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
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
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
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 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) U
n
Rated operational voltage (of a circuit of an
Assembly) U
e
Rated insulation voltage (of a circuit of an
Assembly) U
i
Rated impulse voltage (of an Assembly) U
imp
Rated frequency f
n
Required Equipment Ratings
Currents
Rated current (of an Assembly) I
nA
Rated current (of a circuit of an Assembly) I
nC
Rated peak withstand current I
pK
Rated short-time withstand current (of a circuit of
an Assembly) I
cw
Rated conditional short-circuit current of an
assembly I
cc
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 (I
nA
), 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 I
cw
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 I
pk
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
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)
2012 Underwriters Laboratories LLC
Design Verification (Annex D)
Overview - IEC 61439-6
Busbar trunking systems
(busways)
Annex D
33
No. Characteristics to be Verified
Clauses 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)
No. Characteristics to be Verified
Clauses or
Subclauses
Verification options Available
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
No. Characteristics to be Verified
Clauses or
Subclauses
Verification options Available
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
2012 Underwriters Laboratories LLC
Low-voltage switchgear and
control gear assemblies
Design Verification (Annex D)
Overview - IEC 61439-1
ANNEX D (continued)
No. Characteristics to be Verified
Clauses or
Subclauses
Verification options Available
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
No. Characteristics to be Verified
Clauses or
Subclauses
Verification options Available
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
Slide 39
Questions
2012 Underwriters Laboratories LLC
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?
2012 Underwriters Laboratories LLC
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Slide 56
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