UL SUBJECT 489D-2012 OUTLINE OF INVESTIGATION FOR US NAVAL COMMERCIAL-OFF-THE-SHELF (COTS) DESIGNATED MOLDED-CASE CIRCUIT BREAKERS AND ACCESSORIES FOR USE ON NON-NUCLEAR NAVAL COMB.pdf

1、UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULAPRIL 27, 20121UL 489DOUTLINE OF INVESTIGATIONFORUS NAVAL COMMERCIAL-OFF-THE-SHELF (COTS) DESIGNATEDMOLDED-CASE CIRCUIT BREAKERS AND ACCESSORIES FOR USE ONNON-NUCLEAR NAVAL COMBATANT SHIPSIssue N

2、o. 1April 27, 2012Summary of TopicsThis is the first issue of the Outline of Investigation for US NavalCommercial-Off-the-Shelf (COTS) Designated Molded-Case CircuitBreakers and Accessories for Use on Non-Nuclear Naval CombatantShips.COPYRIGHT 2012 UNDERWRITERS LABORATORIES INC.UL COPYRIGHTED MATERI

3、AL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULAPRIL 27, 2012UL 489D2No Text on This PageUL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULCONTENTSINTRODUCTION1 Scope .42 Normative References .4CONSTRUCTION3

4、General 5RATINGS4 General 5PERFORMANCE5 Base Design .66 Initial Qualification Testing .66.1 General .66.2 Test program Q1 .76.3 Test program Q2 106.4 Test program Q3 117 Requalification Testing .127.1 General 127.2 Test program RQ1 .137.3 Test program RQ2 .137.4 Test program RQ3 .14MARKINGS8 General

5、 .14APRIL 27, 2012 UL 489D 3UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULINTRODUCTION1 Scope1.1 These requirements cover commercial-off-the-shelf (COTS), three-pole and four-pole molded-casecircuit breakers and applicable accessories (under

6、voltage trip release devices, shunt trip release devices,electrical (motor) operators, auxiliary switches, plug-in mounting adapter blocks/bases, drawout cassette)intended for use aboard non-nuclear Naval combatant ships in electrical assemblies (switchboards andload centers) installed on shock isol

7、ators (mounts).1.2 Successful initial qualification testing and requalification testing of circuit breakers/accessories to therequirements of this Outline shall allow their use in shock-mounted electrical assemblies in non-nuclearNaval combatant ships.2 Normative References2.1 This Outline reference

8、s the following COTS specifications:a) UL 489, the Standard for Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosuresb) UL 489 Supplement SB, Molded-Case Circuit Breakers and Circuit Breaker Enclosures(Naval Use)c) IEC 60947-2, Low-voltage switchgear and controlgear Part

9、2: Circuit-breakers2.2 This Outline references the following military specifications/documents. Specifications/documents canbe accessed at https:/assist.daps.dla.mil/quicksearch/.a) MIL-E-917, Electric Power Equipment, Basic Requirementsb) MIL-HDBK-454, General Guidelines for Electronic Equipmentc)

10、MIL-STD-1399-300, Interface Standard Section 300, Electric Power, Alternating Currentd) MIL-STD-202, Test Method Standard, Electronic and Electrical Component Partse) MIL-STD-130, Department of Defense Standard Practice, Identification Marking of U.S.Military Propertyf) MIL-STD-461, Requirements for

11、 the Control of Electromagnetic Interference Characteristicsof Subsystems and Equipmentg) DI-EMCS-80200, Electromagnetic Interference Test Report (EMITR)h) DI-EMCS-80201, Electromagnetic Interference Test Procedures (EMITP)APRIL 27, 2012UL 489D4UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPR

12、ODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULCONSTRUCTION3 General3.1 Circuit breakers and all accessories shall meet the Section 6 construction requirements of UL 489except as modified or added to by the requirements of this Outline.3.2 Mounting adapter blocks/bases shall be plug-in type and s

13、hall allow for rear connection of cableand/or bus bar. Drawout cassettes may also be used. Drawout cassettes shall enable the circuit-breakerto be disconnected from the main circuit, in the withdrawn position, to achieve an isolating distance.3.3 The following materials and coatings are non-preferre

14、d and shall be identified in the qualification andrequalification reports:a) Navy-prohibited materials as defined by MIL-E-917 Section 3.4.1 including estimatedmaximum weight per circuit breaker and per accessory.b) Insulating materials which contain halogens, e.g. chlorine, fluorine, and bromine, w

15、hichevolve gases during combustion including estimated maximum weight per circuit breaker andper accessory.c) Corrosion-susceptible materials and coatings not in accordance with MIL-E-917 Section 3.10requirements.d) Organic materials not inherently fungus resistant or validated to be fungus resistan

16、t. Refer toMIL-HDBK-454, Guideline 4.e) Lead free solder.3.4 All printed circuit boards shall be conformal coated.3.5 Aluminum conductors or terminals shall not be used.RATINGS4 General4.1 Rated voltage as defined by UL 489 shall be 480VAC and/or 250 VDC as applicable.4.2 Rated frequency as defined

17、by UL 489 shall be 60 Hz.4.3 Recommended frame sizes are shown in Table 4.1 of this Outline. Frame size (maximum continuouscurrent rating) shall be verified by temperature rise testing in accordance with Sections 6 and 7 of thisOutline.APRIL 27, 2012 UL 489D 5UL COPYRIGHTED MATERIAL NOT AUTHORIZED F

18、OR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM ULTable 4.1Circuit breaker ratingsFrame size (amps) AC voltage60 Hz60 HzHigh available faultcurrent rating (rmssymmetrical kA)DC voltage DC high available faultcurrent rating (kA)100 480 15 250 10100 480 100250 480 20 250 15250 480 10040

19、0 480 30 250 20400 480 100800 480 50800 480 1001600 480 751600 480 1004.4 High available fault current rating as defined by UL 489 shall be stated by the manufacturer in rmssymmetrical or DC amperes as applicable. Recommended high available fault current ratings are shownin Table 4.1 of this Outline

20、. High available fault current ratings greater than those shown in Table 4.1 maybe substituted to reduce the number of circuit breakers subjected to the testing required by this Outline.The high available fault current rating shall be verified by testing in accordance with Sections 6 and 7 ofthis Ou

21、tline.4.5 Recommended nominal operating voltages for accessories are 120 Vac, 480 Vac, and 125 Vdc.PERFORMANCE5 Base Design5.1 Circuit breakers shall comply with the performance requirements in IEC 60947-2 and/or Section 7.1of UL 489 and in addition shall comply with performance requirements in Sect

22、ions 6 and 7 of this Outline.6 Initial Qualification Testing6.1 General6.1.1 Test Programs Q1, Q2, and Q3 shall be conducted as defined by this Outline. Test order for eachprogram is shown in Table 6.1 of this Outline.APRIL 27, 2012UL 489D6UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCT

23、ION ORDISTRIBUTION WITHOUT PERMISSION FROM ULTable 6.1Initial qualification test programsTest program Q1 Test program Q2 Test program Q3Vibration High available fault current test sequence Electromagnetic interference (circuitbreakers with electronic devices only)Voltage spike (circuit breakers with

24、electronic devices only)Temperature rise 50C ambient Shock FragilityCircuit breaker endurance loadoperations (“with current”) and selectedaccessory temperature riseVerification of accessoriesCircuit breaker and selected accessorytemperature rise 50C ambientCalibration 50C ambientDielectric voltage w

25、ithstand6.2 Test program Q16.2.1 General6.2.1.1 One (1) circuit breaker sample of maximum continuous current rating (per frame size) andapplicable 120VAC accessories shall be subjected to Test Program Q1 as defined by this Outline and inthe order shown in Table 6.1 of this Outline. Note that all ele

26、ctrical accessories shall be subjected toverification tests in accordance with 6.2.5 of this Outline but only 120VAC accessories shall be installedin the circuit breaker sample for all testing required by Test Program Q1.6.2.2 Vibration6.2.2.1 Vibration shall be conducted in accordance with UL 489 S

27、B2. During testing, circuit breakers shallbe installed in plug-in mounting adapter blocks/bases or drawout cassette as specified in 3.2 of thisOutline.6.2.3 Voltage spike6.2.3.1 Circuit breakers with electronic devices such as trip units and accessories (if applicable) shall besubjected to voltage s

28、pike testing in accordance with MIL-STD-1399-300. Testing shall not cause falsetripping, failure of trip unit, or failure of accessories.APRIL 27, 2012 UL 489D 7UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL6.2.4 Endurance6.2.4.1 Circuit bre

29、akers shall be subjected to the applicable number of endurance load (“with current”)operations at rated current and voltage in accordance with 7.1.5 of UL 489. Electrical (motor) operators,if applicable, shall be used to reset and close the circuit breaker for all operations. The shunt trip releasea

30、nd undervoltage trip release devices shall be used to trip the circuit breaker in accordance with 15.2.4and 15.3.4 of UL 489. Temperature rise of electrical (motor) operator, shunt trip release device, andundervoltage trip release device shall be measured as applicable while the accessories are used

31、 to cyclethe circuit breaker. Sensors shall be located on the housing of the electrical (motor) operator, shunt triprelease device, and undervoltage trip release device to determine the temperature rise for eachaccessory. The total temperature (assuming 50 C ambient + temperature rise) of accessorie

32、s shall notexceed the temperature rating of the insulating material.6.2.5 Verification of accessories6.2.5.1 Verification of accessories shall be conducted in accordance with Sections 15.2 (shunt triprelease device), 15.3 (undervoltage trip release device), 15.5 (electrical (motor) operator), and 15

33、.6(auxiliary switches) of UL 489.6.2.6 Temperature rise6.2.6.1 Temperature rise testing shall be conducted in accordance with 6.2.6.2 6.2.6.6 of this Outline.6.2.6.2 Circuit breakers shall be operated at maximum continuous current rating and any convenientvoltage in a 50 C ambient. During testing, c

34、ircuit breakers shall be installed in plug-in mounting adapterblocks/bases or drawout cassette as specified in 3.2 of this Outline. Auxiliary contacts and undervoltagetrip release devices shall be operated at rated current or voltage as applicable. Bus bars shall be used forconnecting to the top stu

35、ds of plug-in mounting adapter blocks/bases or drawout cassette and cable shallbe used for connecting to the bottom studs of plug-in mounting adapter blocks/bases or drawout cassette.Size of the bus bar and cable shall be in accordance with Table 6.2. The copper cross-section of the leadsshall remai

36、n constant for at least 3 feet from each stud on the plug-in mounting adapter blocks/bases ordrawout cassette. The copper cross-section for DC jumpers using customer connections shall be inaccordance with Table 6.2.Table 6.2Bus bar and cable sizes for temperature rise testingCircuit breaker frame si

37、ze Cable size(AC and DC as applicable)Copper bus size100 AWG 3 3/4 X 1/8250 AWG 0000 1 X 1/8400 400 MCM 1.5 X 1/8800 (2X) 400 MCM 2.5 X 1/41600 (4X) 400 MCM (2X)3X1/46.2.6.3 Temperature rise shall be measured at the hottest point where the following current-carrying partsare in touch with the insula

38、ting material:a) At the circuit breaker line and load connectors on each phase (see Figure 6.1).b) At the plug-in mounting base/block or drawout cassette line and load terminals on eachphase (see Figure 6.1).APRIL 27, 2012UL 489D8UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDIST

39、RIBUTION WITHOUT PERMISSION FROM ULc) On the housing of the undervoltage trip release device and at the insulation material nearestto the “a” auxiliary contact.This is generated text for figtxt.6.2.6.4 The ambient temperature shall be determined by two temperature sensors. The sensors shall belocate

40、d within two feet of each side of the circuit breaker at half the depth and half the height of the circuitbreaker.6.2.6.5 All temperature readings shall be recorded during the same time frame and shall be of sufficientduration to allow stabilization of the measured temperatures to a rate of rise wit

41、hin 2 C per hour. Ambienttemperature shall be maintained at 50C 5C. An average ambient temperature shall be determined byaveraging together the ambient sensor readings. The average ambient temperature shall be used todetermine the temperature rise of monitoring points.6.2.6.6 Pass/fail criteria shal

42、l be as follows:a) Temperature rise for plug-in mounting base/block line or drawout cassette and loadterminals and circuit breaker line and load connectors shall not exceed 65C.b) The total temperature (temperature rise + 50C ambient) for all other monitoring points shallnot exceed the temperature r

43、ating of the insulating material.c) The circuit breaker shall complete an electrical close/open cycle at stabilized temperature in50C ambient to verify proper operation.Figure 6.1Thermocouple locations for circuit breaker and mounting base/block or drawout cassetteAPRIL 27, 2012 UL 489D 9UL COPYRIGH

44、TED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL6.2.7 Calibration6.2.7.1 Calibration testing at 50 C ambient shall be conducted in accordance with UL 489 SB3.6.2.8 Dielectric voltage-withstand test6.2.8.1 Dielectric voltage withstand testing shall be con

45、ducted in accordance with 7.1.9 of UL 489.6.3 Test program Q26.3.1 General6.3.1.1 One (1) circuit breaker sample of maximum continuous current rating (per frame size) shall besubjected to Test Program Q2 as defined by this Outline and in the order shown in Table 6.1 of thisOutline.6.3.2 High availab

46、le fault current6.3.2.1 High available fault current test sequence shall be conducted in accordance with Section 7.1.11of UL 489 with the following notes/exceptions:a) Circuit breakers shall be installed in plug-in mounting adapter blocks/bases or drawoutcassette as specified in 3.2 of this Outline.

47、b) Installation of the ground fuse is not required.c) Circuit breakers are not required to be mounted in an enclosure.d) Installation of other accessories during testing shall not be required.e) 480VAC or 250VDC shall be used for the interruption tests as applicable. Manufacturersintending to qualif

48、y a dual rated (AC and DC) circuit breaker shall subject separate samples tothe high available fault current test sequence at each voltage rating.6.3.3 Temperature rise6.3.3.1 Temperature rise testing shall be conducted in accordance with Section 6.2.6 of this Outline withthe following exceptions:a)

49、 Temperature rise for plug-in mounting adapter block/base or drawout cassette terminals andcircuit breaker line and load side connectors shall not exceed 80 C.b) Monitoring of undervoltage trip release device and “a” auxiliary contact shall not be requiredsince these accessories are not installed during testing.APRIL 27, 2012UL 489D10UL COPYRIGHTED MATERIAL NOT AUTHORIZED FOR FURTHER REPRODUCTION ORDISTRIBUTION WITHOUT PERMISSION FROM UL6.4 Test program Q36.4.1 General6.4.1.1 One (1) circuit breaker sample of maximum continuous current rating and applicabl