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
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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
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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 Certificate of Verification by Testing (Full Type Test)
Training & Design Verification
Short Circuit Test / Temperature Rise Tests Verification Report (partial)
UL Classification Mark
IEC CB Scheme Certificate
UL Classification Mark (to IEC 61439 or 62271) 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 to IEC 61439 or IEC 62271 UL Classification mark
IEC CB Scheme Certificate to IEC 61439
What is UL Listing? 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
UNDERWRITERS LABORATORIES A brief history and overview of services
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Slide 56
