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Introduction
The new series of IEC 61439 standards were published in January 2009. The new standard follows the philosophy of IEC 60947 series i.e. IEC 61439-1 is
General Rules standard to be referred to by subsidiary product parts of IEC 61439 series. (Refer Table 1 below)
Introduction
One of the main features of IEC 61439-1 is that the discrimination between
Type Tested Assemblies (TTA) and Partially Type Tested Assemblies (PTTA) has been eliminated by the verification approach. The three different but equivalent types of verification methods are introduced and these are; a) Verification by Testing. b) Verification by Calculation/ Measurement. c) Verification by Design rules. The requirements regarding short circuit performance, temperature rise, dielectric properties and rated diversity factor have been covered in more detail.
Main Functions
Main Functions
Main Functions
Main Functions
Verification Requirements
Verification Requirements
Verification Requirements
Examples of the limitations and margins applied to verification without type test include:
All assemblies connected to a supply with a prospective short circuit
current in excess of 10kA rms or having a cut-off current of 17kA peak must be of a type-tested design or the verification must be an interpolation from a reference design. Under no circumstances can the assigned short circuit current rating be higher than that of the reference design. So as to take account of the air temperature within the enclosure, thermal interactions and possible hot spots; components within a circuit that has not been temperature rise tested, must be de-rated to 80% of their free air current rating. Comparison of the power loss of the components within an assembly with the known heat dissipation capability of an enclosure, is restricted to assemblies having a rating of 630A. Confirmation of temperature rise performance by calculation is limited to assemblies with a rating not exceeding 1600A. Test or interpolation from a tested design must be used to verify higher ratings.
rated current of 1600 A only. Assemblies, verified by design rule from a similar tested assembly, should comply with the following: oFunctional units shall belong to the same group as functional unit selected for test. oSame type of construction. oSame or increased overall dimensions. oSame or reduced internal separation. oSame or reduced power losses in the same section of assembly. oSame or reduced number of outgoing circuit for every section. Rated diversity factor (RDF) is elaborated in more details with incoming and outgoing circuit diagrams. The average ambient temperature for the duration of test shall not exceed 35 oC.
value in Table - 4.
comes into contact with electrical equipment housed within the enclosure. o Requirements for empty enclosures for assemblies (IEC 62208) have been incorporated in the standard.
Mechanical operation
o Rated numbers of operating cycles have been increased from 50 to 200.
changed from IPXXB (the protection of person against access to hazardous parts with finger) to IPXXD (the protection of person against access to hazardous parts with wire).
changed from IPXXB (the protection of person against access to hazardous parts with finger) to IPXXD (the protection of person against access to hazardous parts with wire).
Procedure:
o A ball pressure test apparatus is used to verify the suitability of insulating materials.
The test shall be carried out on an insulating material of minimum 2 mm thickness. The test shall be made in a heating cabinet at a temperature as stated below: o parts supporting live components 125 o C o other parts 70 o C o After 1 hr, the sample is removed and cooled within 10 s to approx. room temperature by immersion in cold water.
Assessment criteria:
The diameter of the impression caused by the ball shall be measured and shall not exceed 2 mm.
Procedure:
Sample: Thinnest wall thickness of the completed application. Pre-treatment: 24 hours at 23 o C at 50% RH. Temperatures of glow wire: 650, 850 or 960 degrees C (depending on the relevant specification). 960 degrees C for parts necessary to retain cur rent carrying parts in position; 850 degrees C for enclosures intended for mounting in hollow walls: 650 degrees C for all other parts, including parts necessary to retain the protective conductor. Force: 1 N Contact time: 30 s Assessment criteria: There is no flame and glowing on the sample or flames/glowing of the sample extinguish within 30 s. The cotton or the paper underlay doesnt ignite or burn.
Procedure:
UV Test according to ISO 4892 2 method A; 1000 cycles of 5 min of watering and 25 min. of dry period with xenon lamp providing a total test period of 500 hrs. The value of temperature and humidity for the test are (653) o C and (655) %.
Assessment criteria:
Adherence of synthetic material (according to ISO 2409) shall have minimum 50% retention. Sample shall not show cracks or deterioration visible to normal or corrected vision without any additional magnification. This test is not required if synthetic material supplier demonstrates that materials of same thickness or thinner comply with this requirement. NOTE: This test is applicable only for enclosures and external parts of ASSEMBLIES intended to be installed Outdoors.
Procedure:
o The test is carried out on a sample having weight 1.25 times its maximum shipping weight. o From a standstill position, the ASSEMBLY shall be raised smoothly without jerking in a vertical
plane to a height of (10.1) m and lowered in the same manner to a standstill position. This test is repeated a further two times. o After this the ASSEMBLY is raised up and suspended for 30 min at a height of (10.1) m without any movement. o Following this test the ASSEMBLY shall be raised smoothly without jerking from a standstill position to a height of (10.1) m and moved (100.5) m horizontally, then lowered to a standstill position. o This sequence shall be carried out three times at uniform speed, each sequence being carried out within 1 min.
Assessment criteria:
During the test, with the test weights in place, the ASSEMBLY shall show no deflections and after the test show no cracks or permanent distortions visible to normal or corrected vision without additional magnification, which could impair any of its characteristics.
Procedure:
o Number of impacts on each exposed face shall be five unless otherwise specified in relevant
product standard. o The impacts shall be evenly distributed on the faces of the enclosure under test. o At the surrounding of any point of enclosure, not more than three impacts shall be applied.
Assessment Criteria:
o Structural integrity shall be maintained. o Degree of protection (IP) shall be unaffected. o Functionality of electrical products shall not be hampered.
NOTE: Mechanical Impact test is not applicable to low voltage power switchgear and controlgear (PSC) assemblies.
Ambiguities clarified
Previously a manufacturer had to assign a current rating to each circuit, but they
were never required by the standard to prove its rating. In accordance with the new standard, the manufacturers have to verify the rating of each type of circuit. Each type of circuit will have its rating verified within the assembly and the capability of the assembly as a whole will be proven by loading adjacent outgoing circuits to their rated current, multiplied by the diversity factor. Historically it has been assumed that if nothing was said, the neutral could have a current rating equal to 50% of that of its associated phase. However, because this has not been stipulated in any low-voltage standards for many years, any query could only be answered by its custom and practice. IEC 61439 includes a default current rating in accordance with custom and practice for circuits with conductors above 16mm, but a specifier can ask for a higher rating to suit the needs of his application. In addition the ongoing question in respect of forms of separation has been answered. A devices integral enclosure, for example the case of a moulded case circuit breaker, is defined as a means of providing separation from an adjacent circuit.
Classification of assemblies
Open-type and enclosed assemblies
- Enclosed assembly An assembly is enclosed when there are protected panels on all its sides so as to provide a degree of protection against direct contact not lower than IPXXB . Assemblies intended to be installed in common environments shall be of enclosed type - Open-type assembly An assembly, with or without front covering, in which the live parts of the electrical equipment are accessible. Such assemblies can be used only in places where skilled persons have access for their use.
External design
- Cubicle-type (column)
Used for large distribution and control equipment; mechanically joined multi-cubicle-type assemblies are obtained by combining side by side more cubicle-type assemblies. - Desk-type Used to control complex machines or plants in mechanical, iron and steel and chemical industries. - Box-type Intended to be mounted on a vertical plane, both jutting out as well as built-in; such assemblies are used mainly for the department or area distribution in industrial or service sector environments. - Multi-box-type A combination of boxes, generally of protected type and with fixing flanges, each housing a functional unit which may be an automatic circuit-breaker, a starter, a socket completed with a blocking or protective circuitbreaker.
Classification of assemblies
Conditions of installation
- Assembly for indoor installation Assembly which is designed for use in locations where the normal service Conditions for indoor use as specified in the Std. IEC 61439-1 are fulfilled. - Assembly for indoor installation Assembly which is designed for use in locations where the normal service conditions for outdoor use as specified in the Std. IEC 61439-1 are fulfilled. - Stationary assembly Assembly which is designed to be fixed at its place of installation, for instance to the floor or to a wall, and to be used at this place. - Movable assembly Assembly which is designed so that it can readily be moved from one place of use to another.
Conclusion
With the ever-increasing pressures of demand for higher network utilization, assembly design optimization and more stringent safety, the changes included in the assembly standard IEC 61439-2 are important and overdue. All assemblies that do not have a specific product standard are covered and there is no opportunity to avoid compliance. In the new standard, the methods of confirming design performance are practical and pragmatic, reflecting the different market needs and ways in which assemblies are produced. Several alternative and equivalent means of verifying a particular characteristic of an assembly are included. These are defined and their use restricted. Where alternatives to type tests are used, a compensatory approach is taken and margins are added to ensure equivalence. Overall, the standard is performance based.
Bibliography
IEC 61439-1 - Low-voltage switchgear and controlgear assemblies
Part 1: General Rules IEC 61439-2 - Low-voltage switchgear and controlgear assemblies Part 2: Power switchgear and controlgear assemblies Introduction to IEC 61439: A new standard on Switchgear & Controlgear Assemblies by Mr. A P Rao; Mr. D A Chavan; Mr. P Patel; Mr. T N Shah Switchgear Design & Development Center Improving safety and performance in electrical assemblies - A guide to IEC 614392 by Schneider Electric IEC 61439 The new Standard for Low-Voltage Switchgear Assemblies Changes and Effects in respect of Tests by GE Ronald Borchert, IPH Berlin The new IEC 61439 Series Technical Seminar, 10th November, 2010 Singapore, KEMA Quality