Sharing session with JKR on IEC 60439 and IEC 61439

Er. Lim Say Leong, Region Marketing Manager, South Asia, Automation Products Division, 18 August 2009

My talk today

Title: Low voltage switchgear and controlgear assemblies - Requirements of today and tomorrow Sypnosis: This sharing session covers the current IEC 60439 series and also the development of IEC 61439 for tomorrow. Salient requirements will be presented in details leaving time for discussions such as: difference between IEC 60439 and IEC61439, type tested & partially type tested assemblies, how to confirm/check construction compliance of assemblies as per test report, trend of busbar trunking system, etc.

IEC worldwide requirement in a global economy

Situation Many manufacturers could comply with IEC 60439. Many also do not comply due to various reasons: Lack of knowledge. Difficulties to meet customization of their product. Product not verified. Pressure to reduce costs.

Share our knowledge and experience

ABB sets the standard Local presence and expertise Best technology for the process Cost-effective solutions Responsive local service A supplier with global guidance and direction

IEC 60439 - structure

Part 1 Type-tested and partially type-tested assemblies. Part 2 Particular requirements for busbar trunking systems. Part 3 Particular requirements for distribution boards. Part 4 Particular requirements for assemblies for construction sites (ACS). Part 5 Particular requirements for cable distribution cabinets (CDC).

Supported by other IEC specifications

IEC 60890 Method of temperature-rise assessment by extrapolation for partially type-tested assemblies (PTTA). IEC 61117 Method of assessing the short-circuit withstand strength of partially type-tested assemblies (PTTA). IEC 61641 Guide for testing under conditions of arcing due to internal fault.

IEC 60439 series IEC 60439-1

Part 1 Type-tested and partially type-tested assemblies.

ABB Group August 18, 2009 | Slide 7

IEC 60439 series IEC 60439-2

Part 2 Busbar trunking system.

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IEC 60439 series IEC 60439-3

Part 3 Distribution boards where unskilled persons have access for their use.

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IEC 60439 series IEC 60439-4

Part 4 Assemblies for construction sites

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IEC 60439 series IEC 60439-5

Part 5 Cable distribution cabinets (CDCs) power distribution and installed outdoors in public places.

IEC 60439 series

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Standards for switchboards IEC 60439-1

Specification for type-tested (TTA) and partially typetested assemblies (PTTA) Defines and specifies the service conditions, constructional requirements, technical characteristics and tests of TTA & PTTA Non-prescriptive Allows the manufacturer to be innovative Specified as minimum requirements for supplying of switchboards in projects together with ASTA or equivalent Certification locally

Low voltage switchgear & controlgear assemblies

A combination of one or more switching devices together with associated: control, measuring, signaling, protective, regulating equipment, etc., completely assembled under the responsibility of the manufacturer.

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What is TTA and PTTA?

H. T109-I-01
maggio '97

Quadri per distribution Quadri elettrici per bassa tensione

TTA

TypeType-tested assemblies
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.

ABB Elettrocondutture

catalogue

PTTA Partially Type-tested assemblies TypeA low voltage switchgear and controlgear assembly containing both type-tested and not type tested arrangements provided that the latter are derived (e.g. by calculation ) from type-tested arrangements which have complied with the relevant tests.
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calculation

Testing of switchboards

8 Type test 1 verify temperature rise limits 2 verify dielectric properties Performed and 3 verify short-circuit withstand carried out on a 4 verify protective circuit effectiveness representative unit 5 verify clearances and creepage distances 6 verify mechanical operation 7 verify degree of protection 8 verify emc + 3 Routine tests 9 Test 8-3-1: Overall inspection The 3 routine tests 10 Test 8-3-2 or 8-3-4: Insulation check must be carried out 11 Test 8-3-3: verify protection measures & on every
electrical continuity of protective circuits

switchboard

ABB Group August 18, 2009 | Slide 16

Maximum safety and reliability

Characteristics of switchboards
Defined by a number of key parameters. Specified by the manufacturer, sometimes by agreement between the manufacturer and user of the equipment. These characteristics, for example, may depend upon the environment in which the equipment is required to operate and the fault level of the supply to the equipment. The manufacturer must specify the relevant characteristics for the relevant type-tests to be conducted by the testing station.

ABB Group August 18, 2009 | Slide 17

Electrical characteristics of switchboards

Rated Voltage
Rated Operational Voltage (Ue) Rated Insulation Voltage (Ui) Rated Impulse Withstand Voltage (Uimp)

Rated Current (In) Rated Short-time Withstand Current (Icw) Rated Peak Withstand Current (Ipk) Rated Conditional Short-circuit Current (Icc) Rated Fused Short-circuit Current (Icf) Rated Diversity Factor Rated Frequency
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Information to be provided
On Nameplates manufacturer's name or trade mark type designation or identification number, or any other means of identification making it possible to obtain relevant information from the manufacturer On Nameplates or Technical documentation IEC 60439-1; Type of current (and frequency, in the case of a.c.); Rated operational voltages (see 4.1.1); Rated insulation voltages (see 4.1.2); Rated impulse withstand voltage, when declared by the manufacturer (see 4.1.3); Rated voltages of auxiliary circuits (if applicable);
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Information to be provided (contd)

On Nameplates or Technical documentation Limits of operation (see clause 4); Rated current of each circuit (if applicable; see 4.2); Short-circuit withstand strength (see 7.5.2); Degree of protection (see 7.2.1); Measures for protection of persons (see 7.4); Service conditions for indoor use, outdoor use or special use, if different from the usual service conditions as given in 6.1; Pollution degree, when declared by the manufacturer (see 6.1.2.3); Types of system earthing for which the ASSEMBLY is designed; Dimensions, preferably in the order of height, width (or length), depth; Weight;
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Information to be provided (contd)

On Nameplates or Technical documentation Form of internal separation (see 7.7); Types of electrical connections of functional units (see 7.11); Environment 1 or 2 (see 7.10.1).

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Service condition
Ambient air temperature Ambient air temperature for indoor installations Does not exceed +40 and its average over a period C of 24 h does not exceed +35 C. The lower limit of the ambient air temperature is 5 C. Ambient air temperature for outdoor installations Does not exceed +40 and its average over a period C of 24 h does not exceed +35 C. The lower limit of the ambient air temperature is: 25 in a temperate climate, and C 50 in an arctic climate. C

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Service condition
Atmospheric conditions Atmospheric conditions for indoor installations The air is clean and its relative humidity does not exceed 50 % at a maximum temperature of +40 C. Higher relative humidity may be permitted at lower temperature, for example 90 % at +20 C. Atmospheric conditions for outdoor installations The relative humidity may temporarily be as high as 100 % at a maximum temperature of +25 C.

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Service condition
Pollution degree Refers to the environmental conditions for which the ASSEMBLY is intended. For switching devices and components inside an enclosure, the pollution degree of the environmental conditions in the enclosure is applicable.

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Service condition
Pollution degree (contd) To evaluate clearances and creepage distances, the following four degrees of pollution are established. Pollution degree 1 No pollution or only dry, non-conductive pollution occurs. Pollution degree 2 Normally, only non-conductive pollution occurs. Occasionally, however, a temporary conductivity caused by condensation may be expected. Pollution degree 3 Conductive pollution occurs or dry, non-conductive pollution occurs which becomes conductive due to condensation. Pollution degree 4 The pollution generates persistent conductivity caused, for instance, by conductive dust or by rain or snow.

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Service condition
Altitude Site of installation does not exceed 2 000 m (6 600 ft). Note: For electronic equipment to be used at altitudes above 1 000 m, it may be necessary to take into account the reduction of the dielectric strength and of the cooling effect of the air. Electronic equipment intended to operate in these conditions should be designed or used in accordance with an agreement between manufacturer and user.

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Design & construction

Mechanical design Materials capable of withstanding the mechanical, electrical and thermal stresses as well as the effects of humidity which are likely to be encountered in normal service. Protection against corrosion shall be ensured by the use of suitable materials or by the application of equivalent protective coatings to the exposed surface, taking account of the intended conditions of use and maintenance. All enclosures or partitions including locking means for doors, withdrawable parts etc., shall be of a mechanical strength sufficient to withstand the stresses to which they may be subjected in normal service. The apparatus and circuits in the ASSEMBLY shall be so arranged as to facilitate their operation and maintenance, and at the same time to ensure the necessary degree of safety.
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Design & construction

Clearances, creepage distances and isolating distances Clearances and creepage distances Apparatus forming part of the ASSEMBLY shall have distances complying with the requirements of their relevant specifications, and these distances shall be maintained during normal service conditions. When arranging apparatus within the ASSEMBLY, the specified creepage distances and clearances or impulse withstand voltages shall be complied with, taking into account the relevant service conditions. For bare live conductors and terminations (e.g. busbars, connections between apparatus, cable lugs), the creepage distances and the clearances or impulse withstand voltages shall at least comply with those specified for the apparatus with which they are directly associated.
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Design & construction

Clearances, creepage distances and isolating distances (contd) In addition, abnormal conditions such as a short circuit shall not permanently reduce the clearances or dielectric strength between busbars and/or connections other than cables below the values specified for the apparatus with which they are directly associated. Isolating distances on Withdrawable parts In the case of functional units being mounted on withdrawable parts, the isolation provided shall at least comply with the requirements in the relevant specification for disconnectors with the equipment in new condition, taking account of the manufacturing tolerances and changes in dimensions due to wear.

ABB Group August 18, 2009 | Slide 29

Design & construction

Dielectric properties Terminals for external conductors Enclosures and degree of protection Temperature rise Protection against electric shock Short-circuit protection and short-circuit withstand strength Switching devices and components installed in ASSEMBLIES Internal separation of ASSEMBLIES by barriers or partitions Electrical connections inside an ASSEMBLY: bars and insulated conductors Requirements for electronic equipment supply circuits Electromagnetic compatibility (EMC) Description of the types of electrical connections of functional units
ABB Group August 18, 2009 | Slide 30

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Switchboards Common problems

ABB Group August 18, 2009 | Slide 31

Switchboards What are the common problems?

Overheating Fire Electric shock

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How we react? The usual way is to blame down the chain Can we overcome it? Yes

Overheating What causes it? Poor connection - Mitigation There is proper tightening torque Equipment Value Correct selection of termination Regular checking

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Overheating What causes it? Under-size - Mitigation Correct sizing for cable and busbar. At termination oversize to have heatsink effect. Overdoing it results in costs increase

Overheating What causes it? Ventilations - Mitigation Heat concentration Chimney effect Do not block it Regular checking and cleaning

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Overheating What causes it? Harmonics - Mitigation Know the load in advance Filters
Have sufficient rating for the inductor. Have capacitor that takes the overvoltage and the flame-retardant

Enclosed Capacitor Units CLMD

Fire protection The capacitor elements are surrounded by vermiculite which is an inorganic, inert, fire-proof and non-toxic granular material. The vermiculite safely absorbs the energy produced within the capacitor box and extinguishes any possible flame. Thermal equalizers Thermal equalizers are fitted to surround each capacitor element and provide effective heat dissipation. The CLMD capacitor is equipped with discharge resistors High reliability The CLMD capacitor complies with requirements to IEC60831-1 & 2 and is UL listed.

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Overheating What causes it?

Poor connection Under-size Ventilations Harmonics

Fire What causes it?

Prolonged overheating Flammability of material Source of ignition

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Electric Shock What causes it?

Deterioration of insulation Access to live parts Explosion Flashover

Testing and acceptance Classification of tests in IEC 60439-1 type tests routine tests Practice of acceptance in addition to standard Factory acceptance test - FAT Site acceptance test SAT Operation and maintenance manual O&M

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Switchboards Testing & acceptance

ABB Group August 18, 2009 | Slide 43

Type tests certificate.

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Testing and acceptance Type tests to verify compliance with standard & carried out on a sample to be manufactured to the same or a similar design. They shall be carried out on the initiative of the manufacturer.

Testing and acceptance Routine tests on every production unit intended to detect faults in materials and workmanship.
a) b) c)

Inspection Dielectric test Checking of protective circuit

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Testing and acceptance Factory acceptance test Materials and construction Setting and verifying Site acceptance test Transportation damage Setting, sealing, signed off Operation and maintenance manual Learning to use and maintenance

Switchboards Protection against overvoltages

ABB Group August 18, 2009 | Slide 48

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Overvoltage requirement for IEC 60439-1

overvoltage category a conventional number based on limiting (or controlling) the values of prospective transient overvoltages occurring in a circuit (or within an electrical system having different nominal voltages) and depending upon the means employed to influence the overvoltages. surge arrester a device designed to protect the electrical apparatus from high transient overvoltages and to limit the duration and frequently the amplitude of the follow-on current

Overvoltage requirement for IEC 60439-1

Overvoltages Supply overvoltages are specified in figure 1. This figure applies to the non-periodic overvoltages as a deviation from the rated peak value within the short-time range. The ASSEMBLIES shall be so designed that their service ability in the case of overvoltages below the values represented by curve 1 is ensured. If overvoltages occur within the range between curves 1 and 2, the operation may be interrupted by the response of protective devices safeguarding the ASSEMBLY, no damage to the ASSEMBLY being allowed to occur up to a peak value of the voltage equal to 2 Ui + 1 000 V.

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Overvoltage requirement for IEC 60439-1

Overvoltage requirement for IEC 60439-1

Temporary variations in voltage and frequency The equipment shall operate without damage when there are temporary variations in the following conditions. voltage drops not exceeding 15 % of rated voltage for periods not longer than 0,5 s. supply frequency deviation of up to + 1% of rated frequency. the maximum admissible duration of an interruption of the supply voltage for equipment shall be indicated by the manufacturer.

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Overvoltage requirement for IEC 60439-1

Overvoltage requirement for IEC 60439-1

Impulse withstand voltages category to IEC 60364-4-44 , 60439 and 60947.

System voltage
Uimp

400 V~ 6000 V

230 V~ 4000 V

230 V~ 60 V~ 2500 V II

1500 V I

Category

IV

III

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Location of SPD to IEC 60439-1

Category IV Origin of installation overhead lines cable networks busbars cutouts

Category III Distribution circuit final circuit stationary installation

Category II Load level portable equipment

Category I
Special equipment communication equipment electronics

Location of SPD to IEC 60439-1

Category IV 6 kV 25 kA 10/350 class 1

Category III 4 kV 10 kA 8/20 class 2

Category II 2.5 kV 1.5 kA 8/20 class 3

Category I 1.5 kV

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Why to protect against overvoltage?

Decreasing robustness of equipment : sensitive electronic equipments telecommunication equipments

Increasing propagation of disturbance : interconnection and complexity of power and telecommunication networks. switching operations of power electronics.

Why to protect against overvoltage?

Statistics from insurance shows high percentage of damage to electronics due to overvoltages Loss of operation Loss of service

Damage to semiconductor device due to overvoltage Loss of data Loss of production

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What is an overvoltage?

8000V during 140s

Lightning surge Switching surge

460V during 10s
Vrms 230V 50Hz

Transient overvoltage Purpose of SPD

Temporary overvoltage Enemy of SPD

Lightning strikes

direct lightning strike

Direct lightning strike on a lightning rod

Close lightning strike on aerial line

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Lightning strikes
Iimp 90%
V ALUE in kA

10/350 waveshape
10/350 is used to test Type 1

10/350

50%

10% 10s 350s

TIM E (s)

10/350 wave shape

Lightning strikes

indirect lightning strike

Distant lightning strike on aerial line

Inductive coupling

Earth potential rise

+ switching operations

Capacitive and inductive equipments are switched on or off Fuse or breaker operations Power electronics

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Lightning strikes

8/20 waveshape
8/20 is used to test Type 2 and Type 3

Imax 90%
VALUE

8/20

50% I 10% 8s 20s

TIME

(s)

8/20 wave shape

Comparison of the energy

V A LU E in kA

10/350 8/20
T IM E in us

10/350 energy >> 8/20 energy

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Strike size and frequency

100%

Cumulative frequency

80%

40% of lightning strikes are higher than 20kA (or 60% of lightning strikes are below 20kA) 5 % of lightning strikes are higher than 60kA (or 95% of lightning strikes are below 60kA) 0.1 % of lightning strikes are higher than 200kA

60%

40%

20%

0% 0

Amplitude of Lightning Strokes (kA) Amplitude of lightning strokes (kA)

20

40

60

80

100

120

140

160

180

200

Cumulative frequency of lightning strikes positive and negative- versus their amplitude. Data from Meteorage. Measurement campaign on 5.4Million strokes between 1995-2005

Typical current sharing on direct strike (10/350)

200 kA

TV network 48,3 kA
power network

33 kA 33 kA 33 kA

PE 100 kA
water and gas pipes

10 100 kA

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OVR Over Voltage Range

IEC EN NFC VDE
CLASS A TYPE I TYPE II TYPE III International TYPE I TYPE II TYPE III Europe France SPD CLASS B CLASS C CLASS D Germany TVSS United states

UL

Withstand of equipment
Equipments are divided into withstand categories : Category IV : Industrial equipment, meters Category III : Distribution panels, switchgear Category II : Domestic electrical equipment Category I : Sensitive electronic circuits overvoltage < 6000V overvoltage < 4000V overvoltage < 2500V. overvoltage < 1500V

Overvoltage value due to lightning or switching : 500V to 200 000V

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Level of protection = Up

Unetwork

SPD
Up=1,2kV

UProtected
Equipment

Iimp: OVR T1 25-255 7kA 10/350

Iimp 90%
V ALUE in kA

Iimp

15kA 10/350 25kA 10/350

10/350

50%

10% 10s 350s

TIM E (s)

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Imax: OVR T2 40-275 s P TS 15kA 8/20

Imax 90%
VALUE

Imax

40kA 8/20

8/20

70kA 8/20

50% I 10% 8s 20s

TIME

(s)

8/20 wave shape

Type I+II / Combined SPD

OVR T1+2 25 255 TS OVR T1+2 7 275s P Wave shape Techno Iimp Imax Up 10/350 Spark Gap + MOV 25kA 1,5kV 10/350 & 8/20 MOV 7kA 70kA 1,5kV

Reason to call the SPD T1+2

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Type I+II / Combined SPD

When the surge comes, the electronic will detect and amplify it
At this stage, a little spark is generated at the needle head Little spark commutes the air gap, thus surge energy is driven to ground

OVR T1 25-255

Once the surge is earthed, arc enters in the arc chamber. this is self extinguishing time

Hot gas exit passing through the exhaust channel that avoid any fire risks

IEC 61439 series Now and the future

ABB Group August 18, 2009 | Slide 75

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Towards the future - IEC 61439

What would it be IEC 61439?

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IEC 61439 Structure

Part 1 General rules

Part 2 Power switchgear & Controlgear Assemblies

Part 3 Distribution Boards

Part 4 Assemblies for Construction Sites

Part 5 Assemblies for Power Distribution

Part 6 Busbar trunking Systems

New world standard

IEC 61439 provides detail guidelines on how to prove that assemblies derived from fully typetested assemblies comply with the new standard.

IEC 60439 standard was not so easy to assess whether partially type tested assemblies are compliant.

IEC 61439 standard will specify: by testing by calculations by design rules

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IEC 60439 Future classification IEC 61439

Today, due to a lack of clarity of IEC 60439 there is wide range of interpretations on: How to carry out the verification, What is the acceptance criteria, and How many required number of verifications on different specimen. Verification by Type test Calculation Design rules

IEC 60439 Future classification IEC 61439

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IEC 60439 Future classification IEC 61439

The new structure

Previous ambiguities have been addressed, e.g. diversity, rating of circuits and substitution of devices. The standard requires that the performance of every assembly is demonstrated at design and manufacturing stages by a combination of stringent and defined verification processes : proving tests, inspection, design rules and/or calculation.

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The new structure

Tests carried out on devices to their own product standard do not need to be duplicated when installed in an assembly. The new standard fully recognises the use of switchboards assembled from kit systems in accordance with the original manufacturers instructions. The verification process no longer recognizes the classifications of TTA. and PTTA., alternative and equivalent methods to type tests are included

The new structure

Tests carried out on devices to their own product standard do not need to be duplicated when installed in an assembly. The new standard fully recognises the use of switchboards assembled from kit systems in accordance with the original manufacturers instructions. The verification process no longer recognizes the classifications of TTA. and PTTA., alternative and equivalent methods to type tests are included

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ArTu K

The completely type tested assembly (TTA) and competitive solution designed to be assembled by an Authorized Panel builder In kit form mainly for power distribution. A pre-engineered product from to be Authorized Panel builder assembled by

Main characteristics

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Main characteristics
Integrated range of structures up to 4000A with common accessories

Possibility of fullfilling all application requirements in terms of installation and degree of protection (IP31, IP41, IP42, IP65) Segregations in kits up to Form 4

Maximum integration with the ABB Components

Main characteristics
ArTu complies with the CEI EN60439 Standards Production system certified ISO 9001 and ISO 14000

ArTu has obtained ACAE/LOVAG & ASTA Certification ArTu is in accordance with UL50 and UL891

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Main characteristics
Compliance with IEC 60439-1 Standard
ArTu K Switchboards have undergone TTA tests foreseen by IEC 439-1 in the ABB & Falcon laboratories. The results guarantee the performance of ArTu K by using the structures and ABB SACE circuit breakers, therefore the assembler does not have to carry out any further type test by following the selection criteria and the assembly instruction for the various components

Temperature rise (ref. para. 8.2.1 of the standard)

Temperature limits are within the limits specified in the standard and tested for rated current 4000A

Dielectric properties (ref. para. 8.2.2 of the standard)

Rated service voltage: up to 690V Rated insulation voltage: up to 1000V Rated impulse withstand voltage: 8KV

Short circuit withstand current (ref. para. 8.2.3 of the standard)

Rated short time short circuit current: Rated max. Pick short circuit current: 105 KA (1s) & 50 KA (3s) 254 KA

Short circuit efficiency (ref. para. 8.2.4 of the standard)

Protection circuit short circuit withstand current: Phase-earthing busbar: 60 KA (1s)

Main characteristics
Insulation distances (ref. para. 8.2.5 of the standard)
The insulation distances are guaranteed by following the ABB SACE assembly & mounting instructions, and those for ABB SACE circuit breakers

Mechanical operation (ref. para. 8.2.6 of the standard)

Mechanical operation is verified by following the assembly and mounting instruction of the metal workstructures and ABB SACE circuit breaker

Degree of protection (ref. para. 8.2.7 of the standard) & to IEC 529
Without door : Without door : With door: IP 31 IP 41 IP 65

Impact resistance IK
Strong structure and tempered glass

40c

5kg Impact energy in Joules: 20.00

ABB Declaration of conformity

We confirm that ArTu K has undergone all the above tests and declared TTA by ACAE-LOVAG certification authority

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ArTu K Modular Switchboards

Distribution Systems

A complete system: Busbars with shaped section up to 3200A Flat Drilled Busbars up to 4000A

Compliance to IEC60439-1 Simple to assemble

ArTu K Modular Switchboards

Advantages of the Busbar Systems

Easy & fast in mounting

Rapid coupling

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ArTu Distribution Switchboards

Segregations
ArTu is available with or without segregations Comply with IEC 60439-1 Segregation Compartments available as: - Form 2 - Form 3A and 3B - Form 4 Simple kit to convert from Form 3 to Form 4 Form 4 available both for MCCBs and ACBS Maintenance without Service Interruption

New world standard

IEC 61439 the new standard for low-voltage switchgear and controlgear assemblies was issued Jan 2009. One of the main improvements is that the definition of fully Type Tested Assemblies (TTA) and Partially Type Tested Assemblies (PTTA) have been removed from the standard.

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New world standard

IEC 61439 provides detail guidelines on how to prove that assemblies derived from fully typetested assemblies comply with the new standard. IEC 60439 standard was not so easy to assess whether partially type tested assemblies are compliant. IEC 61439 standard will specify: by testing by calculations by design rules

How it affects us?

If we have existing products that have already been tested properly, this will not affect your IEC 60439 certification. Tendency to provide more proof that their product families follow the correct design guidelines and rules to comply with IEC 61439. It is no longer acceptable to provide an assembly without a full design being fully proven. It is difficult to make substitutions of one component or product for another without stringent assurances

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How it affects us?

Certification and acceptance of products from IEC 60439 to IEC 61439. Moving our MS to IEC 61439 It is no longer acceptable to provide an assembly without a full design being fully proven. It is difficult to make substitutions of one component or product for another without stringent assurances.

Smissline

sayleong.lim@sg.abb.com

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 ABB Group August 18, 2009 | Slide 102

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