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IEC – 61439, way ahead

Low voltage
switchgear and controlgear assembly
standard
Applicable Standards
Low-Voltage Switchgear and Control gear Assemblies, Part 1:
IS 8623 (Part1) -1993
Requirements for Type-Tested and Partially Type-Tested
IEC 439 (Part1) - 1985
Assemblies

IS 8623 (Part2) -1993 Low-voltage Switchgear and Controlgear Assemblies - Part 2 :


IEC 439 (Part2) - 1987 Particular Requirements for Busbar Trunking Systems (Busway)

Low-Voltage Switchgear and Controlgear Assemblies - Part 3 :


IS 8623 (Part3) -1993
Particular Requirements for Equipment Where Unskilled
IEC 439 (Part3) - 1990
Persons have Access for Their Use
Degrees of protection provided by enclosures for low voltage
IS 2147 -1962
switchgear and controlgear
General requirements for switchgear and controlgear for
IS 4237 -1982
voltages not exceeding 1 000 volts ac or 1 200 volts dc
IS / IEC 60529 - 2001 Degrees of protection provided by enclosures (IP CODE)
IEC 60439-1 (2004) Low-voltage Switchgear and Controlgear Assemblies
Type tested & Partially Type tested Assemblies
Salient features of 60439–1
Few important points

 Concept of TTA & PTTA


 Only Performance Related tests
 Verification Tests
 Clause 8.2.1 – Verification of TR limits
 Clause 8.2.2 – Verification of the dielectric properties
 Clause 8.2.3 – Verification of short-circuit withstand
 Clause 8.2.4 – Verification of protective circuit
 Clause 8.2.5 – Verification of clearance & creepage
 Clause 8.2.6 – Verification of mechanical operation
 Clause 8.2.7 – Verification of degree of protection
 EMC tests (if applicable)
Concept of TTA & PTTA as per 60439–1
ASSEMBLY
Low-voltage switchgear and controlgear assembly

Type tests for verification of conformity

TTA – Type tested Type tested Non-type tested


ASSEMBLIES arrangements arrangements

PTTA – partially type


tested ASSEMBLIES

Routine test

Completed ASSEMBLY
Low voltage switchgear and controlgear
assembly standard

IEC 61439
Major changes in IEC 61439

( 1 ) Application based standards


( 2 ) Original Manufacturer & Assembly Manufacturer
( 3 ) TTA, PTTA v/s Design Verified Assembly ( DVA )
Guidelines for extending DVA to other configuration by calculation
or by design rules.
Characteristics verifications – 8 nos. v/s 13 nos. for DVA
( 4 ) More clarity on major tests like SC, TR, IP etc.
Status Summary of IEC 61439 series
Each part of standard is developed based on application
IEC/TR 61439-0 Guidance to specifying assemblies

IEC 61439-1 General Rules

IEC 61439-2 Power switchgear and control gear assemblies

IEC 61439-3 Distribution boards


IEC 61439-4 Assemblies for construction sites
IEC 61439-5 Assemblies for power distribution in Public Networks
IEC 61439-6 Busbar trunking systems
Assemblies for specific application - operated by
IEC 61439-7 ordinary persons (Marinas, Market squares,Electrical
vehicle charging Station etc.)
Salient Features of IEC 61439 – 1
Original manufacturer and Assembly manufacturer :
Responsibility
 Original manufacturer responsible for the basic design and its
verification

 Assembly manufacturer responsible for completing final assembly


with in the scope , guidelines specified by Original manufacturer. He
is also responsible for conducting routine tests on final assembly.
Responsibilities

Low voltage switchgear and controlgear assembly

Manufacturer
Original
Design verification carried by original manufacturer
Original Manufacturer

Testing Calculation Application of design rules

Assembly system – Assembly manufacture can decide ;


To deviate guidelines from original manufacture
To manufacture the assembly as per original
and incorporate this own arrangement then he is
manufacturer guidelines
deemed to be “ Original Manufactures ”

Manufacturer
Assembly
Routine verification / Design Verify

Complete the assembly


Salient Features of IEC 61439 – 1
Electrical Panel is a system…than an integration of
components
Manufacturer 1
Type Tested Components
(IEC 60947 Standard)

Manufacturer
Manufacturer
2
Type
TypeTested
TestedComponents
Components
(IEC
(IEC60947
60947Standard)
Standard)

Panel End
Builder Customer
Single manufacturer supplying
Manufacturer 3 Type Tested Panels
all products
Type Tested Components (IEC 61439
60439 Standard)
(IEC 60947 Standard)

• Performance of various components • More safer, Reliable ,


•working together
As per IEC during
60439, panel faultsasisan integration of individual components than a single
acts more
system
tested in IEC61439 Robust system
• Performance of Various components working together is never tested
Salient Features of IEC 61439 – 1
TTA, PTTA v/s Design Verified Assembly ( DVA ) :

 Elimination of difference between PTTA and TTA

 Verification by 3 different means


 Testing
 Calculations/measurements (Verification assessment)
 Design Rule (Verification comparison)
Salient Features of IEC 61439 – 1
Characteristics verification : 8 nos. v/s 13 nos. for DVA
IEC 61439 - 1 : Aug. 2011
IEC 60439
( Design verification - Annexure D )
Clauses Verifications options available Clauses or
No. Characteristics to be verified or sub- Compariso Assessme sub-
Testing
clauses n nt clauses
Strength of material and parts: 10.2 NA
Resistance to corrosion 10.2.2 YES NO NO NA
Properties of insulating materials: 10.2.3 NA
Thermal stability 10.2.3.1 YES NO NO NA
Resistance to abnormal heat and
1 10.2.3.2 YES NO YES NA
fire due to internal electric effects
Resistance to ultra-violet(UV) radiation 10.2.4 YES NO YES NA
Lifting 10.2.5 YES NO NO NA
Mechanical Impact 10.2.6 YES NO NO NA
Marking 10.2.7 YES NO NO NA
2 Degree of protection of enclosures 10.3 YES NO YES 8.2.7
3 Clearances 10.4 YES NO NO 8.2.5
4 Creepage Distances 10.4 YES NO NO 8.2.5
Protection against electric shock and integrity of protective
10.5
circuits:
Effective continuity between the
5 exposed conductive parts of the 10.5.2 YES NO NO 8.2.4
ASSEMBLY and the protective circuit
Short-circuit withstand strength of the
10.5.3 YES YES NO 8.2.4
protective circuit
Salient Features of IEC 61439 – 1
Characteristics verification : 8 nos. v/s 13 nos. for DVA
IEC 61439 - 1 : Aug. 2011
IEC 60439
( Design verification - Annexure D )

Verifications options available


Clauses Clauses or
No. Characteristics to be verified or sub- Compariso Assessme sub-
clauses Testing clauses
n nt

6 Incorporation of switching devices and components 10.6 NO NO YES 7.6

7 Internal electrical circuits and connections 10.7 NO NO YES 7.8


8 Terminals for external conductors 10.8 NO NO YES 7.1.3
Dielectric properties: 10.9
9 Power-frequency withstand voltage 10.9.2 YES NO NO 8.2.2
Impulse withstand voltage 10.9.3 YES NO YES Optional
10 Temperature-rise limits 10.10 YES YES YES 8.2.1
11 Short-circuit withstand strength 10.11 YES YES NO 8.2.3
12 Electromagnetic compatibility(EMC) 10.12 YES NO YES 8.2.8
13 Mechanical operation 10.13 YES NO NO 8.2.6
Status Summary of IEC 61439 series
More clarity on important performance tests

 Temperature rise requirements , rated diversity factor and short circuit requirements
are explained more clearly
New Tests – Strength of material and parts
Additional test focusing on assurance and reliability aspect
for product life cycle

Characteristics verification : Additional tests

Verification optionsClause/Sub-
Characteristic clause
Compariso Assessm IEC 61439
Testing
n ent
Resistance to corrosion    10.2.2
Thermal stability of enclosure    10.2.3.1
Glow wire test    10.2.3.2
Resistance to UV radiation    10.2.4
Lifting    10.2.5
Mechanical impact test (IK)    10.2.6
Marking    10.2.7
1.1 Resistance to Corrosion
Testing (10.4) Comparison Assessment
  
Test objective:
To ensure that deterioration of metallic component caused by corrosion shall not
impair the mechanical strength of switchboard.

 Severity A: Metallic indoor enclosures, external metallic parts of indoor, and internal
metallic parts of indoor/ outdoor assemblies.
 Severity B: Metallic Outdoor enclosures, external metallic parts of outdoor assemblies.

The specimen has to undergo following test:


Severity A Severity B
24 hr damp heat cycle 6 cycles 5 cycles
24 hr Salt mist cycle 2 cycles 7 cycles

Severity B: 2 identical cycles


 Sample shall shows no evidence of iron oxide, cracking etc.
 Doors, Hinges, Locks and fastenings works without abnormal effort
Typical Salt mist chamber
1.2 Verification of Thermal stability
Testing (10.4) Comparison Assessment
  

Test objective:
To verify the thermal properties of the enclosure made up of insulating material.

 The specimen is kept in a heating chamber at 70°C for 7 days. After that the sample is
kept at ambient temperature for 4 days.

 The sample shall show no cracks nor the material has become sticky or greasy, to test,
sample is pressed with the forefinger wrapped in a dry cloth with a force of 5N.

 No traces of cloth shall remain on the sample or vice-versa.


1.3 Resistance to Abnormal heat and fire (Glow wire)
Testing (10.4) Comparison Assessment
  

Test objective:
To checks the capability of insulation material to handle thermal stresses produced by
sources of heat or ignition.
 Tests as per IEC 60695-2-10 & 60695-2-11
 The test at different temperature are mandatory for insulating materials.
 960°C - for parts supporting conducting parts
 650°C - for all other parts

Fail Pass
1.4 Resistance to UV radiation
Testing (10.4) Comparison Assessment
  

 The test applies only to enclosures and external parts of ASSEMBLIES intended to be
installed outdoors.

 Not applicable for INDOOR USE

 UV Test according to ISO 4892 – 2 method A; 1000 cycles of 5 min of watering and 25
min. of dry period with xenon lamp providing a total test period of 500hrs.
1.5 Lifting
Testing (10.4) Comparison Assessment
  

Test objective:
To ensure that there should be no damage to the panel during transportation &
installation. The test is carried out on a sample having weight 1.25 times its maximum
shipping weight.

 The specimen is raised vertically to a height of 1 m before returning to its normal


position. This test is repeated twice and then the specimen is raised up and suspended
at a height of 1 m for 30 min.
 After this the specimen is raised up at a height of 1 m and moved horizontally (10 m),
then returned to its normal position. This is repeated 3 times.
 After the test the specimen shall show no cracks or permanent distortion
1.6 Protection against mechanical impact
Testing (10.4) Comparison Assessment
  

Test objective:
To verify a resistance of enclosure against external impact forces.

 Verified in accordance with IEC 62262


 The degree of protection provided by an enclosure against impacts is indicated by the IK
code.
Protection against mechanical impact

Impact Energy
IK code
J

IK 00 *
IK 01 0.14
IK 02 0.2
IK 03 0.35
IK 04 0.5
IK 05 0.7
IK 06 1
IK 07 2
IK 08 5
IK 09 10
IK 10 20
1.7 Marking
Testing (10.4) Comparison Assessment
  

Test objective:
To ensure that the markings are legible.

 Markings made by molding, pressing, engraving or similar shall not be submitted to this
test.

 This test is made by rubbing the marking by hand for 15 sec with a piece of cloth
soaked in water and then for 15 sec with petroleum spirit.

 After the test the marking shall be easily legible.


Achieving the balance between manufactures pain area as
well as performance assurance for end customer

 It is not practicable and commercially possible to test all


configurations. New IEC allows manufacture to test few important
variants and extend them to other ratings. Thus manufacture need not
test all combinations / configurations
Internal Arc Test Video
Failed & Passed Tests

MOTOR CONTROL CENTRE


Seismic Test
Elements of Arc Flash safety

• Calculation of degree of arc


flash hazard

• Personal protective
equipment

• Training

• Tools for safe work

• Warning labels on equipment


PPE – Typical Requirements

Hazard/Risk Eye protection, ear canal Arc rated Face & Head Flash Suit
Category inserts, long sleeve shirt clothing Protection Hood
and pants

0 
1   
2   
3    
4    
Arc Flash - Video

Remote Operation of Equipment


Ti range of panels …. A Smart solution
Ti range of panels …. Design philosophy

Simple Built For India

Flexible

Engineered

Design verified
assembly
Safe & Reliable
Ti range of panels …. Specifications

Operation Voltage 380-690 V AC


Rated Frequency 50 / 60 Hz
Insulation Voltage 690 V
Short time withstand Up to 70 kA for 1 sec
Peak withstand Up to 154 kA
Rated Current (maximum) Up to 5000A
Conforming Standards IS8623, IS13947, and IEC 61439
Form of Separation Up to Form 4B
Degree of protection Up to IP 54
Panel types Fixed type - PCC, MCC, PMCC, Drives, APFC
Horizontal Bus bar Material Aluminum / Copper
Horizontal Bus bar Location Top / Bottom
SUP (for ACBs) – Top / Bottom
Cable Entry
DB Panel type – Top / Bottom
Ti range of panels …. Total offering

 Power Control Centre ( PCC )

 Motor control Center ( MCC )


PCC
 Power & Motor Control Center ( PMCC )
Special
purpose MCC  Main Distribution Board ( MDB )
panels
 Sub Main Distribution Board –
Floor mounted ( SMDB )
Floor
Mounted PMCC  Special Purpose Panels
SMDB
 Automatic Power Factor Control
MDB Panels ( APFC )
 IP 65 panels
 Fire panels
 SMART Panel
Ti stands for ….

Value for
Safety
Money

Convenienc
Reliability
e

• •
Ti stands for ….

• • Safety

Value for
Safety
Money

Reliability Convenience

• •
Ti stands for …. Safety
Available above 1250 A rating
Unique busbar arrangement
Conventional Double Deck
Arrangement arrangement

Double Reduction in Increase


deck
Proximity Reduction in Reduction in d safety
effect, Skin Impedance and
stress on
busbar effect and losses and Heat system during
system Electro- improves
losses fault
dynamic forces product
on busbar life

More robust system with saving of energy


Ti stands for …. Safety
Significantly higher clearance
Better clearances
than prescribed by IEC61439-2
(14 mm)

Phase to phase – Min. 25 mm

Phase to phase – Min. 25 mm

Phase to Neutral – Min. 19 mm

Ensures unmatched safety


Ti stands for …. Safety All major insulating material
components are
Best in-class insulation supplied from L&T factory

 Polyester glass supports

 Better insulation property &


mechanical strength

 FR grade material for non metallic


Single Deck HBB barriers
Dropper Support
Support
 Does not spread fire in
case of eventuality

 Higher CTI – 600 V


 Impulse withstand – 12 kV

 Reliable performance even


in adverse condition
Single Deck HBB &
Double Deck HBB
ACB Cable Link
Support
Support

Robust design - Ensures reliable performance for product lifecycle


Ti stands for …. Safety
Tested at NABL accredited lab
Higher withstand capacity

 Design verified for short circuit withstand up to 70 kA for 1s

Highly capable of withstanding electromechanical and thermal


stresses in adverse condition
Ti stands for …. Convenience

• •

Value for
Safety
Money

Reliability Convenience

• • Convenience
Ti stands for …. Convenience
Covers all required configurations
Flexible panel configuration Busbar

 Top and Bottom busbar option BUSBAR CHAMBER


BUSBAR CHAMBER

 Sleeved and non sleeved busbars BUSBAR CHAMBER

ALLEYALLEY

DROPPER
FEEDER
 Shared and non-shared dropper

CABLE ALLEY

CABLE ALLEY
DROPPER
ALLEY

SHARED
CABLECABLE
FEEDER

FEEDER
options

DROPPER
DROPPER
FEEDER
FEEDER
CABLE
Sleeved busbar
Non-sleeved
Shared
BUSBAR busbar
CHAMBER
busbar

Non-shared
Top Busbar
Bottom Busbar
busbar
Facilitates different options to choose as per requirement
Ti stands for …. Convenience
Flexible panel configuration : Single Unit Panel ( SUP )
Covers all required configurations

Busbar Busbar Busbar Busbar


Chamber Chamber Busbar Chamber
Chamber Chamber

Metering Metering Metering Metering Metering

800-1600 800-1600 A 2000-3200 A 2000-3200 A 4P


3200-4000 A 4P ACB
A 3P ACB 4P ACB 3P ACB ACB

Auxiliary Auxiliary Auxiliary Auxiliary Auxiliary

440 600 600 800 1000

Wide range of choice for different configurations


Ti stands for …. Convenience

Flexible panel configuration : Add on chamber (AOC)

SUP
500 ADD
ADD ON
ON
400 ADD ON
300 CHAMBER AOC
CHAMBER
500 ADD
ADD ON
ON
400
300
ADD ON
CHAMBER
CHAMBER  300 mm
CHAMBER CABLE ALLEY
 400 mm
CABLE  500 mm
600
ALLEY
440
FEEDER
FEEDER Can be chosen
depending
on no. of cables,
440 600 no. of CTs required
TOP VIEW

Wide range of choice for different configurations


Ti stands for …. Convenience
Flexible panel configuration-width wise
BUSBAR
BUSBAR CHAMBER
CHAMBER BUSBAR CHAMBER
BUSBAR CHAMBER BUSBAR CHAMBER

CABLE ALLEY
CABLE ALLEY

CABLE ALLEY

CABLE ALLEY
CABLE ALLEY

CABLE ALLEY
CABLE ALLEY
CABLE ALLEY

DROPPER

DROPPER

DROPPER
DROPPER
FEEDER

FEEDER
FEEDER
DROPPER

FEEDER
FEEDER

FEEDER
FEEDER

FEEDER

300 500 500 300 300 500 300 300 300 250 300 250 300
300 300 500 300 250 300 250 300

AAA Panel
Panel
AB Panel BB Panel
B Panel

Wide range of choice for different configurations


Ti stands for …. Convenience
Flexible panel configuration-Height wise

BUSBAR CHAMBER
BUSBAR CHAMBER AB Panel
BUSBAR CHAMBER
BUSBAR CHAMBER  1800 mm
 2000 mm
 2200 mm
ALLEY

ALLEY
ALLEY
ALLEY

DROPPER

ALLEY
2400 mm
ALLEY

FEEDER

FEEDER
DROPPER

ALLEY
ALLEY

FEEDER

FEEDER
DROPPER

FEEDER
FEEDER

DROPPER

2400
FEEDER

FEEDER
CABLE

CABLE
2200
CABLE

CABLE
2000
CABLE

CABLE
1800

CABLE
CABLE

Flexibility for varied site


conditions
300
300 500
500 300 250 300
Wide range of choice for different configurations
Ti stands for …. Reliability

• •

Value for
Safety
money

Reliability Convenience

• Reliability •
Ti stands for …. Reliability
Compliance to latest switchgear and controlgear assembly standard

Design Verified Assembly


Tested at NABL accredited lab

 Compliance to latest IEC 61439- 1 & 2

 Third party NABL certified reputed


testing laboratories(ERDA & CPRI)

Performance characteristics Ti verified


Power frequency withstand voltage 
Impulse withstand voltage 
Temperature rise limits 
Short circuit withstand strength 
Electromagnetic compatibility(EMC) 

Design verified – Performance guaranteed


Ti stands for …. Reliability Design Verified Assembly
Tested at NABL accredited lab
Design verified assembly

 Design verification in compliance to latest IEC 61439

Constructional characteristics Ti verified


Strength of material and parts 
Resistance to corrosion 
Thermal stability of enclosures 
Glow wire test 
Lifting 
Marking 
Degree of protection of enclosures 
Clearance and creepage distances 
Effectiveness of earth fault for external faults 

Design verified – Performance guaranteed


Ti stands for …. Reliability Design Verified Assembly
Tested at NABL accredited lab
Certification

Compliance to latest
IEC standard
Design verified – Performance guaranteed
Ti stands for …. Reliability
Simple , Flexible , Engineered ,
Close profile structure Clean assembly
 Design with close
profile structural
member over the
conventional C, H
and G type

 It will provide
 Useful longer life
 Protection against mechanical
damage

Better mechanical strength – Increases product life


Ti stands for …. Reliability Higher Impact resistance
Higher impact resistant
IK
 It is an international numeric 10
classification for the degrees of
protection provided by enclosures
to electrical equipment against
external mechanical impacts

 Verified for higher impact resistant


(IK 10) as per IEC 62262(2002)-
relates to IK ratings

IK Code IK 00 IK 01 IK 02 IK 03 IK 04 IK 05 IK 06 IK 07 IK 08 IK 09 IK 10
Impact
* 0.14 0.2 0.35 0.5 0.7 1 2 5 10 20
Energy J

Better mechanical strength – Increases product life


Ti stands for …. Reliability Safety and Reliability Assurance
beyond IEC requirement
Certification
Internal Arc Compliance
• 70 kA for 0.5 sec as per IEC TR 61641

• Ti solution reduces the arcing hazards

• More safer & reliable solution even in stringent condition

• Safety to human , equipment & safer installation

Seismic Compliance
• Zone 5 Seismic as per IS 1893
• 2.6 g ICC

• More robust solution even for Earthquake prone zone

Exceeding performance limits – Safer for operating personnel


Ti stands for …. Reliability
Perfectly matched L&T switchgear for you Backup with track record of
smart, safe & sure switchgear

Enhancing reliability with decade proven switchgear


Ti stands for …. Cost effectiveness

• Cost •
Effectiveness

Cost
effectivenes Safety
s

Reliability Convenience

• •
Ti stands for …. Cost effectiveness
Increases feeder density
Compactness spells cost effectiveness : Space saving, compact panels

 Choose from a range of full or


half-width modules. H F
200  
300  
340  
400  
440  
500  
540  
600  
640 
700 

Reduces overall foot print of panel – Saves space , money


Ti stands for …. Cost effectiveness
Increases feeder density
Compactness spells cost effectiveness : Shared droppers

 An innovation of shared dropper


allows you to accommodate
more number of feeder

 Increases feeder density

Double front variant


 Double front construction
improves feeder density
drastically with a minimal
changes in dimensions

Increased feeder density – Saves space , money


Ti range of panels …. A Smart solution

Ti offering : Power Control Centre ( PCC )

PCC PCC
PCC L shape
U shape
Ti range of panels …. A Smart solution

Ti offering : Motor Control Centre ( MCC )


Ti range of panels …. A Smart solution

Ti offering : Main Distribution Boards ( MDB )


Ti range of panels …. A Smart solution

Ti offering : Special solutions


Automatic Power Frequency Control Panels (
APFC ) Operation Voltage 440 V AC
Rated Frequency 50 +/-5% Hz
kVAr rating Up to 250KVAr per
Vertical panel.
Insulation Voltage Up to 3 kV
Over current withstand 1.8 to 3.0 times of rated
current at rated kVAr
Peak inrush current 200 to 500 times of rated
current
Conforming Standards IEC 61921, IEC 61439
and IS 13947
Form of Separation Form3B
Degree of protection IP42
Horizontal Bus bar Aluminium /Copper
Material
Ti range of panels …. A Smart solution
Prestigious customers
Thank you