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PANEL INFORMATION PACKAGE

GENERAL INFORMATION WHAT IS THE DEFINITION OF A PANEL?: Underwriters Laboratories considers industrial control panels as an assembly incorporating two or more pieces of industrial control equipment or related control circuit devices. In addition, this assembly shall incorporate interconnecting wiring and terminals for connections in the field and electrical ratings and instructions to allow the installer sufficient information to properly install the equipment in accordance with the National Electrical Code and local codes. This assembly may be installed in an enclosure as "enclosed type" equipment or arranged onto a mounting panel as "open type" equipment where the assembly will be installed in an enclosure provided by others or at the installation site. WHAT DOES THE UL LISTING MARK PROVIDE?: The UL Listing Mark on an industrial control panel provides evidence of a third party certification to the municipal inspection authority and/or to the purchaser of the panel that the assembly complies with an acceptable safety standard. The Listing Mark may be applied to a wide variety of designs ranging from custom built "one-of-a-kind" panels to standardised designs with only minor variations. WHAT IS COVERED BY THE UL LISTING MARK?: The UL Listing Mark on an "enclosed type" control panel only covers the enclosure and the components that are installed within the enclosure at the manufacturer's facility. The UL Listing Mark on an "open type" control panel only covers the mounting panel and those components that are mounted to it at the manufacturer's facility. Please note that the UL Listing Mark does not include coverage of any externally connected loads, even if provided by the panel manufacturer. Also the UL Listing Mark does not include coverage of any components shown on the wiring diagram that are indicated as being customer provided or as being not in the panel. If a complete equipment Listing is required, please contact us regarding our Factory Automation Equipment program. REQUIREMENTS FOR LISTING GENERAL USE PANELS: The requirements used to evaluate general use industrial control panels are covered by UL 508A Industrial Control Panels. This standard was derived from the Standard for Industrial Control Equipment, UL 508, the National Electrical Code, NFPA 70, and the Standard for Industrial Machinery, NFPA 79. A panel report will consist of general requirements that apply to all panels and a further section that is customised for each individual panel builder. This is intended to contain additional construction requirements and specific UL Recognised Components that have been found acceptable as a result of an engineering investigation. SPECIAL USE PANELS: Requirements covered by part 2 of UL508A shall be applied to panels which are intended for any of the following special uses: elevator control, overhead crane control, metal working machine tools, plastic injection moulding machinery, flame safety supervision control, power press, and service equipment use. If you intend to build any panels of these types, please notify us at the time of initiating the investigation.

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Page 2 ENGINEERING INVESTIGATION OVERALL LENGTH OF THE INVESTIGATION:

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Normally our investigation will be completed in approximately 6 weeks after receipt of a signed Application form. However, if you require panels to be labelled in less than 6 weeks, please advise us of the date by which you require Listing when returning the Application form and we will work with you to expedite completion of the investigation. TYPES OF APPLICATION FORMS: Multiple sets of Application forms may be sent to you once you have returned the attached request to open a project. One will be for UL Listing of General Use Industrial Control Panels and other forms may be for UL Classification of Power Press Control, Elevator Control and/or Flame Control Panels if requested. Please note that any additional Application forms are to be executed concurrent with the general use Application form. Also, a set of Follow-Up Service Agreement forms may be enclosed with the applications if Follow-Up Service has not yet been established by us for your manufacturing facility. These forms are to be signed by an authorised officer of your company. Instructions for the completion of these Agreements are included. These Agreements must be signed and received by UL before any labels may be applied. ENGINEERING COSTS: The cost limit specified on the Application form has been established based on the assumption that all components used within the panel are either UL Listed or Recognised and used as intended and within their marked ratings. Also this cost limit assumes only a single day will be needed at your facility for the required engineering visit. This cost limit does not anticipate evaluation of panel designs and constructions other than those discussed prior to this letter date. Subsequent designs/components may be submitted to us for evaluation, however there will need to be adjustments made to the cost and time necessary to complete this investigation. ADDITIONAL COSTS: The engineering cost limit specified on the Application form does not include travel expenses (such as airline tickets, hotel, rental car, meals, etc.) Any charges due to these activities or other non-engineering activities will be added to the final invoice statement. INITIATING THE INVESTIGATION: Please return the attached quotation acceptance so that application forms can be sent to you. Upon receipt of the signed Application form and the preliminary deposit in the amount specified on the form, we will open an engineering investigation to establish Listing service for your facility. ENGINEERING VISIT: A meeting will need to be held at your manufacturing facility in which we will discuss our requirements for building Listing panels. After this meeting, we will want to examine a representative panel design. After examining this panel, we will provide comments on any features that are not in compliance with our requirements. Note: During or prior to this meeting, it will be most beneficial if schematics are available for review. Also, it will be helpful if a list was available that contains only the UL Recognised Components that are to be used in the representative panel that will be examined at your facility.

Page 3 INITIAL PRODUCTION EXAMINATION:

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Before we can authorise the use of the Listing Mark on the panels covered by the application forms, we must have received properly executed Follow-Up Service Agreements, and your Local Field Representative must then conduct a first-of-production examination visit. This visit win be arranged in the best way possible to accommodate your production schedule. To assist us in this, we need complete information from you on your factory representative's name and telephone number, and the date when your panels are scheduled for production.

FOLLOW-UP SERVICE: Once Engineering has determined that your product meets the necessary requirements, we will establish a Factory Follow-Up Service Examination Program to audit the continued compliance of your panels with the specifications developed during this investigation. These specifications will be contained in a UL Procedure document that will provided to you. The product will then be eligible to bear a UL Listing and/or Classification Mark. Charges associated with this factory examination program will begin after your product becomes authorised to use our Marking. Further information on our Factory Follow-Up Service Examination Program, its fees and label information will be forwarded to your attention upon receipt of the signed grey Follow-Up Service Agreements.

Following are some general guidelines associated with the investigation of Industrial Control Panels.

Recognised Components. These devices may be marked with a symbol. Our Recognised Component Directory (yellow books, 3 volumes) contains the catalogue numbers and the manufacturers name for various categories. Details may now also be obtained free of charge at http://www.ul.com/database. The Recognised Components have certain Conditions of Acceptability (COA) associated with them. It is strongly advised that the Panel Manufacturer requests a copy of these COA from the Component Manufacturer to ensure that all the required conditions are met.

Listed Devices. All Listed Devices display the Listing Mark . This is the only method of identifying a product if it is Listed. Our "Green Book" contains names of manufacturers of Listed Components for various categories. Details may also be obtained from http://www.ul.com/database.

Unevaluated Componens. This means that the component is neither Listed nor Recognised.

Page 4 Please be advised of the following concerning the Panel investigations:

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Prior to visiting the manufacturing location, UL would like to receive a list of Components used and an electrical drawing of a typical industrial control panel construction. The list of components should include the device type cat no or model number, the manufacturers name, an indication if it is Listed or Recognised and the manufacturers UL file number if available. It should be noted that you may build panels and have no two that are identical. The intent of the control panel standard is to give the manufacturer as much flexibility as possible provided they manufacture panels within the guidelines. If not all of the components used are UL Recognised or Listed, they may be acceptable if provided with a GFCI - ground fault circuit interrupter (and certain restrictions), or testing will be required. The standard (UL508A) gives additional details in Appendix B. After the report is issued the panel manufacturer may add as many UL Listed or Recognised devices as required. If the device is Listed it is NOT necessary to inform UL (providing it is used within the specific ratings). if the component to be added is Recognised the panel manufacturer must inform UL so the file can be updated. We will provide panel manufacturers with several alternatives (where possible) allowing them to choose components from several different component manufacturers. If the enclosure is UL Listed and is used for the specific type for which it was investigated no further evaluation is necessary. If the enclosure is not UL Listed, it will be evaluated in accordance with sections 62 to 64 of UL508A.
NOTE: components intended to be mounted outside an enclosure with specific Type ratings such as disconnect switches, pilot lights, meters ETC., must be Listed/Recognised or be evaluated for the same rating as the enclosure. Example Type 4, 4X, 12 ETC.

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6. 7.

To conduct the investigation, the panel manufacturer needs to construct a TYPICAL Industrial Control Panel for UL's evaluation. Upon successful completion of the investigation (and assuming that there are no outstanding items needed from the manufacturer), the report will be issued in 2-3 weeks. If the manufacturer has to have the panel labelled in less time, arrangements can be made for an Initial Product Inspection and a temporary Follow-Up Services Procedure will be sent to the local UL Field Representative with Labels. It should be noted that we can cover the end product as well as the Industrial Control Panel. The category for this type of equipment would most likely be Factory Automation Equipment. You may want to inform your end product users that an investigation can be initiated by them to evaluate the overall equipment when they use your Industrial Control Panels.

8.

If you have any questions or comments once you have read the Panel Standard (UL508A) and the information provided, please do not hesitate to contact us. We will be happy to assist you in any way to help you complete the approvals process.

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UL 508A Control Panels Most Common Mistakes List


The following list of items has been compiled based on recurring issues encountered by our Field Representatives and Engineers when conducting industrial control panel inspections. A few moments spent now to review and avoid these pitfalls may save valuable time and money at your next inspection! 1) Misuse of supplementary fuses (and fuse holders) and supplementary protectors where Branch Circuit Protection is required. (Example, using UL Listed Miscellaneous Fuses instead of Listed Class J, K, R or CC fuses Because the Miscellaneous Fuses are only rated for supplementary circuit protection. Reference UL White Book for Listed product use limitations.) Supplementary devices are ignored when determining compliance with branch circuit protection requirements in 508A. The fuseholders intended for use with branch circuit fuses also have to be Listed for the proper fuse class! -These fuseholders will reject a non-branch circuit type fuse. Most Supplementary Protectors (a.k.a miniature circuit breakers) evaluated to UL 1077 are tested with a Listed fuse or Breaker (rated at 400% max of the supplementary protector) when shortcircuit tests are conducted. When installed in a panel the supplementary protector must be installed with upstream listed fuse or breaker to match conditions under which it was evaluated. 2) Variable Frequency Drives (VFDs) not protected in accordance with their markings VFDs may or may not be provided with motor overload protection and branch circuit protection. Drives provided with a motor overload function are marked to indicate the level of protection and have instructions on how to adjust the setting of the overload protection. (A current limiting function is not motor overload protection!) Drives that do not provide motor overload protection are marked to indicate this and the need for a separate motor overload to be provided, and sized per the NEC. Drives not provided with branch circuit protection include markings recommending specific size and type of branch circuit protection required. These markings will appear on the drive, drive stuffer, or drive instruction manual! Field wiring and branch circuit protection connected to the line side of the drive are sized based on the input current rating of the drive (not the motor current) 3) Use of Recognised Instantaneous Trip Breakers in place of branch circuit protection a.k.a Mag Only Breakers or Motor Circuit Protectors or MCPS) These breakers have only a magnetic trip operation for short-circuit protection capabilities, and have no thermal overload trip protection (it will never trip at the ampere rating on the handle) as in a conventional Listed breaker. These breakers may only be used as branch circuit protection for a motor circuit when purchased as part of a Listed combination motor controller or otherwise the breaker must be investigated for use with the specific vendor and part no. of the contactor and overload relay to be used (and described in file.) 4) Transformer Protection- The NEC is the bible here; we simply took their requirements and used them in UL 508A. Read the section on transformer fusing thoroughly and call us if you are not sure about the size or type of fuses required, if any! Do not confuse control circuitry with power circuitry. read the definitions in UL508A! Some transformer vendors supply a table of recommended fuse sizes for protection of their transformers; however, we have found that these tables do not always comply with the 508A requirements! The calculations are not difficult, take a few moments to work through them. your UL Field Representative will do this during the inspection. 5) Markings are always a killer for the first time UL panel builder! The fuse replacement markings and field wiring and terminal markings (Terminal Torques, field wire temperature ratings and type-Cu) are the most overlooked. Also, the panel schematics and motor overload heater (replacement) table markings must be provided. Overload relay manufacturers provide a crack and peel label with this information in every box but you must sift through all the packaging to find it. If the markings arent overlooked, they are not properly printed or misplaced so as not to comply with the requirements in 508A. The purpose for providing these markings is to aid, instruct or caution the user, installer and service person-hence ALL MARKINGS ON THE PANEL ITSELF MUST BE VISIBLE AFTER INTALLATION!

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6) Control circuit wire sizing- (See table 29.1 in UL508A) Many builders undersize the wiring. The wires must be sized based upon the rating of the fuse upstream. 3 ways to address this are to: 1) fuse smaller wires separately, 2) use larger conductors or 3) use smaller fuses upstream. 7) Destroying Evidence of UL Listing or Recognition and Component Ratings- The UL panel program and the flexibility afforded to panel builders is largely based on the use of UL Listed and/or Recognized Components. The UL Field Representative needs trace ability for each component (including wire) in order to determine the condition of acceptability for a UL Recognised component and compliance with 508A requirements. The trace ability is maintained when all the original manufacturers marking, (whether on the component itself, on the packaging or on stuffer sheets provided by the manufacturer) are available for review by the UL Field Representative at the time of the inspection. Most panel builders want a tidy, clean shop, so once they install a terminal block or an overload relay or even conduit fittings, they throw away the box and everything in it! For some components, the UL Listing or Recognition Mark and ratings may be on the packaging and not on the part itself. This is true for small components, heat elements, wiring and many others. The unavailability of this essential information usually costs time, an hour or more on average, considering phone calls have to be made to the supplier(s) or a UL Engineering Office during the UL inspection to determine what the part they have installed is rated, and is it UL Listed or Recognized? Very costly...it is best to save one copy of all different component cartons, info sheets and installation instructions for listed and Recognized components! 8) Enclosure-mounted devices- Many panel builders buy an enclosure with specific environmental rating only to cut holes for conduit, components or for mounting components directly to the enclosure. This practice immediately brings the environmental rating of the enclosed panel into question and requires an evaluation to determine the environmental rating for the modified panel enclosure (note even popping rivets through the enclosure to hold the name plate will effect the environmental Type rating. For any rating other than type 1, the components installed in these openings must be tested for desired type rating. Unless all of the components are Listed or Recognized with marked type ratings equal or better than the rating of the enclosure, the panel may need to be derated or tested. Tables 19.1 and 19.2 in UL508A is what our field representatives will refer to when determining an environmental rating on your panel. Note- do not confuse something marked with NEMA__ as a listed Type Rating (We accept Type __ or NEMA Type __) 9) Placing UL508A Labels on panels for use in Hazardous Locations or on panels including Intrinsically safe circuitry- The scope of UL508A does not cover Intrinsically Safe or Hazardous Location Panels, they are covered under two separate UL Standards. UL508A currently does not prohibit panel builders from using UL Listed Intrinsic Safety Barriers or other Hazardous Locations components (e.g. PLCs for use in Hazardous Locations) in panels with a 508A label as long as the panel and all connected circuits are installed in an ordinary (non-hazardous) location. No references to class and division or zones can be made on the panel or its literature. If the load side of intrinsic safety barriers will extend into hazardous location, there are additional requirements for increased space, physical separation of circuit wiring, special conduit fittings and markings that may require significant re-work or re-design of the panel. An electrical inspector would be correct to red-tag a 508A panel being misused by installation in or connected to a hazardous location. If doing any Haz. Loc. Panels, please contact UL. 10) Power Supplies- The only circumstances under which a power supply secondary can be loaded at more than 50% of its ampere rating is when it has passed the temperature test rating in accordance with UL508, is fully enclosed and provided with means of connection to conduit, or if it is fused (each secondary) at 50% of its rated load. If fused, secondary conductors should be sized according to the fuses protecting them. 11) Enclosure Ventilation- General rule of thumb: Enclosures, which are ventilated, should be submitted to UL Engineering for evaluation and description in the UL procedure. Even UL recognized Fan/Ventilation kits have certain conditions of acceptability which are integral to their recognition and these conditions must be met when used in a listed control panel. KEEP THESE SHEETS HANDY!

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SIGNIFICANT INTERPRETATION FOR SCOPE OF NITW


Background: NITW has become a catch-all category. In an attempt to redefine the scope the following is a compilation of additional Listings which may provide for a more accurate investigation. Although the components in these products may be similar to industrial control panels, the applications are very different.

Interpretation: The following categories should be utilized instead of NITW as appropriate.

SWITCHBOARDS, DEAD FRONT TYPE (WEVZ) Dead front switchboard sections are designed particularly to provide safety to the operator, but they are not necessarily dead back boards. The basic standard used to investigate products in this category is UL 891, DeadFront Switchboards.

SPECIAL PURPOSE SWITCHBOARDS (WFJX)- This listing covers theatre switchboards, incandescent lighting switchboards with dimmers, and laboratory switchboards rated at 600 volts or less, The basic standards used to investigate products in this category is UL 891, Dead-Front Switchboards.

PACKED PUMPING SYSTEMS (QCZJ) This category covers fluid handling systems consisting of pumps, electrical motors, frequency drives, control valves, gauges and piping mounted on a structural steel base. They are used for plumping boosters, heat transfer, hot water heating, HVAC chilled and hot water packages, irrigation, boiler feed and condensate packages, and similar applications. The basic standards are used to investigate products in this category are UL 508, Industrial Control Equipment UL 778, Motor Operated Water Pumps and UL 508A the outline investigation for Industrial Control Panels Packaged pumping systems for heating and cooling equipment are evaluated in accordance with UL 1995, Heating and Cooling Equipment.

POWER DISTRIBUTION CENTER FOR COMMUNICATIONS EQUIPMENT (OPQY) This listing covers power distribution centres for communication equipment rated 600 volts or lees. Power distribution centres contain equipment such as circuit breakers, suitable investigated supplementary protectors, contactors, fuses, switches, including pull-out types and related accessory equipment.

POWER DISTRIBUTION EQUIPMENT PORTABLE (QPRW) This listing covers (1) portable power distribution units and devices, and (2) portable power distribution panels intended for use in the following locations: carnivals, circuses, fairs and similar locations in accordance with article 525 of the NEC; exhibition halls or similar locations in accordance with article 518 of the NEC; theatres, audience areas of motion picture and television studios and similar locations in accordance with article 520 of the NEC; motion picture and television studios and similar locations in accordance with article 530 of the NEC; and construction sites in accordance with article 305 of the NEC. The basic standard used to investigate products in this category is UL 1640 Portable Power Distribution Units. Similar products not in this category: units for use in theatre or studio rigging immediately adjacent to stage lighting fixtures are covered under the category Stage and Studio Fixtures (IFDZ). Portable cord connected units rated 250 volts ac or less, 20 amps or less, which are intended for indoor use as multiple outlet extensions of a branch circuit to a central location supply laboratory equipment, a home workshop, home movie lighting control, etc are covered under the category Re-locatable Power Taps (XBYS). Connector assemblies consisting of factory assembled plugs and cord connectors attached to extra hard service cords or cables are covered under the category Cord Sets and Power Supply Cords (ELBZ.)

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PORTABLE POWER DISTRIBUTION UNITS AND DEVICES (QPSH) This Listing covers portable power distribution equipment of standardized type of configuration. Portable power distribution units are assemblies of listed products, Recognized components, or both, contained in complete electrical enclosures. They may incorporate disconnecting means, over current devices control components, receptacles for attachment plugs, stage and studio type inlets and connectors and the like. This listing also covers cable mounted bus bar clamps for use with portable power distribution units as well as partially enclosed, plastic framed cable splicing blocks.

PORTABLE POWER DISTRIBUTION PANELS (QPSM) This listing covers portable power distribution panels built for specific applications. These products are assemblies of listed products, Recognised components, or both, contained in complete electrical enclosures. They may incorporate disconnecting means, over current devices, receptacles for attachment plugs, stage and studio type inlets and connectors, and the like. These panels are intended for the use in applications specified for Portable Power Distribution Units in the NEC.

POWER OUTLETS AND POWER OUTLET FITTINGS (QPYV) This listing covers power outlets rated at 600 volts or less. Although not restricted to such use, power outlets are intended for use in indoor and outdoor installations where power is required to operate portable, mobile or temporarily installed equipment. The basic standard used to investigate products in this category is UL 231, Power Outlets.

UNIT SUBSTATIONS (YEPR) This listing covers unit substations rated 600 volts or less intended to be installed in accordance with the requirements of the NEC and in accordance with the installation instructions provided on the unit substation. A unit substation consists of a transformer in combination with primary and/or secondary over current protective devices or switching devices housed in a single enclosure. The basic standard used to investigate products in this category is UL 1062, Unit Substations.

UNIT SUBTATIONS OVER 600 VOLTS (YEFV) This listing covers articulated and integral unit substations. They are three phase, for step down operation. Articulated substations are rated through 10,000 KVA, at primary voltages of 601 volts through 38KV (nominal 35KV.) Integral substations are rated through 2500 KVA at primary voltages of 601 volts through 38KV. The articulated unit substations consist of a transformer section(s) together with input section(s), and output section(s), or both. Transition sections may also be provided. These unit substations are designed, co-ordinated, and assembled as multiple self-enclosed pieces of equipment intended for connection in the field. The basic standard used to investigate articulated unit substations is ANSI/IEEE C37.121-1989, Unit Substation Requirements. The integral unit substations consist of a transformer section(s) together with an input section(s), and output section(s), or both. Transition sections may also be provided. These unit substations are designed, coordinated, and assembled as a single self enclosed piece of equipment. The basic standard used to investigate integral unit substations is ANSI C37.120th 19XX (17 draft 7/12/79). Proposed American National Standard for Integral Three Phase Unit Substations.

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