ELECTRICAL SERVICES MINIMUM REQUIREMENT

(Referred to as MEW E101)

Part 1 2 3 4 5 6 General Installation Switchboards and Associated Equipment Accessories Luminaires - Supply and Installation Electric Motors Painting, Colour Coding and Labelling

September 2007

DOCUMENT OWNERSHIP CROWN COPYRIGHT:

No part of this work may be reproduced or copied without the written permission of the publisher. This document is published by NSW Water Solutions, NSW Department of Commerce, 2-24 Rawson Place, Sydney 2000.

ACCREDITATION:
Only design consultants who have attended the NSW Department of Commerce Accreditation Course and are accredited by the NSW Department of Commerce for MEWE101 usage, are legally permitted to use this document as part of design documentation. A fee for such usage per project will apply. This Accreditation would be reviewed every 3 years or when this document is updated, whichever is the earlier. Apply to the Senior Electrical Engineer, NSW Department of Commerce, McKell Building, 2-24 Rawson Place, Sydney 2000 (Tel 937 28162) for accreditation.

Part 0 - General

PART - GENERAL 0.1 SCOPE

This document covers the minimum requirements for Low Voltage and Extra Low Voltage Switchboards and electrical installation for Sewage and Water Supply Schemes. Read this document in conjunction with the specification clauses and exhibited drawings as well as relevant standards. Should a higher or more onerous standard requirement be specified in the Service and Installation Rules of New South Wales than is specified in MEW E101 or in the specification clauses and/or exhibited drawings, then that higher or more onerous standard requirement shall apply. Should a higher or more onerous standard/requirement be specified in AS/NZS3000 than is specified in MEWE101 or in the specification clauses and/or exhibited drawings, then that higher or more onerous standard/requirement shall apply.

0.2

USER GUIDELINE FOR THE SELECTION OF SWITCHBOARD CLASSIFICATION

Switchboard classifications are defined in this document. The correct classification for the electrical installation should be specified in the main body of specification clauses or on the exhibited drawings. The selection of the correct classification is dependent on a number of criteria such as: Fault level Importance of the installation Standby arrangements Supply Authority requirements Risk and Consequences of a major fault Acceptable time to restore services in the event of a major fault Incidence of lightning Type of equipment installed in the Switchboard.

Only design consultants who have attended the NSW Department of Commerce Accreditation Course and are accredited by the NSW Department of Commerce for MEW E101 usage, are legally permitted to use this document. A fee for the use of this document per project will apply.

MEW E101

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0.3
AS 1000 AS 1023 AS 1029 AS 1042 AS 1100 AS 1102 AS 1103 AS 1110 AS 1111 AS 1125 AS 1202 AS 1220 AS 1284 AS 1345 AS 1359 AS 1360 AS 1417 AS 1431 AS 1531 AS 1580 AS 1627 AS 1648 AS 1650 AS 1675 AS 1746 AS 1882 AS 1930 AS 1939 AS 2005 AS 2052 AS 2053 AS 2184 AS 2648 AS 2700 AS 2768 AS 3000 AS 3008 AS 3012 AS 3013 AS 3100 AS 3111 AS 3112 AS 3117 AS 3126 AS 3131 AS 3133 AS 3137 AS 3140 AS 3147 AS 3190 AS 3191

STANDARDS
The International system of Units (SI) and its application Low Voltage Switchgear and Controlgear - Protection of Electric Motors Low Voltage Contractors Direct-acting Indicating Electrical Measuring Instruments and their Accessories Technical Drawing Graphical symbols for Electrotechnology Diagrams, Charts and Tables for Electrotechnology ISO Metric Hexagon Precision Bolts and Screws ISO Metric Hexagon Commercial Bolts and Screws Conductors in Insulated Cables and Flexible Cords AC Motor Starters (up to and including 1000V) Aluminium Conductors Steel Reinforced for Overhead Power Transmission Purposes Electricity Metering Identification of the contents of piping, conduits and ducts Rotating Electrical Machines - General Requirements Rotating Electrical Machines of Particular Types or for Particular Applications Rules for Antennas for the Reception of Radio and Television Broadcasting for the Range 30 to 1000 MHz. Low Voltage Switchgear and Controlgear - Control Circuit Devices and Switching Elements Aluminium Conductors for Overhead Power Transmission Purposes Paints and Related Materials - Methods of Test Metal Finishing - Preparation and Pre-treatment of Surfaces Visually Stress Graded Cypress Pine for Structural Purposes Hot-dipped Galvanised Coatings on Ferrous Articles Current Transformers - Measurement and Protection Hard-drawn Copper Conductors for Overhead Power Transmission Purposes Earth and Bonding Clamps Circuit Breakers for distribution Circuits (Up to and including 1000 V ac and 1200 V ac) Degrees of Protection Provided by Enclosures for Electrical Equipment Low Voltage Fuses - Fuses with Enclosed Fuse-Links Metallic Conduits Non-metallic Conduits and Fittings Low Voltage Switchgear and Controlgear - Moulded Case Circuit-Breakers for Rated Voltages (up to and including 600 V ac and 250 V dc) Underground Marking Tape - Part 1 - Non-detectable Tape Colour Standards for General Purposes Electrical Insulating Materials - Evaluation and Classification SAA Wiring Rules Electrical Installations - Selection of Cables Part 1 - Cables for alternating voltages up to and including 0.6/1 kV Electrical Installations - Construction and Demolition sites Electrical Installations - Wiring Systems for Specific Applications Approval and Test Specification - General Requirements for Electrical Equipment Approval and Test Specification for Miniature Overcurrent Circuit-Breakers Approval and Test Specification - Plugs and Socket-outlets Approval and Test Specification - Bayonet Lamp holders Approved and Test Specification - Extra Low Voltage Transformers Approval and Test Specification - Plugs and Socket-outlets for Use in Installation Wiring Systems Approval and Test Specification - Air Break Switches Approval and Test Specification - Luminaires (Lighting Fittings) Approval and Test Specification - Edison Type Screw Lamp holders Approval and Test Specification - Electric Cables - Thermoplastic Approval and Test Specification - Residual Current D (current operated earth leakage devices) Approval and Test Specification for Electrical Flexible Cords

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Part 0 - General

AS 3300 AS 3439.1 :2002 AS 3760 AS 3766 AS 3947.3 IEC 96-3

Approval and Test Specification - General Requirements for Household and Similar Electrical Appliances Low Voltage Switchgear and Controlgear Assemblies In-service Safety Inspection and Testing of Electrical Equipment Mechanical Fittings for Low Voltage Aerial Bundled Cables Air Break Switches, Isolators and Fuse Combination Units (1000v AC and 1200 V dc) Radio-frequency cables Part 3 - General requirements and tests for single-unit coaxial cables for use in cable distribution systems Service and Installation Rules of NSW, October 2006 (issued by the Department of Energy, Utilities and Sustainability) Australian Regulatory Arrangement Handbook Communication Cabling Handbook National Standard for Manual Handling Occupational Health and Safety Regulation 2001 Carry out all work in accordance with the above standards. The latest editions of the above are to be used unless otherwise specified. Where a standard has been superseded, the latest standard shall be used.

HB 243 HB 29 NOHSC: 1001

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0.4

ABBREVIATIONS
Abbreviations where occurring in this Section of the Specification are in general to AS 1100. Metric units have been abbreviated in accordance with AS 1000. Where other abbreviations and expressions occur in the Specification, they shall mean as follows:ACMA AS BS BWL BFL C/O CFS ELV FCU FL FLC HD-UPVC HDHC I/O IP Rating LD-UPVC LED MCC MEN MEPS MIMS MWL N/C N/O NAASRA PA PAX pf PLC PLYSWS PVC RSS SAA SCA SPO TPI TPS TWL TFL UPVC XLPE Australian Communication and Media Authority Australian Standard British Standard Bottom Water Level Bottom Flood Level Change Over Combination Fuse Switch Unit Extra Low Voltage Fuse Combination Unit (i.e. a combination switch fuse or combination fuse switch) Full Load Full Load Current Heavy Duty Unplasticised PVC Hard Drawn High Conductivity (Copper) Input/Output Degree of Protection as described in AS 1939 Light Duty Unplasticised PVC Light emitting diode Motor Control Centre Multiple Earthed Neutral (System) Minimum Energy Performance Standard Mineral Insulated Metal Sheathed (Cable) Maximum Water Level Normally Closed Normally Open National Association of Australian State Roads Authorities Public Address (System) Private Automatic Exchange (Telephone) Power Factor Programmable Logic Controller Paper Insulated Lead Alloy Sheathed Steel Wire Armoured and Served (Cable) Polyvinylchloride Rolled Steel Section Standards Association of Australia Switchgear and Controlgear Assembly Special Purpose Outlet Thermoplastic Insulated (Cable) Thermoplastic Insulated and Sheathed (Cable) Top Water Level Top Flood Level Unplasticised Polyvinylchloride Cross Linked Polyethylene

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PART 1 101

- INSTALLATION SETTING OUT OF RUNS

Apply the following minimum requirements when setting out the work: (a) (b) Fix cables and conduits parallel to building members, walls, doors, etc. and run on the square wherever possible. In slabs, conduits may be run diagonally. Unless otherwise indicated, cable from below any circuit supplying floor mounted equipment. Conduits shall not be surface mounted on floors. They shall instead be sunk or concealed under floor boards or in concrete floor slabs. Run in separate conduits circuits originating at different switchboards. Locate cables and conduits run in roof spaces below the roof heat insulation and sarking and run above the insulation, or if insulation is not installed, derate the cables in accordance with AS 3008.1 for an assumed ambient temperature of 55oC. Protect surface or recessed wiring in TPS cables to switches, outlets and similar terminations by conduit drops sized to accept the TPS cables and originating at an accessible point in the roof space. Arrange all cables and conduits to run parallel to floors and building members. Install TPS cabling so that it may be fully replaced. Where TPS cabling passes through an inaccessible space it shall be capable of being drawn through the space such that rewiring can be readily performed. Note: This may require the installation of conduit through the space. (h) Install site reticulation cables in underground conduits unless stated otherwise. Direct buried cables are not permitted. Lay underground pipes straight with minimum deviation from the horizontal and vertical planes but graded for drainage. TPI cables are not permitted underground. No conduits allowed in the floor slab of boiler rooms.

(c) (d)

(e)

(f) (g)

(i)

102
102.1

PENETRATIONS
Generally Use mortar of a 3 : 1 sand cement mix with surfaces "Bondcreted" prior to applying the mortar for repairs to all penetrations and repairs. No penetrations through damp courses are permitted.

102.2

Penetrations Through Waterproof Membranes Pipes which enter a building at ground level shall run under the waterproof membrane and vertically penetrate the membrane and the concrete slab at the appropriate position. Where pipes pass through roofs, proprietary sealing shall be provided between the pipes and the waterproof membrane.

102.3

Penetrations Through External or Existing Structures Where pipes pass through external walls, existing ground floor slabs or existing ground floor beams, a penetration 10 greater than the pipe diameter shall be provided. The penetration space around the pipe shall be made waterproof by using a proprietary sealing method.

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102.4

Unenclosed Cables Passing Through Slabs Unenclosed cables in slabs are not permitted.

103
103.1

AERIAL RETICULATION (POWER)

Attachment to Poles Attach aerial conductors to poles by: (a) (b) Pin insulators mounted on a horizontal crossarm provided that the conductors do not change direction by more than 10 degrees, or Shackle insulators secured by hooks on poles and bolts on crossarms at tee-offs, terminations, and other locations. These shackle insulators shall be fixed with galvanised nuts and bolts. Where aerial bundled conductors are used, terminate in accordance with AS 3766.

(c)

Conductors shall be fastened to pin insulators with tie-wire of 2.5mm stranded black insulated building wire or a suitable proprietary fixing method. 103.2 Attachment to Buildings Attach aerial conductors to buildings with shackle insulators and the shackle support shall be bolted to masonry or a structural member. Pass the conductor through or around the insulator and then around itself. Alternatively, a proprietary fixing method may be used. Conductors shall enter the building via a conduit sloping upwards into the building at a minimum angle of 45 degrees to the horizontal for weatherproofing. Where upstands are required, they shall be of a proprietary manufacture acceptable to the Supply Authority for service attachments. 103.3 103.3.1 Poles Generally Unless otherwise indicated, poles shall be hardwood. Provide where required by the Supply Authority, a weatherproof box and/or service fuses. Protect cables and conduits running down the exterior of a pole to a height of 2000 above ground by a galvanised water pipe for conduits under 40 or a 3.2mm thick hot dipped galvanised channel fixed to the pole for all other conduit sizes. Extend the protection 150 below the surface. Bury, unless otherwise indicated, poles to a minimum depth of 1600. Baulk and stay to prevent leaning or bending where poles will be subject to bending stresses, e.g. where the aerial cables change direction or terminate. 103.3.2 Hardwood Poles Provide only dressed, natural round poles with all sapwood removed treated against fungus and termites as described in the Wiring Rules to 600 above ground level. An alternative fungus treatment may be used only with the approval of the Supply Authority and the Superintendent. This alternative treatment requires that the soil around and beneath the pole be treated with creosote during the ramming and setting process. The pole shall be liberally coated with creosote from the base to 600 above ground level. Fit all poles with a galvanised steel domed cap extending 25 down the sides and fastened at the side with galvanised steel nails. 103.3.3 Crossarms

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Supply crossarms 75 x 75 x 1500 (minimum) finished size hardwood. Notch all hardwood poles to accept the crossarms, and securely bolted to the pole using M20 galvanised bolts, nuts and washers. Brace each crossarm with two braces each 5 x 40 x 690 galvanised steel fixed at 45 degrees to the pole below the crossarm with an M12 x 75 galvanised coach screw in the pole and with M12 galvanised bolts, nuts and washers in the crossarms. 103.3.4 Service Poles Generally service poles shall be hardwood complying with the above requirements; however, approved aluminium, steel or concrete poles will be accepted. Hot dipped galvanised steel poles after fabrication, cap to prevent moisture entry and set in concrete or fixed by means of a galvanised rag bolt assembly. Detail proposed poles other than hardwood in the submitted drawings and must have the prior written approval of the Supply Authority. Drawings must clearly indicate the installation method, particularly the running of cables in or on the pole. 103.4 Aerial Cables For details of aerial cables, refer to Clause 106.8.

104.
104.1 104.1.1

UNDERGROUND RETICULATION
Trenching, Backfilling and Reinstatement Generally The work associated with trenching includes clearing, grubbing, excavation, filling and consolidation of the trench and all necessary pumping, drainage, shoring and bracing. Excavate all trenching included in the works to an even surface free from sharp projections. Where crossing or running parallel to other services, underground cabling shall be spaced as approved. Comply with the requirements of the telecommunication authority, gas, water and sewerage authorities. Refer to Clause 109 for telecommunication authority requirements. Cut existing concrete or bitumen surfaces to be disturbed in a straight line with a masonry saw to 75 minimum depth before excavation is commenced. Where solid rock is encountered, cables may be chased into rock if approved. Enclose direct buried cables that pass under buildings in heavy duty non-metallic conduits of adequate size complying the AS 2053. Seal all pipes from pits to items of equipment in the pit using expanding foam. Minimum conduit depth 600mm to top of conduit.

104.1.2

Inspection Leave all cable trenches ready for inspection at the following stages: (i) (ii) after laying conduit, but before any backfilling or laying marker tape, and after laying marker tape.

The entire underground reticulation system shall be inspected prior to cable installation. At this time the drainage system will be checked using water inserted at various points and the system must drain free of water within two (2) hours.

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Notify the Superintendent of required inspections two (2) working days prior to the inspection. 104.1.3 Backfilling and Reinstatement Bed PVC conduits on 50 minimum of clean sand and cover by a further 50 of clean sand before backfilling the trench. After laying the conduits in unpaved areas, backfill the trench and consolidate to about 10 above the natural ground level. Remove all excess spoil from the site. Existing grassed areas shall be backfilled and turf re-laid on prepared bed or otherwise re-grassed to 10 above natural ground level. In existing concrete or brick paved areas, backfill the trench with clean sand to the underside of the reinstated pavement and consolidated by watering and mechanical compaction. Reinstate surfaces to the original level. For concrete surfaces use approved reinforced steel, keyed to the existing to prevent the reinstalled concrete from subsiding and cracking. In existing bitumen paved areas, camber the reinstated surfaces so that the edges are flush and the centre is 10 above the existing pavement. The top 150 (minimum) immediately below the bitumen, shall consist of finely crushed gravel mechanically compacted into the trench. Prime the existing bitumen edges of the trench shall be prime coated with bitumen prior to laying 75 minimum of hot "pre-mix" bitumen to the finished cambered surface. If it can be shown that hot pre-mix is not available, cold pre-mix will be accepted. 104.2 Underground Cable Protection To preclude damage, cables installed in pipes shall be drawn using rollers, drumjacks and a cable stocking of the correct size. A 150 wide orange marker tape bearing the words "WARNING - ELECTRIC CABLE BURIED BELOW" or similar and manufactured in accordance with AS 1648, Part 1, shall be laid in the trench 150 below ground level for the entire length of all underground cable and conduit runs. Marker tape is also to be provided over conduits and pipes installed underground for future use. 104.3 Underground Cable Draw-In Pits Provide draw-in pits for underground cables as indicated. Where the size of the pit is indicated, the dimensions refer to inside dimensions. The pits walls and bottoms to be minimum 100 reinforced concrete. The concrete shall contain an approved additive to prevent ingress of water. Alternatively proprietary type glass reinforced moulded cement pits or "Polycrete" with minimum 10 thick walls and bottom may be used and installed in accordance with the manufacturer's instructions on a minimum 100 thick gravel aggregate bed which shall extend under the entire pit bottom. Encase the pit in a 100 thick reinforced concrete surround with the top neatly finished. Drain all pits. The minimum drainage requirement is a 300 x 100 deep rubble drain graded away from the pit for a distance of 2000. Pits greater than 400 wide shall be fitted with covers and frames of cast iron or aluminium and concrete. The covers shall maintain a stabilising fit with the frame by a taper contact on the sides. All vertical mating surfaces to be fitted to a maximum clearance of 0.25 mm. Covers and frames shall be suitable for the particular loading conditions. Ensure, unless shown otherwise, the loadings are low speed, heavy vehicle loads. The maximum mass of any individual section of the cover shall not exceed 40 kg. Fit pits 400 wide and less with proprietary concrete covers.

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Install all pits with the top of the cover 25 above the surrounding finished level and grade the surface for 500 around the pit. Provide one set of lifting handles for the covers and store on site as directed. Where the size of the pit is not indicated, minimum dimensions are 600 x 600 x 900 deep. The word "ELECTRIC" in 25 high letters shall be moulded into the lids of all such pits which contain electric power cables. Pits used for the purpose of the telecommunications authoritys telephone services shall bear the marking Telecommunication as required by the ACMA standard. Also see Clause 108.9 for draw-in box details.

105
105.1

MARKING PLATES FOR UNDERGROUND RETICULATION

Generally Install marking plates on all underground cable or conduit runs. Manufacture plates from minimum 1mm thick brass or other approved material 75 x 75 and fix with approved waterproof adhesive and four brass or stainless steel screws to suit the material of the marking plates. Use stainless steel plates and screws at sewage treatment works and sewage pumping stations. Do not install marking plates on cable pit lids but may be installed on the concrete lip of a cable pit. Engrave marking with minimum 4 mm high lettering. Install marking plates flush with the finished ground level. Recess or bevel marking plates in paved areas. Prepare accurate record scale drawings of proposed marker locations and underground reticulation prior to backfilling and will be retained by the Superintendent until markers are installed.

105.2

Indication of Cable Entry to Buildings Where underground cables enter a building fix a marking plate to the wall at a height of 300. Engrave the plate with an arrow pointing downwards and the words "ELECTRIC CABLE". In addition, fix a marking plate to concrete paving or the top face of a concrete block approximately 150 x 150 x 300 deep located immediately above the cable and as close as practical to the building. Engrave the plate with an arrow, pointing in the direction in which the cable is laid, and the words "ELECTRIC CABLE". The distance to the next marker, in metres is required.

105.3

Indication of Directional Changes Where an underground cable changes direction, fix two marking plates or alternatively a plate with two arrows to a concrete block approximately 200 x 200 x 300 deep located immediately above the cable. Engrave each plate with an arrow pointing in the direction in which the cable is laid and the words "ELECTRIC CABLE". Neatly stamp the distance to the next marker, in metres, into the face of the plate.

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105.4

Indication of Cables Under Roads and Paths Where a cable passes under a road or path, place a marking plate at each side of the road or path. Engrave the marking plate as detailed in Clause 105.3 and fixed to a concrete block approximately 150 x 150 x 300 deep. Alternatively, marking plates may be fixed to the kerb of a kerbed road.

105.5

Indication of Terminated Conduits Where conduits are terminated underground and beyond the perimeter of a building or paved area, fix a marking plate to a concrete block approximately 150 x 150 x 300 deep located above the termination point. Engrave the plate with the words "ELECTRIC CONDUIT TERMINATED UNDER".

106
106.1

CABLES AND WIRING

Generally Supply cables, terminations, fittings and accessories suitable for the voltage, current, frequency, temperature and environmental duty. Terminate copper conductors either into tunnel type connectors or by suitably sized lugs sweated or crimped in an approved manner. Ross Courtney (solderless) terminations may be used on conductors up to 4mm2. No joints in cables can be made between equipment terminal connections unless required by AS 3000. Stranded conductors are required above 1mm. Cable colours and codes are as follows: red, white, blue red black white (numbered cores) green-yellow active conductors in multi-phase mains and circuits. active conductors in single phase mains and circuits. neutral conductor. control circuit cabling outside of switchboards. earth wires.

Refer to Clause 205.2 for Cable Identification. Carry insulation resistance testing out with a minimum 1000 V DC testing instrument. Make final connections to equipment generally using flexible conduit, seal the flexible conduit at each end using expanding foam or a cable gland. All cables to be PVC insulated PVC sheathed circular unless otherwise specified. 106.2 Consumer's Mains and Metering Run the consumer's mains underground from the Point of Attachment as sheathed copper cable in conduit for its entire length to the main switchboard (in the case of current transformer metering) or the Supply Authority metering panel (in the case of Direct Metering). The minimum size of consumers mains is 16mm, however the following requirements apply:(a) (b) (c) Current carrying capacity to suit the maximum demand and any stated future extensions with an excess current carrying capacity of 30% minimum. Be sized so the voltage drop is less than 1.5% at plant future maximum demand at (a) above. Be either single core PVC/PVC cables or four core PVC/PVC cable XLPE insulation may be used.
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(d)

Comply with the requirements of the Supply Authority.

Where direct metering is employed the cable between the meter panel and the Main Switchboard shall be the same size as the consumers mains and the voltage drop above shall include the voltage drop in this cable. Where required by the Supply Authority the cable shall be protected by a circuit breaker of the same type and frame size as the Main Switchboard Main Switch. Install a metering enclosure generally on an exterior wall of the building so that it is accessible without entering the building. The panel shall generally be reused. Surface mounting on existing buildings is acceptable. The metering enclosure and panel shall be Energy Authority approved and suitable for the installation of the metering equipment required by the Supply Authority. All metering equipment shall be supplied and installed under this Contract including:(a) (b) (c) (d) (e) (f) (g) (h) Plug-in meter bases (if required) Service fuses Current transformer metering equipment All necessary wiring Active link (if required) Neutral link Earth link Other equipment required by Supply Authority.

Paint meter boxes using acrylic gloss in a colour to match the surrounding building. 106.3 106.3.1 Final Sub-Circuit Wiring Generally The minimum size conductors shall be as follows: Power Circuits Lighting Circuits Clock Circuits Control Circuits Ceiling Fan Circuits 2.5mm, copper conductors 1.5mm, copper conductors 1.5mm, copper conductors 1.5mm, copper conductors 1.5mm, copper conductors

Final sub-circuit wires shall generally be terminated in tunnel type connectors. Where stud or pillar connections are made, stranded conductors shall be prevented from spreading; twisting multi-stranded conductors is not considered adequate. Connection of single strand conductors to tunnel terminals on moulded case circuit breakers shall be made by doubling the conductor back in "open loop" form. Wiring shall be carried out using the "draw-in, loop-in" system for both TP1 and TPS cables. No intermediate connections to be made except for TPS cables where looping terminals may be used at switches, light fittings etc. Final connections to equipment having parts of the surface at a temperature greater than the temperature rating of the circuit cable shall be made with cable having insulation at least rated to 200 degrees Celsius maximum operating temperature. Supply all motors with a local rotary isolator connected in the control circuit adjacent to the motor. Make final connections to all equipment using flexible conduit.

106.4

Instrumentation Cables Instrumentation cables shall be cables that:

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i. ii. iii.

Carry ELV analogue signals e.g. 4-20 mA dc. Connect to instruments for the purpose of signalling or monitoring. Connect to the inputs of PLC's or alarm annunciators.

Cables shall be min. 0.5mm PVC insulated aluminium polyester screened PVC sheathed. A separate 2 core cable shall be supplied for each analogue signal (equal to Dekron IEB183 type). Digital signals may use a multi, twisted pair overall screened PVC cable. Each digital signal shall have its own pair as, common returns are not permitted. Cable shall be equal to Dekron IEC183 type. The screen of each cable shall be earthed at the switchboard only. 106.5 Insulated Non-Armoured Cables in Enclosures (TPI) Cables shall be 0.6/1 kV grade with minimum V75 or XLPE insulation. 106.6 Underground Grade Insulated and Sheathed Non-Armoured Cables (TPS) Cables shall be 0.6/1 kV grade with minimum V75 or XLPE insulation. The cables shall have the manufacturer's name and reference and the word "UNDERGROUND" clearly indented in the sheathing. 106.7 Armoured and Sheathed Cables (Other than Paper Insulated) Cables shall be 0.6/1 kV grade with minimum V75 or XLPE insulation and shall have armouring of galvanised steel wire (double or single), steel tapes, or aluminium strip/wire. Tape armouring shall not be used to support the cables during installation. Armouring shall be cleaned, clamped and connected to earth at the origin of the cable. It shall not be used as an earth conductor. 106.8 Aerial Cables Cables shall comply with AS 1746 "Hard-Drawn Copper conductors for Overhead Power Transmission Purposes" or AS 3607 "Bare Overhead Aluminium Conductors Steel Reinforced", or AS 1531 "Aluminium Conductors for Overhead Power Transmission Purposes". Aerial cables attached to buildings shall be insulated. Connections between aluminium able and copper aerial cable shall be made with a bail clamp having aluminium and tinned copper connectors. Where aluminium cables are terminated to copper cables the aluminium cable shall be physically above the copper cable. 106.9 106.9.1 Special Purpose Essential Service Cables Unless other indicated, cables supplying power to designated "Essential Services" shall consist of MIMS copper conductor copper sheath cables. Where run horizontally, the cable shall be as high as possible, separately fixed directly to the building structure (eg underside of slab). Where run vertically, the cables shall be mechanically protected. Where a number of services cross or follow a similar route the "Essential Services" cable shall be located at the highest point and closest to the structural support. Metal cable fixings shall be used; the use of nylon or plastic material is prohibited. 106.9.2 Telephone Cables

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Cables used for communication purposes (Telephone, Intercom etc) shall be multi-pair telephone cables of nominal conductor diameter 0.5mm minimum to ACMA Specification. Cables installed within buildings shall be PVC insulated and sheathed. Cables installed external to a building shall be Polythene insulated and sheathed. All work associated with telephone line connections shall comply with the following: 106.9.3 Australian Regulatory Arrangement Handbook HB 243-2007 (Communication Cabling Manual Module 1) Communication Cabling Handbook HB29-2007 (Communication Cabling Module 2) Requirements for Customer Cabling Products (AS/ ACIF S008-2006) Installation Requirements for Customer Cabling (AS/ACIF S009-2006)

Fire Alarm Cables Cables used for the connection of thermal, smoke and manual fire detectors, or other associated equipment within the building shall be TPI or TPS minimum 1.5mm2 stranded copper cable. TPS cable shall have red coloured sheathing.

106.9.4

Security Cables Cables used for window and door seals, and associated equipment shall be minimum 0.5mm stranded copper TPI cable, figure 8 configuration. Cables for space detectors (ultrasonic, infra-red, microwave, etc) shall be minimum 0.5mm stranded copper TPI, shielded twisted pairs or as per the manufacturer's installation requirements.

106.10

Control Cabling (a) General The insulation of each cores shall indelibly be numbered consecutively (e.g. one 1) for each core. (b) 240 Volt a.c. Control Cabling Control cables shall be PVC insulated PVC Sheathed cables with copper conductor minimum 1.5mm. (c) ELV Control Cabling for Connection to Digital I/O ELV control cables external to the switchboard connecting to digital I/O shall be V90HTPVC insulated with overall screen and drain wire of minimum size 0.5 mm. (d) ELV Control Cabling for Connection to Analogue I/O ELV control cables external to the switchboard connecting to analogue I/O shall be overall screened, PVC sheathed twisted pair cabling with a minimum conductor size of 1.5 mm.

107
107.1

EARTHING
Generally The earthing system shall comply with the Statutory and/or Supply Authority requirements. Generally earthwires shall be enclosed in conduits with submains and subcircuits. A separate MEN system for each building shall be used except where an earthing conductor is indicated to be run with the submain to that building.

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Metallic pipes used for other services, such as gas, water, sprinkler systems, etc., shall be considered as unavoidably in contact with metallic enclosures of electrical equipment and shall be effectively bonded to the earthing system. 107.2 Earthing Conductors for Underground Cables Earthing conductors other than the copper sheathing of MIMS cables shall be copper stranded conductors sized as per AS 3000, protected by a green-yellow insulation and installed as follows: (a) (c) (c) 107.3 Separate earthing conductors for TPI conductors in conduit. Separate earthing conductors attached to the cable at 1000 intervals. Earthing conductors laid up with the cable.

Earth Electrodes Earth electrodes shall consist of copper, stainless steel or copper sheathed rods not less than 16 diameter driven to a depth of not less than 2400 to reach the permanent moisture level. Unless disallowed by the Supply Authority, the indicated footing in each building shall be used as an electrode in addition to the above. The earthing conductor shall be connected to the reinforcing steel of the indicated footing and the driven electrode. Each electrode shall generally be installed in an earthing pit similar to "Polycrete" PEP 22. Each pit shall have a reinforced concrete surround minimum 250 wide and 200 deep complete with cable markers.

108
108.1

CONDUITS, FITTINGS AND JOINTS

Generally Conduits and fittings shall comply with either AS 2052 "Metallic conduits and fittings" or AS 2053 "Non Metallic conduits and fittings". Conduits smaller than 20 dia. shall not be used except for fire alarm systems where 16 dia. will be accepted. Conduits shall be in long lengths, straight, smooth and free from rags, burrs and sharp edges. Off cuts shall not be used to fabricate long lengths of conduit. Conduits shall be set wherever possible to minimise the number of joints. Bends shall be of large radius and shall be formed with approved formers. Correctly sized springs shall be used to form bends in UPVC conduits. Conduits manipulated or bent must maintain true effective diameter and shape at all parts of the bend. Conduit sets distorted or showing evidence of kinks, wrinkles, flats or having been heated will not be accepted. Wherever possible, UPVC Conduits bends should be preformed by the manufacturer. Conduits shall be colour coded in accordance with Clause 602 of MEW E101. Saddles supporting conduits shall be effectively secured to the surface on which they run. Saddles shall be a proprietary brand installed as supplied. Conduit systems, including conduits and pipes used to convey cables into buildings, shall be sealed to prevent water entry. The number of cables including earth wires that may be enclosed in any one conduit or pipe shall not exceed that recommended as a guide in AS 3000. All conduits exposed to weather shall be painted with a light coloured paint designed for the purpose.

108.2

Heavy Duty UPVC Conduits to AS 2053 (HD-UPVC) This conduit shall be coloured "light orange" except for conduits enclosing telecommunication authority cables which shall be "white", and may be used underground, above ground is permitted only as specified. All fittings shall be of the same material as the conduit and all joints shall be made with an approved adhesive

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cement of contrasting colour. These conduits are not generally permitted above ground except to sizes above 63 when the conduit must be painted with a light coloured acrylic gloss paint designed for the purpose. 108.3 Steel Conduits All steel conduits shall be heavy protected (hot dipped galvanised), with screw joints and screwed terminations, to AS 2052. End joints and terminations shall be made by screwing the conduit into the fitting with circular galvanised plated lock nuts screwed onto the conduit. Steel conduits shall have screwed ends and screwed joints, all threads being painted with aluminium paint. Steel conduits shall be electrically and mechanically continuous. Electrical continuity tests shall be carried out prior to the installation of draw cords. 108.4 Light Duty UPVC Conduits to AS 2053 (LD-UPVC) This conduit may only be used above ground in positions not exposed to mechanical damage. All associated plastic fittings shall be of the same material as for the conduits. All conduits, plastic fittings and adhesive cement shall be procured from the same manufacturer, and the manufacturer's recommended procedures shall be adopted for the making of joints. All joints and conduit entries shall be made with an approved adhesive cement of a contrasting colour. All wall and junction boxes shall be of the same material as the conduits. Where special size boxes are indicated but are not obtainable in PVC, pre-fabricated metal boxes shall be used where approved. UPVC conduits shall be fixed to such metal boxes with screwed PVC adaptors and lock nuts. metal boxes shall be earthed. UPVC conduit shall be fixed to a PVC wall box with a screwed PVC adaptor and circular lock nuts, unless the conduit enters the wall box via a moulded conduit entry. 108.5 Flexible Conduits Flexible conduits shall be of the plastic sheath, smooth, PVC spiral reinforced type and shall be oil resistant, UV resistant and impact resistant. Flexible conduits shall be equivalent to: i. ii. FLEXICON LPC RHINOFLEX by ADAPTAFLEX

Where the connection is the final connection to an electrical item, the conduit length shall be sufficient to allow decoupling and moving aside of the equipment without disconnection of the cables or conduit. The degree of protection of fittings associated with the conduit shall be IP67. All fittings shall be nickel plated brass except where otherwise indicated. Notwithstanding the previous sentence, the fittings shall be compatible with chemicals in the area of installation. Corrugated flexible conduits are not permitted. Carry out all final connections to equipment using flexible conduit. Fix flexible conduits to a surface with saddles or stainless steel bands. Do not use PVC cable ties for the fixing of flexible conduits. 108.6 108.6.1 Installation Generally Generally, UPVC conduit shall not be installed on exterior surfaces. However, sunlight resistant UPVC conduit and fittings complying with AS 2053 and marked with the letter "T" may be run in locations exposed to direct sunlight. In sewage treatment works all external conduits below 40mm shall be "Clipsal HFT". Also, short runs of HD-UPVC

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pipes from underground submains may be surface run where they enter a building if it is not practicable to conceal them, provided that they are suitably protected from mechanical damage and sunlight. All UPVC conduits shall be terminated into metal boxes and enclosures (draw-in-boxes, joint boxes, switchboards, ducting etc.) via a screwed PVC adaptor with lock nut. Conduits shall be so installed that wiring is carried out using the "draw-in, loop-in" system. The conduit run shall be completely installed before wiring is drawn in. The wiring shall be drawn in only at outlets and switchboards and, if approved, at draw-in boxes. Inspection fittings are allowed only if approved. Conduits shall be run directly from the entry point to the termination point with the minimum number of sets (the number of sets shall not be greater than the equivalent of 3 x 90 degree bends). The installation of elbows, tees, etc., is prohibited on conduits installed in inaccessible locations. All conduits shall be effectively capped during construction. Conduits shall be securely fixed to building members and shall be adequately supported during all stages of building construction. (Particular care shall be taken to support PVC conduit upstands). Generally all conduits shall be concealed and only exposed to view when approved. Surface conduits shall be made to harmonise as far as practicable with the architectural features of the building. Surface conduits shall be run in vertical and horizontal directions except where it is desirable to follow the line of a building, where the approval of the Superintendent shall be obtained. Conduits shall terminate in luminaires, equipment, accessories or in wall boxes and junction boxes of a type compatible with the installation. Do not exceed the following space factors:1 cable in the conduit 2 cables in the conduit 3 or more cables in conduit 108.6.2 Conduit Saddles Conduit saddles shall be either PVC or stainless steel. PVC saddles may be used indoors and in wet wells or areas not exposed to sunlight. All other situations shall be stainless steel saddles. 108.6.3 Expansion Joints Expansion fittings shall be installed on all straight runs of UPVC plastic conduit, except those embedded in concrete or wall chases. The spacing of expansion fittings shall not be greater than 8000. A sample of the type of expansion fitting to be used shall be submitted prior to installation. Conduit clips shall be installed close to expansion fittings; all clips shall be installed to allow the conduit to move freely while expanding or contracting. Expansion couplings shall be installed wherever expansion or contraction joints occur in a building slab. Note: "Bellows" type expansion couplings shall not be used in floor slabs or similar installations. Each expansion coupling in a building slab shall consist of a short length of flexible conduit, to join the two UPVC conduits across the expansion joint, covered by a larger UPVC conduit. The larger conduit shall extend 150 from the flexible conduit in both directions and shall be secured fixed to prevent movement and sealed to prevent concrete entry whilst the slab is poured. For multi-pipe expansion boxes refer to contract drawings for details. 108.7
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50% of the area 30% of the area 40% of the area

Conduits in Roof Spaces

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Where conduits are run in roof spaces, they shall be installed below the heat insulation and sarking but above any insulation on the ceiling. Where PVC conduits are installed in roof spaces and are likely to be walked on, they shall be adequately protected.

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108.8 108.8.1

Conduits in Concrete Generally Unless otherwise indicated, conduits shall not be run in the concrete topping. Conduits run in the fill under floor slabs shall be HD-UPVC. Corrugated conduits are not permitted. Conduits shall be securely fixed to the reinforcing rods, passing above a single layer of rods or between a double layer of rods, generally mid-way in the thickness of the slab. Attention shall be paid to routes of conduits in slabs to avoid cross-over and to keep the number of conduits in any one location to a minimum. Conduits in slabs shall be spaced not less than 75 apart. Conduits may cross providing they intersect at angles greater than 30 degrees and are tied together. The minimum cover over conduits shall not be less than the conduit diameter or 20. Conduits shall not be installed in a slab through the areas around a column to one quarter the distance from the column to the next column, supporting beam or wall, except to outlets in the area. Attendance during the concrete pouring to ensure that conduits are not displaced, broken or damaged is mandatory. Two working days notice shall be given to the Superintendent's Representative to inspect all conduits prior to pouring concrete. Sufficient time for alterations or modifications found necessary during inspection by the Superintendent's Representative shall be allowed.

108.8.2

Conduits in Suspended Slabs Unless otherwise indicated, the maximum diameter of conduits in suspended slabs shall be 25, spaced not less than 75 apart.

108.8.3

Conduits in General Columns Unless otherwise indicated, a maximum of four 20 dia. conduits are permitted in each column. No more than two conduits shall cross any one face of the column and all conduits shall be placed centrally. Bends in conduits entering the columns shall have a minimum radius of 300. Structural columns shall not be chased for conduit installation.

108.9

Draw-In Points For surface run conduit systems, draw-in points shall be provided at suitable intervals not exceeding 30 metres for straight runs and at intervals not exceeding 25 metres for runs including directional changes. Draw-in points shall be agreed with the Superintendent prior to installation. Where used, draw-in boxes shall be of adequate size to prevent undue deformation of the cables. For underground conduit systems, draw-in boxes are not permitted. maximum 50 metre intervals. Provide pit at

Materials used to lubricate cables whilst drawing-in to conduits shall be non-conductive, non-abrasive and non-hygroscopic. 108.10 Conduits and Pipes for Future Use All conduits and pipes for future use shall be provided with polypropylene draw cords. A length of cord 2000 long shall be left securely fixed at the ends of each run. Conduits and pipes shall be labelled in accordance with Clause 603. Conduits and pipes terminated outside a building shall be taken beyond the line of paving, the draw cord shall be secured and the conduit or pipe capped, waterproofed and the location marked in accordance with Clause 105.5.

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108.11

Wall Boxes Wall boxes installed in face brickwork shall be located so that the centre line of the box coincides with the horizontal centre line of the row of bricks nearest to the specified height for the box. In hazardous areas or areas defined as hazardous, the box shall be located at a height not less than the minimum height stipulated in the Wiring Rules. Wall boxes shall be securely fixed. The front edge shall be no more than 10 behind wall finish. Wall boxes installed in face brickwork having raked joints, or in shiplap timber work, shall be set with the face of the box flush with the surface of the work. Deep pattern wall boxes shall be used where conduits are run within brickwork, e.g. when bricks are "biscuited". Wall boxes must not be installed across the junction between different wall finishes. Metal wall boxes must be earthed. Wall boxes having sliding type lugs for attaching flush plates will not be accepted. Plastic wall boxes shall have threaded brass inserts for securing flush plates.

109

CONDUIT SYSTEMS FOR COMMUNICATION SERVICES

Conduit systems shall be mechanically continuous. Conduits shall be of the same type used in the rest of the installation and shall comply with the relevant clauses of this specification. Systems shall comply with the relevant conduit requirements of Clause 108 and the following requirements as applicable.

109.1

Conduits for Telecommunication Facility Cabling Conduits shall be 20 dia. Where run parallel to conduits capable of enclosing power cables, a minimum spacing of 150 shall be observed. Conduits in any one installation shall originate at an approved box or cupboard, sized and located as indicated for use as a distribution frame. Each conduit shall terminate at a floor-mounted box or a flush wall box with coverplate as indicated. Not more than three outlets shall be served by one 20 dia. conduit, looping from outlet to outlet without the use of tees or elbows. Draw boxes within a building shall be installed so that cables do not need to be pulled in for a distance exceeding 12 metres. Draw cords shall be installed in each conduit in accordance with Clause 108.10. Before installation, approval shall be obtained from the local Telecommunication Authority Office.

109.2

Conduits for Telecommunication Lead-In and Block Cabling Lead-in conduits shall originate and terminate at locations as indicated. Block cabling conduits shall originate and terminate at cupboards or approved wall boxes, sized and located as indicated for use as distribution frames. Underground conduits shall be heavy duty UPVC type, coloured white, and shall be spaced from other services to the approval of Telecom. For details on separation from, and crossing of power cables see relevant ACMA Specification. Conduits shall be sized as indicated. Draw cords shall be installed in each conduit in accordance with Clause 108.10. Before installation, approval shall be obtained from the local Telecommunication Authority Office.

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110
110.1

CABLE TRAY, LADDER AND TROUGHING

Generally Cable tray, cable ladder and all accessories shall be proprietary items from a single manufacturer whose range includes splice connections, expansion splices, covers, risers, crossovers, reducers, bends and all other accessories used. Supply covers manufactured from the same material as the tray or ladder up to 2000 above finished floor level.

110.2

Cable Tray Cable tray shall be manufactured from steel, hot dip galvanised after fabrication or from aluminium or stainless steel. Minimum thickness for cable tray shall be: 1mm up to 150 wide 1.2 mm from 150 up to 300 wide 1.6 mm above 300 wide 1.6 for aluminium 2 for aluminium 2.6 for aluminium

All cable trays shall be slotted similar to "Admiralty" pattern and shall have folded or rolled edges. The "standard" tray shall be formed with the perforations punched from outside the folded edge to avoid any sharp edges or burrs existing on the outside face. The "reverse" tray shall be perforated from the inside and shall be used in positions where cables are laid horizontally in the tray or alternatively, trays shall have the metal reinforced by folding to provide equivalent stiffness. Cable trays installed externally must be aluminium or stainless steel. 110.3 Cable Ladder Cable ladder shall consist of two folded steel or extruded structural grade aluminium side rails with cable support rungs between the two rails. The rungs shall be either welded or fitted to the side rails. Unless otherwise indicated rung spacing shall not exceed 300. Cables smaller than 13 OD installed on cable ladder shall be run on perforated tray or ducts installed on the ladder. This requirement does not apply where the rungs of the ladder form a continuous base. 110.4 Installation Cable tray and ladder shall be installed by either: (a) (b) surface fixing to ceilings or walls; or suspending by hangers from ceilings, or by angle brackets out from walls.

Fixings, hangers and angle brackets are to be spaced at a maximum distance of 1000. Joints shall be adequately supported. Where possible, cable tray and ladder shall not be mounted less than 2300 above floor level. Adequate access shall be provided to cable tray and ladder. Where supported by hangers or angle brackets, a minimum distance of 150 shall be allowed above and 600 on one side of the tray or ladder. Alternative systems and supports with greater spacing may be accepted if they give equal rigidity and strength. Where cable tray or ladder span open areas they shall be capable of supporting an additional load of 70kg at mid span without permanent deformation. Cables or groups of cables shall be securely strapped to the tray or ladder using proprietary nylon cable ties or straps: for vertical runs at 1000 maximum; for horizontal runs at 2000 maximum. Cables shall leave the cable tray or ladder in such a manner that no cable shall be in contact with the side rails. In general, cable shall leave the tray or ladder in conduit,
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which shall be securely anchored to the tray or ladder and with the conduit end fitted with a screwed cable gland to suit the cable. 110.5 110.5.1 Cable Troughing Generally Cable troughing, covers and fittings shall be of proprietary manufacture. Troughing shall have screw fixed covers, unless installed in a location not readily accessible, where clipon lids may be used. All fixing methods shall provide a smooth internal surface for the cables, for example, domed headed gutter bolts for joining sections, with the smooth head surface on the inside and nuts on the outside. Self tapping screws are prohibited. Troughing shall be installed with the cover fixing screws accessible and the covers shall be easily removable. The troughing shall be adequately supported in accordance with the Wiring Rules and, where they span open areas, they shall be capable of supporting an additional load of 70 kg at mid span without permanently deforming. Retaining clips shall be installed to retain the wiring at intervals not exceeding 1000 in all locations except where cable troughing is run horizontally with covers uppermost. Where troughing is connected to weatherproof or hoseproof (i.e. IP43 through to IP56) enclosures, the entry shall be made in such a manner as to prevent moisture entering the enclosure. Only PVC/PVC cables are permitted in troughing. 110.5.2 Metal Cable Troughing Metal troughing shall be of an approved design and construction with removable covers fixed by suitably plated bolts and captive nuts. The troughing and covers shall be of galvanised sheet steel or aluminium of minimum 0.8 thickness and shall be free from rags, burrs and sharp edges. 110.5.3 Plastic Cable Troughing Plastic troughing shall be of UPVC. The troughing and covers shall be robustly constructed from heavy gauge material to avoid sagging between supports and to avoid warping. All associated fittings shall be of similar material to the troughings. 110.5.4 Skirting Troughing Skirting troughing shall be of proprietary manufacture and shall have three channels. Where used to extend an existing installation, the skirting troughings shall match that installation. Skirting troughing used for Telecommunication Authority telephone cables shall comply with the relevant ACMA Specifications.

111
111.1

FIXINGS
Generally The following minimum requirements shall be observed. Fixings shall be secure and adequately sized to suit the weight, size, shape and location of the equipment being fixed. Fixings used in external or damp locations, or sewage treatment plants and pumping stations including exterior luminaires, shall be 316 grade stainless steel. All other fixings shall be hot dipped galvanised. Fixings shall be made to adequate firm supports and not to asbestos cement or hardboard sheeting, etc. Holes for screws shall have the correct clearances.

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Holes drilled for masonry anchors shall be 6 mm deeper than the plug or anchor and correctly sized to the manufacturer's recommendations. Pilot holes for timber fixing shall not be larger than the screw root diameter. Plastic or fibre plugs shall not be used. 111.2 Conduits Conduits 20, 25 and 32 dia. shall be fixed as follows: (a) To masonry, concrete, cement rendered walls: 6 expanding sleeve masonry anchor to accommodate an M4.5 thread. However for 20 and 25 conduits indoors nylon anchors with mushroom stainless steel expansion nail may be used. To timber: where directed fixed, wood screw No. 8 x 20, round head. Where fixed through fibrous cement, plaster, plaster board, etc., the screws shall be of sufficient length to allow for the additional thickness. To sheet metal: No. 8 x 13 long, galvanised binding head, self tapping screws. To steel: M5 round head screws of appropriate length tapped or bolted.

(b)

(c) (d)

Conduits 40, 50, 63, 65, 80 and 100 dia. shall be fixed as follows: (a) (b) To masonry, concrete, cement rendered walls: 8 expanding sleeve masonry anchor to accommodate an M8 thread. To timber: where directly fixed, steel wood screw No. 12 x 35, round head. Where fixed through asbestos cement, plaster board, etc, the screws shall be of sufficient length to allow for the additional thickness. To sheet metal: No. 12 x 13 long, galvanised binding head, self tapping screws. To steel: M6 round head screws of appropriate length tapped or bolted.

(c) (d) 111.3

Mounting Blocks Mounting blocks shall be fixed with four screws as specified for conduits 20, 25 and 32 mm diameter.

111.4

Switchboards The fixing of switchboards shall be as described in Clause 112.2.

111.5

Switch Panels, Boxes Switch panels and boxes shall be fixed with four screws in accordance with 112.2. Fixings shall be one of the following, to suit the surface: (a) (b) (c) (d) Steel wood screw, No. 8, round head, or No. 8 electro-galvanised, binding head, self tapping, or M5, round head. M8 masonry anchor.

111.6

Surface Mounted Switches Fixings shall be as indicated in Clause 112.5. Single gang switches shall be fixed with two screws and double gang and larger with four screws.

111.7

Cable Troughing, Cable Tray, Skirting Troughing Cable troughings, trays and skirting troughing wider than 100 shall be fixed at intervals of not more than 1000 with two screws per fixing. Screws shall be steel wood screws, No. 12, round head, cadmium plated or cadmium plated M6 round head screws or No. 12 electro-galvanised, binding head, self tapping screws.

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111.8

Metal Channel Metal channels shall be suspended using galvanised suspension rods with proprietary fittings. Where secured directly to timber, metal channels shall be fixed with M10 x 50, hexagonal head, coach screws.

111.9

Hollow Block Locations Fixing to hollow sections shall be avoided. Where approved, it shall be by means of M5 electro-galvanised, round head screws and spring loaded butterfly toggles. This fixing does not apply to ceiling fans.

111.10

Fixing of Luminaires The fixing of luminaires shall be as indicated in Clause 403.

111.11

Fixing of Ceiling Fans The fixing of ceiling fans shall be 2 off M6.

112
112.1

INSTALLATION OF SWITCHBOARDS
Generally Where a switchboard has been split for installation, it shall be reassembled on site by the switchboard manufacturer. Particular attention shall be given to busbar joints which shall be torque tightened to the manufacturer's recommended torque and shall be insulated or coated in accordance with Clause 204.6 If a switchboard is stored or installed in any area where building work is incomplete, it shall be adequately protected against moisture, corrosion, dust, paint, and mechanical damage.

112.2

Fixings Floor mounted switchboards shall be fixed to the floor or other structure with M12 hot dipped galvanised bolts through the mounting holes provided in the base. Alternatively, a minimum of four hot dipped galvanised clamps may be used, each secured with an M12 hot dipped galvanised bolt. Wall mounted switchboards shall be installed using an adequate number of fixings. However, not less than four fixings per switchboard shall be used. Fixings shall be: (a) To timber: (i) (ii) (b) Proprietary Assemblies - hot dipped galvanised steel No. 12 wood screws of suitable length Custom-built Assemblies - 10 diameter coach screws of suitable length with a full washer under the head.

To masonry and concrete: (i) Proprietary Assemblies - stainless steel 6 diameter expanding sleeve masonry anchors of the projecting stud type each fitted with a full washer and nut. Custom-built Assemblies - stainless steel 10 diameter expanding sleeve masonry anchors of the projecting stud type each fitted with a full washer and nut.

(ii)

112.3

Cables, Cable Enclosure and Busway Entry and Termination

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Where switchboards are fitted with cable-entry plates, one or more plates shall be neatly adapted to accept the incoming cable(s). Only the minimum number of plates shall be used thereby leaving spare cable entry plates for future cable entries. Cables entering a switchboard or control panel shall be glanded using non-ferrous metallic or plastic glands with neoprene compression seals conduit with suitable adaptor and locknut may be used where circuit is enclosed in conduit for its entire length. Cable entry shall only be through the detachable gland plate supplied with the switchboard. Where the sheath of a multicore cable enters either a switchboard or an electrical equipment enclosure, the sheath shall be: (i) (ii) (iii) Continued unstripped up to within less than 350 of either its lug terminations if a power cable or its connecting terminal block if a control cable. Continued unstripped after either the related conduit entry or the related cable gland by at least 100 to allow for cable identification marking. Identification marked as indicated within 100 of the end of the sheath.

Where multicore cables with numbered cores are installed, the same numbers shall be continued from the switchboard to the final connections. This may require stripping of the outer sheath and continuation of the cores. This may also require the use of extra earth cables where more than one final connection is made. The unused cores of a multicore cable shall be terminated in the terminals provided in a switchboard and in an insulated screwed connector in the field. The length of the unused cores shall be at least as long as the longest used cores. The unused cores shall be looped and tied so as to be easily accessible. Terminations of multicore cables shall be such as to minimise the length of the unsheathed cores, but sufficient core length in the form of a neat loop shall be left to ensure that no termination is under tension and to allow for connectors to be relocated. Cores with the same insulation colours or numbers shall not be run together. There shall be no more than one conductor per terminal and all field cables shall enter switchboards via terminals (except instrument cables where indicated). Cables enclosures shall continue to the switchboard, but each cable shall be separately glanded at the gland plate. Cable and cable cores shall be identified in accordance with Clause 205 of this document. Where more than five separate surface run cables or cable enclosures are to enter a switchboard through the top or bottom, enclose all this wiring within U-shaped metal covers or ducts run from ceiling or floor to within 150 of the switchboard. Gland all cables when they enter the switchboard. Covers shall be earthed to switchboard cubicle, fixed to walls generally in accordance with Clause 112, painted to match switchboard and shall maintain the switchboard IP rating. The metal cover or duct shall have minimum 50% spare capacity for future wiring. Cables shall not enter through the top of externally mounted switchboards. To minimise eddy current effects, where single core cables rated over 300 A pass separately through a steel cable entry plate, the entry holes shall be joined with slots and the slots brazed or epoxy filled. In addition, metal cable saddles shall not be fitted over these cables. All mains and submains shall be supported or tied within 200 of the terminations. This support or tie shall be substantial due to the stresses under short circuit conditions. Where a busway is brought into a switchboard, the insulated cable entry plate shall have a close tolerance cut-out to fit the busbars. The busway enclosure shall be flanged at the switchboard and shall be bolted and sealed to the switchboard enclosure. The busway enclosure shall be earthed to the switchboard cubicle. Busbar clearances entering the switchboard shall comply with Clause 204.8.

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Terminations of mains and submains shall be fully insulated or coated in accordance with Clause 204.6. 112.4 Schedules and Drawings Neat and legible schedules and drawings as described below shall be installed in insectproof mounting frames having clear plastic covers and located on or adjacent to the relevant switchboard but away from direct sunlight. Schedules and drawings required are: (a) (b) (c) (d) For each distribution board a type-written circuit schedule. For each switchboard a copy of the relevant "as installed" lighting and power layout floor plans. For each site a copy of the "as installed" drawing showing all main site reticulation including details and accurate positions of all spare conduits. Drawings shall be minimum A3 size photocopies.

113

WORK AS EXECUTED DRAWINGS

Progressively produce Work As Executed Drawings and secure accuracy of detail for all work covered by this contact. Number Work As Executed Drawings with the suffix X. Provide a dated notation on Work As Executed Drawings indicating all changes that were made as modifications to exhibited drawings. All abbreviations shall be in accordance with AS 1000. Drawings shall conform to AS 1100 Drawing Practice, SAA HB7-1993-1989 Engineering Drawing Handbook, AS 1102 Graphical Symbols for Electrotechnology and AS 1103 Diagrams, Charts and Tables for Electro-technology and AS3702-1989. Printing shall be minimum 2.5 high.

113.1

Drawings Produced by Modification of Exhibited Drawings (Exhibited drawings are defined to be drawings which are part of the original documentation.) Drawings which are produced by modification of exhibited drawings shall be based on a clean print of the exhibited drawing which shall contain modifications and additions neatly marked up in red pen. At the completion of the commissioning, these marked up drawings shall be signed by the contractor. Five copies of these drawings shall be supplied.

113.2

New Drawings Submitted by the Contractor Where new drawings are required to be produced as part of this contract to supplement the modified exhibited drawings, produce the drawings using the latest versions of Computer Aided Drafting software and print the drawings using a laser quality printer of minimum resolution 1200 x 1200 dots per inch. Use minimum 80 grams per square metre paper. Five prints of these drawings shall be supplied.

114

ACCREDITATION FOR CONTESTABLE WORKS

Where the NSW Office of Fair Trading of the NSW Department of Commerce requires the accreditation of Service Providers for such works as are deemed contestable, such accreditation shall be required to carry out the works as follows:

114.1

Level 1 Accreditation Work on the electricity distributors distribution system (ie construction work relating to distribution network assets).

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114.2

Level 2 Accreditation Work associated with service lines between the distribution system and the point of supply to the premises, energising and metering services. (i.e. construction and/or installation of the service line interface between the distribution system and consumer terminals, including metering services).

114.3

Level 3 Accreditation Design work associated with Levels 1 and 2 above. (i.e. design of transmission and distribution works for categories overhead and underground).

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Part 2 - Switchboards and Associated Equipment

PART 2 201

- SWITCHBOARDS AND ASSOCIATED EQUIPMENT SCOPE

The section covers the design, manufacture and testing of extra low voltage and low voltage switchboards and associated equipment.

202

GENERALLY
All Custom-built Assemblies for one contract shall be manufactured by the one manufacturer with all equipment sourced from the same suppliers for all switchboards. All equipment shall be positioned so as to provide safe and easy access for operation and maintenance. All switchboards shall be totally enclosed and shall comply with the requirements of AS 1939 with a minimum degree of protection as indicated in the relevant section herein or as indicated in the Specification. Switchboards shall be designed and manufactured such that they may be readily moved to, and installed at the indicated locations. If a switchboard is split for installation, all materials necessary for reassembly shall be provided. In addition to complying with the Specification, all switchboards shall comply with the special requirements of the relevant Supply Authority.

202.1

Classification of Switchboards Switchboards are classified as Custom-built Assembly Type CT, Custom-built Assembly Type CU, Custom-built Assembly Type DT, Custom-built Assembly Type DU, Custom-built Assembly Type DUPLUS, Custom-built Assembly Type DTPLUS or Proprietary Assembly. A Proprietary Assemblies is defined as a low or extra low voltage switchgear and controlgear assembly available as a catalogue item, which consist of the manufacturers standard layouts and equipment. A Custom-built Assemblies is defined as a low or extra low voltage switchgear and controlgear assembly manufactured to order.

202.1.1

Proprietary Assemblies The following details shall apply to Proprietary Assemblies:

(a) (b) (c) (d)

They shall be front connected, surface mounted with minimum protection IP 30. Enclosures shall be metallic. Circuit Breakers or switches mounted in enclosures shall have the circuit breaker/switch toggle protruding through a metallic escutcheon. Space shall be provided within a proprietary assembly containing circuit breakers/switches for a minimum of 20% spare poles or 4 spare poles, whichever is the greater. Lifting handles or substantial knobs shall be provided for front covers and escutcheons. All edges of all covers shall rest on the cubicle body or on a mullion. Interlocked covers are not acceptable.

(e) (f)

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202.1.2

Custom-built Assembly Type CT The following details shall apply to Custom-built Assemblies Type CT: (a) (b) A Type CT assembly shall be a stationary cubicle-type assembly as defined in AS/NZS 3439.1:2002. A Type CT assembly shall comply with AS/NZS 3439.1:2002 as defined by the following requirements: (i) (ii) Form of separation shall be Form 1. The degree of protection after installation in accordance with the manufacturers instructions shall be IP51 for indoor installation and IP56 for outdoor installation. Assemblies shall be front access with top and/or bottom cable entry. Assemblies shall be floor mounted or wall mounted. Wall mounting is acceptable only if the frontal area of the assembly has an area less than 2 square metres. For outdoor switchboards containing busbars, pollution degree 3 shall apply at locations further than 1km in a direct line from the coast or at altitudes below 1000 metres. Otherwise, pollution degree 4 shall apply.

(iii) (iv)

(v)

For indoor switchboards, pollution degree 3 shall apply. (vi) The following safety measures against direct contact shall apply: Requirement of a key or tool to gain entry into the switchboard. (Meet clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) Shielding all live parts in such a manner that they cannot be unintentionally touched when the door is opened or the cover is removed. (Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.) (vii) Assemblies shall be Partially Type Tested Assemblies or Type Tested Assemblies with type test certificates or satisfactory test reports for the type tests listed in clause 8 of AS/NZS 3439.1:2002. Documentation shall be available to demonstrate that the results of type tests were satisfactory. The testing facility shall be accredited by NATA or registered with the Association of Short-Circuit Testing Authorities. The standard Internal Arcing-Fault Test specified in Annex ZD of AS/NZS 3439.1:2002 (limited arc, initiated on the load side of a protective device within the functional unit being tested) shall be met and a test certificate demonstrating that the results of the type tests were satisfactory shall be available. The testing facility shall be accredited by NATA or registered with the Association of Short-Circuit Testing Authorities.

(viii)

202.1.3

Custom-built Assembly Type CU The following details shall apply to Custom-built Assemblies Type CU: Note that type test certificates or satisfactory test reports for the type tests listed in clause 8 of AS/NZS 3439.1:2002 are not required. (a) (b) A Type CU assembly shall be a stationary cubicle-type assembly as defined in AS/NZS 3439.1:2002. A Type CU assembly shall comply with AS/NZS 3439.1:2002 as defined by the following requirements: (i) (ii) Form of separation shall be Form 1. The degree of protection after installation in accordance with the manufacturers instructions shall be IP51 for indoor installation and IP56 for outdoor installation.

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(iii) (iv)

Assemblies shall be front access with top and/or bottom cable entry. Assemblies shall be floor mounted or wall mounted. Wall mounting is acceptable only if the frontal area of the assembly has an area less than 2 square metres For outdoor switchboards containing busbars, pollution degree 3 shall apply at locations further than 1km in a direct line from the coast or at altitudes below 1000 metres. Otherwise, pollution degree 4 shall apply.

(v)

For indoor switchboards, pollution degree 3 shall apply. (vi) The following safety measures against direct contact shall apply: Requirement of a key or tool to gain entry into the switchboard. (Meet clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) Shielding all live parts in such a manner that they cannot be unintentionally touched when the door is opened or the cover is removed. (Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.) 202.1.4 Custom-built Assembly Type DT The following details shall apply to Custom-built Assemblies Type DT: (a) (b) A Type DT assembly shall be a stationary cubicle-type assembly or multicubicle-type assembly as defined in AS/NZS 3439.1:2002. A Type DT assembly shall comply with AS/NZS 3439.1:2002 as defined by the following requirements: (i) (ii) Form of separation shall be Form 3b or 4a. The degree of protection after installation in accordance with the manufacturers instructions shall be IP51 for indoor installation and IP56 for outdoor installation. Assemblies shall be front access with top and/or bottom cable entry. Assemblies shall be floor mounted. For outdoor switchboards containing busbars, pollution degree 3 shall apply at locations further than 1km in a direct line from the coast or at altitudes below 1000 metres. Otherwise, pollution degree 4 shall apply.

(iii) (iv) (v)

For indoor switchboards, pollution degree 3 shall apply. (vi) The following safety measures against direct contact shall apply:

For Main Incoming Supply Compartments, Motor Starter Compartments and Distribution Feeder Compartments with one feeder in the Distribution Feeder Compartment: Requirement of a key or tool to gain entry into the switchboard. (Meet clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) Disconnection of all live parts that can be unintentionally touched after the door has been opened. (Meet clause 7.4.2.2.3 b) of AS/NZS 3439.1:2002.) Shielding all live parts in such a manner that they cannot be unintentionally touched when the door is opened or the cover is removed. (Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.)

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For Common Control Compartments: Requirement of a key or tool to gain entry into the switchboard. (Meet clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) Shielding all live parts in such a manner that they cannot be unintentionally touched when the door is opened or the cover is removed. (Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.) For Distribution Compartments with one main protective device plus a number of subcircuit protective devices: Requirement of a key or tool to gain entry into the switchboard. (Meet clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) for the compartment door and for the escutcheon. (vii) Assemblies shall be Partially Type Tested Assemblies or Type Tested Assemblies with type test certificates or satisfactory test reports for the type tests listed in clause 8 of AS/NZS 3439.1:2002. Documentation shall be available to demonstrate that the results of type tests were satisfactory. The testing facility shall be accredited by NATA or registered with the Association of Short-Circuit Testing Authorities. The special Internal Arcing-Fault Test (unlimited arc, initiated on the line side of the protective device within the functional unit being tested) required by Appendix ZD.6 of AS/NZS 3439.1:2002 shall be met and a test certificate demonstrating that the results of the type tests were satisfactory shall be available. The duration of the test shall be chosen by the manufacturer according to the time response of the electrical protection devices. If details of these devices are not known, a power supply duration of at least 100 milliseconds shall apply. The testing facility shall be accredited by NATA or registered with the Association of Short-Circuit Testing Authorities.

(viii)

202.1.5

Custom-built Assembly Type DU The following details shall apply to Custom-built Assemblies Type DU: Note that type test certificates or satisfactory test reports for the type tests listed in clause 8 of AS/NZS 3439.1:2002 are not required. (a) (b) A Type DU assembly shall be a stationary cubicle-type assembly or multicubicle-type assembly as defined in AS/NZS 3439.1:2002. A Type DU assembly shall comply with AS/NZS 3439.1:2002 as defined by the following requirements: (i) (ii) Form of separation shall be Form 3b or 3bi, 3bh, 3bih, 4a, 4b, 4ah, 4ai, 4aih, 4bh, 4bi, 4bih. The degree of protection after installation in accordance with the manufacturers instructions shall be IP51 for indoor installation and IP56 for outdoor installation. Assemblies shall be front access with top and/or bottom cable entry. Assemblies shall be floor mounted. For outdoor switchboards containing busbars, pollution degree 3 shall apply at locations further than 1km in a direct line from the coast or at altitudes below 1000 metres. Otherwise, pollution degree 4 shall apply.

(iii) (iv) (v)

For indoor switchboards, pollution degree 3 shall apply. (vi) The following safety measures against direct contact shall apply:

For Main Incoming Supply Compartments, Motor Starter Compartments and Distribution Feeder Compartments with one feeder in the Distribution Feeder Compartment:

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Requirement of a key or tool to gain entry into the switchboard. (Meet clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) Disconnection of all live parts that can be unintentionally touched after the door has been opened. (Meet clause 7.4.2.2.3 b) of AS/NZS 3439.1:2002.) Shielding all live parts in such a manner that they cannot be unintentionally touched when the door is opened or the cover is removed. (Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.) For Common Control Compartments: Requirement of a key or tool to gain entry into the switchboard. (Meet clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) Shielding all live parts in such a manner that they cannot be unintentionally touched when the door is opened or the cover is removed. (Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.) For Distribution Compartments with one main protective device plus a number of subcircuit protective devices: Requirement of a key or tool to gain entry into the switchboard. (Meet clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) for the compartment door and for the escutcheon. 202.1.6 Custom-built Assembly Type DUPLUS

The following details shall apply to Custom-built Assemblies Type DUPLUS: Note that type test certificates or satisfactory test reports for the type tests listed in clause 8 of AS/NZS 3439.1:2002 are not required except for the Verification of short-circuit withstand test, Clause 8.2.3 of AS/NZS 3439.1:2002, for the busbar system. (a) (b) A Type DUPLUS assembly shall be a stationary cubicle-type assembly or multicubicle-type assembly as defined in AS/NZS 3439.1:2002. A Type DUPLUS assembly shall comply with AS/NZS 3439.1:2002 as defined by the following requirements: (i) (ii) Form of separation shall be Form 3b or 3bi, 3bh, 3bih, 4a, 4b, 4ah, 4ai, 4aih, 4bh, 4bi, 4bih. The degree of protection after installation in accordance with the manufacturers instructions shall be IP51 for indoor installation and IP56 for outdoor installation. Assemblies shall be front access with top and/or bottom cable entry. Assemblies shall be floor mounted. For outdoor switchboards containing busbars, pollution degree 3 shall apply at locations further than 1km in a direct line from the coast or at altitudes below 1000 metres. Otherwise, pollution degree 4 shall apply.

(iii) (iv) (v)

For indoor switchboards, pollution degree 3 shall apply. (vi) The following safety measures against direct contact shall apply:

For Main Incoming Supply Compartments, Motor Starter Compartments and Distribution Feeder Compartments with one feeder in the Distribution Feeder Compartment: Requirement of a key or tool to gain entry into the switchboard. (Meet clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.)

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Disconnection of all live parts that can be unintentionally touched after the door has been opened. (Meet clause 7.4.2.2.3 b) of AS/NZS 3439.1:2002.) Shielding all live parts in such a manner that they cannot be unintentionally touched when the door is opened or the cover is removed. (Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.) For Common Control Compartments: Requirement of a key or tool to gain entry into the switchboard. (Meet clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) Shielding all live parts in such a manner that they cannot be unintentionally touched when the door is opened or the cover is removed. (Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.) For Distribution Compartments with one main protective device plus a number of subcircuit protective devices: Requirement of a key or tool to gain entry into the switchboard. (Meet clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) for the compartment door and for the escutcheon. 202.1.7 Custom-built Assembly Type DTPLUS The following details shall apply to Custom-built Assemblies Type DTPLUS: (a) (b) A Type DTPLUS assembly shall be a stationary cubicle-type assembly or multicubicle-type assembly as defined in AS/NZS 3439.1:2002. A Type DTPLUS assembly shall comply with AS/NZS 3439.1:2002 as defined by the following requirements: (i) (ii) Form of separation shall be Form 4b. The degree of protection after installation in accordance with the manufacturers instructions shall be IP51 for indoor installation and IP56 for outdoor installation. Assemblies shall be front access with top and/or bottom cable entry. Assemblies shall be floor mounted. For outdoor switchboards containing busbars, pollution degree 3 shall apply at locations further than 1km in a direct line from the coast or at altitudes below 1000 metres. Otherwise, pollution degree 4 shall apply.

(iii) (iv) (v)

For indoor switchboards, pollution degree 3 shall apply. (vi) The following safety measures against direct contact shall apply:

For Main Incoming Supply Compartments, Motor Starter Compartments and Distribution Feeder Compartments with one feeder in the Distribution Feeder Compartment: Requirement of a key or tool to gain entry into the switchboard. (Meet clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) Disconnection of all live parts that can be unintentionally touched after the door has been opened. (Meet clause 7.4.2.2.3 b) of AS/NZS 3439.1:2002.) Shielding all live parts in such a manner that they cannot be unintentionally touched when the door is opened or the cover is removed. (Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.)

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For Common Control Compartments: Requirement of a key or tool to gain entry into the switchboard. (Meet clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) Shielding all live parts in such a manner that they cannot be unintentionally touched when the door is opened or the cover is removed. (Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.) For Distribution Compartments with one main protective device plus a number of subcircuit protective devices: Requirement of a key or tool to gain entry into the switchboard. (Meet clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) for the compartment door and for the escutcheon. (vii) Assemblies shall be Partially Type Tested Assemblies or Type Tested Assemblies with type test certificates or satisfactory test reports for the type tests listed in clause 8 of AS/NZS 3439.1:2002. Documentation shall be available to demonstrate that the results of type tests were satisfactory. The testing facility shall be accredited by NATA or registered with the Association of Short-Circuit Testing Authorities. The special Internal Arcing-Fault Test (unlimited arc, initiated on the line side of the protective device within the functional unit being tested) required by Appendix ZD.6 of AS/NZS 3439.1:2002 shall be met and a test certificate demonstrating that the results of the type tests were satisfactory shall be available. Further to Clause ZD.2 (Relevance of Tests) of AS/NZS 3439.1:2002, the special internal arcing-fault test shall be applicable to all compartments. The duration of the test shall be chosen by the manufacturer according to the time response of the electrical protection devices. If details of these devices are not known, a power supply duration of at least 100 milliseconds shall apply. The testing facility shall be accredited by NATA or registered with the Association of Short-Circuit Testing Authorities.

(viii)

202.1.8

Manufacturer of the Switchboard. (a) Custom-built Assemblies Type DTPLUS The firm in whose name the test certificates have been issued shall completely manufacture the switchboard at its workshop. (b) Other Custom-built Assemblies For Custom-built Assemblies, other than Type DTPLUS, where a proprietary modular switchboard system is offered, the switchboard builder shall have been appropriately trained and have the appropriate level of accreditation to build the switchboard from the manufacturer of the modular switchboard system.

203
203.1

FAULT LEVELS AND LIMITATION

Fault Levels and Time of Duration The indicated fault level shall apply. The fault level being the prospective symmetrical r.m.s. value at the switchboard input terminals. Conductors and equipment shall be suitable for a time not less than that determined in the following manner: (a) On any conductor or equipment:one (1) second. (b) On any conductor or equipment protected by a consumer's line side fuse or fast acting circuit breaker: the actual cut-off time or trip out time at the indicated fault level where it is not less than 10 milliseconds. Where the actual cut-off time or trip out time of the consumer's line side fuse or fast acting circuit breaker is less than 10 milliseconds, then the conductors and

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equipment shall be suitable for the actual fault let through energy and peak cut-off current of the protective device corresponding to the indicated fault level. Equipment shall not be used at a higher fault level than that for which it has been tested, irrespective of fault duration. 203.2 Fault Current Limiting Fault current limiting, either by fuses or suitable circuit breaker combinations shall only be used where indicated and shall be of the form indicated. Selection of fault current limiting equipment shall be in accordance with a selection table accepted by the relevant Supply Authority. 203.3 Short Circuit Co-ordination Type 2 short circuit co-ordination in accordance with AS 60947.4.1 is required for the short circuit protective device, the motor contactor and the overload device if either of the following conditions apply: (a) (b) (c) Main busbar fault level of 31.5kA or greater at 415Volts has been specified. Starter size is greater than 37kW when direct on line started. Starter size is greater than 45kW when reduced voltage started.

Type 1 short circuit co-ordination in accordance with AS 60947.4.1 is required for the short circuit protective device, the motor contactor and the overload device in all cases other than (a), (b), and (c) above, except for the following condition: Where ventilation fans are installed to provide a safe environment for personnel, Total Co-ordination for the short circuit protective device, the motor contactor and the overload in accordance with AS 60947.6.2 is required.

204
204.1

BUSBARS
Generally Busbars for Proprietary Assemblies may be of the manufacturer's standard. Multi-pole proprietary busbar assemblies for circuit breakers shall be of an accepted type. When busbar systems have been verified by type testing, such arrangements are acceptable in lieu of the methods specified below. Busbars shall be arranged to ensure that the phase sequence at all switchboard equipment terminals is red, white and blue from left to right and from top to bottom, when viewed from the front of the switchboard.

204.2

Material Busbars shall be hard-drawn high-conductivity copper. Square-edged busbars shall not be used.

204.3

Sizes Busbar sizes in relation to current ratings shall be to AS 3000, assuming the switchboards are of magnetic materials, located indoors in a well ventilated room and the appropriate enclosure rating shall apply. However, smaller busbars may be used in accordance with an approved Testing Authority Temperature Rise Test Certificate for a switchboard with a similar internal physical configuration. For purposes of withstanding thermal stresses due to fault currents, active busbars shall be sized in accordance with AS 3439.1, unless smaller busbars can be substantiated with

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an approved Testing Authority Type Test Report. membrane shall be regarded as insulated).

(Busbars coated with copolymer

Unless otherwise indicated, incoming busbar current rating to the first tee-off shall not be less than the maximum possible current rating of the frame size of the busbar protection device. However, for main switchboards with no main protection device, the incoming busbar current rating shall not be less than the current rating of the consumers mains. Tee-off busbars to other controlling devices shall have a current rating equal to the maximum frame size rating of that controlling device. In determining other than incoming and tee-off busbar sizes (eg vertical droppers etc), the actual frame size rating of the controlling devices and spare spaces shall be used and the load diversity reduction factors given in AS 3439.1 shall be applied. Busbars so sized need not exceed the size of that section's incoming busbars. Accepted proprietary busbar assemblies shall not be used at higher than the assigned ratings. Busbars connected to fault current limiters shall be rated to 100% of indicated current limiter rating.

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204.4

Jointing Busbar jointing shall maximise the copper-to-copper contact area under the "shadow area" of the bolt head and nut. Bolt holes shall be round, square edged with a maximum bolt clearance of 1. Deburring shall be the minimum necessary to remove any projections. Joint surfaces shall be flat and shall be deliberately roughened by sanding or draw filing immediately prior to making the joint. Tinned or electroplated joints are an acceptable alternative. Where the fault rating of any busbar section of a switchboard does not exceed 14kA, and for all proprietary multi-pole busbar assemblies, the minimum requirements shall be plated steel commercial bolts to AS 1111, with minimum strength grade of 4.6. Where the fault rating of any busbar section of a switchboard exceeds 14 kA, the minimum requirements for all size busbars throughout that section shall be M10, plated steel precision bolts to AS 1110 with minimum strength grade of 8.8, which shall be confirmed by the marks "M" and "8.8" appearing on the bolt head. This applies to busbar joints and where busbars are bolted to insulators and support. For the purposes of joint inspections, a joint as nominated by the Superintendent shall be stripped of its finish coating dismantled, reassembled and re-finished during the factory inspection. Where busbars are bolted to proprietary equipment, the proprietary bolts and terminating methods supplied by the manufacturer are acceptable. The number of bolts used per joint shall be consistent with first grade jointing practice. A minimum of two bolts per joint is preferred. Busbar jointing bolts shall not be used to support the busbar. For both commercial and precision bolts, use one plated steel full flat washer on each side of the joint, and one plated steel full nut (no spring or serrated washer, or locknut). The full nuts shall be torque-tightened to the bolt manufacturer's recommended levels. For both commercial and precision bolts, use one plated steel full flat washer on each side of the joint, and one plated steel full nut (no spring or serrated washer, or locknut). The full nuts shall be torque-tightened to the bolt manufacturer's recommended levels. Written agreement shall be obtained to alternative jointing methods, before commencing manufacture.

204.5

Supports Busbar support spacings shall be determined by reference to "Copper for Busbars" issued by the Copper Development Association and to other appropriate engineering principles and data. Spacings greater than those indicated by these references shall be substantiated by an approved Testing Authority Type Test Report. Busbar supports shall be made of non-hydroscopic insulating material and shall be capable of holding busbars at a temperature of 105C. Supports shall be capable of withstanding thermal and magnetic stresses associated with relevant fault levels and times of duration. Supports shall be of adequate size and shall rigidly hold all busbars by being rigidly fixed to the cubicle where possible. Floating supports shall be kept to a minimum. Clamp type supports shall suit the busbar cross-sectional shape so as to minimise distortion and migration of busbar insulation or coating during normal service.

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204.6 204.6.1

Prevention of Arcing Faults Rigid Insulation Where hook-stick links, open blade type fuse links or the like are installed within a switchboard, suitable rigid, fixed insulating barriers shall be provided to prevent inadvertent electrical contact between phases by a foreign straight metallic object. Barriers shall be provided on both sides of each link or fuse link (eg four barriers for a three phase set).

204.6.2

Coating of Busbars and Terminations Active busbars shall be coated with polyethylene. All joints and jointing bolts not so coated shall be either taped, insulated with air drying plastic coating or have a water based copolymer membrane coating applied. As an alternative, all active busbars including joints and jointing bolts may be coated with a water based copolymer membrane coating. Those parts of busbars which are fully encapsulated need not be coated. One system deemed to be equivalent to encapsulation is proprietary close fitting busbar insulation mouldings not less than 1.0 thick. In the case of equipment providing integral shrouding between the main active terminals, the coating shall not extend into the shrouded area. Mating surfaces of the main plugs or connections of demountable or withdrawable functional units shall not be coated. Busbar flags for the connection of future equipment shall not be coated, but shall be covered with readily removable insulating material of minimum thickness 0.4.

204.6.3

Application of Busbar Coatings (a) Polyethylene Polyethylene shall be applied by a fluidised bed process in which the material is directly cured onto the bars. Preparation of the busbars and method of application shall be strictly in accordance with the supplier's recommendations. The thickness of the coating shall be not less than 0.4 and the minimum dielectric strength of the coating shall be 2 kV rms for one minute. The colours shall be either the correct phase colours or all white with phase colour bands. (b) Acrylic Copolymer Membrane Coating Before coating, all surfaces shall be cleaned down, treated with an etch cleaner and then completely dried. One substantial coat approximately 0.15 to 0.2 thick shall then be applied. The material used shall have a minimum titanium dioxide content of 10%. Coating colour shall be cream with phase colour bands. Care shall be taken to prevent the coating being applied over any insulation between phases or phase to earth at busbar barriers and supports or on any switchboard equipment. (c) Taping at Joints Taping shall be with non-adhesive stop-off half lapped to achieve a thickness not less than 0.4 and the ends shall be tied off. The colour shall match the adjoining busbar coating. (d) Air Drying Plastic Coating at Joints

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Plastic coating material shall achieve a tensile strength of greater than 17 MPa and have a minimum ultimate elongation of 300%. Application of air drying plastic coating shall be in accordance with the manufacturer's recommendations to achieve a thickness of not less than 0.4. Coating colour shall match the adjoining busbar coating. 204.7 Phase Identification Busbars shall be identified by minimum 25 wide colour bands neatly and permanently applied and located at not more than 500 intervals along the active, neutral and earth busbars with a minimum of one colour band for each busbar piece. Adhesive type material is not acceptable. MEN links shall have green-yellow and black bands. Colours shall be red, white and blue respectively for the phases A, B, and C, black for neutral and green-yellow for earth. 204.8 Busbar Clearances Clearance between phases and phase to earth shall be not less than that required by AS 3000. All busbars shall be treated as being bare. Where busbars are connected to proprietary equipment, clearances less than that required by AS 3000 are acceptable provided the busbars are insulated. 204.9 Cable Connection Flags All equipment, having main terminals inadequate for the cable size, shall be fitted with busbar flags. The size of the flags shall be appropriate for the cable lugs to be terminated and shall have a current rating of not less than the maximum frame size of the equipment. Busbar flags shall be suitably supported. 204.10 Neutral and Earth Busbars The ratio of neutral to active busbars size shall be equal to that of the incoming cable cores. Earth busbar cross sectional areas shall be in accordance with AS 3000. The minimum cross sectional area of the neutral and earth busbars throughout the switchboard shall be sized in accordance with Appendix C of AS 136 to suit 50% of the indicated fault level for 100% of the time of duration (eg a fault level of 43 kA for one second requires a minimum uninsulated busbar of 124mm2 cross-sectional area). The metal frames of switchboard cubicles and equipment (eg air break circuit breaker, FCU's etc) shall be effectively bonded to the earth busbar. To achieve a good metal-tometal contact, painted surfaces shall be stripped and given a corrosion resistant coating just prior to bolting to the earth busbar. 204.11 Flexible Busbars Take Offs Notwithstanding other requirements of this document, the conductors between the rigid busbars and the supply side of a single functional unit may consist of flexible, insulated copper woven busbars which are forged to a solid unit at both ends. In any case, comply with Clause 7.5.5.1.2 of AS/NZS 3439.1:2002.

205
205.1

CABLING
Generally Interconnecting cables may be used instead of busbars for all ratings and shall comply with the requirements of this clause.

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Cables are not to be used to link adjacent circuit breakers where multi-pole busbar assembly can be used for this purpose. Except for I/O cabling, internal cabling shall be at least V75 insulated with stranded copper conductors of a size not less than that determined from AS 3008.1 for enclosed in free air conditions but shall not be less than 1.5mm2. Cable sizes determined shall include the principles explained in Clause 204.3 and 204.10. Digital PLC I/O wiring shall be carried out in minimum 0.5mm2 PVC flexible cable. The current rating of cables between fault current limiting fuses and a fixed setting circuit breaker used to limit the maximum demand, need not exceed the current rating of that circuit breaker. Cables shall be adequately supported and run clear or busbars and metal edges. Adhesive supports are not permitted. Phase, neutral and earth cables shall be capable of withstanding the maximum thermal and magnetic stresses associated with the relevant fault level and time of duration. Thermal performance shall be based on AS 3008.1. All cables shall be neatly run and shall be supported and tied at maximum 150 intervals unless enclosed in a duct. Ducts shall be of a slotted type adequately sized for present and all anticipated future cables. Switchboard design shall allow wiring to be run to future equipment without removal of existing equipment. All cables shall have suitable palm type crimp lugs fitted. Crimp lugs shall be fitted with the correct tooling. Flexible cables to be terminated in tunnel terminals shall be fitted with insulated sleeved ferrules. For all sewage treatment works and sewage pumping stations, immerse the exposed conductor at the end of the flexible cables in petroleum jelly prior to termination. Looping of earth cables is not permitted, and all earth cables shall terminate at an earth link or at a minimum M6 earthing stud adjacent to the equipment. Cables shall be arranged to ensure that the phase sequence at all switchboard equipment terminals is red, white and blue from left to right and from top to bottom, when viewed from the front of the switchboard. Control wiring shall originate from white phase throughout an installation. 205.2 Cable Identification Colours Cable insulation shall be coloured in accordance with the following table: Phase wiring (A, B & C) - red, white and blue Voltmeter and current transformer connections - red, white, blue and black 240 V control active (controlled by isolator on the board) - grey 240 V control active (not controlled by isolator on the board) - orange 240 V neutral - black ELV AC active - brown-red ELV AC common - brown-white ELV devices eg thermistor - brown ELV DC positive - blue-red ELV DC negative - blue-white Telemetry - violet

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Earth - green-yellow Cables listed in two colours (eg brown-red) shall consist of a base colour (ie brown) and a spiral trace colour (ie red). Cable trace colours shall cover between 20% and 40% of the cable surface and extend the full length of the cable. As an alternative for cables above 50mm2, all double insulated cables, phase identification may be 25 wide heat shrink bands of the colours tabulated above applied at each end and at not more than 500 intervals along the entire run. Identification (a) Control Wires All control wires shall be individually identified at each end. All control cables shall have the same identifying number over its entire length even when it passes in and out of a terminal block. (b) Multicore Control Cables Each cable core shall be individually identified with a number in numerals and spelt out in letters. Such identification shall be in black on to the cable cores during manufacture. Cable cores shall be consecutively numbered. (c) Plastic Cable Ferrules Cable cores which do not have integral number identification shall be identified using proprietary cable ferrules. Cable ferrules shall be flexible plastic sleeve type Z type with indelible alphanumerics. The cable ferrules shall be designed for the cable core diameter. The use of Critchley Multi-Mark and Grafoplas identification systems is acceptable. (d) Cable Sheaths Identification All cable sheaths shall be identified at both ends. Identification shall include cable number prefixed by J for instrumentation, C for control and P for power, circuit name (e.g. Pump 1) and type and size of cable (e.g. 3C + E 2.5 mm). Identification shall be neat, permanent and legible and the following will be acceptable: (e) Stamped aluminium tags Proprietary write-on tags

Visibility Cable and core identification shall be fully legible and visible from the front of the switchboard, control panel, equipment etc. ferrules, embossed alphanumerics, tags, etc., shall be arranged such that all letters and numerals are in line and can be readily read from the front without manipulation. Alphanumerics shall be vertically upright on horizontal cables and cores, and shall be read from the right hand side on vertical cables and cores.

205.3

Large Cables (Cables above 6mm) Not more than one cable shall terminate in a tunnel terminal, and not more than two cables shall terminate at any other connection point or terminal. Active links shall comply with paragraphs (a) to (d) of Clause 206.2. Large cables shall not be run to hinged panels or doors. In addition to the cable supports described in Clause 205.1, rigid non-metallic fixings to the switchboard cubicle shall be provided within 200 of all terminations and at not more than 400 intervals along the entire run. If the cables are in a duct, the intermediate fixings shall be within the duct. To minimise eddy current effects metal cable saddles shall not be fitted over single core cables rated over 300A.

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For arcing fault prevention, large cable terminations shall be treated in accordance with Clause 204.6 205.4 Small Cables (Cables up to and including 6mm) Each cable core shall be marked at both ends with neat fitting ring type identification ferrules and the markings shall agree with the endorsed circuit diagram. Markings shall comply with AS 1103. Marked cables to connect with external controls shall terminate in correspondingly marked terminals located within the switchboard, adjacent to the external cable route. Cables to items of equipment mounted on hinged panels or doors shall run at the hinge side in such a manner as to not impede opening of the panel or door. Spiral type sheathing shall be applied to the cables between the fixing at the switchboard cubicle and the fixing on the panel or door.

206
206.1

ACTIVE, EARTH AND NEUTRAL LINKS

For Proprietary Assemblies Links for Proprietary Assemblies may be the manufacturer's standard.

206.2

For Custom-built Assemblies For small cables (up to and including 6mm2), two screw tunnel terminals with minimum M4 brass or plated steel screws shall be provided. Screw diameter shall be not less than 70% of tunnel diameter. For large cables (above 6mm2), one of the following is acceptable: (a) (b) Minimum M8 brass screws, tapped and sweated into a minimum 6 thick brass or copper bar. A full nut and flat washer shall be provided for each stud. Minimum M8 hexagon head plated steel or brass set screws with flat washer, tapped into a brass bar. The length of engaged thread shall be not less than the diameter of the screw. Minimum M8 plated steel screws through clearance holes not more than 1.0 larger than the screw diameter, in a minimum 6 thick busbar. A plated full nut and two plated flat washers, one under the head and one under the nut, shall be provided. This method shall only be used where there is adequate spanner access to both the screw head and the nut. Tunnel terminals with one Allen head grub screw per terminal of diameter not less than 90% of the tunnel diameter. Approved nut tightened line-tap type clamp which securely clamps the conductors and prevents the cable strands from spreading.

(c)

(d) (e)

For aluminium cables, only methods (a), (b) and (c) are acceptable. Spring washers shall not be used at links. Each incoming and outgoing switchboard control shall be numbered with consecutive numbers starting at 1 and no number shall be repeated on the same switchboard. The same number shall appear at the corresponding neutral and earth terminals. Switchboards with 36 poles or less and where single pole circuit breakers can be fitted shall have one neutral and one earth terminal for each pole. Switchboards with more than 36 poles shall have one neutral and one earth terminal for every indicate circuit with a minimum of 36 neutral and 36 earth terminals. Where spare spaces are indicated, one neutral and one earth terminal shall be provided for each pole space or indicated future control. In determining the type of spare terminals, the ratio of small cable to large cable terminals for the indicated circuits shall

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be maintained, except that no less than two spare neutral and two spare earth large cable terminals shall be provided. Spare large cable terminals are not to be identified with a circuit number. Where the number of interchangeable circuit breaker poles in a switchboard exceeds 36, at least one neutral link and one earth link shall be provided at the top and at the bottom of the circuit breaker section. Generally, it is preferred that the links be of equal size although consideration must be given to circuit grouping and the links allocated accordingly. For example a 60 pole switchboard could have terminals 1 to 24 at the top and 25 to 60 at the bottom. The conductor linking the top and bottom neutral links shall have a current rating of not less than the active conductors on the load side of the controlling device. Neutral links shall be mounted on an insulated base. All earth links shall be bonded to the main earthing conductor with a conductor suitable for 100% of the indicated fault level for 100% of the time of duration. Bonding by means of cubicle contact is not acceptable. Control circuit neutrals and earths shall not occupy terminals designated for outgoing cables.

207
207.1

EQUIPMENT
Compliance with Australian Standards Proof of compliance with the relevant Australian Standard shall be provided if requested by the superintendent. Such proof shall comprise a complete Test Certificate from an accepted independent Testing Authority or a Certificate of Suitability issued by an Australian Electricity Authority.

207.2

Ambient Temperature All outdoor SCA's equipment shall be rated for min 60 C. All equipment for indoor SCA's shall be rated at min 50 C.

207.3

Miniature Overcurrent and Moulded Case Circuit Breakers Circuit breakers with current ratings of up to and including 100 A, and interrupting capacities up to but not including 10 KA, and/or a projected panel mounting area not exceeding 4000 sq. mm per pole, shall comply with AS 3111. This shall include Miniature Overcurrent Circuit Breakers fitted with or incorporating a current operated core balance core leakage relay or auxiliary contacts. Circuit breakers with an interrupting capacity of 10 kA and above shall comply with AS 2184. The trip current rating shall be clearly visible with the switchboard covers in place. Separate labels on the switchboard cover for this purpose are not acceptable. Identification of the contact positions shall be clearly marked on the circuit breaker in a contrasting colour. Horizontally mounted circuit breakers shall be capable of successful operation under full load and short-circuit conditions in the horizontal position. Where switchboards are supplied as a group of one or more switchboards from the one manufacturer, then within that group all circuit breakers of each frame size shall be of the same manufacture. However, the selection of all circuit breakers for any project shall ensure full overload and short circuit compatibility with each other and with all existing circuit breakers. This latter requirement is particularly important where, for fault current limiting, the use of series circuit breaker combinations is indicated.

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To limit the possibility of low level short circuit arcing faults, all adjustable short circuit trip settings are to be set to the "low" position. To assist in phase balancing, circuit breakers for two phase circuits shall be either three pole circuit breakers or two pole circuit breakers that occupy two pole spaces. Where locking is indicated, circuit breakers shall be provided with the facility for locking in the "open" position. 207.4 207.4.1 Drawout Circuit Breakers and Tripping Battery Drawout Circuit Breaker Drawout circuit breakers shall comply with AS 1930 and shall incorporate the following features: (a) (b) (c) Rated duty shall be "uninterrupted type" for a non-ventilated enclosure. "Rated short circuit breaking capacity" shall be not less than the switchboard fault level Closing shall be either: (i) (ii) (d) (e) "Independent manual closing", or "Stored energy closing" with a separate release button.

Drawout construction Auxiliary contacts shall be rated to AC-11 requirements with a minimum rated operational current of 6 A, 240 V. A minimum of one spare normally open contact and one spare normally closed contact shall be provided. Ability to be padlocked in the "open" position. Automatic main contact shutters. A door interlock to prevent the compartment door being open while the circuit breaker is in the "closed" position, except where the door serves merely as a cover to the circuit breaker and its operating mechanism. (i) (i) (ii) (iii) Racking gear shall prevent the withdrawal or engagement of the circuit breaker when its contacts are closed and shall have the following positions: Connected Test/Isolate Disconnected.

(f) (g) (h)

(j) (k) (l)

All stored energy devices shall be automatically discharged before any racking operation. Separate racking handles and all special installation, operation and servicing tools shall be supplied. The protection system shall be either: (i) (ii) An integral part of the circuit breaker, either solid state protection relay type or adjustable magnetic instantaneous relay type, or externally mounted relays operating a d.c. trip coil, either adjustable induction disc type, or solid state protection relay type.

(m)

An earthing connection shall be provided to earth the movable carriage and mounting frame. This connection shall "make" no later than and "break" no earlier than any other connection. It shall be suitable for busbar termination.

207.5

Fuses Fuses shall comply with AS 2005 (All Parts).

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Fuses shall be suitable for the fault level of the installation and shall discriminate properly with other protective equipment. Let-through energy and peak current cut-off shall suit the protected equipment. Fault current limiter fuse links shall be held in proprietary holders, and shall be mounted for withdrawal directly towards the operator. Holders for open blade type fuses shall have barriers complying with Clause 204.6.1. Where fuse extraction handles are required, they shall be clipped inside the switchboard cubicle adjacent to the fuses. Where the fuses are located behind more than one cover, one handle shall be provided behind each cover. Fuse links shall clearly state the name of the Australian manufacturer or distributor. A minimum of three spare fuse links shall be provided for every fuse size included in the switchboard, with the exception of fuses installed solely for fault current limiting. The spare fuse links shall be mounted in clips in the spare parts cabinet or space described in Clause 214, and where more than one size is provided, rating labels shall be fitted. 207.6 Fuse Combination Units Fuse combination units shall comply with AS 1775 and shall incorporate the following features: (a) Be either of the totally enclosed type or constructed such that the fixed live parts of the switches and fuses are fully and directly shrouded to prevent faults developing between phases by introduction of a foreign straight metallic object. The shrouding shall be fully effective throughout the entire movement of the air break switch. Switching shall be "independent manual operation". Rating duty shall be "uninterrupted type". Derating shall be applied, if appropriate, for units mounted in a compact formation (eg stacked formation). Utilisation category shall be in general AC-21 minimum, with AC-23 for motor loads. Ability to be padlocked in the open position, if indicated. Contact position shall be clearly shown both with the cover in place and with the cover removed. A secondary indication independent of the handle position shall additionally be provided. Where the fuses are mounted in a withdrawable carriage which ensures isolation from the supply before access to the fuses is possible, then the secondary indication may be omitted. Identification of the contact position shall be clearly marked on the F.C.U. in a contrasting colour.

(b) (c) (d) (e) (f) (g)

(h)

207.7

Main Switches This clause shall apply to main switches on main switchboards and local main switches on distribution boards. Main switches shall comply with AS 1775 and shall be suitable for fault-making/loadbreaking duties. Suitable switches are automatic circuit breakers, fused F.C.U.'s and fault-making/load-breaking switches. Non-automatic breakers, F.C.U.'s with solid links, or load-making/load-breaking style switches are not acceptable unless they have been tested for fault-making/load-breaking duties to AS 1775. The following features shall be incorporated: (a) (b) Type of switching shall be "independent manual operation". Rated duty shall be "uninterrupted type" for a non-ventilated enclosure.

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(c) (d) (e)

"Rated short time withstand current" shall be not less than the switchboard fault level. Utilisation category shall be in general AC-21 minimum, with AC-23 for motor loads. Identification of contact position shall be clearly marked on the switch in a contrasting colour.

207.8

Contactors AC contactors shall comply with AS 1029. The following details and minimum features shall apply: (a) (b) (c) (d) (e) (f) (g) (h) (i) Block style electromagnetic, air break type generally from the one manufacturer. Quiet in operation. Rated duty "intermittent class .03". Utilisation category "AC-3" or "DC-3" as applicable. Mechanical endurance "class 10". Contact life 1 million operations at AC-3 or DC-3 as applicable. Three phase contactors shall have minimum rating of 16 A, 415 V at category AC-3. For motor below 0.5 kW 8A is allowed.. Be designed to allow for fitting of auxiliary contacts with rating (Ie) of 4 A at 240 V a.c. Series or parallel contacts shall not be used to achieve the required ratings.

207.9

Control Switching Devices Control switching devices eg instantaneous relays, time delay relays, control switches and push button switches, shall comply with AS 1431. Contact arrangements and numbering to EN50011 is required.

207.9.1

Instantaneous Relays Instantaneous relays shall be of the type and contact arrangement as indicated but, if not indicated, shall be Type 3 as described below. Where practical, relays shall be selected from the one manufacturer's range and must be common in regard to contact switching in any one voltage range. Where relays are used as on interposing relay between a PLC and other equipment, the relays may be Type 2. Type 2 relays shall be 11 pin round plug-in with Push to test feature. Where specified as a DC relay, they shall be complete with suppression diode and an indicator to show energisation bases shall have screw connections with scissor action contacts. Relay coils shall be capable of operating under the required duty in the surrounding ambient conditions with a supply voltage variation of 1-%. Where indicated a minimum of 1 N/O and 1 N/C spare contacts shall be provided within each relay. Relays shall have visual indication of contact operation. Type 3 relays shall be of the 4/8 pole style and shall be of identical width in both configurations. The following details and minimum features shall apply:

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Relay Type

Mech. Life 6 x 10 Operations 5 10 10

Base

Contact Rating

Min. No. of Contact Elements 2 2 4

1 2 3

Plug-in Plug-In Fixed Mounting

1.25IL 7A @ 240V @ COS = 0.4 5A @ 240V

Plug-In Unit Retention Clips Yes Yes -

207.9.2

Time Delay Relays Time delay relays shall be adjustable over the entire range, as indicated, and the timing range shall not exceed 400% of the indicated setting. Time delay relays shall be capable of operating under the required duty in the surrounding ambient conditions with a supply voltage variation of 10% and a timing repeat accuracy of 2.5%. The details and minimum features indicated in the table in Clause 207.9.1 excluding minimum number of contact elements, also shall apply to time delay relays. Unless otherwise indicated, time delay relays shall be electronic operation. Electronic relays shall incorporate a LED which shall indicate energisation of the output relay.

207.9.3

Control Switches Control switches shall be of the rotary switch type with cam operation and switch positions arranged with a displacement of 60 and, if an "OFF" position is required, it shall be located at the "12 o'clock" position. Contacts shall have minimum rated operational current (Ie) of 6 A at 240 V a.c. to utilisation category AC-15 or AC-23. Escutcheon plates shall be rectangular and shall allow function and switch position labelling to be included on the plate. Escutcheon plates shall be silver with black lettering. Where control switches are input to a PLC the contacts shall be low resistance wiping type.

207.9.4

Push Button Switches Push Button switches shall be of the oil-tight type with minimum rated operational current (Ie) of 4 A at 240 V a.c. to utilisanaln category AC-15. Buttons shall be not less than 22 diameter and shall all be selected from the same size range. Each switch shall be provided with a legend plate indicating its functions. In the case of latched "STOP" or "EMERGENCY STOP" push buttons instructions for releasing the latch shall be included either on the legend plate or on the face of the button. Buttons shall be colour coded to AS 1431 Part 2, Table 5.4.1 or the Drawings. In addition, illuminated push button switches shall comply with requirements of Clause 207.20.

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207.10

Phase Failure Relays Phase failure relays shall be of the electronic type and shall detect under voltage (80% of nominal voltage), voltage or phase angle imbalance and reverse phase sequence. The sensing circuit shall reject signals of other frequencies, i.e. ripple control and spurious voltage spikes; either in the supply or induced by the protect loads. The relay shall be suitable for protecting motor loads under starting and running conditions. A LED shall indicate when the power supply is normal. Contacts shall have minimum rated operational current (Ie) of 5 A at 240 V a.c. to utilisation category AC-15. Each relay shall be individually protected by external protective devices of maximum 10 A rating.

207.11

Residual Current Devices (RCD) RCD's shall be current-operated (core balance) type to AS 3190. Rated trip current shall be 30 mA unless otherwise indicated. All equipment associated with an individual earth leakage circuit section shall be grouped together in a regular and logical manner.

207.12 207.12.1

A. C. Motor Starters General Unless otherwise indicated and except where limitations on starting current preclude their use, motor starters shall be of the D.O.L. type. Each starter shall be complete with overload protection incorporating at least one of the classes of motor protection described in Clause 207.12. Where indicated, further protective devices, as described by the classes of motor protection in Clause 207.12, shall be incorporated. Motor starters shall have the following minimum ratings: Rated duty Utilisation category Mechanical endurance One million on-load operating cycles Minimum 16 A current rating : : : intermittent duty 0.1 AC3 Class 10

The voltage rating of the coil shall be such as to be compatible with other components in the control circuit and the operating voltage applicable. Contactors used in motor starters shall be designed to allow the fitting of auxiliary contacts with minimum rating (Ie) of 4 A at 240 V a.c. AC 15 Motor starters shall be rated for motor full load currents and shall be suitable for operation in the enclosures used. Supply each motor starter with control field isolation terminals to disconnect power to the contactors. 207.12.2 Direct-On-Line Starters These shall incorporate a direct switching electromagnetic contactor together with overload protection relay, offering overload protection in each phase of the supply, suitable for starting motors "direct-on-line" in accordance with AS 1202 Part 1.

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207.12.3

Reduced Voltage Starters Reduced voltage starters shall be of the electromagnetically operated type complying with AS 1202 Parts 2 and 3, offering overload protection in each phase of the supply or motor circuit and incorporating the following features. (a) Star Delta Starter Star-delta starters shall include: (i) (ii) (iii) One (1) main line contactor or equivalent. Star and Delta contactors mechanically and electrically interlocked to prevent simultaneous operation. One (1) triple pole overload relay, fitted to the line contactor. Where the star-delta starter configuration is such that the overload is connected into the motor phase winding circuit, a nameplate shall be fixed to the starter stating the full load current of the motor phase wind, i.e. 58% of the full load line current of the motor. One (1) time delay relay with nominal 0-30 second adjustable time delay period to control the star to delta switching contactors. Where closed transition type starters are indicated, suitably rated stainless steel resistor banks, transition contactor and time delay relay shall be provided.

(iv) (v)

(b)

Auto-Transformer Starters Auto-transformer starters shall be parallel, closed transition (Korndorfer connections) type in accordance with Diagram B1, Appendix G of AS 1202, Part 3, utilising three poles of the star contactor ("K1"), Mechanical and electrical interlocking shall be employed between the star contactor ("K1") and the run contactor ("K3") to prevent simultaneous closing. Each auto-transformer starter shall include: (i) One (1) three core auto-transformer tapped at 50%, 65% and 80% and rated for enclosed operation. Provide Auto-transformers with insulation class 155 to AS 2768. Provide Auto-transformers suitable for a minimum of 12 starts per hour. House each auto-transformer in its own segregated compartment. One (1) triple pole thermal overload relay. Star, auto-transformer and run contactors (K1, K2 and K3). One (1) set of three embedded thermistors, complete with manual reset, operating relays and indicators, to protect the auto-transformer. One (1) time delay relay with nominal 0 to 30 second adjustable time delay period to control the start and run contactors.

(ii) (iii) (iv) (v)

207.12.4

Reversing Starters Reversing starters shall generally comply with Clause 207.12.1 and shall include: (i) (ii) (iii) Two (2) main line contactors, mechanically and electrically interlocked to prevent simultaneous closure. One (1) triple pole overload relay. One (1) time delay relay with nominal 0 to 30 second adjustable time delay period, to prevent plugging of the motor.

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207.12.5

Electronic Soft Starter Electronic soft starters shall comply with AS 1202 Part 5 and be selected from a manufacture with a range from 10A to 500A using a three wire rating. The starter shall incorporate the following features:(i) (ii) (iii) (iv) (v) Automatic restart in the event of failure. Breakaway torque adjustment. Motor starting current limit adjustment. Adjustable acceleration time. adjustable deceleration time.

The starter shall incorporate: (i) (ii) (iii) (iv) Phase loss trip. Shorted SCR trip Open circuit output trip. Motor stalled trip.

dV suppression and be capable dt of withstanding (min) 1400 VDC PIV: Temperature rating shall be 0-60 C minimum.
The starter shall incorporate a RL snubber network for 207.13 207.13.1 Motor Protection Devices Three Phase Motor Protection Three phase motors required by AS 3000 to have overload protection shall be protected, as indicated, by one or more of the means listed in Clause 207.13.2 and shall in all cases include thermal overload protection connected on the load side of appropriate contactor. The protection equipment shall operate in the event of: (a) (b) (c) (d) 207.13.2 Overloading in continuous or intermittent service. Extended acceleration times. Failure of one phase resulting in single phasing. Mechanical seizure of the rotor.

Motor Protection Thermal Overloads Thermal overload relays shall comply with AS 1023, Part 2 and shall incorporate the following features: (a) (b) An overload sensing element in each phase. Ambient temperature compensation shall be such that the temperature of the air surrounding the overload relay within the starter enclosure can vary over the range from 5C to 50C without effectively altering the tripping time of the relay. Single phasing detection by differential trip bar mechanism which shall operate at 60% of motor full load rating under single phasing conditions. An integral manual reset button. One N/O and one N/C auxiliary contact with minimum operational current (Ie) of 4 A at 240 V a.c. Except where operated separately by C.T.'s, T.O.L.'s shall be directly connected to contactor by "proprietary" links. C.T.'s used to operate T.O.L.'s shall be protection type, saturating at 10 to 15 times

(c) (d) (e) (f) (g)

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full load current, and shall comply with AS 1675, Class 10P. also refer to Clause 207.17. Note: Where used on fire-pump motors T.O.L.'s shall be used to indicate motor overload only. Thermistors Thermistors shall be installed in the motor winding as detailed in Clause 505. The thermistor protection relay shall be compatible with the thermistors installed in the motor and shall comply with AS 1023 Part 1. The relay shall have at least one (1) normally open and one (1) normally closed set of contacts rated at the starter control circuit voltage and minimum 4 A 240V ac AC 15. The contacts shall be connected to open the starter at the setting temperature. The control unit shall be of a type that does not reset following a power failure. The circuit shall be arranged so that failure of any thermistor by going very low resistance or open circuit or other component in the control system, or excessive winding temperature, results in the motor circuit being opened. In addition, on open, a circuit shall also trip. A manual reset device shall be provided to restore the motor circuit when tripped due to excessive winding temperature. A LED shall be installed on the thermistor control unit to indicate that the circuit is in normal operating mode. Electronic Motor Protection Relays Electronic motor protection relays shall incorporate the following features: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Single phasing protection and phase sequence protection. Thermal overload protection. Loss of load protection. Excessive motor run-up and stall protection. Earth fault protection. LED indication of fault conditions. Manual reset facilities. Adjustable settings of protection parameters (items (b) to (e)). One (1) normally open and one (1) normally closed set of auxiliary contacts with minimum current rating (Ie) of 4 A at 240 V a.c. AC 15. C.T.'s used to operate these relays shall be protection type, saturating at 10 to 15 times full load current complying with AS 1675 class 10P. The relay shall incorporate adjustment facilities to allow matching of C.T. characteristics. Also refer to Clause 207.17. Test facilities shall be incorporated to allow testing of the relay.

(k) 207.13.3

Single Phase Motor Protection Single phase motors required by AS 3000 to have overload protection shall be equipped with one of the following forms of overload protective devices: (a) Proprietary type integral overload units within the motor, sensing either motor winding temperature or motor current. Preference shall be given to overload units having manual reset facilities. Where motors incorporating integral overload units are installed in inaccessible positions, the overload devices shall be disconnected and, in lieu, one of the types referred to in (b) below shall be used. (b) Overload units generally meeting the requirements of Clause 207.13.1 with the three individual phase overload elements wired in series..

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207.14

Time Switches Time switches shall incorporate the following features: (a) (b) Electronic with quartz crystal control. Reserve power supply to operate time switch during mains supply failure shall have minimum capacity of 24 hours and battery reserves shall have minimum initial capacity of 100 hours and 10 year battery field life. Displays shall be digital with liquid crystal. Minimum 16 A AC-15, 140 V contacts.

(c) (d) 207.15

Hour Run Meters Hour run meters shall incorporate the following features: (a) (b) (c) (d) Minimum six digits, indicating up to 99999.9 hours. Digits shall be at least 3.5 high. A running indicator. Non reset type

207.16

Indicating Counters Indicating counters, eg number of starts counters, shall incorporate the following features: (a) (b) (c) (d) (e) Minimum 6 digits. Digits shall be at least 3.5 high. Continuous duty Non reset type. Surge diverters shall be fitted. Diverters shall be varistors min 4500A 100 joule 275 Volt.

207.17

Extra-Low Voltage Transformers Transformers shall comply with AS 3126. The following features shall be incorporated: (a) (b) The primary and secondary windings shall be brought out at opposite sides of the transformer case. The primary and secondary windings shall be separated by means of an earthed screen: this screen shall be brought out to an insulated terminal where the transformer is installed in a double insulated situation. The output loading shall not exceed 80% of the transformer continuous rating. Note that such rating shall take account of the degree of ventilation and ambient temperature of the transformer and supplied load.

(c)

207.18

Current Transformers (CTS) (Not Applicable to Supply Authority Equipment or Protection CTS) Current transformers shall be resin encapsulated window type and shall comply with AS 1675. The following details shall apply: (a) (b) Rated primary current shall have a current rating equal to the maximum current rating of the frame size of the controlling device. Secondary windings of measurement current transformers shall be rated at 5 A. The burden shall be 0.4 ohms (10 VA) minimum and the accuracy shall be class 2 minimum.

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(c)

Secondary windings of protection current transformers shall be rated 5 A and shall be suitable for burden.

Current transformers shall be capable of withstanding the indicated switchboard fault level for the appropriate time of duration and shall be suitable for operation in an ambient temperature of 30C with a temperature rise of 75C. Where fitted on busbar systems each C.T. shall be fitted on removable links to allow easy removal from the switchboard. Where fitted on cables C.T.'s shall be installed to allow easy removal from the switchboard. Where C.T.'s are associated with ammeters M.D.I.'s or energy meters, each C.T. shall be provided with test link terminals. 207.19 207.19.1 Meters and Associated Controls (Not applicable to Supply Authority Equipment) Voltmeters, Ammeters, Maximum Demand Indicators and Associated Controls Meters shall comply with AS 1042 and the following details shall apply: (a) (b) (c) (d) (e) Flush mounting. Accuracy class 1.5 (minimum). Meter movements shall be jewel and pivot or taut band type, with oil damping. Impact resisting anti-glare face. Voltmeter transfer switches shall be seven position type with positions designated R-W/W-B/B-R/OFF/R-N/W-N/B-N and shall be mounted under or adjacent to the relevant voltmeter. Also refer to Clause 207.9.3. Ammeter transfer switches shall be four position type with positions designated R/W/B/OFF and shall be mounted under or adjacent to the relevant ammeter. Also refer to Clause 207.9.3 Meters shall be minimum 72 square bezel with 90 degree quadrant scale. Meter scales shall be direct reading. Meters shall be mounted on hinged panels and wired with maximum 6mm2 cable. Where associated exclusively with one phase, meters shall be labelled "RED", "WHITE" or "BLUE" as applicable. Potential protection devices for meters shall be grouped together behind a cover or hinged door, preferably adjacent to the current transformer test links. Ammeters subject to motor starting currents shall be overscaled a minimum of five times. Meter scales shall be as indicated. Ammeter scales shall be selected such that running current is at 45 approx. Maximum demand indicating meters shall have a 15 minute response time and provision for sealing of the reset mechanism. Where M.D.I. metering is indicated, a meter in each phase shall be provided. An accuracy of Class 3 is acceptable.

(f)

(g) (h) (i)

(j) (k) (l) (m)

207.19.2

Energy Meters These requirements shall apply to rotating element induction type meters designed to register kWh. Meters shall be general purpose type complying the AS 1284 Part 1. Where metering is on three phases a polyphase meter shall be used. For two or one phase metering single phase meters shall be used. Meters shall be selected to suit load and probable overload conditions. Whole current meters shall be 15 to 100 A current rating and meters supplied with current transformers shall be suitable for 5 A secondary.

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Registers shall be large figure cyclometer type and shall be direct reading. Meters shall be supplied with calibration error figures and shall have the main cover sealed. Calibration error figures shall be supplied to the Superintendent together with relevant technical data and wiring diagrams. 207.20 Indicating Lights Indicating lights shall be of the oil-tight type with heat resistant plastic or glass lens. Size classification shall be uniformly D30 or D22. Lamps shall be maximum 28 V incandescent type supplied from integral or separate transformer and shall be suitable for the indicating light used with maximum rating of 1.2 W. Higher voltage globes shall be used where available e.g. 28 V globes for 24V. Lamps shall be changed from front of switchboard and lampholders shall remain rigidly fixed in panel during lamp changing. Lamps shall not become disconnected under conditions of vibration. Three (3) spare lamps per 10 indicating lights or part thereof and tools for removal of lamps (if applicable) shall be provided. Indicating light colours shall comply with AS 1431 Part 2, Table 5.3.1 (A) "Colours of indicating lights and their meanings" or as per the drawings. 207.21 Variable Speed Drives The following clause applies to VSDs controlling 415V, 3 phase, squirrel cage induction motors: The adjustable speed electrical power drive system (PDS) shall comply with AS61800.3 and shall comply with intended use sub clause 3.2.2 (second environment) and sub clause 3.2.5 (PSS of Category C3). Compliance with Australian EMC Framework C Tick is also required. The VSD shall be suitable to drive its associated motor throughout its entire speed range under all conditions of operation to achieve: Continuous and smooth operation through all speeds Torque speed curves which rise continuously with increasing speed with variable torque which increases with increasing speed and flat torque speed curves for constant torque loads Correct operating and commutation characteristics Minimum ripple current, motor heating and noise generation Correct running and starting sequences Ability to operate on a 3 phase input voltage of 415 V a.c. with prolonged periods of 440 V a.c. Suitable for 3 phase, 415 V a.c. motors of the ratings specified in the contract documentation Minimum a.c. network harmonic distortion within the limits required by the Electricity Supply Authority or as specified in AS 61000, whichever is the more onerous. As well, the maximum level of total harmonic current distortion shall be no greater than 5%.

. One VSD unit shall be dedicated to each variable speed driven motor. Cabling for VSDs Control cables shall be shielded/armoured with the shield connected by means of a cable clamp at both ends to the metal enclosure.

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Control cables and the filtered line cable shall be installed separately to the motor cables at a distance of separation as large as possible and in accordance with the manufacturers recommendations. Motor cabling specifically designed to suit the requirements of the variable speed drive shall be used. Such cables shall have features which reduce the transmission of electromagnetic interference. Air Conditioning Where installed outdoors, switchboards containing VSDs shall have one suitable air conditioning unit per VSD. Where installed indoors, the room containing the VSD(s) shall be suitably air conditioned. The level of air conditioning shall be such that the temperature at the VSD does not exceed the maximum allowable operating temperature of the VSD minus 5 degrees Celsius. Starting Limitations Each speed controller shall be capable of starting its motor from rest for all speed settings without exceeding a supply current of twice full load current of the motor and shall be able to achieve this starting current without falsely tripping or operating any protective device or overheating the motor. Motor Insulation Considerations When selecting the VSD, protection against damage to the motor windings and bearings shall be provided to meet the recommendations of IEC 60034:17 for limiting the maximum peak voltage and the rise time at the motor for up to 150 metres of screened cable. The use of soft switching of the insulated gate bipolar transistor or provision of output filters to limit the peak voltages is acceptable. Additional Filters Where indicated in the documentation, make provision for advanced harmonic filters and wave filters to ensure. Filtering equipment shall meet the manufacturers recommendations for the application. Single Phase Fault Response The VSD shall be capable of Autoderating when losing a single mains phase and recover upon the restoration from the single phase fault. Hence, the VSD shall neither trip nor require to restart upon a temporary single phase fault. Power Supply Each speed controller shall be suitable for operation from a 415V, 3 phase, 4 wire, 50 Hz supply having a prospective fault level of at least 50kA as far as thermal and magnetic overcurrent effects are concerned and a voltage tolerance of plus or minus 10% and rating to suit the motor and drive selected. Efficiency The speed controller will be required to control the speed of the unit within close tolerance of speed setting with maximum efficiency. The V/F output curve of the VSD shall match the V/F profile that the load curve of the driven mechanical item requires. This is, the load curve of the driven item shall be matched by an adjustable V/F output curve of the VSD, in order to save energy that would be wasted if the V/F ratio of the voltage output of the VSD and the V/F profile that the load curve of the driven mechanical item requires are different. Accuracies The speed controllers shall be designed such that the drive speed is independent of load conditions, motor iron losses and fluctuations in supply voltages and frequency in order to give good speed stability and accurate speed control with motor current limited to a safe

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level for all speeds. The speed shall be controlled to within plus or minus 2.5% of input speed for a range of 10% to 100% speed. Harmonics Generated harmonics shall be limited to one third of the limits set down in AS 61000 and as required by the Supply Authority through appropriate design of equipment and any devices necessary to achieve this, such as capacitors and/or inductors. For the purpose of the design of the harmonic filter components, use the current actual fault level of the installation. For the purpose of thermal and magnetic ratings against fault overcurrents, assume a fault level rating of 50kA unless otherwise specified in the documentation. Care shall be taken in the harmonic filter design to ensure that there is no interference which may cause malfunction with other electronic equipment in the switchboard. The maximum total harmonic current distortion shall be 5% or less. Filters shall not cause power system resonance nor attract harmonics from other non linear loads. Filters shall meet the requirements of IEEE-519. As an alternative to providing dedicated harmonic filters for all drives, filtering can be provided such that the whole of the installation meets the requirements of the Supply Authority, AS61000 and the limitation of total harmonic current distortion of less than 5%. Status and Faults Provide the following fault indication with reset provisions for each fault: Earth fault in motor Input undervoltage fault Input overvoltage fault Over temperature fault Output overcurrent Regeneration overcurrent

Provide the following status: Remote Trip Power on Unit enabled Acceleration limit operating Deceleration limit operating Unit at zero speed

VSDs shall be able to drive a 0-5/10 Vdc meter with a voltage signal which shall be linearly proportional to load motor frequency. Programming Aspects It shall be possible to upload/download to copy the set up program from one VSD to another. Provide an operating keypad on each VSD which is detachable so as to provide upload/download functionality which allows the copying of one set up program from one VSD to another. Electromagnetic Interference Electromagnetic interference emitted by the equipment shall be within the limits stipulated by AS 61800.3. Provide RFI filters for each of the motor drives. Converter Stage The converter stage shall include a full wave bridge rectifier and any required line side short circuit protection. The converter stage shall also include all supply line voltage surge

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filtering, RFI filtering and line side harmonic filtering. For converter stages which comprise controlled rectifier bridges include all required auxiliary control equipment and firmware. DC Link Stage The DC link stage shall comprise all control and monitoring devices required to establish DC voltage and current conditions applicable to the type of inverter used. Inverter Stage The inverter stage shall provide dc to ac inversion at the voltage and frequency appropriate to the speed setting. All control and monitoring including capacitors, inductors and components required by the methods of modulation and commutation shall be included. The inverter stage shall include the motor protection and monitoring devices including thermal overload and thermistor relays. The converter, link and inverter stages shall incorporate protection devices and circuitry to ensure maximum reliability under all operating conditions. Degree of Protection For stand alone enclosures, the degree of protection shall be IP51. Single Phase VSDs Single phase VSDs providing a three phase output are permitted up to a maximum size motor of 0.37kW. 207.22 Audible Alarm Devices Audible devices such as buzzers, small bells or electronic alarms shall be suitable for the application. Where several different alarms are included in one location and where distinction between alarms is required immediately, different tones or devices shall be used. 207.23 Terminals Terminals shall be screw tightened, clip-on, 32 DIN rail mounted, flexible, non-flammable and, as a minimum, suitable for the insertion of blade of a screwdriver width 3mm. The cable shall be secured by a moving plate actuated by the screw. Direct contact of the screw to the wire is not permitted. For up to cable size 70mm, terminals shall be from the same manufacturer and shall be capable of accepting the indicated cable size plus a minimum of 10%. Above 70mm cable size, terminals shall be of the stud type fixed to the switchboard (not rail mounted). Terminals shall be located such as to provide easy access to outgoing terminations, with cable holes clearly visible. Mounting rails shall be riveted or screwed to the switchboard at not more than 500 centres and shall be of sufficient length to accept a further 20% terminals or 3 terminals, whichever is the greater. For each type of control terminal, install on the mounting rail 10% spare terminals or 3 terminals, whichever is the greater. Terminal rails may be used as earthing conductors only if they are aluminium and earthed separately to the main earth. Maximum rating of rail shall be 80A. 207.24 Locking Where lockable doors are indicated, locks shall be "keyalike" "E" type DPWS, or approved alternative. Two keys shall be provided for each switchboard. Lock handles and surrounds shall be nickel or chromium plated. 207.25 Ambient Temperature

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All outdoor SCA equipment shall be rated for an external air temperature of 45 C. All indoor SCA equipment shall be rated for an external air temperature of 40 C. Relative humidity shall be 0-90% non-condensing.

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208
208.1

SWITCHBOARD CONSTRUCTION
Generally For Proprietary Assemblies, manufacturer's standard construction may be accepted. Cubicles shall be sized to suite the location and purpose and shall be fitted with removable access covers. The arrangement of equipment within each section shall be such as to allow easy access, maintenance and, where applicable, adjustment. All terminations shall be visible from the front, or the rear of the cubicle for rear access switchboards. Internal equipment shall be mounted on equipment mounting panels. Suitable supports (e.g. cable trays or adequate support straps) shall be provided within switchboards for all external cabling. As far as practicable such supports shall be located along the entire cable route length. Adequate space shall be provided within each switchboard to accommodate all cables and cable terminations. Cables gland plates shall be fitted from within the cubicle with adequate room for access to the plates. Plate shall be 5mm thick aluminium. Switchboards mounted externally shall not be provided with top cable entries. To prevent the ingress of dust, ventilation louvres shall not be provided unless required to cool heat developing equipment such as ballasts and transformers. If ventilation louvres are fitted they shall be metal screened to minimise vermin entry and maintain the IP rating. Wall mounted switchboards shall be provided with an adequate number of M10 clearance fixing holes. However, not less than four fixings per switchboard shall be provided. The holes shall be clear of all switchboard equipment, readily visible and accessible from the front with the switchboard covers removed. All wall mounting switchboards shall contain additional internal reinforcing to prevent distortion of the cubicle after mounting and through which the fixing bolts shall pass. Floor mounted switchboards shall be mounted on a full perimeter minimum 75 high x 40 wide x 6 thick mild steel channel base. The base shall be drilled with at least four M12 clearance holes per channel base section to allow fixing of the switchboard to the floor. Fixing holes shall be positioned to allow easy access to all floor mounting bolts. Additionally, the base shall be hot dipped galvanised to AS 1650 to a minimum thickness of 85 micrometres and shall not be painted. As an alternative to using fixing holes and bolts floor mounted switchboards may be clamped in position using suitable galvanised clamps internal to the switchboard. Mechanical equipment containing fluids or steam such as pressure gauges, pressure switches, etc., shall not be installed in these switchboards. In the case of pneumatic controls they shall be located generally in a separate panel except when of a minor nature.

208.2

Externally Mounted Switchboards Externally mounted switchboards shall have a minimum degree or protection IP 56. If the externally mounted switchboard contains a variable speed drive unit, air conditioning of the outdoor switchboard shall be provided. Switchboards, with an overall volume 1m shall be fitted with ventilation louvres located at the top and bottom of the vertical surfaces and which maintain the IP ratings. Openings in the enclosure shall be flanged to prevent the entry of water running down the vertical surfaces when any cover or door is open. Drain holes shall be provided in the bottom of the enclosure and shall be metal screened to minimise vermin entry and to maintain the IP rating.

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Where an outer roof is indicated, it shall be spaced from the top of the enclosure by a ventilated air space. The outer roof shall overhang the enclosure by 50 on all sides, shall have a minimum pitch of 5 away from all openings a nd shall be provided with a gutter at all openings. The top of the enclosure, or the outer roof where fitted, shall be free of openings, bolts, rivets or other penetrations and shall have sufficient strength to support a person without distortion. Thermostatically controlled anti-condensation heaters shall be fitted to weatherproof switchboards with an external surface area in access of 4m, and shall be on the basis of 10 watts/m of exposed surface area. Anti-condensation heaters shall be of the black heat type, shall be able to be touched without harm and shall be mechanically protected. 208.3 General Cubicle Construction Cubicles, covers and doors shall be manufactured from zinc coated sheet steel not less than 1.5 thick except for exterior surfaces of weatherproof switchboards where marine grade sheet aluminium not less than 2.0 thick shall be used. Marine grade sheet aluminium shall be grade "5251 H34" with finish "MILL". Panels forming the body of the cubicle shall be straight and of sufficient rigidity to prevent warping and excessive flexing with or without covers and doors fitted. Cubicles shall be all-welded construction, with sheets bent to minimise the number of welded joints. Consideration will be given to non-welded forms of construction but written acceptance shall be obtained from the Superintendent before manufacture. Edges shall be rounded to remove sharp or irregular projections, etc. Internal equipment panel supports shall be heavy metal angles or plates bolted or welded to the cubicle sides. For earth continuity, serrated washers shall be placed under bolt heads and nuts of all painted, structural metal-to-metal contact points. Equipment mounting panels shall be minimum 2.6 thick and equipment shall be mounted by studs brazed to the panel or be set screws into proprietary threaded inserts. Alternatively, small items (e.g. relays) may be set screw fixed into tapped holes in the panel. Mounting of equipment panels shall be by minimum M6 plated steel screws. All metal in contact shall be as close as possible on the electrochemical series to minimise corrosion due to dissimilar metals in contact. 208.4 Construction of Covers and Doors Covers and doors shall be manufactured with right angle welded corners, shall be straight and of sufficient rigidity to prevent warping and flexing when fitted to, or removed from, cubicle. The construction of covers and doors shall allow easy removal and replacement. Covers shall fit neatly to expose only the toggles and escutcheons of flush mounted equipment, but shall allow interchangeability of 1, 2 and 3 pole circuit breakers. All covers and doors shall be fitted with neoprene seals around openings for breakers. The minimum requirement for doors and covers shall be a single right angle return on all four sides, with adhesive U-section sealing rubber or other accepted means to prevent paint damage. For Custom-built Assemblies the seal shall be a neoprene section. Foam rubber shall not be used. The surfaces involved in forming the seal shall be at least as wide as the sealing strip, a minimum of 12, and the seal shall be effectively retained in a U-channel section.

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Each cover shall have a minimum of four fixings, each consisting of an M8 plated stud fixed to the cubicle and fitted with a serrated star washer and a nickel or chromium plated acorn nut. All edges of all covers shall rest on the cubicle body or on a mullion. Interlocked covers are not acceptable. All covers shall be fitted with chromium plated "D" type handles. Doors shall be fitted with chromium plated pintle hinges, and doors above 1m in height shall have three hinges. Doors which are removable shall have staggered pin lengths to achieve progressive engagement as the door is fitted. Non lift-off doors shall have the hinges opposed and shall be fitted with a restraining device to prevent damage to adjacent surfaces or equipment. The arrangement of door mounted equipment shall allow for ease or operation. All equipment and terminals on the inside of doors shall be shrouded or otherwise protected to prevent inadvertent contact with live terminals and/or wiring. An insulated panel covering the equipment is an acceptable method. Doors shall have a maximum width of 900, be hinged on a vertical side and be fitted with a stay to hold the door open at minimum angle of 120o. 208.5 208.5.1 Spacing and Mounting of Circuit Breakers Generally Circuit breakers shall be mounted in a regular and logical manner with the toggles operating in either the vertical or the horizontal plane. When operating vertically the "on" position shall be uppermost. Circuit breakers with interchangeable trip units shall be connected so that the trip units are not "live" when the circuit breaker contacts are open. 208.5.2 Circuit Breakers Not Larger than 160 Amps Adequate and unimpeded space for access to external cabling is required around multipole proprietary busbar assemblies in switchboards. Clearances shall be measured from the return edges or folds of the cubicle to the busbars or circuit breakers, whichever is the lesser. The following are minimum requirements. (a) (b) On all sides of a busbar assembly a clearance of 100 shall be provided, except where a switchboard compartment contains a total of more than 60 poles, a clearance of 150 on all sides of a busbar assembly shall be provided.

208.5.3

Circuit Breakers Larger than 160 Amps Adequate uninterrupted internal air space shall be provided for the natural convection cooling of all circuit breakers. The volume of the total possible number of circuit breakers shall not exceed 25% of the volume of the compartment, unless verification in the form of an approved Testing Authority Test Report is available proving that circuit breakers can successfully operate at full load under more compact arrangements.

208.5.4

Circuit Breakers of the Drawout Type Each circuit breaker shall be housed in an individual compartment in accordance with the manufacturer's recommendations.

208.6

Spacing and Mounting of Fuse Combination Units FCU's shall be arranged in a regular and logical manner and connected such that the fuse links are isolated when the switch contacts are open.

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The extended operating handle of an FCU shall, in any position, remain clear of all other equipment and be not less than 100 from the floor. 208.7 Space for Future Circuit Breakers and Fuse Combination Units Where space is provided for future circuit breakers and FCU's the switchboard shall be fitted with the necessary holes, connection studs and busbar connections to allow installation and connection. Front covers shall have all necessary cut-outs for the future equipment and individual or proprietary blanking plates shall be fitted. Blanking plates shall be installed such that when removed and the equipment fitted, no unused holes are visible. Fixing of blanking plates by adhesive material is not acceptable. 208.8 Mounting Heights (a) (b) No equipment or cable termination, other than neutral and earth links, shall be mounted less than 200 from floor level. Mounting heights above floor level of fuse links and toggles of circuit breakers and fuse combination units shall be between: (i) (ii) (c) 300 and 2000 for Custom-built Assemblies Type CT and CU 200 and 2000 for Custom-built Assemblies Type DT,DU,DUPLUS& DTPLUS.

Mounting heights above floor level for control switches, indicating lights, meters and other equipment requiring operator interface or viewing shall be between: (i) (ii) 300 and 1700 for Custom-built Assemblies Type CT and CU 200 and 1800 for Custom-built Assemblies Type DT,DU,DUPLUS& DTPLUS.

208.9

Extra Low Voltage Extra-low voltage control circuits shall preferably be 24 volts a.c. or 24 volts d.c.

208.10

Auto-transformer Compartment Each auto-transformer of an auto-transformer motor starter shall be located in a separate ventilated compartment segregated from the remainder of the switchboard cubicle by steel partitions. This separate compartment may have a minimum degree of protection IP 41.

208.11

Arrangement of Equipment (a) Switch/control gear shall be mounted on horizontal combination rail and shall be set out in a logical manner in functional groups which shall be separated by cable ducts or an equivalent space. The following minimum requirements shall apply: 180mm centre to centres spacing between rows of equipment. (b) (c) All internal cabling shall be run in slotted ducts. Readily accessible terminals grouped in conventional locations shall be provided for the connection of all external control cables and out-going power circuit cables. These terminals shall be labelled to correspond to the identification shown on switchboard workshop drawings. Control switches, indicating lights, meters and other equipment requiring operator interface or viewing shall be set out in a logical manner in functional groups and shall be able to be accessible without the use of a key (to be able to be operated).

(d)

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209
209.1

PAINTING OF SWITCHBOARDS
Generally Proprietary assemblies shall be painted in accordance with the manufacturers standard except that the external colour of the assembly shall be orange X15 and the internal colour and escutcheon colour shall be off white Y35. All metal surfaces of the switchboard cubicle and covers shall be painted. Stainless steel, electroplated, anodised or galvanised equipment mounting panels need not be painted. Insulating materials, and door and cover sealing strips shall not be painted.

209.2

Paint Materials All paint and other preparations shall be of the best quality, non-poisonous, lead-free synthetic products, conforming to the relevant Australian Standards. Paint materials shall be used strictly in accordance with the manufacturer's recommendations.

209.3

Surface Preparation Where the protective coating of any steel surface is removed through welding, grinding, etc., the standard of surface preparation shall be to AS 1627 with minimum power tool clean to grade "St 3", followed by the application of a cold galvanising compound. Surfaces shall be degreased using solvent or alkaline solutions.

209.4

Painting and Finish One coat of etch primer having a suitable corrosion inhibiting compound shall be applied. If required, a putty sealer, rubbed back to cover major imperfections, and undercoats rubbed back to cover minor imperfections shall be applied. Undercoats shall be applied as a base for the final coats unless otherwise recommended by the paint manufacturer. The finish shall be full-gloss heat cured enamel or 2-pack polyurethane paint which shall be applied on internal and external surfaces in accordance with the manufacturer's recommendations to achieve a completely smooth finish with no noticeable imperfections. Minor paint surface ripple due to the use of galvanised sheet steel will be accepted. The minimum thickness of the finished paint coating shall be 60 micrometres for indoor switchboards and 90 micrometres for weatherproof switchboards. Minimum pencil lead hardness factor shall be "H" to AS 1580 (method 405.1). Switchboard colours shall comply with AS 2700 and shall be: (a) (b) (c) Indoor switchboards Weatherproof switchboards Removable equipment panels X15 orange G52 eucalyptus Y35 off white

210
210.1

LABELLING OF SWITCHBOARDS
Generally Every switchboard, switchboard control, contactor, time switch, relay, indicator lamp, meter, motor starter, link and any control or protection equipment within or on a switchboard shall be clearly and accurately labelled under the equipment. Labels shall be engraved laminated plastic and shall comply with the following requirements:Except where otherwise required, labels shall not be on any item of equipment.

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Exterior labels associated with door mounted components (eg. indicating lights) shall be mounted directly beneath that equipment. In addition, circuit reference labels shall be fixed on the inside of the door adjacent to the equipment. Engraved lettering shall be black on a white background, except that the label for a main switch shall have red lettering on a white background, and warning and caution labels shall have white lettering on a red background. The minimum height of lettering shall be 3 and of sufficient definition to allow easy reading. 210.2 Fixing of Labels Labels shall be securely fixed by: (a) (b) (c) Screws and adhesive, or Fixed in an extruded aluminium section which shall be countersunk screw fixed or countersunk riveted to the panel. Plastic drive pin and adhesive.

Screws shall be tightened with nuts or into tapped holes in the switchboard. Mechanically expanded plastic rivets of minimum 6 head diameter are acceptable instead of screws. Aluminium or monel rivets may be used to fix aluminium labels only. Self-tapping screws, thread-cutting screws or other fixing are not acceptable. 210.3 Labels on Exterior of Switchboards and Schedules All switchboards shall be labelled with the manufacturer's name and the manufacturers type designation or identification number or other means of identification making it possible to obtain relevant information from the manufacturer. Custom-built Assemblies shall be provided with a name plate containing the following minimum data to AS/NZS 3439.1:2002: The manufacturers name The manufacturers type designation or identification number Rated Operational Voltages Rated Main Busbar Current Rated short-time withstand current of the Main Busbars Short-circuit withstand strength of the Assembly (see 7.5.2 of AS/NZS 3439.1:2002) Degree of Protection Form of Separation This documents classification of the switchboard (eg. NSW Dept of Commerce - MEW E101-Custom-built Type DT )

A switchboard designation label shall be provided (eg. West Haven Sewage Pumping Station No. 3 - Main Switchboard). For other than main switchboards, the designation label shall also state the source of electrical supply. Separate sections of enclosures shall be identified. The label for any section or enclosure containing Supply Authority equipment shall be to the satisfaction of the Superintendent and the Supply Authority. Every switchboard control shall be labelled and shall include:(a) (b) (c) (d) Circuit designation for all main switches, main controls and submain controls. Details of consumers mains and all submains. Incoming busbar or cable rating to the first tee-off. Fuse link size fitted to each FCU.

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For uniformity, the labels shall agree with the following examples and be of the minimum lettering height shown:

ITEM Main Switchboard Distribution Board Main Control on a Main Switchboard Submain Control Main Control on a Distribution Board Control for Section of Switchboard ELCB Control for Section of Switchboard

ENGRAVING EXAMPLE MAIN SWITCHBOARD DISTRIBUTION BOARD 3 (SUPPLIED FROM MSB) MAIN SWITCH
SUBMAIN CONTROL TO DB 3

MINIMUM HEIGHT 10 8 3 6 3 6 6 3 6 3 3 3 3 3 3

LOCAL MAIN SWITCH MAIN CONTROL SECTION NAME MAIN CONTROL ELCB PROTECTED CIRCUITS SECTION NAME Cu Al 8 x 1 CORE 150mm Cu PVC/PVC INCOMING BUSBAR (or CABLE) TO FIRST TEE-OFF: 800A FAULT CURRENT LIMITERS BEHIND 160A FUSES SPARE FUSES/PARTS BEHIND RED, WHITE & BLUE

Copper Aluminium Cable Designation Incoming Busbar (or Cable) Rating Fault Current Limiters behind cover F.C.U. Fuse Link Size Spare Parts Section Phases

3 3 6 3

For identification of final subcircuits, a typed schedule, cross-referenced to the lighting and power layout plans, shall be provided. The schedule shall be protected by a plastic sheet and fixed in a suitable frame mounted on the inside of the relevant switchboard door of, if the switchboard has no door, on the wall immediately adjacent to the switchboard. Refer to Clauses 114.5 and 214. 210.4 Labels on Interior of Switchboards Labels identifying equipment within a switchboard shall be located such that the item referred to is obvious and the lettering is not substantially obscured by the temporary or permanent position of any equipment or wiring. For plug-in equipment where items are physically but not functionally interchangeable, the label wording shall be expanded to clearly identify the removable section (e.g. to identify the contact configuration or timing range). Where this is not possible, a second identifying label shall be glue fixed to the removable section. The function and coding shown on the circuit diagram shall be used. The MEN link shall be labelled or stamped and infilled MEN LINK on the link. Labels for fault current limiters shall indicate the rating of the fuse links fitted, for example: FAULT CURRENT LIMITERS 160A. 210.5 Warning Labels Where copolymer membrane coating is used anywhere on live conductors without further insulation, a warning label shall be provided on the front cover near the main switch or

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local main switch and in a prominent position within each section of the switchboard. The label shall have the following wording in 6 high lettering: WARNING PAINTED COATING ON BUSBARS OR TERMINATIONS IS NOT INSULATION In each section of a switchboard containing fault current limiters, a warning label as follows shall be fixed adjacent to the fault current limiters: WARNING DO NOT REPLACE FAULT CURRENT LIMITERS UNTIL SOURCE OF FAULT HAS BEEN CLEARED, REPLACE ONLY WITH IDENTICALLY RATED FUSE CARTRIDGES Should any item of equipment on a switchboard not be isolated by the main switch or local main switch (eg a relay fed from another switchboard) a warning label shall be provided adjacent to the equipment. An example of a suitable label is: WARNING ORANGE WIRING IS NOT CONTROLLED BY THE MAIN SWITCH ON THIS SWITCHBOARD If a stand-by power supply is installed, an appropriate warning label shall be fixed at the main switch or local main switch. An example of a typical label is: WARNING IN THE EVENT OF LOSS OF NORMAL SUPPLY A.C. GENERATOR SET WILL AUTOMATICALLY START AND BE CONNECTED TO THIS SWITCHBOARD When anti-condensation heaters are fitted, a label shall be provided at each heater reading: WARNING THERMOSTATICALLY CONTROLLED ANTI-CONDENSATION HEATER - DO NOT SWITCH OFF

210.6

Special Label on Custom-built Assemblies Where the removal and non-replacement of any insulation or shrouding during normal switchboard maintenance could lead to the possibility of arcing faults, a label with appropriate wording shall be provided for each function unit. An example of a suitable label is: WARNING REPLACE LINE SIDE SHROUDS AND INSULATING MATERIAL BEFORE REACTIVATING These labels shall be positioned to be readily seen, adjacent to, or in impracticable, on the busbar chamber covers of functional units, and also behind the front cover of functional units. A circuit identification label shall be provided in the cabling chamber of each functional unit. This label shall be positioned adjacent to the external terminations.

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211
211.1

INSPECTION AND TESTING

Generally The following clauses refer to inspection and testing which shall be performed in the factory or on site, as indicated. Final inspection and testing will be carried out on site. The provision of all required testing apparatus shall be the responsibility of the Contractor. Witnessing of any or all tests will require ten working day minimum notice of all tests.

211.2

Inspection Normally Serial "A" and "B" switchboards will be inspected on site. If indicated, a factory inspection of fully assembled switchboards will be carried out at the place of manufacture. Inspection of fully assembled Custom-built Assemblies will be carried out at the place of manufacture. Ten working days minimum notice shall be given for a factory inspection.

211.3

Residual Current Equipment Testing A functional check of residual current equipment on completed switchboards shall be performed before delivery to site. Suitable testing apparatus shall be used which, as a minimum, shall consist of an adjustable resistance and a.c. millimetre to produce an out of balance current adjustable between 5 mA and 40 mA through the toroid.

211.4

Dielectric Tests The dielectric tests described in AS/NZS 3439.1:2002 shall be performed at the factory or, if indicated, on site, except that the duration of the application of the test voltage shall be 60 seconds. A verification of insulation resistance test in accordance with clause 8.3.4 of AS 3439.1:2002 shall be carried out before and after the dielectric test. The resistance shall be recorded. The tests shall be carried out between all live parts and the frame of the SCA and also between each pole and all other poles connected to the frame of the SCA. For the tests, either close all switching devices or apply the tests successively to all parts of the circuit. Any equipment which is not rated to withstand the tests shall be nominated by the tester and either disconnected or otherwise protected during testing. With Proprietary Assemblies a 1 kV d.c. test is required and for Custom-built Assemblies both 1 kV d.c. and 2 kV r.m.s. a.c. tests are required. Tests shall be conducted with all functional unit isolators switched "on". Special care must be taken to isolate equipment which could be damaged during the tests.

211.5

Functional Testing Prior to delivery to a site a check of all switchboard equipment shall be performed. This check shall include the manual operation of all switches, circuit breakers, F.C.U.'s, contactors etc. Following the above check, functional testing shall be performed to ensure satisfactory operation of all interlocking, control protection and alarms. Where necessary, appropriate input and output devices shall be used to simulate external circuit conditions.

211.6

Checking of Safety Measures and Electrical Continuity of Earthing Circuit Prior to delivery to site all safety measures against direct and indirect contact with live parts shall be checked and the earthing circuit shall be checked for compliance with requirements of AS/NZS 3439.1:2002.

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212
212.1

DRAWINGS
Generally Each drawing shall have a discrete number. Resubmitted drawings shall be identified by a different suffix added to the drawing number for each re-submission, and a dated notation shall appear on the drawing indicating all changes which were made for each resubmission. All abbreviations shall be in accordance with AS 1000. Drawings shall conform to AS 1100 Drawing Practice, SAA HB7-1993-1989 Engineering Drawing Handbook, AS 1102 Graphical Symbols for Electrotechnology and AS 1103 Diagrams, Charts and Tables for Electro-technology and AS3702-1989. Printing shall be minimum 2.5 high. Drawings shall be prepared on ISO standard drawing sheets size A1 or A3. For Proprietary Assemblies, details may be submitted in the form of drawings, engineering schedules and/or correspondence each quoting numbers and issue identification of endorsed standard drawings. In the case of Custom-built Assemblies, all information shall be on a drawing. Equipment schedules shall be in drawing form. Proprietary Assembly drawings shall be on sheets separate from Custom-built Assembly drawings.

212.2

Switchboard Drawings and Equipment Schedules Drawings and equipment schedules shall be submitted containing the following information: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Manufacturer's name, address, postcode and telephone number with STD code. Switchboard designation (e.g. Main Switchboard) and classification (e.g. Custombuilt Type CU). Indicated input fault level. Overall dimensions of the switchboard and any separate enclosures (e.g. cable termination enclosure). If surface or flush mounted. If a door is fitted, and if so the hinge side of the door. Confirmation of external paint colour. Quantities and full details of all equipment, i.e. brand names and full catalogue numbers of equipment associated with each individual circuit and drive. Proprietary circuit breaker busbar manufacturer's name, number of poles and continuous current rating. Nameplate data (as per 210.3)

212.3

Additional Information on Custom-built Assembly Drawings The following shall be shown in addition to that required by Clause 212.2: (a) (b) An overall line diagram and circuit diagrams of main, auxiliary circuits, starters and control showing wire numbers, terminals, terminal numbers and all equipment. One complete general arrangement and wiring diagram for each different switchboard. Typical diagrams and cross-references are not acceptable unless switchboards are identical. Full details and sizes of the consumers mains and submains, and termination routes of these within the switchboard by means of dashed line.

(c)

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Part 2 - Switchboards and Associated Equipment

(d)

Spacing between proprietary circuit breaker busbar assembles and spacing between these assemblies, the switchboard cubicle and other equipment, either to scale or by dimensioning. Proposed numbering of all circuit breakers, F.C.U.'s and the associated neutral and earth links. The trip or fuse rating of circuit breakers and F.C.U.'s, together with the actual frame ratings derated due to duty or physical arrangement (e.g. 100A fuse/130A frame). Details of all busbar and internal interconnecting cable sizes, spacing and configuration. Details of busbar supports including materials, sizes, spacing and fixing methods. Details of all internal segregations. Clearance dimensions between the switchboard surfaces and permanent obstructions including the walls, ceiling and floor. Doors and hinged covers shall be shown in the open position and withdrawable equipment shall be shown racked out.

(e) (f)

(g) (h) (i) (j)

212.4

Drawings Produced by Modification of Exhibited Drawings (Exhibited drawings are defined to be drawings which are part of the original documentation.) Drawings which are produced by modification of exhibited drawings shall be based on a clean print of the exhibited drawing which shall contain modifications and additions neatly marked up in red pen. These marked up drawings shall be signed by the contractor. Five copies of these drawings shall be supplied.

212.5

New Drawings Submitted by the Contractor Where new drawings are required to be produced as part of this contract to supplement the modified exhibited drawings, produce the drawings using the latest versions Computer Aided Drafting software and print the drawings using a laser quality printer of minimum resolution 1200 x 1200 dots per inch. Use minimum 80 grams per square metre paper. Five prints of these drawings shall be supplied.

213

OPERATION AND MAINTENANCE INSTRUCTIONS MANUALS

Where indicated, Operation and maintenance instructions manuals shall be supplied with the switchboard. Each copy shall be assembled in a suitably labelled orange A4 size ring type binder of adequate size and with durable plastic covered hard covers, containing the following: Where the number of drawings exceeds 30 the drawings shall be bound in a separate A3 ring binder. Each drawing shall be separately bound and enclosed in a plastic sleeve. (a) (b) (c) (d) (e) (f) (g) One copy of all "work as executed" drawings, schedules and arrangements. One copy of any drawing supplied by The Department of Public Works and Services not incorporated under item (a). A list of the names, addresses and phone numbers of all equipment suppliers. Descriptive brochures and manufacturer's maintenance instructions recommendations for all switchboard components and equipment. and

A software description of the PLC programme where provided as part of the contract. A complete listing of any PLC programme provided as part of the Contract. A copy of Australian Standard AS 2467.

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Part 2 - Switchboards and Associated Equipment

(g) (h)

SCADA system software description and functional description. A schedule of "Fault Cause Action" for all faults of the plant. The "Cause" shall detail all possible causes. The action shall detail actions by both operator and electrician. Any other information or instructions necessary for operation and maintenance of the switchboard.

(i)

All pages and drawings shall be properly reinforced where attached to the binder. See also Clause 215 Supply five copies of Operation and Maintenance Instruction Manuals.

214

SWITCHBOARD ACCESSORIES
Whenever fuses, racking handles, other spare parts and maintenance instruction books are to be stored, a non-lockable, labelled spare parts cabinet shall be supplied for installation adjacent to the switchboard. If space permits, this cabinet may be part of the switchboard. If the schedule holder is not mounted on the switchboard, it shall be supplied loose for installation in the switchroom. Refer to Clause 114.5. The drawout circuit breaker tripping battery with cabinet and charger shall be supplied loose for installation in the switchroom.

215

HEAVY EQUIPMENT HANDLING

Design objects to be handled for routine or maintenance purposes to, as far as reasonably practical, eliminate risks arising from manual handling. In particular, design switchboards, variable speed drive enclosures and other enclosures such that manual handling of equipment for routine or maintenance purposes is limited to a weight of no more than 16kg per person handling the equipment. If an object weighing more than 16kg for each person who could simultaneously, in a balanced and comfortable posture, access the object for handling purposes is required to be moved, nominate the mechanical aid to facilitate the handling of such an object. Advise the correct use of such a mechanical weight handling aid. Incorporate this data into the Operation and Maintenance Instruction Manual. Refer also to the National Standard for Manual Handling (NOHSC:1001) and the Occupational Health and Safety Regulation 2001.

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Part 3 - Accessories

PART 3 301

- ACCESSORIES ACCESSORIES GENERALLY

Flush mounted light switches, isolating switches, socket outlets and other outlets shall be mounted in wall boxes. Outlets shall not be installed across the junction of different wall finishes. Installation methods are shown below: Wall Construction Rendered brick partition Face brick partition Face brick external Stud partition Installation Requirements Flush wall box - conduit chased into wall. Architrave switch with conduit channels cut in architrave. Flush wall box-conduit concealed in cut bricks. Flush wall box - conduit run in cavity and tied against inner brick surface. Flush wall box - conduit run in cavity. Stud mounting bracket - conduit run in cavity within 25 of the bracket.

302
302.1

LAMPS AND LAMPHOLDERS

Lamps Unless otherwise indicated: (a) All incandescent lamps shall be 250 volt grade, general service internally etched type with normal bayonet caps (B22) up to and including 100 watts, and screw caps (E40) above 100 watts. Fluorescent lamps shall be straight fluorescent tubes of standard lengths, with bipin connection, hot cathodes and a phosphor colour temperature in the range 4100 to 4300 degrees Kelvin. All 26 mm diameter lamps shall be switch start type. (c) Mercury vapour lamps shall be class MBF/U colour corrected mercury fluorescent lamps or class MBTF/U where self ballasted lamps are indicated and shall have E27 or E40 screw caps. Sodium discharge lamps shall be high pressure sodium lamps with tubular or elliptical, frosted or clear glass envelope and shall have E27 or E40 screw caps.

(b)

(d)

All screw caps shall have nickel plated contacts and ceramic insulating material between screw and button contact areas. 302.2 Lampholders Bayonet-type lampholders and batten-holders shall comply with AS 3117 and generally be ceramic type although moulded type with brass lined shell may be used with lamps rated up to and including 60 watts. All screw type lampholders shall be ceramic or moulded glass filled polyester, long skirt type complying with AS 3140 and having the following features: (a) (b) (c) spring loaded and nickel plated contacts, isolated nickel plated fixed screw shell, nickel plated tunnel type terminals.

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303
303.1

WALL MOUNTED SWITCHES

Generally Switches shall be of approved manufacture, of minimum 10 A rating, complying with AS 3133 and the following: (a) (b) (c) (d) Switches shall be of the flush type, fixed in wall boxes to suit the installation located as indicated. Switchplates for switches other than ironclad shall be impact resistant plastic mouldings, suitably reinforced, of selected colour and finish. Ironclad switches shall have the toggle fully recessed, or protected by shrouds. Switches exposed to the weather, installed in trenches, in basement areas or in locations subject to dampness or condensation shall be approved to AS 1939degree of protection IP56, and shall have a rotary action positive contact switch. Switch mechanisms, fitted to a flush plate, shall be secured to the plate with retaining screws, or constructed so that switch mechanisms cannot be displaced. Isolating switches shall be selected to meet the requirements of the location and function. A sample of the isolating switch to be used shall be submitted for approval prior to installation. Where indicated, a pilot indicator comprising a neon lamp and ruby lens shall be incorporated within the switch or enclosure.

(e) (f)

(g)

303.2

Installation of Switches Switches installed adjacent to door openings shall be installed on the lock side of the door. Flush mounted wall switches shall be located vertically with a maximum of four switches to a single gang plate. Adjacent switches connected to different phases shall be shrouded. Mounting heights for switches shall be approximately 1200 to the centre of plate unless otherwise indicated.

304
304.1

240 VOLT COMBINATION SWITCH SOCKETS

Generally Fittings and accessories shall be of approved manufacture and rating and shall be selected to meet the requirements of the location and function. Socket outlets shall have the earth pin located at the 6 o'clock position. Unless otherwise indicated, outlets shall have a 10 A rating. Where indicated, a pilot indicator, comprising a neon lamp and ruby lens, shall be incorporated in the enclosure. Unless otherwise indicated, flush plates for outlets other than ironclad, shall be impact resistant plastic mouldings, suitably reinforced, of selected colour and finish. Generally, power outlets shall be located in the fifth brick course above floor level or at 300 above bench top height or as indicated. For walls of different construction a similar mounting height shall be used. For school projects, safety shutters shall be incorporated in 240 volt outlets.

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Part 3 - Accessories

304.2

Socket Outlets - Plastic Type Socket outlets shall comprise a combination switch and three-pin (flat pin) socket assembly. Where approved, the assembly may be installed on an impact resistant plastic moulded mounting block.

304.3

Special Purpose Outlets SPO's shall comprise a combination switch and socket assembly, shall comply with AS 3000 and shall be polarised as for socket outlets.

305

240 VOLT COMBINATION SWITCH AND PERMANENTLY CONNECTED CORD OUTLET

This outlet shall comprise an approved, three-terminal flush type switch and flex-lock insert assembly with an impact resistant plastic moulded flush plate, set flush in a single gang wall box. The flex-lock entry shall match the size and type of connected flexible cord and shall provide a secure grip for the cord. Where indicated, a pilot indicator, comprising a neon lamp and ruby lens, shall be incorporated within the switch enclosure.

306

415 VOLT POWER OUTLET

This outlet shall comprise an approved, heavy duty, five pin (round pin), surface mounted switch socket assembly, ironclad or of impact resistant plastic, with flap lid and complete with five pin plug top and screw ring for holding plug top in position. Outlets shall have the earth pin located at the 6 o'clock position, neutral pin in centre position and phase conductors connected such that a positive phase sequence will be indicated by a phase rotation meter connected by red, white and blue leads in a clockwise direction. Plugs shall be connected in a similar manner. The capacity of each outlet shall be suitable for the indicated load. Outlets shall be installed with a neutral conductor in all cases.

307

EXTRA LOW VOLTAGE POWER OUTLET

This outlet shall comprise a 2 pin socket outlet with flat pins at 90 degrees for DC, and flat parallel pins for AC, flush mounted, with flushplate to Clause 304.1, or surface mounted with ironclad or impact resistant plastic enclosures.

308

CLOCK OUTLET
This outlet shall comprise an approved 4 pin (round pin) receptacle complete with a plug top. When installed, the entire plug top and outlet shall be flush with the surface of the wall. Unless otherwise indicated, the mounting height shall be 2400 above finished floor level.

309

LABELLING
For labelling of items covered by Clauses 302 to 308 inclusive refer to Clause 603.

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Part 4 - Luminaires - Supply and Installation

PART 4 401

- LUMINAIRES - SUPPLY AND INSTALLATION GENERAL

Luminaires shall be complete with incandescent lamps, fluorescent tubes, discharge lamps, and accessories necessary for their proper functioning and shall be in accordance with the provisions indicated herein. All fluorescent luminaires shall have low loss lead/lag ballasts and be switch start 26mm tubes. All discharge luminaires shall be power factor corrected to minimum of 0.85 lagging. Other blocking inductors shall be incorporated where indicated and/or where required by the Supply Authority.

402
402.1

SUPPLY OF LUMINAIRES
Luminaires Other than "Contract" Type These luminaires shall be purchased from a reputable supplier, and shall be manufactured in accordance with SAA Approval and Test Specification AS 3100, AS 3300 and AS 3137. The catalogue numbers or trade designations for luminaires used in the schedule of equipment are intended to indicate the required quality, style and performance of the luminaires. Where an alternative luminaire is offered, all performance data shall be submitted for approval. If requested, a sample shall be submitted for approval.

403
403.1

INSTALLATION OF LUMINAIRES
Generally All screws, battens, roses, noggings, trims, packing, etc., necessary for the proper fixing of luminaires shall be provided by the Contractor as part of the works. Packing pieces of approved material shall be fitted where required to level the luminaires and to prevent distortion. Noggings shall be of similar size to the timber joists, and of minimum size 75 x 50. Unless otherwise indicated, in rooms with only one luminaire, the luminaires shall be centrally placed for even illumination. Where painted surfaces are damaged, they shall be made good by painting in accordance with Clause 601 to the same standard as the original paintwork. Fittings are to be installed subject to the agreement of the Main Contractor and the approval of the Superintendent. All luminaires shall be effectively earthed. All fixings in outdoor locations shall be stainless steel. Where rod suspensions are indicated, standard rod suspension sets as supplied by the fluorescent luminaires supplier shall be used, or, alternatively, rods shall be steel water pipe with gimbal mounting from ceiling. Rod length shall be adjusted so that the luminaires hang true. Where chain suspensions are indicated, standard chain suspension sets as supplied by the fluorescent luminaires contract supplier shall be used or alternatively, electroplated welded steel link chains/minimum 3 diameter steel shall be used. Chains shall be hook mounted from ceiling and lengths adjusted so that the luminaires hang true.

403.2

Fluorescent Luminaires

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Part 4 - Luminaires - Supply and Installation

Luminaires shall be supported by two fixing at each end. One fixing at each end of a narrow fitting will be accepted where a 1.6 mm thick back plate reinforces each fixing screw. End to end luminaires shall be correctly aligned using packing strips where necessary. Luminaires shall not be erected on sprayed acoustic ceilings until at least one week after the spraying of the ceilings has been completed. Luminaires shall not be supported or suspended from plastic boxes or fittings. Plastic boxes attached to luminaires for cable protection shall not be used as part of the fixing method. Where a PVC conduit enters a luminaire, a screwed PVC adaptor with circular lock nuts shall be used to secure the conduit to the luminaire. Lock nuts are not required for luminaires with screwed conduit entries. 403.3 Surface Mounted Luminaires Luminaires shall be securely fixed to structural members of the ceilings or walls, or fixed by hangers or brackets which are securely fixed to structural members. 403.3.1 Fixings for Surface Mounted Luminaires The minimum size of fixing for luminaires, hangers, or brackets for various surfaces shall be as follows: (a) (b) (c) Fixing to timber: steel wood screw No. 10 x 25, round head, cadmium plated. Fixing to concrete: approved screw expanding bolts M5 x 40. Fixing to hollow blocks: M5 electro galvanised, round head screws with spring loaded butterfly toggles. Where a deep cast iron junction box is provided in the centre, M5 metal screws shall be used with approved expanding fixing at each end. Fixing to suspended ceilings shall be as indicated.

(d)

All fixings shall be fitted with large diameter (minimum 3 x screw dia.) cadmium plated washers under the heads of each screw. 403.3.2 Recessed Luminaires Recessed luminaires shall be fitted with flexible cords and 3 pin plugs. The flexible cord shall be PVC insulated, 3 core with 0.75 mm2 conductors, and shall comply with AS 3191. It shall be of suitable length not greater than 1500. A plug socket shall be located within 500 from the edge of the access aperture to allow the luminaire to be plugged-in prior to fixing. Recessed luminaires installed in timber-framed ceilings shall be fixed to the ceiling members and noggings using the proprietary fixings supplied by the luminaires manufacturer, subject to the approval of the Superintendent. Recessed luminaires using incandescent or discharge lamps and installed in a confined space (e.g. covered way, counter canopy, integrated ceiling/roof) shall be wired to a nearby junction box using cable having insulation at least rated to 200C maximum operating temperature. Recessed luminaires for suspended or modular ceilings shall be attached to suspended ceilings with proprietary mounting brackets supplied by the luminaire manufacturer.

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Part 4 - Luminaires - Supply and Installation

403.4

Post Top Luminaires Post-top luminaire shall be mounted on tapered steel lighting columns. Unless otherwise indicated, lighting columns shall consist of proprietary brand steel poles, hot dipped galvanised and suitable for base plate mounting on galvanised rag bolt assembly set in a concrete pad. The poles shall be adequately drained and shall be fitted with an approved weatherproof lockable enclosure to house the control gear and fuse(s), in the lower section of the pole, within 1000 of the ground.

403.5

Emergency Luminaires Emergency luminaires shall be non-maintained mode. 10W halogen fittings with separate battery pack. They shall be flush mounting on the ceiling with a charged LED and a discharge push-button. Battery shall provide a minimum two hours full illumination.

403.6

Bollard Luminaires Bollards shall be flange plate mounted on a 500 x 500 x 500 reinforced concrete block. The bollard shall have integral controlgear. Body of the bollard shall be manufactured from minimum 2mm aluminium 150 diameter. Bollards shall be epoxy painted eucalyptus green or similar. Unless specified otherwise, bollards shall have 18W fluorescent tubes.

MEW E101

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Part 5 - Electrical Motors

PART 5 501

- ELECTRICAL MOTORS GENERAL

All electric motors except special purpose motors shall have dimensions and outputs to AS 1360. Motors shall be three phase. However, single phase motors will be acceptable for smaller motors (e.g. 0.37 kW and below), where three phase motors are not manufactured. Motor design, marking, rating, performance and testing shall be in accordance with the requirements of AS 1359. Motors shall be designed to have a winding temperature rise to Class B (Class 130) requirements and be provided with Class H (Class 180) insulation to AS 2768. The motor and drive unit torque/speed characteristics shall ensure smooth positive acceleration in conjunction with the specified starting method. Motor ratings shall be continuously rated at an ambient temperature of at least 40C. Where a motor is installed in a location at which an ambient temperature greater than 40C is indicated or, where due to design, a motor is installed in an ambient temperature greater than 40C, the motor shall either be rated for continuous operation at or above the ambient temperature or be oversized to the extent that its continuous operating temperature in the installed ambient shall not exceed its rated operating temperature. A motor oversized as above shall be derated by fixing to the frame a suitable label which will indicate the derated full load and the correct setting of the motor protective devices. The derated full load and the current drawn by the motor at the derated full load shall be used wherever reference is made to full load or full load current respectively in later clauses. Motors shall satisfy the Electricity Supply Authority's requirements particularly in regard to interference to other consumers and frequency injection systems. Motors shall be capable of starting direct on line and of operation within the voltage range of 370 to 440 volts, where three phase and 216 to 264 volts where single phase. Motors shall have a synchronous speed not exceeding 1500 r/min, except where higher speeds are specified. Nameplates shall be stamped or embossed, corrosion resistant, permanently fixed to the motor in a location adjacent to the terminal box and shall not be painted. Motors having pressed metal end shields are not acceptable.

502

MOTOR BEARINGS
Motors shall be fitted with ball or roller bearings. Bearings shall be either or the sealed type or have provision for greasing. For motors having a frame size greater than 132, provision shall be made for regular greasing of the bearings during their in-service life. (Sealed bearings are not acceptable). Where bearings require greasing, the greasing system shall permit the addition of grease whilst the motor is running, without the risk of over lubrication or injury to personnel and shall include a pressure relief grease valve to expel excess grease external to the motor. It shall allow old grease to be purged from the bearing during the regreasing operation. A name plate shall be attached to motors fitted with regreasable bearings stating the type of bearing installed and the lubrication instructions. For variable speed driven motors, which are sized at 90kW, 4 pole or greater (or an equivalent frame size for other than 4 pole motors), protect the non drive end bearings from shaft voltages using ceramic insulation material or equivalent.

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Part 5 - Electrical Motors

For variable speed driven motors, which are sized at 90kW, 4 pole or greater (or an equivalent frame size for other than 4 pole motors) and which are located in hazardous locations, do not provide earthing brushes designed to remove the effect of electrical discharge through the bearings but provide drive and non drive end insulated bearings, using ceramic insulation material or equivalent.

503

POWER FACTOR
Single speed motors, when operating at rated full load and rated speed, shall exhibit power factors equal to or greater than those indicated in the following table:

2 Pole kW Rating Range Less than 0.5 kW 0.5 kW to less than 1.1 kW 1.1 kW to less than 5. 5 kW 5.5 kW to less than 30 kW 30 kW to 100 kW Greater than 100 kW p.f. 0.62 0.83

4 Pole p.f. 0.62 0.74

6 Pole p.f. 0.62 0.71

8 Pole p.f. 0.56 0.64

0.84

0.77

0.72

0.65

0.87

0.83

0.77

0.74

0.87 0.89

0.87 0.87

0.81 0.81

0.75 0.77

In selecting motors to drive the specified plant, the motors selected shall be sized to allow operation at the highest efficiencies possible, allowing for standard motor sizes and starting conditions, and shall operate at load factors between 75% and 95% of the motor full load ratings.

504

MEPS COMPLIANCY
Three phase squirrel cage induction motors, other than submersible motors, hazardous area motors and motors that are integral with and not separable from a driven unit or motors meeting clause 1.2 (Exclusions) of AS/NZS 1359.5:2004, shall be compliant to the Minimum Energy Performance Standard (MEPS) requirements of AS/NZS 1359.5:2004, for all motors with ratings from 0.73kW to 185kW. Such motors shall meet either Table A3 (Heff-A) Minimum High Efficiency Test Method A or Table B3 (Heff-B) Minimum High Efficiency Test Method B of AS/NZS 1359.5:2004. Provide a stainless steel label on the motor identifying MEPS compliancy as follows: MEPS COMPLIANT TO AS/NZS 1359.5.2004, Table A3 or MEPS COMPLIANT TO AS/NZS 1359.5.2004, Table B3 as applicable. Use minimum size lettering of 2.5 high for the above label.

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Part 5 - Electrical Motors

505

POWER FACTOR CORRECTION

When power factor correction capacitors are permitted and required they shall be supplied in three phase delta-connected units, fitted with fuses and internal discharge devices. All capacitors shall be housed in the SCA. When audio-frequency rejection is specified, the capacitors shall be fitted with frequency rejection devices tuned to the specified frequency. Power factor correction equipment is to comply with the requirements of the Electricity Distributor. In addition to the requirements of AS 1013 Clause 6.1 the capacitor unit rating plate shall be labelled "CAPACITOR UNIT DETAILS".

506

MOTOR ENCLOSURES
Enclosures for motors shall comply with the minimum requirements of the following table:

Motors operating in Areas designated hazardous Areas subject to hosing and external area Other Areas

Enclosure Flameproof as specified IP 56 IP 54

Motor cooling requirements shall be to IC 0141.

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Part 5 - Electrical Motors

507

EMBEDDED OVERLOAD PROTECTION

Embedded overload protection shall comprise thermistors embedded in the winding of each phase and connected to fixed terminals in the motor terminal section. The thermistors shall comply with AS 1023 Part 1 and shall be Class 1. Details of the type installed shall be attached to the motor nameplate. The thermistors shall be suitable for windings having a temperature rise meeting Class B requirements. All motors rated 15 kW and higher, and all motors used on water supply or sewerage projects rated 5.5 kW and higher, shall be fitted with thermistors unless otherwise indicated. A thermistor control unit in accordance with Clause 207.12.2 shall only be provided when indicated.

508

ANTI-CONDENSATION HEATERS
When indicated, two 240 volt 50 Hz anti-condensation heaters, connected in parallel, shall be fitted in the motor and connected to terminals in a separate terminal box. A nameplate on the motor shall state: (1) (2) (3) (4) Heater Details Number of Heaters Voltage (240 V 50 Hz) Power Rating.

Anti-condensation heater terminal boxes shall be fitted with a sign stating: "WARNING: 240 VOLT ANTI-CONDENSATION HEATER CIRCUIT LIVE WHEN THE MOTOR IS OFF".

509

MOTOR TERMINAL BOX

Motor terminal boxes shall be of metallic construction, and be of adequate dimensions suitable for the entry and termination of the appropriately sized cables. All terminals shall be identified and coded in accordance with the requirements of AS 1359.3 and an earth terminal shall be provided within the terminal box. Where thermistors and/or anti-condensation heaters are provided, terminals shall be suitably segregated and identified and a separate terminal box shall be provided for the anti-condensation heaters terminals. Each end of the motor phase windings shall be terminated on separate terminals within the motor terminal box for all single speed motors 5.5 kW and larger. In addition to the requirements of AS 1023.1 Clause 1.5 the thermistor nameplate shall be labelled. "THERMISTOR DETAILS" When specified, two 240 volt 50 Hz anti-condensation heaters, connected to terminals in a separate terminal box. A nameplate on the motor shall state: (1) (2) (3) (4) "Heater Details" Number of Heaters Voltage (240 V 50 Hz) Power Ratings

Anti-condensation heater terminal boxes shall be fitted with a sign stating: "WARNING: ANTI-CONDENSATION HEATER CIRCUIT LIVE WHEN THE MOTOR IS OFF".

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Part 5 - Electrical Motors

Motor terminal boxes shall be metallic construction and shall be of adequate dimensions and suitable for the entry and crimp-lug termination of the specified cable. All terminals shall be identified and coded. An earth terminal shall be provided inside the motor terminal box.

510

PART WINDING START MOTORS

These motors shall have two separate windings arranged so that for starting only one winding is energised. When the motor is up to speed the second winding is connected in parallel. The time delay between energising the two windings shall be set to that specified by the motor manufacturer and sealed by the installer of the equipment.

511

HERMETICALLY AND ACCESSIBLE SEALED MOTORS

These shall comprise proprietary units constructed by the recognised manufacturers to comply with current industrial practice. The protection shall comprise a suitable temperature sensing method arranged to interrupt the electricity supply in the event of the winding temperature exceeding the limit of the insulation temperature rating from whatever cause. This protection shall be in addition to over current protection in the control circuit and, for air conditioning plants, preferably shall be manually reset.

512

SUBMERSIBLE MOTOR REQUIREMENTS

The motor and driven unit torque/speed characteristics shall ensure smooth positive acceleration in conjunction with the scheduled starting method under all specified conditions of operation. The final speed during the first step of starting shall exceed the speed of breakdown torque. All motors will be started by means of automatic starters designed to AS 1202. Motors shall satisfy the Electricity Supply Authority's requirements particularly in regard to interference to other consumers and frequency injection systems. Motors shall be rated for type S1 duty in air, i.e. maximum continuously rated (MCR) in air using a method of cooling consistent with continuous operation with a water level at the top of the volute. The motor power required over the entire operating range, i.e. between maximum total head pipeline characteristic and 10% in excess of flow rate at flood head pipeline characteristic shall be less than the motor rating. Within the operating range the current in each phase shall be less than the MCR current for a supply voltage within the specified range, and for a voltage variation between phases which is within the tolerance that the Electricity Supply Authority permits. Motor starting, or continuous operation at MCR shall not cause a temperature rise in excess of that specified, and shall not cause nuisance operation of any protective device. Starting characteristics shall be Design B to AS1359.41. Motor winding insulation shall be Class 155, but the design of the motor shall ensure that the temperature of the windings does not exceed the limits for Class 130 insulation. All terminals shall be identified and coded to drawing E94A. Phase time sequence of the electricity supply will be red/white/blue (clockwise rotation) and the motor shall be suitable for connection of the motor cables directly to this supply sequence. Any interchanging of phases to achieve correct shaft rotation shall be within the motor terminal box. An earth terminal shall be provided inside the motor terminal box. The motor finish shall be in accordance with that indicated for the pump.

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Part 5 - Electrical Motors

Each motor shall be supplied with cables suitable for use in sewage. Conductors shall be flexible with high conductivity tinned copper wire, ethylene propylene rubber (or equal) insulated and chlorosulphinated and polyethylene (CSP) or polychloroprene (PCP) sheathed. Power cores shall be continuously coloured, continuously numbered or fitted with wire numbers using one of the identification systems shown on Drawing E94A. Each cable shall be terminated at the motor using a cable gland, in such a way that there will be no undue mechanical stress on either the conductors or the motor terminals to which the cable is connected. Further, the termination system shall be such that water cannot reach the motor windings from a cut cable under a pressure of fifteen (15) metres head of water. Cables shall include control cores for each specified and other installed protection devices. Two control cores per device shall be provided. Each motor shall have no more than three cables and the cables shall be tied together with black nylon cable ties at 300 mm centres. Control cores shall be in one cable or may be part of the power cables. When determining cable sizes, the three motor cores of motors for Direct-on-Line starting only shall be taken as each carrying a current equal to MCR current. The rating of the motor power cores and earth cores shall be suitable for the motor supplied taking into account all debating factors of AS 3008.1, as the cables are run in conduit to the switchboard with the cables for each pump in a single conduit, and with the conduits for different pumps spaced by not less than 100 mm or more. Cables shall also be sized to ensure that with the pump operating at MCR, the total voltage drop in the motor cores shall not exceed 2.5% of the supply voltage. For stardelta or auto transformer starting cables shall be sized to ensure reliable starting in star. All motors above 4.5kW shall have six (6) power conductors for star-delta starting. Suitable precautions shall be taken to ensure that signal noise of sufficient quantity to produce nuisance tripping is not induced in the thermistor, seal failure or any other control cores. Control cores shall be permanently and indelibly marked at the free end as S1 and S2 for seal failure cores, T1 and T2 for thermistor cores and TB1 and TB2 for thermostat cores. The free end of each motor cable shall be fitted with a heat shrink seal giving a degree of protection of IPX8 to AS 1939 at 15 m head of water during delivery and prior to installation. Each cable or cable group to each motor shall be provided with a means of support. This support shall be by means of a stainless steel cable support hook provided by the Contractor and suitably sized stainless steel or nylon support stockings similar to those manufactured by MACEY CABLE PTY. LTD. of Newcastle, N.S.W.

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Part 6 - Painting, Colour Coding and Labelling

PART 6 601
601.1

- PAINTING, COLOUR CODING AND LABELLING PAINTING

Generally This section shall apply to "on site" painting of equipment. Unless otherwise indicated all surfaces of conduits, fittings, accessories, equipment and supports installed as part of the works shall be painted. Sheet metal enclosures shall be painted internally and externally. All equipment delivered to site already painted shall be thoroughly cleaned down and damaged or unsatisfactory painting made good. For painting of switchboards refer to Clause 209. Surface preparation and painting shall take place in a tradesman-like manner and coatings shall be applied free from runs, pinholes, misses, patchiness, non-uniform appearance or any other surface defects and all work shall be to the complete satisfaction of the Superintendent. All painter's plant, tool, gear, steps, trestles, scaffolding, dust covers, masking, etc., shall be provided by the Contractor as necessary for the completion of the work and for the protection of finished work. Painting shall not be carried out under adverse weather conditions or when work is wet with fog, mist or dew or when the work would be subject to damage by such conditions. Dust sheets, drop sheets and masking shall be used whenever necessary to protect finished work and any other surfaces or equipment from dirt or paint spotting. Paint spots and splashes shall be removed immediately from adjacent surfaces and any surface so damaged shall be restored. Under no circumstances shall paint be sprayed to surfaces unless prior approval has been given by the Superintendent in writing. Approval will be granted only in exceptional conditions he applies. The following surfaces shall not be painted: (a) (b) (c) (d) (e) (f) (g) (h) Concealed conduits. Chrome plated, stainless steel or anodised surfaces. Bearing surfaces, slides, adjusting screws and any surface that is required to be unpainted for the correct operation or adjustment of the equipment. Internal surfaces of galvanised cable troughs. Galvanised steel poles, unless otherwise indicated. Galvanised cable tray and ladder, unless otherwise indicated. Motor and equipment nameplates. Plastic or fibreglass surfaces, other than conduits, ducts and associated fittings.

601.2

Paint Materials All paint products and surface preparation material shall comply with S.A.A. standards. AS 2204 AS 2603 GPC-P-12/1 AS 2673 AS 2602 AS 4025.1 AS 3730 Zinc rich organic primer 2 pack epoxy Inhibitive metal primer. Solvent borne paint for galvanised steel. Alkyd micaceous iron oxide Full gloss exterior polyurethane Full gloss oil and petrol resistant enamel. Vinyl gloss exterior paint.

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Part 6 - Painting, Colour Coding and Labelling

All paint and other preparations shall be best quality, non-poisonous, lead-free, prepared synthetic products of approved brand. They shall be brought to site in their original unopened containers, bearing the manufacturer's label, batch number, instructions for application and date of expiry where applicable. All materials in any one complete coating system shall be manufactured by the same manufacturer and shall be compatible with each other. All paint shall be stored under conditions which will not lead to deterioration of the paint and no paint shall be used after expiration of its shelf life and, in the case of a multi-pack paint, after expiration of its pot life. Surfaces which shall operate at temperatures in excess of 100C shall be primed, undercoated and finish coated with approved heat-resisting materials suitable for the temperature to be encountered. 601.3 Preparation of Surfaces All surfaces shall be thoroughly dry, cleaned down, free from weld spatter, burrs, dust, rust, cement and grease. Metal surfaces shall be thoroughly wire brushed to remove loose rust and scale. All sharp edges shall be rounded off to a radius of curvature of not less than 1. Butt welds shall be ground to a reasonably smooth surface free of sharp crests. Deposits of oil or grease shall be removed by solvent cleaning generally in accordance with AS 1627.1. Galvanised or zinc coated steel surfaces shall be cleaned by washing with potable water using nylon pads or brushes. After cleaning, the surface shall be thoroughly degreased by washing with mineral turpentine; alternatively a dispersion cleaner may be used if so recommended by the paint manufacturer. Soaps and detergents shall not be used for degreasing. The prime coat of the coating system shall be applied within 4 hours of completion of surface preparation. 601.4 601.4.1 Application of Coating Materials General The paint manufacturer's printed recommendations shall be strictly observed, with particular reference to requirements for mixing, thinning, application techniques, drying time between coats and dry film thickness of each coat. No painting shall be carried out at ambient temperatures below 10C or above 30C or if the surface to be painted is less than 3C above the dew point or if the relative humidity is greater than 85%. Where two coats of otherwise identical paint are to be applied consecutively, each coat shall be of a different shade in the selected colour. The final coat shall be left smooth, even and free from visible brush marks and other defects. Painting of steel surfaces shall be to AS 2312 MP4-A. 601.4.2 Prime Coating Steel surfaces shall be prime coated with a zinc rich organic primer. The prime coat shall be applied to a minimum dry film thickness of 70 micrometres. Galvanised or zinc coated steel surfaces shall be prime coated with a zinc dust pigmented drying oil primer for galvanised surfaces, followed by a micaceous iron oxide long oil alkyd or phenolic modified alkyd paint. Each prime coat shall be applied to a minimum dry film thickness of 40 micrometres. Non-ferrous metal surfaces shall be lightly abraded by light whip blasting or sanding then prime coated with a non-reactive two-pack epoxy primer to a dry film thickness of not less than 20 micrometres not more than 35 micrometres. Plastic surfaces shall be etch prime coated with an automotive lacquer thinner.

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Part 6 - Painting, Colour Coding and Labelling

601.4.3

Finish Coating Steel surfaces shall be finish coated with two coats of a pigmented gloss alkyd enamel paint conforming to S.A.A. The total dry film thickness of the completed coating system shall be not less than 140 micrometres. Galvanised or zinc coated steel surfaces shall be finish coated with two coats of a pigmented gloss alkyd enamel paint. The total dry film thickness of the completed coating system shall be not less than 150 micrometres. Non-ferrous metal surfaces shall be finish-coated as for galvanised surfaces. Plastic surfaces shall be finish coated with two coats of a pigmented water borne gloss acrylic paint. The total dry film thickness of the completed coating system shall be not less than 70 micrometres.

602

COLOUR CODING
All exposed conduits, cable enclosures and cable troughing installed in switchrooms, boiler rooms, plant rooms, tank rooms, accessible trenches and masonry ducts shall be coloured light orange, colour X15 AS 2700. Elsewhere all such exposed material shall be coloured to match its surroundings, unless otherwise indicated. Cable enclosures, etc., within switchboard cupboards shall be considered concealed and need not be colour-coded or painted except that enclosures which form an extension of the switchboard shall be painted to match the switchboard.

603

LABELLING
Switches, socket outlets, SPO's, permanently connected outlets and power outlets, etc., shall be labelled in an approved manner to provide ready identification. Hand painted, embossed plastic or metal tapes and adhesive fixed labels are not acceptable. A stamped metal tag shall be securely tied to the termination of the consumer's mains cable, giving details of the size, number and material of the conductors. A similar metal tag shall be attached to each end of all spare pipes and conduits, stating purpose and point of termination. An approved traffolyte label with 10mm high black lettering reading: "WARNING - DO NOT USE THIS ROOM FOR STORAGE" shall be supplied for each switchroom and switchboard cupboard. The label shall be installed in a prominent location on the door or switchrooms/switchboard cupboards, as directed. For labelling of switchboards refer to Clause 210. For labelling of MEPS compliant motors, refer to Clause 504.

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Index

TABLE OF CONTENTS
PAGE

PART 0.1 0.2 SCOPE

- GENERAL

1 1

USER GUIDELINE FOR THE SELECTION OF SWITCHBOARD CLASSIFICATION STANDARDS ABBREVIATIONS

1 2 4 5 5 5
5 5 5 6

0.3 0.4

PART 1- INSTALLATION 101 102 SETTING OUT OF RUNS PENETRATIONS

102.1 102.2 102.3 102.4 Generally Penetrations Through Waterproof Membranes Penetrations Through External or Existing Structures Unenclosed Cables Passing Through Slabs

103

AERIAL RETICULATION (POWER)

103.1 103.2 103.3 103.3.1 103.3.2 103.3.3 103.3.4 103.4 Attachment to Poles Attachment to Buildings Poles Generally Hardwood Poles Crossarms Service Poles Aerial Cables

6
6 6 6 6 6 6 7 7

104.

UNDERGROUND RETICULATION
104.1 Trenching, Backfilling and Reinstatement

7
7

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INDEX

104.1.1 104.1.2 104.1.3 104.2 104.3

Generally Inspection Backfilling and Reinstatement Underground Cable Protection Underground Cable Draw-In Pits

7 7 8 8 8

105

MARKING PLATES FOR UNDERGROUND RETICULATION

105.1 105.2 105.3 105.4 105.5 Generally Indication of Cable Entry to Buildings Indication of Directional Changes Indication of Cables Under Roads and Paths Indication of Terminated Conduits

9
9 9 9 10 10

106

CABLES AND WIRING

106.1 106.2 106.3 106.3.1 106.4 106.5 106.6 106.7 106.8 106.9 106.9.1 106.9.2 106.9.3 106.9.4 106.10 Generally Consumer's Mains and Metering Final Sub-Circuit Wiring Generally Instrumentation Cables Insulated Non-Armoured Cables in Enclosures (TPI) Underground Grade Insulated and Sheathed Non-Armoured Cables (TPS) Armoured and Sheathed Cables (Other than Paper Insulated) Aerial Cables Special Purpose Essential Service Cables Telephone Cables Fire Alarm Cables Security Cables Control Cabling

10
10 10 11 11 11 12 12 12 12 12 12 12 13 13 13

107

EARTHING
107.1 Generally

13
13

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Index

107.2 107.3

Earthing Conductors for Underground Cables Earth Electrodes

14 14

108

CONDUITS, FITTINGS AND JOINTS

108.1 108.2 108.3 108.4 108.5 108.6 108.6.1 108.6.2 108.6.3 108.7 108.8 108.8.1 108.8.2 108.8.3 108.9 108.10 108.11 Generally Heavy Duty UPVC Conduits to AS 2053 (HD-UPVC) Steel Conduits Light Duty UPVC Conduits to AS 2053 (LD-UPVC) Flexible Conduits Installation Generally Conduit Saddles Expansion Joints Conduits in Roof Spaces Conduits in Concrete Generally Conduits in Suspended Slabs Conduits in General Columns Draw-In Points Conduits and Pipes for Future Use Wall Boxes

14
14 14 15 15 15 15 15 16 16 16 18 18 18 18 18 18 19

109

CONDUIT SYSTEMS FOR COMMUNICATION SERVICES

109.1 109.2 Conduits for Telecommunication Facility Cabling Conduits for Telecommunication Lead-In and Block Cabling

19
19 19

110

CABLE TRAY, LADDER AND TROUGHING

110.1 110.2 110.3 110.4 110.5 110.5.1 Generally Cable Tray Cable Ladder Installation Cable Troughing Generally

20
20 20 20 20 21 21
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INDEX

110.5.2 110.5.3 110.5.4

Metal Cable Troughing Plastic Cable Troughing Skirting Troughing

21 21 21

111

FIXINGS
111.1 111.2 111.3 111.4 111.5 111.6 111.7 111.8 111.9 111.10 111.11 Generally Conduits Mounting Blocks Switchboards Switch Panels, Boxes Surface Mounted Switches Cable Troughing, Cable Tray, Skirting Troughing Metal Channel Hollow Block Locations Fixing of Luminaires Fixing of Ceiling Fans

21
21 22 22 22 22 22 22 23 23 23 23

112

INSTALLATION OF SWITCHBOARDS
112.1 112.2 112.3 112.4 Generally Fixings Cables, Cable Enclosure and Busway Entry and Termination Schedules and Drawings

23
23 23 23 25

113

WORK AS EXECUTED DRAWINGS

113.1 113.2 Drawings Produced by Modification of Exhibited Drawings New Drawings Submitted by the Contractor

25
25 25

114

ACCREDITATION FOR CONTESTABLE WORKS

114.1 114.2 114.3 Level 1 Accreditation Level 2 Accreditation Level 3 Accreditation

25
25 26 26

PART 2 - SWITCHBOARDS AND ASSOCIATED EQUIPMENT

27

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Index

201 202

SCOPE GENERALLY
202.1 202.1.1 202.1.2 202.1.3 202.1.4 202.1.5 202.1.6 202.1.7 202.1.8 Classification of Switchboards Proprietary Assemblies Custom-built Assembly Type CT Custom-built Assembly Type CU Custom-built Assembly Type DT Custom-built Assembly Type DU Custom-built Assembly Type DUPLUS Custom-built Assembly Type DTPLUS Manufacturer of the Switchboard.

27 27
27 27 28 28 29 30 31 32 33

203

FAULT LEVELS AND LIMITATION

203.1 203.2 203.3 Fault Levels and Time of Duration Fault Current Limiting Short Circuit Co-ordination

33
33 34 34

204

BUSBARS
204.1 204.2 204.3 204.4 204.5 204.6 204.6.1 204.6.2 204.6.3 204.7 204.8 204.9 204.10 204.11 Generally Material Sizes Jointing Supports Prevention of Arcing Faults Rigid Insulation Coating of Busbars and Terminations Application of Busbar Coatings Phase Identification Busbar Clearances Cable Connection Flags Neutral and Earth Busbars Flexible Busbars Take Offs

34
34 34 34 36 36 37 37 37 37 38 38 38 38 38
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INDEX

205

CABLING
205.1 205.2 205.3 205.4 Generally Cable Identification Large Cables (Cables above 6mm) Small Cables (Cables up to and including 6mm)

38
38 39 40 41

206

ACTIVE, EARTH AND NEUTRAL LINKS

206.1 206.2 For Proprietary Assemblies For Custom-built Assemblies

41
41 41

207

EQUIPMENT
207.1 207.2 207.3 207.4 207.4.1 207.5 207.6 207.7 207.8 207.9 207.9.1 207.9.2 207.9.3 207.9.4 207.10 207.11 207.12 Compliance with Australian Standards Ambient Temperature Miniature Overcurrent and Moulded Case Circuit Breakers Drawout Circuit Breakers and Tripping Battery Drawout Circuit Breaker Fuses Fuse Combination Units Main Switches Contactors Control Switching Devices Instantaneous Relays Time Delay Relays Control Switches Push Button Switches Phase Failure Relays Residual Current Devices (RCD) A. C. Motor Starters

42
42 42 42 43 43 43 44 44 45 45 45 46 46 46 47 47 47 47 47 48 48
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207.12.1 General 207.12.2 Direct-On-Line Starters 207.12.3 Reduced Voltage Starters 207.12.4 Reversing Starters
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Index

207.12.5 Electronic Soft Starter 207.13 Motor Protection Devices

49 49 49 49 50 51 51 51 51

207.13.1 Three Phase Motor Protection 207.13.2 Motor Protection 207.13.3 Single Phase Motor Protection 207.14 207.15 207.16 207.17 207.18 Time Switches Hour Run Meters Indicating Counters Extra-Low Voltage Transformers Current Transformers (CTS) (Not Applicable to Supply Authority Equipment or Protection CTS) Meters and Associated Controls (Not applicable to Supply Authority Equipment)

51 52 52 52 53 53 56 56 56 56

207.19

207.19.1 Voltmeters, Ammeters, Maximum Demand Indicators and Associated Controls 207.19.2 Energy Meters 207.20 207.21 207.22 207.23 207.24 207.25 Indicating Lights Variable Speed Drives Audible Alarm Devices Terminals Locking Ambient Temperature

208

SWITCHBOARD CONSTRUCTION
208.1 208.2 208.3 208.4 208.5 208.5.1 208.5.2 208.5.3 208.5.4 208.6 Generally Externally Mounted Switchboards General Cubicle Construction Construction of Covers and Doors Spacing and Mounting of Circuit Breakers Generally Circuit Breakers Not Larger than 160 Amps Circuit Breakers Larger than 160 Amps Circuit Breakers of the Drawout Type Spacing and Mounting of Fuse Combination Units

58
58 58 59 59 60 60 60 60 60 60
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INDEX

208.7 208.8 208.9 208.10 208.11

Space for Future Circuit Breakers and Fuse Combination Units Mounting Heights Extra Low Voltage Auto-transformer Compartment Arrangement of Equipment

61 61 61 61 61

209

PAINTING OF SWITCHBOARDS
209.1 209.2 209.3 209.4 Generally Paint Materials Surface Preparation Painting and Finish

62
62 62 62 62

210

LABELLING OF SWITCHBOARDS
210.1 210.2 210.3 210.4 210.5 210.6 Generally Fixing of Labels Labels on Exterior of Switchboards and Schedules Labels on Interior of Switchboards Warning Labels Special Label on Custom-built Assemblies

62
62 63 63 64 64 65

211

INSPECTION AND TESTING

211.1 211.2 211.3 211.4 211.5 211.6 Generally Inspection Residual Current Equipment Testing Dielectric Tests Functional Testing Checking of Safety Measures and Electrical Continuity of Earthing Circuit

66
66 66 66 66 66 66

212

DRAWINGS
212.1 212.2 212.3 212.4 Generally Switchboard Drawings and Equipment Schedules Additional Information on Custom-built Assembly Drawings Drawings Produced by Modification of Exhibited Drawings

67
67 67 67 68
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Index

212.5

New Drawings Submitted by the Contractor

68

213 214 215

OPERATION AND MAINTENANCE INSTRUCTIONS MANUALS SWITCHBOARD ACCESSORIES HEAVY EQUIPMENT HANDLING

68 69 69 70 70 70
70 70

PART 3- ACCESSORIES 301 302 ACCESSORIES GENERALLY LAMPS AND LAMPHOLDERS

302.1 302.2 Lamps Lampholders

303

WALL MOUNTED SWITCHES

303.1 303.2 Generally Installation of Switches

71
71 71

304

240 VOLT COMBINATION SWITCH SOCKETS

304.1 304.2 304.3 Generally Socket Outlets - Plastic Type Special Purpose Outlets

71
71 72 72

305

240 VOLT COMBINATION SWITCH AND PERMANENTLY CONNECTED CORD OUTLET 72 415 VOLT POWER OUTLET EXTRA LOW VOLTAGE POWER OUTLET CLOCK OUTLET LABELLING 72 72 72 72 73 73 73

306 307 308 309

PART 4- LUMINAIRES - SUPPLY AND INSTALLATION 401 402 GENERAL SUPPLY OF LUMINAIRES

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INDEX

402.1

Luminaires Other than "Contract" Type

73

403

INSTALLATION OF LUMINAIRES
403.1 403.2 403.3 403.3.1 403.3.2 403.4 403.5 403.6 Generally Fluorescent Luminaires Surface Mounted Luminaires Fixings for Surface Mounted Luminaires Recessed Luminaires Post Top Luminaires Emergency Luminaires Bollard Luminaires

73
73 73 74 74 74 75 75 75

PART 5- ELECTRICAL MOTORS 501 502 503 504 505 506 507 508 509 510 511 512 GENERAL MOTOR BEARINGS POWER FACTOR MEPS COMPLIANCY POWER FACTOR CORRECTION MOTOR ENCLOSURES EMBEDDED OVERLOAD PROTECTION ANTI-CONDENSATION HEATERS MOTOR TERMINAL BOX PART WINDING START MOTORS HERMETICALLY AND ACCESSIBLE SEALED MOTORS SUBMERSIBLE MOTOR REQUIREMENTS

76 76 76 77 77 78 78 79 79 79 80 80 80 82 82
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PART 6- PAINTING, COLOUR CODING AND LABELLING 601

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PAINTING

Index

601.1 601.2 601.3 601.4 601.4.1 601.4.2 601.4.3

Generally Paint Materials Preparation of Surfaces Application of Coating Materials General Prime Coating Finish Coating

82 82 83 83 83 83 84

602 603

COLOUR CODING LABELLING

84 84

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