TECHNICAL REPORT HYDRO ALUMINIUM HYDAL ENVIRONMENTAL AND EMC TESTING OF ALUFLEX 2000 REPORT NO REVISION NO. 02 DET NORSKE VERITAS

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1 HYDRO ALUMINIUM HYDAL A.S ENVIRONMENTAL AND EMC TESTING OF ALUFLEX 2000 REPORT NO REVISION NO. 02 DET NORSKE VERITAS

2 Date of first issue: Project No.: 7. August Approved by: Organisational unit: Testing and Cert. of El. Equipment Amund Westin Head of Section Client: Hydro Aluminium Hydal a.s Client ref.: Arvid Grimstvedt DET NORSKE VERITAS REGION NORGE Testing and Cert. of El. Equipment Veritasveien 1 N-1322 HØVIK Norway Tel: Fax: Org. No: NO MVA Summary: An aluminium enclosure for outdoor use made by Hydro Aluminium Hydal A.S., type ALUFLEX 2000, has been EMC and Environmentally tested according to the following specifications: ETS : Equipment engineering (EE): Environmental conditions and environmental tests for telecommunications equipment: Classification of environmental tests, Stationary use at non-weatherprotected locations. Bundesamt für wehrtechnik und Beshaffnung, VG , Teil 15: Electromagnetische Verträglichkeit von Geräten, Meβverfaren für kopplungen und Schirmungen. The following tests have been performed: Shielding efficiency Vibration Shock Protection provided by enclosure (IP) With the modifications stated in chapter 0 the EUT passed all the tests. Revision 2 An additional corrosion test and an additional IP test were added. The added text are marked with vertical lines in the left border. Report No.: Subject Group: R1 Indexing terms Report title: Environmental and EMC testing of Enclosure Shielding efficiency Aluflex 2000 ETS : VG Work carried out by: Per-Ole Sætren, B. Spongsveen, P. O. Øyberg Work verified by: Odd H. Solumsmoen No distribution without permission from the Client or responsible organisational unit Limited distribution within Det Norske Veritas Date of this revision: Rev. No.: Number of pages: Unrestricted distribution Head of Office: Veritasvn. 1, N-1322 HØVIK, Norway 4 September 2000, POO/00aaaajm_rev02

3 Table of Content Page 1 SCOPE OF WORK TEST LABORATORY TEST PERIOD EQUIPMENT UNDER TEST Equipment submitted for tests Modifications during testing 3 5 TESTS Shielding efficiency Vibration Shock Protection provided by enclosure (IP) Protection against solid foreign objects, code IP 5X Protection against ingress of water, code IP X Protection against solid foreign objects, code IP 4X Corrosion test (salt mist) 9 6 SUMMARY OF TEST RESULTS TEST FACILITIES AND INSTRUMENTS...10 Page i

4 1 SCOPE OF WORK An aluminium enclosure for outdoor use made by Hydro Aluminium Hydal A.S., type ALUFLEX 2000, has been EMC and Environmentally tested according to the following specifications: ETS : Equipment engineering (EE): Environmental conditions and environmental tests for telecommunications equipment: Classification of environmental tests, Stationary use at non-weatherprotected locations. Bundesamt für wehrtechnik und Beshaffnung, VG , Teil 15: Electromagnetische Verträglichkeit von Geräten, Meβverfaren für kopplungen und Schirmungen. 2 TEST LABORATORY The tests were carried out in the Environmental Laboratory at Det Norske Veritas, Høvik, Norway. Ambient conditions in the laboratory: Parameter Required (IEC 68-1) Actual Temperature [ C] Humidity [% RH] (45-75 for ESD, 1st. ed.) (30-60 for ESD, 2nd. ed.) Barometric pressure [mbar] For details about the test facilities and instruments used, see Chapter 8. 3 TEST PERIOD The Aluflex 2000 was received for test 3 May The tests were carried out between 3 May and 30 June. Page 1

5 4 EQUIPMENT UNDER TEST 4.1 Equipment submitted for tests Overall designation of system/product: Description Make Type Ser. no. SW ver. / Other info Enclosures for outdoor use Hydro Aluminium a.s. Aluflex 2000 NA NA From now on the above will be referred to as EUT (Equipment Under Test). The EUT consisted of the following enclosures: Unit no. Description Make Type Hydal Ser. no. 1 Enclosure for outdoor use. 2 Enclosure for outdoor use. 3 Enclosure for outdoor use. 4 Enclosure for outdoor use. Hydro Aluminium a.s. Hydro Aluminium a.s. Hydro Aluminium a.s. Hydro Aluminium a.s. Aluflex 2000 BxHxD 600x1000x 400 Aluflex 2000 BxHxD 600x1000x 400 Aluflex 2000 BxHxD 800x1500x 500 Test encl. #1 Test encl. #2 Test encl. #4 SW ver. / Other info NA EMC-version, also used for lower level IP tests. With equipment shelf mounted. 500x750x500 NA Smaller version with additional sealing used for IP- and corrosion testing Page 2

6 4.2 Modifications during testing The unit 4 was modified as follows during the Protection provided by enclosure (IP) test in order to pass: Additional sealing of the inner enclosure was performed. Enclosure for IP-testing was produced without ventilation holes trough the inner cabinet walls. Door lock was replaced by a waterproof version. The significance of the modifications on other tests previously carried out was evaluated. Adding silicone between the parts of the inner cabinet may reduce the electrical contact. A possible reduction in electrical contact is likely to influence on the shielding efficiency. The following representative from the client was present during parts of the testing, and took part in the performance testing and in the evaluation of the same. Øyvind Håstø Page 3

7 5 TESTS 5.1 Shielding efficiency. Referenced standard: Bundesamt für wehrtechnik und Beshaffnung, VG , Teil 15: Electromagnetische Verträglichkeit von Geräten, Meβverfaren für kopplungen und Schirmungen. The measurements were performed according to the two following test set-ups: Meβverfaren KS 03 G, Messung des Schirmdämpfungsmaβes von Gehaüsen im Frequenzbereich 30Hz 30MHz. (H-field attenuation) Meβverfaren KS 04 G, Messung des Schirmdämpfungsmaβes von Gehaüsen im Frequenzbereich 30MHz 1GHz. (E-field attenuation) Test set up for KS 03 G and KS 04 G are illustrated in Appendix II Figs. 3 & 4 (copied from the standard). Upon request the upper frequency limit was extended beyond the scope of this standard to 2GHz. Configuration: A female/female N-connector was inserted in the centre of the bottom plate of units 1 & 2, in order to transmit the received antenna signal from the antennas inside the box to the measuring receiver. When using the isotropic E-field probe the N-connector was removed and the fiberoptic cable passed through the hole. Due to the physical dimensions of the EUT the emitting loop antenna used in KS 03 G had to be 2m in diameter. According to the standard the large antenna diameter limited the upper frequency of the H-field attenuation measurements to 5MHz. Attenuation measurements of E-field from 5MHz to 2GHz were performed with the EUT rotating around three perpendicular axes. The axes are labelled Standing, Lying, On edge For each frequency and each axis the EUT was rotated ±180 and the measured value corresponding to the lowest attenuation was recorded. Page 4

8 Field attenuation measurements: Measurements were performed using the antennas listed below. Frequency range E r or H r Transmitting antenna Receiving antenna khz H r 200cm screened current Active loop antenna loop 10kHz 20MHz E r E-field generator Active Rod antenna 20MHz 150MHz E r Biconical antenna Dipole antenna 150 MHz 1 GHz E r Log periodic Isotropic field probe 1-2 GHz E r Horn antenna Isotropic field probe For antenna details see chapter 7. Measurement results: Measurement results for unit 1 (Standard version) are shown in Appendix I plots 1 & 2. Results for unit 2 (EMC improved version) are shown in Appendix I plots 3 & 4. Comment: Generally the nature of radiated EMI noise sources both internally and externally is random both in the matter of origin and the polarisation of a transmitted wave. This taken into consideration only the lowest of the three attenuation curves (worst case) at any frequency will be applicable during design. Page 5

9 5.2 Vibration Test specification: ETS : 1994, Class 4M5 Referenced standard: IEC , Test Fc. Test particulars: Test parameters Units Severity levels Frequency range Hz 5-62/ Velocity/acceleration mms -1 /ms /10 Number of axes - 3 Sweep rate Oct./min 1 Test time/axis number of double sweep cycles 5 Acceptance criterion for the vibration test The vibration test shall not cause any mechanical degradation A visual inspection was performed before and after the test along each axis. The EUT was mounted by its original means of attachment in its normal orientation with respect to the vertical. During the test the EUT was fitted with four shelves each carrying a mass of 10 kg. i.e. total mass was 40 kg. The set up is shown in picture 3 in Appendix III. Result: After the completion of the vibration test the gasket around the door got some minor degradation due to the severe vibration. This degradation was considered as cosmetic only. The acceptance criteria were met. The EUT passed the test. Page 6

10 5.3 Shock Test specification: ETS : 1994, Class 4M5 Referenced standard: IEC , Test Eb Test particulars: Test parameters Units Severity levels Acceleration ms Pulse duration ms 6 Pulse shape - Half sine Number of bumps - 6 x 500 (3000 total) Acceptance criterion for the shock test The shock test shall not cause any mechanical degradation A visual inspection was performed before and after the test along each axis. The EUT was mounted by its original means of attachment in its normal orientation with respect to the vertical. During the test the EUT was fitted with four shelves each carrying a mass of 10 kg. i.e. total mass was 40 kg. Result: No malfunctions were observed during or after the shock test. The acceptance criteria were met. The EUT passed the test. Page 7

11 5.4 Protection provided by enclosure (IP) Protection against solid foreign objects, code IP 5X Referenced standard: EN 60529, code IP5X, Category 1 Unit 4 was subjected to the test. Additional acceptance criterion: In order to pass the test, the unit may have a deposit of dust inside the EUTs at the end of the test, but not in a quantity or location such that, as with any other kind of dust, it could interfere with the correct operation of mounted equipment or impair safety. As the extraction rate at 20 mbar depression was less than 10 times per hour, the test was, according to the standard, carried out for 8 hours. The test was performed according to code IP 5X. After the test the EUT was visually inspected. Result: A small amount of talcum powder had entered two of the bottom corners of the unit. This will not interfere with the correct operation of the equipment or impair safety. The acceptance criterion was met and unit 4 passed the test Protection against ingress of water, code IP X5 Referenced standard: EN 60529, code IPX5 Unit 4 and unit 2 were subject to the test. Test levels: Test parameters Units Severity levels Water flow rate litre / minute 12,5 Directions - all practical Test time minute 3 Additional acceptance criteria: If water has entered, it shall not: - Be sufficient to interfere with the correct operation of the equipment or impair safety - Deposit/Droplets on insulation parts where it could lead to tracking along the creepage distance - Reach live parts or windings not designed to operate when wet Page 8

12 - Accumulate near the cable end or enter the cable The test was performed by spraying the unit from five directions. Since the water temperature was more than 5 K below the room temperature, a pressure balance device was mounted on the unit. The test was performed according to code IPX5. After the testing the unit was inspected for ingress of water. Result: A few drops of water had entered the bottom corner of the enclosure. This will not be sufficient to interfere with the correct operation of the equipment or impair safety. The acceptance criteria were met and unit 4 and 2 passed the test Protection against solid foreign objects, code IP 4X Referenced standard: EN 60529, code IP4X, Category 1 Unit 2 was subjected to the test. Additional acceptance criterion: In order to pass the test, the object probe shall not penetrate the enclosure. Result: The object probe did not penetrate the enclosure. The acceptance criteria was met and unit 2 passed the test Corrosion test (salt mist) Unit 4 was subject to the test. Referenced standard: IEC , test Kb. Test particulars: Text Test parameters Units Severity levels Salt mist period Saline solution % 5% NaCl and distilled water, ph 7.0 Temperature ºC 35 Duration Hours 2 Humidity period Humidity % RH Page 9

13 Temperature ºC 40 Duration Hours 168 (7 days) No of cycles - 4 Total Duration Hours 680 (4 weeks) After the test the EUT was inspected for corrosion attacks. Picture of the unit after the completion of the test is found on page 20. Acceptance criterion for the corrosion test No significant corrosion attach shall occur. Result: No corrosion was observed, the EUT passed the test. 6 SUMMARY OF TEST RESULTS With the modifications stated in chapter 0 the EUT passed all the tests. 7 TEST FACILITIES AND INSTRUMENTS The following test facilities and instruments were used during the tests: Instrument Description Make Model Serial number Loop Antenna Set Eaton NA Power Amplifier AR 200W1000M Field Monitor AR FM Double Ridged Guide Antenna EMCO EMI Test Receiver Rohde & Schwarz ESAI /009 Test probe/pin 16, IEC 1032 Ljungmann 1.0 x 20.0 mm - Log-periodic antenna AR AT Power Amplifier AR 1000L Remote control for 1000L AR CP Field Strength Probe AR FP E-field Generator AR AT Spray nozzle code IP X5 DNV LABH-96-2 NA Spray nozzle code IP X6 DNV LABH-96-3 NA Rotameter for IP X6 testing Tecfluid PT-11 (1 1/2 '') NA Signal Generator Rohde & Schwarz SMT /006 Signal Generator Rohde & Schwarz SMP /0017 Rotameter for IP X5 testing Tecfluid PT-11 (3/4 '') NA Spectrum Analyser Rohde & Schwarz FSEM /001 Active Rod Antenna EMCO 3301B Dust chamber Weiss ST1000U Page 10

14 Appendix I Attenuation plots. Page 11

15 Aluflex 2000, H-field Attenuation Standing Lying flat On egde ,0E+04 1,0E+05 1,0E+06 1,0E+07 Plot 1: H-field attenuation Frequency [Hz] Aluflex 2000, standard version, E-field Attenuation Standing Lying flat On egde ,0E+04 1,0E+05 1,0E+06 1,0E+07 1,0E+08 1,0E+09 1,0E+10 Frequency [Hz] Plot 2: E-field attenuation Page 12

16 Aluflex 2000, EMC version, H-field Attenuation Standing Lying flat ,0E+04 1,0E+05 1,0E+06 1,0E+07 Plot 3: H-field attenuation Frequency [Hz] Aluflex 2000, EMC version, E-field Attenuation Standing Lying flat On egde ,0E+04 1,0E+05 1,0E+06 1,0E+07 1,0E+08 1,0E+09 1,0E+10 Frequency [Hz] Plot 4: E-field attenuation Page 13

17 Appendix II Attenuation measurement set up. Page 14

18 Figure 1: Set Up for H-field attenuation Page 15

19 Figure 2: Set Up for E-field attenuation Page 16

20 Appendix III Pictures Page 17

21 Picture 1: Aluflex 2000, Unit 1 front view. Page 18

22 Picture 2: Door and inside details of unit 1. Page 19

23 Picture 3: The EUT during the vibration test Picture 4: The EUT after the corrosion test - o0o - Page 20