IEC 61439 An introduction 28 March 2012 By Craig McKee Technical Manager
We recommend that you purchase your relevant national standard, or the International Standard which is available directly from the IEC. This training expresses the interpretation and opinions of 3 Phase Design
IEC 61439:- The Series Part 1: General Rules Part 2: PSC Assemblies Part 3: Distribution boards Part 4: Assemblies for Construction Sites (not launched) Part 5: Assemblies for power distribution Part 6: Busbar trunking systems (pre release available) Part 7: Assemblies for use in marinas and similar locations, camping sites and similar locations, market squares and other similar external public sites (not launched)
IEC 61439:- The Series Part 1: General Rules Part 2: PSC Assemblies Part 3: Distribution boards Part 4: Assemblies for Construction Sites Part 5: Assemblies for power distribution Part 6: Busbar trunking systems Part 7: Assemblies for use in marinas and similar locations, camping sites and similar locations, market squares and other similar external public sites
61439-Part 1 Edition 2-2011 General Rules Cross referenced by all other parts of the series. Does not need to be specified, compliance to one of the other parts of the standard automatically determines its compliance.
61439-Part 2 Edition 2-2011 Power Switchgear and Controlgear Assemblies. low voltage switchgear and controlgear assembly used to distribute and control energy for all types of loads, intended for industrial, commercial and similar applications operated by skilled or instructed persons
What is an assembly? Enclosure Earth Bar (protective conductor) Incoming Device Air Circuit Breaker (ACB) Moulded Case Circuit Breaker (MCCB) Isolator Busbars Main Distribution Outgoing Devices Circuit Breakers (MCB, MCCB) Fused Isolators Additional power circuits Auxiliary circuits (controls)
Complying with the standard Design Verification Routine Verification Performed on representative samples and designs Performed on every supplied assembly by checking against Design Verification
Who is responsible for verification? The Standard recognises that there maybe more than one company responsible for the verification of the final assembly. Original Manufacturer Assembly Manufacturer
Who is responsible for verification? Assembly Manufacturer Manufacture to Design Routine Verification Original Manufacturer Design Production Design Verification (By Test) Original & Assembly Manufacturer Manufacture to Design Design Verification Routine Verification
Achieving design verification Verification by test Verification by Comparison with a reference design Verification by Assessment Not all characteristics can be verified by each of the above in all circumstances. Table D. 1. For example, Lifting can only be verified by test
Design verification characteristics Construction Strength of materials and parts Degree of protection of enclosures Clearances and creepage distances Protection against electric shock and integrity of protective circuits Incorporation of switching devices and components Internal electrical circuits and connections Terminals for external conductors Performance Dielectric properties Temperature rise limits Short circuit withstand strength Electromagnetic compatibility Mechanical operation
Design verification characteristics Construction Strength of materials and parts Degree of protection of enclosures Clearances and creepage distances Protection against electric shock and integrity of protective circuits Incorporation of switching devices and components Internal electrical circuits and connections Terminals for external conductors Performance Dielectric properties Temperature rise limits Short circuit withstand strength Electromagnetic compatibility Mechanical operation
Strength of Materials & Parts Construction Strength of materials and parts Protection against corrosion Properties of insulating materials Normal heat Abnormal heat Resistance to UV radiation Lifting Mechanical strength Marking
Design verification characteristics Construction Strength of materials and parts Degree of protection of enclosures Clearances and creepage distances Protection against electric shock and integrity of protective circuits Incorporation of switching devices and components Internal electrical circuits and connections Terminals for external conductors Performance Dielectric properties Temperature rise limits Short circuit withstand strength Electromagnetic compatibility Mechanical operation
Design verification characteristics Construction Degree of protection of enclosures
Internal separation of assemblies IEC 61439 clarifies that there is a difference between Constructional Requirements and internal separation. Form of separation does not specify the construction If each functional unit is to be contained in its own compartment That is what should be stated.
Design verification characteristics Construction Strength of materials and parts Degree of protection of enclosures Clearances and creepage distances Protection against electric shock and integrity of protective circuits Incorporation of switching devices and components Internal electrical circuits and connections Terminals for external conductors Performance Dielectric properties Temperature rise limits Short circuit withstand strength Electromagnetic compatibility Mechanical operation
Design verification characteristics Construction Strength of materials and parts Degree of protection of enclosures Clearances and creepage distances Protection against electric shock and integrity of protective circuits Incorporation of switching devices and components Internal electrical circuits and connections Terminals for external conductors Performance Dielectric properties Temperature rise limits Short circuit withstand strength Electromagnetic compatibility Mechanical operation
Design verification characteristics Construction Strength of materials and parts Degree of protection of enclosures Clearances and creepage distances Protection against electric shock and integrity of protective circuits Incorporation of switching devices and components Internal electrical circuits and connections Terminals for external conductors Performance Dielectric properties Temperature rise limits Short circuit withstand strength Electromagnetic compatibility Mechanical operation
Design verification characteristics Construction Strength of materials and parts Degree of protection of enclosures Clearances and creepage distances Protection against electric shock and integrity of protective circuits Incorporation of switching devices and components Internal electrical circuits and connections Terminals for external conductors Performance Dielectric properties Temperature rise limits Short circuit withstand strength Electromagnetic compatibility Mechanical operation
Design verification characteristics Construction Strength of materials and parts Degree of protection of enclosures Clearances and creepage distances Protection against electric shock and integrity of protective circuits Incorporation of switching devices and components Internal electrical circuits and connections Terminals for external conductors Performance Dielectric properties Temperature rise limits Short circuit withstand strength Electromagnetic compatibility Mechanical operation
Design verification characteristics Construction Strength of materials and parts Degree of protection of enclosures Clearances and creepage distances Protection against electric shock and integrity of protective circuits Incorporation of switching devices and components Internal electrical circuits and connections Terminals for external conductors Performance Dielectric properties Temperature rise limits Short circuit withstand strength Electromagnetic compatibility Mechanical operation
Design verification characteristics Construction Strength of materials and parts Degree of protection of enclosures Clearances and creepage distances Protection against electric shock and integrity of protective circuits Incorporation of switching devices and components Internal electrical circuits and connections Terminals for external conductors Performance Dielectric properties Temperature rise limits Short circuit withstand strength Electromagnetic compatibility Mechanical operation
Temperature rise limits Assemblies are now rated for there operational current and each circuits is also assigned a rating. Rated current Of a circuit (I nc ) Of the Assembly (I na )
Temperature Rise I na There are 3 options to achieving the assembly rating by test: Verification by test option a: (10.10.2.3.5) Verification by test option b: (10.10.2.3.6) Verification by test option c: (10.10.2.3.7)
Device to IEC 60947 Temperature Rise I nc
Temperature Rise I nc Device to IEC 60947 Mounted in enclosure
Temperature Rise I nc Device to IEC 60947 Mounted in enclosure Circuit reaches limits at <100%
Temperature Rise I nc Device to IEC 60947 Mounted in enclosure Circuit reaches limits at <100% XX Amps Disclosed rating I nc = XX Amps This rating is the MAXIMUM allowable current for that circuit design
Rated Diversity Factor The RDF may only be applied to outgoing circuits, there can be more than one RDF applied within a single assembly. The RDF is applied to the I nc rating The RDF shall not be applied to incoming circuits or the busbars
Temperature Rise Test Connections Image taken at
Temperature rise limits As well as verification by test there are other methods of verification: Derivation of ratings for similar values This can only be performed from a tested design Assessment based on design rules. This can only be done on single compartment assemblies below 630Amps Assessment based on design rules and IEC 60890 On a single or multiple compartment assembly below 1600A
Design verification characteristics Construction Strength of materials and parts Degree of protection of enclosures Clearances and creepage distances Protection against electric shock and integrity of protective circuits Incorporation of switching devices and components Internal electrical circuits and connections Terminals for external conductors Performance Dielectric properties Temperature rise limits Short circuit withstand strength Electromagnetic compatibility Mechanical operation
Short circuit withstand strength Short circuit tests (Icw) Withstand test on main incoming device & busbar system (Icc) Short circuit test on both incoming and outgoing devices (Icc) Phase to Earth short circuit on outgoing devices
Short Circuit Test Connections
Design verification characteristics Construction Strength of materials and parts Degree of protection of enclosures Clearances and creepage distances Protection against electric shock and integrity of protective circuits Incorporation of switching devices and components Internal electrical circuits and connections Terminals for external conductors Performance Dielectric properties Temperature rise limits Short circuit withstand strength Electromagnetic compatibility Mechanical operation
Design verification characteristics Construction Strength of materials and parts Degree of protection of enclosures Clearances and creepage distances Protection against electric shock and integrity of protective circuits Incorporation of switching devices and components Internal electrical circuits and connections Terminals for external conductors Performance Dielectric properties Temperature rise limits Short circuit withstand strength Electromagnetic compatibility Mechanical operation
Design verification characteristics On successful completion of the above design verifications the original manufacturer will be issued with a certificate. But that is not the end of the story
Routine verification requirements...every assembly is required to pass through a routine verification process. This process ensures that all production assemblies are still in compliance to the design verified assembly that was certified, with any modifications being accounted for.
Routine verification characteristics Construction Degree of protection of enclosures Clearances and creepage distances Protection against electric shock and integrity of protective circuits Incorporation of switching devices and components Internal electrical circuits and connections Terminals for external conductors Mechanical Operation Performance Dielectric properties Wiring, operational performance and function
Routine verification characteristics Why does a manufacturer need to carry out routine verification? Ensure the equipment remains compliant with IEC 61439 Reduces the risk of failure on production assemblies Puts the onus onto the manufacturer for continued quality As a customer what should I ask for? An inspection of the complete design verification document A list of any deviations from the verified assembly A copy of the routine verification checklist with your delivery
Complying with the standard Design Verification Routine Verification Performed on representative samples and designs Performed on every supplied assembly by checking against Design Verification
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