IEC 61439 Design, Type Testing & Certification ...

1 2012 Underwriters Laboratories LLCIEC 61439 Design, Type Testing & Certification requirements forLV switchgear & controlgear assembliesPaul D BarnhartShelesh Tiwari`IntroductionPaul Barnhartis 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 manufacturingIntroductionShelesh Tiwari is a Senior Project Engineer in UL India.

2 His primaryfocus includes low voltage switchgear and controlgearasemblies, components and related equipment , including busbartrunkingsystemsBackground: Masters in Electronics JamiaMilliaIslamiaUniversity, Delhi, India 10 years experience in Low Voltage switchgear and controlgear product Certification and Testing 3years experience in Low Voltage switchgear and industrial controls Introduction Purpose of Standards / IEC objectives IEC 60439 Series versus IEC 61439 Series Design Verification Process Example -Busbartrunkingsystems per IEC 61439 -6 Services UL provides for IEC 61439 Brief history and overview of ULand our serviceWhat is the purpose of standards?

3 To set safety and performance levels of the products covered by the standard To manage customer and user expectations associated with those productsMain 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 SeriesIEC 60439 versus IEC 61439 Series New structure New terms (OEM and Assembly manufacturer) New ways to show compliance More flexibilityIEC 60439 versus IEC 61439 Series-StructureDescriptionOld IEC StandardNew IEC StandardNorth American Standard (for reference)

4 General RulesIEC 60439-1 IEC 61439 -1No equivalentPower Switchgear & Control gear AssembliesIEC 60439-1 IEC 61439 -2 ANSI / UL 845 / 1558 / 891 NEMA PB2 Distribution BoardsIEC 60439-3 IEC 61439 -3 ANSI / UL 67 NEMA PB1 Assemblies for Construction SitesIEC 60439-4 IEC 61439 -4No equivalentAssemblies for power distribution in public networksIEC 60439-5 IEC 61439 -5No equivalentBus bar Trunking SystemsIEC 60439-2 IEC 61439 -6 ANSI/UL 857 Requirements Manual -Specifier sGuideIEC /TR 61439 -0No equivalentIEC 60439 versus IEC 61439 Series-TermsIEC 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 arrangementsIEC 61439 has modified this approach, by replacing it with three different (but equivalent) methods to verify compliance.

5 Verification by Testing verification by calculation/measurement verification by satisfying design rulesIEC 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 rulesincluding appropriate safety marginsIEC 60439 versus IEC 61439 SeriesManufacturersThe 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 -ManufacturersAssembly manufacturer(panel builder/assembler)OEM manufacturerContractor / User / SpecifierNew Type Test ReportType Test Report (for Original System)(no new Type tests)

6 Are all OEM requirements and instructions met by the Assembly Manufacturer?NOYESIEC 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 ( -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.

7 Clause 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 about designs previously certified to IEC 60439 do they need to be retested?

8 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 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 Verification Process An overviewusing IEC 61439 -6 as an exampleClause 1: ScopeClause 2-7: General Requirements Terms, ratings, service conditionsClause 8: Constructional requirementsClause 9: Performance requirementsClause 10.

9 Design Verification Construction PerformanceClause 11: Routine Verification Factory test and verificationRequired equipment RatingsVoltages 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 fnRequired equipment RatingsCurrents 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)

10 Icw Rated conditional short-circuit current of an assembly IccRequired equipment RatingsAdjustments to current ratings may be needed: Ambient Temperature Mounting orientation -Unless specified, current ratings are basedon 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 equipment RatingsDiversity FactorThe 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 influencesMay be stated for.