DesignVerification_SYS1

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Design verificationas per IEC 61439-1 and IEC 61439-2

shown in detailfor

Rittal Ri4Power

Original manufacturer:Rittal GmbH & Co.KGAuf dem Stützelberg

D-35745 Herborn

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Table of Contents:

1. Proof of the strength of materials and parts 32. Proof of the protection categories of enclosures 53. Proof of the creepage distances and clearances 54. Proof of the protection against electrical shock and continuity of the PE

conductor circuits 65. Proof of the installation of switchgears and components 76. Proof of the interior electrical power circuits and connections 77. Proof of the connection for conductors fed in from the outside 88. Proof of the insulation properties 89. Proof of the heat generated 910. Proof of the short-circuit resistance 1011. Proof of the electromagnetic compatibility (EMC) 1012. Proof of the mechanical functions 11

13. Appendix A: Proof of the heat generated 12

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1. Proof of the strength of materials and partsas per IEC61439-1 Section 10.2

fulfilled by testing of sub-sections 1.1 to 1.6.

1.1. Proof of the corrosion resistance in compliance with severity class "A"as per IEC61439-1 Section 10.2.2

fulfilled by testing in accordance with test report 68/10The test applies to: Metal enclosures for indoor installations; External metal parts for switchgear assemblies used in indoor installations; Interior metal parts for switchgear assemblies used in indoor and outdoor

installations, on which depend mechanical functions

1.2. Proof of the properties of the insulating materials as per EC61439-1 Section 10.2.3

fulfilled by testing of sub-sections 1.2.1 to 1.2.3

1.2.1. Proof of the resistance of the enclosure to heatas per EC61439-1 Section 10.2.3

fulfilled by testing (manufacturer's data sheet)Testing applies to the sections of the enclosure made from insulating materials at atemperature of 70°C

1.2.2. Proof of the resistance of the insulating materials against normal heatas per IEC61439-1 Section 10.2.3.2

fulfilled by testing (manufacturer's data sheet)The test applies to: Parts that are needed to hold live parts in place (125 ± 2)°C Other parts (70 ± 2)°C

1.2.3. Proof of the resistance of insulating materials to exceptional heat and fire causedby internal electrical effectsas per IEC61439-1 Section 10.2.3.3

fulfilled by testing (manufacturer's data sheet)The test certificate has been issued for: 960°C for parts used to hold live parts in place; 850°C for enclosures that have to be installed in hollow walls; 650°C for all other parts including the parts that are needed to hold the PE

conductor

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1.3. Proof of the resistance against ultra-violet (UV) rays as per IEC61439-1 Section 10.2.4

Proof is not required for interior installation systems.

1.4. Proof of liftingas per IEC61439-1 Section 10.2.5

fulfilled by test report 60/99Technical load specifications are listed in the TS 8 load capacity brochure

1.5. Proof of impact testingas per IEC61439-1 Section 10.2.6

Protection category IK10 fulfilled by testing, report 490/09

1.6. Proof of the labellingas per IEC61439-1 Section 10.2.7

fulfilled by mechanically formed signs or equivalent inscriptions.

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2. Proof of the protection categories of enclosuresas per IEC61439-1 Section 10.3

Protection categories IP54, IP43 and IP2X have been fulfilled by testing, report386/2010

3. Proof of the creepage distances and clearancesas per IEC61439-1 Section 10.4

Requirements stipulated in the standard for rated surge voltage resistance of 8 KV:Minimum clearance distance >= 8.0 mm

Requirements stipulated in the standard for: Rated insulation voltages up to 1,000 V; Level of contamination 3; Material groups I,II & IIIa

Minimum creep distance >= 16.0 mm

fulfilled by testing for:

Rail systems Report nos. RiLine60 1579.0263.7.163 / ASTA 16699 Maxi-PLS 1600/2000 1579.1373.7.957 / ASTA 17744 Maxi-PLS 3200 1579.1373.7.955 / ASTA 17110 Flat-PLS 60 1579.2080837.416 / ASTA 16940 Flat-PLS 100 1579.2081170.851 / ASTA 17165

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4. Proof of the protection against electrical shock and continuity of the PEconductor circuitsas per IEC61439-1 Section 10.5

The power circuit's resistance never exceeded the permissible rating of 0.1 Ω during thetesting of the continuity of the connection between the switchgear assembly parts.

fulfilled by testing of sub-sections 4.1 to 4.2

4.1 Proof of the continuity between the switchgear assembly partsas per IEC61439-1 Section 10.5.2

The power circuit's resistance never exceeded the permissible rating of 0.1 Ω duringthe testing of the continuity of the connection between the switchgear assembly parts.

fulfilled by test report 1579.2080837.421 / ASTA 16942

4.2 Proof of the short-circuit resistance of the PE conductor circuitas per IEC61439-1 Section 10.5.3

For the following PE earthing systems proof has been issued through testing:

PE bracket Short-circuit resistance Test report30 x 5 up to 18kA 1 sec 1579.0930.6.862e30 x 10 up to 30kA 1 sec 1579.0263.7.289 / ASTA 1670340 x 10 up to 60 kA 1 sec 1579.2080837.421 / ASTA 16942

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5. Proof of the installation of switchgears and componentsas per IEC61439-1 Section 10.6

Proof fulfilled by adhering to the design regulations stipulatedin sub-sections 5.1 to 5.2

5.1 Proof of the installation of switchgears and components – General informationas per IEC61439-1 Section 10.6.1The "Operating equipment installation" checklist (Appendix 1) will be processed by themanufacturer of the switchgear assembly.

Conformity with the design requirements stipulated in Section 8.5 of IEC 61439-1 forthe installation of the operating equipment was verified by inspection and certified inaccordance with the requirements stipulated in this standard.

5.2 Proof of the installation of switchgear and components – Electromagnetic compatibilityas per IEC61439-1 Section 10.6.2

The properties requirements stipulated in Section J.9.4 of IEC 61439-1 forelectromagnetic compatibility were confirmed by inspection:

a. The installed operating equipment has been designed for use in the stipulated A orB environment in compliance with the applicable EMC product or basicspecifications (verified by the original manufacturers of the equipment)

b. The internal installation and the wiring has been designed in compliance with thedetails provided by the operating equipment manufacturer (laid out with regard tointeractive interference, shielded cables, earthing, etc.)

6. Proof of the interior electrical power circuits and connectionsas per IEC61439-1 Section 10.7

fulfilled by adhering to the design regulations

Conformity with the design requirements stipulated in Section 8.6 of IEC 61439-1 forinterior electrical power circuits and connections was verified by inspection and certifiedin accordance with this standard.

The "Interior electrical power circuits and connections" checklist (Appendix 2) will beprocessed by the manufacturer of the switchgear assembly.

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7. Proof of the connection for conductors fed in from the outsideas per IEC61439-1 Section 10.8

fulfilled by adhering to the conductor design regulations

Conformity with the design requirements stipulated in Section 8.8 of IEC 61439-1 for theconnections for conductors fed in from the outside was verified by inspection.

The "Connections for conductors fed in from the outside" checklist (Appendix 3) will beprocessed by the manufacturer of the switchgear assembly.

8. Proof of the insulation propertiesas per IEC61439-1 Section 10.9

fulfilled by testing of sub-sections 8.1 to 8.3

8.1 Proof of the operating frequency dielectric strengthas per IEC61439-1 Section 10.9.2

Proof has been issued for a rated insulation voltage Ui of 1,000 V.

fulfilled by test report 404/2010

8.2 Proof of the impulse voltage resistanceas per IEC61439-1 Section 10.9.3

Proof of the impulse voltage resistance has been issued for systems in overvoltagecategory IV, power supply planes for rated operating voltages up to 400 V/690 V usinga test voltage of 9.8 KV. A rated surge voltage resistance of 8 KV was realised in thiscase.

See test report 1579.2081170.851 / ASTA 17165

8.3 Proof of enclosures made from insulating materials as per IEC61439-1 Section 10.9.4for a rated insulation voltage where Ui = up to 1,000 V (main power circuits)

Proof based on the use of sheet steel enclosures is not required.

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9. Proof of the heat generatedas per IEC61439-1 Section 10.10

fulfilled by testing1)

There is an overview in appendix A on page 12.

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10. Proof of the short-circuit resistanceas per IEC61439-1 Section 10.11

fulfilled by testing for:

Busbar system / Design Max. short-circuitresistance

Test report

RiLine60 – Cu 30 x 10 32kA 1sec 1579.0930.6.862e

RiLine60 – PLS1600 32kA 1sec 1579.0263.7.289 / ASTA 16703

Maxi-PLS 1600 50kA 1sec 1579.0949.6.474e

Maxi-PLS 2000 50kA 1sec 1579.1373.7.957 / ASTA 17744

Maxi-PLS 3200 70kA 1sec 1579.1373.7.955 / ASTA 17110

Maxi-PLS 3200 with stabiliser 100 kA 1sec 1579.2080903.414 / ASTA 16945

Flat-PLS 60 55kA 1sec 1579.0331.8.064e

Flat-PLS 60 with busbar claws 60kA 1sec 1579.0331.8.064e

Flat-PLS 60 with stabiliser & claws 70kA 1sec 1579.2080837.416 / ASTA 16940

Flat-PLS 100 75kA 1sec 1579.0331.8.065e

Flat-PLS 100 with busbar claws 80kA 1sec 1579.0331.8.065e

Flat-PLS 100 with stabiliser & claws 100 kA 1sec 1579.2081170.851 / ASTA 17165

11. Proof of the electromagnetic compatibility (EMC)as per IEC61439-1 Section 10.12

The properties requirements stipulated in Section J.9.4 of IEC 61439-1 forelectromagnetic compatibility were confirmed by inspection:

a. The installed operating equipment has been designed for use in the stipulated A or Benvironment in compliance with the applicable EMC product or basic specifications(verified by the original manufacturers of the equipment)

b. The internal installation and the wiring has been designed in compliance with thedetails provided by the operating equipment manufacturer (laid out with regard tointeractive interference, shielded cables, earthing, etc.)

If the use of devices is foreseen that do not fulfil the requirements stipulated in SectionJ.9.4.2 a) and b) in IEC 61439-1, then additional testing must be carried out by themanufacturer of the switchgear in compliance with Section J.10.12.

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12. Proof of the mechanical functionsas per IEC61439-1 Section 10.13

Proof is not required for Ri4Power systems as the mechanical functions involved inoperating the system have been verified during the testing of the installed equipment.

The validity of the proofs mentioned above depends on strictly adhering to the currentRi4Power assembly instructions. The Rittal Power Engineering planning software willconfigure the standard section types to which the previously mentioned proofs apply.

Herborn 1 June 2010 Michael Schell, Product management PM-PS

Michael Schell, Product management PM-PS

1).Details covering the relevant switchgear and busbar systems can be found in the planning manual.

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13. Appendix A: Proof of the heat generated

Busbar systems:

Main busbarsystem

RiLine PLS 1600 900 3 IP2X No 35 105 1400 1250

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Equipment:

ACB ABB E1 rack-mounted

1250 1200 3 IP2X

No 1250 1 1250

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Compartments and modules:

enclosure forcircuit-breaker 1

module withmounting platewithout cutout

2 600 600 193 120

enclosure forcircuit-breaker 1

module withmounting platewithout cutout

3 600 600 193 0

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Appendix 1

ChecklistInstalling the operating equipment (as per Section 10.6 - IEC 61439)

Switchgear assembly manufacturer:

Project name.:System name:System: Ri4PowerNumber of sections:

Inserts (fixed modules installed in the equipment)Removal is only possible using tools Tested OK / NOKComplies with the production documents Tested OK / NOKInspection of the installed inserts Tested OK / NOK

Removable partsReliably isolated from the main power circuit Tested OK / NOKCannot be removed under load Tested OK / NOKComplies with the production documents Tested OK / NOKInspection of the installed parts Tested OK / NOK

Selection of operating equipmentOperating equipment complies with the product standards Tested OK / NOKOperating equipment dimensioning Tested OK / NOKShort circuit protection and selectivity Tested OK / NOKOperating equipment co-ordination Tested OK / NOKComplies with the production documents Tested OK / NOKInspection of the installed operating equipment Tested OK / NOK

Operating equipment installationInstallation complies with the manufacturer's details Tested OK / NOKInstallation complies with Rittal's details (if stipulated) Tested OK / NOKComplies with the production documents Tested OK / NOKInspection of the installed operating equipment Tested OK / NOK

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ChecklistInstalling the operating equipment (as per Section 10.6 - IEC 61439)

AccessibilityEasy access to adjusting and resetting devices Tested OK / NOKAccess to maintenance points Tested OK / NOKAccess to clamping connections Tested OK / NOKDisplays positioned between 0.2 and 2.2 m above the basearea

Tested OK / NOK

Controls positioned between 0.2 and 2.2 m above the basearea

Tested OK / NOK

Actuation of emergency-off equipment positioned between0.8 and 1.6 m above the base area

Tested OK / NOK

Complies with the production documents Tested OK / NOKInspection of the installed operating equipment Tested OK / NOK

CoverSafe covering for manually operated devices Tested OK / NOKComplies with the production documents Tested OK / NOKInspection of the installed covers Tested OK / NOK

Direction of actuation and switching position displayOperating positions for operating equipment are clearlyidentified

Tested OK / NOK

Direction of actuation clearly identified Tested OK / NOKComplies with the production documents Tested OK / NOKInspection of the installed operating equipment Tested OK / NOK

Indicator lights and push-buttonsColours comply with IEC 60073 Tested OK / NOKComplies with the production documents Tested OK / NOKInspection of the installed operating equipment Tested OK / NOK

Electromagnetic compatibilityEnvironment classification Environment A / B(A = own power supply network; B = public power supplynetwork)Suitability of the devices for use in the listed environment Tested OK / NOKInstallation and wiring complies with the manufacturer'sdetails

Tested OK / NOK

Complies with the production documents Tested OK / NOKInspection of the installed operating equipment Tested OK / NOK

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ChecklistInstalling the operating equipment (as per Section 10.6 - IEC 61439)

Electromagnetic compatibilityEnvironment classification Environment A / B(A = own power supply network; B = public power supplynetwork)Suitability of the devices for use in the listed environment Tested OK / NOKInstallation and wiring complies with the manufacturer'sdetails

Tested OK / NOK

Complies with the production documents Tested OK / NOKInspection of the installed operating equipment Tested OK / NOK

______________________ Name in block letters

______________________ ____________________ Date / Signature Stamp

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Appendix 2

ChecklistInterior electrical power circuit and connections(as per Section 10.7 - IEC 61439)

Switchgear assembly manufacturer:

Project name.:System name:System: Ri4PowerNumber of sections:

Main circuitsShort-circuit resistance Target

valuekA Actual

valuekA

Version complies with the manufacturer's details Tested OK / NOKNeutral conductor dimensioning Target

valuemm² Actual

valuemm²

PEN conductor dimensioning Targetvalue

mm² Actualvalue

mm²

PE conductor dimensioning Targetvalue

mm² Actualvalue

mm²

Complies with the production documents Tested OK / NOK

Auxiliary power circuitsShort-circuit protection present Tested OK / NOKSelection of conductor cross-sections Tested OK / NOKComplies with the production documents Tested OK / NOK

Bare and insulated conductorsInsulation meets the rated insulation voltage Ui Tested OK / NOK

Tightness of screw and clamping connections Tested OK / NOK(Details as per the torque details given in the assemblyinstructions or switchgear manufacturer's details)Random sample check of the tightness of screw andclamping connections

Tested OK / NOK

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ChecklistInterior electrical power circuit and connections(as per Section 10.7 - IEC 61439)

Identification of the conductors in the main and auxiliary power circuitsas per the details listed in the circuit diagrams Tested OK / NOK

Identification of the PE conductor and neutral conductor in the main power circuitsPE conductor identification (name or colour) Tested OK / NOKNeutral conductor identification (name or colour) Tested OK / NOK

______________________ Name in block letters

______________________ ____________________ Date / Signature Stamp

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Appendix 3

ChecklistConnections for conductors fed in from the outside(as per Section 10.8 – IEC 61439)

Switchgear assembly manufacturer:

Project name.:System name:System: Ri4PowerNumber of sections:

Production documentsNumber, cross-section and type details of the conductorscorrectly recorded

Tested OK / NOK

Identification of the connection points correctly recorded Tested OK / NOK

Low-voltage switchgear assemblySufficient number of connecting clamps Tested OK / NOKSelection of conductor cross-sections Tested OK / NOKClamping area for the connection clamps sufficientlydimensioned

Tested OK / NOK

Cable / wire entries prepared / provided Tested OK / NOKIdentification of the connection points complies with thedocumentation

Tested OK / NOK

Inspection of the connection points for conductors fed infrom the outside

Tested OK / NOK

______________________ Name in block letters

______________________ ____________________ Date / Signature Stamp