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 IEC 60439-1 IEC 61439-2 ANSI / UL 845 / 1558 / 891

Switchgear & NEMA PB2
Control gear
Assemblies
Distribution IEC 60439-3 IEC 61439-3 ANSI / UL 67
Boards NEMA PB1

Assemblies for IEC 60439-4 IEC 61439-4 No equivalent

Construction
Sites
Assemblies for IEC 60439-5 IEC 61439-5 No equivalent
power
distribution in
public networks
Bus bar Trunking IEC 60439-2 IEC 61439-6 ANSI/UL 857
Systems

Requirements IEC /TR 61439-0 No equivalent

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
OEM manufacturer
(panel builder/assembler)

Are all OEM

Type Test requirements and
Report (for instructions met by
Original System) the Assembly
YES
Manufacturer?

(no new NO
Type tests)

New Type
Test Report
Contractor / User / Specifier
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 RDF = ?
- The whole assembly
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

Clauses or Comparison
No. Characteristics to be Verified with
Subclauses Testing Assessment
Reference
Design
1 Strength of material and parts

Resistance to corrosion 10.2.2 YES NO NO

Properties of insulating materials

Thermal stability 10.2.3.1 YES NO NO

Resistance to abnormal heat and fire due 10.2.3.2 YES NO YES

to internal electric effects

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

33
ANNEX D (continued)
Verification options Available

Clauses or Comparison
No. Characteristics to be Verified with
Subclauses Testing Assessment
Reference
Design
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 10.5
of protective circuits

Effective continuity between the exposed

conductive parts of the ASSEMBLY and the 10.5.2 YES NO NO
protective circuit

Short-circuit withstand strength of the the 10.5.3 YES YES NO

protective circuit

6 Incorporation of switching devices and 10.6 NO NO YES

components
7 Internal electrical circuits and connections 10.7 NO NO YES

34
Annex D (continued)

Verification options Available

Clauses or Comparison
No. Characteristics to be Verified
Subclauses with
Testing Assessment
Reference
Design

8 Terminals for external conductors 10.8 NO NO YES

9 Dielectric properties 10.9

Power-Frequency withstand 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

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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

Clauses or Comparison
No. Characteristics to be Verified with
Subclauses Testing Assessment
Reference
Design
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 10.5
protective circuits

Effective continuity between the exposed

conductive parts of the ASSEMBLY and the 10.5.2 YES NO NO
protective circuit

Short-circuit withstand strength of the the 10.5.3 YES YES NO

protective circuit

6 Incorporation of switching devices and 10.6 NO NO YES

components
7 Intenral electrical circuits and connections 10.7 NO NO YES

37
Annex D (continued)

Verification options Available

Clauses or Comparison
No. Characteristics to be Verified
Subclauses with
Testing Assessment
Reference
Design

8 Terminals for external conductors 10.8 NO NO YES

9 Dielectric properties 10.9

Power-Frequency withstand 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 Training &
Test) 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

© 2012 Underwriters Laboratories LLC

Underwriters Laboratories
 Founded in 1894
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Number of countries
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73 Number of UL Marks
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23 billion
© 2011 Underwriters Laboratories Inc.
The journey started in 1894
following the appointment of
UL founder Mr. William Henry
Merrill to review the
questionable wiring methods
used in close proximity to
some of the highly flammable
materials in a Chicago
Exposition. The investigation
revealed many things about
safety requirements paving the
way for the birth of
“Underwriters Laboratories”

48
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49
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55
Thank You

Slide 56