IEC 61439-1&2

Importance of the new standard of low-voltage switchgear and controlgear

assemblies
for planer, panel builder and end users

Introduction
A low-voltage switchgear and controlgear assembly (ASSEMBLY) is a combination of low-voltage
switching devices together with associated equipment (for controlling, measuring, monitorin etc.)
complete with all the internal mechanical and electrical interconnections and structural parts. As
with every component of an electrical installation, the ASSEMBLY also has to comply with its
appropriate standard.

Safety requirements of electrical equipment are set today as general rules in the regulation of EN
/IEC to observe the protection objectives for people and panels and this rules are continuously
updated.

Appearing first in the year 1993, the EN 60439 regulated the different types of switchgears to
one standard and classified them as TTA (type-tested switchgear assemblies) or PTTA (partially
type-tested switchgear assemblies).

Now the new standard has a general part (EN 61439-1) and product specific parts (EN 61439-
2,,-6) which define the requirements of the detailed products more precisely.

The new standards IEC 61439-1 and IEC 61439-2 replaced the previous standard IEC 60439-1
in January 2009. All new assemblies must comply with these new standards. Standard IEC
61439-1 defines the general rules for low voltage switchgear assemblies. It gives the definitions
and indicates the conditions of use, construction requirements, technical characteristics and
verification requirements. IEC 61439-2 is a product standard which defines the specific
requirements (assembly rules).

The new IEC 61439 series of standards thus defines the construction of low voltage
switchgear assemblies and their inspection more precisely, specifying the responsibilities
of those involved and differentiating between the role of the original manufacturer (Rittal)
and that of the assembly manufacturer (panel builder). Rittal, as the original manufacturer,
is responsible for carrying out the 13 design verifications defined in Annex D of standard
IEC 61439-1, leading to the issuing of certificates of conformity.
New Standard IEC 61 439
❑ Replaces IEC 60 439-1
❑ New structure: General requirements + specific requirements
❑ The terms TTA and PTTA will be replaced by Design Verification
❑ Differentiation between original and assembly manufacturer
❑ IEC-Standard is valid since January ´09, EN-Standard is valid since June 2010

What has changed under the new standard?

❑ Design and Routine verification of the equipment.
❑ For new switchgear and controlgear assemblies, the type test report will be replaced by
the design verification. The former routine test report will be replaced by the routine
verification.
❑ The new IEC 61439 is divided into two sections, one containing general requirements,
the other outlining a separate product standard for specific types of switchgear and
controlgear assemblies.

What does the new standard meant for the User?

❑ By applying the new standard correctly, manufacturers can prove definitively that their
products are safe and reliable to use.
❑ Any manufacturer wishing to produce and market standard- compliant switchgear or
controlgear assembly after November 2014 must prepare a design verification and a
routine verification.
❑ The switchgear or controlgear assembly manufacturer is responsible for preparing the
design verification.
❑ Preparation of a design verification is much easier with tested system solutions.
Design Verification as per IEC 61439-1
Verification made on a sample of an assembly or on parts of assemblies to show that the design
meets the requirements of the relevant assembly standard“
▪ The tests shall be performed on a representative sample of an assembly in a clean and
new condition.
▪ Where tests have been conducted in accordance with the IEC 60439 series and the test
results fulfill the requirements of the relevant part of IEC 61439, the verification of these
requirements need not be repeated.
▪ Tests on individual devices to their respective product standards are not an alternative
to the design verifications in this standard for the assembly.
▪ The number of assemblies or parts thereof used for verification and the order in which
the verification is carried out shall be at the discretion of the original manufacturer.
▪ The used datas, calculations and made comparisons for the verification of assemblies
shall be recorded in a verification report.

Routine verification as per IEC 61439-1

Routine verification is intended to detect faults in materials and workmanship and determine
proper functioning of the manufactured assembly. This verification is made on every assembly.

Power switchgear and controlgear assembly (PSC-assembly) as per IEC 61439-2

Low-voltage switchgear and controlgear assembly used to distribute and control energy for all
types of loads, intended for industrial, commercial and similar applications where operation by
ordinary persons is not intended“

Ordinary persons may have access to the place of installation, but they shall not have a possibility
to operate at the panel.
Design verification may comprise one or more equivalent and alternative
methods consisting of:
▪ Testing (mechanical, electrical and thermal tests)
▪ Assessment (physical measurement, calculation temperature rise only for PSC InA ≤
1.600 Amp; to show that the assembly fulfill the requirements of the standard)
▪ Comparison (structured comparison referencing on base of a tested solution)

List of necessary Verification as per IEC std.

Design verification acc. to IEC 61439-1 / EN 61439-1

No. items to be proofed Chapter possible verification method
Verification by Verification by Verification by
test comparison assessment
1 Verification of strength of materials and parts : 10.2
Verification of resistance to corrosion 10.2.2 YES NO NO
Verification of properties of insulating materials 10.2.3
Verification of thermal stability of enclosures 10.2.3.1 YES NO NO
Verification of resistance of insulating materials 10.2.3.2
to abnormal heat and fire due to internal electric YES NO YES
effects
Verification of resistance to ultra-violet (UV) 10.2.4
YES NO YES
radiation
Verification of Lifting 10.2.5 YES NO NO
Verification of mechanical impact 10.2.6 YES NO NO
Design verification
Verification acc. to IEC 61439-1 / EN 61439-110.2.7
of marking YES NO NO
No.
2 items to beofproofed
Verification protection of assemblies Chapter
10.3 YES possible verification
NO method YES
3 Verification of clearances 10.4 Verification
YES by Verification
NO by Verification
NO by
4 Verification of creepage distances 10.4 test
YES comparison
NO assessment
NO
5 Verification of protection against electric shock 10.5
and integrity of protective circuits:
Verification of effective earth continuity between 10.5.2
the exposed conductive parts of the assembly YES NO NO
and the protective circuit
Verification of short-circuit withstand strength of 10.5.3
YES YES NO
the protective circuit
6 Verification of incorporation of switching devices 10.6
NO NO YES
and components
7 Verification of internal electrical circuits and 10.7
NO NO YES
connections
8 Verification of terminals for external conductors 10.8 NO NO YES
9 Verification of dielectric properties 10.9
Verification of power frequency withstand voltage 10.9.2
YES NO NO
Verification of impulse withstand voltage 10.9.3 YES NO YES
10 Verification of temperature rise 10.10 YES YES YES
11 Verification of short-circuit withstand strength 10.11 YES YES YES
12 Verification of electromagnetic compatibility 10.12
YES NO YES
(EMC)
13 Verification of mechanical operation 10.13 YES NO NO
Benefits of IEC 61439
Role of Original Manufacturer
Rittal as “Original Manufacturer”
Rittal, with the TS Enclosure assembly system, has manufactured assemblies with different
components brands (switches), and these assemblies have been tested by the independent
laboratory.

Rittal becomes an “original manufacturer”, and in conclusion all assemblies manufactured using
the Rittal assembly system and following the design and manufacturing rules included in the Rittal
manual; do not need to be tested again. The tested assemblies can be used as a reference design
verified by test.

Therefore Rittal can state: “Rittal has a tested assembly system according to IEC 61439”

Product Portfolio in Power Distribution

Rittal Ri4 Power Software to design a perfect system
Design Verification of PSC Using Rittal Ri4 Power Software

Documentation of PSC Using Rittal Ri4Power Software

FAQs

Until what point is it possible to manufacture and to install ASSEMBLIES in accordance with IEC
60439? The validity of the two standards will overlap until 2014 and prior to this date,
ASSEMBLIES can be manufactured according to IEC 61439 or IEC 60439.

Is it possible to manufacture an ASSEMBLY in accordance with the new IEC 61439, with
enclosures from Rittal, busbars from another manufacturer, circuit breakers from another
manufacturer, etc.?

Yes, it is possible but it is not easy and it is expensive. The panel builder that decides to mix
different “elements” from different manufacturers is not only the ASSEMBLY Manufacturer, but
becomes the Original Manufacturer and has to perform both the first and the second stage
verification: design verification and routine verification.

Because there are much more methods of verification can I comply with the new standard
without carrying out tests

No. The new standards still mainly based on type tests. It defines more accurately the
verification of a variant by comparison with a configuration already tested.

Is it the original manufacturer or the Panel Assembler is final responsible for the switchboard ?

As before, the panelbuilder is responsible for the final switchboard assembly according to his
customer’s. specifications and to the “original manufacture’s” instructions, and by carrying out
the routine tests. The original manufacturer is still responsible for the design of the Assembly
system and certification of the panel.
Conclusion

The new standard IEC 61439 introduces important modifications in comparison with the current
standard IEC 60439 on low-voltage switchgear and controlgear ASSEMBLIES. The structure of
the new standard is clearer with a general part and product specific parts. New definitions have
been written (e.g. “Original Manufacturer” and “ASSEMBLY Manufacturer”). New compulsory
characteristics have to be specified (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, and the compliance of an ASSEMBLY can now not only be verified by means of
tests, but also with alternative methods: calculation/measurement and design rules. The new
standard is more precise, eradicating the “grey” areas contained in the previous standard. The
responsibilities for an ASSEMBLY are clearly defined, making the job of each “actor” on the
electrical market easier nowadays.