DEKRA

Low voltage switch and

controlgear assemblies.
Testing, inspections, auditing
and certification.

Risk reduction and certification

Low voltage switch and controlgear assemblies.

A low voltage distribution and control panel is the product of a long supply chain; the road from design to customer applications
can be full of twists and surprises. The issue with panels in general is compliance to standards and, indeed, basic safety itself.
At best a grey area for regulators, consultants, underwriters and end users alike the questions remain: How do I specify safety
for my purpose? Which risks do I reduce to what extent in a given application with which measures? What is the value of all the
documents and certificates presented to me? Who is responsible in case something happens?

>

All testing, inspection, auditing

and certification activities of
the former KEMA Quality are
an intergral part of the
DEKRA Certification Group. This
also applies to all related safety,
conformity and certification marks,
such as KEMA-KEUR

Regulators
Underwriters

Original
Panel
Manufacturer

Assembly
Manufacturer
Component
Manufacturers

What is the nature of your

interest?

As an end user you want to avoid personal

injury of your clients and employees, prevent
loss of energy supply which affects your
operations or, even worse, a business
consumed by fire. But can you be sure that
the tailor-made panel or motor control centre
that is delivered to you meets the optimum
safety level? And do you have the extensive
knowledge and time needed to verify this?
As a consultant you take the interests of
the end user into account, but you are also
faced with the requirements set by other
stakeholders. For you, in your spin-in-theweb position, it will be especially important
to be aware of the risk reduction effects of
testing and certification. When you have
written the specification it will be your task
to evaluate tender entries, We hope this
overview helps you do exactly that.
As an underwriter you want to assure that
the object you cover meets an acceptable
risk level. Both high frequencies of smaller
incidents as well as risk involving substan
tially insured projects have your attention.
The question is: have you made optimum

End user

Modular
Panel
System

(Switching)
Component

use of what testing and certification has to

offer?
As a regulator you want to control the power
supply and protect people and assets. You
want to avoid accidents and power outages
and therefore you define the specifications
for applications connected to the grid. But
each installation connected to the network
comes with a different risk. How can testing
and certification serve your purpose?
As an original panel system manufacturer
you want customers to be satisfied about
your products. Your products fit a certain
marketing mix. Safety and compliance
with standards are an integral part of this.
Therefore there is a need to control the
whole chain from production to end use.
Arm your local assembly operations
with the written evidence of DEKRA
testing & certification. DEKRA hands you
the tools to distinguish your product and
to access those (niche-) markets out there!
As an assembly manufacturer you want to
deliver a tailor-made panel assembly that
meets customers requirements and also
complies with legal requirements set by
regulators in different national markets.

Tailor-made
Panel

define the specs.

Consultant

You want to make clear to regulators, original panel system manufacturers, consultants
and end-users that you are a reliable player
in this field, able to transform expectations
into reality. You take your role in the chain
seriously and seek a way to document your
performance. You target those markets that
best fit your business expectations. But does
the testing and certification of your products
help you achieve those goals or is it working
against you?
As a component manufacturer you have
to make sure your products meet the needs
of assembly manufacturers. Or, one level
up, comakership with an original panel
system manufacturer. You are well aware
that components nearly always end up in
a panel of some sorts. But are you aware
that your clients can only include the
switchgear in the certification of their
product if the components are individually
certified to their own standard? Why not
add value to your products with certifi
cation by DEKRA to make them more
attractive?

What about current practice?

Current practice of testing and certification

for low voltage switch- and controlgear
assemblies can be rather vague in terms of
objectivity, interpretation of the standards,
scope, acceptability and the accuracy
of the chosen measure. Actually, the
IEC/EN 61439 itself leaves much room for
interpretation. As a result, some suppliers
cannot really distinguish their products
contribution to safety while others make
use of the fog and successfully claim
compliance with products that could just

as easily be the cause of accidents. Some

examples we will all recognize: perfectly
good panel system is fitted with switching
components which failed individual tests,
type tested sample panel passed the IP test
with use of lots of sealant while commercially produced units are leaky, basic panel
passes temperature rise test while units
sold are fitted with additional components.

test reports, certificates and other documen

tation provided by an assembly manufacturer in order to demonstrate compliance.
It pays to put in the effort though, since
stakeholders are faced with considerable
variation in the value of both panel type
test reports and certificates.

Who will bear the financial consequences

when things go wrong? To complicate
matters further, it takes an expert to study

Its your responsibility to assess

the projects risk level, its our job to
offer useful measures to control it.

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Reports and certificates

This is where DEKRA

can help you

DEKRA offers a full range of services in

the field of testing and certification of low
voltage switch- and controlgear assemblies;
from type testing only up to certification
programs that include both type testing and
verification of quality processes. Dependent
on the desired degree of risk reduction you
can choose the most appropriate measure.
From a simple IP test up to our latest
comprehensive panel certification scheme
DEKRA World Panel Program. All services
share the same basics: any document clearly
describes the testing/certification activity.
All data is trustworthy. Where possible we
follow international procedures. The result
is that DEKRA probably scores highest
worldwide on trust and acceptance.

EN/IEC 61439

The international standard for low voltage

switchgear and controlgear assemblies is the
EN/IEC 61439. The prefix EN/IEC means
that the requirements of both European
EN standards (issued by CENELEC) and
worldwide IEC standards are harmonized
and presented in one single document.
This international standard forms the basis
for all DEKRA services in the field of
testing and certification of low voltage
panels. Any type test can be performed
by a market party or an independent and
objective so called third party. It should
be obvious that only properly accredited
third parties have the objectivity required
to issue test results that can be used for
official purposes. Our project managers are
well experienced in testing according this
standard and are involved in the development of the new version of this standard by
participating in the relevant IEC standar
dization committees.

DEKRA/KEMA Quality Test

Report

Ongoing surveillance
One time testing

Degree of risk reduction

This measure is most appropriate during

the development phase of a product or to
demonstrate fulfillment of a particular
requirement a market party may have.
One or a few tests from the total sequence
prescribed by the EN/IEC 61439 are carried
out. A partial type test is insufficient to
demonstrate total compliance to a certain
standard and cannot form the basis of any
certification by itself. Examples: IP testing
or temperature rise testing.

DEKRA/KEMA Quality Test

Certificate

A DEKRA/KEMA Quality Test Certificate

means that the product is subjected to a
complete sequence of tests prescribed by
the EN/IEC 61439 and demonstrates full
compliance to the standard. Often the cause
of confusion: type test certificates do not
include aspects of the quality system of
either the original panel system manufacturer or the assembly manufacturer (panel
builder). Nor do they include any yearly
follow-up factory inspections or product
re-examinations.

A (panel-) type test certificate and a

(panel-) certification scheme are different
things. Or rather: when carried out
correctly a type test forms the starting point
for a certification scheme. A type test
always is a once only demonstration of a
products compliance, a snap-shot.

+ quality process of original panel system

manufacturer (total chain approach)
+ initial and yearly inspection
manufacturing process of panel builder
Yearly product
re-examinations

Full type test

according IEC/EN 61439

DEKRA/KEMA
Quality Test
Certificate

One time
testing

Testing
one/several
aspact(s)
(e.g. short circuit)

Product

DEKRA/KEMA
Quality Test
Report

Product & Process

DEKRA
service

The extent of a measure

A full range of services in the field of

testing and certification of low voltage
switch and controlgear assemblies.

4|5

Overview of services and certificates

KEMA-KEUR for panels

The certification mark

KEMA-KEUR gives
you the assurance that
the type tested product
can be manufactured by a local assembly
manufacturer on that specific location,
on a continuous basis with the same
required safety level. Starting point is a
DEKRA Test Certificate based on a full
type test. The type test is complemented
by yearly factory inspections at the assembly
manufacturer regarding the quality system
and assembly process. Issues addressed
during the inspection are for example:
training and expertise of employees,
storing and handling of incoming goods
and documentation of each individual
end-product.
It should be obvious that KEMA-KEUR
is a serious step up from type testing only
and that it implies continuous surveillance
by yearly inspections by KEMA staff of
both product and manufacturing process.

World Panel Program

You require maximum risk

reduction? The standards and
procedures on which the other
services are based still leave
room for interpretation and may result in
a variable scope of individual certificates;
for example: with or without components.
Our World Panel Program offers you more
risk reduction.
The World Panel Program of DEKRA standard combines purpose written clauses
with existing standards and procedures.
The program is characterized by a total
chain approach and demands a single
high level of compliance.
All main components must carry individual
certification. Every complete unit supplied
under this comprehensive scheme has to
comply with the World Panel Program
standards on an individual basis. No if s
or buts. Both the original- and assembly
manufacturer are subject to verification

of the quality process to dedicated World

Panel Program requirements. The quality
system certification at original manufacturer
level includes product quality aspects, com
munication with assembly manufacturers
and verification of the assembly manual
against the original type test that was carried
out. At the assembly manufacturer level the
program deals with all relevant issues that
have an impact on safety and compliance:
staff, documentation, quality system,
communication with clients and conditions
of use. A unique feature is that assemblies
supplied under this type of certification
are numbered individually and as-built
drawings are stored in an DEKRA extranet
environment.

Welcome to our world

of expertise
DEKRA is one of the worlds leading expert
organisations. The company currently
maintains a presence in more than 50
countries. Around 22,000 employees, of
which 40 percent work outside of DEKRAs
domestic market in Germany, are committed
to ensuring long-term safety, quality and
environmental protection.
DEKRA SE is a wholly-owned subsidiary
of DEKRA e.V. and is responsible for the
companys operational business. The DEKRA
business units Automotive, Industrial and
Personnel provide skilled and innovative
services in the fields of vehicle inspections,
expert appraisals, international claims
management, consulting, industrial and
product testing, certifications, environmental
protection, qualifications and temporary
work in addition to out- and new placement.
All testing, inspection, auditing and
certification activities of the former DEKRA
are an integral part of the DEKRA Certification Group. This also applies to all related
safety, conformity and certification marks,
such as KEMA-KEUR.

Measure
Characteristics

Individual Tests
performed by
DEKRA*

KEMA Type test to

IEC/EN 60439-1*

KEMA-KEUR for panels

(based on CENELEC
procedure)

World Panel Program

Thrid party according to

CENELEC procedures.
DEKRA is signatory to
the European CENELEC
Certification Agreement (CCA).

Certification according to DEKRA World Panel

Program, which combines purpose written
clauses with existing standards and procedures. Introduced in May 2006.

IEC/EN 61439, full

sequence of tests.

IEC/EN 61439. CENELEC

procedures.

IEC/EN 61439 and DEKRA World Panel

Program standard.

Often executed to
bare minimum of
requirements. Typically
focused on enclosure
and busbar only.

Often executed to bare

minimum of requirements.
Typically focused on
enclosure and busbar only.

Components can be included if

type tested with the assembly
and carry individual certification.
Yearly product re-examinations.

Complete panel in question. All main

components must be type tested with the
assembly and carry individual certification.
Type tested arrangements are subject to
re-examinations.

Scope of (Type) test

results:

As described in
the test report.

As described in the type

test report.

The product as described in the

test report is qualified for
KEMA-KEUR. Unapproved
components used during testing
are excluded from KEMA-KEUR.
This difference will be explicitly
mentioned in the test report.

The product as described in the test report is

qualified for DEKRA World Panel Program.
Versions accepted on basis of calculations are
included also. The use of unapproved
components is only possible to a limited extent
when the standard allows this.

Requirements for
original system
manufacturer

Not included.

None other than type test

mentioned under scope
of measure

None other than type test

mentioned under scope of
measure

Yes. Verification of the quality system, product

quality aspects, the assembly manual against
the original type test and communication with
assembly manufacturers.

Inspection of the
assembly
manufacturer
- Product focused:

Not included.

Not included.

R
 outine test according to
IEC 61439 will be performed.
Inspection of the production of
the product according to the
KEMA-KEUR test report.

Inspection according to IEC 60204,

IEC 61439, checklist and risk analysis and
type test report.
Product inspection according to the manual
so that it becomes clear which components
must be used.
Assembly manufacturer must be able to
demon strate that any changes to the
product do not affect compliance to the
World Panel Program standard.
A number of projects will be evaluated by
DEKRA staff.

Inspection of the
assembly
manufacturer
location Process focused:

Not included.

Not included.

Yearly inspection of the

production location according
to CIG023 (ISO 9003 based).
Routine tests according to IEC
61439 are part of it.

Based on dedicated ISO system with

additional requirements (e.g. staff, equipment).
Audit on subjects such as communication with
clients, conditions of use, validity of
certification and national installation codes
(risk analysis).

Traceability of
testing and
certification of
individual panels:

Not included.

Not included.

Every assembly manufacturer is

obliged to store documention on
each and every panel.

Excellent. Individual panels are numbered.

Extranet environment: based on database
containing relevant data of total chain from
production to supply of individual panels.

Barely.

Enormous potential for

variation. The actual
panel assembly is
unsupervised. Actual
panels may be different
from those tested.

Enormous potential for variation.

From poor to adequate and very
much depending on the scope of
what is type tested.

Good. Fixed level of risk reduction. Complete

panel in question. Total chain approach.

Sample projects:

During development
phase or a particular
requirements a
market party may
have..

Exceptions may exist, but

in general suitable for
low risk projects only.

Low- to moderate risk projects

where additional investment in
risk reduction in advance is
recommended.

High risk projects where potential effect of

power loss or accidents is substantial. Also:
prestige projects. Examples: petrochemical,
warehousing, airports,production industry,
large hotels, shopping malls.

Specific knowledge
and effort required
for stakeholders to
interpret scope and
effectiveness of this
measure:

High.

Very high.

Substantial.

Limited.

Level of
objectivity:

Product scope of
measure:

Risk reduction

Third party.

Third party.

IEC/EN 61439,
incomplete sequence
of tests.

potential:

* Note: individual tests and type tests in general are available from many market parties. When not performed by an accredited third party the level of
objectivity, interpretation of the standards, scope, acceptability and accuracy may vary significantly.

6|7

DEKRA

DEKRA
P.O. Box 5185
6802 ED Arnhem
The Netherlands
T. +31 26 3 56 20 11
F. +31 26 3 52 58 00
components.global@dekra.com
www.dekra-certification.com