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Type Tests Defined in IEC 61439

The document discusses type tests defined in IEC 61439 that are performed on low voltage switchgear assemblies to certify their design and construction. The key type tests cover temperature rise limits, dielectric properties, short-circuit resistance, protective circuit effectiveness, clearances and creepage distances, mechanical operation, and degree of protection. Additional type tests specified in IEC 61439-1 include resistance to mechanical impact, rust resistance, resistance to damp conditions, insulating material heat resistance, fire resistance, and mechanical performance of assemblies and fixings. The type tests are intended to ensure the switchgear can operate safely and reliably under expected operating conditions.

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Sharif Khan
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5K views12 pages

Type Tests Defined in IEC 61439

The document discusses type tests defined in IEC 61439 that are performed on low voltage switchgear assemblies to certify their design and construction. The key type tests cover temperature rise limits, dielectric properties, short-circuit resistance, protective circuit effectiveness, clearances and creepage distances, mechanical operation, and degree of protection. Additional type tests specified in IEC 61439-1 include resistance to mechanical impact, rust resistance, resistance to damp conditions, insulating material heat resistance, fire resistance, and mechanical performance of assemblies and fixings. The type tests are intended to ensure the switchgear can operate safely and reliably under expected operating conditions.

Uploaded by

Sharif Khan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Type tests defined in IEC 61439

Certification of distribution assemblies is defined by international


standard IEC 61439-1. This standard provides common rules that are
recognized worldwide. Compliance with the standard is certified,
depending on the country or market, by a declaration of the panel builder,
the design office, the installer or the user.

13 most important type tests of a low voltage switchgear performed in a


factory (photo credit: eksiton.ru)
Just to mention before going into test, that low voltage switchgear and
controlgear assemblies (Un ≤ 1000 V AC) may be used at the origin of an
electrical installation with:

1. Low Voltage Main switchboard (transformer area)


2. Low Voltage Main Distribution Board (technical area) and
3. Sub Distribution boards
To avoid checks and tests that take a long time, are sometimes
destructive, and above all too costly, the standard permits them to be
reduced to the minimum, using ‘type tests’ carried out and guaranteed by
the manufacturer.
Seven type tests are carried out officially on low voltage assemblies
representative of the usual wiring configurations and equipment layouts.
These assemblies are called ‘standard assemblies’. By definition,
standard assemblies only contain layouts that have undergone type tests.
Table of contents:
They cover the following checks for type tests:

1. Type tests:
1. Temperature rise limits
2. Dielectric properties
3. Short-circuit resistance
4. Effectiveness of the protective circuit
5. Clearances and creepage distances
6. Mechanical operation
7. Degree of protection (IP)
And there are also six tests designed to check the construction quality are
added to the above type tests in standard IEC 61439-1.

2. Additional type tests:


1. Resistance to mechanical impact
2. Rust resistance
3. Resistance to damp
4. Resistance of insulating materials to heat
5. Fire resistance
6. Mechanical performance of assemblies and fixings

1. Type tests
1.1 Temperature rise limits
Verification in temperature rise limits test is one of the most critical in
determining the reliability and long service capability of a low voltage
assembly and must not be overlooked. Excessive temperatures result in
premature ageing of components and insulation, and ultimately failure.
Current ratings of components are valid  only when the temperature
around them is within the limits  specified by the component
manufacturer.
When temperature rise verification is carried out by test, the manufacturer
can select from three options to suit the design and the total time to be
devoted to testing:
Option 1
The incoming circuit and at least one outgoing circuit of each rating are
loaded to their rated current. If a circuit of each basic type is not included
in the test, further tests are carried out until one  outgoing circuit of each
type has been included.  This approach is suitable  where a specific
arrangement and design of assembly is to be verified with the minimum
amount of testing .
As the outgoing circuits are tested with a diversity (loading) factor of
unity, it does, however, result in a more onerous test than necessary for
most applications.

Figure 1 – IEC 61439 temperature rise test

Option 2
Outgoing circuits are temperature rise tested individually to verify they
are capable of carrying their rated current. The incoming circuit is then
supplied to its rated current. This is distributed through as many outgoing
circuits as practical, including one outgoing circuit of each basic type and
in the most onerous configuration, with each circuit loaded to its rated
current multiplied by the  rated diversity (loading) factor .

Again, this test regime is  only suitable for a specific arrangement and
design of assembl y, but it does better reflect the normal loading of an
assembly.

Option 3
This alternative has been included to enable  modular assembly systems
to be fully verified . Horizontal busbars, vertical busbars and outgoing
functional units are tested individually. The assembly as a whole is then
verified as in Option 2.

Whilst this method of temperature rise testing involves a lot of testing,


once it is completed  it covers all the possible arrangements available in a
flexible modular system , and avoids any concerns that may previously
have arisen due to the specific arrangement supplied not being exactly as
that tested.
Note that temperature rise tests are time consuming.  A lot of time is
required to connect all the circuits to be included in the test, balance the
current and insert the thermocouples. Current is applied until conditions
stabilize, usually around eight hours, and, in the final hours, temperatures
are monitored, normally with thermocouples.

Critical areas for temperature measurement are covers, operating


handles, busbars and joints, insulators, cable terminals, device and/or
internal air temperatures.

1.1.1 Temperature rise test on assemblies


This test checks that assemblies operate correctly under maximum
operating conditions (current, number of devices, volume of enclosure). It
is used to define the heat balance data for an  average temperature rise of
the air in assemblies of less than 30 K and a temperature rise of the
terminals of less than 70 K.

Note that temperatures rises are given in Kelvin to differentiate them from
temperatures given in °C.

1.1.2 Temperature rise test on busbars


The various currents given for all the bar and distribution systems have
been checked under the most severe conditions, according to the degree
of ventilation of the enclosure ( IP ≤ 30 and IP > 30), so that the
temperature rise of the busbars does not exceed 65 K.

1.2 Dielectric properties


The dielectric tests check the insulation performance levels for the
maximum operating voltage. They are carried out at the industrial
frequency of 50 Hz and in the form of voltage waves simulating a lightning
strike.
Impulse withstand voltage test performed on assemblies (on photo: Tests
in the impulse current laboratory by DEHN)

1.3 Short-circuit resistance


The tests carried out ensure the resistance of busbars and their supports,
breaking and protection devices and enclosures to thermal and
electrodynamic stresses.

1.4 Effectiveness of the protective circuit


The continuity of the protective circuit is a  decisive factor for safety . It is
checked in accordance with standard IEC 61439-1 at a test current of 25 A
between the terminal connecting the protective conductors and all the
exposed conductive parts.

The continuity of the protective circuit  is also checked at a high fault
current that could occur following accidental detachment of a conductor.

The protective circuits (conductors, terminals or collector bars), are sized


and tested to withstand the maximum short-circuit thermal stress that
could occur according to the current at the supply end of the assembly.

1.5 Clearances and creepage distances


The methods for measuring creepage distances and clearances in
standard IEC 60664-1 are repeated in full in appendix f of standard IEC
61439-1. The distances are measured between live parts with different
polarities, and also between live parts and the exposed conductive parts.

When modular devices and equipment are installed in accordance with the
specified conditions, the distances are observed for the insulation
voltages of these devices.  Experience has shown that the greatest risk is
in the wiring.
Connections, bundles of conductors and busbars must be meticulously
checked.

Unsuitable connectors, bolted connections, joints and metal supports can


reduce the initially planned insulation values.

Figure 3 – Clearances in air

Go back to Table of Contents ↑

1.6 Checking mechanical operation


In accordance with the provisions of the standard, tests are carried out on
parts and devices that are not subject to any specific requirements.
Correct mechanical operation is checked by  50 operating cycles on
drawout racks and faceplate fixings .
Testing drawout rack

Go back to Table of Contents ↑

1.7 Checking the degree of protection (IP)


The IP defines the ability to protect people and to prevent entry of solid
objects (first number) and against liquids (second number). The additional
letter indicates the protection against access to dangerous parts.

Table 1 – IP degrees of protection in accordance with standard IEC 60529


Table 1 – IP degrees of protection in accordance with standard IEC 60529

Go back to Table of Contents ↑

2. Additional type tests


Defined by standard IEC 61439-3, six tests designed to check the
construction quality are added to the seven type tests in standard IEC
61439-1.

They are applied to distribution panels whose  incoming current is not


more than 250 A at the supply end  and which are to be installed in
locations that are accessible to unqualified people (residential and
commercial applications, public buildings, etc.).

They cover the following checks:

1. Resistance to mechanical impact


2. Rust resistance
3. Resistance to damp
4. Resistance of insulating materials to heat
5. Fire resistance
6. Mechanical performance of assemblies and fixings
2.1 Resistance to mechanical impact
2.1.1 Spring hammer test
This test is carried out in accordance with IEC 60068-2-63  at a temperature
of – 5°C with a spring hammer delivering an energy of 0.7 joule .

2.1.2 Pendulum impact test


Pendulum impact test is carried out in accordance with European
standard EN 62262, this test determines  the degree of impact protection
(IK).

Pendulum impact test on the low voltage enclosure


Table 2 – IK degrees of protection against mechanical impacts according
to standard EN 50102
Table 2 – IK degrees of protection against mechanical impacts according
to standard EN 50102

Go back to Table of Contents ↑

2.2 Rust resistance


2.2.1 Ammonium chloride test
Ammonium chloride test checks that  there is no rust present after 10
minutes’ immersion in a solution of ammonium chloride  (according to IEC
61439-3).
2.2.2 Salt spray test
Salt spray test, carried out in accordance with IEC 60068-2-11,
ensures more than 168 hours’ resistance to salt spray on enclosures .

2.3 Resistance to damp


Resistance to damp test, carried out in accordance with standard IEC
60068-2-3, checks that the insulation characteristics of the enclosure,
busbars and conductor supports  are not affected after 4 hours’ exposure
in a steam chest  (40°C at 95% relative humidity).

The insulation used has a tracking current resistance of at least 400 V,


which means it is not very sensitive to damp (group I and group II
according to IEC 60664-1).

2.4 Resistance of insulating materials to


heat
2.4.1 Test involving 168 hours’ exposure at 70°c
After 168 hours’ exposure at 70°C, in accordance with standard IEC 61439-
3, the assemblies tested do not show any damage likely to affect their use.

2.4.2 Ball impact test


Ball impact test is carried out on the materials themselves  to check that
there is no warm creep . After exposure to the test temperature of 125°C
for parts that hold live parts in place and 70°C for the others, the
measured impression of the ball must not exceed 2 mm.

Ball impact test


2.5 Fire resistance
The glow wire test in standard IEC 60695-2-1 checks the  fire behaviour of
the materials and their ability to extinguish themselves (self-extinguishing
ability). The test temperature is 960°C for the parts that hold live parts in
place, and 650°C for other parts.

Extinguishing must take place  in less than 30 seconds . All elements that
make up LV assemblies comply with this requirement.

Glow wire tester for IEC60695-2-10


The testing device (model ZLT GTR) is designed  to carry out fire hazard
testing on electrotechnical products  in accordance with the provisions of
International standards.

The control unit is supplied with all the controls and metering necessary
to accurately set the temperature of the glow wire. The wire current is
continuously variable by means of the panel mounted controller and is
monitored by the built in ammeter. A digital temperature indicator is fitted
which, in conjunction with the thermocouple supplied, accurately
measures the glow wire temperature.

The electrical circuit of the control unit is fully protected by fuses and
a miniature circuit breaker  and incorporates mains on off switching and
push button control of the output current. Self contained cabinet with
large viewing window and dark colored interior.

2.6 Mechanical performance of assemblies


and fixings
The test consists of tightening screws and nuts up to the torque required
by standard IEC 61439-3 and then loosening them:  five times for metal
screws and nuts and ten times for those made of insulating materials .

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