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EDITION
2006
LOW-VOLTAGE
SWITCHGEAR AND
CONTROLGEAR
ASSEMBLIES
A guide to
BS EN 60439 -1
Foreword
Under current electrical and safety legislation
it is a requirement that equipment
purchased should be both fit for purpose
and safe. This may be demonstrated through
meeting the requirements of a European
harmonised standard. In the field of
switchgear and controlgear assemblies, this
standard is BS EN 60439-1.
This guide has been compiled by members
of the GAMBICA Controlgear Systems
Group to provide specifiers, designers and
purchasers of switchgear and controlgear
assemblies with a clearer understanding of
BS EN 60439-1 to assist in the selection of
fully compliant and safe products related to
this standard.
(i)
Contents
1.
2.
1.1
1.2
1.3
2
4
4
TYPE TESTING
2.1
2.2
2.3
2.4
2.5
2.6
2.7
5
5
6
8
9
10
11
11
3.
ROUTINE TESTS
12
4.
13
5.
15
6.
THE CE MARKING
27
6.1
6.2
6.3
28
29
31
32
(iii)
BS EN 60439
Low-voltage switchgear and
controlgear assemblies
BS EN 60439-1:
Specification for type-tested and partially
type-tested assemblies
BS EN 60439-2:
Particular requirements for busbar
trunking systems (busways)
BS EN 60439-3:
Particular requirements for
assemblies intended to be installed
where unskilled persons have access for
their use - Distribution boards
BS EN 60439-4:
Particular requirements for assemblies
for construction sites (ACS)
BS EN 60439-5:
Particular requirements for assemblies
intended to be installed outdoors in
public places - Cable distribution cabinets
(CDCs) for power distribution in networks
Figure 1. The BS EN 60439-series
Temperature-rise limits
Dielectric properties
Short-circuit withstand strength of
main circuits
Effectiveness of protective circuit
Short-circuit withstand strength of
protective circuits
Clearances and creepage distances
Mechanical operation tests
IP degree of protection
Summary
The principal standard for LV switchgear and
controlgear assemblies is BS EN 60439-1,
but it only covers those which can be
designated as TTA or PTTA.
Assemblies conforming to this standard
are deemed to satisfy the essential safety
requirements of the Low Voltage
Directive and can bear the CE marking
accordingly.
2. Type testing
Introduction
BS EN 60439-1 details eight type tests in
Table 7 (see Figure 2) which are carried
out to verify equipment designs. All eight
type tests must be carried out on each
design of TTA and in the majority of cases,
type tests on similar designs must form
the basis of design verification for PTTAs.
At first sight, all type tests may appear to
be associated with constructional and key
performance aspects of the assembly.
Careful examination shows that most are
also very much related to safety, as will be
identified.
Type tests are expensive to conduct but
they are vital and the only effective means
of verifying the design of a TTA and of
Parts of assemblies
Built-in components
Limited by:
mechanical strength of conducting material
possible effect on adjacent equipment
permissible temperature limit of the
support insulating material
the effect of the conductor temperature
on equipment connected to it
nature and treatment of plug-in contact material
15
25
30
40
70
10
11
3. Routine Tests
This chapter gives a brief introduction to
routine tests, with specific reference to LV
Motor Control Centres.
The introductory text in the standard sets
out the basic requirements, as follows:
Routine tests are intended to detect faults in
materials and workmanship. They are carried
out on all parts of each new ASSEMBLY.
Another routine test at the place of installation
is not required.
ASSEMBLIES which are assembled from
standardised components outside the works
of the manufacturer of these components, by
the exclusive use of parts and accessories
specified or supplied by the manufacturer for
this purpose, shall be routine-tested by the
firm which has assembled the ASSEMBLY.
Routine tests include:
a) inspection of the ASSEMBLY including
inspection of wiring and, if necessary,
electrical operation test (8.3.1);
b) dielectric test (8.3.2);
c) checking of protective measures and of
the electrical continuity of the
protective circuit (8.3.3).
These tests may be carried out in any order.
Note: The performance of the routine tests
at the manufacturers works does not relieve
the firm installing the ASSEMBLY of the duty
of checking it after transport and installation.
[BS EN 60439-1 Clause 8.1.2]
12
Main busbars
The fault-free
zone
SCPD in
functional unit
The solution
Figure 5. The fault-free zone
In such cases, the dilemma is resolved by
clause 7.5.5.1.2 of the standard which allows
that the conductors between the main
busbars and the supply side of functional
units may be rated on the basis of the
reduced short-circuit stresses occurring on
the load side of the short-circuit protective
devices in the functional units.This relaxation
13
Type of conductor
Requirements
14
15
Separation objectives
The standard only considers the two
objectives detailed in Figure 7. Either one or
both of these objectives may be used as the
basis of a classification of the Form of
internal separation.
16
Form 1 No separation.
Form 2a Separation of the busbars from the functional units. The terminals for external
conductors are not separated from the busbars.
Form 2b As 2a but the terminals for external conductors are separated from the busbars.
Form 3a Separation of the busbars from the functional units and separation of all the functional
units from one another. The terminals for external conductors are separated from
the functional units, but not from each other or from the busbars.
Form 3b As 3a but the terminals for external conductors are separated from the busbars.
Form 4a Separation of the busbars from the functional units and separation of all functional
units from one another, including the terminals for external conductors which are
an integral part of the functional unit.The terminals for external conductors are in
the same compartment as the associated functional unit.
Form 4b As 4a but the terminals for external conductors are not in the same compartment
as the associated functional unit, but are in individual, separate, enclosed protected
spaces or compartments.
Figure 8. The Forms of separation
17
18
19
Forms of separation/Types of
construction
The Forms of internal separation and the
associated Types of construction are
illustrated in Figures 10.1 through 10.6.
Form 1
Main Criteria
No internal separation
20
Form 2a
Main Criteria
Separation of busbars from the functional units
Sub-Criteria
Terminals for external conductors
NOT separated from busbars
Typical variants
Form 2b
Main Criteria
Separation of busbars from the functional units
Sub-Criteria
Terminals for external conductors
separated from busbars
Type 1:
Busbar separation is achieved by
insulated covering e.g sleeving,
wrapping or coatings 1)
Type 2:
Busbar separation is by metallic or
non-metallic rigid barriers or
partitions
i)
21
Form 3a
Main Criteria
Separation of busbars from the
functional units
+
Separation of all functional units from one another
+
Separation of the terminals for external conductors from the functional units
but not from each other
Sub-Criteria
Terminals for external conductors
NOT separated from busbars
22
Form 3b
Main Criteria
Separation of busbars from the
functional units
+
Separation of all functional units from one another
+
Separation of the terminals for external conductors from the functional
units but not from each other
Sub-Criteria
Terminals for external conductors
separated from busbars
Typical variants
Type 1:
Busbar separation is achieved by
insulated covering e.g sleeving,
wrapping or coatings 1)
Type 2:
Busbar separation is by metallic or
non-metallic rigid barriers or
partitions
i)
23
Form 4a
Main Criteria
Separation of busbars from the functional units
+
Separation of all functional units from one another
+
Separation of terminals for external conductors which are an
integral part of the functional units
Sub-Criteria
Terminals for external conductors in same
compartment as functional unit
Typical variants
Type 1:
Busbar separation is achieved by
insulated covering e.g. sleeving,
wrapping or coatings 1). Cables may
be glanded elsewhere.
Type 2:
Busbar separation is by metallic or
non-metallic rigid barriers or
partitions. Cables may be glanded
elsewhere.
Type 3:
Busbar separation is by metallic or
non-metallic rigid barriers or
partitions.
The termination for each functional
unit has its own integral
glanding facility.
i)
24
Form 4b
Main Criteria
Separation of busbars from the functional units
+
Separation of all functional units from one another
+
Separation of terminals for external conductors which are an
integral part of the functional units
Sub-Criteria
Terminals for external conductors
NOT in same compartment as the
associated functional unit, but in individual
separate enclosed protected spaces
or compartments
Typical variants
Type 4:
Busbar separation is achieved by
insulated coverings e.g. sleeving,
wrapping or coatings.
Cables may be glanded elsewhere.
Type 5:
Busbar separation is by metallic or
non-metallic rigid barriers or partitions.
Terminals may be separated by insulated
coverings 1) and glanded in common
cabling chamber(s).
Type 6:
All separation requirments are by metallic or
non-metallic rigid barriers or partitions. Cables
are glanded in common cabling chamber(s).
Type 7:
All separation requirements are by metallic
or non-metallic rigid barriers or partitions.
The termination for each functional unit has
its own integral glanding facility.
i)
25
internal separation by
compartments or barriers
enclosure
busbars
functional units
including terminals for external
conductors
cable gland
NOTE: Conductors which are connected to a functional unit, but where they are external to
its compartment or enclosed protective space (e.g. control cables connected to a common
marshalling compartment) are not considered to form part of the functional unit.
26
6. The CE Marking
Introduction
In order to demonstrate that certain
products are legal within Europe, it is a
requirement of national legislation
implementing EU New Approach Directives
to apply CE marking to certain categories of
products.
The CE marking of an assembly represents a
declaration by the manufacturer (or his
authorised representative in the EEA, in the
case of products imported into Europe)
that it complies with the essential
requirements of all directives relevant to
assemblies.These directives (see also
Figure 11) are:
27
EU Directive
Implemented in UK through:
Abbreviated title
Full title
Low Voltage
Directive
EMC Directive
28
29
Environment 1, corresponding to
residential, commercial and light industrial
locations/installations; or
Environment 2, corresponding to nonpublic or industrial networks, locations or
installations.
30
31
2.
3.
4.
kA
seconds
IP
6.
IP
Form of construction:
Fixed / Withdrawable
8.
Front / Rear
9.
Front / Rear
Top / Bottom Entry
10.
Form of Separation:
Form
Type
11.
32
Ask for test data on ALL aspects of design before ordering and ask for a Declaration
of Conformity to the Low Voltage Directive when equipment is delivered.
33