Brief introduction on Heat run tests

Energy loses in bus bar/electrical apparatus represents financial loss over period of time and if not kept within
safe limits may give rise to generation of heat, Sufficient to cause the temperature of the current carrying parts
and surrounding enclosures, insulation etc, to rise excessively and so produce a condition detrimental to the
satisfactory performance of the apparatus Energy losses are proportional to the resistance of the conductor and
to the square of the current flowing

Energy losses = I²R Watts

High conductivity –means a low loss and is a factor which becomes increasingly important as the magnitude of
current increases.

The capacity of modern electrical plant and machinery has become so large, the amounts of power to be dealt
with by control apparatus have reached enormous proportions. With present day trend towards centralized
generation and ever increasing degree of interconnection, provision has often to be made for possible short-
circuits of the order of few MVA and it becomes evident that the forces brought into play in such circumstances
must be very great.

Busbars, like all other apparatus in circuit have to withstand these forces without damage, and it is essential,
therefor that the material used in their construction should have the best possible mechanical proper ties also.
This division of CPRI has been carrying out Temperature rise tests of low as well as high voltage Switchgear
control gear,Bus ducts, Isolated Phase Busducts, segregated Phase ducts & non segregated busduct sandwich
busduct& Tap off, Distribution boards and feeder pillars Etc.

Need for temperature rise test

Temperature rise test is one of the Type testType tests are intended to verify compliance with the requirements
laid in the standard for given type of an assembly.The temperature rise shall not cause any damage to the current
carrying parts or adjacent parts of the assembly. In particular insulating material,

Rated Current : The rated current of assembly is stated by the assembly manufacturer, taking in consideration
the ratings of the devices within the circuit, their disposition and application.
This current shall be carried without the temperature rise of the various parts a of the assembly exceeding the
limits specified. The rated current of the circuit may be lower than the rated current of the devices installed in
the circuit.
The rated current of the main busbar is the rated current of the assembly.
The current carrying capacity of a conductor is usually determined by the maximum temperature at which the
conductor is permitted to operate. This sets a limit by consideration of the fact that, above this temperature the
rate of oxidation of the conductor in the presence of air increases rapidly and may give rise to cumulative and
excessive local heating at joint

Consideration such factors as the mechanical stresses set due to expansion and contraction, possible damage to
the insulation and risk of fire, makes such a temperature limitations necessary.
Quit apart from the fact that a plant operating at high load factor, the value of the energy loss may become
appreciable, over a long period.

SIGNIFICANCE

The amount of heat generated in a conductor is proportional to its resistance and to the square of the current
flowing, while the temperature rise depends upon the rate at which the heat is generated is dissipated.
The effective resistance depends upon the operating conditions. The heat is dissipated in varying degrees in the
following ways,
CONDUCTION
CONVENTION
RADIATION
Brief exposure to high temperature such, as those that accompany a short circuit condition generally has less
effect on electrical properties. In contrast, longer duration exposures produce significant reduction in electrical
even all lower temperatures.
In case of conductors completely surrounded by insulation, the heat is removed by radiation which is dominated
by the thermal resistivity of the insulating material.
But in case of conductors freely exposed to air most of the heat generated is dissipated by convection
&radiation, both of which are dependent, among other things, upon the nature of the surface of the conductor
and the difference between the means may vary between wide limits.
With similar conductors the heat dissipated due to convection is proportionally increased, while in case of
longer conductors it is decreased. The total heat dissipation per unit of surface is also greater for large
conductors.
In normal circumstances the temperatures of the conductor attains a steady value when the rate of heat
generation is equal to the rate of dissipation by the above means.
It is against this back ground that it becomes necessary to carry out temperature rise tests or heat run tests on
various electrical equipment's, in order to ensure that the temperature of the various elements of an equipment
various standards prescribe this test as a type or as a supplementary test after short circuit test and can be carried
out on one or more representative combinations of circuits so chosen as to cover with reasonable accuracy, the
worst condition for which the equipment is designed.

It is against this back ground that it becomes necessary to carry out temperature rise tests or heat run tests on
various electrical equipment's, in order to ensure that the temperature of the various elements of an equipment
various standards prescribe this test as a type or as a supplementary test after short circuit test and can be carried
out on one or more representative combinations of circuits so chosen as to cover with reasonable accuracy, the
worst condition for which the equipment is designed.

Temperature-Rise Test

The test shall be made with the specified nature of supply (ac or dc) and if ac at a frequency of 40 to 60 Hz. The
test assembly shall be 3 phase unit or 1 phase unit, as applicable,. Supply leads shall be of proper size to prevent
heat interchange. Ends of the bus shall be sealed. Test current shall flow through all phases, the current in each
phase within of the specific test current value. The test current shall be applied continuously until the
temperature of all the bus bar, parts and supports are substantially constant (threeSuccessive readings at not less
than 30 minutes intervals shall show a maximum variation of ± 1°C in hottest spot temperature). The test shall
be conducted in a room reasonably free of drought. The recommended methods of measurement of temperature
and precautions to be observed while carrying on the temperature-rise measurement are given below

While assessing the temperature-rise of bus-bar the following factors will be considered:
a) Allowance for temperature coefficient of resistance,
b) Skin effect ratio,
c) Proximity effect ratio,
d) Effect of the presence of enclosure

The following methods of measuring temperature are recognized:

a) Thermometer method, and
b) Thermocouple method.

THERMOMETER METHOD:

The thermometer may be bulb thermometer containing mercury or alcohol or resistance thermometer. When
bulb thermometers are used in places where there is any varying or moving magnetic field, those containing
alcohol should be employed in preference to those containing mercury. When a bulb thermometer is used to
measure the temperature of a surface of a conductor, the bulb should be surrounded by a single wrapping of tin
foil of thickness not less than 0.025 mm. The foil shall be turned up at the end to form complete covering for the
bulb and shall then be secured in contact with the surface under test. The exposed part of the wrapped bulb shall
be completely covered with a pad of insulating material without unduly shielding the test surface from normal
cooling.

THERMOCOUPLE METHOD:

The two conductors between which the thermoelectric effect is produced shall be soldered or welded at both the
hot and cold junctions. When applied to the surface of live conductors, the hot junction is covered with
insulation and shall be wrapped with tin-foil as described for bulb thermometers. The thermocouple circuit
should be earthed to minimize the possibility of capacitive currents.
At the end of the tests, the temperature-rise of the different parts of the main circuit shall not exceed the values
specified in Table

Switchgear and controlgear:

IEC 61439-1 Specification for Low-voltage switchgear and controlgear assemblies –

General rules

Throughout this standard, the term ASSEMBLY is used for a low-voltage switchgear andcontrolgear assembly.
This part of IEC 61439 lays down the definitions and states the service conditions,construction requirements,
technical characteristics and verification requirements for low voltageswitchgear and controlgear assemblies.

This standard applies to low-voltage switchgear and controlgear assemblies (ASSEMBLIES) onlywhen required
by the relevant ASSEMBLY standard as follows:

– ASSEMBLIES for which the rated voltage does not exceed 1 000 V in case of a.c. or1 500 V in case of d.c.
– Stationary or movable ASSEMBLIES with or without enclosure
– ASSEMBLIES intended for use in connection with the generation, transmission,distribution and conversion of
electric energy, and for the control of electric energy consuming equipment
– ASSEMBLIES designed for use under special service conditions, for example in ships, inrail vehicles, for
equipment in explosive atmospheres, and for domestic applications(operated by unskilled persons), provided
that the relevant specific requirements arecomplied with;

Supplementary requirements for ASSEMBLIES in ships are covered by IEC 60092-302.

Supplementary requirements for ASSEMBLIES in explosive atmospheres are covered by theIEC 60079 series
and the IEC 61241 series.

– ASSEMBLIES designed for electrical equipment of machines. Supplementaryrequirements for

ASSEMBLIES forming part of a machine are covered by the IEC 60204series.

This standard applies to all ASSEMBLIES whether they are designed, manufactured and verifiedon a one-off
basis or fully standardised and manufactured in quantity.The manufacture and/or assembly may be carried out
other than by the original manufacturer. This standard cannot be used alone to specify an ASSEMBLY or used
for a purpose ofdetermining conformity.

This standard does not apply to individual devices and self-contained components, such asmotor starters, fuse
switches, electronic equipment, etc. which will comply with the relevantproduct standards.

Low-voltage switchgear and controlgear assembly (ASSEMBLY):

Combination of one or more low-voltage switching devices together with associated control,measuring,
signalling, protective, regulating equipment, with all the internal electrical andmechanical interconnections and
structural parts
Service conditions:

Normal service conditions:

ASSEMBLIES conforming to this standard are intended for use under the normal serviceconditions detailed
below.If components, for example relays, electronic equipment, are used which are not designed for
theseconditions, appropriate steps should be taken to ensure proper operation.

Ambient air temperature:

Ambient air temperature for indoor installations

The ambient air temperature shall not exceed +40 °C and its average over a period of 24 hshall not exceed +35
°C.The lower limit of the ambient air temperature shall be –5 °C.
Ambient air temperature for outdoor installations

The ambient air temperature shall not exceed +40 °C and its average over a period of 24 hshall not exceed +35
°C.The lower limit of the ambient air temperature shall be –25 °C.

Atmospheric conditions

Atmospheric conditions for indoor installations

The air shall be clean and its relative humidity should not exceed 50 % at a maximum temperature of+40 °C.
Higher relative humidity may be permitted at lower temperatures, for example 90 % at+20 °C. Moderate
condensation should be borne in mind which may occasionally occur due tovariations in temperature.

Atmospheric conditions for outdoor installations

The relative humidity may temporarily be as high as 100 % at a maximum temperature of+25 °C.

Pollution degree

The pollution degree refers to the environmental conditions for which the ASSEMBLY is intended.For switching
devices and components inside an enclosure, the pollution degree of theenvironmental conditions in the
enclosure is applicable.For the purpose of evaluating clearances and creepage distances, the following four
degreesof pollution in the micro-environment are established.

Pollution degree 1: No pollution or only dry, non-conductive pollution occurs. The pollution has no influence.

Pollution degree 2: Only non-conductive pollution occurs except that occasionally a temporary conductivity
caused by condensation is to be expected.

Pollution degree 3: Conductive pollution occurs or dry, non-conductive pollution occurs which is expected to
become conductive due to condensation.

Pollution degree 4:Continuous conductivity occurs due to conductive dust, rain or other wet conditions.
Pollution degree 4 is not applicable for a micro-environment inside the ASSEMBLY to thisstandard.

Unless otherwise stated, ASSEMBLIES for industrial applications are generally for use in apollution degree 3
environment. However, other pollution degrees may be considered toapply, depending upon particular
applications or the micro-environment.The pollution degree of the micro-environment for the equipment may be
influenced by installation in anenclosure.

Altitude

The altitude of the site of installation does not exceed 2 000 m.For equipment to be used at higher altitudes, it is
necessary to take into account the reduction of thedielectric strength, the switching capability of the devices and
of the cooling effect of the air.
Special service conditions

Where any special service conditions exist, the applicable particular requirements shall becomplied with or
special agreements shall be made between the ASSEMBLY manufacturer andthe user. The user shall inform the
ASSEMBLY manufacturer if such exceptional serviceconditions exist.

Special service conditions include, for example:

a) Values of temperature, relative humidity and/or altitude differing from those specified in normal service
condition
b) Applications where variations in temperature and/or air pressure take place at such aspeed that exceptional
condensation is liable to occur inside the ASSEMBLY
c) Heavy pollution of the air by dust, smoke, corrosive or radioactive particles, vapours or salt
d) Exposure to strong electric or magnetic fields
e) Exposure to extreme climatic conditions
f) Attack by fungus or small creatures
g) Installation in locations where fire or explosion hazards exist
h) Exposure to heavy vibration and shocks
i) Installation in such a manner that the current-carrying capacity or breaking capacity isaffected, for example
equipment built into machines or recessed into walls
j) Exposure to conducted and radiated disturbances other than electromagnetic andelectromagnetic disturbances
in environments other than those described in electromagnetic compatibility
k) Exceptional overvoltage conditions

Conditions during transport, storage and installation

A special agreement shall be made between the ASSEMBLY manufacturer and the user if the Conditions during
transport, storage and installation, for example temperature and humidityconditions, differ from those defined in
normal service conditions.

Verification of temperature rise:

General

It shall be verified that the temperature-rise limits specified in temperature rise limits for the different parts of
the
ASSEMBLY or ASSEMBLY system will not be exceeded.

Verification shall be made by one or more of the following methods:

a) Testing with current
b) Derivation (from a tested design) of ratings for similar variants

The selection of the appropriate verification methods is the responsibility of the originalmanufacturer.
In ASSEMBLIES rated for frequencies above 60 Hz verification of temperature rise by Testing with current
Or by derivation from a similar design tested at the same intended frequency is always required.

If modifications are made to a verified ASSEMBLY, the rules given in verification of temperature rise shall be
used tocheck if these modifications are likely to adversely affect the temperature rise. Newverification shall be
carried out if an adverse effect is likely.For the future derivation of ratings, original manufacturers may find it
useful to determine the power loss ofan ASSEMBLY.

Verification by testing with current

General

Verification by test comprises the following:

1) If the ASSEMBLY to be verified comprises a number of variants, the most onerousarrangement(s) of the
ASSEMBLY shall be selected according to Selection of the representative arrangement.

2) The ASSEMBLY shall be verified by one of the following methods, determined by the originalmanufacturer:

a) Considering individual functional units, the main and distribution busbars and theASSEMBLY collectively
according to Verification of the complete ASSEMBLY

b) considering individual functional units separately and the complete ASSEMBLY includingthe main and
distribution busbars according to Verification considering individual functional units separately and the
Complete ASSEMBLY

c) Considering individual functional units and the main and distribution busbars separatelyas well as the
complete ASSEMBLY according to Verification considering individual functional units and the main and
distribution busbars separately as well as the complete ASSEMBLY.

3) When the ASSEMBLIES tested are the most onerous variants out of a larger product rangethen the test
results can be used to establish the ratings of similar variants without furthertesting. Rules for such derivations
are given in Derivation of ratings for similar variants

Selection of the representative arrangement

General

The test shall be made on one or more representative arrangements loaded with one or morerepresentative load
combinations chosen to obtain with reasonable accuracy the highestpossible temperature rise.The selection of
the representative arrangements to be tested is given in busbarsandFunctional unitsand is the responsibility of
the original manufacturer. The original manufacturershall take into consideration in his selection for test, the
configurations to be derived from thetested arrangements according to Derivation of ratings for similar variants.

Busbars

For busbar systems consisting of single or multiple rectangular sections of conductor, thevariants of which differ
only in the reduction of height, or reduction of thickness or quantity ofbars per conductor, but which have the
same arrangement of bars, the same conductorspacing, the same enclosure and busbar compartment (if any), as a
minimum for the test, thebusbars with the greatest cross-sectional area shall be selected as the
representativearrangement.

Functional units

a) Selection of comparable functional unit groups

Functional units intended to be used at different rated currents can be considered to have asimilar thermal
behaviour and form a comparable range of units, if they fulfil the following conditions

i) The function and basic wiring diagram of the main circuit is the same (e.g. incomingunit, reversing starter,
cable feeder)
ii) The devices are of the same frame size and belong to the same series
iii) The mounting structure is of the same type
iv) The mutual arrangement of the devices is the same
v) The type and arrangement of conductors is the same
vi) The cross-section of the main circuit conductors within a functional unit shall have arating at least equal to
that of the lowest rated device in the circuit. Selection ofconductors shall be as tested or in accordance with IEC
60364-5-52.

b) Selection of a critical variant out of each comparable group as a specimen for test

For the critical variant the most onerous compartment (where applicable) and enclosureconditions (with respect
to shape, size, design of partitions and enclosure ventilation) shall betested.The maximum possible current
rating for each variant of functional unit is established. Forfunctional units containing only one device this is the
rated current of the device. Forfunctional units with several devices, it is that of the device with the lowest rated
current. If acombination of devices connected in series is intended to be used at a lower current (e.g.motor
starter combination), this lower current shall be used.For each functional unit the power loss is calculated at the
maximum possible current usingthe data given by the device manufacturer for each device together with the
power losses ofthe associated conductors. For functional units with currents up to and including 630 A, the
critical unit in each range isthe functional unit with the highest total power loss.

For functional units with currents above 630 A the critical unit in each range is that which has
the highest rated current. This ensures that additional thermal effects relating to eddy currentsand current
displacement are taken into consideration.The critical functional unit shall at least be tested inside the smallest
compartment (if any)which is intended for this functional unit; and with the worst variant of internal separation
(ifany) with respect to size of ventilation openings; and the enclosure with the highest installedpower loss per
volume; and the worst variant of ventilation of the enclosure with respect tokind of ventilation (natural or forced
convection) and size of ventilation openings.If the functional unit can be arranged in different orientations
(horizontal, vertical), then themost onerous arrangement shall be tested.Additional test may be made on the
discretion of the original manufacturer for less critical arrangementsand variants of functional units.

Methods of test

General

The temperature-rise test on the individual circuits shall be made with the type of current forwhich they are
intended, and at the design frequency. Any convenient value of the testvoltage may be used to produce the
desired current. Coils of relays, contactors, releases,etc., shall be supplied with rated operational voltage.The
ASSEMBLY shall be mounted as in normal use, with all covers including bottom coverplates, etc., in place.
If the ASSEMBLY includes fuses, these shall be fitted for the test with fuse-links as specified bythe
manufacturer.
The power losses of the fuse-links used for the test shall be stated in thetest report. Fuse-link power loss may be
determined by measurement or alternatively asdeclared by the fuse-link manufacturer.The size and the
disposition of external conductors used for the test shall be stated in the testreport.The test shall be made for a
time sufficient for the temperature rise to reach a constant value.In practice, this condition is reached when the
variation at all measured points (including theambient air temperature) does not exceed 1 K/h.

To shorten the test, if the devices allow it, the current may be increased during the first part ofthe test, it being
reduced to the specified test current afterwards.When a control electro-magnet is energized during the test, the
temperature is measuredwhen thermal equilibrium is reached in both the main circuit and the control electro-
magnet.Temperature-rise tests on the circuit(s) carried out at 50 Hz are applicable to 60 Hz for ratedcurrents up
to and including 800 A. For currents above 800 A, the rated current at 60 Hz shallbe reduced to 95 % of that at
50 Hz. Alternatively, where the maximum temperature rise at50 Hz does not exceed 90 % of the permissible
value, then de-rating for 60 Hz is not required.

Tests on an individual section of the ASSEMBLY are acceptable provided the conditions ofselection of the
representative arrangement are met. To make the test representative the external surfaces at which
additionalsections may be connected shall be thermally insulated with a covering to prevent any unduecooling.
When testing individual functional units within a section, the adjacent functional units can bereplaced by
heating resistors if the rating of each does not exceed 630 A and theirtemperature is not being measured.In
ASSEMBLIES where there is a possibility that additional control circuits or devices may beincorporated,
heating resistors shall simulate the power dissipation of these additional items.

Test conductors

In the absence of detailed information concerning the external conductors and the serviceconditions, the cross-
section of the external test conductors shall be in accordance with thefollowing.

1) For values of rated current up to and including 400 A:

a) The conductors shall be single-core, copper cables or insulated wires with crosssectionalareas as given in
Table 11
b) As far as practicable, the conductors shall be in free air
c) The minimum length of each temporary connection from terminal to terminal shall be
– 1 m for cross-sections up to and including 35 mm2
– 2 m for cross-sections larger than 35 mm2.

2) For values of rated current higher than 400 A but not exceeding 800 A:

a) The conductors shall be single-core copper cables with cross-sectional areas as givenin Table 12, or the
equivalent copper bars given in Table 12 as specified by theoriginal manufacturer.

b) Cables or copper bars shall be spaced at approximately the distance betweenterminals. Multiple parallel
cables per terminal shall be bunched together and arrangedwith approximately 10 mm air space between each
other. Multiple copper bars perterminal shall be spaced at a distance approximately equal to the bar thickness. If
thesizes stated for the bars are not suitable for the terminals or are not available, it isallowed to use other bars
having the same cross-sectional dimensions + or -10 % and thesame or smaller cooling surfaces. Cables or
copper bars shall not be interleaved.

c) For single-phase or multi-phase tests, the minimum length of any temporaryconnection to the test supply shall
be 2 m. The minimum length to a star point may bereduced to 1,2 m where agreed by the original manufacturer.

3) For values of rated current higher than 800 A but not exceeding 4000 A:

a) The conductors shall be copper bars of the sizes stated in Table 12 unless theASSEMBLY is designed only
for cable connection. In this case, the size and arrangementof the cables shall be as specified by the original
manufacturer.

b) Copper bars shall be spaced at approximately the distance between terminals. Multiplecopper bars per
terminal shall be spaced at a distance approximately equal to the barthickness. If the sizes stated for the bars are
not suitable for the terminals or are notavailable, it is allowed to use other bars having the same cross-sectional
dimensions +or - 10 % and the same or smaller cooling surfaces. Copper bars shall not beinterleaved.

c) For single-phase or multi-phase tests, the minimum length of any temporaryconnection to the test supply shall
be 3 m, but this can be reduced to 2 m provided thatthe temperature rise at the supply end of the connection is
not more than 5 K belowthe temperature rise in the middle of the connection length. The minimum length to
astar point shall be 2 m.

4) For values of rated current higher than 4 000 A:

The original manufacturer shall determine all relevant items of the test, such as type ofsupply, number of phases
and frequency (where applicable), cross-sections of testconductors, etc. This information shall form part of the
test report.

Measurement of temperatures

Thermocouples or thermometers shall be used for temperature measurements. For windings,the method of
measuring the temperature by resistance variation shall generally be used.The thermometers or thermocouples
shall be protected against air currents and heatradiation.The temperature shall be measured at all points where a
temperature-rise limit given in mustbe observed. Particular attention shall be given to joints in conductors and
terminals withinthe main circuits. For measurement of the temperature of air inside an ASSEMBLY,
severalmeasuring devices shall be arranged in convenient places.

Ambient air temperature

The ambient air temperature shall be measured by means of at least two thermometers orthermocouples equally
distributed around the ASSEMBLY at approximately half its height and ata distance of approximately 1 m from
the ASSEMBLY. The thermometers or thermocouples shallbe protected against air currents and heat
radiation.The ambient temperature during the test shall be between +10 °C and +40 °C.

Verification of the complete ASSEMBLY

Incoming and outgoing circuits of the ASSEMBLY shall be loaded with their rated currents that result in the
rated diversity factor being equal to. If several or all circuits of an ASSEMBLY are loaded simultaneously then
the same circuit isonly able to carry its rated current multiplied with the rated diversity factor due tothe thermal
influence of the other circuits. Thus to verify the rated currents of all circuits aseparate test for each type of
circuit is necessary. To verify the rated diversity factor oneadditional test with simultaneous load on all circuits
has to be done.

To avoid the large number of tests that may be necessary this clause describes a verificationmethod where only
one test is made with simultaneous load on all circuits. Because with onlyone test the rated currents and the
rated diversity factor of the circuits cannot be verifiedseparately, it is assumed that the diversity factor is one. In
this case the load currents areequal to the rated currents.

If the rated current of the incoming circuit or distribution busbar system (DBS) is less than thesum of the rated
currents of all outgoing circuits, then the outgoing circuits shall be split intogroups corresponding to the rated
current of the incoming circuit or DBS. The groups asdefined by the original manufacturer shall be formed in a
manner so that the highest possibletemperature rise is obtained. Sufficient groups shall be formed and tests
undertaken so as to include all different variants of functional units in at least one group.

Where the fully loaded circuits do not distribute exactly the total incoming current, theremaining current shall be
distributed via any other appropriate circuit. This test shall berepeated until all types of outgoing circuit have
been verified at their rated current.Change in the arrangement of functional units within a verified ASSEMBLY,
or section of anASSEMBLY may necessitate additional tests as the thermal influence of the adjacent units
maydiffer significantly.

Verification considering individual functional units separately and thecomplete ASSEMBLY

The ASSEMBLY is verified by loading the incoming circuit to its rated current and all outgoingfunctional units
collectively to their rated current multiplied by the diversity factor.If the rated current of the incoming circuit or
distribution busbar system (DBS) is less than thesum of the rated currents of all outgoing circuits, then the
outgoing circuits shall be split into groups corresponding to the rated current of the incoming circuit or DBS.
The groups as defined by the original manufacturer shall be formed in a manner so that the highest
possibletemperature rise is obtained. Sufficient groups shall be formed and tests undertaken so as toinclude all
different variants of functional units in at least one group.

Where the fully loaded circuits do not distribute exactly the total incoming current, theremaining current shall be
distributed via any other appropriate circuit. This test shall berepeated until all types of outgoing circuit have
been verified at their rated current.Change in the arrangement of functional units within a verified ASSEMBLY,
or section of anASSEMBLY may necessitate additional tests as the thermal influence of the adjacent units
maydiffer significantly.

Verification considering individual functional units and the main anddistribution busbars separately as
well as the complete ASSEMBLY

ASSEMBLIES shall be verified by separate verification of standard elements (a) to c)) as selected and
verification of a completeASSEMBLY (d)) under worst case conditions as detailed below

a) Main busbars shall be tested separately. They shall be mounted in the ASSEMBLYenclosure as in normal use
with all covers and all partitions that separate the mainbusbars from other compartments, in place. If the main
busbar has joints, then they shallbe included in the test. The test shall be carried out at rated current. The test
current shallpass through the full length of the busbars. Where the design of the ASSEMBLY permits,
and, to minimise the influence of the external test conductors on the temperature rise, thelength of the main
busbar within the enclosure for the test shall be a minimum of 2 m andinclude a minimum of one joint when the
busbars are extendable.
b) Distribution busbars shall be tested separately from the outgoing units. They shall bemounted in the enclosure
as in normal use with all covers and all partitions that separatethe busbar from other compartments, in place.
Distribution busbars shall be connected tothe main busbar. No other conductors, e.g. connections to functional
units, shall beconnected to the distribution busbar. In order to consider the most onerous condition, thetest shall
be carried out at rated current and the test current shall pass through the fulllength of the distribution busbar. If
the main busbar is rated for a higher current, it shall befed with additional current so that it carries its rated
current to its junction with thedistribution busbar.

c) Functional units shall be tested individually. The functional unit shall be mounted in theenclosure as in
normal use with all covers and all internal partitions in place. If it can bemounted at different places the most
unfavourable place shall be used. It shall beconnected to the main or the distribution busbar as in normal use. If
the main busbarand/or the distribution busbar (if any) are rated for a higher current, they shall be fed with
additional currents so that they carry their individual rated currents to the respectivejunction points. The test
shall be carried out at rated current for the functional unit.

d) The complete ASSEMBLY shall be verified by temperature rise testing of the most onerous
arrangement(s) possible in service and as defined by the original manufacturer. For thistest the incoming circuit
is loaded to its rated current and each outgoing functional unit toits rated current multiplied by the rated
diversity factor. Where there is insufficientincoming current to load a representative selection of outgoing units,
furtherconfigurations may be tested.

Results to be obtained

At the end of the test, the temperature rise shall not exceed the values specified in Table 6.The apparatus shall
operate satisfactorily within the voltage limits specified for them at thetemperature inside the ASSEMBLY.

Derivation of ratings for similar variants

General

The following sub-clauses define how non-tested variants can be verified by derivation fromsimilar
arrangements verified by test.

ASSEMBLIES

The ASSEMBLY that incorporates non-tested variants shall be verified by derivation from similar
tested arrangements.ASSEMBLIES verified in this manner shall comply with the following

a) The functional units shall belong to the same group as the functional unit selected for test
b) The same type of construction as used for the test
c) The same or increased overall dimensions as used for the test
d) The same or increased cooling conditions as used for the test (forced or naturalconvection, same or larger
ventilation openings)
e) The same or reduced internal separation as used for the test (if any)
f) The same or reduced power losses in the same section as used for the test
g) The same or reduced number of outgoing circuits for every section.

The ASSEMBLY being verified may comprise all or only part of the electrical circuits of theASSEMBLY
previously verified. Alternative arrangement(s) of functional units within theASSEMBLY or section compared
to the tested variant is allowed as long as the thermalinfluences of the adjacent units are not more
severe.Thermal tests performed on 3-phase, 3-wire ASSEMBLIES are considered as representing 3-phase, 4-
wire and single-phase, 2-wire or 3-wire ASSEMBLIES, provided that the neutralconductor is sized equal to or
greater than the phase conductors arranged in the samemanner.

Busbars

Ratings established for aluminium busbars are valid for copper busbars with the same crosssectional dimensions
and configuration. However, ratings established for copper busbars shallnot be used to establish ratings of
aluminium busbars.The ratings of variants not selected for test according to busbars mentioned above shall be
determined bymultiplying their cross-section with the current density of a larger cross-section busbar thathas
been verified by test.

Functional units

After the critical variants of a group of comparable functional havebeen subjected to a test for verification of
temperature rise limits, the actual rated currents ofall other functional units in the group shall be calculated using
the results of these tests.For each functional unit tested a de-rating factor (rated current, resulting from the test
dividedby the maximum possible current of this functional unit, shall becalculated.The rated current of each
non-tested functional unit in the range shall be the maximumpossible current of the functional unit multiplied by
the lowest de-rating factor established forthe variants tested in the range.

Functional units – device substitution

A device may be substituted with a similar device from another series to that used in theoriginal verification,
provided that the power loss and terminal temperature rise of the device,when tested in accordance with its
product standard, is the same or lower. In addition, thephysical arrangement within the functional unit and the
rating of the functional unit shall bemaintained.
Temperature rise limits:

The temperature-rise limits given in Table 6 apply for mean ambient air temperatures lessthan or equal to 35 °C
and shall not be exceeded for ASSEMBLIES when verified in accordancewith verification of temperature rise.The
temperature rise of an element or part is the difference between the temperature of thiselement or part measured
in accordance with measurement of temperatures and the ambient air temperatureoutside the ASSEMBLY.

The temperature rises obtained during the test shall not cause damage to current-carryingparts or adjacent parts
of the ASSEMBLY. In particular, for insulating materials, the ASSEMBLYManufacturer shall demonstrate
compliance either by reference to the insulation temperatureindex (determined for example by the methods of
IEC 60216) or by compliance withIEC 60085.
800Amps, 415V, 50Hz, 3 phase & Neutral LT Switch board
IS8623 & IEC-Pub 439 SPE-CIFICATION FOR LOW-VOLTAGE SWITCHGEA-R
AND CONTROLGEAR ASSEMBLIES

PART 1 REQUIREMENTS FOR TYPE-TESTED AND PARTIALLYTYPE-TESTED

ASSEMBLIES

This standard applies to low-voltage switchgear and controlgear assemblies (Type-tested Assemblies(TTA) and
Partially Type-tested Assemblies (PTTA)), the rated voltage of which does notexceed 1000 V a.c. at frequencies
not exceeding 1000 Hz, or 1 500 V d.c.Note. - For higher frequencies, special considerations may be
necessary.This standard also applies to assemblies incorporating control and/or power equipment,
thefrequencies of which are higher. In this case, ‘appropriate additional requirements shall apply.This standard
applies to stationary or movable assemblies with or without enclosures.Additional requirements for certain
specific types of assemblies are given in supplementary standards.

This standard applies to assemblies intended for use in connection with generation, transmission,distribution and
conversion of electric energy and for the control of electric energy consumingequipment.It also applies to such
assemblies designedfor use under special service conditions, for example inships, in rail vehicles, for machine
tools, for hoisting equipment, or in explosive atmospheres, andfor domestic (operated by unskilled persons)
applications, provided that the relevant specificrequirements are complied with.This standard does not apply to
individual devices and self-contained components, such asmotor starters, fuse switches, electronic equipment,
etc., complying with their relevant standards.

L V switchgear and controlgear assembly (hereinafter called “ASSEMBLY”):

A combination of one or more low-.voltage switching devices together with associated control, measuring,
signalling, protective, regulating equipment, etc., completely assembled under the responsibility of the
manufacturer with all the internal electrical and mechanical interconnections and structural parts.

The components of the ASSEMBLY may be electromechanical or electronic. For various reasons, for example
transport or production, certain steps of assembly may be made in a placeoutside the factory of the
manufacturer.

Service conditions

Normal service conditions

ASSEMBLIES conforming to this standard are intended for use under the following service
Conditions.

If components, for example relays, electronic equipment, are used which are not designed for these conditions,
appropriate steps should be taken to ensure proper operation.

Ambient air temperature

Ambient air temperature _for indoor installations

The ambient air temperature does not exceed + 40 “C and its average over a period of 24 h does not exceed +35
“C.The lower limit of the ambient air temperature is - 5 ‘C.

Ambient air temperature for outdoor installations

The ambient air temperature does not exceed + 40 “C and its average over a period of 24 h doesnot exceed + 35
“C.The lower limit of the ambient air temperature is:- 25 “C in a temperate climate, and- 50 “C in an arctic
climate.

The use of ASSEMBLIES in an arctic climate may require a special agreement between manufacturer and user.
Atmospheric conditions

Atmospheric conditions for indoor installations

The air is clean and its relative humidity does not exceed 50% at a maximum temperature of+40 “C. Higher
relative humidities may be permitted at lower temperatures, for example 90% at+ 20 “C. Care should be taken
of moderate condensation which may occasionally occur due tovariations in temperature.

Atmospheric conditions for outdoor installations

The relative humidity may temporarily be as high as 100% at a maximum temperature of+25 ‘C.

Altitude

The altitude of the site of installation does not exceed 2 000 m (6 600 ft).For electronic equipment to be used at
altitudes above 1 000 m (3 300 A) it may be necessary to take into account thereduction of the dielectric
strength and of the cooling effect of the air. Electronic equipment intended to operate inthese conditions should
Lx designed or used in accordance with an agreement between manufacturer and user.

Special service conditions

Where any of the following special service conditions exist, the applicable particular requirementsshall be
complied with or special agreements shall be made between user and manufacturer.The user shall inform the
manufacturer if such exceptional service conditions exist.

Special service conditions are for example:

1) Values of temperature, relative humidity and/or altitude differing from those specified in Normal service
conditions.
2) Applications where variations in temperature and/or air pressure take place at such a speed thatexceptional
condensation is liable to occur inside the ASSEMBLY.
3) Heavy pollution of the air by dust, smoke, corrosive or radioactive particles, vapours or salt.
4) Exposure to strong electric or magnetic fields.
5) Exposure to extreme temperatures, for example radiation from sun or furnaces.
6) Attack by fungus or small creatures.
7) Installation in locations where fire or explosion hazards exist.
8)Exposure to heavy vibration and shocks.
9)Installation in such a manner that the current-carrying capacity or breaking capacity is affected, for
example equipment built into machines or recessed into walls.
10) Consideration of appropriate remedies against electrical and radiated interferences, shall be the
subject of agreement between manufacturer and user.

Conditions during transport, storage and erection

A special agreement shall be made between user and manufacturer if the conditions during transport,storage and
erection, for example temperature and humidity conditions, differ from thosedefined in normal service
conditions.Unless otherwise specified, the following temperature range applies during transport and
storage:between - 25 “C and + 55 “C and, for short periods not exceeding 24 h, up to + 70 “C.Equipment
subjected to these extreme temperatures without being operated, shall not undergoany irreversible damage and
shall then operate normally in the specified conditions.

Temperature rise:
The temperature rise limits given in Table III shall not be exceeded for ASSEMBLIES whenverified in
accordance with Verification of temperature-rise limits.The temperature rise of an element or part is the
difference between the temperature of this element or partmeasured in accordance with Measurement of
temperaturesand the ambient air temperature outside the ASSEMBLY.
1) The term ‘*built-in components” means:
- Conventional switchgear and controlgear:
- Electronic sub-assemblies (e.g. rectifier bridge, printed circuit):
- Parts of the equipment (e.g. regulator. stabilized power supply unit, operational amplifier).

2) The temperature-rise limit of 70 K is a value based on the conventional test of Verification of temperature-
rise limits. An ASSEMBLY used on tested under installation conditions may have connections, the type, nature
and disposition of which will not be the same asthose adopted for the test. And a different temperature rise of
terminals may result and may be required or accepted.

3) Manual operating means within ASSEMBLIES which are only accessible after the ASSEMBLY has been
opened, forexample emergency handles, draw-out handles, which are operated infrequently, are allowed to
assume higher temperaturerises.

4) Unless otherwise specified in the case of covers and enclosures which are accessible but need not be touched
during normaloperation, an increase in the temperature-rise limits by 10 K is permissible.

5) This allows a degree of flexibility in respect of equipment (e.g. electronic devices) which is subject to
temperature-rise limitsdifferent from those normally associated with switchgear and controlgear.

Verification of temperature-rise limits

General

The temperature-rise test is designed to verify that the temperature-rise limits specified in Temperature rise for
the different parts of the ASSEMBLY are not exceeded.
The test shall normally be carried out at the values of rated current in accordance with Temperature-rise test
using current on all apparatus, with the apparatus of the ASSEMBLY installed.The test may be carried out with
the aid of heating resistors of an equivalent power loss inaccordance with Temperature-rise test using heating
resistors with an equivalent power loss.It is permissible to test individual parts (panels, boxes, enclosures, etc.)
of the ASSEMBLY provided proper precautions are taken to make the test representative.

The temperature-rise test on the individual circuits shall be made with the type of current forwhich they are
intended, and at the design frequency. The test voltages used shall be such that acurrent equal to the current
determined according to Temperature-rise test using current on all apparatusflows through the circuits.Coils of
relays, contactors, releases, etc., shall be supplied with rated voltage.

Open-type ASSEMBLIES need not be subjected to the temperature-rise test if it is obvious fromtype tests on the
individual parts or from the size of the conductors and from the arrangement of theapparatus that there will be
no excessive temperature rise and that no damage will be caused to theequipment connected to the
ASSEMBLY, and to adjacent parts of insulating material.

The verification of temperature-rise limits for PTTA shall either be made:

- by test in accordance with Verification of temperature-rise limits, or
- by extrapolation.

Arrangement of the ASSEMBLY

The ASSEMBLY shall be arranged as in normal use, with all covers, etc., in place.When testing individual parts
or constructional units, the adjoining parts or constructional unitsshall produce the same temperature conditions
as in normal use. Heating resistors may be used.

Temperature-rise test using current on all apparatus

The test shall be made on one or more representative combinations of circuits for which theASSEMBLY is
designed so chosen as to obtain with reasonable accuracy the highest possibletemperature rise.
For this test, each circuit is loaded with its rated current multiplied by thediversity factor. If the ASSEMBLY
includes fuses, these shall be fitted for thetest with fuse-links as specified by the manufacturer. The power losses
of the fuse-links used for thetest shall be stated in the test report.The size and the, disposition of external
conductors used for the test shall be stated in the testreport.

The test shall be made for a time sufficient for the temperature rise to reach a constant value(normally not
exceeding 8 h). In practice, this condition is reached when the variation does notexceed 1 K/h.To shorten the
test, if the devices allow it, the current may be increased during the first part of the test, it beingreduced to the
specified test current afterwards. When a control electro-magnet is energized during the test, the temperature
shall be measured when thermalequilibrium is reached in both the main circuit and the control electro-magnet.

In the absence of detailed information concerning the external conductors and the service conditions,the cross-
section of the external test conductors shall be as follows:

For values of test current up to and including 400 A:

a)The conductors shall be single-core, copper cables or insulated wires with cross-sectional areas as
given in Table VIII

b)As far as practicable the conductors shall be in free air

c) The minimum length of each temporary connection from terminal to terminal shall be:
- 1 m for cross-sections up to and including 35 mm2,
- 2 m for cross-sections larger than 35 mm2.

For values of test current higher than 400 Abut not exceeding 800 A:

a) The conductors shall be single-core, p.v.c. insulated, copper cables with cross-sectional areas asgiven in
Table IX, or the equivalent copper bars given in Table IX as recommended by themanufacturer.
b) Cables or copper bars shall be spaced at approximately the distance between terminals. Copperbars shall be
finished matt black. Multiple parallel cables per terminal shall be bunched togetherand arranged with
approximately 10 mm air space between each other. Multiple copper bars perterminal shall be spaced at a
distance approximately equal to the bar thickness. If the sizes statedfor the bars are not suitable for the
terminals, or are not available, it is allowed to use other barshaving approximately the same cross-section and
approximately the same or smaller coolingsurfaces. Cables or copper bars shall not be interleaved.

c) For single-phase or multi-phase tests, the minimum length of any temporary connection to thetest supply shall
be 2 m. The minimum length to a star point may be reduced to 1.2 m.

For values of test current higher than 800 Abut not exceeding 3 150 A:

a) The conductors shall be copper bars of the sizes stated in Table IX unless the. ASSEMBLY isdesigned only
for cable connection. In this case, the size and arrangement of the cables shall be asspecified by the
manufacturer.

b) Copper bars shall be spaced at approximately the distance between terminals. Copper bars shallbe finished
matt black. Multiple copper bars per terminal shall be spaced at a distance approximatelyequal to the bar
thickness. If the sizes stated for the bars are not suitable for theterminals, or are not available, it is allowed to use
other bars .having approximately the samecross-section and approximately the same or smaller cooling surfaces.
Copper bars shall not beinterleaved.

c) For single-phase or multi-phase tests, the minimum length of any temporary connection to thetest supply
shall be 3 m, but thiscan, be reduced to 2 m provided that the temperature rise at thesupply end of the connection
is not more than 5 K below the temperature rise in the middle ofthe connection length. The minimum length to a
star point shall be 2 m.

For values of test current higher than 3 150 A:

Agreement shall be reached between manufacturer and user on all relevant items of the test, suchas type of
supply, number of phases and frequency (where applicable), cross-sections of test conductors,etc. This
information shall form part of the test report.In all cases, the use of single-phase a.c. current for testing multi-
phase ASSEMBLJES is only permissible if magneticeffects are small enough to be neglected. This requires
careful consideration especially for currents above 400 A.

Temperature-rise test using heating resistors with an equivalent power loss

For certain types of enclosed ASSEMBLIES with main and auxiliary circuits having comparativelyLow-rated
currents, the power loss may be simulated by means of heating resistors whichproduce the same amount of heat
and are installed in suitable places inside the enclosure.The cross-section of the leads to these resistors shall be
such that no appreciable amount of heat isconducted away from the enclosure.

This test with heating resistors is considered to be reasonably representative of all ASSEMBLIESusing the same
enclosure, even if they are equipped with different apparatus, provided that the sumof the power losses of the
built-in apparatus, taking into account the diversity factor, does notexceed the value applied in the test.
The temperature rise of the built-in apparatus shall not exceed the values given in Table III. This temperature
rise can be approximately calculated by taking the temperaturerise of this apparatus, measured in the open air,
increased by the difference between the temperatureinside the enclosure and the temperature of the air
surrounding the enclosure.

Measurement of temperatures

Thermocouples or thermometers shall be used for temperature measurements. For windings, themethod of
measuring the temperature by resistance variation shall generally be used. For measuringthe temperature of the
air inside an ASSEMBLY, several measuring devices shall be arranged inconvenient places.The thermometers
or thermocouples shall be protected against air currents and heat radiation.

Ambient air temperature

The ambient air temperature shall be measured during the last quarter of the test period by meansof at least two
thermometers or thermocouples equally distributed around the ASSEMBLY at abouthalf its height and at a
distance of about 1 m from the ASSEMBLY. The thermometers or thermocouplesshall be protected against air
currents and heat radiations.

If the ambient temperature during the test is between + 10 “C and + 40 “C, the values of Table III, are the
limiting values of temperature rise.If the ambient air temperature during the test exceeds +40 “C or is lower than
-I- 10 “C, thisstandard does not apply and the manufacturer and the user shall make a special agreement .

Results to be obtained

At the end of the test, the temperature rise shall not exceed the values specified in Table III. The apparatus shall
operate satisfactorily within the voltage limits specified forthem at the temperature inside the ASSEMBLY.
2500 Amps, ACB Panel
PART –2 PARTICULAR REQUIREMENTS FOR BUSBAR TRUNKING SYSTEMS
(BUSWAYS):

This standard applies to busbartrunking systems intended to supply Iuminaires through tap-off unitsbut
does not apply to supplytrack systems in accordance with IEC Publication 570.

Busbar trunking system (busway):

A type-.tested assembly in the form of a conductor system comprisingbusbars which are spaced and supported
by insulating material in aduct, trough or similar enclosure.

The assembly may consist of units such as:

1. Busbar trunking units with or without tap-off facilities

2. Phase transposition, expansion, flexible, feeder and adapter units
3. Tap-off units

Verification of temperature- rise limits:

Arrangement of the busbar trunking system

The busbar trunking system to be tested shall be arranged as in normal use, with all covers, etc., in place .

The current rating of a busbar trunking system is affected by the mounting arrangement. Therefore the
temperature rise test has to be performed with the rated current appropriate to the mounting arrangement(s)
stated by the manufacturer. If only one test is performed, the most unfavourable mounting arrangement shall be
used.

Temperature-rise tests:

A test shall be performed over a total length of at least 6 mincluding at least one joint.The test currents shall be
substantially equal in the live conductors.Any unintentional circulation of air in the section under test shall
beprevented, e.g. by closing the ends.

Another temperature-rise test shall be made on each size of tap-offunit designed to be connected to the busbar
trunking system. For thistest, the tap-off unit shall carry its rated current and the busbartrunking system shall be
supplied with its rated current.

The size and the disposition of external conductors used for the testshall be part of the test report.The test shall
be made for a sufficient time for the temperature riseto reach a constant value (but not exceeding 8 h). In
practice, thiscondition is reached when the variation does not exceed 1 K per hour.

In practice, to shorten the test the current may be increased during the first part of the test, it being reduced to
the specified test current afterwards. In the absence of detailed information as to the service conditions, the
cross-section of the external conductors shall be as follows: (see Publication 439-l).

Temperature-rise limits:

Unless otherwise specified in the case of external surfaces ofenclosures of busbar trunking systems which are
accessible but do notneed to be touched during normal operation, an increase in the temperature-rise limits by
25 K is permissible for metal surfaces and by15 K for insulating surfaces.
1250Amps, 415V, 50Hz NSPBD