contact Thermal overload relay Overload range (A) Fuse Starter SCCR (kA) Breaker Breaker size (A) Contactor Auxiliary contact Thermal overload relay Overload range (A) Breaker Starter SCCR (kA) Motor circuit protector Contactor Auxiliary contact Thermal overload relay Overload range MCP-Starter SCCR (kA) Combination motor controller Overload range (A) SCCR (kA) CMC
A UL Pending.
3 CC XTCE007B10A 1NO aux built-in XTOB2P4BC1 1.6 to 2.4 100 EGH015FFG 15 XTCE007B10A 1NO aux built-in XTOB2P4BC1 1.6 to 2.4 HMCP003A0C XTCE007B10A 1NO aux built-in XTOB2P4BC1 1.6 to 2.4 35 XTFC2P5BBA 1.6 to 2.5 65
6 CC XTCE007B10A 1NO aux built-in XTOB004BC1 2.4 to 4.0 100 EGH015FFG 15 XTCE007B10A 1NO aux built-in XTOB004BC1 2.4 to 4.0 HMCP007C0C XTCE007B10A 1NO aux built-in XTOB004BC1 2.4 to 4.0 35 XTFC004BBA 2.5 to 4.0 65
10 CC XTCE007B10A 1NO aux built-in XTOB006BC1 4 to 6 100 EGH015FFG 15 XTCE007B10A 1NO aux built-in XTOB006BC1 4 to 6 HMCP007C0C XTCE007B10A 1NO aux built-in XTOB006BC1 4 to 6 15 XTFC6P3BBA 4 to 6.3 65
15 CC XTCE007B10A 1NO aux built-in XTOB010BC1 6 to 10 100 EGH015FFG 15 XTCE007B10A 1NO aux built-in XTOB010BC1 6 to 10 HMCPE015E0C XTCE007B10A 1NO aux built-in XTOB010BC1 6 to 10 65 XTFC6P3BBA 4 to 6.3 65
15 CC XTCE007B10A 1NO aux built-in XTOB010BC1 6 to 10 100 EGH015FFG 15 XTCE007B10A 1NO aux built-in XTOB010BC1 6 to 10 HMCPE015E0C XTCE007B10A 1NO aux built-in XTOB010BC1 6 to 10 65 XTFC010BBA 6.3 to 10 65
15 CC XTCE009B10A 1NO aux built-in XTOB010BC1 6 to 10 100 EGH020FFG 20 XTCE009B10A 1NO aux built-in XTOB010BC1 6 to 10 HMCPE015E0C XTCE009B10A 1NO aux built-in XTOB010BC1 6 to 10 65 XTFC010BBA 6.3 to 10 65
30 J XTCE015B10A 1NO aux built-in XTOB016BC1 12 to 16 100 EGH030FFG 30 XTCE015B10A 1NO aux built-in XTOB016BC1 12 to 16 HMCPE030H1C XTCE015B10A 1NO aux built-in XTOB016BC1 12 to 16 65 XTFC016BBA 10 to 16 50
40 J XTCE025C10A 1NO aux built-in XTOB024CC1 16 to 24 100 EGH040FFG 40 XTCE025C10A 1NO aux built-in XTOB024CC1 16 to 24 50 kA A HMCPE030H1C XTCE025C10A 1NO aux built-in XTOB024CC1 16 to 24 65 XTFC025BCA 20 to 25 18
10
Branch Motor Selection for 230 Vac, continued

HP (230V) FLA Minimum Wire Size (AWG) 10 28 8 15 42 6 20 54 4 25 68 4 30 80 3 40 104 1 50 130 2/0 60 154 3/0
Fuse amperage Fuse type Contactor Auxiliary contact Thermal overload relay Overload range (A) Fuse Starter SCCR (kA) Breaker Breaker size (A) Contactor Auxiliary contact Thermal overload relay Overload range (A) Breaker Starter SCCR (kA) Motor circuit protector Contactor Auxiliary contact Thermal overload relay Overload range (A) MCP-Starter SCCR (kA)
50 J XTCE032C10A 1NO aux built-in XTOB032CC1 24 to 32 100 EGH050FFG 50 XTCE025C10A 1NO aux built-in XTOB032CC1 24 to 32 50 kA A HMCPE050K2C XTCE032C10A 1NO aux built-in XTOB032CC1 24 to 32 65
80 J XTCE050D00A 1NO/1NC side aux XTCEXSBN11 XTOB057DC1 40 to 57 100 EGH080FFG 80 XTCE040D00A 1NO/1NC side aux XTCEXSBN11 XTOB057DC1 40 to 57 50 kA A HMCPE100R3C XTCE040D00A 1NO/1NC side aux XTCEXSBN11 XTOB057DC1 40 to 57 65 XTFC050DDA 40 to 50 65
100 J XTCE065D00A 1NO/1NC side aux XTCEXSBN11 XTOB065DC1 50 to 65 100 EGH100FFG 100 XTCE050D00A 1NO/1NC side aux XTCEXSBN11 XTOB065DC1 50 to 65 50 kA A HMCPE100T3C XTCE050D00A 1NO/1NC side aux XTCEXSBN11 XTOB057DC1 40 to 57 65 XTFC058DDA 50 to 58 65
125 J XTCE065D00A 1NO/1NC side aux XTCEXSBN11 XTOB075DC1 65 to 75 EGH125FFG 125 XTCE065D00A 1NO/1NC side aux XTCEXSBN11 XTOB075DC1 65 to 75 50 kA A
150 J XTCE080F00A 1NO/1NC side aux XTCEXSBN11 XTOB100GC1 70 to 100 100 JGE150FAG 150 XTCE080F00A 1NO/1NC side aux XTCEXSBN11 XTOB100GC1 70 to 100 65 kA A
200 J XTCE150G00A 1NO/1NC side aux XTCEXSBN11 XTOB125GC1 95 to 125 100 JGE200FAG 200 XTCE095F00A 1NO/1NC side aux XTCEXSBN11 XTOB125GC1 95 to 125 65 kA A
225 J XTCE150G00A 1NO/1NC side aux XTCEXSBN11 XTOB150GC1 120 to 150 100 JGE250FAG 250 XTCE115G00A 1NO/1NC side aux XTCEXSBN11 XTOB150GC1 120 to 150 65 kA A
300 J XTCE150G00A 1NO/1NC side aux XTCEXSBN11 XTOB175GC1 145 to 175 100 LGE3300FAG XTCE150G00A 1NO/1NC side aux XTCEXSBN11 XTOB175GC1 145 to 175 42 kA A
1NO/1NC side aux XTCEXSBN11 FDMP 3080L + XTCE080F00A 40 to 80 65
1NO/1NC side aux XTCEXSBN11 FDMP 3160L + XTCE115G00A 100 to 160 65
1NO/1NC side aux XTCEXSBN11 FDMP 3160L + XTCE150G00A 100 to 160 65
Combination motor XTFC032BCA controller or MPCB + contactor Overload range (A) CMC / MPCB + Contactor
A UL Pending.
25 to 32 18
SCCR (kA)
Note: Contactors are shown with a 120 Vac coil. For other coil voltages, replace the "A" suffix with the corresponding letter from the following table.
Coil Voltage Suffix
A TD T B
11
Branch Motor Selection for 460 Vac

HP (480V) FLA Minimum Wire Size (AWG) 1/2 1.1 14 3/4 1.6 14 1 2.1 14 1-1/2 3.0 14 2 3.4 14 3 4.8 14 5 7.6 14 7-1/2 11 14
Fuse amperage Fuse type Contactor Auxiliary contact Thermal overload relay Overload range (A) Fuse Starter Breaker Breaker size (A) Contactor Auxiliary contact Thermal overload relay Overload range (A) Breaker Starter High fault rating Motor circuit protector Contactor Auxiliary contact Thermal overload relay Overload range (A) MCP-Starter Combination motor controller Overload range (A)
3 CC XTCE007B10A 1NO aux built-in XTOB1P6BC1 1.0 to 1.6 EGE3015FFG 15A EG frame XTCE007B10A 1NO aux built-in XTOB1P6BC1 1.0 to 1.6 HMCP003A0C XTCE007B10A 1NO aux built-in XTOB1P6BC1 1.0 to 1.6 XTFC1P6BBA 1.0 to 1.6
3 CC XTCE007B10A 1NO aux built-in XTOB2P4BC1 1.6 to 2.4 100 EGE3015FFG 15A EG frame XTCE007B10A 1NO aux built-in XTOB2P4BC1 1.6 to 2.4 HMCP003A0C XTCE007B10A 1NO aux built-in XTOB2P4BC1 1.6 to 2.4 35 XTFC2P5BBA 1.6 to 2.5 65
3 CC XTCE007B10A 1NO aux built-in XTOB2P4BC1 1.6 to 2.4 100 EGE3015FFG 15A EG frame XTCE007B10A 1NO aux built-in XTOB2P4BC1 1.6 to 2.4 HMCP003A0C XTCE007B10A 1NO aux built-in XTOB2P4BC1 1.6 to 2.4 35 XTFC2P5BBA 1.6 to 2.5 65
6 CC XTCE007B10A 1NO aux built-in XTOB004BC1 2.4 to 4 100 EGE3015FFG 15A EG frame XTCE007B10A 1NO aux built-in XTOB004BC1 2.4 to 4 HMCP003A0C XTCE007B10A 1NO aux built-in XTOB004BC1 2.4 to 4 35 XTFC004BBA 2.5 to 4.0 65
6 CC XTCE007B10A 1NO aux built-in XTOB004BC1 2.4 to 4 100 EGE3015FFG 15A EG frame XTCE007B10A 1NO aux built-in XTOB004BC1 2.4 to 4 HMCP003A0C XTCE007B10A 1NO aux built-in XTOB004BC1 2.4 to 4 35 XTFC004BBA 2.5 to 4.0 65
10 CC XTCE007B10A 1NO aux built-in XTOB006BC1 4 to 6 100 EGE3015FFG 15A EG frame XTCE007B10A 1NO aux built-in XTOB006BC1 4 to 6 HMCPE015E0C XTCE007B10A 1NO aux built-in XTOB006BC1 4 to 6 65 XTFC6P3BBA 4 to 6.3 65
15 CC XTCE009B10A 1NO aux built-in XTOB010BC1 6 to 10 100 EGE3015FFG 15A EG frame XTCE009B10A 1NO aux built-in XTOB010BC1 6 to 10 HMCPE015E0C XTCE009B10A 1NO aux built-in XTOB010BC1 6 to 10 65 XTFC010BBA 6 to 10 65
30 CC XTCE012B10A 1NO aux built-in XTOB012BC1 9 to 12 100 EGE3025FFG 25A EG frame XTCE012B10A 1NO aux built-in XTOB012BC1 9 to 12 HMCPE015E0C XTCE012B10A 1NO aux built-in XTOB012BC1 9 to 12 65 XTFC012BBA 8 to 12 65
High fault rating (kA) 100
High fault rating (kA) 35
SCCR (kA) (480/277V) 65 CMC
12
Branch Motor Selection for 460 Vac, continued

HP (480V) FLA Minimum Wire Size (AWG) 10 14 12 15 21 10 20 27 8 25 34 8 30 40 8 40 52 6 50 65 4 60 77 3
Fuse amperage Fuse type Contactor Auxiliary contact Thermal overload relay Overload range (A) Fuse Starter High fault rating (kA) Breaker Breaker size (A) Contactor Auxiliary contact Thermal overload relay Overload range (A) Breaker Starter High fault rating Motor circuit protector Contactor Auxiliary contact Thermal overload relay Overload range (A) MCP-Starter High fault rating (kA) Combination motor controller or MPCB + contactor Overload range (A) CMC
A UL Pending.
25 J XTCE015B10A 1NO aux built-in XTOB016BC1 12 to 16 100 EGH3035FFG 35A EG frame XTCE015B10A 1NO aux built-in XTOB016BC1 12 to 16 HMCPE030H1C XTCE015B10A 1NO aux built-in XTOB016BC1 12 to 16 65 XTFC016BBA 10 to 16 50
35 J XTCE025C10A 1NO aux built-in XTOB024CC1 16 to 24 100 EGH3040FFG 40A EG frame XTCE025C10A 1NO aux built-in XTOB024CC1 16 to 24 65 kA A HMCPE030H1C XTCE025C10A 1NO aux built-in XTOB024CC1 16 to 24 65 XTFC025BCA 20 to 25 18
50 J XTCE032C10A 1NO aux built-in XTOB032CC1 24 to 32 100 EGH3050FFG 50A EG frame XTCE032C10A 1NO aux built-in XTOB032CC1 24 to 32 65 kA A HMCPE050K2C XTCE032C10A 1NO aux built-in XTOB032CC1 24 to 32 65 XTFC032BCA 25 to 32 18
60 J XTCE040D00A 1NO-1NC side aux XTCEXSBN11 XTOB040DC1 24 to 40 100 EGH3070FFG 70A EG frame XTCE040D00A 1NO-1NC side aux XTCEXSBN11 XTOB040DC1 24 to 40 65 kA A HMCPE050K2C XTCE040D00A 1NO-1NC side aux XTCEXSBN11 XTOB040DC1 24 to 40 65 XTFC040DDA 32 to 40 65
70 J XTCE040D00A 1NO-1NC side aux XTCEXSBN11 XTOB057DC1 40 to 57 100 EGH3080FFG 80A EG frame XTCE040D00A 1NO-1NC side aux XTCEXSBN11 XTOB057DC1 40 to 57 65 kA A HMCPE100R3C XTCE040D00A 1NO-1NC side aux XTCEXSBN11 XTOB057DC1 40 to 57 65 XTFC050DDA 40 to 50 65
150 J XTE080F00A 1NO-1NC side aux XTCEXSBN11 XTOB100GC1 70 to 100 100 JGH3150FAG 150A JG frame XTE080F00A 1NO-1NC side aux XTCEXSBN11 XTOB100GC1 70 to 100 65 kA A HMCPE100T3C XTE080F00A 1NO-1NC side aux XTCEXSBN11 XTOB100GC1 70 to 100 65 FDMP 3080L + XTCE080F00A 40 to 80 65
SCCR (kA) (480/277V)
Note: Contactors are shown with a 120 Vac coil. For other coil voltages, replace the "A" suffix with the corresponding letter from the following table.
Coil Voltage Suffix
A TD T B
13
Heater and lighting load circuits

Heater loads: The branch circuit protection is sized (see Section 31.6.1 exceptions for larger heater loads):
Branch Protection
Reference Sections 31.6, 31.8, 66.7.6
Lighting loads: The branch circuit protection for standard-duty incandescent lampholders or fluorescent ballasts (see Section 31.8.2 for larger lighting loads): 1. Shall not exceed 15A, and 2. Shall not exceed the ampacity of the anticipated field wiring The controllers are sized to the specific lighting ratings.
1. Not less than 125% of the heater load, 2. Not more than 60A, and 3. Not larger than the ampacity of the field wiring to the heater load. Controllers are sized to the heater full-load rating using the controllers general-purpose amp rating or resistive load rating.
Controller
Heater or Lighting Load
14
Contactors
Definite Purpose Contactor Resistive Load (A) Two-Pole Three-Pole Electrically Held Lighting Contactor Ballast or Mercury Vapor Load (at 600V) Tungsten Load (at 480V) 2NO 3NO 4NO
20 35 40 50 65
C25DRF215A C25DRF225A C25DRF230A C25DRF240A C25DRJ250A
C25DRF315A C25DRF325A C25DRF330A C25DRF340A C25DRJ350A
10 20
10 20
CN35AN2AB CN35BN2AB
CN35AN3AB CN35BN3AB
CN35AN4AB CN35BN4AB
General Purpose Amps
IEC Contactor Three-Pole Four-Pole
20 40 63
XTCE015B10A XTCE032C10A XTCE040D00A
XTCF020B00A XTCF045C10A XTCF063D00A
Single-Pole Heater application between Breaker Rating (A) Minimum Maximum Miniature Breaker 10 kA 277V 10 kA 120V
Two-Pole Miniature Breaker 10 kA 480V 10 kA 240V
Two-Pole Molded Case Circuit Breaker 18 kA 480V 25 kA 240V 65 kA 480V 50 kA 240V
Three-Pole Miniature Breaker 10 kA 480Y 10 kA 240V Molded Case Circuit Breaker 18 kA 480V 25 kA 240V 35 kA 480V 43 kA 240V 65 kA 480V 50 kA 240V
0.5 1 1.5 2 3 4 5 6 7 8 10 13 15 20 25 30 35 40 45 50 60
0.4 0.8 1.2 1.6 2.4 3.2 4.0 4.8 5.6 6.4 8.0 10.4 12.0 16.0 20.0 24.0 28.0 32.0 36.0 40.0
0.4 0.8 1.2 1.6 2.4 3.2 4 4.8 5.6 6.4 8 10.4 12 16 20 24 28 32 36 40 48
WMZT1CX0 WMZT1C01 WMZT1CX1 WMZT1C02 WMZT1C03 WMZT1C04 WMZT1C05 WMZT1C06 WMZT1C07 WMZT1C08 WMZT1C10 WMZT1C13 WMZT1C15 WMZT1C20 WMZT1C25 WMZT1C30 WMZT1C35 WMZT1C40
EGB2015FFG EGB2020FFG EGB2025FFG EGB2020FFG EGB2035FFG EGB2040FFG EGB2045FFG EGB2050FFG EGB2060FFG
EGH2015FFG EGH2020FFG EGH2025FFG EGH2020FFG EGH2035FFG EGH2040FFG EGH2045FFG EGH2050FFG EGH2060FFG
EGB3015FFG EGB3020FFG EGB3025FFG EGB3030FFG EGB3035FFG EGB3040FFG EGB3045FFG EGB3050FFG EGB3060FFG
EGE3015FFG EGE3020FFG EGE3025FFG EGE3030FFG EGE3035FFG EGE3040FFG EGE3045FFG EGE3050FFG EGE3060FFG
EGH3015FFG EGH3020FFG EGH3025FFG EGH3030FFG EGH3035FFG EGH3040FFG EGH3045FFG EGH3050FFG EGH3060FFG
15
Power circuit wiring

This section refers to the wiring in the feeder and branch circuits. For information on wiring in the control circuit, see Page 26. Internal wiring (Reference Section 29, 66.5):

Wire color designation (internal power circuit wiring) Black: All ungrounded power circuit conductors regardless of voltage
All internal wiring conductors shall be copper. All conductors in the power circuit should be labeled at the termination point with letters or numbers corresponding with the wiring diagram provided in the industrial control panel. Power circuit conductors should not be smaller than 14 AWG. For single loads, power circuit conductors for motors or heater loads should be sized for an ampacity not less than 125% of the full-load current. For multiple loads, such as multiple motors or a motor with other loads, power circuit conductors shall be sized for an ampacity not less than 125% of all heater loads plus 125% of the largest motor load plus the full-load ampere ratings of all remaining motors and other loads that are simultaneously operable. The wire size is selected from the table on Page 17 based on the calculated wire ampacity. Conductors used in group motor applications should also comply with Table 66.2 (Reference Section 66.7.5).
White or gray or three continuous white stripes on other than green, blue, orange or yellow: Grounded AC current-carrying power circuit conductor regardless of voltage
Exception: Insulated conductors sized 4 AWG (21.2 mm2) or larger and having insulation colored other than as in Section 17.4 shall be identified at each termination point by a white marking, such as tape wrapped around the conductor.
Field wiring (Reference Section 28.3, 66.4):

Not smaller than 14 AWG. For single loads, the field wiring conductors should be sized for an ampacity of 125% of the full-load current. For multiple loads, such as multiple motors or a motor with other loads, the field wiring is sized based on the sum of 125% of the largest motor FLA, plus the sum of the other full-load currents of the remaining loads. The wire size is selected from the table on Page 17 based on the calculated wire ampacity.
16
To determine the wire size for motor loads, add the full-load current ratings found in Table 50.1 for all external loads being carried by the conductor. Then use Table 28.1 on the following page to determine the wire size for the calculated ampacity.
Full-Load Motor-running Currents in Amperes Corresponding to Various AC Horsepower RatingsReference Table 50.1
110120V HP SinglePhase 200V SinglePhase ThreePhase 208V SinglePhase ThreePhase 220240V A SinglePhase ThreePhase 380415V SinglePhase ThreePhase 440480V SinglePhase ThreePhase 550600V SinglePhase ThreePhase
1/10 1/8 1/6 1/4 1/3 1/2 3/4 1 1 1/2 2 3 5 7 1/2 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300 350 400 450 500
3.0 3.8 4.4 5.8 7.2 9.8 13.8 16.0 20.0 24.0 34.0 56.0 80.0 100.0 135.0
2.5 3.3 4.1 5.6 7.9 9.2 11.5 13.8 19.6 32.2 46.0 57.5
2.5 3.7 4.8 6.9 7.8 11.0 17.5 25.3 32.2 48.3 62.1 78.2 92.0 120.0 150.0 177.0 221.0 285.0 359.0 414.0 552.0
2.4 3.2 4.0 5.4 7.6 8.8 11.0 13.2 18.7 30.8 44.0 55.0
2.4 3.5 4.6 6.6 7.5 10.6 16.7 24.2 30.8 46.2 59.4 74.8 88.0 114.0 143.0 169.0 211.0 273.0 343.0 396.0 528.0
1.5 1.9 2.2 2.9 3.6 4.9 6.9 8.0 10.0 12.0 17.0 28.0 40.0 50.0 68.0 88.0 110.0 136.0 176.0 216.0
2.2 3.2 4.2 6.0 6.8 9.6 15.2 22.0 28.0 42.0 54.0 68.0 80.0 104.0 130.0 154.0 192.0 248.0 312.0 360.0 480.0 604.0 722.0 828.0 954.0 1030.0 1180.0
1.0 1.2 1.4 1.8 2.3 3.2 4.5 5.1 6.4 7.7 10.9 17.9 27.0 33.0 44.0 56.0 70.0 87.0 112.0 139.0
1.3 1.8 2.3 3.3 4.3 6.1 9.7 14.0 18.0 27.0 34.0 44.0 51.0 66.0 83.0 103.0 128.0 165.0 208.0 240.0 320.0 403.0 482.0 560.0 636.0 786.0
2.5 3.5 4.0 5.0 6.0 8.5 14.0 21.0 26.0 34.0 44.0 55.0 68.0 88.0 108.0
1.1 1.6 2.1 3.0 3.4 4.8 7.6 11.0 14.0 21.0 27.0 34.0 40.0 52.0 65.0 77.0 96.0 124.0 156.0 180.0 240.0 302.0 361.0 414.0 477.0 515.0 590.0
2.0 2.8 3.2 4.0 4.8 6.8 11.2 16.0 20.0 27.0 35.0 44.0 54.0 70.0 86.0
0.9 1.3 1.7 2.4 2.7 3.9 6.1 9.0 11.0 17.0 22.0 27.0 32.0 41.0 52.0 62.0 77.0 99.0 125.0 144.0 192.0 242.0 289.0 336.0 382.0 412.0 472.0
A To obtain full-load currents for 265 and 277 volt motors, decrease corresponding 220240 volt ratings by 13 and 17 percent respectively.
17
For group motor applications where two or more motors are protected by a single device, wire sizes should comply with the fuse/breaker size in Table 66.2 at right.
Ampacities of Insulated ConductorsReference Table 28.1

Wire Size AWG mm2 Copper 75C (167F)
Relationship Between Conductor Size and Overcurrent Protection Rating for Power CircuitsReference Table 66.2
Conductor Size AWG mm2 Maximum Rating of Non-Time Delay Fuse or Inverse Time Delay or Time Circuit Dual Element Fuse Breaker (Amps) (Amps)
14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0 250 kcmil 300 350 400 500 600 700 750 800 900 1000 1250 1500 1750 2000
2.1 3.3 5.3 8.4 13.3 21.2 26.7 33.6 42.4 53.5 67.4 85.0 107.2 127 152 177 203 253 304 355 380 405 456 506 633 760 887 1013
15 20 30 50 65 85 100 115 130 150 175 200 230 255 285 310 335 380 420 460 475 490 520 545 590 625 650 665
14 12 10 8 6 4 3 2 1 1/0 2/0 3/0 4/0
2.1 3.3 5.3 8.4 13.3 21.2 26.7 33.6 42.4 53.6 67.4 85.0 107.2
60 80 100 150 200 250 300 350 400 500 600 700 800
30 40 50 80 100 125 150 175 200 250 300 350 400
Note: For multiple conductors of the same size (1/0 AWG or larger) at a terminal, the ampacity is equal to the value in this table for that conductor multiplied by the number of conductors that the terminal is able to accommodate.
18
Accessories
Contactor Auxiliary Contacts
Conventional Thermal Current, Open at 60C lth=le, AC-1 in Amps Screw Terminals Contact Configuration Circuit Symbol Package Quantity Catalog Number
EG Frame Multiwire Connectors Ordering Information

Maximum Amps Wires per Terminal Wire Size Range AWG Cu Kit Catalog Number
125 125
3 6
142 146
3TA125E3K 3TA125E6K
Frame BC Front (Top) Mount For use with XTCE... B XTCE... C 16 4NO
53 6373 83 54 6474 84
JG Frame Multiwire Connectors Ordering Information

5 XTCEXFAC40
Maximum Amps Wires per Terminal Wire Size Range AWG Cu Kit Catalog Number
250 5 XTCEXFAC31 250
3 6
142 146
3TA250FJ3 3TA250FJ6
16
3NO-1NC
53 61 73 83 54 62 74 84
Disconnect Fuse Holders Product Selection

5 XTCEXFAC22
Description Standard Pack Catalog Number
16
2NO-2NC
5361 71 83 54 62 72 84
For Class CC Fuse Single-pole fuse holder 1 XTCEXSCC11 12 C383FHCC
Frame C Side Mount For use with XTCE... C 10 1NO-1NC

53 61 54 62
MMP Accessories
Description Catalog Number
Line-side adapter XTPAXLSA For use with XTPR... BC1 5 XTCEXFBG40 Tool-less connector kit For use with XTPR... BC1 XTCE... B 1NO-1NC Front mount auxiliary 5 XTCEXFBG22 Commoning link XTPAXCLKA2 For use with XTPR... BC1 1 XTCEXSBN11 Commoning link XTPAXCLKA3 For use with XTPR... BC1 Commoning link XTPAXCLKA4 For use with XTPR... BC1 Commoning link XTPAXCLKA5 For use with XTPR... BC1 Handle mechanism XTPAXRHMRY XTPAXTPCB
Frame DG For use with XTCE... D XTCE... F XTCE... G 16 4NO-0NC

13 23 33 43 14 24 34 44
16
3NO-1NC
13 21 33 43 14 22 34 44
XTCEXFBG31
XTPAXFA11
16
2NO-2NC
13 21 31 43 14 22 32 44
Frame DR
32 31 44 43
For use with XTCE... D XTCE... F XTCE... G
10
1NO-1NC
13 14
21 22
19
Designing the control circuit

Control circuits provide the logic for the operation of the components in the power circuit. Control circuits are typically a lower, safer voltage, such as 120 Vac or 24 Vdc. Control power transformers (CPTs) and power supplies are used to transform or convert the power circuit voltage to the control circuit voltage. Refer to Page 22 for selection of the CPT and protective devices. Refer to Page 24 for selection of the power supply and protective devices. Refer to Page 26 for control circuit wiring. Eaton also offers a variety of control devices commonly used in control circuits. Refer to Page 27 for pushbutton and pilot devices. Refer to Page 28 for relays, timers, and terminal blocks. Refer to Page 29 for programmable logic controllers and relays.
Branch Protection
20
Common control circuit wiring

Connections for Control Stations Connections for Starters Figure 1 Front View Diagram Figure 2 Fusible Control Transformer Remove Wire C (Figure 1) if Used and Connect as Shown Below. (All Other Starter Wires Remain as Shown in Figure 1) Primary Connections 4 H4
Fuse
Local Control
Figure A START/STOP Pushbuttons 2/13 Yellow Start (ON) 3/14 Black 3 4 Stop (OFF) Red Red 1 1 2 Figure D 2-Position Selector Switch Yellow 3/14 Hand Black 3 Auto 4 Red 1
H1 H1
240V 230V 220V H3 H2 H3 H4 H1
480V 460V 440V H3 H2 H2 H4 H4
1 2
CPT Fusible Control Transformer (If Used) See Figure 2

L1 L2 L3
H2
110V 115V 120V
X2
Fuse Fuse
Figure B START/STOP Selector Switch 3 4 Black 3/14 1 Start (ON) 2 Red 1
Figure E Pilot Light (Motor RUN) Connect to Coil Terminals A1 and A2 X1 Black / White X2 Black / White
D.S. or C.B. Disconnecting Means
Local Control (Flange Mounting if Used)
H1 X1 CPT XF X2 G 1 Secondary Connections
H2 H3 1
240V x 480V Primary, 120V Secondary CPT Wiring Diagram
L1 L2 L3
1 3 5 L1 L2 L3
Omit This Connector 3 if Figure 2 1 Is Used L1 L2

1
5 L3
See Figures A, B, C, D, E and F
1 3 5
OL 96 Reset 95
O -S11
21 22 13 14
A1 A2
Figure C 3-Position Selector Switch Yellow 3/14 To Coil Hand Terminal A1 Black 3 Auto 3 Remote 4 4 Switch 1 Red
Figure F START/STOP with Pilot Light Connect to A1 and A2 Terminals X1 Black / White X2 Black / White 2/13 Start (ON) 3/14 3 4
Stop (OFF)
-Q1 24 6 -Q11 1 3 5 2 46
A1 A2
2/13 3/14 98 Connections for Dual Voltage Rated Transformer See Transformer Nameplate
14 -Q11 13 -Q11 A1 A2
OL
2/ 4/ T1 T2 T1 T2 4 2 6/ T3 T3 6
97 96 Reset 95
Field Conversion to 1-Phase Add Dotted 1 3 5 Connection L1 L2 L3 A1 A2
Combined Remote and Local for Figures 1 and 2 Remote

Start Stop 2/13
M
T1 T2 T3
U V W PE M 3 -M1
Local Start (ON)

4 3 Stop (OFF) 2 1 3/14
Motor
1 Separate Control
Omit Connector
OL 2/ 4/ T1 T2 T1
T1
6/ T3 T2 T2
Manual Motor Controller and Combination Motor Controller Wiring Diagram
Remote Control
2-Wire Control 3/14 1 Not for Use with Auto Reset OL Relays. 3-Wire Control Start Stop 3/14 2/13 1 When More Than One Pushbutton Station Is Used, Omit Connector A and Connect per Sketch Below Start Start Stop A 3/14 2/13 1
Remove Wire C if Supplied and Connect Separate Control Lines to the Number 1 Terminal on the Remote Pilot Device and to the Number 96 Terminal on the Overload Relay
Motor
260878 D4
21
Sizing the control power transformer

CPT Selection Chart
Inrush VA at 20% Power Factor CPT Part Number A Primary Voltage (AC) Secondary Voltage (AC) CPT VA 90% Secondary Voltage 95% Secondary Voltage
C0025E2A C0050E2A C0075E2A C0100E2A C0150E2A C0200E2A C0250E2A C0300E2A C0350E2A C0500E2A C0750E2A C1000E2A
240 x 480 240 x 480 240 x 480 240 x 480 240 x 480 240 x 480 240 x 480 240 x 480 240 x 480 240 x 480 240 x 480 240 x 480
120 120 120 120 120 120 120 120 120 120 120 120
25 50 75 100 150 200 250 300 350 500 750 1000
130 200 410 540 930 1150 1900 2700 3650 5300 11000 21000
100 170 310 370 780 810 1400 1900 3100 4000 8300 15000
1. Use the following formula to determine the inrush power of the control power transformer (CPT) needed to support the components used in the application. CPT INRUSH VA = (INRUSH VA) + (SEALED VA)
2 2
A Add "FB" to the end of the part number to include a double-pole primary fuse block for rejection type fuses. Not available for 25 VA.
Example
Qty Description Inrush VA Sealed VA Total Inrush Total Sealed
Common Control Loads

Description Part Number Inrush VA Sealed VA
1 2 2 6
XTCE007B10A coil XTCE018C10A coil Relays Indicating lights
25 58 29 7.0
3.3 6.5 3.3 7.0 Total
25 116 58 42 241
3.3 13.0 6.6 42.0 65.0
7 to 15A XT Contactor Coil 18 to 32A XT Contactor Coil 40 to 72A XT Contactor Coil 80 to 95A XT Contactor Coil 115 to 170A XT Contactor Coil Definite Purpose Contactor Coil Definite Purpose Contactor Coil Lighting Contactor Coil Lighting Contactor Coil Mini XT Relay LED M22 Indicating Light Intelligent Relay Intelligent Relay EZ Expansion Module
XTCEB XTCEC XTCED XTCEF XTCEG C25DRF C25DRJ C35A C35B XTRM M22-L... EZ512... EZ719... EZ618...
25 58 154 372 170 75 111 80 100 29 0.4 5 10 10
3.3 6.5 14 37.1 3.1 5.8 7.6 7.5 10 3.9 0.4 5 10 10
CPT INRUSH VA = (241)2 + (65)2 = 250 VA 2. Select the CPT size based on the CPT inrush VA needed. Selection Using Data from Previous Example
Part Number Primary Voltage Secondary Voltage Transformer VA Inrush VA (90% Sec. Inrush Voltage)
C0050E2A C0075E2A C0100E2A
240 x 480 240 x 480 240 x 480
120 120 120
50 75 100
200 410 540
C0075E2AFB has enough inrush VA capacity to handle the 250 VA inrush of the components.
22
Sizing protection for CPTs

Reference Accessories Section on Page 19 for Fuse Holders. Primary and Secondary Protection
Reference Section 42.1
C383FHCC Single-Pole Fuse Holder (Type CC)

Primary Two-Pole Breaker Secondary Two-Pole Breaker Primary Fuse Size Secondary Fuse Size
CPT Part Number A
CPT VA
240V Primary: 120V Secondary C0025E2A C0050E2A C0075E2A C0100E2A C0150E2A C0200E2A C0250E2A C0300E2A C0350E2A C0500E2A C0750E2A C1000E2A 480V Primary: 120V Secondary C0025E2A C0050E2A C0075E2A C0100E2A C0150E2A C0200E2A C0250E2A C0300E2A C0350E2A C0500E2A C0750E2A C1000E2A 25 50 75 100 150 200 250 300 350 500 750 1000 WMZT2CX0 WMZT2CX0 WMZT2C01 WMZT2C01 WMZT2CX1 WMZT2C02 WMZT2C03 WMZT2C03 WMZT2C04 WMZT2C05 WMZT2C08 WMZT2C05 WMZT2CX0 WMZT2C01 WMZT2C01 WMZT2CX1 WMZT2C02 WMZT2C03 WMZT2C04 WMZT2C04 WMZT2C05 WMZT2C07 WMZT2C10 WMZT2C15 1 1 1 1 1 1 1 1 1 1 3 3 1 1 1 1 3 3 3 3 3 6 6 10 25 50 75 100 150 200 250 300 350 500 750 1000 WMZT2CX0 WMZT2C01 WMZT2CX1 WMZT2C02 WMZT2C03 WMZT2C04 WMZT2C05 WMZT2C06 WMZT2C07 WMZT2C05 WMZT2C08 WMZT2C10 WMZT2CX0 WMZT2C01 WMZT2C01 WMZT2CX1 WMZT2C02 WMZT2C03 WMZT2C04 WMZT2C04 WMZT2C05 WMZT2C07 WMZT2C10 WMZT2C15 1 1 3 3 3 6 6 6 10 6 10 10 1 1 1 1 3 3 3 3 3 6 6 10
A Add FB to the end of the CPT part number to include a two-pole primary fuse block for rejection type fuses.
23
Control power selection

1. Determine the output capacity needed to support the components used in the application. First, calculate the total load at steady state (nominal load after inrush). This is done by summing the sealed-in or nominal loads. Nominal Load = Sealed Load1 + Sealed Load2 + .... + Sealed Loadn For extended operational life of the power supply, increase the calculated nominal load by 20%. 2. Next, calculate the total inrush or surge loads of the components supported by the power supply. Inrush Load = Inrush Load1 + Inrush Load2 + .... + Inrush Loadn 3. Select the power supply based on the available input voltage, nominal load and inrush (surge) load requirements. 4. Verify that the application of the components on the load does not exceed the surge capacity and other specifications of the selected power supply. Example: Select a 24 Vdc Power Supply with the Following Loads and a 240 Vac Input
Qty Description Inrush W Sealed W Surge Current Nominal Current Total Surge Current Total Nominal Current
Selection Chart
Input Part Number Capacity Voltage Output Voltage Nominal Current Surge Current Surge Capacity
PSG60E PSG120E PSG240E PSG480E PSG60F PSG120F PSG240F PSG480F 1.00 0.08 0.22 0.25 1.55
60W 120W 240W 480W 60W 120W 240W 480W
100240 Vac 24 Vdc single-phase singlephase
2.5A 5A 10A 20A
3.75A 7.5A 15A 30A 3.75A 7.5A 15A 30A
1 second at 10 second intervals
400500 Vac 24 Vdc three-phase singlephase
2.5A 5A 10A 20A
8 4 2 5
XTCE007B10TD Coil XTCE018C10TD Coil Relay Indicating light
3 12 2.6 1.2
3 0.5 2.6 1.2
0.13 0.50 0.11 0.05 Total
0.13 0.02 0.11 0.05
1.00 2.00 0.22 0.25 3.47
Note: Above 55 degrees C, the PSG should be derated. See catalog CA08102001E for additional information and other specifications.
Common Control Loads

Description Part Number Inrush W Sealed W
7 to 9A XT Contactor Coil 12 to 15A XT Contactor Coil 18 to 32A XT Contactor Coil 40 to 72A XT Contactor Coil
XTCEB XTCEB XTCEC XTCED XTCEF XTCEG C25D C35 XTRM M22-L... EZ512... EZ719... EZD-80... EZ618... ELC-PV...
3 4.5 12 24 90 149 69 77 2.6 0.4 2 3.5 3 4 5.3
3 4.5 0.5 0.5 1.3 2.1 3.1 3.4 2.6 0.4 2 3.5 3 4 5.3 2.2
Derating for Extended Operation: Total Nominal Current = 1.55 x 120% = 1.86 Selection using data from previous table.
Part Number Capacity W Input Voltage Output Voltage Nominal Current Surge Current Surge Capacity
80 to 95A XT Contactor Coil 115 to 170A XT Contactor Coil Definite Purpose Contactor Coil Lighting Contactor (10 and 20A) Coil Mini XT Relay LED M22 Indicating Light Intelligent Relay Intelligent Relay EZ Display EZ Expansion Modules ELC Programmable Logic Controller ELC Expansion Modules
PSG60E PSG120E PSG240E
60 120 240
100240 Vac 1-P 100240 Vac 1-P 100240 Vac 1-P
24 Vdc 24 Vdc 24 Vdc
2.5A 5A 10A
3.75A 7.5A 15A
1 second at 10 second intervals 1 second at 10 second intervals 1 second at 10 second intervals
PSG60E has enough nominal and surge current capacity for these components.
ELC-EX..., -AN..., -TC... 2.2
24
Sizing protection for power supplies

Power Supplies
Part Number
Capacity
Input Voltage
Primary Fusing
Class CC Fuse Holder (Qty)
Suggested Power Supply Primary Wire Size
PSG60E PSG120E PSG240E PSG480E PSG60F PSG120F PSG240F PSG480F
60W 120W 240W 480W 60W 120W 240W 480W
100240 Vac single-phase
6A or 10A 6A or 10A 10A or 16A 10A or 16A
C383FHCC (2) C383FHCC (2) C383FHCC (2) C383FHCC (2) C383FHCC (3) C383FHCC (3) C383FHCC (3) C383FHCC (3)
14 AWG 14 AWG 14 AWG 14 AWG 14 AWG 14 AWG 14 AWG 14 AWG
400500 Vac three-phase
6A or 10A 6A or 10A 6A or 10A 6A or 10A
Note: If the sum of the loads on the secondary of the power supply exceeds the output ratings of the power supply, then secondary overload protection is required.
25
Wire selection for control circuits

Wire color designation (internal power circuit wiring) Black: All ungrounded control circuit conductors operating at the supply voltage Red: Ungrounded AC control circuits operating at a voltage less than the supply voltage Blue: Ungrounded DC control circuits
Reference Section 38, 66.9
Wire size for control circuits must be no smaller than 18 AWG, with exception of control circuits for PLC input/outputs. Wire size is determined from Table 38.1 based on the amp rating of the overcurrent protective device for the control circuit or the amp rating of the secondary of the CPT or power supply. Ampacity of Control Circuit ConductorsReference Table 38.1
Conductor Size Ampacity, Amperes AWG mm2
10 7 5 3
16 18 20
1.3 0.82 0.52 0.32 0.20 0.13 0.08 0.05
22 24 26 28 A 30 A
Yellow or orange: Ungrounded control circuits or other wiring, such as for cabinet lighting, that remain energized when the main disconnect is in the OFF position
2 1 0.8 0.5
A Where these conductors are contained in a jacketed multi-conductor cable assembly. These sizes of conductors are only for connection of control circuits for electronics programmable
White or gray or three white stripes on other than green, blue, orange, or yellow: Grounded AC current-carrying control circuit conductor regardless of voltage
input/output and static control (having no moving parts).
White with blue stripe: Grounded DC current-carrying control circuit conductor
White with yellow stripe or white with orange stripe: Grounded AC control circuit current-carrying conductor that remains energized when main disconnect switch is in the OFF position
26
Logic controlpilot devices selection

Rules for Operator Controls 1. Start buttons and switches should be located either above or to the left of the associated stop button. Choosing Operators and Lights
Type Catalog Number Type Description
Catalog Number
Flush green momentary button
M22-D-G
NO contact block
M22-K10
START
Extended red momentary button
M22-DP-R
NC contact block
M22-K01
START
STOP
STOP
Blue RESET with push rod
M22-DZ-B-GB14
LED indicating light
1230 Vac/Vdc Yellow Green Red Blue 85264 Vac/Vdc Yellow Green Red M22-L-Y-230W M22-L-G-230G M22-L-R-230R M22-L-B-230B M22S-ST-GB1 M22S-ST-GB0 M22S-ST-GB10 M22S-ST-GB11 M22-ST-D12 M22-ST-GB12 M22-L-Y-W M22-L-G-G M22-L-R-R M22-L-B-B
2. Every control panel that includes operator controls should include an emergency stop. This emergency stop should be a mushroom or palm type that is self-latching.
Twist-to-release E-Stop with 1NO/2NC
M22-PVT-K12
Two-position maintained selector switch
M22-WKV Legend plates
Blue START STOP OFF ON MAN. AUTO HAND O AUTO MAN. O AUTO
Two-position maintained keyed selector switch
M22-WRS
Three-position maintained selector switch
M22-WRK3
Three-position maintained keyed selector switch
M22-WRS3
27
Logic controlrelays, timers, and terminal block selection

Image Type Catalog Number Image Type Catalog Number
2NO-2NC 10A relay 120 Vac
XTRM10A22A
30A terminal blocks 6.2 mm wide
XBUT4 (Grey) XBUT4BU (Blue) XBUT4BK (Black) XBUT4WH (White) XBUT4RD (Red) XBUT4PE
2NO-2NC 10A relay 24 Vdc
XTRM10A22TD
Ground terminal block
On-delay timer 0.05s to 60h
XTMT6A60H11B
DIN rail end stop
XBAES35C
Single-pole terminal block relays
XRU1D120U XRU1D24U
Terminal block jumpers
XBAFBS262 pos. XBAFBS363 pos. XBAFBS565 pos. XBAFBS10610 pos.
Four-pole, 15A control relays
D7PF4AA (120 Vac) D7PF4AT1 (24 Vdc)
Terminal block end cover
XBACUT10
Four-pole control relay socket
D7PAD
Blank marker strip (strip of 10)
XBMZB6
Multifunction universal timing relay
TRL07
Open three-pole power distribution block 175A
CHDB3213
DIN rail
XBANS3575P
Finger-safe power distribution block 380A
CHDB330F
28
Logic controllogic controllers and relays

PLCs and Intelligent Relays
Controller Catalog Number Expansion Module Options Digital Analog Relay Catalog Input Input Outputs Number Power Supply Options 100240 Vac Input 24 Vdc Catalog Output Number (Amps)
Description
Description
Basic (120 Vac Input) EZ512-AC-RC

EZ500 with Display
Intelligent relay with clock and display Intelligent relay with clock and display
EZ400-POW 1.25
Basic (24 Vdc Input) EZ512-DC-RC Expanded (120 Vac Input) 110240 Vac Relay Inputs Outputs EZ719-AC-RC Expanded (24 Vdc Input) Intelligent relay with clock and display 12 6 EZ618-AC-RE 12 6 EZ400-POW 1.25 8 2 4 EZ400-POW 1.25
EZ700 with Display
24 Vdc Inputs EZ719-DC-RC Advanced (24 Vdc Input) Right Side Module 16 ELC-PV28NNDR Programmable logic controller that has expandable features with add-on modules 12 ELC-EX16NNDR ELC-EX16NNDT ELC-TC04ANNN ELC-MC01 Left Side Module ELC-COENETM 24 Vdc Inputs 8 8 Intelligent relay with clock and display 12 4 6 EZ618-DC-RE 12
Relay Outputs 6 EZ400-POW 1.25
Analog Relay Analog Transistor In Outputs Out Out 4 8 2 8 ELC-PS01 ELC-PS02 1 2
ELC-AN06AANN
Thermocouple J, K, R, S, T plus 4 analog in Motion control, 1 axis module Ethernet Modbus TCP (master/slave)
ELC Logic Controller
EZ Accessories EZSOFTProgramming software EZ-PC-CABPC programming cable EZD-80-BExternal display EZD-CP4-500Display communication module with cable
ELC Power Supply
29
ELC Accessories ELCSOFTELC programming software ELC-GP04External graphic panel display ELC-CBPCELC1PC/graphic panel cable
ELC-GP04
ELCSOFTGPELC-GP programming software
EZ80-B
Sizing the branch protection for a single motor and a control circuit
For single motor load control panel where the branch protective device acts as the main for the panel and the control circuit is tapped off the load side of the device, the branch protective device is sized by the following:
Branch Protection
Branch Circuit Protection

Type Percent of FLA
Non-time delay fuse and Class CC fuse Dual element fuse (time delay) except Class CC Inverse-time circuit breaker Self-protected combination motor controller Manual self-protected combination motor controller
Up to 300% Up to 175% Up to 250% 100% 100%
1. Multiply the motor FLA (from Table 50.1 on Page 32) with the following percentage based on the type of protective device from the table at right: 2. Add the full-load current on the primary of the CPT from the table below. 3. Select the closest standard protective device rating. See Page 8 for selection of the controller and overload protection.
Controller
Overload Protection
Conductors of a control circuit that are tapped from the load side of a branch circuit device (and where the power voltage is the same as the control voltage no CPT) shall be protected by overcurrent devices rated not more than as specified in the table at the right.
Overcurrent Device Ratings for Control Circuit Conductors Tapped from Load Side of Branch Circuit Protective DeviceReference Table 66.4
Conductor Size AWG mm2 Control Circuit Overcurrent Device (Amps) Branch Circuit Overcurrent Device (Amps) Control in Wire Panel Remote Control
Larger than 14 14 16 18
Larger than 2.1 2.1 1.3 0.82
Equal to wire capacity 20 20 20
400% of wire ampacity 80 40 25
300% of wire ampacity 60 20 20
Single Motor Load and Control Circuit with Shared Branch Protection
Note: See table on Page 6 for breaker and fused disconnect part numbers, and Page 19 for fuse holders.
30
Common Formulas and Conversions

Direct Current Single-Phase (AC) Three-Phase (AC)
Current (I) from HP Current (I) from kW Current (I) from kVA Horsepower (HP)
I= I=
HP x 746 V x %EFF kW x 1000 V
I= I= I=
HP x 746 V x %EFF x PF kW x 1000 V x PF
I= I= I=
HP x 746 V x %EFF x PF x 1.73 kW x 1000 V x PF x 1.73
HP =
V x I x %EFF 746
kVA x 1000 V V x I x %EFF x PF HP = 746
kVA x 1000 V x 1.73 V x I x %EFF x PF x 1.73 HP = 746
Voltage Drop Calculations
Conversions
V I L D K Two-wire, single-phase Three-wire, three-phase
Voltage drop Current Length of cable/wire (ft) Conductor cross section (circular mile) Resistivity of conductor K = 12 for circuits loaded more than 50% of rating (copper) K = 11 for circuits loaded less than 50% of rating (copper) V= V= 2K x L x I D 2K x L x I x 0.866 D
1 inch 3.28 feet 1 yard 1 mile 1 mile 144 square inches 9 square feet 640 acres 1 cubic foot
2.54 cm 1 meter 0.91 meters 5,280 feet 1.609 kilometers 1 square foot 1 square yard 1 square mile 7.48 gallons
NEMA/UL/IEC Enclosure Type Cross-ReferenceApproximate NEMA Enclosure Rating
IP10
IP20
IP21
IP22
IP23
IP30
IP31
IP32
IP33
IP40
IP41
IP42
IP43
IP50
IP51
IP52
IP53
IP54
IP55
IP56
IP60
IP61
IP62
IP63
IP64
IP65
IP66
IP67
IP68
1 2 3 3R 3S 4 4X 6 6P 12 13
X X X X X X X X X X X
X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
31
Dimensional Orientation Face Depth Height
Width
Product Specifications
Tightening Torque (in-lb) Protective Devices Part Number Lineside Loadside Mounting Approximate Dimensions (mm) Height Width Depth Type Installation Pub Number
Molded case circuit breakers A
EGB EGE EGH EGC JGE JGS JGH JGC LGE LGH LGU
1410 AWG 35 8 AWG 40 64 AWG 45 33/0 AWG 50 4350 kcmil 180
1410 AWG 35 8 AWG 40 64 AWG 45 33/0 AWG 50 4350 kcmil 180
10
139.7 139.7 139.7 139.7 177.8 177.8 177.8 177.8 257.3 257.3 257.3 48.0 Incremental 48.0 Incremental 81.0 Incremental 81.0 Incremental 152.4
76.2 76.2 76.2 76.2 104.9 104.9 104.9 104.9 139.2 139.2 139.2
75.9 75.9 75.9 75.9 90.7 90.7 90.7 90.7 103.9 103.9 103.9
Three-pole Three-pole Three-pole Three-pole Three-pole Three-pole Three-pole Three-pole Three-pole Three-pole Three-pole
I.L. 29C515C I.L. 29C515C I.L. 29C515C I.L. 29C515C IL01204006E IL01204006E IL01204006E IL01204006E IL01207006E IL01207006E IL01207006E IL01202001E IL01202002E IC01204001E IC01204002E
10
2500 kcmil (2) 375 70 in-lb 25 in-lb 70 in-lb 25 in-lb 1410 AWG 35 8 AWG 40 64 AWG 45 33/0 AWG 50 14-10 AWG... 35 8 AWG... 40 6-4 AWG... 45 3-3/0 AWG... 50 1410 AWG 35 8 AWG 40 64 AWG 45 34/0 AWG 50 27 in-lb 27 in-lb 31 in-lb 35.4 in-lb 200 in-lb 500 in-lb 500 in-lb 1812 AWG 20 108 AWG 25 1810 AWG (2) 25
2500 kcmil (2) 375 70 in-lb 25 in-lb 70 in-lb 25 in-lb 1410 AWG 35 8 AWG 40 64 AWG 45 33/0 AWG 50 14-10 AWG... 35 8 AWG... 40 6-4 AWG... 45 3-3/0 AWG... 50 1410 AWG 35 8 AWG 40 64 AWG 45 34/0 AWG 50 27 in-lb 27 in-lb 31 in-lb 35.4 in-lb 200 in-lb 500 in-lb 500 in-lb 1812 AWG 20 108 AWG 25 1810 AWG (2) 25
25 35 35 96 96 28
Multiwire terminals
3TA125E3K 3TA125E6K 3TA250FJ3 3TA250FJ6
Miniature circuit breakers WMZT Motor circuit protectors HMCP 105.0 86 Three-pole IL01211006E
HMCPE
10
139.7
76.2
75.9
Three-pole
IL29C130D
Motor protective circuit breaker Fusible disconnects
FDMP
35
152.4
105.0
86.0
Three-pole
IL29C115C
R4H3030FJ R4H3030FCC R9J3030FJ and R9J3060FJ R9K3100FJ R9L3200FJ R9M3400FJ R9N3600FJ
20 ? 20 ? 20 ? 20 ? 20 ? 20 ? 20 ?
116.0 116.0 136.0 186.0 291.0 390.0 471.0 81.2
105.0 96.0 149.5 149.5 195.0 276.0 364.0 17.8
99.0 83.5 123.0 123.0 130.0 141.5 250.0 61.0 Single-pole
N/A N/A N/A N/A N/A N/A N/A
Fuse holders
C383FHCC
A Tightening torques are for standard terminal provided with breaker. For alternative lugs, see the installation publication.
32
Product Specifications (continued)

Tightening Torque (in-lb) Controllers Part Number Line Load Coil Auxiliary Contacts Approximate Dimensions (mm) Height Width Depth Type Installation Pub Number
Motor control
XTSCBB XTSCBC XTSCDD XTFCBB XTFCBC XTFCDD XTCEB XTCEC XTCED XTCEF XTCEG XTOBBC1 XTOBCC1 XTOBDC1 XTOBGC1 XTCEXF XTCEXS XTPAXF XTPAXTPCB XTPAXLSA
15.0 15.0 26.6 36 36 36 10.6 26.6 29.2 123.9 123.9 Not required 36 1214 AWG 15 in-lb 10 AWG 25 in-lb 8 AWG 40 in-lb 46 AWG 45 in-lb
10.6 26.6 29.2 10.6 26.6 29.2 10.6 26.6 29.2 123.9 123.9 16.0 16.0 31.0 88.5
10.6 10.6 10.6 10.6 10.6 10.6 10.6 10.6 10.6 10.6 10.6
10.6 10.6 10.6 10.6 10.6 10.6 10.6 10.6 10.6 10.6 10.6 710.6 710.6 710.6 710.6 10.6 10.6 10.6
178.5 228.8 284.0 209.0 266.7 312.1 68.0 85.0 104.0 170.0 170.0 49.8 incremental 51.4 incremental 70 incremental 107 incremental 30.5 incremental
45.0 45.0 55.0 45.0 45.0 55.0 45.0 45.0 55.0 90.0 90.0 45.0 45.0 60.0 118.0 10.5 incremental
95.7 124.3 196.0 95.7 124.3 196.0 75.0 97.4 132.1 160.0 160.0 88.4 105.3 93.6 134 41.2 incremental
Pub51176 Pub51228 Pub51190 Pub51176 Pub51228 Pub51190 Pub51210 Pub51211 Pub51216 Pub51188 Pub51188 Pub51210 Pub51211 Pub51216 Pub51188 Pub51211 or Pub51216 Pub51216 or Pub51188 Pub51198 Pub51176
Definite purpose
C25DR
33

Tightening Torque (in-lb) Power Conversion Part Number Primary Secondary Approximate Dimensions (mm) Height Width Depth Type Installation Pub Number
Control power transformers
C0025E2A C0050E2A C0075E2A C0100E2A C0150E2A C0200E2A C0250E2A C0300E2A C0350E2A C0500E2A C0750E2A C1000E2A
16 16 16 16 16 16 16 16 16 30 30 30 6.948.68 10.4113.89 6.948.68 10.4113.89 6.948.68 10.4113.89 10.4113.89 10.4113.89
16 16 16 16 16 16 16 16 16 30 30 30 6.948.68 10.4113.89 6.948.68 10.4113.89 6.948.68 10.4113.89 10.4113.89 10.4113.89
65.0 65.0 65.0 73.0 81.0 97.0 97.0 97.0 97.0 121.0 121.0 144.0 125.0 126.5 126.5 126.5 126.5 126.5 126.5 126.5
76.0 76.0 76.0 86.0 95.0 114.0 114.0 114.0 114.0 133.0 133.0 171.0 32.0 70.0 50.0 70.0 85.0 85.0 160.0 160.0
64.0 76.0 89.0 86.0 102.0 102.0 111.0 121.0 133.0 140.0 178.0 164.0 120.5 111.4 115.0 111.3 118.5 120.5 111.4 111.4
IL00912001E IL00912005E IL00912002E IL00912006E IL00912003E IL00912007E IL00912004E IL00912008E

Installation Pub Number
Power supplies
PSG60E PSG60F PSG120E PSG120F PSG240E PSG240F PSG480E PSG480F
Tightening Torque (in-lb) Type Part Number Lineside Loadside Mounting
Approximate Dimensions (mm) Height Width Depth Type
Logic controllers
EZ512 EZ719 EZ618 EZ400 ELC-PV ELC-EX16NNDR ELC-EX16NNDT ELC-AN06AANN ELC-TC04ANNN ELC-MC01 ELC-COENETM ELC-PS01 ELC-PS02
5.3 5.3 57 57 2216 AWG 1.7 2216 AWG 1.7 2216 AWG 1.7 2216 AWG 1.7 1.7 2216 AWG 1.7 4.36.9 4.36.9
5.3 5.3 57 57 2216 AWG 1.7 2216 AWG 1.7 2216 AWG 1.7 2216 AWG 1.7 1.7 2216 AWG 1.7 4.36.9 4.36.9
110.0 110.0 110.0 110.0 96.0 96.0 96.0 96.0 96.0 96.0 96.0 96.0 96.0
71.5 107.5 107.5 71.5 70.0 25.2 25.2 25.2 25.2 25.2 33.0 36.5 55.0
58.0 58.0 58.0 56.5 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0 60.0
MN05013003E MN05013003E IL05013009E IL05013008E IL05001004E IL05003004E IL05003004E IL05003003E IL05003009E IL05003023E MN05006001E IL05003007E IL05003007E
34

Tightening Torque (in-lb) Logic Circuit Components Part Number Line Load Mounting Coil Approximate Dimensions (mm) Height Width Depth Type Installation Pub Number
Pushbuttons, switches pilot lights Relays
M22 M22 XTRM XTMT TRL07 D7
7.1 7.1 10.6 10.6 8.8 78 5.37.1 5.37.1 Not required 2/08 AWG 120 5006 AWG 500
46 AWG 35 8 AWG 25 1014 20 23 AWG 50 46 AWG 45 8 AWG 40 1014 AWG35
17.7 17.7
10.6 10.6 8.8 78
58.0 58.0 87.0 79.7 47.5 47.5 101.6 118.4
45.0 45.0 17.5 49.9 6.2 6.2 131.8 39.1
54.0 54.0 60.0 70.0 46.9 46.9 84.3 72.9
IL04716001E Pub51219 Pub51245 IL04910002E Pub51473 Pub51473 Pub51473
Terminal blocks
XBUT4 XBAE XBAF CHDB3213 CHDB330F
With the permission of Underwriters Laboratories, Inc., material is reproduced from UL Standard 508A, Industrial Control Panels, which is copyrighted by Underwriters Laboratories, Inc., Northbrook, Illinois. While use of this material has been authorized, UL shall not be responsible for the manner in which the information is presented, nor for any interpretations thereof. ULs approval to use this information does not imply or warrant that any associated products or materials in this publication are UL Listed. For more information on UL or to purchase standards, please visit our Standards website at www.comm-2000.com or call 1-888-853-3503.
35
36
Eaton Corporation Electrical Sector 1111 Superior Ave. Cleveland, OH 44114 United States 877-ETN-CARE (877-386-2273) Eaton.com 2010 Eaton Corporation All Rights Reserved Printed in USA Publication No. SA08302002E / Z9647 May 2010 PowerChain Management is a registered trademark of Eaton Corporation. All other trademarks are property of their respective owners.

SA08302002E - Control Panel Design Guide

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Control panel design guide

UL 508A control panel design guide

A long history of innovation in control and protection

The power of fusion.

EATON CORPORATION Control panel design guide

Ready to buy? Go to www.eaton.com/controlpanel Got a question? Call 877-ETN-CARE

Designing the panel

Feeder Main Feeder

Single Motor Panel Individual Circuit for Motor Load

Heater or Lighting Lead OR Power Transformer or Power Circuit Supply Wiring

Transformer or Power Controller Supply M

Transformer or Power Supply M L M

Transformer or Power Controller Supply M Overload Protection L M

Overload Overload Protection Protection

Overload Overload Protection Protection

Overload Overload Protection Protection

Control Heater or Circuit Lighting Load

Single Motor Load

Control Single Motor Circuit Load

See Page 20 Circuit

EATON CORPORATION Control panel design guide

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Sizing the feeder

Reference Section 32.3.1 a

Transformer or Power Supply M L M

Motor Load 3.4 FLA

Motor Load 7.6 FLA

Motor Load 14 FLA

Motor Load 65 FLA

Heater Load 20A

Transformer Load (Primary Side) 1.95A

Example Multi-Load Panel

EATON CORPORATION Control panel design guide

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Breaker and Fused Disconnect Selection

NEMA 1/12/3R Rotary Handle Mechanism, 12 Shaft for EG EGHMVD12B

EMA 1/12/3R Rotary Handle Mechanism, 12 Shaft for JG JGHMVD12B

NNEMA 1/12/3R Rotary Handle Mechanism, 12 Shaft for LG LGHMVD12B

JGE3150FAG JGE3175FAG JGE3200FAG JGE3225FAG JGE3250FAG

EATON CORPORATION Control panel design guide

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Group motor design

Reference Section 31.4.1 c

Group MotorMultiple Motors Protected by a Single Set of Fuses or Breaker

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Manual Motor Controllers Short-Circuit Ratings for UL/CSAT Group Installations

XTSC and XTSR Frame B MMP + Frame C Contactor

XTSC and XTSR Frame D MMP + Frame C Contactor

XTSC and XTSR Frame D MMP + Frame D Contactor

120 Vac 24 Vdc 24 Vac 240 Vac

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Individual circuit for motor load

Reference Sections 31.3, 33.2, 34.2, 66.8

EATON CORPORATION Control panel design guide

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Motor Branch Circuit Types

Fuses Short-circuit protection

Breaker Motor disconnect Short-circuit protection

MCP Motor disconnect Short-circuit protection

Contactor Motor controller Overload relay Motor overload protection

Contactor Motor controller Overload relay Motor overload protection

Contactor Motor controller Overload relay Motor overload protection

Contactor Mechanical interlock Reversing link kit