INSTITUTE OF INTEGRATED ELECTRICAL ENGINEERS OF THE PHILIPPINES

39TH ANNUAL NATIONAL CONVENTION

AND
EXPO 2014
a specialized
Electrical, Electronic and Energy Exposition

IEC 61439-2 & IEC 60439-1

Low Voltage Switchgear and Controlgear Assemblies

Presented by Ir Aaron Leong

26 November 2014, Manila
LV Switchboard
It houses devices designed to;
• Distribute electrical power
• Protect circuits
• Protect people
DEPENDABLE
• Control and monitor the installation
Safety

STANDARD Reliable

Availability

Maintainability
Standard body
• International Electrotechnical
Commission (IEC)
• All the major industrialized countries are
involved
• Adopted directly into national specifications and
standards
Standard
• Switchboard design refers to Standards
governing the entire low voltage domain, and
more specifically to standards relating to
assemblies.
• Compliance with standards is the minimum
guarantee of a level of quality and dependability.
IEC 61439-1 & IEC 60439-2
STANDARD PARTS COMPARE
How the standard parts compare
• IEC 60439
• Part 1: Type Tested and Partially type tested Assemblies
• Part 2: Busbar trunking systems
• Part 3: Distribution boards
• Part 4: Assemblies for Construction Sites
• Part 5: Assemblies for power distribution
How the standard parts compare
• IEC 61439
• 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
IEC 61439 – Part 1: 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
IEC 61439 – Part 2
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”
Low voltage switchgear and controlgear
assemblies
 IEC 61439 – Part 2
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
• Moulded Case Circuit Breakers (MCCB)
• Fused Isolators
• Miniature Circuit Breakers (MCB)
• Additional power circuits (for motor control)
• Auxiliary circuits (controls)
ISOMETRIC VIEW – FULL ENCLOSURE
ISOMETRIC VIEW – WITHOUT DOORS
ISOMETRIC VIEW – WITHOUT COVERS
ISOMETRIC VIEW – CABLE & BUS BAR SYSTEM
How do you comply to the standard?
60439: PTTA (partially Type Tested) or
TTA (Type Tested) Assemblies
(these rules have been distorted)

61439: Design Verification &

Routine Verification
 IEC 61439 – Part 2

• The Standard also now recognises that there

maybe more than one company responsible
for the verification of the final Assembly.
– Original Manufacturer
– Assembly Manufacturer
 IEC 61439 – Part 2
• Manufacture
Assembly to Design
Manufacturer
• Routine
Verification

• Design
Production
Original
Manufacturer • Design
Verification
(By Test)

• Manufacture
to Design
Original & • Design
Assembly
Manufacturer Verification
• Routine
Verification
How do you achieve 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.
Refer Table D. 1
IEC 60439-Part 1
• TTA or PTTA
• Temperature rise limits
• Dielectric properties
• Short circuit withstand strength
• Effectiveness of the protective circuit
• Exposed Parts
• Short Circuit withstand
• Clearances and creepage distances
• Mechanical Operation
• Degree of protection
 Design
IEC 61439-Part 2 Verification
Construction characteristics
• Strength of materials and parts (clause 10.2)
• Degree of protection of enclosures (clause 10.3)
• Clearances and creepage distances (clause 10.4)
• Protection against electric shock and integrity of protective circuits (clause 10.5)
• Incorporation of switching devices and components (clause 10.6)
• Internal electrical circuits and connections (clause 10.7)
• Terminals for external conductors (clause 10.8)
Performance
• Dielectric properties (clause 10.9)
• Temperature rise limits (clause 10.10)
• Short circuit withstand strength (clause 10.11)
• Electromagnetic compatibility (clause 10.12)
• Mechanical Operation (clause 10.13)
61439 – Part 2
Strength of materials and parts (10.2)
All of the characteristics require verification by test.
• Resistance to corrosion
• Properties of insulating materials
• Resistance to ultra-violet radiation
• Lifting
• Marking
61439 – Part 2
Strength of materials and parts (10.2)
• Resistance to corrosion
• Ferrous enclosures and internal components of indoor and outdoor
assemblies upon which mechanical operation may depend.
• Resistance to ultra-violet radiation
• If manufactured from / coated in synthetic material and for installation
outdoors
• Lifting
• Marking
• Properties of insulating materials
• Verification of thermal stability of enclosures
• Only relevant to enclosures or technically significant
external parts manufactured of insulating material.
61439 – Part 2
Strength of materials and parts (10.2)
• Properties of insulating materials
• Verification of resistance of insulating materials to normal heat
• Parts that support conductors
• Other parts
• Verification of resistance of insulating materials to abnormal heat
and fire due to internal electric effects
• Parts that support conductors
• Other parts

Note: Verification for normal heat has been removed as a test in

Edition 2
Resistance to
ultra-violet
radiation
Degree of protection of enclosures
IEC 60529
• The IP (Ingress Protection) is broken down to
2 elements

• IP XX – Protection against Solid Objects

• IP XX - Protection against water ingress

Default arrangement (minimum): Indoor IP2X; Outdoor

IP23
Degree of protection
IEC 60529
• IP XX – Protection against Solid Objects
• IP 2X – 12.5 mm Probe
• IP 3X – 2.5 mm Probe
• IP 4X – 1mm Probe
• IP 5X – Dust (no pressure) – 8 hours
• IP 6X – Dust (negative pressure) – 8 hours
Degree of protection
IEC 60529
• IP XX – Protection against water ingress
• IP X1 – Vertical Drips – 10 Minutes
• IP X2 – Drips at 15˚ angle
• IP X3 – Spray at 0˚ & 60 ˚ angle
• IP X4 – Spray at all angles
• IP X5 – Pressured Jet
• IP X6 – High Pressured Jet
• IP X7 – Temporary submersion
• IP X8 - Continuous submersion (depth must be stated)
Degree Protection
IP X3 test
Internal Separation of PSC – 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.
61439 – Part 2
Clearances and Creepage distances (10.4)
• Clearance:
• The distance from a live conductor to
another live conductor or earth through air.

• Creepage:
• The distance over the surface of insulating
material from a live conductor to another live
conductor or earth
Clearances and Creepage distance
61439 – Part 2
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
61439 – Part 2
Protection against electric shock and integrity of
protective circuits (10.5)

• Protection against consequences of a fault within the

assembly
• Resistance Measurement

• Protection against consequences of faults in external

circuits supplied through the assembly
• Short circuit withstand verification
Verification of Effectiveness of
Protective Circuit
61439 – Part 2
Incorporation of switching devices and components
(10.6)
• Selection
• To Suit the assemblies application
• Installation
• To be installed in accordance with the manufacturers instructions
• Not to impair their proper function
• Accessibility
• Adjusting & resetting shall be easily accessible
• Consideration of adjacent functional units
• Not too low or too high
61439 – Part 2
Internal electrical circuits and connections (10.7)
• Main Circuits
• Suitable for short circuit
• Busbars
• connections
• Neutral conductor size
• Auxiliary Circuits
• Bare & Insulated conductors
• Suitable for Temperature rise
• Suitable for Insulation voltage
61439 – Part 2
Terminals for external conductors (10.8)
• Suitability of connection of external conductor
• Type of material – Copper / Aluminium / Both
• Size of external conductor
• Size of cable access
• Enables correct cable installation
• Marking
61439 – Part 2
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
61439 – Part 2
Dielectric Properties (10.9)
• Power Frequency
• Assesses the insulation resistance

• Impulse
• Assesses the ability to the assembly to cope with a
voltage spike
• Manufacturer to define kV
Dielectric Properties
61439 – Part 2
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 that effect the ratings are:

• Built in Components
• Busbars and conductors, Plug-in contacts of
removable or withdrawable parts which
connect to busbars
• Discrete arrangements of plug and socket type
connections
 Temperature Rise Limits
• Maximum Ambient Temperature
• 40 Degrees ˚C
• 50 Degrees ˚C

• Maximum Working Temperature

Maximum Working Temperature – Maximum Ambient Temperature = Temperature Rise
135 ˚C - 50 ˚C = 85 K (˚C)

• The temperature measured and considered is the rise that

is achieved after stabilisation (<1K in 1 Hour)

level of rise is stated in K (Kelvin) 1K = 1˚C

 Temperature Rise Limits
Specified Limits
(Based at 40 Degrees ˚C Maximum Ambient)

• Terminals for external insulated conductors: 70K

• Manual Operating Means
• Of Metal: 15K
• Of Insulating Material: 25K
• Accessible external enclosures and covers:
• Metal Surfaces: 30K
• Insulating Surfaces: 40K
• Bare Copper busbars & Conductors: 105K
• Refer Table 6 in IEC61439
 61439 – Part 2
Temperature Rise Limits
There has been a significant change to the way
assemblies are rated for its operational
current.
• Rated current
– Of the Assembly (InA)
– Of a circuit (Inc)

• Rated diversity factor (RDF)

61439 – Part 2
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
61439 – Part 2
Short Circuit Withstand Strength (10.11)
Verification is not required where:

• The Assembly is rated Icw or Icc below 10kA

• Assemblies and circuits protected by a current limiting

device having a cut off not exceeding 17kA

• Auxiliary circuits connected via a transformer which is

within specified limits.
61439 – Part 2
Short Circuit Withstand Strength (10.11)

Busbars, incoming device &

outgoing devices
Short Circuit Withstand Strength
• Tests conducted
• 3 phase main bars
• 1 phase to neutral main bars

• 3 phase dropper bars

• 1 phase to neutral dropper bars

• 3 phase incoming circuit

• 1 phase to neutral incoming circuit

• 3 phase outgoing circuits

Video
• 1 phase to neutral outgoing circuits
FRONT VIEW – WITHOUT COVERS
61439 – Part 2
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
61439 – Part 2
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
 61439 – Part 2
Routine Verification

Design Routine
Verification Verification

Performed on Performed on
representative every supplied
samples and assembly – by
designs checking against
Design
Verification
 61439 – Part 2
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
 IEC 61439 – Parts 1 & 2
To Summarise
PTTA & TTA replaced by design verification

Original and Assembly manufacturer recognised

Clarity provided in where design rules and calculation can be used

Clarification in the form of separation

New tests required on enclosure

Changes in the temperature rise test procedure

Routine verification improved to cross reference design verification

IEC 61641: 2008
ARCING DUE TO INTERNAL FAULT
IEC 61641 Arcing due to internal fault
• Possible cause of electrical arcs
• Arc due to dielectric breakdown
• Introduction of foreign object
• Faulty connection
• Pressurised ionised gases

Video Video
 Arcing Fault Containment Test

Fail
 Arcing Fault Containment Test

Pass
Arcing Fault Containment Test

Before After
IEC 61641 Arcing due to internal fault
• Load side of the outgoing functional unit
• Supply side of the outgoing functional unit
• Along the distribution busbar
• Along the main busbar
• Load side of the incoming functional unit
• Supply side of the incoming functional unit
Arcing due to internal fault
The Purpose
• To verify the effectiveness of the construction of
Form Separation for the Assembly
• To assess the ability of the Assembly to limit the
risk of personal injury resulting from an internal
Arcing Fault.
• Dielectric tests were performed after the Arcing
Fault Test.
Arcing due to internal fault
The Assessment of Test Results
• All covers, doors and fastenings were intact
• No components were dislodged
• The cotton gauze did not ignite &
damages were confined to that unit,
• Proof of minimum risk of personal injury
• Busbar and all other functional units remain firm
for further service.
QUESTION & ANSWER
Question and answer
• When short circuit occurred to the LV switchboard,
can the switchboard be operated again? Why?

• When an arc occurred at the LV switchboard, can

the switchboard be operated again? Why?

• Why Form 4B and arc fault containment for your

project?