IEC 61439Design Type Testing Certification Requirements ForLV Switchgear Controlgear Assemblies

2012 Underwriters Laboratories LLC

IEC 61439

Design, Type Testing &

Certification requirements for

LV switchgear & controlgear

assemblies

Paul D Barnhart

Shelesh Tiwari

`

Introduction

Paul Barnhart is ULs Principal Engineer (PDE) for Power Transmission and Distribution Equipment. His primary focus includes high and low voltage switchgear, high voltage motor controls and drives, transfer switches, arc mitigation equipment and utility metering equipment.

Background:

BS Electrical Engineering Michigan Technological University

24 years experience in all aspects of standards development, product certification and testing

8 years experience in switchgear and industrial controls manufacturing

Introduction

Shelesh Tiwari is a Senior Project Engineer in UL India. His primary focus includes low voltage switchgear and controlgear asemblies, components and related equipment, including busbar trunking systems

Background:

Masters in Electronics Jamia Millia Islamia University, Delhi, India

10 years experience in Low Voltage switchgear and controlgear product certification and testing

3 years experience in Low Voltage switchgear and industrial controls manufacturing.

Agenda

Introduction

Purpose of Standards / IEC objectives

IEC 60439 Series versus IEC 61439 Series

Design Verification Process

Example - Busbar trunking systems per IEC 61439-6

Services UL provides for IEC 61439

Brief history and overview of UL

and our service

What is the purpose of standards?

To set safety and performance levels of the products covered by the standard

To manage customer and user expectations associated with those products

Main objectives of the IEC

Meet the requirements of Global market

Ensure world-wide use of standards

Contribute to the improvement of human health and safety

Contribute to protection of environment

IEC 60439 Series LV Switchgear & Controlgear Assemblies

Safety of Persons

Protection of Equipment and Property

Availability of Electrical power

IEC 60439 was in need of revisions:

More flexibility was needed

Clarification of requirements was needed

Restructuring of the format would be helpful

IEC 60439 versus IEC 61439 Series


New structure

New terms (OEM and Assembly manufacturer)

New ways to show compliance

More flexibility

IEC 60439 versus IEC 61439 Series - Structure

Description Old IEC Standard New IEC Standard North American Standard

(for reference)

General Rules IEC 60439-1 IEC 61439-1 No equivalent

Power

Switchgear &

Control gear

Assemblies

IEC 60439-1 IEC 61439-2 ANSI / UL 845 / 1558 / 891

NEMA PB2

Distribution

Boards

IEC 60439-3 IEC 61439-3 ANSI / UL 67

NEMA PB1

Assemblies for

Construction

Sites

IEC 60439-4 IEC 61439-4 No equivalent

Assemblies for

power

distribution in

public networks

IEC 60439-5 IEC 61439-5 No equivalent

Bus bar Trunking

Systems

IEC 60439-2 IEC 61439-6 ANSI/UL 857

Requirements

Manual -

Specifiers Guide

IEC /TR 61439-0 No equivalent

IEC 60439 versus IEC 61439 Series - Terms

IEC 60439 defined two different approaches to compliance

TTA Type Tested Assembly- An assembly that has been completely type tested

PTTA Partially Type Tested Assembly - An assembly containing some non-tested arrangements

IEC 61439 has modified this approach, by replacing it with

three different (but equivalent) methods to verify

compliance:

verification by testing verification by calculation/measurement verification by satisfying design rules

IEC 60439 versus IEC 61439 Series - Terms

Verification by testing- conducting type tests on the assembly

Verification by comparison to tested reference design

- based on known test data and specific set of conditions

Verification by assessment - satisfying design rules

- correct application of calculations and design rules

including appropriate safety margins


Manufacturers

The concept of Original Manufacturer versus Assembly

Manufacturer has been introduced

Original Manufacturer The organization that has carried out the original design and associated

verification of an assembly in accordance with the

standard

Assembly Manufacturer The organization taking the responsibility for the completed assembly (this may be a

different company than the original manufacturer)

IEC 60439 versus IEC 61439 Series -

Manufacturers

Assembly manufacturer

(panel builder/assembler)OEM manufacturer

Contractor / User / Specifier

New Type

Test Report

Type Test

Report (for Original System)

(no new

Type tests)

Are all OEM

requirements and

instructions met by

the Assembly

Manufacturer?

NO

YES

IEC 60439 versus IEC 61439 Series - more

The requirements regarding temperature rise have been clarified.

The rated diversity factor (RDF) is more detailed

Requirements from the standard for empty enclosures for assemblies (IEC 62208) have been incorporated;

Each part of IEC 61439 (i.e. -2, -3, -4) has been restructured to refer to the new general rules standard

(IEC 61439-1)

IEC 60439 versus IEC 61439 Series - more

The requirements regarding temperature rise at different frequencies have been clarified.

Clause 10.10.3.1 states that

Temperature-rise tests carried out at 50 Hz are applicable to 60 Hz for rated currents up to and including 800 A. In the absence of tests

at 60 Hz for currents above 800 A, the rated current at 60 Hz shall

be reduced to 95 % of that at 50 Hz. Alternatively, where the maximum temperature rise at 50 Hz does

not exceed 90 % of the permissible value, then de-rating for 60 Hz

is not required.

Temperature-rise tests carried out at particular frequencies are applicable at the same rated current to lower frequencies, including

d.c.

What about designs previously certified to

IEC 60439 do they need to be retested?

This depends on the previous investigation:

Has the design changed?

Are the tests conducted per 60439 representative of 61439?

Were the original tests conducted prior to publication of the IEC 61439 product standard?

(for example, Jan 2009 for switchgear)

What about designs previously certified to

IEC 60439 do they need to be retested?

As stated in 10.1 of IEC 61439-1:

Where tests on the assembly have been conducted in

accordance with the IEC 60439 series, prior to the

publication of the relevant product standard in the IEC

61439 series, and the test results fulfill the requirements of

the relevant part of IEC 61439, the verification of these

requirements need not be repeated.

Design Verification Process An overviewusing IEC 61439-6 as an example

Clause 1: Scope

Clause 2-7: General Requirements

Terms, ratings, service conditions

Clause 8: Constructional requirements

Clause 9: Performance requirements

Clause 10: Design Verification

Construction

Performance

Clause 11: Routine Verification

Factory test and verification

Required Equipment Ratings

Voltages

Rated voltage (of an Assembly) Un

Rated operational voltage (of a circuit of an Assembly) Ue

Rated insulation voltage (of a circuit of an Assembly) Ui

Rated impulse voltage (of an Assembly) Uimp

Rated frequency fn


Currents

Rated current (of an Assembly) InA

Rated current (of a circuit of an Assembly) InC

Rated peak withstand current IpK

Rated short-time withstand current (of a circuit of an Assembly) Icw

Rated conditional short-circuit current of an assembly Icc


Adjustments to current ratings may be needed:

Ambient Temperature

Mounting orientation

- Unless specified, current ratings are based

on horizontal orientation

Position may also affect the current rating

- Location of tap-off units (above or below bus)

- Position of bus (flat or edgewise)

The equipment manufacturer may specify

temperature and/or mounting derating factors.


Diversity Factor

The per unit value of the rated current (InA), to which

outgoing circuits of an assembly can be continuously

and simultaneously loaded, considering the mutual

thermal influences

May be stated for:

- Groups of circuits

- The whole assembly

RDF = ?

Rated diversity factor

An example for bus trunking systems (BTS)Unless otherwise specified, the RDF for an entire BTS is 1, meaning

all tap-off units can be continuously and simultaneously loaded with

their full rated current, within the limit of the rated current of the BT

run(s) and feeder BTU(s).

Tap-off units with more than one main outgoing circuit, are suitable

for continuous, simultaneous loading at their rated current multiplied

by the RDF, within the limit of the rated current of the tap-off unit.

Unless otherwise specified, the RDF of such tap-off units shall be

equal to the values given in Table 101

Slide

24

Short-circuit ratings

Rated short-time withstand current Icw Must be no less than the prospective short-circuit of supply

- As determined by Short-circuit calculations at installation site

May have different values for 0,2 s, 1s, 3s durations

Rated peak withstand current Ipk

Other considerations / ratings

Earthing System (TN, TT,..)

Installation requirements IP rating

Ambient temperature

Humidity

Method of connection Number of conductors per phase

Busbar or cables

Copper or Aluminum, etc.

www.proweatherstation.com

www.digplanet.com

Normal Service conditions

Ambient temperature

max + 40C

- 24 h average max + 35C

Min 5 C for indoor

Min 25 C for outdoor

Humidity

Max 50 % @ +40C (max 90% @ +20C) for indoor

Max 100 % @ +25Cfor outdoor

Altitude max 2000 m

Slide

27

Special Service conditions

www.padouttimes.com

www.rsvlts.com

www.tamutimes.tamu.edu.com


Special service conditions are anything other than

normal service conditions, which may include:

Temperature, humidity or altitude different than normal conditions

Applications with rapid temperature or pressure changes that could cause extra condensation

Heavy dust, smoke, corrosive or radioactive particles or vapors

Exposure to strong electric or magnetic fields

and many other conditions as detailed in 61439-1

Slide

29


IEC 61439-6 identifies additional special conditions

for bus trunking systems:

Exposure to special mechanical loads such as

lighting, additional cables, ladder supports, etc.

Applications with high repetitive overcurrent such as resistance welding

Installation near highly sensitive IT equipment, etc.

Applications requiring defined circuit integrity under fire or other conditions

Slide

30

Design Verification Process

Once the characteristics and ratings of the

assembly are defined, the design verification

can begin

Clause 10 provides the method for Design Verification

Construction (compliance with Clause 8)

Performance (compliance with Clause 9)

Annex D provides helpful guidance for the three different

verification options (testing, comparison with a reference

design, and assessment)


Design Verification (Annex D)

Overview - IEC 61439-6

Busbar trunking systems

(busways)

Annex D

33

No. Characteristics to be VerifiedClauses or

Subclauses

Verification options Available

Testing

Comparison

with

Reference

Design

Assessment

1 Strength of material and parts

Resistance to corrosion

Properties of insulating materials

Thermal stability

Resistance to abnormal heat and fire due

to internal electric effects

Resistance to ultra-violet (UV) radiation

Lifting

Mechanical impact

Marking

Ability to withstand mechanical loads

Thermal Cycling Test

10.2.2

10.2.3.1

10.2.3.2

10.2.4

10.2.5

10.2.6

10.2.7

10.2.101

10.2.102

YES

YES

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

YES

YES

NO

NO

NO

NO

NO

Table D.1 List of design verifications to be performed

ANNEX D (continued)


Subclauses


Testing

Comparison

with

Reference

Design

Assessment

2 Degree of protection of enclosures 10.3 YES NO YES

3 Clearances 10.4 YES NO NO

4 Creepage Distance 10.4 YES NO NO

5 Protection against electric shock and integrity

of protective circuits

Effective continuity between the exposed

conductive parts of the ASSEMBLY and the

protective circuit

Short-circuit withstand strength of the the

protective circuit

10.5

10.5.2

10.5.3

YES

YES

NO

YES

NO

NO

6 Incorporation of switching devices and

components

10.6 NO NO YES

7 Internal electrical circuits and connections 10.7 NO NO YES

34

Annex D (continued)

Slide

35


Subclauses


Testing

Comparison

with

Reference

Design

Assessment

8 Terminals for external conductors 10.8 NO NO YES

9 Dielectric properties

Power-Frequency withstand

Impulse voltage withstand

10.9

10.9.2

10.9.3

YES

YES

NO

NO

NO

NO

10 Temperature-rise limits 10.10 YES YES YES

11 Short-circuit withstand strength 10.11 YES YES NO

12 Electromagnetic compatibility (EMC) 10.12 YES NO YES

13 Mechanical operation 10.13 YES NO NO

14 Resistance to flame propagation 10.101 YES NO NO

15 Fire resistance in building penetration 10.102 YES NO NO


Low-voltage switchgear and

control gear assemblies

Design Verification (Annex D)

Overview - IEC 61439-1

ANNEX D (continued)


Subclauses


Testing

Comparison

with

Reference

Design

Assessment

2 Degree of protection of enclosures 10.3 YES NO YES

3 Clearances 10.4 YES NO NO

4 Creepage Distance 10.4 YES NO YES

5 Protection against electric shock and integrity of

protective circuits

Effective continuity between the exposed

conductive parts of the ASSEMBLY and the

protective circuit

Short-circuit withstand strength of the the

protective circuit

10.5

10.5.2

10.5.3

YES

YES

NO

YES

NO

NO

6 Incorporation of switching devices and

components

10.6 NO NO YES

7 Intenral electrical circuits and connections 10.7 NO NO YES

37

Annex D (continued)

Slide

38


Subclauses


Testing

Comparison

with

Reference

Design

Assessment

8 Terminals for external conductors 10.8 NO NO YES

9 Dielectric properties

Power-Frequency withstand

Impulse voltage withstand

10.9

10.9.2

10.9.3

YES

YES

NO

NO

NO

NO

10 Temperature-rise limits 10.10 YES YES YES

11 Short-circuit withstand strength 10.11 YES YES NO

12 Electromagnetic compatibility (EMC) 10.12 YES NO YES

13 Mechanical operation 10.13 YES NO NO

Questions


Services UL provides

for switchgear and controlgear

Certification Services Overview

Certificate of

Verification by

Testing (Full Type

Test)

Short Circuit Test

/ Temperature

Rise Tests

Verification

Report (partial)

UL Classification

Mark

IEC CB Scheme

Certificate

Training &

Design

Verification

Verification Certificate by TYPE TESTS with Online Listing to IEC 61439 or IEC 62271

Full Type Test to IEC 61439-1 & 2,6 - Ed. 2 (2011) or IEC 62271

Constructional verification, Labeling & Marking requirement as per standard

Real-Time Online listing at www.ul.com/database

Type Test Design Conformance Traceability online through unique File Number

Surveillance Inspections for Mark Integrity

UL Classification Mark (to IEC 61439 or 62271)

UL Classification to IEC 61439 or IEC 62271

UL Classification mark

IEC CB Scheme Certificate to IEC 61439

UL & cUL Listing

The US NEC (ANSI / NFPA 70) & Canadian CEC

Mandatory Listing by NRTL for specific categories

Safety Certification to ANSI Standards (UL/NEMA/IEEE)

Online listing with traceability

Marking & Labeling as per guidelines

Continuous Surveillance Inspections

What is UL Listing?


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Documents

IEC 61439Design Type Testing Certification Requirements ForLV Switchgear Controlgear Assemblies