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G59/3-2 and New Panel Standards

Our New Gold Standard Relay Panel


Please click on the image to enlarge.
Our Gold Standard panel has again been upgraded, this time we have included 'Real Time Communication' which enables yourself or your client to access the data direct from the feed in tariff generation meter.

This is much better than any other communication system from inverters because you get the actual production numbers of the whole system. Also this information is coming from a certified and registered meter your client can then use the information from his/her desktop to claim the feed in tariff.

We are also now using the new double isolated tri-rated conductor cable, the conductors in the panel shown within the picture above will carry 540 amps per phase.

We think we now have all the answers when it comes to building top quality control panels, so why not get in touch and discuss your requirements?

The Next Generation of Protection Relay Panels.

The following information relates to G59/3-2 and Type Tested and Non Type Tested Equipment and how this relates to the Electrical Build Standards (IEC 60439) and now the New series of Standards that we are now following (IEC 61439-2).

Since it was first published over 35 years ago, IEC 60439 has provided the basis for specification and testing of low-voltage electrical assemblies. As was the case for many early IEC standards, it was a compromise between different national approaches, some of which were very stringent, even prescriptive, and others that were more subjective.

Our New Gold Standard Relay Panel

new gold small

Please click on the image to enlarge.

The photo above is of one of our new 250 Kw Relay Control Panel which has 120 mm csa Tri Rated Conductors and has Lovato Equipment and comes in a 1000x1250x300 Enclosure.

Where consensus could not be achieved, the subject was ignored, or some vague clause was added that could be interpreted to suit the reader's point of view. These weak foundations have made it difficult to evolve the standard in line with market needs and pressures. Every assembly manufactured should meet minimum performance and safety criteria, in spite of ever increasing demands to optimise manufacture and reduce costs.

Application needs, however, make it impractical to type test every variant that is provided. Some frequently used design concepts, such as modular systems, are not adequately covered. Furthermore, many assemblies produced do not fit neatly into the Type Tested Assembly (TTA) or Partially Type Tested Assembly (PTTA) categories.

Some smaller assemblies may not be covered by either TTA or PTTA and are therefore effectively outside the scope of IEC 60439. In the case of a PTTA, the standards' requirements for proving a design are very subjective and entirely dependent on the knowledge and integrity of the particular manufacturer.

When we have been researching and developing our G59/3-2 Relay Protection Panels it has become clear that we can no longer just go along with the old practice of "well that looks alright" as this method has been proved not to work. We have been called out to many Relay Protection Panels of all shapes and sizes over the last 3 Years that have either caught fire or just smouldered away until they no long work.

This situation has been brought about by many basic faults which include but are in no way restricted to some of the following reasons:- Conductors incorrectly sized, Conductor Radii to tight, Enclosure sizes to small, No allowance for either Harmonic build up or DC Injection within the Enclosure, Loose connections causing additional resistance within conductors, Neutral conductors wrongly sized, the list goes on and on.

So now we have taken the massive step of using the more up to Date (IEC 61439-2) assembly standards, this will mean a new approach to both market trends and requirements for assemblies as they evolve, but they will not suddenly change. Assemblies will continue to be manufactured in a wide range of volumes from one-off bespoke arrangements, through adapted standards, to mass-produced units with defined options.

The pressure on operators of electrical distribution networks to improve the utilisation of their assets will continue. Manufacturers are also continuously optimising their designs. Taking all of this into account, together with the need to ensure increasingly demanding safety requirements are met, it is clear that the approach to specifying and demonstrating the capability of assemblies is out-dated and must change radically.

After much debate and deliberation, IEC has taken a practical and pragmatic approach to proving the capability of assemblies. The capability of each assembly will be verified, effectively in two stages: (i) design verification, to prove the design performance of the assembly is in accordance with IEC 61439; and, (ii) routine verification, to confirm the materials and workmanship are in accordance with the design specification. The latter verification is more defined, but otherwise, the requirements are generally as the routine test requirements in the previous standard.

Design verification, however, uses a radical new approach. Where volumes justify it, type testing will remain the preferred option for design verification, since it can, and does, lead to material and labour optimization. When adaptations or bespoke arrangements are required, the standard offers other equivalent routes to design verification.

These include comparison to a verified reference design, calculation, and interpolation from a verified design, measurement, etc. The 'multiple option' route to verification is strictly controlled.

Our New Gold Standard Relay Panel

new standard panel small

Please click on the image to enlarge.

The photo above is of one of our new 200 Kw Relay Control Panel which has 95 mm csa Tri Rated Conductors and has ABB Equipment and comes in a 1000x1250x300 Enclosure.

When, where and how each is used is defined. While it is possible to build a small assembly, of the order of 200A, with the only type tests being an earth continuity measurement and a dielectric test, the standard effectively limits the design verification of assemblies of the higher ratings to type test.

When design verification, other than by type test is used, the standard insists on margins being added to the design, for example; (i) 50% added to clearance if an impulse test is not carried out, (ii) components are de-rated by 20% when the assembly is not temperature tested.

These design margins ensure the alternatives to type testing provide a minimum level of performance in accordance with the standard. Inevitably adding margins has an adverse effect on the physical size of the assembly, the quantity of materials used and if it is an application where a standard design could have been used, commercial implications.

With the ever-increasing pressures of demand for higher network utilisation, assembly design optimisation and more stringent safety, the changes included in the assembly standard IEC 61439-2 are important and overdue.

All assemblies that do not have a specific product standard are covered and there is no opportunity to avoid compliance. In the new standard, the methods of confirming design performance are practical and pragmatic, reflecting the different market needs and ways in which assemblies are produced.

Several alternative and equivalent means of verifying a particular characteristic of an assembly are included. These are defined and their use restricted. Where alternatives to type tests are used, a compensatory approach is taken and margins are added to ensure equivalence. Overall, the standard is performance based, but in some instances where design rules are used, it has to be proscriptive.

In due course IEC 61439-2 will become a European and therefore a British Standard. In the process of this the European Standards should be listed in the Official Journal of the European Union. Meeting this standard in full will then be the simplest route to a 'presumption of compliance' with the EMC Directive and the Low-voltage Directive, compliance with both is, for the majority of applications, essential in order to apply the CE mark to a low-voltage assembly.

So to clarify their will be some instances, where the changes are so fundamental that it may take users some time to adjust to the new order and the benefits it brings. And we must be pragmatic enough to realise that there will be some increase in overall costs to the end user, but these will be easily offset by greater safety and the overall longevity of the equipment.

Our New Gold Standard Relay Panel


Please click on the image to enlarge.

If you would like to see the full list of the Technical Specifications that we will be following with all our Relay Control Systems, please use this link: 

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