Rules for Classification and Construction
VI
Additional Rules and Guidelines
7
Guidelines for the Performance of Type Approvals
7 Test Requirements for Statical Converters with Semi-Conductors
Edition 1999
The following Guidelines come into force on September 1st, 1999.
"General Terms and Conditions" of the respective latest edition will be applicable
(see Rules for Classification and Construction, I – Ship Technology, Part 0 – Classification and Surveys)
Reproduction by printing or photostatic means is only permissible with the consent of Germanischer Lloyd.
Germanischer Lloyd AG
Head Office
Vorsetzen 35, 20459 Hamburg / Germany
Telefon +49 40 36149-0
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Published by: Germanischer Lloyd AG, Hamburg
Printed by: Gebrüder Braasch GmbH, Hamburg
Table of Contents
VI - Part 7
GL
Chapter 6
Page 3
Table of Contents
Section 1
A.
B.
C.
D.
Section 2
A.
B.
Section 3
A.
B.
Annex A
General Conditions
Scope ..........................................................................................................................................
References to other Regulations and Rules ................................................................................
Mandatory Type Testing ............................................................................................................
Submission of Documents ..........................................................................................................
1111-
1
1
1
1
Requirements Related to Products
General .......................................................................................................................................
Environmental Categories ..........................................................................................................
2- 1
2- 1
Test Requirements
General .......................................................................................................................................
Tests ...........................................................................................................................................
Required Tests (Summary)
3- 1
3- 1
VI - Part 7
GL
Section 1
D
General Conditions
Chapter 7
Page 1–1
Section 1
General Conditions
A.
Scope
These regulations apply to the type testing of static
converters with semiconductors, such as line and self
commutated static frequency converters, power converters, power amplifiers etc.
B.
“Rules for Classification and Construction“, I Ship Technology Part 1 - Seagoing Ships, Chapter 3 Electrical Installations
–
„Regulations for the Performance of Type
Tests“, Part 0, Procedure
–
„Regulations for the Performance of Type
Tests“, Part 1, Test Requirements for Electrical/Electronic Equipment, Computers and Peripherals
2.
Reference is made to the following IEC Publications:
–
IEC 60092 “Electrical Installation in Ships”,
Part 304 (Semiconductor Converters)
–
IEC 60092 “Electrical Installation in Ships”,
Part 504 (Special features - Control and Instrumentation)
–
IEC 60146 “Semiconductor Power Converters”
–
IEC 61800 “Adjustable speed electrical power
drive systems”
–
IEC 60533 “Electromagnetic compatibility of
electrical and electronic installations in ships”.
3.
Standards other than those listed under
point 2, above, may be accepted provided that they are
equivalent.
Mandatory Type Testing
Semiconductor static converters are subject to mandatory type testing where these involve
–
standardised switchgear units manufactured in
series with reduced clearance and creepage distances,
–
open- and closed loop controls for speed and
output of internal combustion engines (mainand auxiliary engines,
–
and electrical actuators
References to other Regulations and Rules
1.
In addition to the regulations listed under
point 2, below, the following publications of Germanischer Lloyd shall also apply:
–
C.
or any other applications as described in the „Rules for
Classification and Construction“, I - Ship Technology
Part 1 - Seagoing Ships, Chapter 3, Electrical Installations, Section 18, Paragraph E.
On request a type test may also be performed on semiconductor static converters which are not subject to
mandatory type testing.
D.
Submission of Documents
The following documents have to be submitted:
1.
Product specification together with full performance description, technical data and operating
conditions
2.
Relevant design documents containing information about the used materials and projection-,
assembly- and general arrangement drawings
3.
Detailed equipment description explaining
the principle of operation, along with block diagrams,
operating and servicing instructions, a description of
the self-monitoring facilities and fault handling procedures
4.
List of associated standards and regulations
5.
Test reports together with test records and
certificates related to tests which have already been
performed
6.
Wiring diagrams
Chapter 7
Page 1–2
Section 1
D
General Conditions
VI - Part 7
GL
7.
Parts lists with denomination of components,
types and manufacturers, particularly those of power
semiconductors, fuses, chokes, transformers, filter
circuits and cooling facilities
9.
The works test programmes specified in the
quality management system
8.
Description of the quality management system or the QM certificate
The GL reserves the right to ask for further documents
in individual cases.
VI - Part 7
GL
Section 2
B
Requirements Related to Products
Chapter 7
Page 2–1
Section 2
Requirements Related to Products
A.
General
The requirements for static converters with semiconductors regarding to design, function and conditions of
use are laid down in the relevant Classification Rules
and other associated regulations.
category A (general application) or C (increased thermal stress, e.g. relating to equipment which is installed
in consoles and housings).
Table 2.1
Ambient conditions
B.
Environmental Categories
The environmental categories specified in the Regulations for Type Tests, Part 1, Section 2, Paragraph B
shall apply. General semiconductor static converters
are likely to fall within the environmental
Environmental
Temperature
categories
Relative
humidity
Vibration
A
0° to 45 °C up to 100 %
0,7 g
C
0° to 55 °C up to 100 %
0,7 g
VI - Part 7
GL
Section 3
B
Test Requirements
Chapter 7
Page 3–1
Section 3
Test Requirements
A.
General
1.
Selection of Test Specimen
This inspection includes an evaluation of the mechanical composition of the test piece with regard to:
–
compliance with the specified degree of protection
(Note: where appropriate a test shall be performed to prove the degree of protection according to IEC 529)
–
the possibility of replacing the power semiconductor (IEC 60092-304)
–
accessibility for maintenance and adjustment
work
–
precautions against the interchange of plug-in
assemblies and plug connectors
–
compliance with the clearance and creepage
distances for which allowance is to be made according to the fouling grade and the overvoltage
category on which it is based
Test specimen from serial produced equipment must
be selected from the current production. The choice of
equipment for testing shall be agreed with GL.
Where the test samples are prototypes the GL reserves
the right to perform comparative tests on serial produced equipment at a later date.
Representative samples from a line of products may
be selected for type tests.
2.
Scope of Tests
The scope of the tests is specified by the GL on a case
by case basis depending upon the product type and
use. GL reserves the right to request that additional
tests shall be performed in justified cases.
3.
Test Sequence
The test sequence must be specified by the manufacturer prior to start of testing and agreed with GL.
All tests specified for an equipment shall be carried
out on the same specimen. Deviations from this procedure are subject to authorisation.
4.
Documentation of Tests
The tests performed and its results shall be comprehensively documented in test records including details
of the used measurement- and test equipment, the
ambient conditions and the test methods applied (see:
„Regulations for the Performance of Type Tests“,
Part 0, Procedure, Section 3, G).
B.
Tests
1.
Visual Inspection
Test Procedure
An evaluation of the used material (flame-retardant,
halogen-free), the cooling system, the cable connection spaces etc. shall also be made (IEC 60092-504).
Test Result
The tests shall be evaluated as having been passed if
the specimen meets the requirements of the GL Rules
for Classification and Construction, the GL Regulations, the IEC publications as well as the stipulations
of the specification and in the documentation, and if
there are no visible defects.
2.
Performance Test
Method
In its scope the performance test corresponds to a
normal workshop test where operational functions,
control and monitoring are checked.
Malfunctions such as the failure of forced ventilation
shall be simulated. In UPS systems one of the tests
conducted covers the operation of the system in case
of an earth fault in the load circuit or in case of unbalanced load.
–
the GL Rules for Classification and Construction and also the GL Regulations
For information on the test conditions see: „Regulations for the performance of type tests“, Part 1, Test
requirements for electrical/electronic equipment, computers and peripherals, Section 3, B.2.2
–
–
the manufacturer’s specification
the design drawings
Test Results
–
the specified standards
The test sample shall be checked for conformity with:
Chapter 7
Page 3–2
Section 3
Test Requirements
B
The test is evaluated as having been passed when the
specified functions have been demonstrated, the results are within the prescribed tolerances, the results of
simulated faults conform to specification and the GL
Construction Rules and if the test piece shows no sign
of damage.
Note:
Filter currents which are discharged in the IT network
against the ship’s hull must meet the provisions of IEC
60092-304.
3.
Power Supply Failure
VI - Part 7
GL
Clarification must be given on a case by case basis
whether tests 5 to 8 also need to be conducted with the
power component in different operating states (idling,
operating, braking).
Test Result
The test is evaluated as having been passed when the
variations in the power supply do not lead to a malfunction or cause damage to the test piece.
At larger deviations the test piece must operate in a
safe operating state.
5.
Test Procedure
Input and Output Current and Voltage
Diagrams
The supply voltage shall be interrupted three times for
about 30 seconds within 5 minutes. The test shall be
performed with the rated operational voltage Ue. The
test shall be repeated several times as appropriate, in
various states of operation.
Test Procedure
Test Result
Test Result
The test is evaluated as having been passed if the
power failures forced do not cause any damage to or
malfunctioning of the test piece.
If the test piece is functioning properly the current and
potential curves must be symmetrical. An evaluation
shall be carried out of the voltage peaks (needles) and
commutation breaks. The harmonic content of the
voltage is not permitted to exceed 5 % (GL Construction Rules, Chapter 3, Electrical Installations, Section
1, F.).
4.
Power Supply Variations
Test Procedure
The test piece is connected to a voltage source with
variable frequency and voltage. Several tests shall be
conducted with frequency and voltage deviations:
The test piece shall be operated as specified at full
load, half load and no load. The input and output current and voltage diagrams are to be plotted accordingly.
Note:
Due to the fact that the mains reactance affects the
current and potential curves, additional measures may
have to be implemented on board.
Table 3.1
Test
Voltage
deviation
Frequency Admissible
deviation
period
1
+ 6%
+ 5%
continual
2
+ 6%
– 5%
continual
3
– 10 %
– 5%
continual
4
– 10 %
+ 5%
continual
5
+ 20 %
–
1,5 s
6
– 20 %
–
1,5 s
7
–
+ 10 %
5s
8
–
– 10 %
5s
In the case of the frequency and voltage deviations
which are within the continual category testing must
continue until the test piece attains a steady state.
For battery power supplies voltage deviations of
+ 30 % and – 25 % must be considered.
For semiconductor static converters the fact must be
considered that the power components are also connected to the ship’s fluctuating supply voltage.
6.
Overload Test
Test Procedure
Load which exceeds the permitted load shall be applied to the output of the test piece. Where the manufacturer has specified load limits within a time limit
these loads shall be checked together with monitoring
of the temperatures of endangered parts.
Test Result
Overload of the test piece shall be prevented by effectively limitation of the current (GL Construction
Rules, Chapter 3, Electrical Installations, Section 4,
F.). No component shall suffer damage due to excessive temperatures.
7.
Short Circuit Test
Test Procedure
The test piece output has to be short-circuited.
Test Result
VI - Part 7
GL
Section 3
B
Test Requirements
The short circuit on the load side shall not cause destruction of any components except those of fuses (GL
Construction Rules, Chapter 3, Electrical Installations,
Section 4, F.).
8.
If the test sample is an item such as a power supply
unit, an UPS or a comparable item of equipment this
test shall be conducted. A short circuit has to be initiated behind the largest fuse permitted to be installed in
the network according to manufacturers manual. If a
short circuit current capability is specified the current
values shall be recorded. The test shall be performed
under normal conditions with appropriate load. The
test shall be performed twice. (cf. IEC 146-4).
Test Result
The test is evaluated as having been passed if the
continuance of the output voltage is not affected, the
fuses have been broken in due time and the recorded
current values are within the prescribed limits.
Temperature-rise Test
Test Procedure
a)
b)
The test piece, fitted in an enclosure according
the specified degree of protection, shall be operated at rated load until the steady state temperature is reached. The temperature inside the housing, the temperature of endangered components
and the ambient temperature shall be recorded at
agreed intervals.
Alternatively, a thermal balance (loss calculation) may be accepted.
Test Result
a)
b)
10.
Table 3.2
Conditions inside the test chamber for
environmental categories A and C
Short Circuit Fuse Test
Test Procedure
9.
Chapter 7
Page 3–3
A temperature-time diagram shows that the
maximum permissible temperature in the housing was not exceeded (GL Construction Rules,
Chapter 3, Electrical Installations, Section 5, B).
The thermal balance (loss calculation) indicates
that no unacceptable increase in temperature is
anticipated.
Cold
Test Procedure
The performance of the test shall be according to the
GL „Regulations for the Performance of Type Tests“
Part 1, Section 3, B.5
Temperature
0 °C ± 3 °C
Test duration
2h
Test Result
The test is evaluated as having been passed if the
specified functions have been demonstrated, if the
results are within the prescribed tolerances, the values
of the insulation resistance measurement are within
the prescribed limits and if the test piece shows no
sign of damage .
11.
Dry Heat
Test Procedure
Performance of the test shall be according to the GL
„Regulations for the Performance of Type Tests“,
Part 1, Section 3, B.6.
Table 3.3
Conditions inside the test
chamber for environmental
categories
Temperature
Relative humidity at
test temperature
Test duration
A
C
55°C ± 2°C 70°C ± 2°C
≤ 20 %
≤ 20 %
16 h
2h
Test Result
The test is evaluated as having been passed if the
specified functions have been demonstrated, if the
results are within the prescribed tolerances and if the
test piece shows no sign of damage.
12.
Damp Heat
Test Procedure
Performance of the test shall be according to the GL
„Regulations for the Performance of Type Tests“,
Part 1, Section 3, B.7.
Table 3.4
Conditions inside the test chamber for
environmental categories A and C
Temperature
55 °C ± 2 °C
Relative humidity
95 %
Test duration
2 cycles of tests, 12 h each
Chapter 7
Page 3–4
Section 3
B
Test Requirements
Test Result
The test is evaluated as having been passed if the
specified functions have been demonstrated, if the
results are within the prescribed tolerances, the values
of the insulation resistance measurement are within
the prescribed limits and if the test piece shows no
sign of damage .
13.
Vibration
VI - Part 7
GL
test (-12-). The same terminals shall be used for the
measurement as are used for the high voltage test
Test Result
The test is evaluated as having been passed if the
values are not lower than those given in the table below:
Table 3.6
Test Procedure
Performance of the shall be according to the GL
„Regulations for the Performance of Type Tests“,
Part 1, Section 3, B.9.
Rated
operational
voltage Ue
Test
voltage
AC/DC
DC
Riso before
Riso after
≤ 65 V
2 × U e;
min 24 V
10 MΩ
1 MΩ
> 65 V
≥ 500 V
100 MΩ
10 MΩ
The test may also be performed in several steps on
individual system components.
Table 3.5
General vibration loads conforming to
characteristic 1 for the
ambient conditions A and C
Amplitude
2 (+ 3/ – 0) Hz
Acceleration
± 1,0 mm
High Voltage
Test Procedure
13,2 Hz to 100 Hz
0,7 g
Frequency change
max. 1 octave/ minute
Test Result
The test is evaluated as having been passed if the
specified functions have been demonstrated, if the
results are within the prescribed tolerances and if the
test piece shows no sign of damage.
14.
16.
Minimum insulation
resistance
Inclinations
Test Procedure
Performance of the test shall be according to the GL
Regulations for the Performance of Type Tests, Part 1,
Section 3, B.10. This test is necessary only if it is
expected that due to the mechanical design of the test
piece its function could be affected by the inclination.
Test Result
The test is evaluated as having been passed if the
specified functions have been demonstrated, if the
results are within the prescribed tolerances and if the
test piece shows no sign of damage.
The test shall be made with alternating voltage at the
rated operational frequency.
Table 3.7
Rated operational
voltage [V]
Test voltage
[V]
Ue ≤ 65
2 × Ue + 500
66 to 250
1500
251 to 500
2000
501 to 690
2500
Test voltage shall be applied for one minute. Tests are
carried out on electric circuits with different rated
operational voltages or electrically isolated electric
circuits relative to each other and relative to the housing. The semiconductors may be bridged for this test.
Control fuses and printed circuits with electronic
components may be removed. Overvoltage protection
devices may be bridged, isolated on one side or removed, after having passed a function check.
Test Result
15.
Insulation Resistance
Test Procedure
This test shall be made before and after the high voltage test (-16-), the cold test (-10-) and the damp heat
The test is evaluated as having been passed if no voltage spark-over occurs, the overvoltage protection
devices installed are operative as specified and the
values of the insulation resistance measurement are
within the prescribed limits.
VI - Part 7
GL
17.
Section 3
B
Test Requirements
Electrostatic Discharges
Chapter 7
Page 3–5
21.
Conducted slow Transients (Surge)
Test Procedure
Test Procedure
Performance of the test shall be according to the GL
„Regulations for the Performance of Type Tests“,
Part 1, Section 3, B.15.
Performance of the test shall be according to the GL
„Regulations for the Performance of Type Tests“,
Part 1, Section 3, B.19.
Test Result
Test Result
This must correspond to the GL Regulations for the
Performance of Type Tests, Part 1, Section 3, B.15
(Performance criterion “B”, see the GL „Regulations
for the Performance of Type Tests“, Part 1, Section 3,
A.3).
18.
Electromagnetic Fields
This must correspond to the GL „Regulations for the
Performance of Type Tests“, Part 1, Section 3, B.19
(Performance criterion “A”, see the GL „Regulations
for the Performance of Type Tests“, Part 1, Section 3,
A.3).
22.
Conducted low Frequency Interference
(Harmonics)
Test Procedure
Test Procedure
Performance of the test shall be according to the GL
„Regulations for the Performance of Type Tests“,
Part 1, Section 3, B.16.
Performance of the test shall be according to the GL
„Regulations for the Performance of Type Tests“,
Part 1, Section 3, B.20.
Test Result
Test Result
This must correspond to the GL „Regulations for the
Performance of Type Tests“, Part 1, Section 3, B.16
(Performance criterion “A”, see the GL Regulations
for the Performance of Type Tests , Part 1, Section 3,
A.3).
This must correspond to our Regulations for the Performance of Type Tests, Part 1, Section 3, B.20 (Performance criterion “A”, see the GL „Regulations for
the Performance of Type Tests“, Part 1, Section 3,
A.3).
19.
23.
Conducted fast Transients ( Burst)
Conducted Emission
Test Procedure
Test Procedure
Performance of the test shall be according to the GL
„Regulations for the Performance of Type Tests“,
Part 1, Section 3, B.17.
The EMC property of the test piece as a source of
interference shall be evaluated. The circuit related
interference shall be established in a series of measurements according to GL „Regulations for the Performance of Type Tests“, Part 1, Section 3, B.21.
Test Result
This must correspond to the GL „Regulations for the
Performance of Type Tests“, Part 1, Section 3, B.17
(Performance criterion “A”, see the GL Regulations
for the Performance of Type Tests, Part 1, Section 3,
A.3).
Test Result
20.
Note:
Conducted high Frequency Interference
Test Procedure
Performance of the test shall be according to the GL
„Regulations for the Performance of Type Tests“,
Part 1, Section 3, B.18.
The test is evaluated as having been passed if the test
piece does not exceed the values specified in the GL
„Regulations for the Performance of Type Tests“,
Part 1, Section 3, B.21.
The measurement may be performed using a probe if a
coupling network cannot be used due to high connection power (IEC 61800).
24.
Radiated Emissions from Enclosure Ports
Test Result
Test Procedure
This must correspond to the GL „Regulations for the
Performance of Type Tests“, Part 1, Section 3, B.18
(Performance criterion “A”, see the GL Regulations
for the Performance of Type Tests, Part 1, Section 3,
A.3).
The EMC property of the test piece as a source of
interference shall be evaluated. The radiated magnetic
H and electric E fields shall be established in a series
of measurements according to GL „Regulations for the
Performance of Type Tests“, Part 1, Section 3, B22.
Chapter 7
Page 3–6
Section 3
B
Test Requirements
Test Result
The test is evaluated as having been passed if the
measured levels do not exceed the values specified in
the GL „Regulations for the Performance of Type
Tests“, Part 1, Section 3, B.22.
VI - Part 7
GL
Note:
The voltage rate of rise occurring in the test piece is
severely affected by the grid reactance.
When conducting tests 17 to 24, the test piece should
be supplied by an IT network.
VI - Part 7
GL
Annex A
Required Tests (Summary)
Chapter 7
Page A–1
Annex A
Required Tests (Summary)
Table A.1
No.
Test
Page
1
Visual inspection
3– 1
2
Performance test
3– 1
3
Power supply failure
3– 2
4
Power supply variations
3– 2
5
Current and voltage diagrams
3– 2
6
Overload test
3– 2
7
Short-circuit test
3– 3
8
Short-circuit fuse test
3– 3
9
Temperature-rise test
3– 3
10
Cold
3– 3
11
Dry heat
3– 3
12
Damp heat
3– 4
13
Vibration
3– 4
14
Inclinations
3– 4
15
Insulation resistance
3– 4
16
High voltage
3– 4
17
Electrostatic discharge
3– 5
18
Electromagnetic fields
3– 5
19
Conducted fast transients (Burst)
3– 5
20
Conducted high frequency interference
3– 5
21
Conducted slow transients (Surge)
3– 5
22
Conducted low frequency interference
(Harmonics)
3– 5
23
Conducted emission
3– 6
24
Radiated emissions from enclosure ports
3– 6
Required
Already
performed
Test
accepted