Changes within

IEC 61439-1 & 2 Ed 3

White Paper 11482

Version 1

By Tom Mennell

Executive summary
After nine years of committee debate the 3rd Editions of IEC
61439-1 and IEC 61439-2, the standards for power switchgear
and controlgear assemblies, have been published. The new
editions include changes, the significance of which will affect
the way assemblies are specified and used. All the changes are
either a recognition of the changing needs of assemblies in the
market, technical advances, further options in design verification
or clarifications. These changes have been made with simple
objectives in mind; ensuring assemblies are fit for purpose
and there is a clear understanding of the capabilities of the
assembly between specifier and manufacturer.
The more a. An annex dealing with the specific requirements of assemblies used in
photovoltaic applications; where environmental and operating conditions are
significant harsher than that for typical assemblies.
changes b. A recognition that, whilst the possibility of an arcing fault within a well-
include: designed and manufactured assembly is extremely remote, for safety and
operational reasons, some users wish to reduce the risk even further.
c. A greater focus on DC assemblies to reflect the wider use of DC in
photovoltaic applications, battery storage systems and the increasing
interest in use of DC distribution networks.
d. Closer links with the installation rules by the introduction of a new
characteristic, ‘group rated current of a circuit of an assembly’. This aligns
closely with the design current of a circuit within an electrical installation. It
is the most significant of all the changes and needs to be clearly understood
to avoid misunderstandings. Specifiers are encouraged to provide the
design current of each circuit and make the assembly manufacturer fully
responsible for ensuring the assembly can deliver the necessary load
currents, without overheating.
e. A distinction between the ‘macro’ environment outside the assembly, for
which the assembly as a whole must be suitable, and the ‘micro’ environment
inside the assembly, which must be suitable for the devices enclosed within
the assembly.
f. Requirements to ensure insulating materials will not unacceptably age
during the intended life of the assembly.
g. New temperature-rise verifications without testing the actual arrangements
for actively cooled assemblies and circuits within larger assemblies.
h. Recognition of Class I and Class II assemblies for electrical installations with
different fault protection arrangements.

Economic and environmental pressures are forcing manufacturers of devices and

assemblies to squeeze design margins. Users push to gain efficiencies through
higher utilisation of assemblies. These pressures are making it increasingly
essential to have the capabilities of assemblies well defined and to know in
detail the characteristics of the application. The move toward closer links with
the installation rules, particularly in respect of rating of circuits, is a positive
step towards closely matching the assembly to the application. In addition, it is
imperative that every assembly is fully verified in accordance with the standard to
ensure it meets its declared capability and the needs of the application.

Clearly the changes are diverse, but all are necessary to ensure the assembly
required for a specific application is the assembly provided.

Figure 1
Example of a modern LV
switchboard assembly –
Schneider Electric Prisma P

Changes within IEC 61439-1 & 2 Ed 3

Introduction: After nine years and many hours of discussion within committee, Edition 3 of IEC
61439-1 (Low-voltage switchgear and controlgear assemblies: General rules)
and IEC 61439-2, (Low-voltage switch gear and controlgear assemblies: Power
switchgear and controlgear assemblies) have finally been published. Soon these
documents will become British Standards.

The new editions include many updates which are intended to bring the standards
in line with current market needs, closer alignment with electrical installation rules,
recognise evolving technologies, ease where appropriate design verification,
or clarify areas that have led to confusion in the past. As a result, there are
fundamental changes that will significantly affect all parties with an interest in
assemblies from specifiers, users, manufacturers and certification bodies, to
clarifications that are little more than good practice.

The purpose of this paper is to highlight the main changes in the new editions
of the standards and give the reader a little insight into the logic behind the
changes. However, this paper is not a substitute for reading the standard.

Reminder of The relationship between IEC 61439-1 and IEC 61439-2 has not changed. IEC
61439-1 remains a general rules document; a collection of common clauses
the basis of applicable to most assemblies. It is intended to harmonise as far as practical
the standards: requirements for all types of assemblies. No assembly should be deemed to
conform to or be certified in accordance with this document. IEC 61439-2 is the
standard for power switchgear and controlgear assemblies. It invokes virtually
all of IEC 61439-1 and adds to it as appropriate for power switchgear and
controlgear assemblies.

Market Applications and opportunities continue to evolve in all areas of business, with
low-voltage assemblies being no exception. The need for greener energy,
evolution: enhanced safety, energy efficiency, etc. have all influenced the new editions of
the standards. Increasingly, low-voltage assemblies are at the heart of an energy
management system. Many now include the automation and intelligence necessary
to optimise energy use throughout an installation.

Assemblies for photovoltaic installations (PVA assemblies)

With the move towards renewable energy there continues to be a proliferation
in photovoltaic generation, in some instances at voltages up to 1500V DC. This
has prompted the inclusion of an Annex in IEC 61439-2 to cover the requirements
for assemblies for photovoltaic applications.

The Annex, whilst informative and therefore not mandatory in this edition of
IEC 61439-2, considers previous experiences (e.g. fires in combiner boxes) and
recognises that the application is more onerous than that of typical assembly.
Additional verifications are included to ensure these assemblies are fit for purpose.
These include; (i) temperature rise tests with all circuits operating at rated current,
simultaneously, in the maximum ambient temperature; if the assembly is likely to
be subject to direct sun, the tests are carried out with simulated solar irradiance;
(ii) thermal cycling tests to confirm the ability of an assembly to function correctly
when there are rapid changes in temperature; and (iii) climatic tests to confirm the
assembly is suitable for operation in a hot, damp climate.

Changes within IEC 61439-1 & 2 Ed 3

Figure 2
Assembly under test
conditions with simulated
solar effects

Such verifications are not easy to conduct, specialist laboratory equipment is

required, but they are considered essential by international experts to prove
assemblies will continue to perform correctly over their anticipated life.

Internal arc fault performance for enhanced safety

Historically, many markets, including the UK, have taken the view that the possibility
of an arcing fault within a good quality and correctly operated, low-voltage
assembly is a very remote possibility, a philosophy of prevention rather than cure.

Some industries and markets now wish to reduce the very small risk of an
issue due to an arcing fault even further. They are asking for arc fault tested
assemblies and/or the inclusion of arc fault sensing, and in some instances arc
quenching means.

For the first time IEC 61439-2 acknowledges this emerging market need and refers
to several documents dealing with this subject, namely; (i) IEC 61439-0: Guidance
to specifying assemblies; (ii) IEC 61641: Guide for testing under conditions of
arcing due to internal fault; and (iii) IEC TS 63107: Integration of internal arc
fault mitigation systems in power switchgear and controlgear assemblies (PSC –
Assemblies) according to IEC 61439-2.

The latter document is new and provides details on the testing necessary
to confirm correct incorporation of the arc fault mitigation systems into
assemblies. It also obliges manufactures to identify areas within the assembly
where the arc fault detection system will not effectively detect an arcing fault.

Changes within IEC 61439-1 & 2 Ed 3

 DC assemblies
In the past DC has been rarely used, except in some specialist applications. It
can lead to corrosions issues, it is more difficult to switch than AC and historically
there was only a limited number of DC circuit breakers and switches available.
This is now changing, more power generation is DC, (photovoltaic, wind), battery
storage is more prominent, a wide range of DC devices are now available, and DC
distribution is finding favour in some instances.

In anticipation of a demand for more DC assemblies, IEC 61439-1 & 2 has a greater
focus on DC. The standards now:

• Recognise AC short time current withstand test (not making and

breaking tests) can be used as verification for DC short time current
withstand capability.
• Make frequent reference to AC rms or mean value of DC.
• Provide clarity on when AC and DC dielectric tests should be used.
• Suggest a DC peak factor of 1.42 when conducting DC short
circuit tests.

How far the technical and economic benefits will take this trend remains to be seen.

Technical Significant technical changes have been introduced in the standard that will affect
the way in which assemblies are specified and used. It is crucial these changes
changes: are understood if misunderstandings between the manufacturer and specifier are
to be avoided.

Group rated current

In Edition 2 of IEC 61439 a manufacturer is obliged to declare a rated current for
each circuit within the assembly and a rated diversity factor for a section within an
assembly, or, for the assembly as a whole. This has led to unease and controversy
in some markets where manufacturer’s have carried out a single temperature rise
test with a relatively low current on each circuit, and then claimed the assembly
has a unit diversity factor, but without openly declaring the low-test current in each
circuit of the assembly as the rated current of each circuit of the assembly.

To overcome these issues with Edition 2 in the market and bring the assembly
standard closer to the electrical installation rules, the IEC 60364 series, a new
characteristic has been introduced, the ‘group rated current of a main circuit’.

The introduction of this new characteristic, the ‘group rated current of a main
circuit’ is the most significant change within IEC 61439-1. It is defined as;

‘Rated current which a main circuit can carry considering the mutual thermal
influences of the other circuits that are simultaneously loaded in the same
section of the assembly’

Further amplification of this definition within the standard confirms that a minimum
of one other circuit within the section must be loaded, and that the specific loading
arrangements of the section is defined by the manufacturer.

Changes within IEC 61439-1 & 2 Ed 3

 This provides more flexibility for rating circuits than the previous need to specify
the rated current for each type of a circuit and the diversity factor for a section
or a complete assembly. With the new characteristic, a specific device, e.g. 630A
moulded case circuit breaker, can be incorporated in a circuit within an assembly
and have a multitude of group rated currents depending upon the loading of the
adjacent circuits, heat transfer effects to or from the associated busbar and it’s
relative vertical position (top, bottom, etc.) within the section.

The characteristic ‘rated current of a circuit of an assembly’ has been retained

in Edition 3 of the standard. It is determined in the same way as in Edition 2 and
provides the limit for continuous loading on an individual circuit within an assembly.
The characteristic rated diversity factor has also been kept, but instead of it being
an arbitrary value usually verified by test, it is now defined as the group rated
current of the circuit divided by the rated current of the circuit. Other than being a
link to the past it serves little purpose.

Rated currents of circuits

For a given circuit within an assembly there can be three current ratings to
be considered:
• The rated current of the device. This is the rated current of the device
established in accordance with its product standard e.g. a moulded
case circuit breaker in accordance with IEC 60947-2. Such ratings are
established under defined conditions, usually in free air, with specific
test connections.
• The rated current of a circuit of an assembly, the current the circuit
within the assembly can carry when it is the only circuit loaded within
the section of the assembly or the complete assembly.
• The group rated current of a circuit of an assembly.

Within most assemblies, for a given circuit, the rated current of the device will be
the highest, the rated current of the circuit within the assembly will be lower and
the group rated current the lowest of the three ratings.

In the absence of any other information, IEC 61439-2 suggests, but does not
mandate, manufacturers establish group rated currents based on the rated current
of the device multiplied by the assumed loading factor given in the table below.

Table 1 Type of load Assumed loading factor

These are the same values
of assumed loading as Distribution - 2 and 3 circuits 0,9
given in Edition 2 of
Distribution - 4 and 5 circuits 0,8
IEC 61439-2 and the
values frequently used Distribution - 6 and 9 circuits 0,7
as the diversity factor for
the assembly. Distribution - 10 or more circuits 0,6
Electric actuator 0,2
Motors ≤ 100 kW 0,8
Motors < 100 kW 1,0

Changes within IEC 61439-1 & 2 Ed 3

 Links to the installation rules (IEC 60364 series)
Electrical installation designers usually establish a design current for each circuit
within an installation. Essentially this is the continuous full load current of
the circuit.

IEC 61439-1 states that the design current of the circuit within the installation
should not exceed the group rated current of the corresponding circuit within the
assembly. The only exception to this is when the loading characteristics of circuits
are well known and permit an increase. If one circuit within a section is heavily
loaded and all adjacent circuits lightly, intermittently, or not loaded, for example,
duty and stand-by circuits, the combined thermal effects may permit the load on
a circuit within an assembly to be increased, but the design current of the circuit
within the installation should never exceed the rated current of the circuit within
the assembly.

Assuming the rated current of a circuit within an assembly has been determined
and that it is appropriate, this ability to increase the loading of a circuit within an
assembly above its group rated current provides an opportunity for improved
utilisation of assemblies and cost savings.

With the forgoing in mind, the electrical installation designer is encouraged in the
standard to include the design current of each circuit within the installation in their
specification for the assembly. This enables the assembly manufacturer to put
forward the most cost-effective arrangement, and at the same time, take full
responsibility for providing suitably rated circuits within the assembly.

Current ratings
When considering current ratings of circuits associated with an assembly it is
essential to note:
• According to the standard, if a specifier does not stipulate which
current rating they are specifying, rated current of the device, rated
current of the circuit of the assembly, group rated current of the circuit
of the assembly or the design current in accordance with the electrical
installation rules, the assembly manufacturer will assume it is the
rated current of the device.
• The group rated current of a circuit cannot be specified in amperes
alone. The assembly manufacture must define the loading of the
adjacent circuits for which the group rated current applies.

Changes within IEC 61439-1 & 2 Ed 3

 Group rated currents of circuits within assemblies offer opportunity to optimise
assembly design and increase utilisation of the assembly. Matching assembly
performance to the application through closer association with the installation rules
is a major opportunity to be environmentally friendly and optimise use of scarce
resources. However, with every opportunity there are risks and responsibilities.
Great care is required in the specification and application of assemblies if
misunderstanding and issues are to be avoided.

Assembly environment
Most devices that are to be incorporated in assemblies are suitable for use in a
specific environment as defined by a pollution degree, namely, pollution degree 1,
2, 3 or 4. Power switchgear and control gear assemblies are usually required to
be suitable for installation in a pollution degree 3 environment, whilst many of the
components to be installed in the assembly are only suitable for a pollution degree
2 environment.

Previously when the assembly standard was considering the pollution degree
applicable to the assembly environment, it was not clear if the environment being
considered was that inside the assembly, or the place in which it was installed. In
Edition 3 of IEC 61439-1 this has been clarified.

The environment in which the assembly is to be installed is defined as the Macro

environment and the environment inside the assembly is the Micro environment.
Furthermore, the standard makes it clear that with a suitable enclosure, and
possibly some form of air management system, e.g. use of dust filters or anti-
condensation heaters, the environment inside the assembly can be less polluted
than that outside; thereby facilitating the use of a wider range of components
inside the assembly, without concern.

Insulating materials
Insulating materials are widely used in assemblies. Most are part of devices with
their requirements being dealt with in the associated product standard. However,
some insulated parts, such as busbar support and barriers, that are specific to the
assembly, need to have characteristics suitable for their application.

Some characteristics have always been proven, but this has been by design
verification with the assembly in new condition. Aging, and particularly aging of
insulation, has not been effectively considered.

All hydrocarbon-based insulation ages as a function of temperature and time. At

low-voltage the most likely form of aging is a degradation of mechanical properties,
but the temperature and rate at which this occurs varies markedly between
insulating materials. For example, some grades of acetal will have a life of 5 years
at a constant temperature of 60⁰C, whereas some grades of glass reinforced
polyester have a life of 40 years at a constant 130⁰C.

Edition 3 of IEC 61439-1 now insists consideration is given to the life of

insulation. Insulating materials must have a life at its operating temperature
within the assembly at least equal to the design life of the assembly. Fortunately,
this characteristic is usually available from the material manufacturer or publicly
available data bases such as UL746B.

Changes within IEC 61439-1 & 2 Ed 3

 Further temperature rise verification by analysis
Since its inception the standard has always recognised that it’s impractical to
type test every conceivable arrangement of assembly. Where it is safe to do so,
alternatives to verification by test are permitted. In line with this philosophy,
further areas of temperature rise verification without testing the specific
arrangement of assembly have been included.

Active cooling of assemblies

Earlier editions of the standard did not mention active cooling of assemblies;
leaving the assembly manufacturer no option, other than test, as the means of
temperature rise verification. Edition 3 of IEC 61439-2 now includes verification
of assemblies with active cooling by calculation providing the rating of the
assembly does not exceeding 1600A.

The means of cooling is not prescribed in the standard, it can be by fans, air
conditioning units, heat exchangers, etc. The validity of the result with the
calculation defined is very dependent on the accuracy of the cooling equipment
manufacturer data, but for designers seeking strict compliance with the assembly
standard, it will be very useful, particularly as more static devices are incorporated
where forced cooling cannot be avoided.

Circuits within higher rated assemblies

Concerns around induced heating of steelwork, current displacement within
conductors, etc. have previously limited temperature rise by calculation to
assemblies with a rated current not exceeding 1600A. Since most variations within
assemblies occur in circuits with a relatively low current rating this restriction has
proved problematic. If a change was made to a circuit, or a new circuit created,
with a low current rating in an assembly with a current rating in excess of 1600A,
the only option was temperature rise verification by test.

To ease this issue, whilst ensuring temperature rise conformance, a method of

temperature rise verification using a combination of comparison to a reference
design and calculation has been introduced for circuits with a rating not exceeding
1600A, in an assembly of any rating.

Changes within IEC 61439-1 & 2 Ed 3

 To use this method, the power loss of the components to be included in the new
circuit must be known and a reference design for the assembly must be available.
The current ratings of the reference design assembly must be at least equal to the
rating of the assembly in which the new circuit is to be installed. In addition, the
power loss of the busbars in the reference design must has been measured during
temperature rise tests on the reference design.

As it has not been a requirement to measure the power loss of busbar systems
during temperature rise testing, the lack of this information may restrict the
use of this method until reference designs including this additional information
are available.

Clarifications: As with most standards covering complex equipment such as assemblies, previous
editions of the standard have included areas which have not been comprehensively
addressed or that have led to debate between interested parties. Edition 3 of the
standard resolves a number of these grey areas.

Classes of assemblies
Edition 3 of the standard has adopted the protection system used by other
standards and introduced Class I and Class II assemblies.

Class I assemblies are required for most applications within the UK, since most
electrical installations have protective circuit for fault protection that requires an
earth fault current to return to source via the assembly. Usually, Class I assemblies
are metal enclosed, but they can be housed in insulated enclosures that includes a
protective (earth) circuit.

Class II assemblies are typically used in IT installation where there is no protective

circuit. Usually they are housed in enclosures made of double or reinforced
insulation, with special attention being required for anything that penetrates the
enclosure. Whilst the standard only considers Class II assemblies with protection
by double or reinforced insulation, other methods are available when suitable
precautions are employed.

Figure 3
Example of a Class
II assembly

Changes within IEC 61439-1 & 2 Ed 3

 Incorporation of devices
Increasingly in some circles the need to repeat device verifications as part of
assembly verification is debated. Edition 3 of the standard makes clear the
function of the different verifications. All devices should be fully verified/type
tested in accordance with their product standard to ensure they are capable of
their intended performance as a device.

Verifications in accordance with the assembly standard are intended to confirm the
devices have been incorporated in such a way that the devices performance and
interaction with other devices within the assembly, does not impair the performance
of the device to an extent where it is unable to perform its intended duty within
the assembly.

If a device, for example, a variable speed drive, is incorporated into an assembly,

there is no need to repeat all the variable speed drive tests. The drive should be
incorporated using all the installation guidance from the variable speed drive
manufacturer and then its incorporation verified in accordance with the assembly
standard. Responsibility for the correct incorporation and functioning of the device
within the assembly rests with the assembly designer.

Figure 4
Example of an assembly
containing variable
speed drives

Conductors passing through ferromagnetic materials

Despite it being a very easy to prove by test, over the years there has been much
debate and concern as to when it is permissible to pass a single conductor through
a hole in a ferromagnetic material, typically steel. As the answer is dependent upon
the material, it’s thickness and the amount of material surrounding the hole, there is
no simple arbitrary answer that fits all situations.

However, to provide some clarity, the standard has now confirmed that assuming
the current carried by the conductor does not exceed 200A, there is no issue. If the
conductor is carrying in excess of 200A a test should be performed to ensure
satisfactory performance.

Changes within IEC 61439-1 & 2 Ed 3

 Forms of separation
Forms of separation remains a matter for agreement between user and
manufacturer, but there is now a requirement that when the compartment is opened
via the usual access route, all exposed live conductors must be shrouded in
accordance with IPXXB of IEC 60529. No longer, as is still practiced in some areas
of the world, is it acceptable to have exposed live conductors between the busbars
and the isolating device, once the compartment has been opened.

Essentially this is IEC catching up with UK good practice. All other aspects of
Forms of Separation remains’ essentially unchanged; the use of a device’s integral
enclosure as the means of separation continues to be acceptable.

Future
Out of necessity, the IEC 61439 series will continue to evolve. The application
for assemblies is changing rapidly. Instead of its traditional role of being a dumb
piece of equipment, to allow isolation of a circuit and to take action in the event
of a fault, assemblies are fast becoming the brain and master of the low-voltage
network. IEC TR 63196 places the assembly at the heart of a fully automated
energy efficient network.

The need for total automation coupled with the need for very few, if any,
interruptions in electrical supplies leads to requirements for, defined reliability,
predictive rather than routine maintenance and when necessary, maintenance with
very limited isolation. In turn this, and the general quest for ever more safety,
brings a need for added safety features within assemblies.

To address these emerging needs and other subjects as required by the market,
IEC will continue to update standards and develop new documents. The IEC
61439 series will continue to evolve with consideration given to new topics such
as aluminium conductors. New document associated with low-voltage assemblies
continue to be developed. IEC TR 63196 on energy efficiency has just been
published and a further document, IEC TS 63058 on environmental aspects is
about to be published. In addition, and in support of the evolving market, a
document on ‘intelligent assemblies’ that will ensure smart devices are correctly
incorporated in assemblies, is proposed.

Changes within IEC 61439-1 & 2 Ed 3

Figure 5
Example of a modern
switchboard design
incorporating
communications
and metering

Conclusion It has taken a long time to reach international consensus on the 3rd Editions of IEC
61439-1 and IEC 61439-2. The new editions include many changes, some are very
significant and will affect the way in which assemblies are specified, manufactured
and used, while others will have minimal effect on previous good practice.

All the changes are either a recognition of the needs of assemblies in the
present and future market, technical advances, further options in design
verification or clarifications. These changes have been made with simple
objectives in mind; ensuring assemblies are fit for purpose and there is a clear
understanding between specifier and manufacturer.

As manufacturers of devices and assemblies squeeze design margins, and users

push to gain efficiencies through higher utilisation of assemblies, it is increasingly
essential to know the capabilities of assemblies and the characteristics of the
application. To ensure the assembly characteristics are established and that
it fulfils its declared capability it is essential that every assembly is verified in
accordance with the standard.

The move toward closer links with the electrical installation rules, particularly in
respect of rating of circuits, is a positive step in matching the assembly to the
application. When the electrical installation rules and the assembly standard are
truly applied, the assembly provided will efficiently and effectively meet the needs
of the application

Changes within IEC 61439-1 & 2 Ed 3