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 control
gear 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 assembly, 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.

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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)

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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.

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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.

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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

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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

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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

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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

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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.

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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).

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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

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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.

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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.
Temperature Rise Test / Heat-Run Test for LT
control panels (as per IEC 61439-1&2)
"The verification of temperature rise on a low voltage assembly is a key element in
confirming it is constructed for use within its designed operating capability, as defined in
the IEC 61439 standard. It finds maximum operating temperature of the system, on which
the system works satisfactorily."

With a temperature-rise test, the object will be tested up to reaching the point of steady
temperature condition, according to the rated current, specified by the
manufacturer/customer. The examination, significant for all equipment, is considered as
passed, when the high temperature, determined at different measuring stations, does not
exceed the fixed level specified in the test requirements.

How temperature rise effect Switchboard operation?

Remember Ohm's Law: V=IR. This can be re-arranged to I=V/R. This states that the current
(I) through a circuit is equal to the voltage across the circuit (V) divided by the resistance in
the circuit (R). Since ‘I’ is inversely proportional to R, then for a fixed V, the current will
decrease as the resistance increases. One of the things which increase electrical resistance is
the increased motion of the molecules and free electrons of a conductor caused by heating.
This is due to their random collisions with the electrons making up the current which tends
to interfere with their forward progress. So, it is true that heating of the power line causes
the free electrons to move faster, but in random directions. As a result, the net electron
current will be diminished due to the increased frequency of random collisions.
That means, increase in temperature rise will increase the resistance of the current flow of
copper conductor. See below formula

Temperature rise depend on the circulating electric current, the materials involved, and the
contact resistances, the ambient air temperature, the air velocity and the geometry of
conductors and compartment components.

Test procedure:
All circuit within the assembly shall be individually capable of carrying their rated current
(sec: IEC61439-1/sec.5.3.2). However, the current carrying capacity may be influenced by
adjacent circuits. So, Test shall be conducted with maximum current of each incomer and
outgoer. We have chosen two combinations to match incomer value.
1. Bring all external connections of Breaker 2 meters outside the panel, by using sufficient
cables or busbars as recommended in IEC 61439-1, Sec: 10.10.2.3.2, table 11 & 12.

2. Connect incomer external terminal (2 x 50 x 5 sq.mm. 2 meters, tinned copper busbars)

to Test transformer. (Pls see GA attached).

3. Switch ON incomer and outgoers, which are participating in test (i.e., in test-1, Feeders
IC, OG-1, 3, 5, 6). Make sure that other outgoers, which do not use in this test is in OFF
condition.

4. In each outgoer, connect 2 meter extended external terminals of all phases together
(make star point) as shown in figure1.
5. Inject the current of 800A to the incomer. Read the current in each phase of the extended
terminals of outgoers, which is shorted.

6. If the outgoers load current is not matching with customer requirement (in our case,
Values as shown in Table 1, Test-1/2). Balance the load current to requirement by
adding/removing the cables.
That means, to increase the load current we can either add the cross sectional area of cable
or reduce the cable length and vice-versa.
Switch OFF the transformer main supply after load balancing.

7. After balancing the load, Place the temperature sensor probes (thermocouples) in the
different place where temperature may vary and rise gradually. IEC standard suggests to
place thermocouple at
 a. Busbar joints
 b. Incoming and outgoing terminals of each breaker which are participating in
testing. (OGs & IC)
 c. Terminal blocks of each outgoer which is participating in test.
 d. Body of each breaker which is participating in test.
 e. Extended rotary handle/external knobs of breakers (which is testing)
 f. Body of the panel.
 g. At least two ambient temperature points.

8. These probes shall be connected to a local monitoring system. And we can read the
temperature at every point from here.

9. Switch ON Transformer supply which is feeding our system/panel.