Published by 8 9, Florham Park, New Jersey 07932
File Index: Automatic Transfer Switches
Summary Overview, IEC 60947 Low-Voltage Switchgear and Controlgear
Abstract On the surface, it might appear the criteria for
IEC standards are quite different from those of UL
standards for similar equipment. However, when it is
realized that physics determines equipment performance
in electric power systems, the differences are readily
understood. This paper is intended to review pertinent low
voltage equipment standards of IEC and UL to provide a
better understanding of their content and impact on the
design and selection of products for application in electric
power systems.
Introduction The two most recognized standards in the
world that influence the design of low voltage switchgear
and controlgear are those issued by the Commission
Electrotechnical Internationale, CEI/IEC, an Underwriters
Laboratories, UL. Each of these agencies has had a
positive and profound influence over the design,
manufacture and qualification of low voltage electrical
equipment used in the generation, distribution and control
of electric power. The driving impetus behind these
standards is to provide for a consistent measure of
comparison between the various equipment to assure that
the proper device is selected for a given application. The
underlying purpose is to provide for the safety of people
and property. The work of these bodies has been adopted
by code making agencies and law writing assemblies
throughout the world. Such organizations as the National
Fire Protection Association, NFPA undertook to write
codes governing the installation and use of electric
equipment. Organizations like NFPA, make it a
prerequisite that installed equipment be independently
certified as having met the criteria of the applicable IEC
and/or UL product standards.
Each product has a specific function to serve. Accordingly,
a standard is written for each type of equipment. Where
circuit interruption is the function of the device, the
standards prescribe a qualification regimen that assures
that the product will interrupt current without developing
an environment that will lead to a hazard of fire or
personnel safety. Where load switching is the function to
Volume 3, Number 6
be satisfied, the qualification regimen assures that
sufficient life is designed into the product without
sacrificing safety. Since there is a proliferation of
electrical equipment used in the generation, distribution
and control of electric power, it is a worthwhile endeavor
to identify the range of equipment, applicable standards
and their qualification requirements.
The Standards Table 1 lists the various products and
applicable standards. Not listed, but referred to in the
relevant product standard, IEC 60947-1 specifies the
general rules. Consequently, in complying with the
relevant product standard, such as 60947-6-1, the qualified
product also complies with 60947-1. UL standards, stand
on their own but do make reference to other UL standards
that would apply to parts or components of the product
under investigation. An example of this would be compli-
ance of an insulating material with flammability tests.
Product IEC UL
Switchgear, controlgear 439 891, 1558
Circuit Breaker 60947-2 489, 1066
Switch, Disc, Fuse 60947-3 98, 977
Magnetic Starter 60947-4-1 508
Automatic Transfer Switch 60967-6-1 1008
Table 1. Standards applicable to low-voltage electrical
equipment.
As this discussion unfolds, comparisons will be made
between the two standards that apply to each specific
product within the scope stated herein. The interesting
thing that will become apparent is that a product qualified
to an IEC standard will be suitable for use in the same
function when evaluated against the appropriate UL
standard. This does not say that having met one standard,
the product does not have to undergo qualification testing
to the other standard. It does say that having met one
standard, the product will successfully qualify under the
other standard. This is certainly as one would expect. After
all, it is the laws of physics that govern electricity. As this
discussion will show, the fundamental difference between
the standards of the two agencies, for any given product,
are the measures used to determine successful testing.
The criteria for establishing product performance
requirements come from the environment in which the
products find use. These environments are a function of
codes and physics. It is the code that determines the
location of a product in the power distribution system. It is
the physics of the system that determines the needs of the
product. For example, the codes, NFPA 70 and IEC 60364
specify that overcurrent protection be provided in electric
circuits to protect against overheating conductors. The
purpose is to minimize the hazard for fire. Accordingly,
these codes stipulate that the conductors of a circuit must
have overcurrent protection at the point where the
conductors receive their feed. This makes obvious sense.
These same standards/codes stipulate that load controllers
be placed close to the load they serve. Motor starters and
disconnects are specified to be located at or near the motor
so that they can be observed from the motor. The obvious
purpose of this requirement is to provide personnel safety
to the staff that service electrical loads such as motors and
machinery. There are exceptions stated in many sections
of these standards/codes. However they are narrowly
defined and limited. The overriding concern is to limit
exposure to the hazards of fire and personnel injury.
The physics of the situation determine the required ratings
of the products. A branch circuit having conductors
suitable for 200 amperes of continuous current flow can
be fed from a electric service of any continuous rating.
While the overload setting of the breaker may be required
to be 125% of 200 amperes, the interrupting rating of the
breaker would have to be sufficient to interrupt whatever
value of short circuit current might be available from the
source. If the service is large in comparison to the load, for
example if the service is capable of delivering 10,000
amperes of fault current, the overload protection would
have to be capable of interrupting this value of current
within the qualification requirements of IEC 60947-2 or
UL 489 for circuit breakers. If the available fault current
were fed from a spot network of paralleled transformers,
it could reach values in excess of 100,000 amperes. The
breaker would then be required to safely interrupt this
level of current. At this value, it is likely that the overcur-
rent protective device would either be a fuse or fused
breaker using a current limiting fuse. This discussion
suggests that there are several levels of equipment perfor-
mance. These levels are determined more by the physics
of the circuitry than by the standards/codes. It would be a
relatively simple matter to design an electrical product to
Page 2
deal only with its normal environment. However, it is the
abnormal environment that typically presents the criteria
for product design. And so, electrical products used in the
low voltage generation, distribution and control of electric
power are designed with the normal environment in mind
yet are qualified for the abnormal environment during
which they will be called upon to operate. Circuit
breakers are called upon to interrupt high currents but
typically not frequent interruption of their continuous
rated current. Magnetic starters are called upon to make on
6 X their continuous current but not to make on high fault
currents. While the ATSE does not have to interrupt fault
currents, it does have to make on them and frequently
switch its rated current. From this brief comparison, the
ground work is laid for the performance requirements of
the relevant product standards. At the conclusion of this
evaluation of product standards it will be clear why circuit
breakers are used for protection, motor starters are used
for motor starting and stopping and transfer switches are
used for transferring loads between power sources. While
each product will serve well in its intended role, it does
not serve so well in another of the four roles of equipment
discussed.
Electrical equipment that serve in a switching mode,
breakers, disconnects, contactors, ASTE, etc. are
subjected to a standard regimen of tests. This regimen will
include, among others, dielectric withstand, endurance
and overload switching, temperature rise at rated current,
interruption and close-on at high current. The basic nature
of electric circuits and equipment is typically inductive.
For those few instances where it is capacitive, the
standards require specific qualification tests. Because it is
more cost effective, designers strive to achieve operating
power factors as close to unity as practical. Consequently,
steady state operation of electric equipment typically
presents a high power factor. Accordingly, endurance
switching qualification testing is conducted at high power
factor, 0,8 to 1,0. The severest switching occurs with
motor disconnect in a stalled rotor condition. For this
reason, overload switching qualification tests are
conducted at moderate power factors, 0,5 to 0,8. The worst
case for switching occurs during short circuits. In such
cases, because conductor resistance is initially so low
compared with circuit inductance, close-on and interrup-
tion qualification testing is conducted at low power
factors, 0,2 to 0,5.
The significance of power factor in switching lies in arc
interruption. Arcing erodes contact surfaces and material.
It produces gasses containing conductive particles. These
gases encourage the continuity of current flow across the contact wear. Conversely, for the lower power factor
contact air gap until either the current goes to zero, i.e. in switching duties of electrical equipment, test criteria call for
the zero cross over of the sine wave, or until the gap is fewer switching cycles. In endurance testing (high power
stretched so far that the density of conductive particles factor), switching cycles may number in the thousands; in
reduces to the point where the voltage will no longer overload testing (intermediate power factor), switching
sustain the arc. Figure 1 is a graphical representation of cycles will typically number in the tens; in short circuit
contact voltage and current at circuit interruption. The close on or interruption, (low power factor), switching
example depicts a circuit interruption at about 45o into cycles will number one or two.
the voltage wave. Because there is a current flowing at
the time of contact opening, the voltage across the Both the IEC and UL switchgear and controlgear standards
contacts increases to 100 volts ( the approximate value of are quite demanding with respect to product performance.
arc gap voltage in free air ). As long as the contact gap However, they permit a broad range of product ratings
has not stretched beyond that which will permit current because they recognize the diverse needs of electrical loads
flow and as long as there is current flow, the arc will throughout the world. Both are sound standards because
continue. (Opening speed of low voltage contacts is their qualification requirements are based on physics and
typically not fast enough to stretch the gap beyond a the effects of the generation, distribution and control of low
conducting distance within the first half cycle.) At the voltage electric power. Products qualified to either standard
higher power factor of 0,95, the left hand trace, note that should find ready qualification to the other standard. As will
the current goes to zero at 198,2o. At the lower power be seen throughout this discussion, this theme will repeat
factor of 0,2, the right hand trace, note that the current itself. A product qualified to an IEC standard will gain
goes to zero at 258,5o. qualification to the relevant UL product standard and
vice-versa. This does not say that they will carry the same
The traces assume that the interruption is successful at ratings in both standards, as will be seen when the standard
the first current zero crossover after contact opening. In applicable to circuit breakers is evaluated.
this example, the arcing time is 40% longer for the lower
power factor case.

150.00 150.00

100.00 100.00

50.00 50.00

0.00 0.00
Magnitude
Magnitude

0 50 100 150 200 250 300 350 400 0 50 100 150 200 250 300 350 400
E(C) I(.2)
-50.00 -50.00
I(.95) E(C)

-100.00 -100.00

-150.00 -150.00

-200.00
-200.00

-250.00
-250.00
Phase Angle
Phase Angle

Figure 1 . Effects of power factor on arcing.

The vaporized contact material created by arcing, It would make sense to evaluate the equipment in the order
produces a rapidly expanding pressure wave that can in which it appears in the power distribution system.
have explosive effects. As an indication of the ferocity of Accordingly, the first product to be discussed is switchgear
this pressure wave, when changed from a solid to a vapor, and controlgear assemblies.
copper expands to 6400 times its initial volume. From the
Ideal Gas Law, pV = nRT, it can be determined that the Switchgear and controlgear assemblies. The applicable
pressure associated with a 6400 times increase in volume standards for switchgear and controlgear assemblies are
would produce a substantial and explosive wave front. IEC 60439-1, UL 891 and UL 1558. Aside from the fact
For this reason, electrical equipment is tested in its that UL 1558 applies to the use of low voltage power air
intended enclosure. Given that the arcing time in the circuit breakers in switchgear assemblies only and UL 891
lower power factor case is longer, the material vaporized will allow molded case breakers, fused switches and low
from the contacts will be increased. Thus for the lower voltage air power circuit breakers, there is little difference
power factor case, one can expect significantly more in the qualification testing for similar current ratings of the
Page 3
final product. In UL 891, if the manufacturer uses a bus
design as shown in the standard, type testing is signifi-
cantly reduced. In both IEC 60439-1 and UL 1558, full
type testing is required. The type testing establishes that
the assembly is capable of serving the intended need.
T1 2.5 MVA T2 2.5 MVA
3.6 kA 3.6 kA
400 VAC 400 VAC
M2
TIE
Figure 2. Double ended switchgear assembly.
Switchgear assemblies find use as the main service and
power distribution equipment in buildings. Additionally,
this product finds use as emergency power generator
paralleling controlgear. Because the need for continuity of
power to critical loads has grown significantly over recent
years, emergency power requirements have gone beyond
the ability of single engine generator sets. The most cost
effective means of providing bulk emergency power to
larger facilities is to parallel several sets on a common
bus. It is this element of the application of switchgear and
controlgear that has created a market for high current low
voltage products. Just a decade ago, the typical maximum
current bus available in this class of product was 4,000
amps. This was the case because most switchgear and
controlgear serving as service entrance equipment were
fed by the secondary of a transformer whose maximum
rating rarely exceeded 2500 kVA. In larger facilities, the
utility service may be fed through several of these
transformers arranged as double ended switchgear
assemblies with a tie breaker between the two busses.
Such an arrangement is shown in figure 2. In these large
facilities, the alternate power systems are likely to be
configured from several engine generators paralleled on a
common bus. If it is assumed that a facility uses three of
these double ended switchgear assemblies for normal
power, its demand would be upwards of 15 MVA.
assuming that the critical load comprised only 40% of the
total load, an alternate power supply of 6.0 MVA would
be required. To meet this demand, it would make sense to
parallel four 1.5 MVA engine generators on a common
bus for optimum reliability and redundancy to the most
critical loads. The controlgear for paralleling four 1.5
MVA generators at 400 VAC would require a main bus
rating of 8.66 kA.
Page 4
1.5 MVA
2.17 kA
G1 G2 G3 G4 400 VAC
9kA
Bus
Figure 3. Generator paralleling and power distribution
switchgear.
Figure 3 is representative of such a power system. Note
that the main bus requirement is larger that that of the
normal service busses. This is quite often the case. The
main driving force behind increasing the continuous
ratings of switchgear and controlgear busses is the
demand for larger low voltage generator power systems.
In the past decade, these bus ratings have gone from 4 kA
to 6 kA and more recently to 10 kA.
While the standards don’t restrict the maximum allowable
continuous current to any specific rating, they do establish
the criteria for achieving the qualified status of the
product. This is done by establishing safe guidelines
within which the product must operate. The guidelines are
fundamentally physical limits determined by the service
voltage, continuous current and short circuit current. The
concerns for voltage are centered on the suitability of
insulation material and its ability to withstand voltage
gradients and potential differences. In this regard,
minimum creepage and clearance distances are defined.
Insulating material is judged on the basis of dielectric
strength at ambient and operating temperatures. Since
breakdown of an insulating material is a function of the
material and voltage, the creepage and clearance distances
for the IEC and UL standards are consistent. Typical
dielectric test values for 600 volt class equipment is 2500
VAC and 2 X Ue + 1000 volts.
The continuous current rating of a switchgear bus is
determined by temperature rise tests. The bus is operated
at the sought after rating until it comes to constant
temperature, no more than a 1 k/hr change in temperature.
When the temperature stabilizes, measurements are made
at specified points throughout the bus structure and
compared against allowable temperature rise tables in the
standard. Between the two agencies, the tables are fairly
close. The IEC standard allows a slightly higher tempera-
ture in some cases than the UL standard. All insulating
and support materials are evaluated to assure adequate
performance at the operating temperatures. While not
absolutely demanding copper as the bus material, the
standards strongly suggest copper. In practice, copper is
the bus material of choice. There are some products that
will use aluminum. However, the standards do emphasize
careful consideration of electrolytic and galvanic actions
of dissimilar materials. The major concern for high
continuous current ratings on busses is to maintain
temperature within allowable limits without requiring
forced air cooling. If care is exercised in the design to
accommodate proximity and skin effects, a qualified cost
effective high current bus can be achieved. There are
qualified low voltage busses rated to 10,000 amps and
will probably take a step up to 12,000 amps in the near
future.
The final major area of concern for the qualification of
switchgear and controlgear centers around the ability of
the bus structure to withstand the effects of short circuit
currents. Looking back at the two figures, one could
expect an available fault current of 62,6 kA at the
secondary side of the transformer with an unlimited
utility service on the primary. Given that most generators
of the 1,5 MVA rating today are permanent magnet
generators, one could expect an available fault current
from the four generators of 86,6 kA. It becomes obvious
that this level of short circuit current can cause consider-
able damage if the switchgear bus is not capable of
withstanding forces associated with the magnetic effects
of currents of this magnitude.
In both the IEC and UL standards, busses are rated to
withstand fault currents as determined by the protective
device. The tests conducted are based on the type of
clearing device, (fuse or breaker), the level of current the
device will let through and for how long that current will
be allowed to flow. Fuses are typically rated to interrupt
higher current than breakers, but they do it in a shorter
period. When operating in its current limiting range, a
fuse will clear a fault current typically in less than a half
cycle. The breaker, depending on whether it has a short
delay trip or instantaneous will clear a fault current in 2 to
25 or 30 cycles. Only the larger breakers will have an
appreciable short time delay, up to 30 cycles, for the
higher currents, currents in excess of 20,000 amps. So the
switchgear designer picks the protective device intended
for use and states the current level and time for which the
bus is to be evaluated. If the device is fused, testing will
be done at high currents, perhaps up to 200,000 amps, for
subcycle periods. If a power breaker is selected, the
testing can be done at up to 85,000 amps for 0,5 seconds.
Some breakers will have an ultimate interrupting rating of
100,000 amps with a clearing time of up to two cycles.
Bus short circuit testing can be done at this level as well.
Most manufacturers of switchgear and controlgear
assemblies serve broad market needs. Consequently, their
bus designs will be placed into service with differing
configurations of breakers and fuses. For this reason, the
standards permit testing without protective devices and
require instead that the manufacturer stipulate a time
duration and current level for the test. Since the test is
done on the bus structure, if it survives a current level for
a time that encompasses several protective devices, the
structure is more broadly applicable. One manufacturer
tested its switchgear design for 200,000 amps for 0,066
seconds, and 85,000 amps for 1 second. Since this test
was conducted on the smallest cross section bus structure,
2 kA, the product was qualified for the full range of the
product.
The principle concern over high fault currents is centered
around the mechanical ability of the bus structure and
supports to withstand the magnetic forces accompanying
the current peaks. These forces are a function of the
square of the current and the linear distance between the
parallel current paths. The closer the current paths are, the
stronger the accumulative force is. This force will cause
the conductors to be pulled together if the current in both
paths is flowing in the same direction. The force will push
the conductors apart for currents flowing in opposite
directions. At the conclusion of a test, the structure is
inspected to insure that the damage level does not reduce
the ability of the bus to continue to carry rated current. In
addition, a dielectric test is conducted to assure that none
of the insulators and mounts have deteriorated.
Where testing has been done on a switchgear or control-
gear product to establish qualification to an IEC or UL
standard, and that testing has been witnessed by a third
party, submission of the test results to the other approving
party for an equivalent approval to the remaining standard
should suffice as evidence of qualification. It would seem
that prudent judgment would require an inspection of the
product proposed for qualification but if the test results
are certified, they should be acceptable.
While the IEC standard discusses isolation and barriers
more thoroughly, the segregation requirements are quite
similar to those stipulated in UL 891 and 1558.
Construction of the assemblies is relatively similar with
allowance for differences in the accepted standard height
of these assemblies. UL products tend to be 90 in.
(2,286 m) high. IEC products tend to be 2,0m (78,74 in)
high. Cable terminations are quite similar. These products
Page 5
typically provide hole patterns in the bus landing pads to function as utilization category B. Only category B
accommodate cable lugs. A typical lug is a screw type that breakers are subject to short time withstand current tests.
will accommodate a range of conductor diameters. When Comparable in UL, short time withstand current tests are
crimp lugs are required, the hole pattern is punched to conducted on breakers furnished without instantaneous
match the specified lug. trips. Typical duration for the short time withstand test is
from 0,3 to 0,5 seconds. Before the solid state and
Circuit Breakers The standards applicable to circuit microprocessor trip era, short time trip functions were not
breakers are IEC 60947-2, UL 489 and 1066. UL 1066 available in molded case breakers. The introduction of this
pertains to low voltage air power circuit breakers. UL 489 new trip function sensing technology has enabled more
pertains to molded case and insulated case breakers. IEC flexible coordination and multifunction trips in molded
60947-2 states in its scope,”... It (60947-2) applies what- case breakers. However, short time trip functions in
ever the rated currents, the method of construction or the molded case breakers are typically quite short in time 4 to
proposed applications of the circuit breaker may be. ...”. 6 cycles and relatively low currents in the 10 k A to 15 kA
The UL standards present a list of continuous and short range.
circuit ratings from which the manufacturer is encouraged
to choose when specifying the performance of the circuit The overload and operational performance capability tests
breaker. The IEC standard, with the exception of the ICS are found in the general performance qualification
rating, permits the manufacturer to specify the regimen. Overload testing is conducted at 6 X rated
performance ratings. In either case, the manufacturer continuous current and 0,5 power factor in both standards.
assigns a continuous and interrupting rating to the circuit IEC testing differs in that it does not require the overload
breaker. These assigned ratings determine which, and the test for breakers rated higher than 630 amps continuous.
severity of the tests to be conducted for qualification. The number of cycles of operation differ between the
standards with the UL standard requiring more operations.
To determine suitability for service at the selected Endurance, operational performance capability, test
utilization voltage, Ue, a dielectric test is conducted requirements in switching cycles both with and without
typically at 2500 volts or 2 X rated + 1000 volts current, are comparable between IEC and UL for breakers
depending on if the test is conducted before or after rated over 250 amps.
current performance tests. A dielectric test is conducted
FI LE:
after each regimen of current tests to determine success. A DATE: CONTINUOUS CURRENT
temperature rise test is conducted on a new sample at full STD. MFG. 250 400 RATING
600 630 800 1200 1250 1600
IEC 947-2 A 22 25 25 25 25 25
rating prior to other tests to determine suitability of the 690 VAC G 18 18 18
product for continuous current. The temperature rise at M 10 12 12 40 40
S 18 25 25 35
various points throughout the product are compared with UL 489 C 25 35 35 35 50
the allowable rises for those points in the standard. If the 600 VAC D 25 25 25 65 65
G 25 65 65
actual rise at all points is below the allowable, the product S 25 35 35 50 50 50
passes the test. UL 1066 C 42 50
600 VAC G 42 65
S 42 65
The next series of tests confirm the ability of the breaker
to trip at the calibrated currents in the specified time. NOTES: 630 and 1250 A continuous rating is an IEC rating only

Since each of these current interrupting regimens causes

contact wear, the interruption tests are conducted on
several samples. For example the overload and endurance
make and break tests are conducted on one sample. The
interrupting tests are conducted on one sample. Reference
is made to the three trip functions of overload, short time
and instantaneous. The overload is the long time delay trip
function which will cause the breaker to automatically
open within a few minutes when the current exceeds 1,5 to
2 X its continuous rating. The short time trip function is
not furnished in all breakers. While no distinction in type
is made in the UL standard for a short time trip function,
IEC 60947-2 defines the breaker without a short time trip
function as utilization category A and those with this
Page 6
Table 2. Comparison of breaker interrupting ratings
( kA ). (Icu for IEC breakers)
In the IEC standard there are two levels of short circuit
tests. They are the rated service short circuit breaking
capacity, Ics and the rated Ultimate short circuit breaking
capacity, Icu. Since the test sample must pass a
temperature rise test at rated current after the rated service
short circuit breaking test, the current level is lower than
that of the ultimate short circuit breaking test. Criteria for
passing the ultimate short circuit breaking test is dielectric
withstand and verification of overload releases. This is
similar to the criteria for passing in the UL interrupting
ability test regimen. This argument is supported by the
comparison of breaker interrupting ratings presented in
Table 2. This table lists the Icu rating of several IEC
qualified breakers against the Interrupting rating of UL
qualified breakers.
While there are differences between the qualification
regimens for IEC and UL qualification, there are many
similarities as well. This is as would be expected. Product
performance is a function of physics. While the Icu
ratings given in table 2 are lower than the interrupt ratings
for the UL qualified breakers, the tests for IEC qualifica-
tion are conducted at a higher voltage. The interrupted
MVA in each comparable product is in the same order of
magnitude. It is quite likely that any given breaker tested
to the performance requirements of both standards would
produce the same results as a comparable breaker. Given
an IEC breaker tested to the UL standard, it would likely
achieve similar results to a UL breaker of the same type
and frame rating.
Switches, Disconnectors Switch disconnectors and fused
switches are typically manually operated units. There are
some cases where they are electrically operated. The
scope of IEC 60947-3 includes switches, disconnectors,
switch disconnectors and fused combination units.
Specifically excluded from the scope of IEC 60947-3 is
equipment coming within the scope of IEC 60947-2, -4
and -5. However, this standard allows for a unit that might
be used for individual motor control. Where this is the
case, Appendix A of this standard invokes the fundamen-
tal requirements of IEC 60947-4. In the UL venue, UL 98
& 977 pertain to fused power-circuit devices. UL 508
would cover definite purpose controllers as well as
contactors. The comparative analysis of the standards
with respect to contactors is covered in the next section of
this discussion.
As will be seen from the qualification regimen of IEC
60947-3, devices qualified under this standard are not
intended for frequent or repetitive switching under loaded
conditions. The making and breaking requirements
stipulate only 5 operating cycles. Operational
performance switching requirements are 25% or less of
the requirements for other devices such as breakers,
contactors and ATSE. Short circuit making and withstand
requirements are significantly less than those required of
breakers, contactors and ATSE. The test regimens of these
IEC and UL standards suggest that this type equipment is
not suitable for frequent switching under load or for
making on high currents.
Contactors and motor starters Contactors and motor
starters are evaluated to IEC 60947-4-1 or UL 508, when
they are qualified. For the purpose of this discussion, we
define a contactor as a switching device that is magneti-
cally held in the closed position through an electromag-
net. When control power is applied to the operating coil of
the contactor, the main contacts close. When control
power is removed from the operating coil of the contactor,
the contacts fall to an open position. Performance test
regimens for type qualification of contactors include
temperature rise, operating limits, overload, endurance,
short circuit withstand and closing and dielectric voltage
withstand. As was the case for circuit breakers, the
temperature rise tests allow slightly higher temperatures
for IEC qualified contactors than does the UL standard.
Dielectric withstand voltage tests confirm the insulation
integrity of the device and are used as a measure of
success after the conduction of the various performance
tests.
With respect to AC service, contactors are classed
according to their intended service. As will be seen in the
comparisons made for the various tests, where that service
is motor starting and stopping, more stringent perfor-
mance criteria will prevail. Both standards require that the
overload and endurance performance tests be conducted
on the same sample. Table 3 lists the overload perfor-
mance test criteria for various utilization category contac-
tors. (There are other classes and utilization categories in
the standards which will not be addressed in this
overview.) Note that where a contactor is intended to
switch loads of an inductive nature, i.e. motors and ballast
lighting, the making and breaking current level is higher
than that for other contactor services. Note also that the
power factor is lower for these services as well.
Power Ic/Ie
IEC UL Factor IEC UL Cycles
AC-1 AC general use 0.75-0.8 1.5 50
AC-3 AC across the line motor starting 0.35-0.45 8 6
1
50
AC-5a AC electric discharge lamps 0.4-0.5 30 50
AC-5b AC incandescent lamps, Tungsten 0.75-0.8 1.5 50
1. For AC-3 qualification, the contactor must make 10 x rating.
Test can be done in conjuction with overload test or after
the overload test at the manufacturer's discretion.
Table 3. Overload performance criteria for electromag-
netic contactors.
Page 7
This is directly related to the physics of the controlled tests are essentially the same. Confirmation of conformity
devices. Motors will have high inrush currents, lasting to the test requirements is achieved if there is no
seconds, on turn on. This is due to the locked rotor state of permanent arcing, contact welding, arcing to ground and
the motor at turn on. Because this starting current can be the device passes a dielectric test of 2X rated + 1000 Volts
6 X full load running current, designers must make for 1 minute.
allowance for it in the design of the power distribution
system to the motor. In some cases, a designer may choose Power Ic/Ie Cycles
to place the motor close to the service entrance to mini- IEC UL Factor IEC UL IEC UL
mize the impact of voltage drop in the distribution system AC-1 AC general use 0.75-0.8 1.0 6000
resulting from this inrush. Where that is not practical, a AC-3 AC across the line motor starting1 0.4-0.5 2.0 6000 1000
designer will either specify larger conductors than other- AC-5a AC electric discharge lamps 0.4-0.5 2.0 6000 6000
wise required to carry the full load running current or use AC-5b AC incandescent lamps, Tungsten 0.75-0.8 1.0 6000 6000
one of several reduced voltage starting techniques. Such
starting schemes as Y-∆ and autotransformer will apply Table 4. Endurance performance criteria for
less than line voltage to the motor for initial start. When electromagnetic contactors.
the motor has achieved breakaway and is rotating at some
speed less that synchronous, the starter switches to full The IEC standard departs from the UL standard for short
line voltage mode to accelerate the motor to and maintain circuit product type testing. UL 508 requires short circuit
synchronous speed. Motor starting torque and operating testing for motor control, starters, overload relays and
horse power requirements will also dictate the starting controls incorporating overload relays only. The IEC
scheme to be used. (An aside, as of October 1997, only standard requires short circuit testing for all magnetically
high efficiency motors can be installed in the US market. operated devices within the scope of IEC 60947-4-1.
These motors have higher starting inrush current ranging When a fault occurs in a circuit, the voltage goes to zero
from 8 to 13 times their full load running current.) at the point of fault, therefore, for short circuit testing, the
Contactors serving transformers and ballast lighting loads coils of the magnetically held devices are powered from a
will also experience high inrush currents to meet the separate source in the product qualification regimen. This
magnetizing needs of the load. However, these currents is a provision of both the IEC and UL standards. This
will reduce to normal levels within the first 10 cycles of assures that the magnetic coil maintains its strength for
operation. Consequently, the switching burden is not as closing and withstanding the effects of fault currents on
severe as that of motor loads. the contact assemblies.
There are two operations for qualification of the device for
The overload test regimen of both standards requires 50
short circuits. The first operation is conducted with the
cycles of operation for the conditions stated. The IEC
contacts of the device and its protective device closed. The
standard requires either an additional 50 closing
second operation is done by closing the device, (contactor,
operations at 10 X rated current or as an alternative, the
etc.). The test sequence is identified as O - t - CO. It is read
overload make and break test can be conducted at 10 X
as, Open, time, Close Open. The criteria for passing
making and 8 X beaking for 50 cycles for AC-3 contac-
allows destruction of the contactor contacts and to varying
tors. Upon completion of the overload regimen, an
degrees, contact welding.
endurance regimen is conducted. Table 4 summarizes the
requirements of the endurance test for both standards.
Except for across the line motor starting contactors, the

2000 85 kA
1125 42 kA
750 30 kA
UL 500 18 kA
250 10 kA
65 5 kA
2.6 1 kA 3 kA
16 63 125 315 630 1000 1600
Figure 4. Short circuit test currents, IEC vs. UL
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The test values of fault current for IEC qualification are Unlike the other products covered by IEC 947, ATSE is as
generally lower than those for UL qualification. This much a control system as it is a switching device. Both the
discrepancy arises from the fact the IEC standard specifies UL and IEC recognize this. The tests therefore include
short circuit test currents based on continuous current verification of voltage sensing for over and under voltage
ratings of the device under test. The UL standard specifies conditions, frequency sensing, intentional time delays and
the short circuit test current based on the horsepower or significant operating times. Additionally, where a unique
kW rating of the device under test. As an example, if a con- switching arrangement is provided, the standards allow for
tactor for a 20 hp motor is to be qualified to UL at 480 evaluation of it as well. Such product provisions as closed
VAC, 3Ø, its continuous current rating would be 27 A transition transfer, delayed transition transfer and bypass
(table 42.2, UL 508). The required short circuit test current isolation automatic transfer switch products are
is 5,000 Amps rms Sym. The IEC short circuit test current accommodated by these standards. Each of these product
for a contactor continuously rated 27 amps is 3000 amps derivatives must be evaluated to assure that it complies
rms Sym. This observation is substantiated by figure 4. with the intent of these standards in addition to providing
the enhanced features.
Criteria for passing the short circuit test allows both
The making and breaking, overload, and operational
contact welding and contact destruction in the UL verifica-
performance, endurance, tests are the same for both
tion test. In the IEC test, type “1” coordination for all
standards. The tests are summarized in table 5. In each
devices permits damage to both the contactor and overload
standard, both of these regimens are conducted on the same
relay; type “2” coordination permits contact welding but
sample. In the UL standard, a temperature rise test is
no damage to the overload relay.
required after the overload test. In each standard, a dielec-
tric withstand is required after the endurance test. The data
Automatic Transfer Switching Equipment The
given in table 5 is for qualification to utilization category
applicable standards covering low voltage automatic
AC-33A. Utilization category AC-33A in the IEC standard
transfer switching equipment, ATSE, are UL 1008 and IEC
is the equivalent of the total system load category of UL
947-6-1. While there is no designated difference in class in
1008. There are other less stringent test criteria for the
the UL standard, the IEC standard identifies the circuit
ATSE in overload and endurance qualification when the
breaker scheme ATSE as a Class CB. It designates the
ATSE is intended for infrequent operation or restrictive
double throw type as the Class PC.
load application. However, given the nature of emergency
loads, the total system load rating, AC-33A, is the pre-
To this point in this summary, the equipment discussed has
ferred rating.
been single throw. By nature of the application, switching
a designated load between two power sources, ATSE is
Short circuit tests are conducted on a separate sample.
either double throw equipment or two single throw devices
There are two of these tests for PC class ATSE and three
arranged in a double throw scheme. When conducting
for CB class ATSE. CB class ATSE must make, break and
switching test regimens, they are conducted on each set of
withstand short circuit current. PC class ATSE does not
contacts. For example, a switching cycle for ATSE is
have to break short circuit current. The UL regimen
comprised of the normal source contacts making and
requires the withstand test to be conducted first. The IEC
breaking and the alternate source contacts making and
standard requires the withstand after the making and
breaking. For the short circuit and withstand current tests,
breaking tests. Criteria for success in the IEC standard
they are conducted on one set of contacts only if both sets
adds a temperature rise test after the test regimen, over and
of contacts have the same design. Where the contact design
above the success criteria defined in the UL standard. Each
differs between the normal and alternate main contacts,
of the standards allow conducting the tests with and
these tests are conducted on the set of contacts likely to
without an overcurrent protective device ahead of the
produce the worst case.
sample to be qualified. Where the test is conducted without
an overcurrent protective device ahead of the sample, the
The test regimen for the qualification of ATSE begins with
short circuit current is interrupted by a test station
evaluation of operating controls. Tests include temperature
disconnect after a minimum specified time. For samples
rise, dielectric, making and breaking, operational
having continuous current ratings of 400 A or less, the on
performance, short circuit making, short circuit breaking,
time of the current is 25 ms minimum. For switches rated
short time withstand and conditional short circuit current.
above 400 A, the minimum on time is 50 ms. Where a short
The short circuit testing varies depending on the type of
circuit protective device is used ahead of the ATSE sample
product, class PC or CB.

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 0 < Ie = < 300 < Ie 400 < Ie 600 < Ie 800 < Ie 1600 < Ie 2500 <
300 = < 400 = < 600 = < 800 = < 1600 = < 2500 Ie
Overload
# Cycles 50 50 50 50 50 25 3
I / Ie 6 6 6 6 6 6 6
Endurance
# Cycles w/current 6000 4000 2000 2000 1500 1000 1000
# Cycles w/o current 1000 1000 1500 2000 2000
I / Ie (1) (1) (1) (1) (1) (1) (1)
(1) Half of the cycles are at I / Ie = 1.
(2) The power factor for the overload test is 0, 5; for the endurance test it is 0, 75 to 0, 8.

Table 5. Making and breaking and operational performance test values.

under test, it must be identified in the appropriate reports
and markings. For UL, appropriate identification is the
SCPD label information. For the IEC, one can identify the
SCPD but must provide the Ipk and I2t data as well. In
the withstand test, for magnetically held devices, UL
requires the contactor to be held closed electrically; IEC
imposes the same requirement but allows a separate
power source to be used for the operating coil. The
required test values of short circuit current are the same in
both standards.
makes it mandatory that equipment performance be eval-
uated in higher available current circuits. Not having such
stiff power systems, equipment judged for service in
Europe is judged at lower current levels. For example, a
circuit breaker is deemed to qualify to UL 489 at a current
of 35 kA. That same breaker might qualify to IEC 947-2
at only 25 kA because the operating voltage is 690 VAC
as opposed to 600 VAC. An astute observation is that the
MVA interrupting ratings of the IEC and UL rated break-
ers is about the same. This is as physics would suggest.

Summary It is physics that determines the behavior elec-
tric power. Regardless of where in the world electricity
flows, it is independent of local and national laws.
However, the environments in which electricity flows dif-
fers around the world. For this reason, codes and stan-
dards will vary. These will take into account the environ-
ment in which electrical equipment operate. The breadth
of the electric power distribution system in North America
The question is more “..at what level..” than “..if..” a
device qualified to the one standard can be used where the
other standard predominates. The answer to this question
is one for the engineer. Given knowledge of the applica-
tion and performance characteristics of the equipment per
their respective standards, the engineer would be quite
comfortable in making the necessary design decisions.

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