APRIL 2026
ELECTRICAL NEWS
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REGULARS: CONTRACTORS’ CORNER | FEATURES: MCCs AND MOTOR PROTECTION | CABLES AND CABLE ACCESSORIES | LIGHTING
COMPLIANCE OR CONVENIENCE: THE HIDDEN CRISIS IN SOUTH AFRICA’S BUSWAY MANUFACTURING AND SUPPLY INDUSTRY
By: Asogan Moodley, Registered Electrician | Electrical Contractor | Industry Contributor
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A market in disarray South Africa’s busway (busbar trunking)
manufacturing and supply industry is experiencing a quiet but increasing crisis. Technically, the sector adheres to SANS/IEC 61439-6, which provides detailed standards for low-voltage switchgear and control gear assemblies — including busway systems. In reality, however, non-compliance is becoming normalised. Products that should be tested, certified, and traceable under SABS and IEC standards are being replaced with cheaper, often untested alternatives. The result is an industry plagued by vague specifications, uneven competition, and compromised safety — all made worse by the lack of accountability among professional bodies responsible for ensuring compliance. As contractors, we often find ourselves amidst this chaos — trying to balance cost, compliance, and client expectation in an environment that increasingly rewards the wrong priorities. SABS-approved, yet sidelined One of the most troubling trends is the systematic sidelining of SABS-approved and ISO-certified manufacturers. Companies that invest heavily in full compliance, continuous testing, and certification — including products bearing the SABS mark of approval — are losing out to suppliers offering cheaper, partially tested, or non-tested products. Many of these so-called “type-tested” systems rely solely on limited tests, such as temperature rise or short-circuit withstand, without undergoing the full suite of verifications required by SANS/IEC 61439-6. In some cases, type test certificates are outdated, irrelevant, or issued for configurations that differ completely from the intended product. This raises a vital question: Should type test certifications have an expiry date — similar to a Certificate of Compliance (COC)? As technology develops, materials evolve, and manufacturing methods change, it is unreasonable to assume that a test conducted ten years ago remains valid today. Perhaps it is time for regulators and industry bodies to review this and implement stricter validity periods and re-certification requirements for type-tested systems. The tender trap: when vague specifications breed non-compliance The tendering environment is another area where the system is breaking down. Many tender documents are vague, generic, or incomplete, merely stating “busbar system including all accessories to be provided” without specifying compliance to SANS/IEC 61439-6. A compliant manufacturer may quote for items deemed necessary based on the standards, while a non- compliant or barely compliant manufacturer might
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mainly on price. In a competitive bid environment, cost almost always prevails — and compliance becomes optional, variation orders are deemed necessary, and budgets become limited. The result? Contractors procure products from busbar
not. It is important to note that the difference in products will also result in overall cost differences. Without a detailed bill of quantities or clear specifications, it is not possible to ensure a fair adjudication. This lack of precision shifts responsibility onto contractors, who are then compelled to compete
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The importance of regular fire system maintenance
compliance,” notes van Niekerk. Regular servicing also provides an opportunity to assess whether existing systems remain suitable for the building’s current use. Changes in occupancy, layout, storage methods, or equipment may shift the fire risk profile. What was sufficient five years ago might no longer meet current standards. Maintenance visits enable informed suggestions on upgrades, expansions, or technology improvements to ensure ongoing compliance and maximum protection. Ultimately, fire protection is about prioritising people’s safety. Early detection enables safe evacuation. Effective suppression limits the fire’s spread, reduces smoke damage, and keeps escape routes clear. A well-maintained system provides occupants with valuable time to leave safely and allows emergency services to respond efficiently. “Fire safety cannot be reactive,” concludes van Niekerk. “It requires ongoing commitment. Regular maintenance ensures that when a fire emergency occurs, the system responds exactly as designed. That reliability saves lives and protects assets.” For property owners and facilities managers across South Africa, the message is clear: installation is just the beginning. Regular, scheduled maintenance ensures that fire protection systems perform their vital role. To keep fire detection and suppression systems compliant, reliable, and fully operational, ASP Fire provides a comprehensive maintenance assessment and customised service plan.
Africa’s diverse environmental conditions, from coastal corrosion to dusty industrial environments, environmental factors can significantly affect system performance. Suppression systems, whether water- based sprinklers, gas suppression, or specialised extinguishing agents, rely equally on regular maintenance. Valves can seize, pumps may fail, cylinders can lose pressure, and pipework can become obstructed. Scheduled servicing identifies and addresses these issues before they threaten system integrity. In high-risk environments such as data centres, manufacturing facilities, and healthcare institutions, even a brief delay in activation can lead to catastrophic losses. Beyond compliance and risk mitigation, regular fire system maintenance safeguards business continuity. A fire incident not only endangers lives but can also disrupt operations for months, harm reputations, and cause significant financial losses. Insurers are increasingly demanding proof of ongoing maintenance in accordance with recognised standards. Inadequate records or missed inspections may compromise claims. Proactive servicing shows due diligence and bolsters an organisation’s risk management profile. Maintenance must be systematic and well-documented. “Scheduled inspections should be conducted by competent, accredited technicians in accordance with applicable SANS standards and manufacturer specifications. Each service must be recorded, with clear reports that highlight any defects and the corrective actions taken. This documentation is essential for audits, insurance, and legal
responsibilities to building owners and employers to ensure fire protection systems are properly maintained. The Occupational Health and Safety Act (Act 85 of 1993), along with relevant SANS standards like SANS 10139 for fire detection and alarm systems and SANS 1475 for fire extinguishers, specifies requirements for inspection, testing, and maintenance. Municipal fire by- laws further strengthen these obligations. Non-compliance can lead to legal liability, insurance issues, and, most critically, preventable loss of life. According to Michael van Niekerk, CEO of ASP Fire, regular maintenance should be regarded as an investment in operational continuity rather than an administrative burden. “A fire system is only as effective as its last service. Detection devices can become contaminated, batteries can degrade, sprinkler heads can corrode, and control panels can develop faults over time. Without scheduled inspections, these issues often go unnoticed until it is too late.” Fire detection systems rely on accuracy. Smoke and heat detectors must function within designated sensitivity ranges. Control panels need to correctly interpret signals and activate alarms, evacuation procedures, and connected suppression systems. Routine testing confirms that detectors are properly calibrated, wiring is intact, communication channels are operational, and standby power supplies are dependable. In South
F ire detection and suppression within seconds of an incident occurring. However, their reliability depends not only on proper installation but also on regular inspections, testing, and maintenance. Without these, even the most sophisticated fire protection system can fail when it is needed most. For property owners across South Africa—whether commercial, industrial, or residential—scheduled fire system maintenance is not just a compliance requirement; it is an essential safety measure. South African legislation clearly assigns systems are designed to respond quickly during an emergency, often Regular maintenance should be viewed as an investment.
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CONTINUED FROM PAGE 1 COMPLIANCE OR CONVENIENCE: THE HIDDEN CRISIS IN SOUTH AFRICA’S BUSWAY MANUFACTURING AND SUPPLY INDUSTRY
manufacturers assuming they are getting the best quality at the best price, without verifying compliance. Compliant manufacturers who try to do the right thing by quoting on compliant products are undercut by non-compliant or partially compliant manufacturers, while those willing to cut corners are rewarded. The tender process, instead of promoting technical excellence and adherence to standards, encourages shortcuts and risk-taking. This is fundamentally unfair — and dangerous. Friendship Over Compliance: A Culture Problem The market has also been flooded by small, unregulated manufacturers, often started by individuals leaving established companies. Equipped with insider knowledge and industry contacts, many launch products that do not meet full SANS/IEC 61439-6 requirements — still gain acceptance through friendship-based business networks. It has become far too common for projects to be awarded based on personal or political connections rather than on technical merit. This is especially concerning because these non-compliant systems are being installed in hospitals, shopping centres, data centres, and factories, where public safety should never be compromised. In today’s technologically advanced world, test reports and certificates can be easily altered. Without thorough verification — through SABS, NRCS, SANAS or other
compliant systems should lie with the Professional Engineer or Consultancy Firm. Contractors cannot and should not be expected to select suppliers based solely on price. Design integrity, clear specifications, and test parameters should always be specified by the responsible professional, and the supplier should be chosen based on the level of compliance. The manufacturer should ensure that they adhere to manufacturing regulations. The Client’s Cost Illusion Many clients believe that choosing cheaper systems saves money — but the reality is quite different. A non-compliant busway system not only reduces the lifespan of the installation but also increases fire and safety risks, can invalidate insurance, void warranties, and expose the client to legal and financial consequences. Compliance isn’t a luxury; it’s a safeguard. It protects lives, property, and reputations. Professionals and contractors must take a stand and educate clients on the long- term costs of non-compliance. The SANS/ IEC 61439-6 standard exists to ensure safety, reliability, and interoperability — and every deviation from it compromises that foundation. Rebuilding Accountability and Integrity The way forward is clear: accountability, transparency, and enforcement. Every stakeholder in the value chain must
accredited bodies — there is no assurance that a product is genuinely compliant.
play their part: • Professionals must specify, verify, and enforce compliance with SANS/IEC 61439-6. • Contractors must refuse to install untested, non-certified, or partially certified systems. • Consultants and engineers must insist on documentation, not assumptions. • Regulators and certification bodies must take action against manufacturers who misuse type test reports or circumvent proper testing procedures. • Compliance should not be a competitive disadvantage — it ought to be the industry standard. Conclusion: Choosing Integrity Over Convenience The South African electrical industry faces a crucial crossroads. We can keep neglecting standards, permitting outdated tests, unclear specifications, and non-compliant products to shape our market — or we can demand higher standards. We owe it to ourselves, our clients, our employees, and our profession to maintain the integrity of SANS/IEC 61439-6. The expense of non-compliance exceeds the cost of doing things correctly. It’s time to shift the focus from convenience to compliance, from relationships to responsibility, and from price to performance. Only then can we rebuild trust, fairness, and safety in our industry.
Who Bears the Responsibility? The lack of accountability within the professional hierarchy is one of the biggest enablers of non-compliance. Consulting engineers and designers often copy old specifications or leave details vague, assuming contractors will “know what to do,” or they place trust in a manufacturer, expecting to receive the best solutions and products. Contractors, under pricing pressure, are compelled to interpret incomplete documents and make supplier choices and decisions that should be conducted by professionals. Non-compliant or partially compliant manufacturers, driven by cost, seldom understand the risks of non-compliant Who should be held responsible when non-compliant products are installed? Is it the professional engineer or consultant, the installation electrician signing off the project, the contractor who ordered and purchased the non-compliant or partially compliant product, or the manufacturer who deliberately supplied non-compliant or partially compliant products? While all parties have obligations under the Occupational Health and Safety Act and Electrical Installation Regulations, the primary responsibility for specifying systems until it’s too late. So, the question arises:
SPARKS ELECTRICAL NEWS
APRIL 2026
CONTRACTORS’ CORNER | EDITOR’S COLUMN
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EDITOR’S NOTE W elcome to the April edition of Sparks Electrical News ! As a new season begins, we are pleased to present an issue full of fresh insights and practical advice for professionals across the electrical sector. This month, our focus is on three main areas advancing innovation and dependability in the industry: cables and cable accessories, MCC and motor protection, and lighting. We begin with a detailed examination of cables and cable accessories—the fundamental components for every electrical project. Our team explores new trends in cable technology, from innovative materials to intelligent cable management solutions that meet today’s needs for efficiency and safety. With updates on standards, installation techniques, and
controls, and human-focused solutions. Our articles explore the latest product launches, lighting design strategies, and case studies from commercial, industrial, and residential projects. Whether upgrading existing systems or planning new installations, you’ll find inspiration and practical advice to brighten your projects. At Sparks Electrical News, we are dedicated to promoting excellence and supporting South Africa’s electrical professionals with relevant, up-to-date information. We hope you enjoy this issue and find it both informative and empowering for your work ahead.
product innovations, we aim to help you make well-informed decisions for both routine and complex applications. Our coverage continues with a focus on Motor Control Centres (MCC) and motor protection. As facilities aim to optimise performance and minimise downtime, effective motor control and protection systems have never been more important. In this issue, you’ll find expert commentary on best practices for MCC specification, installation, and maintenance, as well as an overview of the latest protection technologies designed to safeguard your assets and ensure operational continuity. Finally, we focus on lighting—a sector swiftly evolving with
Minx Avrabos sparks@crown.co.za
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The critical importance of circuit breaker compliance I n South Africa’s bustling industrial, commercial and residential
minimises costly downtime. Technological relevance. Advanced functions are only reliable when the base device meets the latest edition of the relevant SANS or IEC standard. Retrofitting older panels with non- compliant replacements often creates coordination gaps that compromise the entire protection scheme. Electrical professionals have a clear duty: specify, install, and maintain only certified circuit breakers. This involves checking test certificates, verifying the SABS or IEC markings, and insisting on documentation from reputable manufacturers. Regular inspection and testing in accordance with relevant SANS codes further ensure ongoing compliance. In an industry where milliseconds separate normal operation from catastrophe, circuit breaker compliance is the foundation of professional integrity. It protects lives, safeguards assets, and upholds the reputation of every electrical practitioner. The cost of compliance is always lower than the price of failure. Choose compliant breakers - every time. Onesto KCM1, KCMD2, and KCM5 breakers ensure the highest compliance standards and are manufactured for various applications. Giving you peace of mind that, behind the scenes, you are safe. For more information, contact: www.mce.co.za
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number of electrical incidents. In an era of increasing load densities—from EV chargers and solar inverters to data-centre expansions—fault currents are higher than ever. Only compliant devices are tested to safely interrupt these currents. Legal and financial protection. The Occupational Health and Safety Act (Act 85 of 1993) imposes strict duties on employers and electrical contractors. Using non-compliant equipment can make an installation illegal, expose the responsible engineer or contractor to personal liability, and invalidate insurance coverage. A single incident involving injury or property damage can lead to fines, litigation, and reputational damage that significantly surpass the modest premium paid for certified products. Reliability and system longevity. curves throughout their service life. They coordinate properly with upstream and downstream devices, preventing nuisance tripping while ensuring selective disconnection. In critical applications such as hospitals, mining operations, and manufacturing plants, this selectivity keeps essential services online and Compliant circuit breakers maintain calibrated tripping
sectors, circuit breakers are the silent guardians of every electrical installation. These compact devices safeguard wiring, equipment, and people from the destructive effects of overloads and short circuits. However, their ability to perform this life-saving function relies entirely on one non- negotiable factor: full adherence to applicable standards. Compliance is not just a bureaucratic tick-box. It is the proven assurance that a circuit breaker will function exactly as intended under fault conditions. In South Africa, there are primary benchmarks for low-voltage switchgear and control gear, miniature circuit breakers (MCBs), and a relevant SANS standard for overarching regulations. Understanding what makes a circuit breaker compliant is one thing, but why does this matter so much? Safety first. A non-compliant breaker may fail to trip, allowing sustained arcing that can ignite insulation and start fires. Statistics from the Department of Employment and Labour and insurance loss-adjusters consistently show that substandard or counterfeit protective devices contribute to a disproportionate
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confidence that the components they use will reliably perform in their specific applications under the most demanding conditions. A key feature of the expanded facility is the new 1500 m² test area, which enhances existing dedicated outdoor and indoor test spaces. Customers can now access testing environments that replicate real operating conditions, including outdoor weather exposure, extreme temperatures as low as -40 °C, cleanroom-compatible formulations, and tailored application trials,” says Ian. He mentions that the test laboratory carries out over 15,000 individual tests at more than 742 test stations each year. These include endurance runs, multi-axis stress tests, and application-specific cycles such as long travel simulations for energy chains and dynamic loads for bearings. The large volume of data generated in the expanded facility feeds into Igus’s online tools, including the service life calculator, product finders, CAD configurators, and predictive maintenance tools. These tools assist engineers and procurement specialists in more accurately selecting the right components for their projects. www.igus.co.za
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SPARKS ELECTRICAL NEWS
APRIL 2026
MCC’s & MOTOR PROTECTION
4
Maximising reliability and safety: the importance of mcc and motor maintenance
By: Minx Avrabos
M otor Control Centres (MCCs) and electric motors are the backbone of many industrial, commercial, and even institutional facilities. For electrical contractors, ensuring these components are properly maintained is not just a client expectation—it is a critical factor in upholding safety, reliability, and operational efficiency. Here’s a comprehensive look at why MCC and motor maintenance should be a top priority for every electrical contractor. 1. Enhancing system reliability and reducing unplanned downtime MCC and motor failures cause unexpected downtime that can halt entire production lines or critical services, leading to lost productivity and revenue. Preventive maintenance—inspections, cleaning, and testing—detects issues like loose connections, degraded insulation, worn contacts, or vibrations early. Predictive maintenance through vibration analysis, thermal imaging, and current monitoring uncovers issues before interruptions arise. By implementing a structured maintenance programme, contractors can assure clients of minimised risk for costly, disruptive failures. 2. Improving electrical safety MCCs operate at high energy levels, and motors experience significant electrical
audits and meets insurance requirements.
of electrical energy in most facilities. Neglected maintenance can lead to increased operating costs. For example: • Dirty or poorly aligned motors draw excess current • Failing insulation causes leakage and losses • Obstructed ventilation leads to overheating and reduced efficiency • Proper maintenance—alignment, cleaning, and timely part replacement—keeps motors running efficiently, reducing waste and supporting sustainability Electrical systems are subject to standards and regulations (e.g., NFPA 70B, OSHA, local codes). Contractors must: • Maintain accurate records of inspections and corrective actions • Ensure systems comply with safety and operational standards • Well-documented maintenance helps during 5. Regulatory compliance and documentation
and mechanical stresses. Poor upkeep creates hazards like: • Electrical fires from loose or corroded connections • Arc flash incidents due to insulation breakdown or faulty breakers • Mechanical failure leading to injury risks Routine maintenance ensures: • Proper torque on terminals and lugs • Functionality of protective devices (like overload relays and circuit breakers) • Insulation integrity and grounding continuity This protects personnel and property and limits legal liability. MCCs and motors require major investment. Regular maintenance extends equipment life by: • Lubricating bearings and moving parts • Replacing worn components before they fail • Cleaning to prevent overheating or contamination 3. Extending equipment life and reducing costs A longer equipment life translates into lower capital expenditure on replacements and fewer major repairs, benefiting both contractors and clients
6. Protecting contractor reputation and client trust Proactive MCC and motor maintenance show a contractor’s commitment to quality, safety, and satisfaction. It demonstrates competence and builds lasting relationships through: • Reduced emergency callouts • Predictable maintenance schedules • Fewer disputes over equipment performance or failures Conclusion Regular, thorough maintenance of MCCs and motors is a cornerstone of electrical contracting best practices. It safeguards people, property, and productivity, while supporting compliance and cost-efficiency. By prioritising maintenance, electrical contractors not only meet their professional obligations but also create tangible value for their clients—and for their own business reputation.
4. Maximising energy efficiency Motors are among the largest consumers
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Understanding the different types of motor control centres M otor Control Centres (MCCs) are essential components in industrial and commercial electrical systems,
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or replaced without major downtime. Draw- out MCCs are preferred in industries where operational continuity is crucial. 3. Intelligent Motor Control Centres Intelligent MCCs (iMCCs) use digital communication, monitoring, and control tools. They include smart devices such as PLCs, networked relays, and meters for real-time diagnostics and remote control. iMCCs suit modern sites aiming for greater efficiency, predictive maintenance, and integrated automation. 4. Low-Voltage vs Medium-Voltage MCCs MCCs are also classified by voltage rating. Low-voltage MCCs (up to 600V) are common in standard industrial applications, while medium-voltage MCCs (above 600V) are used for large motors and heavy-duty equipment in industries like mining and utilities. In summary, choosing the right type of Motor Control Centre depends on factors such as flexibility needs, maintenance requirements, safety, and integration capabilities. Proper selection ensures operational efficiency and system reliability.
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providing centralised control for motors and associated equipment. MCCs house motor starters, circuit breakers, fuses, and other control devices in a single enclosure, making maintenance and monitoring more efficient. There are several types of MCCs, each designed for specific applications and operational environments. type MCCs, feature individually mounted starters and control devices. Components are hardwired, making modifications or expansions more time-consuming. These centres are suitable for applications where changes are infrequent and reliability is paramount. 1. Conventional Motor Control Centres Conventional MCCs, also known as fixed- 2. Draw-Out Motor Control Centres Draw-out or plug-in MCCs allow individual units to be inserted or withdrawn without disconnecting power to the entire centre. This design offers enhanced safety and ease of maintenance, as faulty units can be serviced
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SPARKS ELECTRICAL NEWS
APRIL 2026
MCC’s & MOTOR PROTECTION
5
Motor Control Centres (MCCs) and Motor Protection: essential knowledge for electrical contractors By: Minx Avrabos
M otor Control Centres (MCCs) are essential for the efficient and safe operation of industrial and commercial electrical systems, especially in controlling and protecting motors. For electrical contractors dealing with low- to mid-voltage systems (typically up to 600V), understanding the design, function, and protection features of MCCs is vital for ensuring reliability, safety, and compliance with relevant codes and standards. What are motor control centres (MCCs)? An MCC is a collection of one or more enclosed sections sharing a common power bus, mainly housing motor control units. These units typically include motor starters, circuit breakers, fuses, contactors, overload relays, and sometimes variable-frequency drives (VFDs) or soft starters. MCCs are extensively utilised in manufacturing, water treatment, HVAC, and other industries where multiple motors are operated. Key Components of MCCs • Incoming power section: Receives and distributes power within the MCC. • Vertical bus: Delivers electricity up and down to all parts of the MCC. • Motor starter units: A combination of a contactor, an overload relay, and a disconnect device for each motor. • Control devices: Buttons, warning lights, and switches used by operators to control the motors. • Protection devices: Parts like fuses or breakers that cut off electricity if there is a problem to prevent damage or danger. • Communication modules: Devices that let operators check on the MCC Why MCCs matter for electrical contractors MCCs provide a centralised, organised, and safe means to control and protect multiple motors. They simplify maintenance, troubleshooting, and future expansion. For contractors, correctly installing and commissioning MCCs is essential to system reliability and compliance with safety regulations, such as the National Electrical Code (NEC) and IEC standards. from a distance or connect it to building automation systems. Motor protection: The fundamentals Motors are valuable and vulnerable assets. Their failure can halt production, damage equipment, and create safety hazards. Key threats include overcurrent, overload, phase loss, phase reversal, voltage imbalance, and ground faults. MCCs address these risks through integrated protection features. Overcurrent protection Overcurrent occurs when the current exceeds the motor circuit’s rated capacity. This may be due to a short circuit or a ground fault. MCCs typically
use circuit breakers or fuses to rapidly disconnect the faulty circuit, protecting equipment and personnel. • Circuit breakers: Devices, either mechanical or electronic, that can be set to shut off power when current exceeds a specified threshold. • Fuses: Parts that quickly stop the flow of electricity in case of a short circuit to protect wires and equipment. Overload protection Overloads occur when a motor draws more current than its rated full-load current for an extended period, often due to mechanical issues such as jammed bearings or excessive loads. Overload relays, usually thermal or electronic, sense this condition and disconnect the motor before it overheats. • Thermal overload relays: Devices that use a strip of metal, which bends when it gets hot from too much current, to shut off the motor before it gets damaged. • Electronic overload relays: Provide more precise protection and can monitor additional parameters, such as phase loss or imbalance. Phase loss and phase imbalance protection Three-phase motors are sensitive to phase loss (one phase open) or phase imbalance (unequal voltages across phases). These conditions cause overheating and can rapidly damage motors. Modern MCCs often include phase-monitoring relays that detect these anomalies and shut down affected motors. Ground fault protection Ground faults occur when current unintentionally flows to ground, posing shock and fire hazards. MCCs may include ground-fault relays or circuit breakers with built-in ground-fault detection, especially in sensitive or critical applications. motor switch if power drops too much, stopping damage or unsafe restarts. • Short-circuit protection: Quick-acting parts prevent major electrical faults from causing serious damage. • Motor management relays: Advanced relays that track things like Additional protection features • Undervoltage release: Shuts off the temperature, vibration, and hours of use, so maintenance can be planned before problems happen. Best practices for MCC installation and Motor Protection • Accurate sizing: Select protection devices (breakers, fuses, relays) based on motor ratings and application requirements. • Proper coordination: Ensure that upstream and downstream protective devices operate in the correct sequence to localise faults and prevent unnecessary shutdowns. • Compliance with standards: Adhere to NEC, IEC, and local codes for
Overcurrent occurs when the current exceeds the motor circuit’s rated capacity. This may be due to a short circuit or a ground fault. MCCs typically use circuit breakers or fuses to rapidly disconnect the faulty circuit, protecting equipment and personnel.
• Improper grounding: Inadequate grounding can pose safety hazards and lead to unreliable protection. • Ignoring environmental conditions: MCCs in challenging environments may require specialised cabinets and additional protection from dust, water, or chemicals. • Failing to update Settings: As processes change, protection settings may need to be adjusted to remain effective. Conclusion For electrical contractors working with low- to mid-voltage systems, a strong understanding of MCC design and motor protection strategies is crucial. MCCs not only simplify the control and protection of multiple motors but also improve safety, reliability, and ease of maintenance. Adhere to best practices and stay updated with technological advancements to consistently provide robust solutions that safeguard motors and the facilities they serve—take proactive steps today to uphold the highest standards in every project. Now is the time to focus on understanding MCCs and implementing effective motor protection. Go beyond merely meeting code— take the lead in safeguarding investments, maximising uptime, and building a reputation for quality and reliability in every project you undertake.
clearances, grounding, labelling, and arc flash protection. • Routine testing and maintenance: Periodic inspection and functional testing of MCC components are vital for continued reliability. • Documentation: Maintain up-to-date as- built drawings, operating manuals, and protection setting records. Emerging trends: Intelligent MCCs MCCs are changing as new digital tools are used. Intelligent MCCs (iMCCs) use networks such as Ethernet/IP, Profibus, and Modbus for monitoring and control. These offer benefits for contractors and end-users, such as: • Remote monitoring: Real-time status and diagnostics reduce downtime and maintenance costs. • Predictive maintenance: Condition monitoring helps schedule service before failures occur. • Improved safety: Advanced protection functions and data logging enhance system safety and troubleshooting. Common mistakes to avoid • Underestimating short-circuit ratings: Confirm the MCC’s short-circuit withstand rating aligns with the available fault current.
Variable frequency drives: an essential tool V ariable Frequency Drives (VFDs) are vital in modern electrical work, providing distinct advantages for contractors and Understanding VFDs assists you in meeting these requirements.
users. Knowing how to operate VFDs effectively distinguishes you in an energy-aware market.
Installation considerations When specifying or installing VFDs, ensure correct sizing, motor compatibility, and harmonic mitigation. Verify proper grounding and shielding to minimise electromagnetic interference (EMI). It’s also crucial to educate clients on VFD maintenance and programming to achieve optimal performance. Conclusion Using VFDs adds value for customers and demonstrates your commitment to energy efficiency. Staying updated with VFDs keeps you competitive and guarantees optimal results.
What is a VFD? A VFD is an electronic device that controls the speed and torque of electric motors by adjusting the frequency and voltage of the power supply. This ability allows for precise control of motor-driven equipment, such as pumps, fans, conveyors, and compressors. Why should electrical contractors use VFDs? Energy Efficiency: VFDs optimise motor speed to match load requirements, leading to significant energy savings. In HVAC, water treatment, and industrial processes, this can substantially reduce operating costs for your clients. Extended equipment life: By providing soft starts and stops, VFDs reduce mechanical and electrical stress on motors and connected machinery, minimise maintenance needs and extend equipment longevity. Enhanced process Control: VFDs allow smooth speed adjustments, increasing system design flexibility and improving process results. Regulatory compliance: Many codes and standards now demand variable speed controls.
A VFD is an electronic device that controls the speed and torque of electric motors by adjusting the frequency and voltage of the power supply.
SPARKS ELECTRICAL NEWS
APRIL 2026
MCC’s & MOTOR PROTECTION
6
Motor Protection Circuit Breakers (MPCBs): the contractor’s choice for reliable motor safety F or electrical contractors, reliable motor protection is essential—not just for safeguarding equipment, but for By: Minx Avrabos
indicators and easy reset mechanisms mean less time spent diagnosing and fixing issues. • Adjustable Settings: Many MPCBs feature adjustable current settings, allowing contractors to fine-tune protection for different motor sizes and applications. • Increased Safety: MPCBs can be used as manual isolators, providing safe disconnection during maintenance or emergencies. While fuses and thermal overload relays have been industry staples for decades, they often require multiple components and can lead to nuisance tripping or slow fault response. MPCBs streamline the process, reduce errors, and improve reliability. Installation tips for contractors • Select an MPCB with the right current range for the motor. • Ensure proper coordination with downstream devices for selective tripping. • Regularly inspect and test MPCBs during maintenance routines. Why switch from traditional protection?
ensuring the smooth operation of the entire facility. Motor Protection Circuit Breakers (MPCBs) have become the go-to solution for modern motor safety, offering a range of advantages over traditional protection methods. What is an MPCB? An MPCB is a specialised circuit breaker designed specifically for motor circuits. Unlike standard circuit breakers or thermal overload relays, MPCBs are engineered to provide comprehensive protection against overloads, short circuits, and phase failures, all in a single, compact device. Key benefits for contractors • Comprehensive Protection: MPCBs protect motors from overload, short circuit, phase loss, and unbalanced phases. This reduces the risk of motor burnout and costly downtime. • Space-saving design: With overload and short-circuit protection combined into one unit, MPCBs save valuable panel space and simplify wiring. • Fast Troubleshooting: Clear visual trip
tool. By embracing MPCBs, contractors can provide their clients with better protection, easier maintenance, and greater peace of mind.
Conclusion For electrical contractors aiming to deliver efficient, reliable, and safe motor installations, MPCBs are an indispensable
Intelligent MCCs (iMCCs): a game changer E lectrical contractors are seeking ways to improve efficiency, reliability, and safety. Intelligent Motor Control Centres (iMCCs) offer advanced intelligence and connectivity for motor control.
What are iMCCs? Intelligent MCCs integrate smart devices— such as intelligent overload relays, power meters, and variable frequency drives—alongside robust industrial communications networks (e.g., Ethernet/ IP, Modbus). These components are linked by centralised or distributed control logic, often programmable via PLCs or DCS systems. Unlike conventional MCCs, iMCCs can monitor, control, and diagnose motor operations in real time, providing actionable data to operators and maintenance teams. This data can include motor current, voltage, temperature, energy consumption, and even predictive alerts for potential failures. Key advantages for contractors Streamlined Installation: iMCCs often come with pre-wired, modular components that reduce installation time and minimise wiring errors. Modularity allows contractors to easily scale systems and adapt to changing load requirements on site. Factory-tested configurations further reduce commissioning time and the likelihood of unexpected issues during startup. Enhanced Troubleshooting: Built-in diagnostics quickly pinpoint issues, reducing downtime and maintenance costs. Faults are logged with precise time stamps and can be accessed remotely, enabling contractors to troubleshoot and resolve problems without being physically present at the panel. This reduces the need for costly emergency callouts and improves service response times. Improved Safety: Remote access and
The ability to generate detailed reports, analyse historical trends, and implement remote updates ensures that facilities remain agile and resilient in the face of changing demands.
advanced protection features let users monitor and intervene more safely, reducing the need for physical interaction with live components. iMCCs support arc-flash mitigation strategies and lockout/tagout procedures, and can automatically isolate faulty circuits. Enhanced alarming and data logging also improve compliance with workplace safety standards. Energy Efficiency: Real-time data enables contractors and facility managers to optimise energy use and extend equipment lifespans. Advanced analytics and power monitoring enable the identification of inefficient motors or loads, scheduling preventive maintenance, and reducing peak demand charges. This leads to both
operational and cost efficiencies over the lifetime of the installation.
predictive maintenance strategies, and enhances overall plant productivity. The ability to generate detailed reports, analyse historical trends, and implement remote updates ensures that facilities remain agile and resilient in the face of changing demands. In summary, iMCCs empower contractors to deliver smarter, safer, and more efficient motor control solutions.
Why Embrace iMCCs? For electrical contractors, adopting iMCCs means delivering smarter, future-ready solutions to clients. Seamless integration with plant-wide automation systems enables centralised monitoring and control, supports
SPARKS ELECTRICAL NEWS
APRIL 2026
CABLES & CABLE ACCESSORIES
7
Electrical earth connections through cable glands F irstly, there is no need to earth a plastic cable gland (as it is not conductive), and it is generally not necessary to earth
If the cable has a braid armour/ screen, the associated cable gland cannot have a higher rating than Category A, as the cable’s braid will not be capable of carrying the currents required to meet Category B. In other words, the limitation is typically dictated by the cable construction, not the cable gland. Cable glands for SWA or AWA cables can have a Category B rating as long as the connection between the cable gland and earth is sufficiently good. This can be achieved by either securing the cable gland to a threaded entry on the (earthed) equipment or using an earth tag. Since cable glands can be fitted to clearance holes and secured with a locknut, their electrical rating must default to the lowest value. Therefore, they are often specified as Category A if no earth tag is used and as Category B if an earth tag is fitted. A Category C rating is only achievable with a heavy-duty earth connection cable and a very low resistance path to earth. This can be attained using screw- on earth tags or cable glands with an integrated earth stud. In all these installations, it is vital that the cone and cone ring armour clamp are of good design and quality. Independent tests have shown that glands with loose cones and plastic-to-metal threads cannot carry an earth fault current. Earthing for EMC protection. EMC, or electromagnetic compatibility, is the ability of equipment, cables, or
cable glands used to terminate multi-core unarmoured cables, although installers may choose to do so as part of good practice. The requirements for earth connections in cable glands are defined in the general standards for cable glands, e.g., SANS 1213 and IEC 62444. Why earth a cable gland? In general, cable glands used with armoured cables are earthed for one of the following three reasons: - 1. To prevent induced voltage build-up, possibly leading to sparks. 2. To allow them to carry a fault current to earth in the event of an electrical fault. 3. For EMC protection. We shall look at each of these in turn, but first, a quick reminder about cable construction. The majority of armoured cable construction types fall into two types: those that use steel (SWA) or aluminium (AWA) wires laid in a slow helical form around the cable to form an armour, and those that use much thinner but a larger number of wires that are arranged as a braid around the cable bedding. Less common are armoured cables with a metal tape wound around the bedding, but they are important in certain applications, as we shall see in the section on EMC. It is also worth reviewing how a cable gland is earthed. This can be done by any of four methods. 1. Electrical contact through the armour clamping cone and cone ring, and through the threads of a threaded entry hole in an earthed enclosure when the cable gland is tightened into it. 2. By face-to-face contact with an unpainted (earthed) metal enclosure when the entry holes are clearance holes rather than threaded. Usually, the cable gland is held in place with a locknut and, preferably, a serrated washer to improve electrical contact and prevent slackening due to vibration. Note that this electrical contact is often improved by fitting an earth tag. 3. Using a slip-on earth tag (sometimes known as a ‘banjo’). This is fitted between the cable gland and the enclosure and provides a superior electrical contact with the cable gland. Earth tags are typically made from brass or nickel-plated brass and can be bent, if needed, to allow easier access for connecting a dedicated earth cable. This arrangement provides a visual indication of both an earth connection and an electrical one. An earth tag is essential if the enclosure is not made of metal or painted. 4. The final earthing method is by using a high-current earth connection. This would typically be used when the installation involves power cables with armour used as the earth connection and forming what is known as the CPC, or Circuit Protective Conductor. In this type of installation, the armour may have to be capable of passing high currents to operate a trip or breaker in a fault condition. This means that the cable gland and its connection to earth must also carry the same high current, and a standard earth tag is not capable of doing so. Instead, a screw-on earth tag can be used, or, alternatively, the cable gland can have a dedicated earth lug fitted, usually known as an Integrated Earth connection.
Non-Armoured Cable
Screw-On Earth Tag
Semi-Flexible Braid Armoured Cable
Armoured Cable
Earth Tag
1. Earthing for the prevention of an induced voltage. The armour of a cable is designed to protect or shield the cable and normally does not carry any current. Power cables (excluding single-core cables, which will be discussed in the section on when to isolate a cable gland) are usually constructed so that any magnetic fields produced by the alternating currents in the cores are minimised. Of course, in practice, achieving perfectly balanced electrical fields is Impossible. This means that in a power cable, a voltage may be induced in the cable armour even if it is not electrically connected to the main current-carrying cores. The induced voltage might be sufficient to cause an electric shock if touched, and if a spark occurs, it can harm sensitive electronic equipment. In a hazardous environment, it could act as the ignition source for an explosion. Cable glands for use with armoured cables provide an earth clamp connection by means of a cone and cone ring inside them, so that the armour is electrically connected to the cable gland. If the cable gland is also connected to earth, then, as a consequence, the cable armour will also be earthed, and a potential difference (a voltage) cannot be generated in the armour. CCG Cable Gland Armour Clamping Cone and Cone Ring and metal-to-metal thread engagement. 2. Earthing allows the armour to carry a fault current to earth in the event of an electrical fault. This is applicable when the electrical installation uses the cable armour as a protective earth, and the current that is required to be carried is defined in Table 5 of IEC 62444. In general, the connection between the cable gland and the cable armour is not the limiting factor in selecting the rating category for a cable gland.
systems to operate satisfactorily within their electromagnetic environment without causing unacceptable electromagnetic disturbances to other equipment in the same environment. With the increased use of variable speed drives (VSD), instrumentation and control, wireless data acquisition, and communication in industries, reliance on EMC cables and enclosures to maintain signal and power integrity has become increasingly important. Although cable glands do not emit
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ai177330124516_CCG Ind.180 x130 Advert.pdf 1 2026/03/12 09:40
Cable diameter mm > 4 to 8 > 8 to 11 > 11 to 16
Category A minimum kA rms
Category B minimum kA rms
Category C minimum kA rms
-
-
-
0,5 0,5
3,06 3,06 3,06
10,0 13,1 13,1 13,1 13,1 43,0 43,0 43,0
> 16 to 23 0,5
> 23 to 31
0,5
4,0 5,4 7,2
> 31 to 43 0,5 > 43 to 55 1,8 > 55 to 65 2,3
10,4 10,4
> 65
2,8
SPARKS ELECTRICAL NEWS
APRIL 2026
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