nVent ERIFLEX and the
New IEC 61439 Series
• Updates regarding low-voltage switchgear and control gear assemblies
• What is new for the Assembly Manufacturer/Panel Builder?
• How is nVent ERIFLEX helping Assembly Manufacturers/ Panel Builders comply with the new requirement?
Introduction
In 2011, the International Electrotechnical Commission (IEC) published the new IEC 61439 standard series. This standard governs
the safety and performance of electrical panels. The purpose of the new IEC 61439 is to harmonize, as far as practical, all of
the general rules and requirements that apply to switchgear and control gear assemblies. This new standard aims to align the
requirements for assemblies, promote consistency in the verification of assemblies, and eliminate the need for designers and
installers to verify their work to other standards.
Specific subjects of wide interest, such as temperature rises and dielectric properties, have been gathered in Part 1 of the IEC 61439
series as general rules. More specific assembly standards are included as Part 2. Each assembly must meet both parts to comply
with the standard.
About nVent
nVent is a leading global provider of electrical connection and protection solutions. We believe our inventive electrical solutions
enable safer systems and ensure a more secure world. We design, manufacture, market, install and service high performance
products and solutions that connect and protect some of the world’s most sensitive equipment, buildings and critical processes.
We offer a comprehensive range of enclosures, electrical connections and fastening and thermal management solutions across
industry-leading brands that are recognized globally for quality, reliability and innovation. Our principal office is in London, United
Kingdom and our management office in the United States is in Minneapolis, Minnesota. Our robust portfolio of leading electrical
product brands dates back more than 100 years and includes nVent CADDY, ERICO, HOFFMAN, RAYCHEM, SCHROFF and TRACER.
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What is Changing?
The new IEC 61439 series is expected to have a similar structure to IEC 60439 with several new additions*:
IEC 60439
IEC 61439 Series
New
IEC 60439-1
Standard assemblies and assemblies
derived from the standard
IEC 60439-2
Busbar trunking systems
IEC 60439-3
Distribution boards
IEC 60439-4
Assemblies for construction sites
IEC 60439-5
Assemblies for power distribution
*Othe r parts may be add ed
*For the t ime being, IEC 614 39 will overl ap with IEC 60439. IEC 60439 shall b e completely ph ased out in 2014. Ass emblies can be ma nufactured in acc ordance with ei ther standard th ru the phase out p eriod.
WHAT IS CHANGING?
IEC 61439 removes the terms “type tested assembly” and “partially type tested assembly.” The standard replaces them with the
phrase “design verification”. The new standard also replaces the type test with a 13 point design verification characteristics test.
IEC 61439 also covers common questions such as manufacturing at alternative premises and substitution of alternative functional
components.
One of the most significant differences between IEC 61439 and the previous standard is the introduction of ‘alternative and
equivalent’ methods of design verification. While the modification initially appears to reduce the requirements for actual testing,
in fact the ability to use a reference design has been replaced by three alternative methods of verification (Testing, Comparison,
Assessment). The verification tests described in IEC 61439 confirm the reference design against which subsequent configurations
must be verified by the alternative methods described. The introduction of these methods within the standard enables more
transparent and consistent designs to be offered for specific projects.
Despite these changes, the actual requirements of most of the verification tests are very similar. Some existing testing methods that
conform to IEC 60439 may fulfill the requirements of IEC 61439.**
**Note: Where tests on the ASSEMBLY have been conducted in accordance with the IEC 60439 series, and the test results fulfill the requirements of the relevant par t of
IEC 61439, the verification of these requirements need not be repeated.
[Extract IEC 61439.1: §10:1]
IEC 614 39 -1
General rules
IE C 61439-2
Power switchgear and controlgear assemblies
IE C 61439-6
Busbar trunking systems
IE C 61439-3
Distribution boards
IE C 61439-4
Assemblies for construction sites
IE C 61439-5
Assemblies for power distribution
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Main Denitions
ORIGINAL MANUFACTURER:
Organization that has carried out the original design and the associated verification of an ASSEMBLY in accordance with the relevant
ASSEMBLY standard. [Extract IEC 61439.1: § 3.10.1]
ASSEMBLY MANUFACTURER:
Organization taking the responsibility for the completed ASSEMBLY (e.g panel builder using an ASSEMBLY system from an Original
Manufacturer) (NOTE: The ASSEMBLY manufacturer may be a different organization to the original manufacturer)
[Extract IEC 61439.1: § 3.10.2]
USER:
Party who will specify, purchase, use and/or operate the ASSEMBLY, or someone acting on their behalf.
[Extract IEC 61439.1: § 3.10.3]
ORIGINAL COMPONENT MANUFACTURER:
Party who will design manufacture and sale components which can be used in the assembly. The ORIGINAL manufacturer of the
Component provides the design verification according to the IEC 61439.1 (Ex: nVent ERIFLEX
)
COMPONENT MANUFACTURER:
Party who will manufacture and sell components but does not provide sufficient design verification.
In this case, the assembly manufacturer (Panel builder) needs to realize the design verification of the component. Manufacturer
producing copy of original component Manufacturer is inside this category. The component manufacturer is not able to provide any
test report or certificate.
ASSEMBLY:
(
low-voltage switchgear and controlgear assembly): combination of one or more low-voltage switching devices together
with associated control, measuring, signaling, protective, regulating equipment, with all the internal electrical and mechanical
interconnections and structural parts. [Extract IEC 61439.1: § 3.1.1]
ASSEMBLY SYSTEM:
Full range of mechanical and electrical components (enclosures, busbars, functional units, etc.), as defined by the original
manufacturer, which can be assembled in accordance with the original manufacturer’s instructions in order to produce various
ASSEMBLIES. [Extract IEC 61439.1: § 3.1.2]
BUSBAR:
Low-impedance conductor to which several electric circuits can be separately connected. NOTE the term “busbar” does not
presuppose the geometrical shape, size or dimensions of the conductor. [Extract IEC 61439.1: § 3.1.5]
DISTRIBUTION BUSBAR:
Busbar within one section which is connected to a main busbar and from which outgoing units are supplied. NOTE: Conductors that
are connected between a functional unit and a busbar are not considered as a part of the distribution busbars.
[Extract IEC 61439.1: § 3.1.7]
FUNCTIONAL UNIT:
Part of an ASSEMBLY comprising all the electrical and mechanical elements including switching devices that contribute to
the fulfillment of the same function. NOTE Conductors which are connected to a functional unit but which are external to its
compartment or enclosed protected space (e.g. auxiliary cables connected to a common compartment) are not considered to form
part of the functional unit. [Extract IEC 61439.1: § 3.1.8]
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Verication Tests
THE 13 DESIGN VERIFICATION TESTS
The following tests must be performed on a sample assembly or components of an assembly to demonstrate that the design
satisfies the requirements of IEC 61439. The standard allows either the original manufacturer or the assembly manufacturer to be
responsible for the verification of the final assembly.
Verification option
o
N
1
2
3
4
5
6
7
8
9
10
11
12
13
Characteristic to be checked Items
Strength of materials and parts 10.2
Degree of protection (IP
Clearance 10.4
Creepage distance 10.4
Electric shock protection and integrity of protection circuits 10.5
Integration of connection devices and components 10.6
Internal electrical circuits and connections 10.7
Terminals for external conductors 10.8
Dielectric properties 10.9
Temperature rise 10.10
Short-circuit resistance 10.11
Electromagnetic compatibility 10.12
Mechanical operation 10.13
)
10.3
Tes ts
Yes No -
Yes No Yes
Yes No No
Yes No No
Yes - No
No No Yes
No No Yes
No No Yes
Yes No -
Yes Yes Yes
Yes Yes No
Yes No Yes
Yes No No
Comparison
Assessment
VERIFICATION OPTIONS
Verification test
Test made on a sample of an assembly or on parts of assemblies to verify that the design meets the requirements of the relevant
assembly standard.
NOTE: Verification tests are equivalent to type tests. [Extract IEC 61439.1: § 3.9.1.1]
Verification comparison
Structured comparison of a proposed design for an assembly or parts of an assembly, with a reference design verified by test.
[Extract IEC 61439.1: § 3.9.1.2]
Verification assessment
Design verification of strict design rules or calculations applied to a sample of an assembly or to parts of assemblies to show that
the design meets the requirements of the relevant assembly standard.
[Extract IEC 61439.1: § 3.9.1.3]
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Who is Responsible for Verication?
The Assembly Manufacturer Builds the Assembly as
Designed By the Original Manufacturer
1
Option
In this scenario, the assembly manufacturer uses the exact
design and part specifications provided by the original
manufacturer. Accordingly, the assembly manufacturer is only
required to perform the second stage verification, also known as
“routine verification”.
Advantage for the Assembly Manufacturer:
•
No design responsibility as a sub-contractor of the
Original manufacturer
•
The assembly is a preassembled kit, ready to be installed
Disadvantage for the Assembly Manufacturer:
•
No opportunity for valued added services versus other
Assembly Manufacturers
•
The only cost difference in the assembly between vendors is
directly linked to the labor cost to install the products
•
Only able to offer a generic solution that may not meet the
needs of the end user
1
Original
Manufacturer
• Design Production
• Design Verification
2
Original
Components
Manufacturer
such as
nVent ERIFLEX
• Design Production
• Design Verification
Assembly
Manufacturer
• Manufacture to
design
• Routine Verification
Assembly
Manufacturer
• Manufacture to
Design
• Routine Verification
• Assembly Design
Verif ication
The Assembly Manufacturer Customizes the Assembly According to End User Needs
2
Option
In this scenario, the assembly manufacturer works directly with the end user to define the desired outcomes of a particular
project. Together, the assembly manufacturer and the end user will determine the appropriate specifications for the assembly.
Based on this work, the assembly manufacturer will create the assembly design. By doing specific design or by modifying an
existing assembly system from an original manufacturer, the assembly manufacturer becomes the original manufacturer for the
sake of the requirements of the standard and must conform to the verification requirements placed on the original manufacturer
under IEC 61439. The assembly manufacturer also has to perform the second stage verification, namely “routine verification”.
Advantage for the Assembly Manufacturer:
• Ability to offer customized solutions to the end user that meets their needs
• Opportunity to offer added value services such as professional expertise in the assembly design
• Ability to differentiate from other assembly manufacturers who only offer standard solutions
Disadvantage for the Assembly Manufacturer:
• Time needed to create the technical report about the design verification**
**Note: nVent ERIFLEX as an original component manufacturer, can help the assembly manufacturer significantly reduce the time
required to complete technical reports by providing the assembly manufacturer all needed certificates, tests reports or calculation
for the IEC 61 439.1 compliance file.
*The new IEC 61439 is similar to the IEC 60439 standard in this area but more explicitly specifies the responsibilities of each party
involved in an assembly build.
6 |
Component Substitutions Under IEC 61439
The new standard expressly allows assembly manufactures to replace components in an assembly so long as the characteristics of
the replacement component meets or exceeds the characteristics of the replaced part.
An assembly manufacture with competent and professional skills could easily substitute original component manufacturer products
certified according to this new standard, such as nVent ERIFLEX low voltage power distribution products that are included in the
original manufacturer’s design.
Example 1:
A 3 or 4 pole distribution block 125A, Icc3: 18kA was used in a type-tested panel. The
assembly manufacturer can use a substitute product if the product is equal or better. He
cannot install a distribution block 125A, Icc3 12 kA, but he can install a distribution block
125A, Icc3: 30 kA. The temperature rise also needs to be taken in account. The standard
covers in writing what it was logically done in the past.
[See IEC 61439.1: § 10.10.3.5]
Example 2:
Example 3:
Example 4:
A temperature rise is done by an original manufacturer for 2000 A copper bars 120x10, in
a metallic enclosure 2000x2000x600mm, it is possible to substitute the enclosure if the
thermal characteristics of dissipation of the enclosure is similar or better. (Some other
parameter need to be checked such as IP, mechanical resistance, corrosion resistance…
Note: Verification of the temperature-rise of a single or multiple compartment assembly
with the total supply current not exceeding 1600 A may be made by calculation.
[See IEC 61439.1: § 10.10.4.3.1]
Busbar supports taken from an assembly verified by testing can be replaced if the alternative
has been previously tested for the required mechanical strength. All nVent ERIFLEX busbar
supports have been certified and tested and can be substituted in most all assemblies.
Calculation can be done using our Interactive nVent ERIFLEX Software Available Online at
nVent.com/ERICO/eriflex
[See IEC 61439.1: Annex P.4.4, and P.3 Method of verification]
nVent ERIFLEX Flexibar Advanced is certified as a Class II / reinforced insulation conductor
(
IEC 61439-1 Chapter 8.4.4 Protection by total insulation) and can be used as power
conductor between devices and or busbars while other conductors with only basic insulation
must not be allowed to come into contact with bare live parts with
different potentials.
[See IEC 61439.1: § 8.6.3] Flexibar Advanced can be substituted for the original component.
Other conductors with only basic insulation may only be loaded such that an operating
temperature of 80 % of the maximum permissible conductor operating temperature is not
exceeded. [See IEC 61439.1: Table 4]
)
)
Example 5:
nVent ERIFLEX Power Terminals and Power Blocks have been tested and certified according
to IEC 60947-7-, and have very high short circuit current rating. These products may be
substituted in most all assemblies. Assembly manufacturer must ensure that the necessary
contact pressure corresponding to the current rating and the short-circuit strength of the
apparatus and the circuit is maintained.
[See IEC 61439.1: § 8.8]
| 7
How nVent ERIFLEX helps with IEC 61439 Compliance
Our worldwide team of electrical power connection experts is committed to producing fully certified and tested high quality
components. Assembly manufacturers can be confident specifying and installing nVent ERIFLEX products to meet the
IEC 61439 standard.
To help assembly manufactures, our team provides:
• Design support
• Our proprietary interactive panel software
• Training & assistance during installation
• Early involvement of nVent ERIFLEX experts which results in optimal solutions for compactness, quality, cost-effectiveness, and
compliance to relevant standards
OUR DIVERSE PRODUCT OFFERINGS INCLUDES:
Insulated flexible busbar
(
Flexibar Advanced
)
Insulated braided conductor
(
IBS, IBSB & Advanced
Distribution blocks
and Power Blocks
)
Busbar Supports
8 |
Insulators
Interactive nVent ERIFLEX Software
Available Online from nVent ERIFLEX
With the click of a mouse, nVent ERIFLEX makes it easy to create a technical panel layout with all of the necessary components.
Whether you’re interested in making a complete low voltage busbar system or a distribution kit, or if you need to determine a flexible
connection with Flexibar, you can trust our nVent ERIFLEX software to help simplify the process. The software will even provide you
with technical and commercial datasheets dedicated to your project.
Panorama - main page
Calculate short circuit currentDetermine a connection between conductors
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| 9
Summary
The new standard IEC 61439 introduces clarification on low-voltage switchgear and control gear assemblies in comparison with the
current standard (IEC 60439). The structure of the new standard is easier to understand with Part 1 dedicated to broader topics and
general rules and Part 2 focusing on more specific assembly standards. New definitions have also been included in the standard
(
for example “Original Manufacturer” and Assembly Manufacturer”) and new assembly characteristics have been specified as
compulsory (e.g. rated current of the assembly).
A new “design verified assembly” concept has been specified. This new concept completely discards the categories TTA and
PTTA. The compliance of an assembly can either be verified by testing or by “alternative methods” which may include calculations,
measurements, and design rules. The new standard is more precise, eliminating some vague definitions and requirements contained
in the previous standard.
The responsibilities of each party involved in the design, manufacturing, and installation of an assembly are clearly defined, making
the job of each “stakeholder” on the electrical market easier. Under the new standard, the assembly manufacturer/panel builder
has two main options: The assembly manufacturer builds the assembly as designed by the original manufacturer or the assembly
manufacturer customizes the assembly according to the end user needs.
Components in an assembly can be replaced so long as the replacement component meets or exceeds the performance
specifications of the part that it is replacing. Replacements parts can be from the same manufacturer or a different
manufacturer so long as the requirement is met. Some potential nVent ERIFLEX brand replacement parts include:
• Distribution Blocks / Power Terminals: As nVent ERIFLEX has a wide range of products with highest short circuit current resistance
they can substitute most other products in every Assembly.
• Insulators / Busbar Supports: Because nVent ERIFLEX has made the design verification and provides you an online calculation tool
conform the IEC 61439 series, they can be used in any assembly following the instructions on distances given by
nVent ERICO’s Software.
• Flexibar / Insulated power braid IBSB Advanced: As nVent ERIFLEX manufactures with such high quality standards and class II
insulation, any conductor can be replaced with this good, compact and flexible alternative.
• Using products from nVent ERIFLEX that carry the certificate of compliance with IEC 61439.1 will allow the assembly manufacturer
to more easily carry out the design verification process.
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