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Publication PTSK EN, March 1999

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Copyright 1998 Rockwell International Corporation. All rights reserved. Printed in Switzerland

The easy way to build

switchgear and controlgear
assemblies in compliance with the regulations
A guide for partially type-tested switchgear and
controlgear assemblies in compliance with EN 60 439

What are the requirements?

Technical documentation
must be available for review
from the manufacturer.

EN 60 439 is recognised as the

established engineering practice for
switchgear and controlgear assemblies

My name is Rocky, and Im

looking forward to showing
you the way through these
guidelines.

Contents

Page

EN 60 439 is recognised as the

established engineering practice for
switchgear and controlgear assemblies

What are the bases of

the agencies requirements?

Which control systems and

installations are subject to EN 60 439?

What is considered as a low-voltage

switchgear and controlgear assembly (ASSEMBLY) under EN 60 439?

What is the difference between

a TTA and a PTTA?

What does EN 60 439 define?

Directives for the utilisation of other

components as those applied for the
type-test of a TTA permit a range of freedom

10

Type-tested components simplify work

10

The added value performed by the ASSEMBLY

maufacturer requires safety verification

11

Calculation software simplifies verification

of the temperature rise

12

Special care with short-circuit

currents above 10 kA

12

Which tests must be performed on PTTA?

13

How can the expense for the technical

verification of PTTA be minimised?

13

Important notes regarding national

differences

13

Compilation of verifications and tests

of TTA and PTTA

14

A Manufacturers
Declaration, a Type-testing
Report and Routine Test
Protocol are required as a
safety verification.
2

The legal requirements in the countries of the

European Union (EU) and of the European
Economic Area (EEA) require manufacturers and
operators to ensure compliance with the established
engineering practice in the construction and operation of electrical installations in order to ensure their
safe operation. Existing standards are considered as
established engineering practice and as the state of
the art of technology. Compliance with these
requirements is assumed when the applicable standards have been observed.
For low-voltage switchgear and controlgear assemblies (ASSEMBLIES) the standard EN 60 439
applies in the CENELEC area as the established
engineering practice. Installations which are built
and tested in compliance therewith are considered to
be in compliance with the regulations. EN 60 439
replaces earlier standards and reflects the technical
progress which is expressed in higher rated currents,
higher packing density, higher short-circuit withstand strength and an increased utilisation of electronic apparatus, among others.
Low-voltage switchgear and controlgear assemblies
are considered to be electrical equipment in the
sense of the Low-voltage Directive and as apparatus in the sense of the EMC Directive of the EU.
In accordance with this, a Declaration of Conformity
is to be issued for them and they are to be identified
with the CE-mark.
The Declaration of Conformity must confirm that
the ASSEMBLY complies with EN 60 439 or
exhibits an equal safety standard.
The prerequisite for the Declaration of Conformity
and the CE-marking is testing in accordance with
EN 60 439 and the preparation of compliant technical documentation. In accordance with the standard,
a type-test and a routine test are to be performed
and verified.

The type-test report can refer either to a

TTA (type-tested switchgear and controlgear
assembly) which implies a complete type-test
according to EN 60 439 or to a
PTTA (partially type-tested switchgear and controlgear assembly) containing both type-tested
and non-type-tested arrangements provided that
the latter are derived (e.g. by calculation) from
type-tested arrangements which have complied
with the relevant tests.
All technical documentation must be available from
the manufacturer of the switchgear and controlgear
assembly and it must be presented to the inspecting
agencies for review on demand. It is beneficial that
the routine test record be treated as a part of the
scope of supply. The installation engineer must treat
a switchgear and controlgear assembly as a product.
He is responsible for the supply connections and
their protection. The ratings of the ASSEMBLY
must be provided on the nameplate or in the technical documentation of the manufacturer.
For equipment and installations such as switchgear
and controlgear assemblies which are subject to the
Low-voltage Directive, it must be observed that the
technical documentation has to be maintained within the Community for 10 years following the (last)
manufacturing of the relevant product and that it is
available to the national Agencies for review.
In accordance with the rules of the national and local
market-supervision agencies, the point in time and
the cause for presentation of the verification documents may vary.

What are the requirements?

Technical documentation
must be available for review
from the manufacturer.

EN 60 439 is recognised as the

established engineering practice for
switchgear and controlgear assemblies

My name is Rocky, and Im

looking forward to showing
you the way through these
guidelines.

Contents

Page

EN 60 439 is recognised as the

established engineering practice for
switchgear and controlgear assemblies

What are the bases of

the agencies requirements?

Which control systems and

installations are subject to EN 60 439?

What is considered as a low-voltage

switchgear and controlgear assembly (ASSEMBLY) under EN 60 439?

What is the difference between

a TTA and a PTTA?

What does EN 60 439 define?

Directives for the utilisation of other

components as those applied for the
type-test of a TTA permit a range of freedom

10

Type-tested components simplify work

10

The added value performed by the ASSEMBLY

maufacturer requires safety verification

11

Calculation software simplifies verification

of the temperature rise

12

Special care with short-circuit

currents above 10 kA

12

Which tests must be performed on PTTA?

13

How can the expense for the technical

verification of PTTA be minimised?

13

Important notes regarding national

differences

13

Compilation of verifications and tests

of TTA and PTTA

14

A Manufacturers
Declaration, a Type-testing
Report and Routine Test
Protocol are required as a
safety verification.
2

The legal requirements in the countries of the

European Union (EU) and of the European
Economic Area (EEA) require manufacturers and
operators to ensure compliance with the established
engineering practice in the construction and operation of electrical installations in order to ensure their
safe operation. Existing standards are considered as
established engineering practice and as the state of
the art of technology. Compliance with these
requirements is assumed when the applicable standards have been observed.
For low-voltage switchgear and controlgear assemblies (ASSEMBLIES) the standard EN 60 439
applies in the CENELEC area as the established
engineering practice. Installations which are built
and tested in compliance therewith are considered to
be in compliance with the regulations. EN 60 439
replaces earlier standards and reflects the technical
progress which is expressed in higher rated currents,
higher packing density, higher short-circuit withstand strength and an increased utilisation of electronic apparatus, among others.
Low-voltage switchgear and controlgear assemblies
are considered to be electrical equipment in the
sense of the Low-voltage Directive and as apparatus in the sense of the EMC Directive of the EU.
In accordance with this, a Declaration of Conformity
is to be issued for them and they are to be identified
with the CE-mark.
The Declaration of Conformity must confirm that
the ASSEMBLY complies with EN 60 439 or
exhibits an equal safety standard.
The prerequisite for the Declaration of Conformity
and the CE-marking is testing in accordance with
EN 60 439 and the preparation of compliant technical documentation. In accordance with the standard,
a type-test and a routine test are to be performed
and verified.

The type-test report can refer either to a

TTA (type-tested switchgear and controlgear
assembly) which implies a complete type-test
according to EN 60 439 or to a
PTTA (partially type-tested switchgear and controlgear assembly) containing both type-tested
and non-type-tested arrangements provided that
the latter are derived (e.g. by calculation) from
type-tested arrangements which have complied
with the relevant tests.
All technical documentation must be available from
the manufacturer of the switchgear and controlgear
assembly and it must be presented to the inspecting
agencies for review on demand. It is beneficial that
the routine test record be treated as a part of the
scope of supply. The installation engineer must treat
a switchgear and controlgear assembly as a product.
He is responsible for the supply connections and
their protection. The ratings of the ASSEMBLY
must be provided on the nameplate or in the technical documentation of the manufacturer.
For equipment and installations such as switchgear
and controlgear assemblies which are subject to the
Low-voltage Directive, it must be observed that the
technical documentation has to be maintained within the Community for 10 years following the (last)
manufacturing of the relevant product and that it is
available to the national Agencies for review.
In accordance with the rules of the national and local
market-supervision agencies, the point in time and
the cause for presentation of the verification documents may vary.

What are the bases of the agencies

requirements?
The requirements are based upon the Low-voltage
Directive 73/23/EEC and the EMC Directive
89/336/EEC of the EU, as well as on their supplementation by Directive 93/68/EEC, which concerns
the CE-marking.
In its fundamental requirements, the Low-voltage
Directive postulates the protection of persons, animals and property from the hazards and damage
which may result from electrical apparatus.

The central focus is on the protection of persons, animals and

property as well as operation in
the intended manner without
malfunctions.

The EMC Directive states in Article 4:

The apparatus referred to in Article 2 shall be
so constructed that:
a) the electromagnetic disturbance it generates
does not exceed a level allowing radio and
telecommunication equipment and other
apparatus to operate as intended;
b) the apparatus has an adequate level of
intrinsic immunity of electromagnetic disturbance to enable it to operate as intended.
......

The EU Directives for low-voltage devices

(73/23/EEC) and for Electromagnetic Compatibility
(89/336/EEC) are valid in all countries of the
European Union (EU) and of the European Economic
Area (EEA) and in Switzerland (Ordinance on electrical low-voltage equipment and Ordinance on
electromagnetic compatibility). Similar rules
which are based to a great extent on the directives
of the EU are valid or will soon be introduced in
other countries, such as the Commonwealth of
Independent States (CIS) or Australia.

Which control systems and

installations are subject to EN 60 439?
The standard cites (Subparagraph 1.1)
- stationary or movable assemblies,
- with or without enclosure,
- for use in connection with generation, transmission, distribution and conversion of electric
energy and for the control of electrical energy
consuming equipment.
EN 60 439 does not apply to individual devices for
which valid standards exist (motor starters in compliance with IEC 947, for instance).
It follows from this that all electrical controls, distribution boards and switchgear and controlgear
assemblies fall under EN 60 439.
It may not be concluded that EN 60 439 is the sole
standard to be applied. In the case of machine controls, for instance, additional requirements in compliance with EN 60 204 (Electrical Equipment of
Machines) must be fulfilled.

What are the bases of the agencies

requirements?
The requirements are based upon the Low-voltage
Directive 73/23/EEC and the EMC Directive
89/336/EEC of the EU, as well as on their supplementation by Directive 93/68/EEC, which concerns
the CE-marking.
In its fundamental requirements, the Low-voltage
Directive postulates the protection of persons, animals and property from the hazards and damage
which may result from electrical apparatus.

The central focus is on the protection of persons, animals and

property as well as operation in
the intended manner without
malfunctions.

The EMC Directive states in Article 4:

The apparatus referred to in Article 2 shall be
so constructed that:
a) the electromagnetic disturbance it generates
does not exceed a level allowing radio and
telecommunication equipment and other
apparatus to operate as intended;
b) the apparatus has an adequate level of
intrinsic immunity of electromagnetic disturbance to enable it to operate as intended.
......

The EU Directives for low-voltage devices

(73/23/EEC) and for Electromagnetic Compatibility
(89/336/EEC) are valid in all countries of the
European Union (EU) and of the European Economic
Area (EEA) and in Switzerland (Ordinance on electrical low-voltage equipment and Ordinance on
electromagnetic compatibility). Similar rules
which are based to a great extent on the directives
of the EU are valid or will soon be introduced in
other countries, such as the Commonwealth of
Independent States (CIS) or Australia.

Which control systems and

installations are subject to EN 60 439?
The standard cites (Subparagraph 1.1)
- stationary or movable assemblies,
- with or without enclosure,
- for use in connection with generation, transmission, distribution and conversion of electric
energy and for the control of electrical energy
consuming equipment.
EN 60 439 does not apply to individual devices for
which valid standards exist (motor starters in compliance with IEC 947, for instance).
It follows from this that all electrical controls, distribution boards and switchgear and controlgear
assemblies fall under EN 60 439.
It may not be concluded that EN 60 439 is the sole
standard to be applied. In the case of machine controls, for instance, additional requirements in compliance with EN 60 204 (Electrical Equipment of
Machines) must be fulfilled.

TTA are tested as a type and

are frequently optimised for
specific applications.

What is considered as a low-voltage

switchgear and controlgear assembly
(ASSEMBLY) under EN 60 439?
In accordance with EN 60 439-1, Subparagraph
2.1.1., a low-voltage switchgear and controlgear
assembly is
A combination of one or more low-voltage
switching devices together with associated control, measuring, signalling, protective, regulating
equipment, etc., completely assembled under the
responsibility of the manufacturer with all the
internal electrical and mechanical interconnections and structural parts ().
Note 3 states:
For various reasons, for example transport or
production, certain steps of assembly may be
made in a place outside the factory of the manufacturer.
Thus, an ASSEMBLY is spoken of whenever low-voltage switching devices and protective and regulating
equipment are involved. EN 60 439 applies for
ASSEMBLIES up to 1,000 volts a.c. and 1,500
volts d.c.

PTTA consist of type-tested

components, or such which are
derived from them.

What is the difference between a TTA

and a PTTA?
Type-tested low-voltage switchgear and
controlgear assembly (TTA)
EN 60 439-1 Subparagraph 2.1.1.1:
A low-voltage switchgear and controlgear
assembly conforming to an established type or
system without deviations likely to significantly
influence the performance, from the typical
ASSEMBLY verified to be in accordance with
this standard.
A TTA is thus an ASSEMBLY which has been tested as a type (manner of construction) in compliance
with EN 60 439. Examples are LV distribution
boards and Motor Control Centers (MCC). A worstcase configuration is tested (e.g. regarding temperature rise). TTA are designed for series production,
whereby the individual TTA corresponds to the
established type, but adapted to the specific application (e.g. number and performance of the outgoing
circuits). TTA typically possess structural parts specific to the manufacturer such as plug-in modules,
busbar systems, locking devices, etc., which are not
available as universally-applicable components.
TTA are typically applied with installations
designed for control and distribution and with
installations with high short-circuit current level.

Partially type-tested low-voltage switchgear

and controlgear assembly (PTTA)

EN 60 439-1 Subparagraph 2.1.1.2:

A low-voltage switchgear and controlgear
assembly, containing both type-tested and
non-type-tested arrangements provided that
the latter are derived (e.g. by calculation)
from type-tested arrangements which have
complied with the relevant tests ().

PTTA are thus controls and installations which are

not tested in their entirety as a type. They are compiled from components which are either type-tested
(e.g. contactors, circuit breakers, load break switches, fuses etc.), or which are derived from type-tested
arrangements (e.g. busbar system). The temperature
rise, for example, can be derived (i.e. not measured), either
- in accordance with HD 528 S2 (IEC 890;
A method of temperature-rise assessment by
extrapolation for partially type-tested assemblies (PTTA) of low-voltage switchgear and
controlgear) or
- with the aid of temperature-rise calculation
software programs from enclosure manufacturers (which are based in turn on type-tests)
or
- based on similarity with previously manufactured (and measured) ASSEMBLIES.
The essential difference between TTA and PTTA
exists in the fact that TTA are optimised for specific
(repetitious) applications and that, thanks to the
measurement, it is possible to utilize the components to the limit of their load capacity. TTA are
procured as complete installations from one manufacturer or built under his licence.
In contrast to this, the PTTA construction method is
typically selected by builders of switchgear and
controlgear assemblies who opt for components
from different manufacturers instead of the costly
type-test and the commitment to one manufacturer.
They derive the correct selection of the components
for their specific application from the type-tests of
the manufacturers and install them in accordance
with the established engineering practice. This
applies for single assemblies and also for series production. PTTA generally possess more reserve (e.g.
with regard to temperature rise and the selection of
the conductor cross sections), since the derivation is
based on general rules (e.g. regarding the selection
of conductors).
TTA and PTTA are equal in regard to the fulfilment of
safety requirements.
7

TTA are tested as a type and

are frequently optimised for
specific applications.

What is considered as a low-voltage

switchgear and controlgear assembly
(ASSEMBLY) under EN 60 439?
In accordance with EN 60 439-1, Subparagraph
2.1.1., a low-voltage switchgear and controlgear
assembly is
A combination of one or more low-voltage
switching devices together with associated control, measuring, signalling, protective, regulating
equipment, etc., completely assembled under the
responsibility of the manufacturer with all the
internal electrical and mechanical interconnections and structural parts ().
Note 3 states:
For various reasons, for example transport or
production, certain steps of assembly may be
made in a place outside the factory of the manufacturer.
Thus, an ASSEMBLY is spoken of whenever low-voltage switching devices and protective and regulating
equipment are involved. EN 60 439 applies for
ASSEMBLIES up to 1,000 volts a.c. and 1,500
volts d.c.

PTTA consist of type-tested

components, or such which are
derived from them.

What is the difference between a TTA

and a PTTA?
Type-tested low-voltage switchgear and
controlgear assembly (TTA)
EN 60 439-1 Subparagraph 2.1.1.1:
A low-voltage switchgear and controlgear
assembly conforming to an established type or
system without deviations likely to significantly
influence the performance, from the typical
ASSEMBLY verified to be in accordance with
this standard.
A TTA is thus an ASSEMBLY which has been tested as a type (manner of construction) in compliance
with EN 60 439. Examples are LV distribution
boards and Motor Control Centers (MCC). A worstcase configuration is tested (e.g. regarding temperature rise). TTA are designed for series production,
whereby the individual TTA corresponds to the
established type, but adapted to the specific application (e.g. number and performance of the outgoing
circuits). TTA typically possess structural parts specific to the manufacturer such as plug-in modules,
busbar systems, locking devices, etc., which are not
available as universally-applicable components.
TTA are typically applied with installations
designed for control and distribution and with
installations with high short-circuit current level.

Partially type-tested low-voltage switchgear

and controlgear assembly (PTTA)

EN 60 439-1 Subparagraph 2.1.1.2:

A low-voltage switchgear and controlgear
assembly, containing both type-tested and
non-type-tested arrangements provided that
the latter are derived (e.g. by calculation)
from type-tested arrangements which have
complied with the relevant tests ().

PTTA are thus controls and installations which are

not tested in their entirety as a type. They are compiled from components which are either type-tested
(e.g. contactors, circuit breakers, load break switches, fuses etc.), or which are derived from type-tested
arrangements (e.g. busbar system). The temperature
rise, for example, can be derived (i.e. not measured), either
- in accordance with HD 528 S2 (IEC 890;
A method of temperature-rise assessment by
extrapolation for partially type-tested assemblies (PTTA) of low-voltage switchgear and
controlgear) or
- with the aid of temperature-rise calculation
software programs from enclosure manufacturers (which are based in turn on type-tests)
or
- based on similarity with previously manufactured (and measured) ASSEMBLIES.
The essential difference between TTA and PTTA
exists in the fact that TTA are optimised for specific
(repetitious) applications and that, thanks to the
measurement, it is possible to utilize the components to the limit of their load capacity. TTA are
procured as complete installations from one manufacturer or built under his licence.
In contrast to this, the PTTA construction method is
typically selected by builders of switchgear and
controlgear assemblies who opt for components
from different manufacturers instead of the costly
type-test and the commitment to one manufacturer.
They derive the correct selection of the components
for their specific application from the type-tests of
the manufacturers and install them in accordance
with the established engineering practice. This
applies for single assemblies and also for series production. PTTA generally possess more reserve (e.g.
with regard to temperature rise and the selection of
the conductor cross sections), since the derivation is
based on general rules (e.g. regarding the selection
of conductors).
TTA and PTTA are equal in regard to the fulfilment of
safety requirements.
7

What does EN 60 439 define?

EN 60 439 defines
the design and construction requirements which must
be fulfilled in order to achieve the safety objectives,
the definitions which are significant for ASSEMBLIES,
the referential environmental conditions,
the test requirements, etc.
EN 60 439 thus represents an extremely useful set of
instructions for the set-up and testing of ASSEMBLIES and
forms a basis for communication between manufacturer,
customer and agencies. The manufacturers and operators of
ASSEMBLIES should become familiar with EN 60 439 in
order to meet their responsibility for the safety of the equipment.

EN 60 439 (Low-voltage switchgear and controlgear

assemblies) is organised into the parts listed below:
EN 60 439-1 Part 1: Type-tested and partially type-tested assemblies.
EN 60 439-2 Part 2: Particular requirements for busbar trunking systems
(busways)
EN 60 439-3 Part 3: Particular requirements for low-voltage switchgear and
controlgear assemblies intended to be installed in places
where unskilled persons have access for their use
Distribution boards
EN 60 439-4 Part 4: Particular requirements for assemblies for construction
sites (ACS)
EN 60 439-5 Part 5: Particular requirements for assemblies intended to be
installed outdoors in public places Cable distribution
cabinets (CDCs) for power distribution in networks
There are supplements for some of these Parts which are integrated into the
respective basic Part upon revisions of the standards.
The following documents supplement EN 60 439 for specific areas of technology:
HD 528 S2
(IEC 890)
8

IEC 1117

A method of temperature-rise assessment by extrapolation for

partially type-tested assemblies (PTTA) of low-voltage
switchgear and controlgear.
A method for assessing the short-circuit withstand strength of
partially type-tested assemblies (PTTA)

The contents of EN 60 439-1, the fundamental part of the regulatory ordinance, are compiled below:
1.
2.
3.
4.
5.

General
Definitions
Classification of ASSEMBLIES
Electrical characteristics of ASSEMBLIES
Information to be given regarding the ASSEMBLY
5.1 Nameplates
5.2 Markings
5.3 Instructions for installation, operation and maintenance
6. Service conditions
7. Design and construction
7.1 Mechanical design
7.2 Enclosure and degree of protection
7.3 Temperature rise
7.4 Protection against electric shock
7.5 Short-circuit protection and short-circuit withstand strength
7.6 Switching devices and components installed in ASSEMBLIES
7.7 Internal separation of ASSEMBLIES by barriers or partitions
7.8 Electrical connections inside an ASSEMBLY: bars and insulated
conductors
7.9 Requirements for electronic equipment supply circuits
7.10 Electromagnetic compatibility
8. Test specifications
8.1 Classification of tests
8.2 Type-tests
8.3 Routine tests
Annexes
A
(normative) Minimum and maximum cross-sections of copper conductors suitable for connection
B
(normative) Method of calculating the cross-sectional area of protective conductors with regard to thermal stresses due to currents of
short duration
C
(informative) Typical examples of ASSEMBLIES
D
(informative) Typical arrangements of forms of separation by barriers or partitions
E
(informative) Items subject to agreement between manufacturer
and user
F
(normative) Measurement of creepage distances and clearances
G
(normative) Correlation between the nominal voltage of the supply
system and the rated impulse withstand voltage of the equipment
H
(informative) Bibliography
ZA (normative) Other international publications cited in this standard
with references to the relevant European publications
9

What does EN 60 439 define?

EN 60 439 defines
the design and construction requirements which must
be fulfilled in order to achieve the safety objectives,
the definitions which are significant for ASSEMBLIES,
the referential environmental conditions,
the test requirements, etc.
EN 60 439 thus represents an extremely useful set of
instructions for the set-up and testing of ASSEMBLIES and
forms a basis for communication between manufacturer,
customer and agencies. The manufacturers and operators of
ASSEMBLIES should become familiar with EN 60 439 in
order to meet their responsibility for the safety of the equipment.

EN 60 439 (Low-voltage switchgear and controlgear

assemblies) is organised into the parts listed below:
EN 60 439-1 Part 1: Type-tested and partially type-tested assemblies.
EN 60 439-2 Part 2: Particular requirements for busbar trunking systems
(busways)
EN 60 439-3 Part 3: Particular requirements for low-voltage switchgear and
controlgear assemblies intended to be installed in places
where unskilled persons have access for their use
Distribution boards
EN 60 439-4 Part 4: Particular requirements for assemblies for construction
sites (ACS)
EN 60 439-5 Part 5: Particular requirements for assemblies intended to be
installed outdoors in public places Cable distribution
cabinets (CDCs) for power distribution in networks
There are supplements for some of these Parts which are integrated into the
respective basic Part upon revisions of the standards.
The following documents supplement EN 60 439 for specific areas of technology:
HD 528 S2
(IEC 890)
8

IEC 1117

A method of temperature-rise assessment by extrapolation for

partially type-tested assemblies (PTTA) of low-voltage
switchgear and controlgear.
A method for assessing the short-circuit withstand strength of
partially type-tested assemblies (PTTA)

The contents of EN 60 439-1, the fundamental part of the regulatory ordinance, are compiled below:
1.
2.
3.
4.
5.

General
Definitions
Classification of ASSEMBLIES
Electrical characteristics of ASSEMBLIES
Information to be given regarding the ASSEMBLY
5.1 Nameplates
5.2 Markings
5.3 Instructions for installation, operation and maintenance
6. Service conditions
7. Design and construction
7.1 Mechanical design
7.2 Enclosure and degree of protection
7.3 Temperature rise
7.4 Protection against electric shock
7.5 Short-circuit protection and short-circuit withstand strength
7.6 Switching devices and components installed in ASSEMBLIES
7.7 Internal separation of ASSEMBLIES by barriers or partitions
7.8 Electrical connections inside an ASSEMBLY: bars and insulated
conductors
7.9 Requirements for electronic equipment supply circuits
7.10 Electromagnetic compatibility
8. Test specifications
8.1 Classification of tests
8.2 Type-tests
8.3 Routine tests
Annexes
A
(normative) Minimum and maximum cross-sections of copper conductors suitable for connection
B
(normative) Method of calculating the cross-sectional area of protective conductors with regard to thermal stresses due to currents of
short duration
C
(informative) Typical examples of ASSEMBLIES
D
(informative) Typical arrangements of forms of separation by barriers or partitions
E
(informative) Items subject to agreement between manufacturer
and user
F
(normative) Measurement of creepage distances and clearances
G
(normative) Correlation between the nominal voltage of the supply
system and the rated impulse withstand voltage of the equipment
H
(informative) Bibliography
ZA (normative) Other international publications cited in this standard
with references to the relevant European publications
9

What must be observed in the construction, modification

and testing of a PTTA?
Directives for the utilisation of other
components as those applied for the
type-test of a TTA permit a range of
freedom
EN 60 439 states in Subparagraph 8.1.1:
If modifications are made to the components
of the ASSEMBLY, new type tests have to be
carried out only in so far as such modifications are likely to adversely affect the results
of these tests.
This rule provides the manufacturer of a specific
TTA a relatively wide range of freedom regarding
the selection of the switchgear and other components. It is entirely feasible that devices other than
those employed in the type-test may be installed
without affecting the validity of the type-test, for
example when:
- the maximum temperature rise is not exceeded
(e.g. through selection of devices of the same
or lower power dissipation),
- the insulation withstand strength is not lowered (e.g. through selection of devices of the
same or better insulation),
- the short-circuit withstand strength is maintained (e.g. through selection of circuit breakers with the same or higher breaking capacity
and the same or more favourable let-through
values).

Type-tested components simplify work

PTTA represent the majority of control systems or
distribution boards in unit production. Observing
established engineering practice, careful selection of
products, and competent construction, the assembly
of a control system which conforms to directives
poses no problem and corresponds to the established
practice of reliable switchboard manufacturers.
The documentation of the component manufacturers
are an essential support tool for project planners as
well as the builders of ASSEMBLIES. In accordance
with the Low-Voltage and the EMC Directive, all
components must fulfil the relevant directives and be
type-tested. The type-tests of the components are
performed in compliance with the respective standards for the components (e.g. in compliance with
EN 60 947 for low-voltage switching devices) and
not in compliance with EN 60 439 (refer to EN
60 439-1 Subparagraph 1.1: This standard does not
apply to individual devices and self-contained components, such as motor starters, fuse switches, electronic equipment, etc., complying with their relevant
standards).
The component manufacturers issue relevant
Declarations of Conformity and identify the
products for the EU with the CE-mark. The user of
such type-tested components can assume that the
relevant standards are fulfilled, provided that these
components are installed in accordance with the
manufacturers specifications (those which form the
basis of the type-test). This applies for the areas of
the Low-voltage Directive as well as the EMC

Directive. Among other things which deserve special

attention are the manufacturers specifications
regarding load capacity with increased ambient temperature, the performance data for short-circuit
stress, the safety distances from arcing apertures,
etc.
The job of the ASSEMBLY manufacturer is simplified if he can refer to type-tests or technical documentation from the component manufacturer for
component subassemblies, as is the case with the
MCS-Star provided by Rockwell Automation for
motor starters of the Modular Control System
(MCS). He is thus freed from the burden of selecting and dimensioning the components installed in
the subassembly.

While it is possible to rely upon the type-tests conducted for devices by the component manufacturer,
the ASSEMBLY manufacturer bears the responsibility for work he has performed, such as selecting
correctly-dimensioned conductors and their protection. Here, he can rely upon the relevant guidelines
such as those set down in Harmonization Document
HD 384.5.523, with consideration for the type of
conductor, the temperature limit of the conductor
insulation, the ambient temperature, the conductor
loading and the method of installation.

Which starter?

Helpful software tools such as

MCS-Star produced by Rockwell
Automation simplify the work of
ASSEMBLY manufacturers.

Starter selection

Circuit diagram

Starter selection
Catalog Nr.

170-C16NKF10-A1G-TY-E-X

Layout

Function

Motor protection

Star-Delta starter

Electrical motor protection relay, terminal 10 man.

Mechanical locking
Without mechanical locking

Current limiter

Control type

Star-Delta time relay

Electronic timer module, 30 seconds

Short-circuit coordination
Coordination Type "1"

Assembly system

Control voltage

Motor output at 400 /415 V 50 Hz

7.50 kW / 14.8 A
9.00 kW / 19.0 A
11.0 kW / 21.5 A
15.0 kW / 29.0 A

220-230V 50Hz
230V 50 / 60Hz
230-240V 50Hz
240V 50Hz / 277V 60Hz

10

The added value performed by the

ASSEMBLY maufacturer requires
safety verification

Bills of Materials

Circuit diagram

Layout

Circuit diagram 170-005 Layout S00SEATX

Project

Assembly test

Terminate

11

What must be observed in the construction, modification

and testing of a PTTA?
Directives for the utilisation of other
components as those applied for the
type-test of a TTA permit a range of
freedom
EN 60 439 states in Subparagraph 8.1.1:
If modifications are made to the components
of the ASSEMBLY, new type tests have to be
carried out only in so far as such modifications are likely to adversely affect the results
of these tests.
This rule provides the manufacturer of a specific
TTA a relatively wide range of freedom regarding
the selection of the switchgear and other components. It is entirely feasible that devices other than
those employed in the type-test may be installed
without affecting the validity of the type-test, for
example when:
- the maximum temperature rise is not exceeded
(e.g. through selection of devices of the same
or lower power dissipation),
- the insulation withstand strength is not lowered (e.g. through selection of devices of the
same or better insulation),
- the short-circuit withstand strength is maintained (e.g. through selection of circuit breakers with the same or higher breaking capacity
and the same or more favourable let-through
values).

Type-tested components simplify work

PTTA represent the majority of control systems or
distribution boards in unit production. Observing
established engineering practice, careful selection of
products, and competent construction, the assembly
of a control system which conforms to directives
poses no problem and corresponds to the established
practice of reliable switchboard manufacturers.
The documentation of the component manufacturers
are an essential support tool for project planners as
well as the builders of ASSEMBLIES. In accordance
with the Low-Voltage and the EMC Directive, all
components must fulfil the relevant directives and be
type-tested. The type-tests of the components are
performed in compliance with the respective standards for the components (e.g. in compliance with
EN 60 947 for low-voltage switching devices) and
not in compliance with EN 60 439 (refer to EN
60 439-1 Subparagraph 1.1: This standard does not
apply to individual devices and self-contained components, such as motor starters, fuse switches, electronic equipment, etc., complying with their relevant
standards).
The component manufacturers issue relevant
Declarations of Conformity and identify the
products for the EU with the CE-mark. The user of
such type-tested components can assume that the
relevant standards are fulfilled, provided that these
components are installed in accordance with the
manufacturers specifications (those which form the
basis of the type-test). This applies for the areas of
the Low-voltage Directive as well as the EMC

Directive. Among other things which deserve special

attention are the manufacturers specifications
regarding load capacity with increased ambient temperature, the performance data for short-circuit
stress, the safety distances from arcing apertures,
etc.
The job of the ASSEMBLY manufacturer is simplified if he can refer to type-tests or technical documentation from the component manufacturer for
component subassemblies, as is the case with the
MCS-Star provided by Rockwell Automation for
motor starters of the Modular Control System
(MCS). He is thus freed from the burden of selecting and dimensioning the components installed in
the subassembly.

While it is possible to rely upon the type-tests conducted for devices by the component manufacturer,
the ASSEMBLY manufacturer bears the responsibility for work he has performed, such as selecting
correctly-dimensioned conductors and their protection. Here, he can rely upon the relevant guidelines
such as those set down in Harmonization Document
HD 384.5.523, with consideration for the type of
conductor, the temperature limit of the conductor
insulation, the ambient temperature, the conductor
loading and the method of installation.

Which starter?

Helpful software tools such as

MCS-Star produced by Rockwell
Automation simplify the work of
ASSEMBLY manufacturers.

Starter selection

Circuit diagram

Starter selection
Catalog Nr.

170-C16NKF10-A1G-TY-E-X

Layout

Function

Motor protection

Star-Delta starter

Electrical motor protection relay, terminal 10 man.

Mechanical locking
Without mechanical locking

Current limiter

Control type

Star-Delta time relay

Electronic timer module, 30 seconds

Short-circuit coordination
Coordination Type "1"

Assembly system

Control voltage

Motor output at 400 /415 V 50 Hz

7.50 kW / 14.8 A
9.00 kW / 19.0 A
11.0 kW / 21.5 A
15.0 kW / 29.0 A

220-230V 50Hz
230V 50 / 60Hz
230-240V 50Hz
240V 50Hz / 277V 60Hz

10

The added value performed by the

ASSEMBLY maufacturer requires
safety verification

Bills of Materials

Circuit diagram

Layout

Circuit diagram 170-005 Layout S00SEATX

Project

Assembly test

Terminate

11

Calculation software simplifies

verification of the temperature rise
Harmonization Document HD 528 S2 (IEC 890)
applies as the established engineering practice for
the determination of the temperature rise in the
switchgear cabinet with natural cooling.
Suppliers of enclosures and cabinets provide software for temperature-rise calculation based on
proven calculation methods and which allow verification of temperature rise and any cooling measures
required without undue outlays for the user.
The project planner takes the power dissipation of
the components from the catalogues or databases of
the product manufacturers, while the software
ensures the correct sizing.
In the event that similar control units (e.g. same
cabinet size with comparable power dissipation of
the components in a similar construction) are built
successively, the verification for temperature rise
can also be derived from the observance of similarity with the first system whose temperature rise was
either measured or calculated.

Special care with short-circuit

currents above 10 kA
EN 60 439 exempts testing of short-circuit withstand strength at rated short-circuit currents below
10 kA. Nor is verification of the short-circuit withstand strength required for protection with currentlimiting devices such as current-limiting fuses or
circuit breakers when the let-through current does
not exceed 15 kA at rated breaking capacity.
As a result, significant costs for testing are eliminated for many control systems and installations.
Short-circuit currents of 10 kA presuppose the
direct connection to a transformer with an output of
approx. 400 kVA (at 400 V secondary voltage and
6% short-circuit voltage) and are rare with smaller
loads. Because of the hazards of short circuits,
extreme caution regarding the short-circuit withstand strength should be taken and it must be
12

Which tests must be performed on PTTA?

ensured that either the limits of 10 kA and 15 kA
respectively are not exceeded, or that the installation
possesses the necessary robustness at higher levels
of short circuit current.
It is advisable to rely upon type-tested components
and arrangements, even for PTTA where busbars are
involved. The selection and application of the busbar in compliance with manufacturers specifications (based on his type-test) ensures a design that
conforms to requirements.
In addition, Technical Report IEC 1117 provides
instructions for the design of PTTA which is resistant to short-circuits, especially regarding connection of the equipment.

Current limiting circuit breakers can

eliminate the necessity for verification of short-circuit withstand
strength.

Careful routine testing

ensures the safety of the
individual ASSEMBLY.

Software for calculation of temperature rise and short-circuit current

are helpful support tools.

Table 7 of EN 60 439-1 lists the tests which are to

be performed on PTTA (and TTA). In the selection
of type-tested components, or those derived from
them, and for the execution of calculations in compliance with recognised methods, verification may
be achieved without difficulties.
It is recommended that standardised protocols are
prepared for the documentation of the tests or
whenever available that protocol forms made
available by professional societies are used.

How can the expense for the technical

verification of PTTA be minimised?
Together with the selection of type-tested components for which no further verification is required
since reference may be made to the type-test of the
respective manufacturer, it is recommended to standardise the internal bespoke documentation and procedures for the services of the planning engineer
and builder of ASSEMBLIES and to incorporate
these standards into a quality assurance system.
Given careful work in compliance with these internal standards, technical verification for all installations assembled in compliance with them is guaranteed. With sizing for which either standards or
industry-specific table references are available, for
example, it is recommended that these be incorporated. It may be anticipated that industrial societies
will support their members increasingly in the fulfilment of this task.

Important notes regarding national

differences
The standards and Harmonization Documents
referred to in this brochure are cited with the numbers and designations in accordance with CENELEC or IEC. The numbers and designations may
deviate in some countries because of national systems. However, the national standards are identi13
cal in their contents and cite the documents
which form the basis at the European level in all
cases.

Calculation software simplifies

verification of the temperature rise
Harmonization Document HD 528 S2 (IEC 890)
applies as the established engineering practice for
the determination of the temperature rise in the
switchgear cabinet with natural cooling.
Suppliers of enclosures and cabinets provide software for temperature-rise calculation based on
proven calculation methods and which allow verification of temperature rise and any cooling measures
required without undue outlays for the user.
The project planner takes the power dissipation of
the components from the catalogues or databases of
the product manufacturers, while the software
ensures the correct sizing.
In the event that similar control units (e.g. same
cabinet size with comparable power dissipation of
the components in a similar construction) are built
successively, the verification for temperature rise
can also be derived from the observance of similarity with the first system whose temperature rise was
either measured or calculated.

Special care with short-circuit

currents above 10 kA
EN 60 439 exempts testing of short-circuit withstand strength at rated short-circuit currents below
10 kA. Nor is verification of the short-circuit withstand strength required for protection with currentlimiting devices such as current-limiting fuses or
circuit breakers when the let-through current does
not exceed 15 kA at rated breaking capacity.
As a result, significant costs for testing are eliminated for many control systems and installations.
Short-circuit currents of 10 kA presuppose the
direct connection to a transformer with an output of
approx. 400 kVA (at 400 V secondary voltage and
6% short-circuit voltage) and are rare with smaller
loads. Because of the hazards of short circuits,
extreme caution regarding the short-circuit withstand strength should be taken and it must be
12

Which tests must be performed on PTTA?

ensured that either the limits of 10 kA and 15 kA
respectively are not exceeded, or that the installation
possesses the necessary robustness at higher levels
of short circuit current.
It is advisable to rely upon type-tested components
and arrangements, even for PTTA where busbars are
involved. The selection and application of the busbar in compliance with manufacturers specifications (based on his type-test) ensures a design that
conforms to requirements.
In addition, Technical Report IEC 1117 provides
instructions for the design of PTTA which is resistant to short-circuits, especially regarding connection of the equipment.

Current limiting circuit breakers can

eliminate the necessity for verification of short-circuit withstand
strength.

Careful routine testing

ensures the safety of the
individual ASSEMBLY.

Software for calculation of temperature rise and short-circuit current

are helpful support tools.

Table 7 of EN 60 439-1 lists the tests which are to

be performed on PTTA (and TTA). In the selection
of type-tested components, or those derived from
them, and for the execution of calculations in compliance with recognised methods, verification may
be achieved without difficulties.
It is recommended that standardised protocols are
prepared for the documentation of the tests or
whenever available that protocol forms made
available by professional societies are used.

How can the expense for the technical

verification of PTTA be minimised?
Together with the selection of type-tested components for which no further verification is required
since reference may be made to the type-test of the
respective manufacturer, it is recommended to standardise the internal bespoke documentation and procedures for the services of the planning engineer
and builder of ASSEMBLIES and to incorporate
these standards into a quality assurance system.
Given careful work in compliance with these internal standards, technical verification for all installations assembled in compliance with them is guaranteed. With sizing for which either standards or
industry-specific table references are available, for
example, it is recommended that these be incorporated. It may be anticipated that industrial societies
will support their members increasingly in the fulfilment of this task.

Important notes regarding national

differences
The standards and Harmonization Documents
referred to in this brochure are cited with the numbers and designations in accordance with CENELEC or IEC. The numbers and designations may
deviate in some countries because of national systems. However, the national standards are identi13
cal in their contents and cite the documents
which form the basis at the European level in all
cases.

Compilation of verifications and tests of TTA and PTTA (Table 7 from EN 60 439-1) supplemented with
recommendations for the practical execution with PTTA.
Seq
no.
1

Requirements
to be tested
Limiting excess
temperature

Section

TTA

PTTA

Comments for PTTA

8.2.1

Insulation withstand
strength

8.2.2

Verification of compliance
of limiting excess
temperature by testing (type-test)
Verification of the insulation
withstand strength by testing
(type-test)

Determination in accordance with HD 528 S2 or

with the use of temperature-rise calculation
software from enclosure manufacturers
The verification of the insulation resistance
(measurement at 500 V) will be the
easiest to conduct in most instances.

Short-circuit
withstand strength

8.2.3

Verification of short-circuit withstand

strength by testing (type-test)

Verification of compliance
of limiting excess temperature
by testing or extrapolation of TTA
Verification of the insulation withstand
strength in compliance with Section 8.2.2
or verification by insulation test in compliance with Section 8.3.2 or verification
of the leakage resistance in compliance
with Section 8.3.4 (refer to Seq. no. 11)
Verification of short-circuit withstand
strength by testing or extrapolation of
similar type-tested arrangements

Efficiency of the
protective conductor

8.2.4

Verification of the proper connection

between conductive parts of the
switchgear and controlgear
assembly and protective conductors
by inspection or resistance measurement
(type-test)

Verification of the proper connection

between conductive parts of the
switchgear and controlgear
assembly and protective conductors
by inspection or resistance measurement

Verification of the short-circuit withstand

strength of the protective conductor
by testing
(type-test)

Verification of the short-circuit withstand

strength of the protective conductor by
testing or corresponding execution and
arrangement of the protective conductor
(refer to Section 7.4.3.1.1, last paragraph)
Verification of the creepage
distances and clearances

Proper connection between 8.2.4.1

conductive parts of the
switchgear and controlgear
assembly and protective
conductors
Short-circuit withstand
8.2.4.2
strength of the protective
conductor

Creepage distances and

clearances

8.2.5

Mechanical
function
Type of protection

8.2.6

8.2.7

Verification of the creepage

distances and clearances
(type-test)
Verification of the mechanical
function (type-test)
Verification of the type of protection
(type-test)

Verification of the mechanical

function
Verification of the type of protection

Not required up to 10 kA (or 15 kA let-through current respectively).

Beyond this, use of type-tested busbar systems recommended.
Extrapolation in accordance with manufacturer's documents and
execution in accordance with IEC 1117.

For PTTA, separate protective conductors must be provided (protective

connections via constructional parts are not allowed) in such a manner
that the influence of the electromagnetic forces of the busbars may be
ignored (i.e., at a distance from the busbars).
Use of type-tested components and special attention to the clearances
from enclosures and other conducting parts.
Observance of arcing spaces.
Especially for plug-in modules and locking devices. Occurs rarely with
PTTA or is covered by the use of type-tested components.
Use of suitable type-tested enclosures and installation components.
Installation of components in the switchgear cabinet surface in
compliance with instructions of the component manufacturer
for the relevant type of protection.

Subparagraphs 8 to 11 are routine tests

14

Wiring,
electrical function

8.3.1

Insulation

8.3.2

10

Protective measures

8.3.3

11

Leakage resistance

8.3.4

Visual inspection of the switchgear and

controlgear assembly, including the wiring
and electrical function test where required
(routine test)
Insulation test
(routine test)
Inspection of protective measures and visual
inspection of the continuous protective
conductor connection (routine test)
-

Visual inspection of the switchgear and

controlgear assembly, including the
wiring and electrical function test
where required
Insulation test or verification of the
leakage resistance in compliance with
Section 8.3.4 (refer to Seq. no. 11)
Inspection of protective measures

Verification of the leakage resistance,

if the test was not conducted in compliance with Section 8.2.2 or 8.3.2
(refer to Seq. no. 2 and 9)

See note regarding Subparagraph 2

Visual inspection of the protective conductor connections and random

sample tests of the threaded connections.
See note regarding Subparagraph 2
15

Compilation of verifications and tests of TTA and PTTA (Table 7 from EN 60 439-1) supplemented with
recommendations for the practical execution with PTTA.
Seq
no.
1

Requirements
to be tested
Limiting excess
temperature

Section

TTA

PTTA

Comments for PTTA

8.2.1

Insulation withstand
strength

8.2.2

Verification of compliance
of limiting excess
temperature by testing (type-test)
Verification of the insulation
withstand strength by testing
(type-test)

Determination in accordance with HD 528 S2 or

with the use of temperature-rise calculation
software from enclosure manufacturers
The verification of the insulation resistance
(measurement at 500 V) will be the
easiest to conduct in most instances.

Short-circuit
withstand strength

8.2.3

Verification of short-circuit withstand

strength by testing (type-test)

Verification of compliance
of limiting excess temperature
by testing or extrapolation of TTA
Verification of the insulation withstand
strength in compliance with Section 8.2.2
or verification by insulation test in compliance with Section 8.3.2 or verification
of the leakage resistance in compliance
with Section 8.3.4 (refer to Seq. no. 11)
Verification of short-circuit withstand
strength by testing or extrapolation of
similar type-tested arrangements

Efficiency of the
protective conductor

8.2.4

Verification of the proper connection

between conductive parts of the
switchgear and controlgear
assembly and protective conductors
by inspection or resistance measurement
(type-test)

Verification of the proper connection

between conductive parts of the
switchgear and controlgear
assembly and protective conductors
by inspection or resistance measurement

Verification of the short-circuit withstand

strength of the protective conductor
by testing
(type-test)

Verification of the short-circuit withstand

strength of the protective conductor by
testing or corresponding execution and
arrangement of the protective conductor
(refer to Section 7.4.3.1.1, last paragraph)
Verification of the creepage
distances and clearances

Proper connection between 8.2.4.1

conductive parts of the
switchgear and controlgear
assembly and protective
conductors
Short-circuit withstand
8.2.4.2
strength of the protective
conductor

Creepage distances and

clearances

8.2.5

Mechanical
function
Type of protection

8.2.6

8.2.7

Verification of the creepage

distances and clearances
(type-test)
Verification of the mechanical
function (type-test)
Verification of the type of protection
(type-test)

Verification of the mechanical

function
Verification of the type of protection

Not required up to 10 kA (or 15 kA let-through current respectively).

Beyond this, use of type-tested busbar systems recommended.
Extrapolation in accordance with manufacturer's documents and
execution in accordance with IEC 1117.

For PTTA, separate protective conductors must be provided (protective

connections via constructional parts are not allowed) in such a manner
that the influence of the electromagnetic forces of the busbars may be
ignored (i.e., at a distance from the busbars).
Use of type-tested components and special attention to the clearances
from enclosures and other conducting parts.
Observance of arcing spaces.
Especially for plug-in modules and locking devices. Occurs rarely with
PTTA or is covered by the use of type-tested components.
Use of suitable type-tested enclosures and installation components.
Installation of components in the switchgear cabinet surface in
compliance with instructions of the component manufacturer
for the relevant type of protection.

Subparagraphs 8 to 11 are routine tests

14

Wiring,
electrical function

8.3.1

Insulation

8.3.2

10

Protective measures

8.3.3

11

Leakage resistance

8.3.4

Visual inspection of the switchgear and

controlgear assembly, including the wiring
and electrical function test where required
(routine test)
Insulation test
(routine test)
Inspection of protective measures and visual
inspection of the continuous protective
conductor connection (routine test)
-

Visual inspection of the switchgear and

controlgear assembly, including the
wiring and electrical function test
where required
Insulation test or verification of the
leakage resistance in compliance with
Section 8.3.4 (refer to Seq. no. 11)
Inspection of protective measures

Verification of the leakage resistance,

if the test was not conducted in compliance with Section 8.2.2 or 8.3.2
(refer to Seq. no. 2 and 9)

See note regarding Subparagraph 2

Visual inspection of the protective conductor connections and random

sample tests of the threaded connections.
See note regarding Subparagraph 2
15

More Than 500000 Ways To Make Automation Work

Power devices

Circuit breakers
Motor contactors and starters
Motor protection
Motor Control centers
Power monitoring

Sensors

Limit, photoelectric and proximity switches

Pressure and temperature controls
Radio frequency identification
Bar code
Encoders
Vision systems

Operator interface

Push buttons and pilot devices

Cam switches
Message displays
Operator panels, terminals

Motion Control

AC and DC drives
Drive systems
Computer numerical controls
General purpose motion control

Logic devices

Programmable controlers
Universal I/O
Control and information processing
Relays
Terminal blocks

Communication
products

Automation control networks

Multivendor connectivity (MAP)

Application systems Custom engineered control systems

Batch control
Burner management systems
Distributed discrete manufacturing control
SCADA
Stamping press control systems
Quality management SPG/SQC data collection and analysis
Global support
services

Publication PTSK EN, March 1999

Technical training
Field engineering and service
Repair and exchange services
Technical support

Copyright 1998 Rockwell International Corporation. All rights reserved. Printed in Switzerland

The easy way to build

switchgear and controlgear
assemblies in compliance with the regulations
A guide for partially type-tested switchgear and
controlgear assemblies in compliance with EN 60 439