EC&M - February 2024 by Endeavor Digital Editions

FEBRUARY 2024 ecmweb.com

THE MAGAZINE OF ELECTRICAL DESIGN, CONSTRUCTION AND MAINTENANCE

EC&M Magazine Onsite Power • National Electrical Code • Solar

TOP CHANGES IN THE 2023 NEC FOR ENERGY STORAGE SYSTEMS Why even the smallest modifications in the Code can be relevant to your system design. Read more on pg. 28

IN THIS ISSUE

How to Avoid Hazard Communication System Citations pg. 8 EV Charging Configuration Options Explained pg. 12 The Importance of Root Cause Failure Analysis pg. 14

February 2024 • Vol. 123, No. 2

The Benefits of Energy Storage Systems and Microgrids pg. 36 Code Basics: NEC Requirements for Energy Storage Systems pg. 54 2402ECM_C1_Cover.indd 1

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CONTENTS COVER STORY

28 Top Changes

in the 2023 NEC for Energy Storage Systems

February 2024 • Volume 123 • Number 2

Why even the smallest modifications in the Code can be relevant to your system design

OTHER FEATURES

32 Energy Storage Systems: Opportunities,

Limitations, and Constraints

Understanding the basic principles behind how these systems work enables electrical professionals to better harness their power

36 The Benefits of Energy Storage Systems and Microgrids

An inside look at how they’re being used by businesses and communities

40 Keeping California Golden

How will the change to net energy metering (NEM) 3.0 regulations impact solar adoption in the long term?

44 Bumper Crop

As demand for new solar farms soars, so does a host of challenges including community pushback, equipment and labor shortages, and a congested grid. Here’s how the industry is overcoming them.

NATIONAL ELECTRICAL CODE

54 Code Basics

NEC requirements for energy storage systems

58 Code Quiz of the Month Test your Code IQ

60 Illustrated Catastrophes 60 More Code catastrophes

62 Practically Speaking A continuous load conundrum

64 What’s Wrong Here? 62 Can you spot the Code violations?

DEPARTMENTS 6 Industry Viewpoint 8 Safety Corner How to avoid receiving hazard

communication system citations

12 EV Update

EV installations on the home front — part 3 of 4

14 Motor Facts

The importance of root cause failure analysis

20 Around the Circuit

Three things every tradesperson must know about their power tool batteries

24 Design

State ground largely not fertile for microgrids

50 New Product Showcase

Focus on boxes and enclosures

52 Product News 63 Ad Index Cover Photo: ID 160098927 © Malpetr | Dreamstime.com

February 2024 • www.ecmweb.com

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ECMWEB.COM

February 2024, Vol. 123/No. 2

www.ecmweb.com

With its exclusive online content, ecmweb.com is a valuable source of industry insight for electrical professionals. Here’s a sample of what you can find on our site right now: Editorial Photo 138115006 | 1099 © Karenr | Dreamstime.com

Group Editorial Director - Buildings & Construction: Michael Eby, meby@endeavorb2b.com Editor-in-Chief: Ellen Parson, eparson@endeavorb2b.com Managing Editor: Ellie Coggins, ecoggins@endeavorb2b.com Editor: Michael Morris, mmorris@endeavorb2b.com Art Director: David Eckhart, deckhart@endeavorb2b.com Consultants and Contributors

DOL ANNOUNCES NEW INDEPENDENT CONTRACTOR RULE Construction New federal guidelines on classifying workers will impact contractors in the construction industry. ecmweb.com/21281674

NEC Consultant: Mike Holt, mike@mikeholt.com NEC Consultant: Russ LeBlanc, russ@russleblanc.net Sales and Marketing Vice President: Mike Hellmann, mhellmann@endeavorb2b.com Regional/Territory Account Manager: David Sevin, dsevin@endeavorb2b.com Regional/Territory Account Manager: Jay Thompson, jthompson@endeavorb2b.com Media Account Executive – Classifieds/Inside Sales: Steve Suarez, ssuarez@endeavorb2b.com Production and Circulation Production Manager: Brenda Wiley, bwiley@endeavorb2b.com Ad Services Manager: Deanna O’Byrne, dobyrne@endeavorb2b.com User Marketing Manager: James Marinaccio, jmarinaccio@endeavorb2b.com Classified Ad Coordinator: Terry Gann, tgann@endeavorb2b.com

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CHANGES TO THE 2024 REVISION OF NFPA 70E

Safety The 2021 revision of NFPA 70E brought much-needed clarity and detail compared to the previous edition. The 2024 revision continued that effort. ecmweb.com/21281838

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Chief Administrative and Legal Officer: Tracy Kane EVP, Group Publisher – Buildings/Lighting/Digital Infrastructure: Lester Craft Electrical Construction & Maintenance (USPS Permit 499-790 , ISSN 1082-295X print, ISSN 2771-6384 online) is published monthly by Endeavor Business Media, LLC. 201 N. Main St 5th Floor, Fort Atkinson, WI 53538. Periodicals postage paid at Fort Atkinson, WI, and additional mailing offices. POSTMASTER: Send address changes to Electrical Construction & Maintenance, PO Box 3257, Northbrook, IL 60065-3257. SUBSCRIPTIONS: Publisher reserves the right to reject non-qualified subscriptions. Subscription prices: U.S. ($68.75 year); Canada/Mexico ($ 112.50); All other countries ($162.50). All subscriptions are payable in U.S. funds. Send subscription inquiries to Electrical Construction & Maintenance, PO Box 3257, Northbrook, IL 60065-3257. Customer service can be reached toll-free at 877-382-9187 or at electricalconstmaint@omeda.com for magazine subscription assistance or questions. Printed in the USA. Copyright 2024 Endeavor Business Media, LLC. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopies, recordings, or any information storage or retrieval system without permission from the publisher. Endeavor Business Media, LLC does not assume and hereby disclaims any liability to any person or company for any loss or damage caused by errors or omissions in the material herein, regardless of whether such errors result from negligence, accident, or any other cause whatsoever. The views and opinions in the articles herein are not to be taken as official expressions of the publishers, unless so stated. The publishers do not warrant either expressly or by implication, the factual accuracy of the articles herein, nor do they so warrant any views or opinions by the authors of said articles.

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EC&M ON AIR — AI INSIGHTS IN THE ELECTRICAL CONSTRUCTION INDUSTRY

Podcast In Episode 38, a panel of industry experts breaks down the current state and future use of AI on job sites. ecmweb.com/21281236

Reprints: Contact reprints@endeavorb2b.com to purchase custom reprints or e-prints of articles appearing in this publication. Photocopies: Authorization to photocopy articles for internal corporate, personal, or instructional use may be obtained from the Copyright Clearance Center (CCC) at (978) 750-8400. Obtain further information at www.copyright.com. Archives and Microform: This magazine is available for research and retrieval of selected archived articles from leading electronic databases and online search services, including Factiva, LexisNexis, and ProQuest. Privacy Policy: Your privacy is a priority to us. For a detailed policy statement about privacy and information dissemination practices related to Endeavor Business Media products, please visit our website at www.endeavorbusinessmedia.com. Please Note: The designations “National Electrical Code,” “NE Code,” and “NEC” refer to the National Electrical Code®, which is a registered trademark of the National Fire Protection Association.

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INDUSTRY VIEWPOINT

Emerging Trends in Energy Storage By Ellen Parson, Editor-in-Chief

iven the fact that U.S. battery storage capacity is expected to nearly double this year, trends in energy storage continue to be a hot topic among the EC&M audience. In fact, according to a report released in January from the U.S. Energy Information Administration (EIA), U.S. battery storage capacity “could increase by 89% by the end of 2024 if developers bring all of the energy storage systems they have planned online by their intended commercial operation dates” — which would expand U.S. battery capacity to more than 30GW. EIA also revealed that planned and currently operational U.S. utility-scale battery capacity totaled around 16GW at the end of 2023 with another 15GW to come in 2024 and 9GW expected in 2025, according to its latest “Preliminary Monthly Electric Generator Inventory.” Not surprisingly, California and Texas, both of which are home to rapidly growing wind and solar energy generation resources, are leading the pack when it comes to states with the most installed battery capacity. Per EIA, as of November 2023, California boasted 7,302MW while Texas posted 3,167MW. According to the EIA report, five of the largest new battery storage projects scheduled to be deployed in California and Texas in the next two years include: • Lunis Creek BESS SLF (Texas, 621MW) • Clear Fork Creek BESS SLF (Texas, 600MW) • Hecate Energy Ramsey Storage (Texas, 500MW) • Bellefield Solar and Energy Storage Farm (California, 500MW) • Dogwood Creek Solar and BESS (Texas, 443MW) However, expansion in this area can be seen all across the country. In Indiana, for example, AES Indiana, a subsidiary of The AES Corporation, announced a milestone in its energy transition in early February with the recent approval from the Indiana Utility Regulatory Commission of a stand-alone battery energy storage system. The Pike County Battery Energy Storage Project will add up to 1,300MW of wind, solar, and battery energy storage from new procurements in the next five years. Currently the world’s largest lithium-ion battery energy storage facility, Moss Landing Energy Storage Facility in Monterey County, Calif., also just got bigger, expanding to 750MW/3,000MWh. In October 2023, the U.S. Department of Energy announced up to $3.5 billion in Grid Resilience and Innovation Partnerships (GRIP) Program investments for 58 projects across 44 states to strengthen electric grid resilience and reliability across America. For an excellent analysis on what this entails and how funds will specifically be earmarked, read “Getting a GRIP on Grid Upgrades” by Ryan Baker with EC&M’s sister publication T&D World (www.tdworld.com/21278416). Considering the expected growth in this area, emerging trends in energy storage systems (ESSs), battery energy storage systems (BESSs), and microgrids will be critical for many electrical professionals of all types, including those who design, install, maintain, and troubleshoot these systems. In this month’s issue, we’ve put together a comprehensive content package that addresses some of the most important aspects surrounding everything energy storage, including articles on: why more states aren’t prepared for the robust build out of microgrids (page 24); top changes in the 2023 NEC for energy storage systems (page 28); opportunities, limitations, and constraints surrounding ESSs (page 32); the benefits of ESSs and microgrids (page 36); how a change to net energy metering (NEM 3.0) regulations could impact solar adoption in the long run (page 40); overcoming obstacles related to solar farm expansions (page 44); and NEC requirements for ESSs (page 54).

February 2024 • www.ecmweb.com

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SAFETY CORNER

How to Avoid Receiving Hazard Communication System Citations Steps for preventing HCS violations By Mark Lamendola, Electrical Consultant

hen I think about the topic of hazard communication system (HCS) requirements, a famous quote from Strother Martin in “Cool Hand Luke” comes to mind: “What’s we’ve got here is failure to communicate.” Violations of OSHA’s HCS requirements consistently rank among the top five, year after year, for “most citations” by type of safety category (e.g., fall protection, scaffolding, etc.). In fact, HCS often occupies the No. 2 slot. These aren’t citations against employees for breaking the company’s rules on HCS. Rather, they are citations against 8

the company for failing its employees when it comes to meeting HCS requirements. Notice the difference? The real shame of any OSHA citation isn’t that the company got caught; it’s that the company failed its employees.

WHAT IS HCS?

Think of HCS as an information system. The point of it is to inform employees how to protect themselves against hazards arising from the storage, handling, and use of chemicals on the job. If you were to grab a can of Solvent X off the shelf and ask a randomly selected electrician how to safely use it, what would the answer be? Doing this is a good test

of whether your HCS is likely to violate OSHA regulations. The requirements for HCS are in 29CFR 1910.1200. The fact that it’s a lot of text may contribute to the high rate of citations. But it’s also well-organized, which helps you easily understand and accurately apply it. The first half consists of purpose, scope, and definitions [1910.1200(a), (b), and (c)]. One of the definitions is the word “workplace,” and that should give you some sense of how much (if any) of that first half you need to strain your noggin to understand. If you focus a bit, you can knock this out in five minutes. That brings us to the meat of the HCS standard, “Written hazard communication program” [1910.1200(e)]. This is followed by: • 1910.1200(f). Labels and other forms of warning. • 1910.1200(g). Safety data sheets (SDSs). • 1910.1200(h). Employee information and training. • 1910.1200(i). Trade secrets. • 1910.1200(j). Effective dates. The typical administrator can ignore those last two sections, so now we’ve boiled this down to about one-third of the original material. You can’t ignore this part. Focused attention here can practically ensure your company never gets cited for an HCS violation — but to fulfill the intention of the HCS regulations, more is required.

FULFILLING THE INTENTION

It is possible to do a bit better than a “surface only compliance” job, allowing

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Having a hazard communication system helps ensure your company is unlikely to commit HCS-related violations and keeps workers safe from hazardous chemicals.

you to check off the boxes and avoid a citation. But the intention of the HCS standard isn’t that you play a box checking game with inspectors. You must communicate effectively with your employees about hazardous chemicals they may use on the job. It is also possible to treat your HCS program as a means to protect the people in your charge — people whose families depend on them. With this mindset, instructors treat a training session as an opportunity instead of a burden, and that attitude comes across clearly. Trainees understand the training is for good reasons; that understanding is reinforced throughout each training session. The training is never “quick and dirty,” but instead is as good as it needs to be for each employee to safely deal with chemicals on the job whether a supervisor is around or not. The main value in treating the HCS program as a means to protect your people is your employees will have a low probability of being injured by chemicals on the job. A side benefit is your company is unlikely to commit violations of the HCS regulations — and even if an OSHA inspector finds such a violation, you’ll get the benefit of the doubt.

Let’s look deeper into the four main areas where violations occur and against which citations are written.

THE PROGRAM

This is a document that, at a minimum, describes how the criteria for 1910.1200(f), (g), (h), and (i) will be met. You must have such a document for each workplace. The document is workplace-specific — a point that some employers overlook (and get cited for). It must include a list of the hazardous chemicals known to be present at that workplace [1910.1200(e)(1)(i)]. The product identifier referenced on the appropriate safety data sheet (SDS) must be used to identify each hazardous chemical on the aforementioned list. The list can be for the workplace, or you can have individual lists for individual work areas. If there’s a mismatch between the name used on the list and the name used on the SDSs, you’ve earned a citation (and probably confused people who read the list). The program is meant to serve as a guide to management in making sure the company’s HCS is understood and implemented. But if an employee asks for a copy of the HCS, the employer is legally obligated to provide it [1910.1200(e)(4)].

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LABELS AND OTHER WARNINGS ON SHIPPED CONTAINERS

INFORMING AND TRAINING

The wording is “shipped containers,” not “shipping containers,” If a spray can of Solvent X ships from the manufacturer to your distributor, it is a shipped container. Each shipped container of a hazardous nature must be labeled, tagged, or marked with six pieces of information [1910.1200(f)], which is listed below, along with where it is referenced according to OSHA: 1. Product identifier [1910.1200(f)(1)]. 2. Signal word [1910.1200(f)(1)(ii)]. 3. Hazard statements [1910.1200(f)(1)(iii)]. 4. Pictogram(s) [1910.1200(f)(1)(iv)]. 5. Precautionary statements [1910.1200(f)(1)(v)]. 6. Name, address, and telephone number of the manufacturer, importer, or other responsible party [1910.1200(f)(1)(vi)]. Many labels today also have a QR code and a URL for the manufacturer’s website. The QR code is especially helpful because one problem with can labels is they can be difficult to read due to small text. OSHA requires that labels be legible [1910.1200(f)(10)], and clearly the implication is that they are legible to the enduser of the product. Not all cans will have QR codes, and a URL is a bit inconvenient when you just want to know what PPE and ventilation requirements apply to the product you’re holding in your hand. A good solution here is to have the storage area well lit and provide readily available lighted handheld magnifiers. Labels for a given product are subject to change for many reasons, so anyone using a given product should read the label on that particular can. Sometimes the product itself changes, but more often, the precautions change due to accident reports or other information from users.

OSHA requires HCS training to be effective [1910.1200(h) (1)]. If you try to dog and pony show the training, you violate not just the intent of OSHA’s rule but also the rule as explicitly stated. OSHA provides some details on what this training must cover. For example, methods and observations that may be used to detect the presence of a hazardous chemicals [1910.1200(h)(3(i)] and the measures employees can take to protect themselves [1910.1200(h)(3(iii)]. OSHA refers to its list with the words “at least,” which means do all of that — but think about how else you can make that training effective. What must you cover to ensure your employees understand and correctly implement your HCS? If you ask the hard questions here and answer them, your company will neither face hard questions from an OSHA inspector nor endure an even worse experience — trying to answer hard questions from the attorney of an employee whose death or disfigurement would have been prevented by making a solid effort to communicate to your employees about hazardous chemicals. Mark Lamendola is an electrical consultant based in Merriam, Kan. He can be reached at mark@mindconnection.com.

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SAFETY DATA SHEETS

The requirements for generating and using an SDS are in 1910.1200(g). Much of that text applies to manufacturers and distributors of hazardous chemicals. The main responsibility of the employer is to make the SDS for a given hazardous chemical readily accessible to employees who wish to use that chemical [1910.1200(g)(8)]. An SDS provides extensive safety information. The correct way to use the SDS is to read it before using a given chemical and ensure you can comply with all the safety requirements. SDSs have a standard format that all manufacturers must follow; this helps greatly with usability. The SDS is divided into 16 sections. You can see what those sections are by looking at any SDS or by referencing 1910.1200(g)(1)(i) through (xvi). These include first-aid measures, handling and storage, firefighting, and disposal considerations. The four aforementioned are “understand before using” sorts of things. For example, if you need a given type of extinguishing agent, then it’s a little late to go looking for it once the chemical ignites. Have it on hand before using the chemical. This “read first” method must be SOP for all hazardous chemical users, so make it clear in your HCS and your HCS training. In some cases, a given section of an SDS doesn’t apply to a particular chemical. This will also be indicated on the SDS. Everything not so indicated applies.

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EV UPDATE

Installation Options for Configuring EV Charging Infrastructure A quick review of charging configuration options By Dan Carnovale, Eaton

In a typical residential system, a homeowner can choose between various wall-mount charger options.

he growing adoption of electric vehicles amid the energy transition is creating new avenues of opportunity for electrical contractors to become trusted advisors for homeowners seeking to install electric vehicle (EV) charging infrastructure in single-family homes. To do this successfully, however, there are important factors contractors need to consider. One is energy capacity, 12

and ensuring the appropriate amount of energy is available to meet charging demands. Another is installing charging infrastructure in a way that positions electrical safety at the top of the priority list. In the third installment of this four-part series, we’ll look at configuration — specifically, different options for configuring charging infrastructure — and how it can function as a critical opportunity for contractors to

enhance customers’ experiences with their EV investments.

THE IMPORTANCE OF PROPER CONFIGURATION

Of all the major considerations for charging installation, a proper configuration allows the contractor to set up the system in a way that fits the unique application for the homeowner’s expected use of their vehicle. This will

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go a long way toward optimizing the operation of the system and meeting the specific needs of the homeowner. The first step in any charging installation project is to consult the homeowner and ask the right questions. Some examples of important questions to ask include: • If they only have one EV, do they plan to add a second? • How many miles do they anticipate driving every week? • Are they aware of their electric utility’s rate programs such as time-ofuse rates and incentives for EVs related specifically to how the EV charging system should be programmed to minimize the homeowner’s electricity bill? In general, electrical contractors should advise homeowners to plan for a second EV as doing so will help save time and the cost of additional installation down the road. As they perform more installations over time, electrical contractors should keep a running checklist of commonly asked questions and run through these with the customer before starting each project. This will help them to better understand the customer’s unique needs so they can configure the system accordingly. Let’s look at different configuration options and considerations, which can be broken into two categories: configuration of physical infrastructure (e.g., the load center, vehicle charger, vehicle cord, and other individual components that make up the system) and the software, which is an important element in optimizing vehicle charging.

PHYSICAL CONFIGURATION CONSIDERATIONS

Selecting the type of EV charger will dictate how you move forward with the configuration of the charging system. In a typical residential system, a homeowner can choose between various wall-mount charger options, which include: • EV wall charger with plug. Install an EV wall charger that plugs directly into a 240V receptacle at a strategic location inside or outside the house. This allows versatility and faster installation. Electrical contractors should ensure adequate ground-fault protection at the outlet level.

• EV wall charger. Hardwire an EV wall charger directly to a load center, located in a similar strategic location. This is ideal for new construction where you can be flexible with wiring and installation of the charger. Both the EV wall charger and EV wall charger with a plug can include a smart breaker and give homeowners added levels of flexibility and control in addition to enabling them to leverage benefits and features inherent in the charger, such as a mobile control application. This helps follow and manage the charging process. A final important consideration in physical infrastructure is ensuring compatibility between the charging plug and the EV. Additionally, understanding the homeowners’ expectations for a potential second EV — and configuring the plug accordingly — can help future-proof the system for additional EV purchases. The J1772, a charging connector that supports most EV manufacturers, cannot only be used with most Level 1 and Level 2 AC chargers but also enables breakout capabilities in EV hardware and software. The exception is Tesla, which developed the North American Charging Standard (NACS) charging connector, the J3400, that is now open for use by other manufacturers — many of which will include the NACS connector as an option starting in 2024. Tesla also includes dedicated plugs that require an adapter to fit a J1772 plug.

SOFTWARE SETUP

While effectively configuring the charging hardware is essential to a successful installation and meeting homeowner needs, it’s only the first step. With extensive digital capabilities built into EV charging infrastructure and opportunities to integrate with smart home energy systems, electrical contractors should work with the homeowner to configure the software in the charger, onboard system, and associated applications to optimize their investment. Think of this step like setting up a smartphone — while a user can use it to make calls and send texts, doing so is only scratching the surface of its capabilities. Remember, as an electrical contractor setting up EV chargers,

you will likely repeat this procedure hundreds of times, but a typical homeowner may only do this once in 10 years. Software can be intimidating for your customers, so try to simplify the more difficult parts of the setup for them. They will greatly appreciate it. Leaving software setup to the homeowner may create confusion, and you will likely be called back for service after the installation. Taking the lead on this part will save you and the homeowner time and money in the long run. Electrical contractors should familiarize themselves with the ins and outs of charging software and speak to the homeowner about available options that can enhance their experience. At a minimum, this should include aligning the capabilities of the charging infrastructure with the capacity of the onboard system to ensure the vehicle charges at a rate that fits the application. Beyond this, software setup can include configuring capabilities like automated charging that starts at a certain time of night to take advantage of better electrical utility rates or setting charging speed to throttle up or down based on a certain threshold depending on how much the user plans to drive. This can help the user optimize energy costs and ensure they pay only for the energy they need — and do so at the best possible rate offered by their utility.

CHARGING AHEAD

As EV adoption continues to grow and more homeowners add EVs to their homes, electrical professionals play a key role in helping homeowners choose the proper charging infrastructure. By communicating with the homeowner and configuring both hardware and software to meet their unique needs, professionals can help set their customers up for charging success for years to come. Dan Carnovale is the director of the Eaton Experience Centers in Pittsburgh and Houston. He is a registered professional engineer in the states of Pennsylvania, California and Alaska, a certified energy manager (CEM) and a senior member of IEEE. He can be reached at danieljcarnovale@eaton.com. www.ecmweb.com • February 2024

2402ECM_12-13_EV_Update.indd 13

2/13/2024 3:50:18 PM

MOTOR FACTS

The Importance of Root Cause Failure Analysis

When an electric motor fails, use a proven methodology that incorporates cause analysis and the 5-why method. By Tom Bishop, P.E., EASA application requirements, and the efficiency/reliability of the repaired motor versus those of a new one. Once identified, many causes of failure are easily remedied. For example, studies show motor failures commonly involve the bearings, for which replacement can be a simple, cost-effective repair. Other solutions may include improved maintenance, condition monitoring, a motor rewind, or a replacement motor. However, unless the root cause of failure is determined, neither efficiency nor reliability will improve — even with a new motor.

APPLYING RCFA

Note how the winding of this motor is completely overheated in all phases.

wo expectations informed end-users have of electric motor service centers are reliable best practice repairs and root cause failure analysis (RCFA) to prevent recurring failures. Service centers strive to meet these expectations by performing repairs that conform with ANSI/EASA Std. AR100: Recommended Practice for the Repair of Rotating Electrical Apparatus. These service centers can also provide RCFA using a proven methodology such as that in EASA’s Root Cause Failure Analysis Seminar, which incorporates cause analysis and 5-why methods. This article focuses on the importance of performing RCFA when an electric motor fails. 14

THE BIG PICTURE

For end-users, determining the root cause of a failure is the first step toward improving the efficiency and reliability of a motor-drive system. Was there a maintenance issue or a previous failure? Was the motor well suited for the application load, torque, start-stop, and environmental requirements? Was it installed and aligned properly? Did the process change after installation? Some maintenance professionals have the experience to analyze motor failures, but usually, it’s a task for a qualified service center. A qualified service center can also help determine what to do next, weighing such factors as the type of repair/rewind needed, the cost and availability of new equipment, the

To appreciate the value of RCFA, consider what might happen without it. A good example is the case history of a failed 200-hp (150kW) air compressor motor with a thoroughly overheated winding (Photo). Since the motor’s service factor (SF) was within the operating range of many compressors — and with no other evidence available — the service center logically concluded the cause of failure was an overload/overcurrent condition. After conferring with the end-user, the service center rewound the motor, upgrading its insulation system from class B (130°C) to class H (180°C) to prevent a recurrence. Unfortunately, the initial failure analysis in this case was cursory. The service center jumped to the conclusion that an overload/overcurrent condition fried the winding without asking what else could have caused it. Applying the RCFA methodology would have examined the motor’s failure mode, pattern, and appearance as well as its application and maintenance

February 2024 • www.ecmweb.com

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history. RCFA also would have considered the entire motor-drive system, not just the motor. System elements include the motor’s power supply, foundation, method of connection to driven equipment, and the driven equipment (Fig. 1). Before continuing with this case history, let’s take a deeper dive into using cause analysis and the 5-why methods for RCFA.

CAUSE ANALYSIS AND 5-WHY METHODS

RCFA is the focus here, but it draws lessons from the cause analysis (CA) and 5-why methods. Compared with RCFA, CA is a more generic way to identify the potential root cause(s) of any problem and prevent or at least minimize its recurrence. The 5-why methodology offers a simple yet effective way to

use CA. Despite its name, the intent of 5-why is not to ask “why” five times but to emphasize the need to drill down through several levels when investigating some problems. Sometimes, two levels are enough; other times, it may take more than five. Figure 2 on page 16 shows a 5-why flowchart, the first step of which is called problem characteristics. For RCFA, this

Fig. 1. Here’s an overview of a typical motor and its associated electrical system. www.ecmweb.com • February 2024

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MOTOR FACTS

Fig. 2. The 5-why method offers a simple yet effective way to use cause analysis.

typically means gathering enough data in each of five categories to analyze the cause(s) of a problem or failure: • Failure mode: Manifestation, form, or arrangement of the failure (e.g., stator winding turn-to-turn, phase-to-phase). • Failure pattern: Configuration of the failure (e.g., symmetrical or nonsymmetrical). • Appearance: Damage, contamination, moisture, cracks, or other signs of stress in the failed part, other motor parts, and the motor-drive system. 16

• Application: The work the motor performs and its load characteristics. • Maintenance history: The work that has been done to keep the motor and system operating properly. Ideally, a service center will have all relevant information about the system’s application, appearance, and maintenance history before it inspects a motor or failed component. But the urgency to return the motor to service often dictates that inspection comes first. Application and

February 2024 • www.ecmweb.com

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2402EC

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MOTOR FACTS historical data may only be available later, if ever. Testing and verification of potential causes of failure should be as thorough as practical, comparing the failed motor with identical motors in the same application, if possible. For example, voltage unbalance is easy to test on-site, but a suspected transient voltage event should not be duplicated intentionally to verify that it damages windings.

APPLYING RCFA

Given that background, how did RCFA change the case history of our failed compressor motor? First, recall the information initially available — a motor with an SF rating suitable for its application with thermal degradation in all phases of its winding. Based on this, the service center attributed the cause of failure to an overload/overcurrent condition and rewound the motor with an upgraded class H insulation system to prevent recurrence. When the motor continued to fail after multiple rewinds, including a redesign to a higher rating, the service center turned to RCFA. As part of the RCFA process, the service center methodically examined the motor and system trying to narrow down possible causes of failure. Following the 5-why approach, they kept asking “why” until they ruled out or identified a probable root cause of failure. For example, when they measured the subject motor’s actual operating current with load and recorded it on the RCFA template shown in Fig. 3, they found it did not exceed the nameplate rating. That led them to look for other reasons “why” the motor’s operating temperature kept getting hot enough to damage the winding, including the possibility of reduced airflow or a restricted ventilation system. As a result of the RCFA and 5-why process, they discovered that the cooling fan in the compressor enclosure was rotating in the wrong direction. Due to reduced airflow, the ambient temperature was more than 40°F (22°C) above normal, which would be recorded in the blank template shown in Fig. 4. As this case history of a compressor motor shows, the initial misdiagnosis of overload as the cause of failure resulted 18

Power Supply Information

Fig. 3. Use this RCFA template for recording a motor’s load voltage and current.

Enclosure and Environment

Fig. 4. Use this RCFA template for recording a motor’s ambient conditions, including temperature.

in multiple unnecessary rewind-failure cycles. Once RCFA correctly identified the direction of cooling fan rotation as the root cause of failure, the problem was corrected. That same compressor motor has been operating successfully now for more than a decade.

CONCLUSION

The lesson learned for the end-user and the service center that repaired the compressor motor is that there are times when RCFA should be used, even

if it may appear to be costly and timeconsuming. Tom Bishop, P.E., joined the staff of the Electrical Apparatus Service Association (EASA) following more than 30 years of engineering experience at electrical machinery manufacturers and electrical apparatus service firms. He is chairman of EASA’s Technical Services Committee and a principal member of the National Fire Protection Association Electrical Equipment Maintenance Committee (NFPA 70B).

February 2024 • www.ecmweb.com

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AROUND THE CIRCUIT

Three Things Every Tradesperson Must Know About Their Power Tool Batteries Tips for making the most out of your power tools’ lithium-ion batteries and avoiding dangerous situations By Susan Orenga, Power Tool Institute

Photo 120224997 © Nomadsoul1 | Dreamstime.com

s an electrical contractor, your power tools are your livelihood. Without them, your work would be impossible. However, there’s one important component of your power tools that you might not be paying enough attention to: the batteries. There are three crucial things you must know about your power tool batteries.

1. USING COUNTERFEIT BATTERIES IS DANGEROUS.

Not only do counterfeits and knockoffs have a shorter lifespan and poorer performance than original equipment manufacturer (OEM) batteries, but they also pose a risk of explosion or fire. You should always purchase OEM batteries from a reputable source, and avoid cheap imitations that could put your safety at risk. Why buy OEM? Because the consequences of doing otherwise can be very dangerous. An OEM battery is designed for seamless compatibility with your power tool/charger and has undergone rigorous testing to back it up. Even if you find a battery online that says it works with your power tool model, use extreme caution when considering the purchase. The retail space is where an abundance of counterfeit and knock-off power tool batteries are sold. Scammers leverage vulnerabilities in the global supply chain (as well as tradespeople’s continuing need for new batteries) to sell a wide variety of 20

counterfeits or unauthorized replicas. It’s gotten so bad, even the FBI issued a warning about these scams. While the exterior appearance of a counterfeit or knockoff may seem wellmade and reassuring, what matters is what’s on the inside. Each OEM has its proprietary control circuitry that is not available to third-party component suppliers. No knock-off battery can match the OEM. What seems to work well out of the box may deliver dire consequences later.

You also don’t want to buy on price alone. Purchasing a battery from an unknown seller without having any verification of the seller’s qualifications or experience (or of the battery’s construction, testing, or certification) can leave you with an unsatisfying — and potentially dangerous — experience. Pay close attention to the packaging so you don’t accidentally pick up a knock-off battery (makers of these knockoffs sometimes use colors and typefaces similar to those of the recognized brands specifically to

February 2024 • www.ecmweb.com

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AROUND THE CIRCUIT confuse buyers). Purchase batteries from authorized dealers, and be suspicious of any price that seems too good to be true. It probably is.

2. IT’S IMPORTANT TO HANDLE YOUR BATTERIES SAFELY DURING STORAGE AND TRANSPORTATION.

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Lithium-ion batteries are particularly sensitive to heat and cold, so you should avoid leaving them in direct sunlight or freezing temperatures. Furthermore, you should never carry loose batteries in your pocket or bag, as they could come in contact with metal objects and short-circuit. Start by reading the manufacturer’s instruction manual for proper care and storage of the battery. Do not strike or damage a battery (e.g., do not use it as a hammer; use it solely for the defined purpose as specified by the manufacturer). If a battery has received a sharp blow, been dropped, or is damaged, discontinue use. Regularly inspect batteries for signs of damage, such as crushing, cuts, or punctures. Be mindful of abnormal battery behavior, such as failure to fully charge or hold a charge, longer-thanusual charging times, a noticeable drop in performance, liquid leakage from the battery, or melted plastic anywhere on the pack. These are indications of an internal problem. Never modify, disassemble, or tamper with the battery because the performance can become unpredictable and dangerous. As a general practice, it is best to unplug battery chargers and remove battery packs from them when not in use.

3. IT’S CRUCIAL TO RECYCLE YOUR POWER TOOL BATTERIES PROPERLY.

These batteries contain hazardous chemicals that can harm the environment if not disposed of correctly. Many hardware stores and battery manufacturers offer recycling programs, so make sure you take advantage of them rather than throwing your batteries in the trash. Lithium-ion batteries have revolutionized power tools and other devices, providing long-lasting, reliable power

that has higher energy density, charges quickly, and holds its charge longer. But, like all batteries, even lithium-ion batteries reach the end of their service life eventually. When this happens, the first impulse might be to toss it in the trash — but don’t! These batteries must be disposed of properly by a qualified recycler. Why not put them in the trash? Improperly disposing of the battery could subject them to corrosion, punctures, crushing, or other damage during the transport and processing of household trash. This could lead to a battery fire — one that is difficult by its nature to extinguish. Federal law even requires lithium-ion batteries (and others) to be recycled, not thrown away. A violation carries heavy fines. In addition, 29 states have their own battery recycling laws. To see how your state handles battery disposal, visit https://www.call2recycle.org/recycling-laws-by-state/. Keep in mind that states without their own laws are still governed by the federal recycling law. Recycling your lithium-ion battery isn’t as hard as you might think. Most big-box hardware retailers have recycling bins specially designated for lithium-ion batteries; do not place batteries in a recycling bin not designated for lithium-ion batteries. The bins are often positioned right by the entrance for maximum convenience. Simply place the battery in the bin, and the recycler does the rest. For other recycling options, call your local solid waste district to find out if your community has a collection program. In conclusion, taking care of your power tool batteries is just as important as using the right tools for the job. By following these three tips, you can ensure your batteries are safe, reliable, and longlasting, which will help you work more efficiently and effectively. Susan Orenga is the executive manager of the Power Tool Institute, a trade organization whose members represent market-leading brands of portable and stationary power tools. For more information about power tool battery safety, please visit www.takechargeofyourbattery.com.

February 2024 • www.ecmweb.com 3/30/18 7:04 PM

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YEARS

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DESIGN

State Ground Largely Not Fertile for Microgrids

Report reveals most U.S. states and territories are not prepared for the robust build-out of microgrids. Photo 29634968 © Phase4photography | Dreamstime.com

By Tom Zind, Freelance Writer

mploying proven design, microgrids are all but destined to be a part of the nation’s future electrical infrastructure. But gaps in supportive policy could act as a powerful brake on their development and hinder their path forward. Surveying the ground in all 50 states, Think Microgrid, a Boulder, Colo.-based microgrid advocacy organization, concludes that all but a handful are sorely lacking the regulatory and statutory framework needed to give powerful impetus to a timely build-out of a robust microgrid infrastructure. Its findings are summarized in a state scorecard report issued in early November, — one that paints a picture of an inspired energy 24

production and distribution concept in danger of being held hostage to footdragging, inertia, lack of planning, and entrenched interests. “Policy, not technology, remains the limiting factor for microgrid commercialization,” the report states. Rating each state on a set of five criteria deemed central to microgrid support and development, the report finds only four attaining a “B” grade: Hawaii, Texas, Colorado, and Connecticut. Fifteen states and Puerto Rico got a middling “C” grade. The rest were given a barely passing “D” grade. Whether it’s the current state of deployment; the presence of proactive policy; a commitment to energy resilience; the existence

of grid interface platforms; or a strong community equity approach to energy investments, most states don’t currently have anything close to the foundation needed to bring more microgrids into the picture on any kind of expedited timeline. And that may be slowly exacting a toll on microgrid deployment, which has been tailing off since 2020 (see the Figure on page 26). Describing the challenge, the report observes that “most states have not identified significant and meaningful strategies for incorporating microgrids into the physical grid and creating market designs necessary to support them. Microgrid policies that do exist — including incentives/programs, retail

February 2024 • www.ecmweb.com

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YEARS

ARLINGTON

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DESIGN

Microgrid Market Overview

ANNUAL MICROGRID PROJECTS COMPLETED 345

337

350 300

344

329 28%

283

250 350

27%

200

261

18%

Number of Projects

microgrid tariffs, and resilience planning processes — are often severely limited in scope.” While many states can be applauded for taking a more proactive stance on building an energy infrastructure to address the issue of the day (climate change), too few are up to speed on understanding the role that microgrids can play in that effort by utilizing alternative energy, storing power, and relieving pressure on fossil fuel-heavy utility generation. Given the stakes, the report says there’s an urgent need to bring more online, but the barriers are high. “Many states have responded to climate challenges by prioritizing decarbonization, equity, and economic development benefits. However, state legislation and policy have generally prevented the commercialization and enablement of microgrids that can maximize resilience, decarbonization, equity, and economic development.” Allan Schurr, chief commercial officer with Enchanted Rock, a Houston-based developer of resilience microgrids, and a Think Microgrid founding member, views mounting concerns over the adequacy of power redundancy as one of the leading drivers of future microgrid development. And much of the impetus for that will have to come from policy developed at the state level to address risks to life and property that accompany the prospect of extended power outages. “We’re more dependent than ever today on electricity, and because we’re starting to realize how fragile the grid is the need is greater now than ever for what microgrids can offer,” he says. One obvious gap that microgrids might be able to play in the resiliency challenge immediately, Schurr notes, is in emerging as a replacement for dieselpowered generators. Though carrying a higher up-front price tag, microgrids that provide power in isolation from the grid offer a host of long-run advantages in reliability, climate-friendliness and maintenance requirements over generators that can sit idle for long periods. “We may be coming to a tipping point with generators, which are much dirtier and limited by the amount of fuel on site and may not be reliable if not

150 100

Basic

Advanced

Undisclosed

2017

2018

2019

2020

2021

2022

2023

ANNUAL MICROGRID PROJECTS COMPLETED Military/Federal

20 MW

12%

Community

10%

Education

6% 1,883 MW

841 MW

5% 3% 3%

45%

16% Basic

Advanced

Undisclosed

Manufacturing/Food/Agriculture Transportation Critical Facility Telecommunications/Data Center Other Sectors

Microgrid deployment has been decreasing since 2020, according to the latest report from Think Microgrid.

exercised and tested regularly,” he says. “Microgrids might be a better option than traditional backup power. As one of numerous examples of state dysfunction, the report highlights the California Public Utilities Commission’s (CPUC) refusal in April of last year to hold a hearing on a detailed plan to develop privately owned microgrids for residential communities. Think Microgrid says the denial is seemingly at odds with a 2018 state “micro-utility” statute directing the commission to facilitate microgrid commercialization in the state, which earned a “C” on the report scorecard. So far, it claims, CPUC has largely restricted its facilitation efforts to utility-owned microgrids. The decision further proves that “California is hostile to distributed energy,” says Cameron Brooks, Think Microgrid’s executive director. “It’s a prime example of a state that seems to be in the throes of incumbency influence.” The consequences of California’s stance are tangible, Brooks says. With the state seemingly blessing utilities’ plan to put more power lines underground to limit fire risk, microgrids are

being overlooked as a possibly superior solution. “Some economists are saying microgrids would cost 10% of what it would take to bury power lines.” That underappreciation of microgrids, possibly stemming from a lack of basic knowledge and understanding, forms part of the logjam microgrids face at the state level. The task for microgrid interests, knowing the importance of fertile ground development, Brooks says, will be keeping a close eye on the distributed energy policy trajectory and leaning heavily into advocacy for microgrids and microgridfriendly stances at multiple levels. “All states have an opportunity to take better advantage of what microgrids have to offer (and align with) what the U.S. Department of Energy says is a distributed energy future where up to half of the nation’s power comes from the distributed resources,” he says. “Microgrids are key to aggregating that, but as of now we’re nowhere close to that aligning with that vision.”

Tom Zind is a freelance writer based in Lee’s Summit, Mo. He can be reached at tomzind@att.net.

February 2024 • www.ecmweb.com

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By Ryan Mayfield, Mayfield Renewables

Top Changes in the 2023 NEC for Energy Storage Systems Why even the smallest modifications in the Code can be relevant to your system design

hether you are an industry veteran or a DIYer out over your skis, you’ll have to grapple with the National Electrical Code (NEC) if you want to install an energy storage system (ESS). More specifically, you’ll have to grapple (metaphorically, of course) with your local electrical inspector. In the world

of solar and battery storage, the NEC is king — and it’s what your inspector will be thinking about when you’re closing out your construction permits. Since 1897, the good folks at the National Fire Protection Association (NFPA) have been helping keep you and your neighbors safe by making the rules for properly designing and installing electrical systems. As technology advances and industry workers identify

and find solutions to new problems, the Code itself gets updated. This happens every three years, and 2023 marked the latest revision to the NEC. While only some jurisdictions have adopted the 2023 version as of this writing, it will be adopted by other states and jurisdictions over time. Much of the Code remains unchanged from cycle to cycle, so why take the time to peruse the new version of the NEC?

February 2024 • www.ecmweb.com

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Missing seemingly small modifications relevant to your system design can make the difference between a smooth-sailing install and one caught up in a permitting logjam. In addition, inspectors are, while admirable in their service, subject to the same human flaws as you and me. If you spend time studying the latest version of NEC, you might find you can clear up otherwise costly misunderstandings on inspection day with a simple conversation. Mayfield Renewables recently spoke with members of the NFPA Code Making Panel involved in developing the 2023 NEC to help clarify and illuminate ESS-related changes in Art. 706. Let’s walk through them one by one.

SECTION 706.1 — SCOPE AND RELOCATION OF DEFINITIONS

The first notable change is around definitions, which, in prior versions of the NEC, were scattered throughout various Articles. Definitions are now aggregated into Art. 100. Looking up a term (from anywhere in the NEC) just got much more straightforward. The scope of Art. 706 states: “This article applies to all energy storage systems having a capacity greater than 3.6 MJ (1 kWh) that may be stand-alone

or interactive with other electric power production sources. These systems are primarily intended to store and provide energy during normal operating conditions.” The 2023 NEC now includes a new Informational Note that clarifies what types of ESSs require compliance with Art. 706. Informational Note No. 1 states: “See Art. 480 for installations that meet the definition of stationary standby batteries.” Article 480 was developed before Art. 706, and this note clarifies that certain types of systems apply to one or the other. Article 706 applies to the vast majority of ESS installed nowadays. The “stationary standby batteries” referenced in the note indicate that Art. 480 applies to legacy-type systems designed purely for backup power. Stationary standby batteries are programmed exclusively for resilience and do not cycle during normal operation. Except during charging, they should not interact with the grid, a generator, or even PV equipment. For ESSs that are not stationary standby systems, Art. 706 applies.

SECTION 706.15(A) — ESS DISCONNECTING MEANS

Disconnects are basically big switches that can be flipped by a technician,

utility worker, or firefighter to turn off all or part of an electrical system. A typical ESS will have one or more disconnect switches, with additional disconnects to isolate the PV portion of a system. This usually includes disconnects in the DC and AC portions of the circuitry. Section 706.15, which is not new in 2023, describes the special requirements for ESS disconnecting means, which are in excess of other disconnects found in the system. Importantly, the language of Sec. 706.15(A) has been cleaned up to make clear that these special requirements apply only to the ESS disconnecting means. “Means shall be provided to disconnect the ESS from all wiring systems, including other power systems, utilization equipment, and its associated premises wiring.” This is a welcome change because many inspectors have previously misinterpreted the requirements of Sec. 706.15 to apply to all disconnects in the system. Since this is a clarification and not a change of substance, you may be able to work with a benevolent inspector to avoid misunderstandings and the burden they create — even when the jurisdiction has not adopted the NEC. www.ecmweb.com • February 2024

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What are these special requirements for the ESS disconnecting means? There are several. One updated requirement is related to location and control. “The disconnecting means shall be readily accessible and shall comply with one or more of the following: “1) Located within the ESS “2) Located within sight and within 3 m (10 ft) from the ESS “3) Where not located within sight of the ESS, the disconnecting means, or the enclosure providing access to the disconnecting means, shall be capable of being locked per Sec. 110.25.” These rules exist to protect technicians working on the ESS by ensuring it does not become energized without their knowledge. Note that the ESS disconnecting means must meet only one of these conditions. The first applies to an ESS that is packaged within a single unit and contains an integrated disconnecting means, which can be the simplest solution for the designer if it’s an available option. Disconnects not within sight and within 10 ft of the ESS must also be lockable per Sec. 110.25.

SECTION 706.15(B) — ESS EMERGENCY SHUTDOWN FUNCTION

Section 706.15(B) also contains language that has been relocated and modified, which relates to a required “emergency shutdown function” of the ESS in oneand two-family dwellings. “For one- and two-family dwellings, an ESS shall include an emergency shutdown function to cease the export of power from the ESS to the premises wiring of other systems. An initiation device(s) shall be located at a readily accessible location outside the building and shall plainly indicate whether in the ‘off ’ or ‘on’ position. The ‘off ’ position of the device(s) shall perform the ESS emergency shutdown function.” Crucially, this does not describe a disconnect, but only a shutdown initiation function device. Therefore, the system does not need to send an energized circuit from the ESS location outside the building. Instead, this function can be accomplished with a switch that sends a control signal to a device within the ESS that can initiate the emergency shutdown. 30

Photo 286394348 © Altitudevs | Dreamstime.com

SECTION 706.15(B) — ESS DISCONNECTING MEANS REQUIREMENTS

Unlike the disconnect itself, that switch does not need to be lockable. This is not a rapid shutdown function, so don’t confuse these two things. However, it may be possible for the industry to provide methods of combining the ESS emergency shutdown function with PV rapid shutdown. Finally, in cases where the ESS disconnecting means is incorporated into the ESS system itself (e.g., an ESS with an integrated inverter), the device manufacturer may provide a means of operating it with a control circuit.

SECTION 706.15(E) — DISCONNECTING MEANS FOR BATTERIES

In case you haven’t had enough of disconnecting means, the 2023 NEC also has new requirements for such means in an ESS where the batteries are separate from the ESS electronics and are subject to field servicing. As per Sec. 706.15(E), “In cases where the battery is separate from the ESS electronics and is subject to field servicing, 706.15(E)(1) through (E)(4) shall apply. “1) A disconnecting means shall be provided for all underground conductors. A disconnecting means shall be readily accessible and located within sight of the battery. “2) Battery circuits exceeding 240VDC nominal between conductors or to ground shall have provisions to disconnect the series-connected strings into segments not exceeding 240VDC nominal for maintenance by qualified persons. Non-load-break bolted or

plug-in disconnects shall be permitted. “3) Where a disconnecting means is provided with remote controls to activate the disconnecting means and the controls for the disconnecting means are not located within sight of the battery, the disconnecting means shall be capable of being locked in the open position, in accordance with Sec. 110.25, and the location of the controls shall be field marked on the disconnecting means. “4) The disconnecting means shall be legibly marked in the field. The marking shall be of sufficient durability to withstand the environment involved and shall include the following: “1) Nominal battery voltage “2) Available fault current derived from the stationary standby battery system “3) An arc-flash label in accordance with acceptable industry practice “4) Date the calculation was performed.” While this may appear to add a significant burden to ESS design, note that these requirements only apply when the batteries are both separate from the ESS electronics and require field servicing. These rules are there to protect technicians and the sites where they are installed in cases where they apply. Ryan Mayfield has been working in the renewable energy field since 1999 and is the CEO and founder of Mayfield Renewables. He teaches nationwide PV courses on various topics and holds a Limited Renewable Energy Technician (LRT) license in Oregon.

February 2024 • www.ecmweb.com

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Energy Storage Systems: Opportunities, Limitations, and Constraints Understanding the basic principles behind how these systems work enables electrical professionals to better harness their power

This is a caption.

By Bryanna Krekeler, Kevin Standlee, P.E., and Krista McDonald Biason, P.E., HGA Architects and Engineers

efore jumping into the benefits and opportunities for energy storage systems (ESSs), we first need to level set. What is an ESS, and why do we use them? An ESS collects energy when it is abundant — or at low cost — and releases it at a designated time. This could be during peak energy demand, during peak utility cost time frames to reduce overall utility charges, or deployed at any time to create less reliance on the utility grid. The most common type of ESS used in the construction industry is a battery storage system with lithium-ion batteries. Other types of storage systems consist of ice storage, pumped hydro, green hydrogen, and compressed air energy. These alternate storage systems aren’t as prevalent in traditional construction projects, so we will focus on the battery style for this discussion. Energy storage devices are starting to be more widely used, especially when there is a priority for renewable energy sources and where the use of solar photovoltaic (PV) and other energy collecting systems have the potential to produce more energy than a facility can utilize in real time.

February 2024 • www.ecmweb.com

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ENERGY STORAGE OPTIONS

There are several ways ESSs can be utilized. Battery energy storage systems (BESSs) can be operated in a gridtied mode or as part of a microgrid to provide power during grid failure. The electrical design and associated components will change based on the assets utilized, code requirements, interconnection to the grid, and distribution methodology. In a grid-tied operation, the storage system is programmed to charge and discharge at various times to help with load shedding and demand response. Typically, the system will discharge the storage system during times of high demand or when on-site production is low to help reduce the energy usage and cost of the facility. Even though this sounds like a simplistic concept, it is a complex technology and feat as demand, production, and storage are all monitored and controlled. The controller is constantly trying to optimize its decisions — charge, discharge, or do nothing — aiming to maximize economic benefits based on the available energy assets. This is one of the most challenging aspects of installing an ESS. In contrast, the ESS could be incorporated into a microgrid. In a microgrid design, the storage system would act as a buffer for one or more on-site power generating devices (e.g., traditional generator, fuel cell, solar PV, wind turbine, CHP, etc.) and interact with the traditional utility source, helping the microgrid controller to balance power production and demand more effectively. The microgrid system is significantly more complex as the system constantly works to balance all resources and demands on the system; however, it can also provide a very high level of resiliency that could allow operation without utility power for long durations of time.

DESIGN DECISIONS

Careful consideration of the electrical distribution system should be taken when implementing an ESS to maximize the effectiveness of generation and storage. A connection on the main switchgear creates a cohesive system with the most flexibility. However, this may not be the optimal solution for an existing building. Existing electrical 34

services require tailored solutions to meet the needs of a given building. One limitation of the ESS that should be acknowledged is that the round-trip efficiency of storage and retrieval processes causes energy losses. Battery storage systems’ round-trip efficiency ranges between 85% and 95%, but losses to heat and parasitic loads are the current hurdles. This hurts the site’s energy usage. All the constraints of the ESS require ongoing technology advancements, optimization, and planning to ensure the demand can be accommodated by the equipment and the design. And let’s not forget about the code requirements, opportunities, and constraints for the utilization of ESSs. Battery storage has been in NFPA 70 (National Electrical Code) for decades, but it wasn’t until 2016 when NFPA 855, Standard for the Installation of Stationary Energy Storage Systems, was initiated with the first edition issued by the Standards Council in 2019. (Fun fact: Lore says that the standard number “855” was created because it looked like “ESS”). This document focuses solely on ESSs and provides minimum requirements for mitigating the hazards associated with ESS. This standard works in conjunction with other codes such as: the NEC; NFPA 99, Health Care Code; NFPA 110, Standard for Emergency and Standby Power Systems; and NFPA 111, Stored Electrical Energy Emergency and Standby Power Systems. Each iteration of these documents continues to refine and address how these storage systems have evolved and how adherence to energy constraints has modified acceptability and design opportunities. We would strongly suggest picking up a copy of each of these documents and reading through the “Origin and Development” chapter of each code or standard. It helps paint a picture of how far we have come from an energy distribution perspective and creates context on how to understand where an ESS is acceptable by code. And, as always, it is important to understand which codes and standards are adopted, modified, and enforced in each jurisdiction and how energy targets for states and jurisdictions interact with these requirements.

ESS APPEAL

So, with some of these constraints and limitations, what is the allure of utilizing an ESS? The potential to offset energy costs and boost resilience, especially with the increase in natural disasters, power outages, and other emergencies, is a solid start. Standalone systems are typically not practical yet (due to the large capacity and duration many facilities would need to operate solely on an ESS), but pairing an ESS with conventional energy sources reduces utility costs and limits fuel consumption. But not everyone is jumping on the ESS bandwagon. Initial costs are still high, and return on investment (ROI) is often long without external incentives. Not only is the cost high but the technology to control the system is also still relatively new, scaring some away until the technology is further developed. The new Inflation Reduction Act (IRA) Section 48 Investment Tax Credit (EITC) now expands the projects and credit thresholds to include energy storage technology if the construction begins by Jan. 1, 2025. This enables non-taxable entities to get a tax refund. HGA has helped clients apply for and win grants to help offset the initial cost of an ESS and has collaborated with schools and public safety buildings to develop and install BESSs. Moreover, we have conducted a comprehensive feasibility study for implementing a BESS in a hospital. HGA is tackling this complexity by analyzing and optimizing the controller and operational performance of the BESS at a net-zero school in Wisconsin, which is designed to offset 100% of its on-site energy needs. As our society becomes more ecoconscious, renewables paired with ESSs are starting to take center stage to align with states and cities adopting energy usage targets. Energy storage is the future — and understanding the options, constraints, cost, ROI, and opportunities will help integrate them into more of our power distribution systems. Bryanna Krekeler is an energy specialist, Kevin Standlee, P.E., is a senior electrical project engineer, and Krista McDonald Biason, P.E., is the national electrical practice leader at HGA Architects and Engineers.

February 2024 • www.ecmweb.com

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The Benefits of Energy Storage Systems and Microgrids Understanding the basic principles behind how these systems work enables electrical professionals to better harness their power. By Ryan Mayfield, Mayfield Renewables

n today’s rapidly evolving energy landscape, businesses face increasing pressure to enhance their energy efficiency, reduce costs, and achieve business operations reliability while contributing to sustainability efforts. Two innovative solutions that have gained prominence recently are energy storage systems (ESSs) and microgrids. These technologies not only transform how energy is managed but also the role of energy in a business’s strategy. In this article, we delve into the intricacies of energy storage and microgrids, exploring their unique benefits to businesses and communities and their role in shaping the future of energy consumption.

THE BASICS

Before we explore their applications, let’s get aligned on the basics of what energy storage and microgrid systems entail. As the name implies, an ESS stores energy to be released for use later. These systems are designed to bridge the gap between energy generation and consumption, enabling excess energy to be stored when demand is low and released when demand is high. Spurred by the Inflation Reduction Act (IRA), battery deployment has grown 300% in the last two years in the United States and is predicted to increase exponentially. The primary equipment in an ESS is the battery and the inverter, which are 36

Solar

Main Utility Grid

Wind

Generator

Control Center

Energy Storage

Homes & Businesses

Fig. 1. Key components and energy flow in a microgrid.

coupled either externally or within a single form factor to provide grid-level AC electricity. Although “microgrid” is a buzzword these days, these systems are often not fully understood. The Department of Energy’s definition of a microgrid is: • An easily identifiable boundary from the rest of the grid. • Resources within the microgrid are controlled together. • The microgrid can function whether or not it is connected to the larger grid. The key components of a microgrid include: • Energy generation source (solar panels, wind turbines, generators, and others). • Energy storage systems (most often batteries).

• Load (things that use energy). Microgrids can be as small as a single building or as large as a whole community (Fig. 1). Microgrids are distinguishable from solely solar-plusstorage systems in that the equipment must have the ability to isolate (i.e., islanding) from the grid (if grid-tied) and manage the power quality (voltage and frequency control), which is usually the grid’s responsibility. You may be wondering, “Why all the hype around energy storage? And how will this help a community or business?” Let’s take a look at some energy storage use cases to gain perspective.

ENERGY STORAGE USE CASES

There are various distinct usages of energy storage, each with its benefits, that

February 2024 • www.ecmweb.com

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MICROGRID USE CASES

If the situation calls for power independence from the grid, then a microgrid is the best option. Here are some use cases for microgrids. 38

(A)

ESS in Peak Shaving

(B)

ESS in Load Leveling

S Battery Discharge

Battery Charge Demand Charge Threshold Load

Battery Charge

Battery Discharge

Load

must be considered and prioritized for any system. It should be noted that since microgrids include energy storage, they also have these use cases, but microgrids go further (Fig. 2). Peak demand management: Also referred to as “peak shaving,” businesses are often subject to peak demand charges at high rates, which can be caused by equipment start-up, business energy usage timing, or any number of things. This shows up as short-duration, high spikes in your electricity usage. Energy storage can provide the source of electricity to offset these spikes to limit the demand the grid sees. Load shifting: Also referred to as “time of use” operation or “energy arbitrage,” the energy storage charges up when electricity is cheap (like during peak solar times) and discharges when rates are higher, often in the late afternoon/evening time frame. By shifting energy consumption to off-peak hours, businesses can capitalize on lower electricity prices, resulting in significant cost savings over time. Power quality: Whether you have integrated renewables or are near the end of the power line, maintaining good power quality is essential for business operations. Poor voltage and frequency regulation can lead to damaged, or offline, equipment. Variable renewables, such as solar and wind, are not only varying by the hour but also by the minute, which can be mitigated with energy storage. Regulatory compliance and sustainability: Energy storage supports businesses to meet regulatory requirements and sustainability goals by optimizing energy usage and reducing carbon emissions. Be aware that regulatory/sustainability programs and tax credits can impact the design and equipment selection to receive the full benefit. Grid services and revenue generation: In markets that allow it, an ESS can provide grid services, such as frequency regulation, earning additional revenue for the facility owner. This is anticipated to become more commonplace as utilities seek ways to manage their renewable energy sources and grid electrification.

Load Profile

Discharge Schedule Load Profile

Hours

Fig. 2. Energy storage can provide the source of electricity to offset spikes to limit the demand the grid sees.

Energy resilience: Microgrids can operate independently from the main grid during outages or disruptions, ensuring continuous power supply for critical operations. Safety critical backup power: Microgrids are a necessary solution when electricity is required for safetycritical operations. These systems are often characterized by their fast response to loss of grid power and loadsharing capabilities. Remote and off-grid locations: In remote areas or locations with unreliable grids, microgrids provide a reliable, localized energy solution. Energy independence: Whether it be for sustainability goals or energy security reasons, microgrids can provide the reassurance that comes with energy independence.

DESIGN, EQUIPMENT, AND COST IMPLICATIONS

The choice between an ESS or a microgrid also depends on the specific goals of the end-user and the characteristics of the application. Design: The desired use case drives the design of the system, particularly as it impacts the sizing and available functionality. The ESS is usually limited to a single connection point within the electrical system. On the other hand, a microgrid must integrate with all aspects of generation, storage, and load. As such, early feasibility assessments and understanding of project goals are essential for an effective design. Equipment: The key equipment for an ESS includes the battery, battery inverter, and associated battery management system (BMS). In a microgrid,

grid-isolation switches are needed along with grid-forming inverters (also referred to as bi-directional inverters). A microgrid controller is also essential and can be coupled or independent of the BMS. Both systems need the appropriate safety equipment, disconnect, relays, monitoring, and remaining balance of system components. Capital costs: An ESS generally has a lower upfront cost compared to a microgrid. Microgrids involve more significant capital investment due to the need for diverse energy sources, components, and distribution networks. Long-term savings: Both an ESS and a microgrid can lead to long-term cost savings. An ESS reduces peak demand charges and energy costs over time. Microgrids provide energy resilience and backup power, minimizing losses during outages and potential downtime.

CONCLUSION

An ESS and a microgrid are transformative solutions, revolutionizing how energy is managed, consumed, and generated. While energy storage focuses on optimizing energy usage, reducing costs, and integrating renewables, microgrids prioritize energy resilience, backup power, and localized energy control. Each approach has its unique value proposition and impact on the system design, upfront cost, and long-term cost. Ryan Mayfield has been working in the renewable energy field since 1999 and is the CEO and founder of Mayfield Renewables. He teaches nationwide PV courses on various topics and holds a Limited Renewable Energy Technician (LRT) license in Oregon.

February 2024 • www.ecmweb.com

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2312EC

ST EEL

2 Snap it connectorS ®

NO TOOLS

NEW!

ONE-PIECE ALL STEEL

EASY SNAP IN INSTALLATION

TINTED 40STS

38STS

Arlington’s new, one-piece Snap2It® steel connectors offer easy, secure installation. And save time! Just push the cable into the connector and rotate it clockwise. Available in 3/8" trade size, both connectors install into a 1/2" knockout, and are listed for steel and aluminum AC, HCF, MCI and MCI-A cable. The tinted 40STS has more room inside for easier cable insertion.

In Canada both connectors are Listed for use with AC90 and ACG90 cable. • Tested to UL 514B and Listed to meet UL ground fault requirements • Removable Unscrew the connector counterclockwise to remove it from the cable. Remove the connector from the box using a flat blade screwdriver. Release the snap tangs from the inside of the box while pulling the connector out of the knockout. • Packed in heavy-duty, 200 piece boxes

Easy Snap-in Insertion

Easy Screwdriver Removal NO SPECIAL TOOL

CATALOG NUMBER

120

38STS

CABLE RANGES STEEL Snap2It® connectors AC, HCF, MCI, MC!-A 14/2 w ground, 14/3, 14/2 12/2 w ground, 12/3, 12/2 • 10/2 w ground, 10/3, 10/2

.405” Dia. Minimum to .605” Dia. Maximum 40STS Tinted

AC, HCF, MCI, MC!-A 12/2 w ground, 12/3, 12/2 • 10/2 w ground, 10/3, 10/2

.480” Dia. Minimum to .605” Dia. Maximum

2312ECM_Arlington_866434-1223_120.indd 1 2402ECM_36-39_ESS.indd 39

www.aifittings.com • 800/233-4717 Scranton, PA 18517 Product info aifittings.com/landing/38STS-40STS

11/14/23 1:35 2/13/2024 4:02:29 PMPM

Courtesy of SolarEdge

After NEM 3.0 was put into place last year, bringing with it a drastic change to net metering rates, this has led to some market uncertainty with concerns about a possible dip in demand.

How will the change to net energy metering (NEM) 3.0 regulations impact solar adoption in the long term?

or several years, driven by lucrative financial incentives, California saw a massive increase in solar installations. However, with the changes to the state’s net metering incentives introduced in April of last year, homeowners and installers of solar equipment alike are now trying to operate in the California solar industry’s “new normal.” In recent years, the Golden State shined brightly, with solar at the forefront of its transformational shift to sustainable living. Leading the solar industry in the United States, the market grew exponentially, driven by the lucrative incentives available under the previous net energy metering (NEM) regulations — NEM 2.0. However, in April, NEM 3.0 was put into place, bringing with it a drastic change to net metering rates that is projected to make it around 70% less profitable for homeowners to sell excess energy to the grid. Naturally, this has led

By Chris Thompson, SolarEdge 40

to some market uncertainty with concerns about a possible dip in demand. Recently, the California Public Utilities Commission (CPUC) rejected an overturn proposal on their recently proposed NEM 3.0 regulations — and even more recently decided to change net metering regulations further with the introduction of virtual net metering (VNEM). VNEM regulates how solar is used and credited on multimeter properties and is expected to make solar unprofitable for California small businesses, apartment renters, schools, and farms. With these decisions at the forefront of the solar industry’s mind, the industry is again debating what NEM 3.0 will mean for the solar market moving forward.

sell (as expected with NEM and VNEM), it is more cost-effective to store energy for personal use when the sun goes down. What you get is a net metering market shifting to a self-consumption market with solar + storage becoming the norm. In both Belgium and Germany, for example, the same pattern emerged. Demand for solar increased significantly in the run-up to the tariff change and then dipped slightly afterward. However, in both countries, this proved to be a blip rather than a trend. Both countries have realized a substantial increase in demand for solar + storage installations, which has made these two markets very profitable for German solar installers.

LEANING ON THE PAST TO BETTER UNDERSTAND THE FUTURE

HELPING HOMEOWNERS TO PROSPER IN A SELFCONSUMPTION MARKET

Fortunately for California, this situation is not new. Similar changes have occurred in many other countries across Europe. When energy becomes more expensive to buy than it is profitable to

With storage presenting a larger, longterm investment, homeowners will look for systems that offer a good value and will last. For installers, the key to maintaining sales is to add as much value for

February 2024 • www.ecmweb.com

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2/13/2024 4:04:18 PM

2402EC

SAVE TIME. NO TOOLS. EASY PUSH ON INSTALLATION

PUSH-ON CONNECTORS ! NEW g r er

for NON-METALLIC LIQUID-TIGHT CONDUIT TYPE B

La izes S

1.25"•1.5"•2" Non-metallic PUSH ON

NMLT20 2"

NO TOOLS!

Conventional installation

NMLT50

SAVE 40 seconds per connector!

DONE. NON-METALLIC

Save time and money with Arlington’s plastic or zinc Snap2It® push on connectors. They offer the fastest, easiest installation on non-metallic liquid-tight conduit, type B. FORGET the TOOLS! Simply push the connector on to conduit. That’s it!

Competitively priced, they’re removable and reusable too. 93A

Straight and 90° 1/2", 3/4" and 1" trade sizes* NEW LARGER Non-metallic sizes 1-1/4", 1-1/2" and 2"

LARGER

You’ll get a super-secure, liquid-tight seal. Plus, they ship fully assembled – No disassembly required.

NMLT12 1-1/4"

Catalog Number

Trade Size

NMLT5 NMLT905 NMLT7 NMLT907 NMLT10 NMLT9010 NMLT12 NMLT9012 NMLT15 NMLT9015 NMLT20 NMLT9020

1/2" 1/2" 3/4" 3/4" 1" 1" 1-1/4" 1-1/4" 1-1/2" 1-1/2" 2" 2"

Straight 90°

4 4 4 4 4 4 4 4 4 4 4 4

* Also available in zinc for metallic and non-metallic liquid-tight conduit, type B

www.aifittings.com Scranton, PA 18517 800/233-4717 Product Info aifittings.com/landing/nmlt20

2402ECM_Arlington_902061-0224_93A.indd 1 2402ECM_40-43_PV_on_NEM.indd 41

1/23/24 4:32 2/13/2024 4:04:21 PMPM

Courtesy of SolarEdge

While there’s no doubt the Californian solar market is undergoing a major change, it presents a huge opportunity for installers.

homeowners as possible. This starts by advising homeowners on the help available to reduce the cost of purchasing a solar + storage system. The introduction of the Inflation Reduction Act (IRA) in 2022 brought with it rebates for energy efficiency retrofits of up to $4,000 for single-family homes and up to $400,000 for multifamily buildings, which can put a significant dent in the initial purchase price of the system. Even with this financial help, purchasing a solar + storage system may seem out of reach for some homeowners. Therefore, it is essential to offer a range of solutions to meet every budget. Currently, most batteries in the United States are purchased in combination with a backup unit. However, this is not essential for homeowners who are looking to store energy simply to increase their self-consumption. Investing in a solar + storage solution will also be more appealing to homeowners educated on time of use (ToU) savings. Under NEM 3.0, export rates for solar energy will differ from hour to hour, which can make it difficult to determine the revenue homeowners can generate by selling energy back to the grid. On average, homeowners will receive about 5 cents/kWh. The exception is that during September between 6 p.m. and 8 p.m., the rate will increase to $3/kWh. This means that homeowners could receive a potential paycheck of $750 to $850 for September with careful management of the process. Another way to add value for customers is to talk to them about the role that load shifting can play in increasing solar energy self-consumption. For example, scheduling heavier electrical loads such as EV chargers, heat pumps, pool pumps, and air conditioners to run at times when solar production is at its 42

highest will help customers use much more of the energy produced by their home systems. This functionality will become even more important because of how EV charging increases the amount of energy required in homes. Therefore, offering a complete end-to-end smart energy management system within the home that automates this process will become a major selling point under NEM 3.0 and VNEM. Oversizing PV arrays also becomes a more important consideration in a selfconsumption market. Oversizing the array (in comparison to the inverter’s AC power) ensures that PV systems produce more power more of the time — even during low-light conditions. The result is a higher energy yield for the home and a faster return on investment for the homeowner through greater ToU savings and load shifting.

HOW INSTALLERS CAN THRIVE IN NEM 3.0

For solar installers to thrive in the new reality of a self-consumption market, they need to consider all battery options available and the factors that make installing batteries easier for themselves as well as beneficial to the customer. A DC-coupled battery provides the highest efficiency energy storage by eliminating what is known as the “triple conversion penalty,” with two fewer power conversions required than AC-coupled batteries. In some cases, this can result in an additional 10 days of saved energy per year. Right now, homeowners are hyper-aware of how much their energy use is costing them, so it’s easy for them to quickly calculate how much extra savings this will generate. However, the benefits of DC-coupled batteries also extend to installers. Unlike

AC-coupled batteries, DC batteries do not require additional breakers to be installed in the home’s load center, which, in most cases, removes the need for a main panel upgrade (MPU). MPUs can be expensive for the homeowner and are extremely time-consuming for installers. Reducing the time it takes to complete each project means installers can move on to the next one much quicker, which is great news for their bottom line. Long commissioning times for batteries are another source of frustration for installers. We often hear stories about batteries that can take up to a day to commission because of the time needed to upload firmware to the battery bank.

WILL CALIFORNIA STAY GOLDEN?

While there’s no doubt the Californian solar market is undergoing a major change, it presents a huge opportunity for installers. As we’ve seen in other self-consumption markets that have experienced a similar shift, sales may dip in the short-term, but this will be followed by a resurgence in demand driven by solar + storage installations. The market that emerges will be more mature, stronger, and resilient. For installers who understand how to best implement batteries into their sales mix, they will be well positioned to become more profitable than ever. Chris Thompson is the vice president of product and technical marketing at SolarEdge, where he manages grid services, technical marketing, and regulatory functions in North America. With more than 30 years of diversified global experience in the power electronics and power systems markets, he has held roles on all sides of the solar industry. He can be reached at https://www.linkedin.com/ in/solarchris/.

February 2024 • www.ecmweb.com

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2/13/2024 4:04:26 PM

ARLINGTON

YEARS

NON-METALLIC

NEW

THE SCOOP TM

ice

Dev Entry h s w Bru g openin

ENTRANCE PLATES, HOODS, DEVICES E The SCOOP™ series of reversible, non-metallic ENTRANCE HOODS, PLATES AND DEVICES protect cable while delivering good looks and installation versatility. They also reduce labor and eliminate extra connections. Our newest CABLE ENTRY DEVICES come with or without a wall plate for efficient cable management. HOODS for decorator-style wall plates, single and two-gang PLATES install facing in or out...and save time!

CED135 Arlington’s TVBU505 TV BOX

• Low voltage cable protection

(with wall plate, order CED135WP)

• Best way to run cable

CED1 facing OUT

CER1

800/233-4717 • www.aifittings.com

2312ECM_Arlington_866400-1223_19.indd 1

CE1 facing IN

CED130

entry device w slotted cover

CE2 facing OUT

Product info aifittings.com/landing/scoop-series/

Patented

11/14/23 11:16 AM

RECESSED FOR FLUSH-TO-THE-WALL MOUNTING OF LED, HI-DEF TVs

STEEL TV BOX™KIT CO M B O BOXES FOR USE WI TH METAL RACEWAYS Arlington’s recessed STEEL combination power/low voltage TV BOX™ is the best way to mount an LED or Hi-Def TV flush against a wall.

retrofit

Mounting wing screws hold box in the wall

TV BOX provides power and/or low voltage in one or more of the openings. Plugs and connectors stay inside the box, without extending past the wall. Designed for use in new or retrofit commercial construction where metal raceway is used, we have a STEEL TV BOX for almost any application!

New work

2-GANG TVBS505

Mounting screws hold box on stud

• Steel box; non-metallic paintable white trim p plate • Easy, secure installation

! NEW 1-GANG TVBS503

• Optional covers Patented

3-GANG TVBS507

800/233-4717 • www.aifittings.com

2312ECM_Arlington_866438-1223_98.indd 1 2402ECM_40-43_PV_on_NEM.indd 43

Product Info aifittings.com/landing/recessed-tv-boxes

11/14/23 1:50 PM 2/13/2024 4:04:29 PM

Courtesy of Burns & McDonnell

By Tim Kridel, Freelance Writer

BUMPER CROP As demand for new solar farms soars, so does a host of challenges including community pushback, equipment and labor shortages, and a congested grid. Here’s how the industry is overcoming them. 44

nterconnection is the process of hooking a generation source to the grid. That term also describes the delicate relationship between the land, labor, lines, zoning, grid capacity, and equipment that make up a solar farm. If just one piece isn’t in place, the whole project falls apart. Sometimes multiple pieces are absent simultaneously, while other times putting together a project can feel like a game of Whac-A-Mole. “Elevated financing costs, transformer shortages, and interconnection bottlenecks are impacting the utility-scale segment, which saw its lowest level of new contracts signed in a quarter since 2018,” according to the latest U.S. Solar Market Insight report from the Solar Energy Industries Association (SEIA) and Wood Mackenzie. “However, improvements in the module supply chain have led to a record 12GW of utility-scale deployment in the first nine months of 2023.” No wonder solar farming can seem as feast or famine as agriculture, with the political equivalents of droughts and floods emerging out of nowhere. “You get large federal regulatory items like the Inflation Reduction Act (IRA) that drive a bunch of demand and new projects,” says Robert Wright, solar and storage business line lead at 1898 & Co., a Burns & McDonnell consultancy subsidiary. “But then you get issues with anti-dumping tariffs for international imports on stuff like solar modules and a couple-year lag bringing on domestic products.” The U.S. Department of Commerce anti-dumping investigation created so much uncertainty that it prompted the cancellation or delay of 318 projects in 39 states worth a total of $52 billion, according to a 2022 SEIA study, which added that this “represents only a fraction of likely impacts.” “You start solving one piece — modules — but right now it’s the high-voltage equipment that’s the longest lead times on our utility-scale [projects],” Wright says. “Main power transformers and high-voltage breakers are the critical path item on a lot of these. Even compared to transmission constraints and the queue times to get interconnect applications through, a lot of times we’re seeing those long lead procurement items being even more of a constraint on when we can actually get facilities online.”

February 2024 • www.ecmweb.com

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2/13/2024 4:05:55 PM

YEARS

ARLINGTON

STEEL BOX WITH BRASS COVER

LISTED SINGLE GANG

FLOOR BOX KITS CONVENIENT, FLUSH-TO-THE-FLOOR RECEPTACLE INSTALLATION

FLB5331NL Single gang steel box kit w nickel-plated brass cover

Our Listed Single Gang Steel Floor Boxes deliver easy, flush-to-the-floor installation. • Brass covers hide miscut flooring; gaskets prevent water intrusion; flip lids protect the box when it’s not in use. • Single gang brass and nickel-plated Brass Covers fit our boxes and other manufacturers’ single gang boxes. Covers also sold separately. FLB5331MB Single gang steel box kit w brass cover

for NEW or existing floors

FLB5331MB Single gang Kit w brass cover

119

800/233-4717 • www.aifittings.com

Product info aifittings.com/landing/flb5331-flb5551-kits

2312ECM_Arlington_866439-1223_119.indd 1 Patented/other patents pending

11/14/23 1:58 PM

IN BOX RECESSED COVER KITS ®

! EW

INSTALLS INSIDE 4.5" CONCRETE BOXES

Arlington’s IN BOX® Recessed Cover Kits are the neat way to install a receptacle in an installed 4.5" concrete floor box, including our FLBC4500 or FLBC4502 boxes.

FLBC4560DNL

Plugs stay inside recessed cover

IN BOX covers install fast, inside the can reducing trip hazards caused by plugs sticking out of the box. They look great. And, you can have power and low voltage in the same box. Assembled IN BOX, comes with matching in-use slotted cover and cover blank for unused boxes in brass or nickel-plated brass

Slotted in-use cover

FLBC4560DMB Brass

FLBC4560DNL Nickel-plated

Cover blank

Slotted cover

FLBC4560DBR Brown

Courtesy of Burns & McDonnell

Arlington’s STEEL FLOOR BOX KITS give installers a low cost, convenient way to install a receptacle in a new or existing floor.

...and plastic in FIVE colors. FLBC4560DMB FLBC4500 FLOOR BOX FOR NEW CONCRETE

800/233-4717 • www.aifittings.com

2312ECM_Arlington_866440-1223_57.indd 1 2402ECM_44-49_Solar.indd 45

Easy to install in concrete box

FLBC4560DGY FLBC4560DCA Gray FLBC4560DBL Caramel Black

Product info aifittings.com/landing/inbox-cover-kits/

FLBC4560DLA Light almond

Patented

11/14/23 2:11 PM 2/13/2024 4:05:57 PM

PRIME REAL ESTATE IS ELUSIVE

GIRDING THE GRID

The limited number of viable interconnect locations around the country is just one grid-related challenge. As the solar farm market grows, so does the number of interconnect applications and thus the length of the approval queues. 46

Land Requirement (Million Acres)

To meet the goal of supplying 45% of all U.S. power by 2050, solar panels will need to blanket about 10.3 million acres, according to the U.S. Department of Energy’s Solar Futures Study, as shown in the Figure at right. That’s more than all of Connecticut and Massachusetts combined. Some of that will be atop homes and businesses, but most will be on the ground in the form of solar farms spanning hundreds of acres apiece. That scale makes them a tough sell — even in rural areas. Many communities have blocked or delayed projects amid concerns about their impact on the environment, property values, and arable land. The same objections often stand in the way of the transmission lines that those farms need in order to be built. “What I’m seeing in working with some of the larger clients is there are definitely siting challenges: getting available land at a reasonable cost and proximity to high-voltage lines that are not congested,” says Dan Akselrod, principal electrical engineer at Centennial, Colo.-based Stanley Consultants. A big plot of land on the edge of town with high-voltage lines nearby might look ideal. However, digging into the ground and local codes can uncover issues that drive up the project’s complexity and cost. “A lot of times that area is split up — gas lines underground, telecom lines, easements, and rights of way for rail or roadways — so there’s a lot that we have to build around,” Akselrod says. “Depending on the location, local fire codes also are an issue. On one of my battery energy storage projects, the fire department is considering the location to not be a rural or isolated location. That is affecting our ability to even build the project because we don’t have space for a 100-foot offset from the property line. There are a lot of regulatory issues like that.” But in other cases, government control can enable projects that wouldn’t be viable elsewhere. For example, Nevada has about 50 days more sunshine than the national average, but that’s not the reason why it’s home to so many utility-scale solar farms. Roughly 80% of the state is owned by federal agencies such as the Bureau of Land Management (BLM). “You have the advantage of tremendous insulation [and] a lot of available land,” Akselrod says. “Also, at least north of Las Vegas, there are available transmission lines.” More is on the way. In January, the BLM updated its 2012 Western Solar Plan, which originally identified areas in Arizona, California, Colorado, Nevada, New Mexico, and Utah with “high solar potential and low resource conflicts.” These areas have “fewer sensitive resources, less conflict with other uses of public lands, and close proximity to transmission lines.” The 2024 plan adds Idaho, Montana, Oregon, Washington, and Wyoming, bringing the total amount of public land available for solar farms to about 22 million acres.

Decarb+E Benchmark: Maryland ~ 7.9 million acres

Decarb 5 Reference

2010

2030

2050

National solar deployment land-use projections for the three core scenarios (2010-2050), as outlined in the Solar Future Study conducted by the U.S. Department of Energy.

“Nationwide, they’re getting longer and longer,” says 1898 & Co.’s Wright. The good news is that grid operators have a vested interest in streamlining this process. “The transmission owner/planner [thinks]: ‘How can I make my grid more attractive to renewable developers?’” says Debrup Das, Hitachi Energy’s head of renewables for North America. “All the counties, states — you name it — they want to have this energy transition. So, if I don’t make my grid attractive to developers, they will invest somewhere else.” But those upgrades require a lot of time and money, according to the U.S. Department of Energy’s October 2023 National Transmission Needs Study. “Their finding was when it comes to transmission within a region, we have to grow 64% or so,” Das says. “In terms of interregional transfer, we have to grow more than 110%. The bottom line is if we want to go through this energy transformation really quickly, we have to really invest a lot in transmission.” High-voltage direct current (HVDC) technology could provide flexibility on a national scale, according to the National Renewable Energy Laboratory’s Interconnections Seam Study. HVDC lines would bridge the seam between the country’s eastern and western interconnections to create a national macrogrid. “We need to have more interregional transmission because when it is peak usage on the eastern side [of the country], it’s not peak on the western side,” Das says. “Their conclusion was out of the various technologies that can help, HVDC is the most effective and [has] a benefit-to-cost ratio of 1.2 to 2.5 [to 1].” Another emerging option is dynamic line rating (DLR) technology. Each transmission operator has ratings that determine how much power its lines can safely handle. DLR uses sensors on that infrastructure to monitor aspects such as temperature and wind, which affect each line’s thermal capacity. For example, strong winds can cool a line enough that it can accommodate more generation while they’re blowing.

February 2024 • www.ecmweb.com

2402ECM_44-49_Solar.indd 46

2/13/2024 4:05:58 PM

YEARS

ARLINGTON

GALVANIZED STEEL

NEW

CABLE SUPPORT ECONOMICAL...HOLDS UP TO FOUR MC CABLES • EASY TO INSTALL

Nail or screw on CUS6

Foldline (centerline)

Locking tab

Nail or screw to stud through these holes

Bend right side of strap in and over cable

Holds up to four MC cables centered on a 2x4!

Arlington’s economical CUS6 galvanized steel Cable Support holds cable secure and centered on a metal or wood stud. It’s perfect for fastening and positioning up to four individual metal clad cables – or six NM cables on a 2x4.

Insert locking tab here

Installation is quick and easy. Nail or screw CUS6 to a wood or metal stud, and position the cables. Next bend the strap at the foldline (centerline). Fold the strap over the cables and insert the locking tab in the opening as shown to hold them securely in place. • Complies with 2020 NEC, article 300.4(D)

CUS6 holds FOUR metal cables...or SIX NM cables 800/233-4717 • www.aifittings.com

Product info aifittings.com/landing/cus6/

2312ECM_Arlington_866442-1223_22.indd 1

11/14/23 2:20 PM

NON-METALLIC • VENTED FOR EASIER STACKABILITY

CONCRETE PIPE SLEEVE THE EASY, ECONOMICAL WAY TO SLEEVE THROUGH CONCRETE POURS!

Arlington’s Concrete Pipe Sleeves are the economical way to sleeve through concrete pours in tilt-up construction WALLS – and FLOORS allowing cable and conduit to run easily from one floor to the next. No costly core drilling – No cutting holes in the form. Plus, you can position the hole prior to pouring the concrete. CPS40 Pipe Sleeve for 4" hole

• Attaches to form with nails or screws • Stackable up to 23" h for extra deep pours • Vents keep wet pipe sleeves from sticking together

CPS40

• Multiple hole sizes: 1-1/2" • 2" • 3" • 4" • 5" • 6"

21 Nail sleeve to form.

800/233-4717 • www.aifittings.com

2312ECM_Arlington_866432-1223_21.indd 1 2402ECM_44-49_Solar.indd 47

After concrete sets, cut sleeve flush with surface.

Insert conduit into sleeve.

Product info aifittings.com/landing/concrete-pipe-sleeve

11/14/23 1:21 PM 2/13/2024 4:05:59 PM

Courtesy of Burns & McDonnell

If solar production were a line on a graph, it would look like a duck’s back and neck, with output dropping and then increasing during the course of 24 hours. BESS helps flatten this “duck curve.” “One of the ways that we’re mitigating it in this project I’m working on is the inclusion of a BESS to pick up that load in the very late afternoon and early evening,” Akselrod says. “As more coalfired generation is retired, this is going to be even more important. We need more energy storage in general.”

HELP WANTED

A tremendous opportunity exists for electrical contractors taking on this utility-scale solar wiring work.

“The whole point of DLR is there’s the ability to flow more power on these lines than a static limit would entail,” says Patrick Finn, a Wood Mackenzie senior analyst who covers North American power markets. “They’re giving realtime information to the transmission operator saying, ‘Based on the temperature on this on this sensor and the wind speed, the actual limit of this line right now is 120 as opposed to 100.’” A couple of Pennsylvania transmission operators studied how DLR compares to reconductoring or rebuilding lines in terms of time, money, and additional capacity. “In their presentation, PPL said DLR would be the more cost-effective solution and increase the capacity of that line by 10% to 30%,” Finn says. “I think Duquesne [was] similar: around a 20% increase.” DLR also could complement battery energy storage systems (BESSs) by enabling the grid to handle more stored power — and not just from solar farms. “Technologies such as DLR allow us to maximize the existing transmission infrastructure by helping move all resource types,” says Brandon Morris, a Midcontinent Independent System Operator (MISO) spokesperson. “Renewable technologies like solar and wind are weather dependent, and their availability can fluctuate. We’re focused 48

on answering the questions of how to ensure both adequate resources and necessary grid services to manage the grid under increasing penetrations of renewable energy.” Solar farms also could leverage the coal-fired plants that they’re helping replace. “When they’re decommissioned, you could use the existing generator and electrical interconnections as a synchronous condenser to provide voltamp reactive (VAR) power to the grid and inertia,” says Stanley’s Akselrod. “That is something that the solar power plants do not provide. The power generated must equal the power consumed in any given instance. The reason why the grid doesn’t collapse when you turn on the lights is that inertia. Solar fields don’t have that spinning energy storage that traditional power plants have.”

BESS IS MORE

Grid bottlenecks are one of the reasons why solar farms increasingly include colocated BESSs — either from day one or as a follow-up project. Utility-scale BESS can store power that the grid can’t handle at certain times of the day and then release it when capacity becomes available. “I think it’s becoming more of the norm,” Akselrod says. “I’m seeing more demand for just standalone BESS at the distribution level to help local utilities.”

As with electric vehicle charging infrastructure and so many other sectors, capitalizing on the utility-scale solar business opportunity requires an ample supply of people and equipment. “There is a lot of wiring work,” Akselrod says. “This is not master electrician-level stuff. It’s more journeyman level. There’s a tremendous opportunity for electrical contractors. It’s not like building a nuclear power plant. It can be fairly cookie-cutter, so these guys can make a lot of money.” The catch is that they can make a lot of money close to home, too. “That is one of the issues I see on my project in Nevada,” Akselrod says. “It’s a fairly rural area not too far from Las Vegas. They would rather work close to home in Vegas versus driving all the way up to the project site.” On the equipment side, solar farm developers are becoming more flexible to keep projects on schedule. “We’re seeing our clients expand their approved vendor lists [to] consider more OEMs that they otherwise would not,” says 1898 and Co.’s Wright. “If you can shave a year off a 345kV breaker, that makes sense.” But despite all of the challenges, the future looks bright. “These issues are really the result of a very strong industry with a ton of demand,” Wright says. “So, it’s a good problem to have.” Kridel is an independent analyst and freelance writer with experience in covering technology, telecommunications, and more. He can be reached at tim@timkridel.com.

February 2024 • www.ecmweb.com

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2/13/2024 4:06:01 PM

YEARS

ARLINGTON

UV RESISTANT • 100% RECYCLED MATERIAL

ROOF TOPPER

NEW SLED STYLES

RELIABLE ROOFTOP SUPPORT OF CONDUIT, CABLE TRAY ROOF TOPPER® supports raise conduit/raceway 4" or more off the roof surface, allowing contractors to comply with the 2017 NEC® for temperature adjustment for circular conduit.

RTSE405 5" w

5-5/8" H RTSE409 9" w

The heavy-duty base, made of 100% recycled material, sits on the roof deck. There’s no need to mount ROOF TOPPER to the surface with mechanical fasteners.

RTS4

Offered in a variety of sizes and configurations, ROOF TOPPER supports up to 2000 lbs, and stands up to extreme rooftop conditions protecting and elevating conduit or raceway above the roof deck. 5-5/8" H RTS4

STRUT ATTACHED w END CLAMPS RTSE1209 9" w x 12" h

12" H

9" wide

RTS421

114

21" w

Ra Raceway raised 12 above the roof 12"

RTS12 9" w

800/233-4717 • www.aifittings.com

Product info aifittings.com/landing/rooftopper

RTS1221 21" w

Patented

2312ECM_Arlington_866443-1223_114.indd 1

11/14/23 2:57 PM

A NEAT COVER UP...

Patented.

FOR UNUSED FAN/FIXTURE BOXES – FITS PAN BOXES TOO!

CP3540 Box Cover

Our non-metallic, paintable CP3540 Box Cover is the neatest way to cover unused fan/fixture boxes, pan boxes or poorly cut drywall.

Versatile bracket design with ‘A’ and ‘B’ openings for use on flat or uneven ceilings.

• No visible screws on ceiling plate 20

Easy installation. Attach the e bracket to the box with #8 or • Fits 3.5", 4" round #10 screws. Back the screws out enough or octagonal boxes to slip the bracket on. 800/233-4717 • www.aifittings.com

2402ECM_Arlington_902122-0224_20.indd 1 2402ECM_44-49_Solar.indd 49

‘A’ for flat ceilings Push stud into opening to seat cover

Versatile Bracket Design Stud

‘B’ for uneven or textured ceilings Thread stud into opening until tight

Product Info aifittings.com/landing/CP3540

1/23/24 2:43 PM 2/13/2024 4:06:02 PM

NEW PRODUCT SHOWCASE

Focus on Boxes and Enclosures Fiberglass Box New to the SLIDERBOX family of products, the company has introduced the 1099-AB adjustable fiberglass box. The product features fiberglass BOX material, so no putty pad is needed when following the Uniform Building Code. The box is sound rated up to a Sound Transmission Class (STC) rating of 54, is equipped with 0 in. to 2 in. of adjustability to fit most wall finishes, and arrives preset for ½-in. standard drywall applications. The product also has 6-32 UNC tapped holes for easy device mounting, a corrosion-resistant metal bracket for a solid hold to a wood or metal wall stud, and a one-screw design for easy adjustability. Allied Moulded

Square Box The new EZ-Hang box (4SDB-MKO-S) is a 4-in. square, 21/8-in. deep box. According to the company, the unique design speeds up the installation process for boxes that are suspended by replacing the traditional bottom center K.O. with a thru-hole. The thruhole accepts 3/8-in. threaded rod. It is also available in a 411/16-in. square box option. The EZ-Hang boxes remove the need for a washer and comes with a 10-32 ground screw for secure grounding. Finally, the product is compatible with the company’s BCHS plates. Orbit Industries

Double-Seal Enclosure 4Xxtreme double seal enclosures for extreme indoor and outdoor environments feature patented double seal and double stud mounting technology, an ultra-clean free-draining design, and a field-replaceable blue gasket system. The enclosures are UL Type 4X rated, with additional ratings of IP66 and IP69K. The 4Xxtreme double seal technology offers multiple layers of protection. According to the company, the outer seal rejects 99.9% of water, so the inner seal never sees any water pressure. Any water that does get through the outer seal is minimal and easily passes through the weep holes in the bottom of the enclosure door, ensuring there’s never water build up between the two seals. Custom Stainless Enclosures

Wall-Mounted Rack Enclosure The company has added a new wall rack enclosure in its ERWEN Series: the 19-in. 22U ERWENF22E. The wall-mounted rack enclosure features internal 4-Post rails that are numbered and adjustable, while the cabinet offers a reversible tempered glass front door and locking/ removable side panels. Additional features of the wall rack enclosure include welded steel construction, rails that have numbered spaces with standard 10-32 threading, adjustable front and rear rails, and a vented top and bottom. The product ships fully assembled and has overall dimensions of 42.6-in. height × 23.6-in. width × 23.5-in. depth. Video Mount Products

February 2024 • www.ecmweb.com

2402ECM_50-51_Product_Showcase.indd 50

2/13/2024 4:07:52 PM

ARLINGTON

YEARS

POWER & LOW VOLTAGE

LOWEST COST • L-SHA PED

COMBO BOX

FAN/FIXTURE BOX

FOR RETROFIT PROJECTS

UL rated fans up to 70 lbs; fixtures to 200 lbs.

This convenient combo box has power and low voltage openings in the same box for a neat, time-saving installation. The box adjusts to fit wall thicknesses from 1/4" to 1-1/2". Mounting wing screws hold it securely in place. LVDR2

• 2-Hour Fire Rating

• Includes NM cable connector (power side)

No loose parts! Installation screws ship captive, ready to install box and bracket.

Product info aifittings.com/ landing/ combo-boxes

800/233-4717 • www.aifittings.com

Installed NM cable connector

• Low voltage side has a combo 1/2" and 3/4" KO for raceway

Super-secure installation! Our lowest cost, L-shaped fan/fixture box mounts to single or double joists with a captive center screw.

FB442 13.4 cu. inch

• For 1/2" or 5/8" drywall • Fast, easy installation • Locator posts assure proper positioning of fan/fixture bracket

• 2-hour Fire Rating Product info aifittings.com/landing/joist-mount-fan-fixture-box 800/233-4717 • www.aifittings.com

Patented

SECURE MOUNTING TO SINGLE, DOUBLE JOISTS

LOW VOLTAGE • COMMERCIAL GRADE, HEAVY-DUTY ZINC

MOUNTING BRACKETS

2312ECM_Arlington_866407-1223_84.indd 1

11/14/23 2402ECM_Arlington_902126-0224_36.indd 10:48 AM 1

FOR CLASS 2 LOW VOLTAGE WIRING

NEW!

Arlington’s mounting brackets are the best way to install Class 2 wiring. They seat wall plates flush with the mounting surface and install fast!

COMMERCIAL GRADE EXTRA HEAVY DUTY

Sturdy Non-bendable zinc

1/23/24 4:34 PM

LV1M L

Our new single gang, zinc mounting bracket, LV1M, for existing construction, offers extra rigidity so it won’t bend as easily as plastic. Plus, it has threaded holes for easy, fast device installation – and LABOR SAVINGS.

E Extra heavy-duty h ZINC Z for Existing fo W Walls

Save Time! Threaded holes for easy device installation Also available, a variety of single-, two-, three- and four-gang NON-METALLIC low voltage brackets, and others for specialty applications.

118

Patent pending

800/233-4717 • www.aifittings.com

2312ECM_Arlington_866401-1223_118.indd 1 2402ECM_50-51_Product_Showcase.indd 51

Product Info aifittings.com/landing/lvm1

11/14/23 11:26 AM 2/13/2024 4:07:53 PM

PRODUCT NEWS

Cordless Tools Crimp Tool

The PTS (pass through standard) pro crimp tool combines multiple tools into one design and allows for termination of all of the company’s terminators (including ezEX-RJ45 connectors and the legacy EZ-RJ45 connectors) in a single tool with no part changes. The tool utilizes a sliding plate to change between the different types of connectors and a captive thumb screw to make swapping between connector styles seamless. The crimp tool features a connector locking mechanism so connectors “click” into the tool for termination. It also includes the cutting and stripping blades for Cat 5e and 6 built directly into the handle. Crimp Tool

Type A/B LED

The new 48-in., 15W direct wire linear LED T8 has a flexible design that allows for single- or double-end operation on 120V-277V for maximum energy savings. This versatile plug-and-play solution can work on electronic ballasts and be direct wired to line voltage quickly with no lamp holder modifications necessary. The new A/B hybrid LED lamp has color selectable options of 3,000K, 3,500K, 4,000K, 5,000K, or 6,500K and can be adjusted in the field by sliding the switch to the desired color. The linear LED delivers 2,100 lm with 220° beam angle and a CRI greater than 80 to provide the perfect replacement for T8 fluorescent tubes. It is engineered for high lumen maintenance over its 50,000-hr rated performance life. Suitable for damp and dry locations, the LED is listed by the Design Lights Consortium (DLC), UL Classified Type A and B, NSF, FCC, and RoHS. EarthTronics 52

Push-In Technology

The new push-in technology ensures a secure and reliable fit while significantly reducing installation time when making electrical connections, according to the company. Key benefits of this push-in technology include quick and tool-free wire insertion, reducing labor time/costs and minimizing the risk of errors during installation. Secure connections offer enhanced safety, reducing the risk of loose or improperly tightened connections that can lead to electrical hazards or equipment failure, while a compact design saves valuable space in control panels, making it ideal for applications with limited room. Additionally, the product is compatible with a wide range of wire types and sizes, making it suitable for various applications across industries such as industrial automation, construction, and more. Eaton

EV Charger Pedestal

The EV cable management pedestal is designed to deliver a well-organized and hasslefree charging experience. With the ability to mount two of the company’s EV chargers side by side, this pedestal ensures a streamlined cable management solution that elevates charging cables above ground, providing easy accessibility to users. The dual-sided EV charger pedestal is designed to benefit users and property owners, emphasizing streamlined cable management that eliminates tripping hazards and maintains equipment. It includes two cable management hooks with two plug holders. Legrand

The company has announced new cordless tools on the 22V Nuron battery platform to offer greater value through its subscription tool service called Fleet Management. New additions include the SC 6WP-22 plunge saw, which is designed for more precise cutting in wood, fiber board, drywall, and solid surfaces, including straight and bevel cuts and intricate cut-outs. The 6½-in. saw has been engineered for cutting speed and dust collection efficiency for a safer and more productive plunge cutting option. The SC 6WP-22 will run along the company’s 55-in. track and is compatible with other tracks on the market. Other additions include the TE 50-22 Combi hammer with active vibration reduction (AVR) and active torque control (ATC) technologies, which provide users with longer runtimes, greater safety/comfort, and broader versatility on the job site. Hilti

Liquidtight Conduit

This antimicrobial flexible nonmetallic liquidtight conduit Type LNMP (food grade) offers an antimicrobial jacketing with a wide working temperature range and is made with a food-processing blue jacketing. Type LNMP is constructed from flexible PVC, reinforced with a nylon braid, and is UL-listed. It is engineered for applications requiring continuous flexing, as its design excludes a metal core, preventing fatigue from repeated flexing. The flexible PVC jacketing contains an antimicrobial biocide additive. According to the company, this additive inhibits the growth of commonly known food processing microbes, such as E. coli, listeria, and salmonella and shows a reduction of these microbes over a 24-hr period. Electri-Flex Company

February 2024 • www.ecmweb.com

2402ECM_52-53_Regular_Products.indd 52

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2312EC

SNAP2IT® CONNECTORS E AS IE ST C AB LE I NSERTI ON • N O TOOLS • S E CURE H O L D

SAVE

seconds

4010AST 1/2” KO

4110ST

5010AST

LISTED SNAP2IT ® CONNECTORS FOR

NEW MC-PCS CABLE ...lighting & low voltage circuits in the same cable

1/2" KO

Easy to Snap into Box!

505010AST 3/4" KO

Fully assembled, SNAP2IT® fittings handle the widest variety of MC cable AND THE NEW MC-PCS cables. Compared to fittings with a locknut and screw, you can’t beat these snap in connectors for time-savings!

• Fits widest range and variety of MC cable 14/2 to 3/3 AC, MC, HCF, MC continuous corrugated aluminum cable and MCI-A cables (steel and aluminum)...including the new MC-PCS cable that combines power and low voltage in the same MC cable ANY Snap2It Connectors LISTED for MC cable are also LISTED for MC-PCS cable! These products offer the greatest time-savings. • Fast, secure snap-on installation • Easy to remove, reusable connector From cable Loosen screw on top. Remove connector from cable. From box Slip screwdriver under notch in Snap-Tite® ring. Twist. Remove connector. CATALOG NUMBER

Snap2It® connectors

DESCRIPTION

CABLE OUTSIDE DIA (OD)

4010AST

Snap in, 1/2" KO w insulated throat

.405 to .610

5010AST

Snap in, 1/2" KO w insulated throat

.580 to .780

505010AST

Duplex Snap in, 3/4" KO w insulated throat

(2) .590 to .820

4110ST

Snap in, 1/2" KO

.525 to .705

414110ST

Duplex Snap in, 1/2" KO

(2) .525 to .640

4141107ST

Duplex Snap in, 3/4" KO

(2) .525 to .690

4141107ST

Patented. Other patents pending.

www.aifittings.com • Scranton, PA 18517 • 800/233-4717

Product info aifittings.com/landing/snap2it-mc-cable-connectors

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CODE BASICS

NEC Requirements for Energy Storage Systems

The high energy levels in energy storage systems make them especially dangerous if they are not installed and maintained per Code. By Mike Holt, NEC Consultant

rticle 706 applies to energy storage systems (ESSs) that have a capacity greater than 1kWh and that can operate in stand-alone (off-grid) or interactive (grid-tied) mode with other electric power production sources to provide electrical energy to the premises wiring system (Fig. 1). ESSs can have many components, including batteries and capacitors. They include inverters or converters to change voltage levels or to make a change between an alternatingcurrent and a direct-current system. Only qualified persons may install or maintain an ESS [Sec. 706.3]. Each ESS must be listed [Sec. 706.5] and have eight bits of data marked on a nameplate, for example rated frequency and rating in kW or kVA [Sec. 706.4]. Multiple ESSs are permitted on the same premises [Sec. 706.6]. As with PV systems, ESSs may be composed of multiple pieces of equipment assembled into a single system, or each piece of equipment may be considered an ESS on its own. The best way to identify an ESS is to look for a nameplate and review the instructions, both of which are part of the equipment’s listing.

COMMISSIONING AND MAINTENANCE

For other than one- and two-family dwellings, ESSs must be commissioned upon installation [Sec. 706.7(A)]. NFPA 855, Standard for the Installation of Stationary ESS, guides commissioning. For other than one- and two-family dwellings, ESSs must be maintained in proper and safe operating condition as 54

Fig. 1. ESS requirements are found in Art. 706 of the NEC.

per manufacturer and industry standards [Sec. 706.7(B)]. A written (this includes computerized) record of repairs and replacements must be kept. For information on developing an effective electrical preventive maintenance program, see NFPA 70B, Recommended Practice for Electrical Equipment Maintenance, or ANSI/ NETA ATS-2017, Standard for Acceptance Testing Specifications for Electrical Power Equipment and Systems.

DISCONNECTING MEANS

A disconnecting means must be provided to disconnect the ESS from other sources of power, utilization equipment, and premises wiring [Sec. 706.15(A)].

In other than one- or two-family dwelling units, the disconnect marking must include the identification and location of the circuit source that supplies the disconnect unless located and arranged so the identification and location of the circuit source is evident [Sec. 110.22]. The marking must be sufficiently durable to withstand the environment involved. The ESS disconnect must be readily accessible and located either within the ESS or within sight of (and not more than 10 ft from) the ESS [Sec. 706.15(B)]. Where the disconnect is not within sight of the ESS, the disconnect (or the enclosure providing access to the disconnect) must be capable of being locked in the open position per Sec. 110.25.

February 2024 • www.ecmweb.com

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ARLINGTON

YEARS

LOW COST • ZINC

MC CABLE FITTINGS

NEW ! SIZE

3-1/2"

THAT FIT SEVERAL CABLE SIZES

Save time and money! Arlington’s low cost MC cable fittings, for dry locations only, are super-convenient and cost-effective. End stop bushings vary the size of the opening so ONE trade size fits several cable sizes!

Changing end stop bushings is fast and easy. No need to remove the strap. Insert the bushing that works the best with the cables you’re installing. Reduce inventory – Costs much less than steel and malleable iron fittings Built-in end stop

8418 for 1000 Mcm wire and TECK90 Catalog Number

Trade Size

Cable O.D. Min Max

Wire Bundle O.D. Min Max

Conductor size # of Conductors* (AWG/KCMIL)

8412

.780

1.120

.660

1.000

6/3, 6/4, 4-3, 4-4, 2-3, 2-4, 1-3

8413

1-1/4"

1.000

1.460

.870

1.370

2-3, 2-4, 1-3, 1-4, 1/0-3, 1/0-4, 2/0-3, 2/0-4, 3/0-3

8414

1-1/2"

1.360

1.770

1.250

1.590

2/0-4, 3/0-3, 3/0-4, 4/0-3, 4/0-4, 250-3, 250-4

8415

1.700

2.200

1.550

2.050

250-4, 300-4, 350-3, 350-4, 500-3

8416

2-1/2"

2.100

2.700

1.950

2.400

500-3, 500-4, 600-3, 600-4, 750-3

8417 8418

3" 3-1/2"

2.500 3.300

3.300 3.600

2.350 3.031

3.000 3.500

600-4, 750-3, 750-4 750-3, 750-4, 1000-4

NEW

* Examples of 3- and 4-conductor cables accommodated.

Patented

3-1/2" 8418

800/233-4717 www.aifittings.com

Product info aifittings.com/landing/8412

2312ECM_Arlington_866402-1223_14.indd 1

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UL LISTED • 2-HOUR FIRE RATING

LISTED BOX EXTENDERS E X T E N D S S E T B A C K B O X E S U P TO 1- 1 / 2 I N C H E S

Arlington’s UL/CSA Listed Box Extenders extend set back electrical boxes up to 1-1/2".

BE2

Made of heavy-duty, non-conductive plastic, they level and support wiring devices, protecting wires against damage and stripping. BE1R

BE1

BE4

BE3

BE1R for round or octagonal boxes, the single-gang (BE1), two-gang (BE2) for all standard devices, switches and GFCIs and three- and four-gang box extenders for multiple gang boxes! Try them all, including our Patented ‘Larger Flange’ one-, two-, three- and four-gang styles, for the safe, easy way to obtain Listed installations in set back boxes!

Larger Flanges BE1

800/233-4717 • www.aifittings.com

2312ECM_Arlington_867648-1223_16.indd 1 2402ECM_54-57_Code_Basics.indd 55

BE1X

(patented)

BE2X

for use with Metallic and Non-Metallic boxes Product Info aifittings.com/landing/box-extenders/

11/14/23 3:02 PM 2/13/2024 4:10:06 PM

CODE BASICS

CodeWatch This e-newsletter, published twice-monthly, is dedicated to coverage of the National Electrical Code. The content items are developed by three well-known Code experts.

CodeWatch promises to: • Address changes in the Code • Explain how to properly apply the Code • Test your knowledge of the Code • Provide information on upcoming Code-related seminars and shows

Subscribe Today See all of our EC&M e-newsletters at www.ecmweb.com

56 1 ECM-ads.indd

Fig. 2. The initiation device for the ESS emergency shutdown function must be in a readily accessible location outside the building.

In one- and two-family dwellings, the ESS must include an emergency shutdown function to cease power export from the ESS to premises wiring. The initiation device for the ESS emergency shutdown function must be in a readily accessible location outside the building (Fig. 2). The ESS emergency shutdown initiation device must plainly indicate whether it is in the “off ” or “on” position. The requirements in Sec. 706.15(A) can be met with disconnects that are integral to the listed ESS equipment. Since an ESS application may have multiple individual ESS units, each may require a disconnect, but this does not necessarily mean each will require a separate disconnect switch adjacent to the units. Many ESS manufacturers choose to incorporate a means of disconnect into their ESS units. These disconnects are evaluated during the system’s listing. The ESS disconnect must plainly indicate whether it is in the open (off) or closed (on) position and be marked “ENERGY STORAGE SYSTEM DISCONNECT” [Sec. 706.15(C)]. For other than one- and two-family dwellings, the ESS disconnect must be legibly marked to withstand the environment involved and include nominal battery voltage, available fault current, an arc-flash label per acceptable industry

practice, and the date the arc-flash calculation was performed. Information Note 1: Industry practices for equipment labeling are described in NFPA 70E, Standard for Electrical Safety in the Workplace. This standard provides specific criteria for developing equipment arc-flash labels that provide nominal system voltage, incident energy levels, arc-flash boundaries, minimum required levels of personal protective equipment, and so forth. Information Note 2: ESS electronics could include inverters or other types of power conversion equipment. If line and load terminals within the ESS disconnect could be energized in the open position, the disconnect must be marked: “WARNING ELECTRIC SHOCK HAZARD TERMINALS ON THE LINE AND LOAD SIDES MAY BE ENERGIZED IN THE OPEN POSITION.” The marking must have sufficient durability to withstand the environment involved [Sec. 110.21(B)]. Where ESS circuits pass through a wall, floor, or ceiling, a readily accessible disconnect within sight of the ESS is required [Sec. 706.15(D)]. This provision will not apply to every ESS application where circuit conductors travel through walls, floors, or ceilings. It

February 2024 • www.ecmweb.com 3/30/18 7:04 PM

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is for those applications (typically large ones) where the battery is in one room and other equipment that is part of the ESS is in another. In those cases, a disconnect must be in the room containing the battery. This does not apply to situations where the entire ESS is in one room and the output circuit from the ESS connects to other systems in other rooms. In those cases, the disconnect location requirements in Sec. 706.15(A) are all that apply. Batteries could include an enclosure, battery monitoring and controls, or other related battery components. Where the battery of the ESS is separate from the electronics and subject to field servicing, the following applies [Sec. 706.15(E)]: • A readily accessible disconnect is required within sight of the battery. See Sec. 240.21(H) for information on the location of the overcurrent protective device (OCPD) for battery conductors. • Where the battery disconnect has remote controls not within sight of the battery, the battery disconnect must be capable of being locked in the open position per Sec. 110.25, and the location of the controls must be field marked on the battery disconnect. • The battery disconnect must be legibly marked to withstand the environment involved and include nominal battery voltage, available fault current, an arc-flash label per acceptable industry practice, and the date the arc-flash calculation was performed.

PARALLELED WITH OTHER POWER SOURCES

ESSs in parallel with other power sources must comply with the following [Sec. 706.16]: (A) All power sources must have a disconnecting means. (B) All power sources must use interactive (grid-tied) inverters. (C) Upon loss of electric utility power, the interactive (grid-tied) inverter must automatically disconnect from the electric utility per Sec. 705.40. (D) Unbalanced AC connections must comply with Sec. 705.45. (E) The parallel connection of the ESS to other power sources must be per Sec. 705.12. (F) Where the ESS is operating in stand-alone (off-grid) mode, the requirements of Sec. 710.15 apply.

Fig. 3. The working space for ESSs must comply with Sec. 110.26.

WORKING SPACES

The working space about ESSs must comply with Sec. 110.26 (Fig. 3). ESSs must be spaced apart per the manufacturer’s instructions [Sec. 706.20(C)(2). Additional space may be needed to accommodate ESS hoisting equipment, tray removal, or spill containment.

CIRCUIT CURRENT RATING

The maximum current for an ESS is as follows [Sec. 706.30(A)]: (1) Nameplate-Rated Circuit Current. The rated current indicated on the ESS nameplate. (2) Inverter Output Current. The continuous inverter output AC current rating. (3) Inverter Input Current. The continuous inverter input DC current at the lowest input voltage. (4) Inverter Utilization Output Circuit Current. The continuous inverter output AC current rating. (5) DC-to-DC Converter Output Current. The continuous DC-to-DC converter’s nameplate current rating.

CONDUCTOR AMPACITY

The ampacity of the output circuit conductors of the ESSs to the wiring system supplying the load must be at least 125% of the current rating of the ESS per Sec.

705.30(A) or the rating of the OCPD [Sec. 706.31].

OVERCURRENT PROTECTION

OCPDs must be compliant per Sec. 706.31(B) through (F). For example, OCPDs must have an ampere rating of at least 125% of the current marked on the ESS nameplate [Sec. 706.30(A)] Exception: Where the assembly (including the OCPDs) is listed for operation at 100% of its rating, the ampere rating of the OCPDs can be not less than the currents calculated in Sec. 706.30(B).

FOR A SMOOTH START-UP

Once your ESS is installed, it must be commissioned — but don’t wait until commissioning to discover engineering errors and Code violations that can result in scheduling delays and cost overruns. Review the commissioning plan well ahead of time. Do a dry run of the relevant parts of the plan as you work on specific stages of the project, correcting errors as you find them. These materials are provided by Mike Holt Enterprises in Leesburg, Fla. To view Code training materials offered by this company, visit www.mikeholt. com/code. www.ecmweb.com • February 2024

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CODE QUIZ OF THE MONTH

Test Your Code IQ

How much do you know about the National Electrical Code?

By Mike Holt, NEC Consultant Photo 284201775 © Dominic Trudel | Dreamstime.com

All questions and answers are based on the 2023 NEC.

Q1: In other than dwelling units, all

125V through 250V receptacles supplied by single-phase branch circuits rated 150V or less to ground, 50A or less, and all receptacles supplied by 3-phase branch circuits rated 150V or less to ground, 100A or less, installed in _____, shall be provided with GFCI protection. a) laundry areas b) finished basements c) attics d) guest rooms and suites

Q2: The total degrees of bends in a run of FMC _____ between pull points. a) shall not be made b) need not be limited (in degrees) c) shall not exceed 360° d) shall not exceed 180°

Q3: Metal enclosures and raceways

containing _____ conductors shall be connected to the grounded system conductor if the electrical system is grounded. a) feeder b) service c) branch-circuit d) outside feeder or branch-circuit

Q4: The ampacity of UF cable shall be that of _____ conductors in accordance with Sec. 310.14. a) 60°C b) 75°C c) 90°C d) 105°C

Q5: A connection used for no other

purpose shall be made between the metal box and the equipment grounding conductor(s). The equipment bonding jumper or equipment grounding conductor shall be sized from Table 250.122 58

based on the largest _____ conductors in the box. a) overcurrent device protecting circuit b) ungrounded c) grounded d) neutral

Q6: Where PVC, RTRC, or HDPE is

used in Class I, Division 1 underground locations, the concrete encasement shall be permitted to be omitted where RMC

or IMC conduit is used for the last _____ of the underground run to emergence or to the point of connection to the aboveground raceway. a) 12 in. b) 18 in. c) 24 in. d) 30 in. See the answers to these Code questions online at https://www.ecmweb. com/21281660.

February 2024 • www.ecmweb.com

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CODE VIOLATIONS

Illustrated Catastrophes By Russ LeBlanc, NEC Consultant All references are based on the 2023 edition of the NEC.

NOT A BUNDLE OF JOY! The only supports for most of these cables are the other cables. There are a few pieces of strut secured to the plywood behind this massive bundle of cables, but only the first layer of cables is secured to that strut with cable ties — and that first layer of cables is used to support every additional layer of cables. Section 300.11(D) prohibits cable wiring methods from being used as a means of support for other cables, raceways, or other equipment. I cannot be sure of the exact number of cables in this gigantic bundle, but it is approximately 60 apartment feeder cables. That amount of cables makes me wonder if the installers accounted for the number of current-carrying conductors when determining the cable ampacity. Since these cables are installed without maintaining any spacing between them, Sec. 310.15(C)(1) requires their ampacity to be reduced in accordance with Table 310.15(C)(1). Since there are more

than 41 current-carrying conductors in this bundle, an adjustment of 35% of the ampacity value in Table 310.16 must be used. The writing on the cable jackets indicated that these cables contain 4 AWG aluminum XHHW conductors.

Table 310.16 has 4 AWG aluminum XHHW being rated for 75A. Normally, that might be perfectly fine for a 60A feeder for an apartment. But, when you apply the 35% adjustment factor, it brings the ampacity down to only 26.25A.

SLOPPY SUPPORT METHODS The first two 11/2-in. EMT raceways installed here are supported on a bracket made of strut. This is fine. However, whoever installed the 3/4-in. EMT and those boxes unfortunately decided to use one of the original 11/2-in. EMTs to support the 3/4-in. EMT and the box assembly. Section 358.12(2) prohibits using EMT to support luminaires or other equipment except conduit bodies no larger than the trade size of the EMT. Section 300.11(C) also restricts using raceways as a means of support for other raceways, cables, and equipment. Sections 314.23(A)-(H) provide plenty of options for supporting and securing boxes. However, if you read through all those permitted options, you will not see permission to use EMT as a means of support for a box. I’m not sure if those are metal-clad (MC) or armored cable (AC), but in either case, they don’t appear to be supported and secured in a Code-compliant manner either. Section 320.30 provides the securing and supporting requirements for Type AC cables. Section 330.30 provides the securing and supporting requirements for Type MC cables. 60

February 2024 • www.ecmweb.com

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2402EC

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PRACTICALLY SPEAKING

A Continuous Load Conundrum Breaking down sizing requirements for a 6,000W, 208V electric water heater By Russ LeBlanc, NEC Consultant

would like to thank Adam Bremer, owner of Bremer Electric in Red Wing, Minn., for presenting a couple of very interesting scenarios when it comes to sizing conductors and overcurrent devices for electric water heaters. He posted questions in the Electrical Code Discussion group on Facebook asking about the sizing requirements for a 6,000W, 208V electric water heater. The first scenario he asked about was whether a 30A branch circuit wired with 10 AWG copper THHN would be Codecompliant. It would not. Section 422.13 requires the branch-circuit overcurrent device and conductors for fixed storagetype water heaters having a capacity of 120 gallons or less to have an ampacity not less than 125% of the rating of the water heater. This 28.8A water heater would need a 40A minimum branch circuit. That seems straightforward. The second scenario gets interesting, though. Instead of a 30A branch circuit, Adam asked if a 30A feeder wired with 10 AWG THHN supplying a 60A fusible disconnect installed at the water heater location would be Code compliant if there were 40A fuses installed in the disconnect and 8 AWG THHN copper installed from the load-side of the disconnect to the water heater. I told him this scenario would be Code compliant only if the water heater was not considered a continuous load. Section 215.3 requires the feeder overcurrent device to be sized to 125% of the continuous load. The 30A feeder would be too small. However, the 40A branch circuit portion would be perfectly fine. This got me wondering whether this water heater is a continuous load or not. Presently, it is not specifically considered a continuous load. However, looking back on previous editions of the Code revealed an interesting situation. 62

The 1968 and 1971 editions of the Code did not require 125% sizing and did not specifically state it was a continuous load. Section 422.14(B) of the 1975 edition introduced the requirement that it be considered a continuous load. The 1981 edition was revised “for clarification of intent.” The Code-Making Panel dropped the continuous load wording and added a 125% sizing requirement for the branch circuit. In 2005, Sec. 422.13 considered it a continuous load yet again. The 2008 edition was

revised to specify it was a continuous load for the purpose of sizing branch circuits. 2017 was the last edition that specifically noted the water heater was a continuous load. The 2020 edition was revised “for clarity” — one more time dropping the continuous load wording and bringing back the 125% sizing requirements. So, is it a continuous load or not? It matters when it comes to sizing feeders and services. Maybe a discussion with your AHJ can help you get an answer to this conundrum.

February 2024 • www.ecmweb.com

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ADVERTISER INDEX Advertiser

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19 21 23 25 27 31 33 35 37 39 41 43 45 47 49 51 53 55 64 IFC BC 59

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Facilities Expo 2024 Helukabel USA, Inc. 17 — www.helukabel.com LightSpec West IBC — www.lightspecwest.com Mike Holt Enterprises 61 888-632-2633 www.mikeholt.com Orbit Industries, Inc. 7 213-451-6091 www.orbitelectric.com Progressive Insurance 1 — www.ProgressiveCommercial.com Socomec 9 — www.socomec.us S-P Products, Inc. 5 800-233-8595 www.SPProducts.com Uline 11 800-295-5510 www.uline.com Underground Devices, Inc. 3 847-205-9000 www.udevices.com (Every effort is made to ensure the accuracy of this index. However, the publisher cannot be held responsible for errors or omissions.)

To place a display ad (1/6 page or larger), call the Advertising Sales Representative for your area. Vice President Mike Hellmann Andover, MA • (978) 289-0098 E-mail: mhellmann@endeavorb2b.com Western U.S. & Western Canada Ellyn Fishman: Key Account Manager (949) 239-6030 • Email: efishman@endeavorb2b.com

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CODE VIOLATIONS

By Russ LeBlanc, NEC Consultant

ow well do you know the Code? Think you can spot violations the original installer either ignored or couldn’t identify? Here’s your chance to moonlight as an electrical inspector and second-guess someone else’s work from the safety of your living room or office. Can you identify the specific Code violation(s) in this photo? Note: Submitted comments must include specific references from the 2023 NEC. Hint: Handle-tie hiccup

‘TELL THEM WHAT THEY’VE WON...’

Using the 2023 NEC, correctly identify the Code violation(s) in this month’s photo — in 200 words or less — and you could win an Arlington Industries 18-in. Slider Bar and plastic box for mounting between studs with non-standard spacing. E-mail your response, including your name and mailing address, to russ@ russleblanc.net, and Russ will select three winners (excluding manufacturers and prior winners) at random from the correct submissions. Note that submissions without an address will not be eligible to win.

DECEMBER WINNER Our winner this month was Timothy Hite, owner of Hite Aviation Consulting in Altoona, Pa. He knew there were problems with the clearances in front of this service disconnect. I am not sure whether the electrician or the plumber was the first trade to install their equipment in this very tight-spaced mechanical room. I do know, however, that the placement of the disconnect and the position of the water line prevent the disconnect’s door from fully opening. When the water shut-off valve is closed, the door can barely be opened. When the valve is open, the door can open a little farther, but not nearly the 90 degrees required by Sec. 110.26(A)(2). There is nowhere to stand in front of the disconnect or the meter enclosure since the working space required by Sec. 110.26(A) is completely blocked by the water piping and water meter. The lack of accessibility to the fuses in the disconnect is a violation of the requirements of Sec. 240.24(A).

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