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IEC 60439 vs IEC 61439

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The new series of IEC 61439 standards were published in January2009.

The new standard follows the philosophy of IEC 60947 series i.e.IEC 61439-1 is General Rules standard to be referred to bysubsidiary product parts

of IEC 61439 series. (Refer Table 1 below)

Introduction

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One of the main features of IEC 61439-1 is that the discriminationbetween Type Tested Assemblies (TTA) and Partially Type TestedAssemblies (PTTA) has been eliminated by the verification approach.

The three different but equivalent types of verification methods are

introducedand these are;

a) Verification by Testing.

b) Verification by Calculation/ Measurement.

c) Verification by Design rules.

The requirements regarding short circuit performance, temperaturerise, dielectric properties and rated diversity factor have beencovered in more detail.

Introduction

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Main Functions

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Main Functions

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Main Functions

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Main Functions

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Verification Requirements

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Examples of the limitations and margins applied to

verification without type test include:All assemblies connected to a supply with a prospective short circuitcurrent in excess of 10kA rms or having a cut-off current of 17kA peak mustbe of a type-tested design or the verification must be an interpolation froma reference design. Under no circumstances can the assigned short circuitcurrent rating be higher than that of the reference design.

So as to take account of the air temperature within the enclosure, thermalinteractions and possible hot spots; components within a circuit that hasnot been temperature rise tested, must be de-rated to 80% of their free aircurrent rating.

Comparison of the power loss of the components within an assembly with

the known heat dissipation capability of an enclosure, is restricted toassemblies having a rating of 630A.

Confirmation of temperature rise performance by calculation is limited toassemblies with a rating not exceeding 1600A. Test or interpolation from atested design must be used to verify higher ratings.


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Verification of temperature rise

For multiple compartment assembly, verification by calculation can bedone up to rated current of 1600 A only.

Assemblies, verified by design rule from a similar tested assembly,should comply with the following:

oFunctional units shall belong to the same group as functional unit

selectedfor test.

oSame type of construction.

oSame or increased overall dimensions.

oSame or reduced internal separation.

oSame or reduced power losses in the same section of assembly.oSame or reduced number of outgoing circuit for every section.

Rated diversity factor (RDF) is elaborated in more details withincoming and outgoing circuit diagrams.

The average ambient temperature for the duration of test shall not

exceed 35 oC.

Salient features of IEC

61439

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Rated divers1ty factor (RDF):The rated diversity factor is the per unit value of the rated current,assigned by the assembly manufacturer, to which outgoing circuits ofan assembly can be continuously and simultaneously loaded takinginto account the mutual thermal influences.

Rated diversity factor can be stated:

for groups of circuits;

for the whole assembly.

The rated diversity factor multiplied by the rated current of the circuits

shall be equal to or higher than the assumed loading of the outgoingcircuits. The assumed loading of outgoing circuits shall be addressedby the relevant assembly standard,

The rated diversity factor is applicable with the ASSEMBLY operating atrated current (lnA)


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Short circuit withstand test

Following requirements are greater than or equal to referencedesign:

oCross-sectional dimensions of the busbars and connections

o Spacing of the busbars and connections

o SCPDs are equivalent, i.e. of the same make with the same or better I2tbased on the device manufacturers data

Following requirements are less than or equal to reference design:

oShort circuit rating of each circuit

o Busbar supports spacing

o Length of unprotected live conductors of each nonprotected circuit

Following requirements are same as that of reference designo Conductor material and its properties

o Enclosure design, type and dimensions

o Compartment mechanical design and dimensions

If all the above requirements are satisfied, then further

verification by calculation or actual testing is not required.


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Power frequency withstand voltage

The values of dielectric test voltage are reduced corresponding torated insulation voltage (Refer Table 3)


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Impulse voltage withstand testo

Verification is mandatory either by test or by design rules.o Test is not required when clearances in the assembly are 1.5 timesthe specified value in Table - 4.


61439

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Degree of protectionoThe IPX1 to IPX6 tests on an assembly are deemed to be failure if water comes into

contact with electrical equipment housed within the enclosure.oRequirements for empty enclosures for assemblies (IEC 62208) have beenincorporated in the standard.

Mechanical operationoRated numbers of operating cycles have been increased from 50 to 200.

Protection provided by barriersoThe protection provided by horizontal top surfaces of easily accessible barriers is changedfrom IPXXB (the protection of person against access to hazardous parts with finger) to IPXXD(the protection of person against access to hazardous parts with wire).

Cross-section area of neutralo100% - for phase cross section area upto 16 mm2

o50 % - for phase cross section area above 16 mm2, with a minimum of 16 mm2o For conductor other than copper, the cross section should be greater than

equivalent copper conductor


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Degree of protectiono

The protection provided by horizontal top surfaces of easilyaccessible barriers is changed from IPXXB (the protection of personagainst access to hazardous parts with finger) to IPXXD (the protectionof person against access to hazardous parts with wire).


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Additional Tests in IEC 61439

Resistance to corrosion TestPurpose:

oTo ensure that deterioration of metallic component caused bycorrosion shall not impair the mechanical strength of switchboard.

Procedure:

oThe test is carried out on a typical switchboard enclosure or on arepresentative sample showing the same constructional details.

6 cycles of 24 hr each to Damp Heat Cycling Test according to IEC60068-2-30 at (403) o C & relative humidity of 95%.


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Verification of Thermal stabilityPurpose:

oTo check the thermal properties of the enclosure

Procedure:

o The specimen is kept in a heating chamber at 70 o C for 7 days. Afterthat the sample is kept

at ambient temperature for 4 days.

Assessment criteria:

o The sample shall show no cracks nor shall the material become sticky or

greasySample is pressed with the forefinger wrapped in a dry cloth with a forceof 5 N; no traces of cloth shall remain on the sample.


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Verification of resistance of insulating materials to heatPurpose:

To ensure the properties of insulating material to normal heat

Procedure:oA ball pressure test apparatus is used to verify the suitability of insulating

materials. The test shall be carried out on an insulating material of minimum 2mm thickness. The test shall be made in a heating cabinet at a temperature asstated below:

oparts supporting live components 125 o C

oother parts 70 o C

oAfter 1 hr, the sample is removed and cooled within 10 s to approx. room

temperatureby immersion in cold water.

Assessment criteria:

The diameter of the impression caused by the ball shall be measured and shallnot exceed 2 mm.


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Additional Tests in IEC 61439Resistance to UV radiation

Purpose:The UV radiation causes deterioration of synthetic material used for enclosures.

Procedure:

UV Test according to ISO 4892 2 method A; 1000 cycles of 5 min of wateringand 25 min. of dry period with xenon lamp providing a total test period of 500 hrs.The value of temperature and humidity for the test are (653) o C and (655) %.

Assessment criteria:Adherence of synthetic material (according to ISO 2409) shall have minimum50% retention. Sample shall not show cracks or deterioration visible to normal or

corrected vision without any additional magnification. This test is not required ifsynthetic material supplier demonstrates that materials of same thickness orthinner comply with this requirement.

NOTE: This test is applicable only for enclosures and external parts ofASSEMBLIES intended to be installed Outdoors.


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Lifting:Purpose:To ensure that there should be no damage to the panel during transportation & installation.

Procedure:oThe test is carried out on a sample having weight 1.25 times its maximum shipping weight.

oFrom a standstill position, the ASSEMBLY shall be raised smoothly without jerking in a vertical plane to

a height of (10.1) m and lowered in the same manner to a standstillposition. This test is repeated a further two times.

oAfter this the ASSEMBLY is raised up and suspended for 30 min at a height of (10.1) m without anymovement.

oFollowing this test the ASSEMBLY shall be raised smoothly without jerking from a standstill position to aheight of (10.1) m and moved (100.5) m horizontally, then lowered to a standstill position.

oThis sequence shall be carried out three times at uniform speed, each sequence being carried outwithin 1 min.

Assessment criteria:During the test, with the test weights in place, the ASSEMBLY shall show no deflections and after thetest show no cracks or permanent distortions visible to normal or corrected vision without

additional magnification, which could impair any of its characteristics.


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Mechanical Impact TestPurpose:This test measures resistance of an enclosure towards external Mechanical Impact. Thedegree of protection provided by an enclosure against impacts is indicated by the lettersIK followed by two digits depending on its ability to withstand the impact (as per IEC62262).

Procedure:oNumber of impacts on each exposed face shall be five unless otherwise specified inrelevant product standard.

oThe impacts shall be evenly distributed on the faces of the enclosure under test.

oAt the surrounding of any point of enclosure, not more than three impacts shall beapplied.

Assessment Criteria:oStructural integrity shall be maintained.

oDegree of protection (IP) shall be unaffected.

oFunctionality of electrical products shall not be hampered.

NOTE: Mechanical Impact test is not applicable to low voltage power switchgear and

controlgear (PSC) assemblies.


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Marking:Purpose:

To ensure that the markings are legible.

Procedure:

Marking made by moulding, pressing, engraving or similarshall not be submitted to the following test.

The test is made by rubbing the marking by hand for 15 swith a piece of cloth soaked in water and then for 15 s

with a piece of cloth soaked with petroleum spirit.Assessment criteria:

After the test the marking shall be legible to normal or

corrected vision without additional magnification.


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Previously a manufacturer had to assign a current rating to each circuit, butthey were never required by the standard to prove its rating. In accordance with

the new standard, the manufacturers have to verify the rating of each type ofcircuit.

Each type of circuit will have its rating verified within the assembly and thecapability of the assembly as a whole will be proven by loading adjacentoutgoing circuits to their rated current, multiplied by the diversity factor.

Historically it has been assumed that if nothing was said, the neutral could

have a current rating equal to 50% of that of its associated phase. However,because this has not been stipulated in any low-voltage standards for manyyears, any query could only be answered by its custom and practice. IEC61439 includes a default current rating in accordance with custom and practicefor circuits with conductors above 16mm, but a specifier can ask for a higherrating to suit the needs of his application.

In addition the ongoing question in respect of forms of separation has beenanswered.

A devices integral enclosure, for example the case of a moulded case circuitbreaker, is

defined as a means of providing separation from an adjacent circuit.

Ambiguities clarified

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Open-type and enclosed assemblies- Enclosed assembly

An assembly is enclosed when there are protected panels on all its sides so as to provide a degree of protectionagainst direct contact not lower than IPXXB . Assemblies intended to be installed in common environments shallbe of enclosed type

- Open-type assembly

An assembly, with or without front covering, in which the live parts of the electrical equipment are accessible.Such assemblies can be used only in places where skilled persons have access for their use.

External design

- Cubicle-type (column)Used for large distribution and control equipment; mechanically joined multi-cubicle-type assemblies areobtained by combining side by side more cubicle-type

assemblies.

- Desk-type

Used to control complex machines or plants in mechanical, iron and steel and chemical industries.

- Box-type

Intended to be mounted on a vertical plane, both jutting out as well as built-in; such assemblies are usedmainly for the department or area distribution in industrial or service sector environments.

- Multi-box-type

A combination of boxes, generally of protected type and with fixing flanges, each housing a functionalunit which may be an automatic circuit-breaker, a starter, a

socket completed with a blocking or protective circuitbreaker.

Classification ofassemblies

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Conditions of installation

- Assembly for indoor installationAssembly which is designed for use in locations where the normalservice Conditions for indoor use as specified in the Std. IEC 61439-1are fulfilled.

- Assembly for indoor installation

Assembly which is designed for use in locations where the normalservice conditions for outdoor use as specified in the Std. IEC 61439-1are fulfilled.

- Stationary assembly

Assembly which is designed to be fixed at its place of installation, for

instance to the floor or to a wall, and to be used at this place.- Movable assembly

Assembly which is designed so that it can readily be moved from oneplace of use to another.

Classification ofassemblies

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With the ever-increasing pressures of demand for highernetwork utilization, assembly design optimization and morestringent safety, the changes included in the assembly standardIEC 61439-2 are important and overdue.

All assemblies that do not have a specific product standard arecovered and there is no opportunity to avoid compliance.

In the new standard, the methods of confirming designperformance are practical and pragmatic, reflecting thedifferent market needs and ways in which assemblies areproduced. Several alternative and equivalent means of verifyinga particular characteristic of an assembly are included. These

are defined and their use restricted. Where alternatives to typetests are used, a compensatory approach is taken and marginsare added to ensure equivalence. Overall, the standard isperformance based.

Conclusion

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IEC 61439-1 - Low-voltage switchgear and controlgear assemblies

Part 1: General Rules

IEC 61439-2 - Low-voltage switchgear and controlgear assemblies

Part 2: Power switchgear and controlgear assemblies

Introduction to IEC 61439: A new standard on Switchgear &Controlgear Assemblies by Mr. A P Rao; Mr. D A Chavan; Mr. P Patel;

Mr. T N ShahSwitchgear Design & Development Center

Improving safety and performance in electrical assemblies - A guideto IEC 61439-2 by Schneider Electric

IEC 61439 The new Standard for Low-Voltage Switchgear Assemblies

Changes and Effects in respect of Tests by GE Ronald Borchert, IPHBerlin

The new IEC 61439 Series Technical Seminar, 10th November, 2010 Singapore, KEMA Quality

Bibliography

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THANK YOU

IEC 61439- 19_5_12.pptx

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