IEC 61439
Design, Type Testing &
Certification requirements for
LV switchgear & controlgear
assemblies
Paul D Barnhart
Shelesh Tiwari
`
© 2012 Underwriters Laboratories LLC
Introduction
Paul Barnhart is UL’s 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 versus IEC 61439 Series
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
IEC /TR 61439-0
No equivalent
Requirements
Manual Specifier’s Guide
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
IEC 60439 versus IEC 61439 Series
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
Type Test
Report (for
Original System)
YES
(no new
Type tests)
Contractor / User / Specifier
Are all OEM
requirements and
instructions met by
the Assembly
Manufacturer?
NO
New Type
Test Report
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 overview
using 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
Required Equipment Ratings
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
Required Equipment Ratings
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.
Required Equipment Ratings
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
www.proweatherstation.com
• Method of connection
− Number of conductors per phase
− Busbar or cables
− Copper or Aluminum, etc.
www.digplanet.com
Normal Service conditions
Ambient temperature
• max + 40°C
- 24 h average max + 35°C
• Min – 5 °C for indoor
• Min – 25 °C for outdoor
Humidity
• Max 50 % @ +40°C (max 90% @ +20°C) for indoor
• Max 100 % @ +25°Cfor outdoor
Altitude max 2000 m
Slide
27
Special Service conditions
www.tamutimes.tamu.edu.com
www.padouttimes.com
www.rsvlts.com
Special Service conditions
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
Special Service conditions
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)
Busbar trunking systems
(busways)
Design Verification (Annex D)
Overview - IEC 61439-6
© 2012 Underwriters Laboratories LLC
Annex D
Table D.1 – List of design verifications to be performed
Verification options Available
No.
1
Characteristics to be Verified
Clauses or
Subclauses
Testing
Comparison
with
Reference
Design
Assessment
Strength of material and parts
Resistance to corrosion
10.2.2
YES
NO
NO
Thermal stability
10.2.3.1
YES
NO
NO
Resistance to abnormal heat and fire due
to internal electric effects
10.2.3.2
YES
NO
YES
Resistance to ultra-violet (UV) radiation
10.2.4
YES
NO
YES
Lifting
10.2.5
YES
NO
NO
Mechanical impact
10.2.6
YES
NO
NO
Marking
10.2.7
YES
NO
NO
Ability to withstand mechanical loads
10.2.101
YES
NO
NO
Thermal Cycling Test
10.2.102
YES
NO
NO
Properties of insulating materials
33
ANNEX D (continued)
Verification options Available
No.
Characteristics to be Verified
Clauses or
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
10.5
Effective continuity between the exposed
conductive parts of the ASSEMBLY and the
protective circuit
10.5.2
YES
NO
NO
Short-circuit withstand strength of the the
protective circuit
10.5.3
YES
YES
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)
Verification options Available
No.
Characteristics to be Verified
Clauses or
Subclauses
8
Terminals for external conductors
10.8
9
Dielectric properties
10.9
Power-Frequency withstand
Testing
Comparison
with
Reference
Design
Assessment
NO
NO
YES
10.9.2
YES
NO
NO
Impulse voltage withstand
10.9.3
YES
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
Slide
35
Low-voltage switchgear and
control gear assemblies
Design Verification (Annex D)
Overview - IEC 61439-1
© 2012 Underwriters Laboratories LLC
ANNEX D (continued)
Verification options Available
No.
Characteristics to be Verified
Clauses or
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
10.5
Effective continuity between the exposed
conductive parts of the ASSEMBLY and the
protective circuit
10.5.2
YES
NO
NO
Short-circuit withstand strength of the the
protective circuit
10.5.3
YES
YES
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)
Verification options Available
No.
Characteristics to be Verified
Clauses or
Subclauses
8
Terminals for external conductors
10.8
9
Dielectric properties
10.9
Power-Frequency withstand
Testing
Comparison
with
Reference
Design
Assessment
NO
NO
YES
10.9.2
YES
NO
NO
Impulse voltage withstand
10.9.3
YES
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
Slide
38
Questions
Slide 39
Services UL provides
for switchgear and
controlgear
© 2012 Underwriters Laboratories LLC
Certification Services Overview
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Verification by
Testing (Full Type
Test)
Training &
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Verification
Short Circuit Test
/ Temperature
Rise Tests
Verification
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Mark
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Certificate
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Verification Certificate by TYPE TESTS with Online Listing to
IEC 61439 or IEC 62271
•
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•
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per standard
•
Real-Time Online listing at www.ul.com/database
•
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•
Surveillance Inspections for Mark Integrity
UL Classification to IEC 61439 or IEC 62271
UL Classification mark
IEC CB Scheme Certificate to IEC 61439
What is UL Listing?
UL & cUL Listing
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UNDERWRITERS
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A brief history and overview of
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© 2012 Underwriters Laboratories LLC
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Thank You
Slide 56