NOVEMBER 2008 - MARCH 2009

Introduction to IEC 61439: A new standard on

Switchgear & Controlgear Assemblies
- Mr. A P Rao; Mr. D A Chavan; Mr. P Patel; Mr. T N Shah
Switchgear Design & Development Center

Introduction:
IEC 60439, the standard for low-voltage
switchgear and controlgear assemblies,
was under restructuring from the last
decade. The new series of IEC 61439
standards were published in January
2009. This standard has brought
considerable clarity in technical
interpretation.
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)
The IEC 60439 standards were
ambiguous about how to assess
compliance of partially type tested
assemblies. As a result manufacturers
and testing bodies often treated
partially type-tested assemblies

differently. 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.

Verification of Requirements:
Table 2 gives the characteristics to be

Table 1: Parts of IEC 61439 series

IEC 61439-1

General rules

IEC 61439-2

Power switchgear and control gear ASSEMBLIES

(Replacing IEC 60439-1)

IEC 61439-3

Distribution boards (to supersede IEC 60439-3)

IEC 61439-4

ASSEMBLIES for construction sites

(to supersede IEC 60439-4)

IEC 61439-5

ASSEMBLIES for power distribution

(to supersede IEC 60439-5)

IEC 61439-6

Busbar trunking systems

(to supersede IEC 60439-2)

verified and options available for

verification.

Salient features of IEC 61439

1. Verification of temperature rise
 For multiple compartment
assembly, verification by
calculation can be done up to
rated current of 1600 A only.
 Assemblies, verified by design
rule from a similar tested
assembly, should comply with
the following:

Functional units shall
belong to the same group
as functional unit selected
for test.

Same type of construction.

Same or increased overall
dimensions.

Same or reduced internal
separation.

Same or reduced power
losses in the same section
of assembly.

Same 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
o
shall not exceed 35 C.

2. Short circuit withstand test

Verification of assembly by design
rules is permitted, if;
 Following requirements are greater
than or equal to reference design

Cross-sectional dimensions of
the busbars and connections

Spacing of the busbars and
connections

SCPDs are equivalent, i.e. of
the same make with the same
or better I 2 t based on the
device manufacturers data
 Following requirements are less
than or equal to reference design

Short circuit rating of each circuit

Busbar supports spacing

Length of unprotected live

conductors of each nonprotected circuit
 Following requirements are same
as that of reference design

Conductor material and its
properties

Enclosure design, type and
dimensions

Compartment mechanical
design and dimensions
If all the above requirements are
satisfied, then further verification by
calculation or actual testing is not
required.


3. Power frequency withstand

voltage
The values of dielectric test voltage

Table-2
No. Characteristic

Verification options
Testing

Calculation

Design
rules

Degree of protection of enclosures

Clearance and creepage distances

Effectiveness of assembly
(protective circuit) for external faults

Incorporation of switching
devices and components

Internal electrical circuits

and connections

Terminals for external conductors

Impulse withstand voltage

Temperature rise limits

Short-circuit withstand strength

10

Electromagnetic compatibility (EMC)

11

Effective continuity between the

exposed conductive parts of the
assembly and the protective circuit

12

Power frequency withstand voltage

13

Mechanical operation

The following characteristics are newly introduced in IEC 61439

14

Resistance to corrosion

15

Thermal stability of enclosure

16

Resistance of insulating material

to heat

17

Glow wire test

18

Resistance to UV radiation

19

Lifting

20

Mechanical impact test (IK)

21

Marking

are reduced corresponding to rated

insulation voltage (Refer Table 3)
4. Impulse voltage withstand test
 Verification is mandatory either
by test or by design rules.
 Test is not required when
clearances in the assembly are
1.5 times the specified value
in Table - 4.
5. Degree of protection
 The IPX1 to IPX6 tests on an
assembly are deemed to be
failure if water comes into
contact
with
electrical
equipment housed within the
enclosure.
 Requirements for empty
enclosures for assemblies (IEC
62208) have been incorporated
in the standard.
6. Mechanical operation
 Rated numbers of operating
cycles have been increased
from 50 to 200.
7. Protection provided by barriers
The protection provided by horizontal
top surfaces of easily accessible
barriers is 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).
8. Cross-section area of neutral
 100% - for phase cross section
area upto 16 mm2
 50 % - for phase cross section
area above 16 mm2, with a
minimum of 16 mm2
 For conductor other than
copper, the cross section
should be greater than
equivalent copper conductor
9. Additional Tests in IEC 61439
 Resistance to corrosion Test
Purpose:
To ensure that deterioration of
metallic component caused by
corrosion shall not impair the
mechanical
strength
of
switchboard.
Procedure:
The test is carried out on a typical
switchboard enclosure or on a
representative sample showing the
same constructional details.

6 cycles of 24 hr each to Damp
Heat Cycling Test according to
o
IEC 60068-2-30 at (403) C &
relative humidity of 95%.

Table - 3

Table - 4

Rated insulation voltage (Ui)

Dielectric test
Dielectric test
(line to line a.c or d.c)
voltage (a.c) r.m.s voltage (d.c)
V
V
V

3.0

6.0

5.5

1500 (2000)

2120

300 < Ui 690

1890 (2500)

2670

690 < Ui 800

2000 (3000)

2830

800 < Ui 1000

2200 (3500)

3110

8.0

8.0

1000 < Ui 1500*

3820

12.0

14.0

2 cycles of 24 hr each to Salt

Mist test according to IEC
60068-2-11 at temperature of
o
(352) C.

Doors, hinges, locks, etc. shall

work without abnormal effects.

Seals shall not damage.

There shall be no iron-oxide,

cracking or other deterioration
more than that allowed by ISO
4628-3 for degree of rusting
Ri1.

Purpose:
To check the thermal properties of
the enclosure

After that the sample is kept

at ambient temperature for 4
days.

Assessment criteria:
The sample shall show no
cracks nor shall the material
become sticky or greasy
Sample is pressed with the
forefinger wrapped in a dry cloth
with a force of 5 N; no traces
of cloth shall remain on the
sample.

 Verification of resistance of
insulating materials to heat

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:
v

parts supporting live

o
components 125 C

other parts 70 C

After 1 hr, the sample is

removed and cooled within 10
s to approx. room temperature
by immersion in cold water.

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.

 Resistance to UV radiation
Purpose:
The UV radiation causes
deterioration of synthetic material
use for enclosures.
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
o
(653) C and (655) %.

Assessment criteria:


The diameter of the impression

caused by the ball shall be
measured and shall not exceed
2 mm.

 Resistance to abnormal heat &

fire (Glow Wire Test)
Purpose:
Glow wire test checks the
capability of insulation material to
handle thermal stresses produced
by sources of heat or ignition.

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.

Procedure:


Sample:
Thinnest
wall
thickness of the completed
application.

Pre-treatment: 24 hours at 23 C
at 50% RH.

Temperatures of glow wire:

550, 650, 750, 850 or 960
degrees C (depending on the
relevant specification).

Purpose:
To ensure the properties of
insulating material to normal heat

Assessment criteria:

Procedure:
The specimen is kept in a
o
heating chamber at 70 C for 7
days.

Based on inhomogeneous field condition and

pollution degree 3.

Procedure:

 Verification of Thermal stability

4.0

60 < Ui 300

The mechanical integrity shall

not be impaired.

1.5

1415

2.5

1000 (1000)

Assessment Criteria:

Minimum
clearance
mm

Ui 60

Note 1: * For d.c only.

Note 2: the values in parentheses are according to IEC 60439-1.


Rated impulse
withstand voltage
Uimp (kV)

Force: 1 N

Contact time: 30 s

NOTE: This test is applicable only for

enclosures and external parts of
ASSEMBLIES intended to be installed
outdoors.

 Lifting:

Relation between IK code & Impact energy.

Purpose:
To ensure that there should be no
damage to the panel during
transportation & installation.
Procedure:


The test is carried out on a

sample having weight 1.25
times its maximum shipping
weight.

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.

After this
raised up
30 min at
m without

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.

the ASSEMBLY is
and suspended for
a height of (10.1)
any movement.

This sequence shall be carried

out three times at uniform
speed, each sequence being
carried out within 1 min.

IK
code

IK
00

IK
01

IK
02

IK
03

IK
04

IK
05

IK
06

IK
07

IK
08

IK
09

IK
10

Impact
Energy
J

0.14

0.2

0.35

0.5

0.7

10

20

Procedure:

Assessment criteria:

Number of impacts on each

exposed face shall be five
unless otherwise specified in
relevant product standard.

The impacts shall be evenly

distributed on the faces of the
enclosure under test.

Validity of certificates as per

IEC 60439:

At the surrounding of any point

of enclosure, not more than
three impacts shall be applied.

Where tests on the ASSEMBLY have

been conducted in accordance with the
IEC 60439 series, prior to the
publication of relevant product standard
in the IEC 61439 series, and the test
results fulfill the requirements of the
relevant part of IEC 61439, the
verification of these requirements need
not be repeated.

Assessment Criteria:


Structural integrity shall be

maintained.

Degree of protection (IP) shall

be unaffected.

Functionality of electrical
products shall not be
hampered.

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.

 Mechanical Impact Test

Purpose:

NOTE: Mechanical Impact test is not

applicable to low voltage power
switchgear and controlgear (PSC)
assemblies.
 Marking:
Purpose:
To ensure that the markings are
legible.
Procedure:


This test measures resistance of

an enclosure towards external
Mechanical Impact.

The test is made by rubbing

the marking by hand for 15 s
with a piece of cloth soaked in
water and then for 15 s with a
piece of cloth soaked with
petroleum spirit.

The degree of protection provided

by an enclosure against impacts
is indicated by the letters IK
followed by two digits depending
on its ability to withstand the
impact (as per IEC 62262).

Marking made by moulding,

pressing, engraving or similar
shall not be submitted to the
following test.

After the test the marking shall

be legible to normal or
corrected vision without
additional magnification.

Conclusion:
The 4th edition of IEC 60439-1 was
published in 1999 with a subsequent
amendment in 2004. This standard did
not mandate compliance to stringent
safety requirements (such as impulse
withstand and resistance to abnormal
heat and fire i.e. glow wire) which are
present in other LV product standards.
In the new standard (IEC 61439-1)
these safety requirements have been
included in addition to others pertaining
to satisfactory performance under
applicable environmental conditions.
Hence, with these additions IEC 61439
series becomes the most updated
document from a technological
perspective.

For further details on this subject, please contact:

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