electrical services minimum requirement - NSW Public Works
electrical services minimum requirement - NSW Public Works
electrical services minimum requirement - NSW Public Works
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Part<br />
ELECTRICAL SERVICES<br />
MINIMUM REQUIREMENT<br />
(Referred to as MEW E101)<br />
∅ General<br />
1 Installation<br />
2 Switchboards and Associated Equipment<br />
3 Accessories<br />
4 Luminaires - Supply and Installation<br />
5 Electric Motors<br />
6 Painting, Colour Coding and Labelling<br />
September 2007
• CROWN COPYRIGHT:<br />
DOCUMENT OWNERSHIP<br />
No part of this work may be reproduced or copied without the written permission of the<br />
publisher. This document is published by <strong>NSW</strong> Water Solutions, <strong>NSW</strong> Department of<br />
Commerce, 2-24 Rawson Place, Sydney 2000.<br />
• ACCREDITATION:<br />
Only design consultants who have attended the <strong>NSW</strong> Department of Commerce<br />
Accreditation Course and are accredited by the <strong>NSW</strong> Department of Commerce for<br />
MEWE101 usage, are legally permitted to use this document as part of design<br />
documentation.<br />
A fee for such usage per project will apply.<br />
This Accreditation would be reviewed every 3 years or when this document is updated,<br />
whichever is the earlier.<br />
Apply to the Senior Electrical Engineer, <strong>NSW</strong> Department of Commerce, McKell<br />
Building, 2-24 Rawson Place, Sydney 2000 (Tel 937 28162) for accreditation.
PART Ø - GENERAL<br />
0.1 SCOPE<br />
Part 0 - General<br />
This document covers the <strong>minimum</strong> <strong>requirement</strong>s for Low Voltage and Extra Low Voltage<br />
Switchboards and <strong>electrical</strong> installation for Sewage and Water Supply Schemes.<br />
Read this document in conjunction with the specification clauses and exhibited drawings<br />
as well as relevant standards.<br />
Should a higher or more onerous standard <strong>requirement</strong> be specified in the Service and<br />
Installation Rules of New South Wales than is specified in MEW E101 or in the<br />
specification clauses and/or exhibited drawings, then that higher or more onerous<br />
standard <strong>requirement</strong> shall apply.<br />
Should a higher or more onerous standard/<strong>requirement</strong> be specified in AS/NZS3000 than<br />
is specified in MEWE101 or in the specification clauses and/or exhibited drawings, then<br />
that higher or more onerous standard/<strong>requirement</strong> shall apply.<br />
0.2 USER GUIDELINE FOR THE SELECTION OF SWITCHBOARD<br />
CLASSIFICATION<br />
Switchboard classifications are defined in this document.<br />
The correct classification for the <strong>electrical</strong> installation should be specified in the main<br />
body of specification clauses or on the exhibited drawings.<br />
The selection of the correct classification is dependent on a number of criteria such as:<br />
• Fault level<br />
• Importance of the installation<br />
• Standby arrangements<br />
• Supply Authority <strong>requirement</strong>s<br />
• Risk and Consequences of a major fault<br />
• Acceptable time to restore <strong>services</strong> in the event of a major fault<br />
• Incidence of lightning<br />
• Type of equipment installed in the Switchboard.<br />
Only design consultants who have attended the <strong>NSW</strong> Department of Commerce<br />
Accreditation Course and are accredited by the <strong>NSW</strong> Department of Commerce for MEW<br />
E101 usage, are legally permitted to use this document. A fee for the use of this<br />
document per project will apply.<br />
MEW E101 Page 1
Part 0 - General<br />
0.3 STANDARDS<br />
AS 1000 The International system of Units (SI) and its application<br />
AS 1023 Low Voltage Switchgear and Controlgear - Protection of Electric Motors<br />
AS 1029 Low Voltage Contractors<br />
AS 1042 Direct-acting Indicating Electrical Measuring Instruments and their Accessories<br />
AS 1100 Technical Drawing<br />
AS 1102 Graphical symbols for Electrotechnology<br />
AS 1103 Diagrams, Charts and Tables for Electrotechnology<br />
AS 1110 ISO Metric Hexagon Precision Bolts and Screws<br />
AS 1111 ISO Metric Hexagon Commercial Bolts and Screws<br />
AS 1125 Conductors in Insulated Cables and Flexible Cords<br />
AS 1202 AC Motor Starters (up to and including 1000V)<br />
AS 1220 Aluminium Conductors Steel Reinforced for Overhead Power Transmission Purposes<br />
AS 1284 Electricity Metering<br />
AS 1345 Identification of the contents of piping, conduits and ducts<br />
AS 1359 Rotating Electrical Machines - General Requirements<br />
AS 1360 Rotating Electrical Machines of Particular Types or for Particular Applications<br />
AS 1417 Rules for Antennas for the Reception of Radio and Television Broadcasting for the<br />
Range 30 to 1000 MHz.<br />
AS 1431 Low Voltage Switchgear and Controlgear - Control Circuit Devices and Switching<br />
Elements<br />
AS 1531 Aluminium Conductors for Overhead Power Transmission Purposes<br />
AS 1580 Paints and Related Materials - Methods of Test<br />
AS 1627 Metal Finishing - Preparation and Pre-treatment of Surfaces<br />
AS 1648 Visually Stress Graded Cypress Pine for Structural Purposes<br />
AS 1650 Hot-dipped Galvanised Coatings on Ferrous Articles<br />
AS 1675 Current Transformers - Measurement and Protection<br />
AS 1746 Hard-drawn Copper Conductors for Overhead Power Transmission Purposes<br />
AS 1882 Earth and Bonding Clamps<br />
AS 1930 Circuit Breakers for distribution Circuits (Up to and including 1000 V ac and 1200 V ac)<br />
AS 1939 Degrees of Protection Provided by Enclosures for Electrical Equipment<br />
AS 2005 Low Voltage Fuses - Fuses with Enclosed Fuse-Links<br />
AS 2052 Metallic Conduits<br />
AS 2053 Non-metallic Conduits and Fittings<br />
AS 2184 Low Voltage Switchgear and Controlgear - Moulded Case Circuit-Breakers for Rated<br />
Voltages (up to and including 600 V ac and 250 V dc)<br />
AS 2648 Underground Marking Tape - Part 1 - Non-detectable Tape<br />
AS 2700 Colour Standards for General Purposes<br />
AS 2768 Electrical Insulating Materials - Evaluation and Classification<br />
AS 3000 SAA Wiring Rules<br />
AS 3008 Electrical Installations - Selection of Cables<br />
Part 1 - Cables for alternating voltages up to and including 0.6/1 kV<br />
AS 3012 Electrical Installations - Construction and Demolition sites<br />
AS 3013 Electrical Installations - Wiring Systems for Specific Applications<br />
AS 3100 Approval and Test Specification - General Requirements for Electrical Equipment<br />
AS 3111 Approval and Test Specification for Miniature Overcurrent Circuit-Breakers<br />
AS 3112 Approval and Test Specification - Plugs and Socket-outlets<br />
AS 3117 Approval and Test Specification - Bayonet Lamp holders<br />
AS 3126 Approved and Test Specification - Extra Low Voltage Transformers<br />
AS 3131 Approval and Test Specification - Plugs and Socket-outlets for Use in Installation Wiring<br />
Systems<br />
AS 3133 Approval and Test Specification - Air Break Switches<br />
AS 3137 Approval and Test Specification - Luminaires (Lighting Fittings)<br />
AS 3140 Approval and Test Specification - Edison Type Screw Lamp holders<br />
AS 3147 Approval and Test Specification - Electric Cables - Thermoplastic<br />
AS 3190 Approval and Test Specification - Residual Current D (current operated earth leakage<br />
devices)<br />
AS 3191 Approval and Test Specification for Electrical Flexible Cords<br />
Page 2 MEW E101
Part 0 - General<br />
AS 3300 Approval and Test Specification - General Requirements for Household and Similar<br />
Electrical Appliances<br />
AS 3439.1 Low Voltage Switchgear and Controlgear Assemblies<br />
:2002<br />
AS 3760 In-service Safety Inspection and Testing of Electrical Equipment<br />
AS 3766 Mechanical Fittings for Low Voltage Aerial Bundled Cables<br />
AS 3947.3 Air Break Switches, Isolators and Fuse Combination Units (1000v AC and 1200 V dc)<br />
IEC 96-3 Radio-frequency cables<br />
Part 3 - General <strong>requirement</strong>s and tests for single-unit coaxial cables for use in cable<br />
distribution systems<br />
Service and Installation Rules of <strong>NSW</strong>, October 2006 (issued by the Department of<br />
Energy, Utilities and Sustainability)<br />
HB 243 Australian Regulatory Arrangement Handbook<br />
HB 29 Communication Cabling Handbook<br />
NOHSC: National Standard for Manual Handling<br />
1001<br />
Occupational Health and Safety Regulation 2001<br />
Carry out all work in accordance with the above standards.<br />
The latest editions of the above are to be used unless otherwise specified. Where a<br />
standard has been superseded, the latest standard shall be used.<br />
MEW E101 Page 3
Part 0 - General<br />
0.4 ABBREVIATIONS<br />
Abbreviations where occurring in this Section of the Specification are in general to<br />
AS 1100.<br />
Metric units have been abbreviated in accordance with AS 1000.<br />
Where other abbreviations and expressions occur in the Specification, they shall mean<br />
as follows:-<br />
ACMA Australian Communication and Media Authority<br />
AS Australian Standard<br />
BS British Standard<br />
BWL Bottom Water Level<br />
BFL Bottom Flood Level<br />
C/O Change Over<br />
CFS Combination Fuse Switch Unit<br />
ELV Extra Low Voltage<br />
FCU Fuse Combination Unit (i.e. a combination switch fuse or combination<br />
fuse switch)<br />
FL Full Load<br />
FLC Full Load Current<br />
HD-UPVC Heavy Duty Unplasticised PVC<br />
HDHC Hard Drawn High Conductivity (Copper)<br />
I/O Input/Output<br />
IP Rating Degree of Protection as described in AS 1939<br />
LD-UPVC Light Duty Unplasticised PVC<br />
LED Light emitting diode<br />
MCC Motor Control Centre<br />
MEN Multiple Earthed Neutral (System)<br />
MEPS Minimum Energy Performance Standard<br />
MIMS Mineral Insulated Metal Sheathed (Cable)<br />
MWL Maximum Water Level<br />
N/C Normally Closed<br />
N/O Normally Open<br />
NAASRA National Association of Australian State Roads Authorities<br />
PA <strong>Public</strong> Address (System)<br />
PAX Private Automatic Exchange (Telephone)<br />
pf Power Factor<br />
PLC Programmable Logic Controller<br />
PLYSWS Paper Insulated Lead Alloy Sheathed Steel Wire Armoured and Served<br />
(Cable)<br />
PVC Polyvinylchloride<br />
RSS Rolled Steel Section<br />
SAA Standards Association of Australia<br />
SCA Switchgear and Controlgear Assembly<br />
SPO Special Purpose Outlet<br />
TPI Thermoplastic Insulated (Cable)<br />
TPS Thermoplastic Insulated and Sheathed (Cable)<br />
TWL Top Water Level<br />
TFL Top Flood Level<br />
UPVC Unplasticised Polyvinylchloride<br />
XLPE Cross Linked Polyethylene<br />
Page 4 MEW E101
PART 1 - INSTALLATION<br />
101 SETTING OUT OF RUNS<br />
Apply the following <strong>minimum</strong> <strong>requirement</strong>s when setting out the work:<br />
Part 1 -Installation<br />
(a) Fix cables and conduits parallel to building members, walls, doors, etc. and run on<br />
the square wherever possible. In slabs, conduits may be run diagonally.<br />
(b) Unless otherwise indicated, cable from below any circuit supplying floor mounted<br />
equipment. Conduits shall not be surface mounted on floors. They shall instead be<br />
sunk or concealed under floor boards or in concrete floor slabs.<br />
(c) Run in separate conduits circuits originating at different switchboards.<br />
(d) Locate cables and conduits run in roof spaces below the roof heat insulation and<br />
sarking and run above the insulation, or if insulation is not installed, derate the<br />
cables in accordance with AS 3008.1 for an assumed ambient temperature of<br />
55 o C.<br />
(e) Protect surface or recessed wiring in TPS cables to switches, outlets and similar<br />
terminations by conduit drops sized to accept the TPS cables and originating at an<br />
accessible point in the roof space.<br />
(f) Arrange all cables and conduits to run parallel to floors and building members.<br />
(g) Install TPS cabling so that it may be fully replaced. Where TPS cabling passes<br />
through an inaccessible space it shall be capable of being drawn through the<br />
space such that rewiring can be readily performed.<br />
Note: This may require the installation of conduit through the space.<br />
(h) Install site reticulation cables in underground conduits unless stated otherwise.<br />
Direct buried cables are not permitted. Lay underground pipes straight with<br />
<strong>minimum</strong> deviation from the horizontal and vertical planes but graded for drainage.<br />
TPI cables are not permitted underground.<br />
(i) No conduits allowed in the floor slab of boiler rooms.<br />
102 PENETRATIONS<br />
102.1 Generally<br />
Use mortar of a 3 : 1 sand cement mix with surfaces "Bondcreted" prior to applying the<br />
mortar for repairs to all penetrations and repairs.<br />
No penetrations through damp courses are permitted.<br />
102.2 Penetrations Through Waterproof Membranes<br />
Pipes which enter a building at ground level shall run under the waterproof membrane<br />
and vertically penetrate the membrane and the concrete slab at the appropriate position.<br />
Where pipes pass through roofs, proprietary sealing shall be provided between the pipes<br />
and the waterproof membrane.<br />
102.3 Penetrations Through External or Existing Structures<br />
Where pipes pass through external walls, existing ground floor slabs or existing ground<br />
floor beams, a penetration 10 greater than the pipe diameter shall be provided. The<br />
penetration space around the pipe shall be made waterproof by using a proprietary<br />
sealing method.<br />
MEW E101 Page 5
Part 1 - Installation<br />
102.4 Unenclosed Cables Passing Through Slabs<br />
Unenclosed cables in slabs are not permitted.<br />
103 AERIAL RETICULATION (POWER)<br />
103.1 Attachment to Poles<br />
Attach aerial conductors to poles by:<br />
(a) Pin insulators mounted on a horizontal crossarm provided that the conductors do<br />
not change direction by more than 10 degrees, or<br />
(b) Shackle insulators secured by hooks on poles and bolts on crossarms at tee-offs,<br />
terminations, and other locations. These shackle insulators shall be fixed with<br />
galvanised nuts and bolts.<br />
(c) Where aerial bundled conductors are used, terminate in accordance with AS 3766.<br />
Conductors shall be fastened to pin insulators with tie-wire of 2.5mm² stranded black<br />
insulated building wire or a suitable proprietary fixing method.<br />
103.2 Attachment to Buildings<br />
103.3 Poles<br />
103.3.1 Generally<br />
Attach aerial conductors to buildings with shackle insulators and the shackle support shall<br />
be bolted to masonry or a structural member. Pass the conductor through or around the<br />
insulator and then around itself. Alternatively, a proprietary fixing method may be used.<br />
Conductors shall enter the building via a conduit sloping upwards into the building at a<br />
<strong>minimum</strong> angle of 45 degrees to the horizontal for weatherproofing.<br />
Where upstands are required, they shall be of a proprietary manufacture acceptable to<br />
the Supply Authority for service attachments.<br />
Unless otherwise indicated, poles shall be hardwood.<br />
Provide where required by the Supply Authority, a weatherproof box and/or service fuses.<br />
Protect cables and conduits running down the exterior of a pole to a height of 2000 above<br />
ground by a galvanised water pipe for conduits under ∅40 or a 3.2mm thick hot dipped<br />
galvanised channel fixed to the pole for all other conduit sizes. Extend the protection 150<br />
below the surface.<br />
Bury, unless otherwise indicated, poles to a <strong>minimum</strong> depth of 1600.<br />
Baulk and stay to prevent leaning or bending where poles will be subject to bending<br />
stresses, e.g. where the aerial cables change direction or terminate.<br />
103.3.2 Hardwood Poles<br />
103.3.3 Crossarms<br />
Provide only dressed, natural round poles with all sapwood removed treated against<br />
fungus and termites as described in the Wiring Rules to 600 above ground level.<br />
An alternative fungus treatment may be used only with the approval of the Supply<br />
Authority and the Superintendent. This alternative treatment requires that the soil around<br />
and beneath the pole be treated with creosote during the ramming and setting process.<br />
The pole shall be liberally coated with creosote from the base to 600 above ground level.<br />
Fit all poles with a galvanised steel domed cap extending 25 down the sides and fastened<br />
at the side with galvanised steel nails.<br />
Page 6 MEW E101
Supply crossarms 75 x 75 x 1500 (<strong>minimum</strong>) finished size hardwood.<br />
Part 1 -Installation<br />
Notch all hardwood poles to accept the crossarms, and securely bolted to the pole using<br />
M20 galvanised bolts, nuts and washers.<br />
Brace each crossarm with two braces each 5 x 40 x 690 galvanised steel fixed at 45<br />
degrees to the pole below the crossarm with an M12 x 75 galvanised coach screw in the<br />
pole and with M12 galvanised bolts, nuts and washers in the crossarms.<br />
103.3.4 Service Poles<br />
Generally service poles shall be hardwood complying with the above <strong>requirement</strong>s;<br />
however, approved aluminium, steel or concrete poles will be accepted.<br />
Hot dipped galvanised steel poles after fabrication, cap to prevent moisture entry and set<br />
in concrete or fixed by means of a galvanised rag bolt assembly.<br />
Detail proposed poles other than hardwood in the submitted drawings and must have the<br />
prior written approval of the Supply Authority.<br />
Drawings must clearly indicate the installation method, particularly the running of cables<br />
in or on the pole.<br />
103.4 Aerial Cables<br />
For details of aerial cables, refer to Clause 106.8.<br />
104. UNDERGROUND RETICULATION<br />
104.1 Trenching, Backfilling and Reinstatement<br />
104.1.1 Generally<br />
104.1.2 Inspection<br />
The work associated with trenching includes clearing, grubbing, excavation, filling and<br />
consolidation of the trench and all necessary pumping, drainage, shoring and bracing.<br />
Excavate all trenching included in the works to an even surface free from sharp<br />
projections.<br />
Where crossing or running parallel to other <strong>services</strong>, underground cabling shall be<br />
spaced as approved. Comply with the <strong>requirement</strong>s of the telecommunication authority,<br />
gas, water and sewerage authorities.<br />
Refer to Clause 109 for telecommunication authority <strong>requirement</strong>s.<br />
Cut existing concrete or bitumen surfaces to be disturbed in a straight line with a masonry<br />
saw to 75 <strong>minimum</strong> depth before excavation is commenced.<br />
Where solid rock is encountered, cables may be chased into rock if approved.<br />
Enclose direct buried cables that pass under buildings in heavy duty non-metallic<br />
conduits of adequate size complying the AS 2053. Seal all pipes from pits to items of<br />
equipment in the pit using expanding foam.<br />
Minimum conduit depth 600mm to top of conduit.<br />
Leave all cable trenches ready for inspection at the following stages:<br />
(i) after laying conduit, but before any backfilling or laying marker tape, and<br />
(ii) after laying marker tape.<br />
The entire underground reticulation system shall be inspected prior to cable installation.<br />
At this time the drainage system will be checked using water inserted at various points<br />
and the system must drain free of water within two (2) hours.<br />
MEW E101 Page 7
Part 1 - Installation<br />
Notify the Superintendent of required inspections two (2) working days prior to the<br />
inspection.<br />
104.1.3 Backfilling and Reinstatement<br />
Bed PVC conduits on 50 <strong>minimum</strong> of clean sand and cover by a further 50 of clean sand<br />
before backfilling the trench.<br />
After laying the conduits in unpaved areas, backfill the trench and consolidate to about 10<br />
above the natural ground level. Remove all excess spoil from the site.<br />
Existing grassed areas shall be backfilled and turf re-laid on prepared bed or otherwise<br />
re-grassed to 10 above natural ground level.<br />
In existing concrete or brick paved areas, backfill the trench with clean sand to the<br />
underside of the reinstated pavement and consolidated by watering and mechanical<br />
compaction. Reinstate surfaces to the original level. For concrete surfaces use<br />
approved reinforced steel, keyed to the existing to prevent the reinstalled concrete from<br />
subsiding and cracking.<br />
In existing bitumen paved areas, camber the reinstated surfaces so that the edges are<br />
flush and the centre is 10 above the existing pavement. The top 150 (<strong>minimum</strong>)<br />
immediately below the bitumen, shall consist of finely crushed gravel mechanically<br />
compacted into the trench. Prime the existing bitumen edges of the trench shall be prime<br />
coated with bitumen prior to laying 75 <strong>minimum</strong> of hot "pre-mix" bitumen to the finished<br />
cambered surface. If it can be shown that hot pre-mix is not available, cold pre-mix will<br />
be accepted.<br />
104.2 Underground Cable Protection<br />
To preclude damage, cables installed in pipes shall be drawn using rollers, drumjacks<br />
and a cable stocking of the correct size.<br />
A 150 wide orange marker tape bearing the words "WARNING - ELECTRIC CABLE<br />
BURIED BELOW" or similar and manufactured in accordance with AS 1648, Part 1, shall<br />
be laid in the trench 150 below ground level for the entire length of all underground cable<br />
and conduit runs.<br />
Marker tape is also to be provided over conduits and pipes installed underground for<br />
future use.<br />
104.3 Underground Cable Draw-In Pits<br />
Provide draw-in pits for underground cables as indicated. Where the size of the pit is<br />
indicated, the dimensions refer to inside dimensions. The pits walls and bottoms to be<br />
<strong>minimum</strong> 100 reinforced concrete. The concrete shall contain an approved additive to<br />
prevent ingress of water.<br />
Alternatively proprietary type glass reinforced moulded cement pits or "Polycrete" with<br />
<strong>minimum</strong> 10 thick walls and bottom may be used and installed in accordance with the<br />
manufacturer's instructions on a <strong>minimum</strong> 100 thick gravel aggregate bed which shall<br />
extend under the entire pit bottom. Encase the pit in a 100 thick reinforced concrete<br />
surround with the top neatly finished.<br />
Drain all pits. The <strong>minimum</strong> drainage <strong>requirement</strong> is a 300 x 100 deep rubble drain<br />
graded away from the pit for a distance of 2000.<br />
Pits greater than 400 wide shall be fitted with covers and frames of cast iron or aluminium<br />
and concrete. The covers shall maintain a stabilising fit with the frame by a taper contact<br />
on the sides. All vertical mating surfaces to be fitted to a maximum clearance of 0.25<br />
mm.<br />
Covers and frames shall be suitable for the particular loading conditions. Ensure, unless<br />
shown otherwise, the loadings are low speed, heavy vehicle loads. The maximum mass<br />
of any individual section of the cover shall not exceed 40 kg.<br />
Fit pits 400 wide and less with proprietary concrete covers.<br />
Page 8 MEW E101
Part 1 -Installation<br />
Install all pits with the top of the cover 25 above the surrounding finished level and grade<br />
the surface for 500 around the pit.<br />
Provide one set of lifting handles for the covers and store on site as directed.<br />
Where the size of the pit is not indicated, <strong>minimum</strong> dimensions are 600 x 600 x 900<br />
deep.<br />
The word "ELECTRIC" in 25 high letters shall be moulded into the lids of all such pits<br />
which contain electric power cables.<br />
Pits used for the purpose of the telecommunications authority’s telephone <strong>services</strong> shall<br />
bear the marking “Telecommunication” as required by the ACMA standard.<br />
Also see Clause 108.9 for draw-in box details.<br />
105 MARKING PLATES FOR UNDERGROUND RETICULATION<br />
105.1 Generally<br />
Install marking plates on all underground cable or conduit runs. Manufacture plates from<br />
<strong>minimum</strong> 1mm thick brass or other approved material 75 x 75 and fix with approved<br />
waterproof adhesive and four brass or stainless steel screws to suit the material of the<br />
marking plates. Use stainless steel plates and screws at sewage treatment works and<br />
sewage pumping stations.<br />
Do not install marking plates on cable pit lids but may be installed on the concrete lip of a<br />
cable pit.<br />
Engrave marking with <strong>minimum</strong> 4 mm high lettering.<br />
Install marking plates flush with the finished ground level. Recess or bevel marking<br />
plates in paved areas.<br />
Prepare accurate record scale drawings of proposed marker locations and underground<br />
reticulation prior to backfilling and will be retained by the Superintendent until markers are<br />
installed.<br />
105.2 Indication of Cable Entry to Buildings<br />
Where underground cables enter a building fix a marking plate to the wall at a height of<br />
300. Engrave the plate with an arrow pointing downwards and the words "ELECTRIC<br />
CABLE".<br />
In addition, fix a marking plate to concrete paving or the top face of a concrete block<br />
approximately 150 x 150 x 300 deep located immediately above the cable and as close<br />
as practical to the building. Engrave the plate with an arrow, pointing in the direction in<br />
which the cable is laid, and the words "ELECTRIC CABLE". The distance to the next<br />
marker, in metres is required.<br />
105.3 Indication of Directional Changes<br />
Where an underground cable changes direction, fix two marking plates or alternatively a<br />
plate with two arrows to a concrete block approximately 200 x 200 x 300 deep located<br />
immediately above the cable. Engrave each plate with an arrow pointing in the direction in<br />
which the cable is laid and the words "ELECTRIC CABLE". Neatly stamp the distance to<br />
the next marker, in metres, into the face of the plate.<br />
MEW E101 Page 9
Part 1 - Installation<br />
105.4 Indication of Cables Under Roads and Paths<br />
Where a cable passes under a road or path, place a marking plate at each side of the<br />
road or path. Engrave the marking plate as detailed in Clause 105.3 and fixed to a<br />
concrete block approximately 150 x 150 x 300 deep.<br />
Alternatively, marking plates may be fixed to the kerb of a kerbed road.<br />
105.5 Indication of Terminated Conduits<br />
Where conduits are terminated underground and beyond the perimeter of a building or<br />
paved area, fix a marking plate to a concrete block approximately 150 x 150 x 300 deep<br />
located above the termination point. Engrave the plate with the words "ELECTRIC<br />
CONDUIT TERMINATED UNDER".<br />
106 CABLES AND WIRING<br />
106.1 Generally<br />
Supply cables, terminations, fittings and accessories suitable for the voltage, current,<br />
frequency, temperature and environmental duty.<br />
Terminate copper conductors either into tunnel type connectors or by suitably sized lugs<br />
sweated or crimped in an approved manner.<br />
Ross Courtney (solderless) terminations may be used on conductors up to 4mm 2.<br />
No joints in cables can be made between equipment terminal connections unless<br />
required by AS 3000.<br />
Stranded conductors are required above 1mm².<br />
Cable colours and codes are as follows:<br />
red, white, blue - active conductors in multi-phase mains and circuits.<br />
red - active conductors in single phase mains and circuits.<br />
black - neutral conductor.<br />
white (numbered cores) - control circuit cabling outside of switchboards.<br />
green-yellow - earth wires.<br />
Refer to Clause 205.2 for Cable Identification.<br />
Carry insulation resistance testing out with a <strong>minimum</strong> 1000 V DC testing instrument.<br />
Make final connections to equipment generally using flexible conduit, seal the flexible<br />
conduit at each end using expanding foam or a cable gland.<br />
All cables to be PVC insulated PVC sheathed circular unless otherwise specified.<br />
106.2 Consumer's Mains and Metering<br />
Run the consumer's mains underground from the Point of Attachment as sheathed<br />
copper cable in conduit for its entire length to the main switchboard (in the case of current<br />
transformer metering) or the Supply Authority metering panel (in the case of Direct<br />
Metering).<br />
The <strong>minimum</strong> size of consumers mains is 16mm², however the following <strong>requirement</strong>s<br />
apply:-<br />
(a) Current carrying capacity to suit the maximum demand and any stated future<br />
extensions with an excess current carrying capacity of 30% <strong>minimum</strong>.<br />
(b) Be sized so the voltage drop is less than 1.5% at plant future maximum demand at<br />
(a) above.<br />
(c) Be either single core PVC/PVC cables or four core PVC/PVC cable XLPE<br />
insulation may be used.<br />
Page 10 MEW E101
(d) Comply with the <strong>requirement</strong>s of the Supply Authority.<br />
Part 1 -Installation<br />
Where direct metering is employed the cable between the meter panel and the Main<br />
Switchboard shall be the same size as the consumers mains and the voltage drop above<br />
shall include the voltage drop in this cable. Where required by the Supply Authority the<br />
cable shall be protected by a circuit breaker of the same type and frame size as the Main<br />
Switchboard Main Switch.<br />
Install a metering enclosure generally on an exterior wall of the building so that it is<br />
accessible without entering the building. The panel shall generally be reused. Surface<br />
mounting on existing buildings is acceptable. The metering enclosure and panel shall be<br />
Energy Authority approved and suitable for the installation of the metering equipment<br />
required by the Supply Authority.<br />
All metering equipment shall be supplied and installed under this Contract including:-<br />
(a) Plug-in meter bases (if required)<br />
(b) Service fuses<br />
(c) Current transformer metering equipment<br />
(d) All necessary wiring<br />
(e) Active link (if required)<br />
(f) Neutral link<br />
(g) Earth link<br />
(h) Other equipment required by Supply Authority.<br />
Paint meter boxes using acrylic gloss in a colour to match the surrounding building.<br />
106.3 Final Sub-Circuit Wiring<br />
106.3.1 Generally<br />
The <strong>minimum</strong> size conductors shall be as follows:<br />
Power Circuits 2.5mm², copper conductors<br />
Lighting Circuits 1.5mm², copper conductors<br />
Clock Circuits 1.5mm², copper conductors<br />
Control Circuits 1.5mm², copper conductors<br />
Ceiling Fan Circuits 1.5mm², copper conductors<br />
Final sub-circuit wires shall generally be terminated in tunnel type connectors. Where<br />
stud or pillar connections are made, stranded conductors shall be prevented from<br />
spreading; twisting multi-stranded conductors is not considered adequate.<br />
Connection of single strand conductors to tunnel terminals on moulded case circuit<br />
breakers shall be made by doubling the conductor back in "open loop" form.<br />
Wiring shall be carried out using the "draw-in, loop-in" system for both TP1 and TPS<br />
cables. No intermediate connections to be made except for TPS cables where looping<br />
terminals may be used at switches, light fittings etc.<br />
Final connections to equipment having parts of the surface at a temperature greater than<br />
the temperature rating of the circuit cable shall be made with cable having insulation at<br />
least rated to 200 degrees Celsius maximum operating temperature.<br />
Supply all motors with a local rotary isolator connected in the control circuit adjacent to<br />
the motor. Make final connections to all equipment using flexible conduit.<br />
106.4 Instrumentation Cables<br />
Instrumentation cables shall be cables that:<br />
MEW E101 Page 11
Part 1 - Installation<br />
i. Carry ELV analogue signals e.g. 4-20 mA dc.<br />
ii. Connect to instruments for the purpose of signalling or monitoring.<br />
iii. Connect to the inputs of PLC's or alarm annunciators.<br />
Cables shall be min. 0.5mm² PVC insulated aluminium polyester screened PVC<br />
sheathed.<br />
A separate 2 core cable shall be supplied for each analogue signal (equal to Dekron<br />
IEB183 type).<br />
Digital signals may use a multi, twisted pair overall screened PVC cable. Each digital<br />
signal shall have its own pair as, common returns are not permitted. Cable shall be<br />
equal to Dekron IEC183 type.<br />
The screen of each cable shall be earthed at the switchboard only.<br />
106.5 Insulated Non-Armoured Cables in Enclosures (TPI)<br />
Cables shall be 0.6/1 kV grade with <strong>minimum</strong> V75 or XLPE insulation.<br />
106.6 Underground Grade Insulated and Sheathed Non-Armoured Cables (TPS)<br />
Cables shall be 0.6/1 kV grade with <strong>minimum</strong> V75 or XLPE insulation.<br />
The cables shall have the manufacturer's name and reference and the word<br />
"UNDERGROUND" clearly indented in the sheathing.<br />
106.7 Armoured and Sheathed Cables (Other than Paper Insulated)<br />
Cables shall be 0.6/1 kV grade with <strong>minimum</strong> V75 or XLPE insulation and shall have<br />
armouring of galvanised steel wire (double or single), steel tapes, or aluminium strip/wire.<br />
Tape armouring shall not be used to support the cables during installation.<br />
Armouring shall be cleaned, clamped and connected to earth at the origin of the cable. It<br />
shall not be used as an earth conductor.<br />
106.8 Aerial Cables<br />
Cables shall comply with AS 1746 "Hard-Drawn Copper conductors for Overhead Power<br />
Transmission Purposes" or AS 3607 "Bare Overhead Aluminium Conductors Steel<br />
Reinforced", or AS 1531 "Aluminium Conductors for Overhead Power Transmission<br />
Purposes".<br />
Aerial cables attached to buildings shall be insulated. Connections between aluminium<br />
able and copper aerial cable shall be made with a bail clamp having aluminium and<br />
tinned copper connectors.<br />
Where aluminium cables are terminated to copper cables the aluminium cable shall be<br />
physically above the copper cable.<br />
106.9 Special Purpose<br />
106.9.1 Essential Service Cables<br />
Unless other indicated, cables supplying power to designated "Essential Services" shall<br />
consist of MIMS copper conductor copper sheath cables.<br />
Where run horizontally, the cable shall be as high as possible, separately fixed directly to<br />
the building structure (eg underside of slab). Where run vertically, the cables shall be<br />
mechanically protected. Where a number of <strong>services</strong> cross or follow a similar route the<br />
"Essential Services" cable shall be located at the highest point and closest to the<br />
structural support.<br />
Metal cable fixings shall be used; the use of nylon or plastic material is prohibited.<br />
106.9.2 Telephone Cables<br />
Page 12 MEW E101
Part 1 -Installation<br />
Cables used for communication purposes (Telephone, Intercom etc) shall be multi-pair<br />
telephone cables of nominal conductor diameter 0.5mm <strong>minimum</strong> to ACMA Specification.<br />
Cables installed within buildings shall be PVC insulated and sheathed. Cables installed<br />
external to a building shall be Polythene insulated and sheathed.<br />
All work associated with telephone line connections shall comply with the following:<br />
106.9.3 Fire Alarm Cables<br />
• Australian Regulatory Arrangement Handbook HB 243-2007 (Communication<br />
Cabling Manual Module 1)<br />
• Communication Cabling Handbook HB29-2007 (Communication Cabling Module<br />
2)<br />
• Requirements for Customer Cabling Products (AS/ ACIF S008-2006)<br />
• Installation Requirements for Customer Cabling (AS/ACIF S009-2006)<br />
Cables used for the connection of thermal, smoke and manual fire detectors, or other<br />
associated equipment within the building shall be TPI or TPS <strong>minimum</strong> 1.5mm 2 stranded<br />
copper cable. TPS cable shall have red coloured sheathing.<br />
106.9.4 Security Cables<br />
Cables used for window and door seals, and associated equipment shall be <strong>minimum</strong><br />
0.5mm ² stranded copper TPI cable, figure 8 configuration.<br />
Cables for space detectors (ultrasonic, infra-red, microwave, etc) shall be <strong>minimum</strong><br />
0.5mm ² stranded copper TPI, shielded twisted pairs or as per the manufacturer's<br />
installation <strong>requirement</strong>s.<br />
106.10 Control Cabling<br />
(a) General<br />
The insulation of each cores shall indelibly be numbered consecutively (e.g. one 1) for<br />
each core.<br />
(b) 240 Volt a.c. Control Cabling<br />
Control cables shall be PVC insulated PVC Sheathed cables with copper conductor<br />
<strong>minimum</strong> 1.5mm².<br />
(c) ELV Control Cabling for Connection to Digital I/O<br />
ELV control cables external to the switchboard connecting to digital I/O shall be V-<br />
90HTPVC insulated with overall screen and drain wire of <strong>minimum</strong> size 0.5 mm².<br />
(d) ELV Control Cabling for Connection to Analogue I/O<br />
ELV control cables external to the switchboard connecting to analogue I/O shall be<br />
overall screened, PVC sheathed twisted pair cabling with a <strong>minimum</strong> conductor size of<br />
1.5 mm².<br />
107 EARTHING<br />
107.1 Generally<br />
The earthing system shall comply with the Statutory and/or Supply Authority<br />
<strong>requirement</strong>s.<br />
Generally earthwires shall be enclosed in conduits with submains and subcircuits.<br />
A separate MEN system for each building shall be used except where an earthing<br />
conductor is indicated to be run with the submain to that building.<br />
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Part 1 - Installation<br />
Metallic pipes used for other <strong>services</strong>, such as gas, water, sprinkler systems, etc., shall<br />
be considered as unavoidably in contact with metallic enclosures of <strong>electrical</strong> equipment<br />
and shall be effectively bonded to the earthing system.<br />
107.2 Earthing Conductors for Underground Cables<br />
Earthing conductors other than the copper sheathing of MIMS cables shall be copper<br />
stranded conductors sized as per AS 3000, protected by a green-yellow insulation and<br />
installed as follows:<br />
(a) Separate earthing conductors for TPI conductors in conduit.<br />
(c) Separate earthing conductors attached to the cable at 1000 intervals.<br />
(c) Earthing conductors laid up with the cable.<br />
107.3 Earth Electrodes<br />
Earth electrodes shall consist of copper, stainless steel or copper sheathed rods not less<br />
than 16 diameter driven to a depth of not less than 2400 to reach the permanent moisture<br />
level. Unless disallowed by the Supply Authority, the indicated footing in each building<br />
shall be used as an electrode in addition to the above. The earthing conductor shall be<br />
connected to the reinforcing steel of the indicated footing and the driven electrode. Each<br />
electrode shall generally be installed in an earthing pit similar to "Polycrete" PEP 22.<br />
Each pit shall have a reinforced concrete surround <strong>minimum</strong> 250 wide and 200 deep<br />
complete with cable markers.<br />
108 CONDUITS, FITTINGS AND JOINTS<br />
108.1 Generally<br />
Conduits and fittings shall comply with either AS 2052 "Metallic conduits and fittings" or<br />
AS 2053 "Non Metallic conduits and fittings". Conduits smaller than 20 dia. shall not be<br />
used except for fire alarm systems where 16 dia. will be accepted.<br />
Conduits shall be in long lengths, straight, smooth and free from rags, burrs and sharp<br />
edges. Off cuts shall not be used to fabricate long lengths of conduit. Conduits shall be<br />
set wherever possible to minimise the number of joints.<br />
Bends shall be of large radius and shall be formed with approved formers. Correctly<br />
sized springs shall be used to form bends in UPVC conduits. Conduits manipulated or<br />
bent must maintain true effective diameter and shape at all parts of the bend. Conduit<br />
sets distorted or showing evidence of kinks, wrinkles, flats or having been heated will not<br />
be accepted. Wherever possible, UPVC Conduits bends should be preformed by the<br />
manufacturer.<br />
Conduits shall be colour coded in accordance with Clause 602 of MEW E101.<br />
Saddles supporting conduits shall be effectively secured to the surface on which they run.<br />
Saddles shall be a proprietary brand installed as supplied.<br />
Conduit systems, including conduits and pipes used to convey cables into buildings, shall<br />
be sealed to prevent water entry.<br />
The number of cables including earth wires that may be enclosed in any one conduit or<br />
pipe shall not exceed that recommended as a guide in AS 3000.<br />
All conduits exposed to weather shall be painted with a light coloured paint designed for<br />
the purpose.<br />
108.2 Heavy Duty UPVC Conduits to AS 2053 (HD-UPVC)<br />
This conduit shall be coloured "light orange" except for conduits enclosing<br />
telecommunication authority cables which shall be "white", and may be used<br />
underground, above ground is permitted only as specified. All fittings shall be of the<br />
same material as the conduit and all joints shall be made with an approved adhesive<br />
Page 14 MEW E101
Part 1 -Installation<br />
cement of contrasting colour. These conduits are not generally permitted above ground<br />
except to sizes above ∅63 when the conduit must be painted with a light coloured acrylic<br />
gloss paint designed for the purpose.<br />
108.3 Steel Conduits<br />
All steel conduits shall be heavy protected (hot dipped galvanised), with screw joints and<br />
screwed terminations, to AS 2052. End joints and terminations shall be made by<br />
screwing the conduit into the fitting with circular galvanised plated lock nuts screwed onto<br />
the conduit.<br />
Steel conduits shall have screwed ends and screwed joints, all threads being painted with<br />
aluminium paint. Steel conduits shall be <strong>electrical</strong>ly and mechanically continuous.<br />
Electrical continuity tests shall be carried out prior to the installation of draw cords.<br />
108.4 Light Duty UPVC Conduits to AS 2053 (LD-UPVC)<br />
This conduit may only be used above ground in positions not exposed to mechanical<br />
damage.<br />
All associated plastic fittings shall be of the same material as for the conduits.<br />
All conduits, plastic fittings and adhesive cement shall be procured from the same<br />
manufacturer, and the manufacturer's recommended procedures shall be adopted for the<br />
making of joints. All joints and conduit entries shall be made with an approved adhesive<br />
cement of a contrasting colour.<br />
All wall and junction boxes shall be of the same material as the conduits. Where special<br />
size boxes are indicated but are not obtainable in PVC, pre-fabricated metal boxes shall<br />
be used where approved. UPVC conduits shall be fixed to such metal boxes with<br />
screwed PVC adaptors and lock nuts. metal boxes shall be earthed.<br />
UPVC conduit shall be fixed to a PVC wall box with a screwed PVC adaptor and circular<br />
lock nuts, unless the conduit enters the wall box via a moulded conduit entry.<br />
108.5 Flexible Conduits<br />
Flexible conduits shall be of the plastic sheath, smooth, PVC spiral reinforced type and<br />
shall be oil resistant, UV resistant and impact resistant.<br />
Flexible conduits shall be equivalent to:<br />
i. FLEXICON LPC<br />
108.6 Installation<br />
108.6.1 Generally<br />
ii. RHINOFLEX by ADAPTAFLEX<br />
Where the connection is the final connection to an <strong>electrical</strong> item, the conduit length shall<br />
be sufficient to allow decoupling and moving aside of the equipment without<br />
disconnection of the cables or conduit. The degree of protection of fittings associated with<br />
the conduit shall be IP67. All fittings shall be nickel plated brass except where otherwise<br />
indicated. Notwithstanding the previous sentence, the fittings shall be compatible with<br />
chemicals in the area of installation.<br />
Corrugated flexible conduits are not permitted.<br />
Carry out all final connections to equipment using flexible conduit.<br />
Fix flexible conduits to a surface with saddles or stainless steel bands. Do not use PVC<br />
cable ties for the fixing of flexible conduits.<br />
Generally, UPVC conduit shall not be installed on exterior surfaces. However, sunlight<br />
resistant UPVC conduit and fittings complying with AS 2053 and marked with the letter<br />
"T" may be run in locations exposed to direct sunlight. In sewage treatment works all<br />
external conduits below 40mm shall be "Clipsal HFT". Also, short runs of HD-UPVC<br />
MEW E101 Page 15
Part 1 - Installation<br />
pipes from underground submains may be surface run where they enter a building if it is<br />
not practicable to conceal them, provided that they are suitably protected from<br />
mechanical damage and sunlight.<br />
All UPVC conduits shall be terminated into metal boxes and enclosures (draw-in-boxes,<br />
joint boxes, switchboards, ducting etc.) via a screwed PVC adaptor with lock nut.<br />
Conduits shall be so installed that wiring is carried out using the "draw-in, loop-in" system.<br />
The conduit run shall be completely installed before wiring is drawn in.<br />
The wiring shall be drawn in only at outlets and switchboards and, if approved, at draw-in<br />
boxes. Inspection fittings are allowed only if approved.<br />
Conduits shall be run directly from the entry point to the termination point with the<br />
<strong>minimum</strong> number of sets (the number of sets shall not be greater than the equivalent of 3<br />
x 90 degree bends). The installation of elbows, tees, etc., is prohibited on conduits<br />
installed in inaccessible locations.<br />
All conduits shall be effectively capped during construction.<br />
Conduits shall be securely fixed to building members and shall be adequately supported<br />
during all stages of building construction. (Particular care shall be taken to support PVC<br />
conduit upstands). Generally all conduits shall be concealed and only exposed to view<br />
when approved.<br />
Surface conduits shall be made to harmonise as far as practicable with the architectural<br />
features of the building. Surface conduits shall be run in vertical and horizontal directions<br />
except where it is desirable to follow the line of a building, where the approval of the<br />
Superintendent shall be obtained.<br />
Conduits shall terminate in luminaires, equipment, accessories or in wall boxes and<br />
junction boxes of a type compatible with the installation.<br />
Do not exceed the following space factors:-<br />
1 cable in the conduit - 50% of the area<br />
2 cables in the conduit - 30% of the area<br />
3 or more cables in conduit - 40% of the area<br />
108.6.2 Conduit Saddles<br />
Conduit saddles shall be either PVC or stainless steel. PVC saddles may be used<br />
indoors and in wet wells or areas not exposed to sunlight. All other situations shall be<br />
stainless steel saddles.<br />
108.6.3 Expansion Joints<br />
Expansion fittings shall be installed on all straight runs of UPVC plastic conduit, except<br />
those embedded in concrete or wall chases. The spacing of expansion fittings shall not<br />
be greater than 8000. A sample of the type of expansion fitting to be used shall be<br />
submitted prior to installation. Conduit clips shall be installed close to expansion fittings;<br />
all clips shall be installed to allow the conduit to move freely while expanding or<br />
contracting.<br />
Expansion couplings shall be installed wherever expansion or contraction joints occur in a<br />
building slab. Note: "Bellows" type expansion couplings shall not be used in floor slabs or<br />
similar installations.<br />
Each expansion coupling in a building slab shall consist of a short length of flexible<br />
conduit, to join the two UPVC conduits across the expansion joint, covered by a larger<br />
UPVC conduit. The larger conduit shall extend 150 from the flexible conduit in both<br />
directions and shall be secured fixed to prevent movement and sealed to prevent<br />
concrete entry whilst the slab is poured.<br />
For multi-pipe expansion boxes refer to contract drawings for details.<br />
108.7 Conduits in Roof Spaces<br />
Page 16 MEW E101
Part 1 -Installation<br />
Where conduits are run in roof spaces, they shall be installed below the heat insulation<br />
and sarking but above any insulation on the ceiling.<br />
Where PVC conduits are installed in roof spaces and are likely to be walked on, they<br />
shall be adequately protected.<br />
MEW E101 Page 17
Part 1 - Installation<br />
108.8 Conduits in Concrete<br />
108.8.1 Generally<br />
Unless otherwise indicated, conduits shall not be run in the concrete topping. Conduits<br />
run in the fill under floor slabs shall be HD-UPVC.<br />
Corrugated conduits are not permitted.<br />
Conduits shall be securely fixed to the reinforcing rods, passing above a single layer of<br />
rods or between a double layer of rods, generally mid-way in the thickness of the slab.<br />
Attention shall be paid to routes of conduits in slabs to avoid cross-over and to keep the<br />
number of conduits in any one location to a <strong>minimum</strong>. Conduits in slabs shall be spaced<br />
not less than 75 apart.<br />
Conduits may cross providing they intersect at angles greater than 30 degrees and are<br />
tied together. The <strong>minimum</strong> cover over conduits shall not be less than the conduit<br />
diameter or 20.<br />
Conduits shall not be installed in a slab through the areas around a column to one quarter<br />
the distance from the column to the next column, supporting beam or wall, except to<br />
outlets in the area.<br />
Attendance during the concrete pouring to ensure that conduits are not displaced, broken<br />
or damaged is mandatory.<br />
Two working days notice shall be given to the Superintendent's Representative to inspect<br />
all conduits prior to pouring concrete. Sufficient time for alterations or modifications<br />
found necessary during inspection by the Superintendent's Representative shall be<br />
allowed.<br />
108.8.2 Conduits in Suspended Slabs<br />
Unless otherwise indicated, the maximum diameter of conduits in suspended slabs shall<br />
be 25, spaced not less than 75 apart.<br />
108.8.3 Conduits in General Columns<br />
Unless otherwise indicated, a maximum of four 20 dia. conduits are permitted in each<br />
column. No more than two conduits shall cross any one face of the column and all<br />
conduits shall be placed centrally.<br />
Bends in conduits entering the columns shall have a <strong>minimum</strong> radius of 300. Structural<br />
columns shall not be chased for conduit installation.<br />
108.9 Draw-In Points<br />
For surface run conduit systems, draw-in points shall be provided at suitable intervals not<br />
exceeding 30 metres for straight runs and at intervals not exceeding 25 metres for runs<br />
including directional changes. Draw-in points shall be agreed with the Superintendent<br />
prior to installation. Where used, draw-in boxes shall be of adequate size to prevent<br />
undue deformation of the cables.<br />
For underground conduit systems, draw-in boxes are not permitted. Provide pit at<br />
maximum 50 metre intervals.<br />
Materials used to lubricate cables whilst drawing-in to conduits shall be non-conductive,<br />
non-abrasive and non-hygroscopic.<br />
108.10 Conduits and Pipes for Future Use<br />
All conduits and pipes for future use shall be provided with polypropylene draw cords. A<br />
length of cord 2000 long shall be left securely fixed at the ends of each run. Conduits<br />
and pipes shall be labelled in accordance with Clause 603.<br />
Conduits and pipes terminated outside a building shall be taken beyond the line of<br />
paving, the draw cord shall be secured and the conduit or pipe capped, waterproofed and<br />
the location marked in accordance with Clause 105.5.<br />
Page 18 MEW E101
108.11 Wall Boxes<br />
Part 1 -Installation<br />
Wall boxes installed in face brickwork shall be located so that the centre line of the box<br />
coincides with the horizontal centre line of the row of bricks nearest to the specified<br />
height for the box. In hazardous areas or areas defined as hazardous, the box shall be<br />
located at a height not less than the <strong>minimum</strong> height stipulated in the Wiring Rules.<br />
Wall boxes shall be securely fixed. The front edge shall be no more than 10 behind wall<br />
finish. Wall boxes installed in face brickwork having raked joints, or in shiplap timber<br />
work, shall be set with the face of the box flush with the surface of the work.<br />
Deep pattern wall boxes shall be used where conduits are run within brickwork, e.g. when<br />
bricks are "biscuited".<br />
Wall boxes must not be installed across the junction between different wall finishes.<br />
Metal wall boxes must be earthed.<br />
Wall boxes having sliding type lugs for attaching flush plates will not be accepted.<br />
Plastic wall boxes shall have threaded brass inserts for securing flush plates.<br />
109 CONDUIT SYSTEMS FOR COMMUNICATION SERVICES<br />
Conduit systems shall be mechanically continuous.<br />
Conduits shall be of the same type used in the rest of the installation and shall comply<br />
with the relevant clauses of this specification. Systems shall comply with the relevant<br />
conduit <strong>requirement</strong>s of Clause 108 and the following <strong>requirement</strong>s as applicable.<br />
109.1 Conduits for Telecommunication Facility Cabling<br />
Conduits shall be 20 dia. Where run parallel to conduits capable of enclosing power<br />
cables, a <strong>minimum</strong> spacing of 150 shall be observed.<br />
Conduits in any one installation shall originate at an approved box or cupboard, sized and<br />
located as indicated for use as a distribution frame.<br />
Each conduit shall terminate at a floor-mounted box or a flush wall box with coverplate as<br />
indicated.<br />
Not more than three outlets shall be served by one 20 dia. conduit, looping from outlet to<br />
outlet without the use of tees or elbows. Draw boxes within a building shall be installed<br />
so that cables do not need to be pulled in for a distance exceeding 12 metres.<br />
Draw cords shall be installed in each conduit in accordance with Clause 108.10.<br />
Before installation, approval shall be obtained from the local Telecommunication Authority<br />
Office.<br />
109.2 Conduits for Telecommunication Lead-In and Block Cabling<br />
Lead-in conduits shall originate and terminate at locations as indicated.<br />
Block cabling conduits shall originate and terminate at cupboards or approved wall boxes,<br />
sized and located as indicated for use as distribution frames. Underground conduits shall<br />
be heavy duty UPVC type, coloured white, and shall be spaced from other <strong>services</strong> to the<br />
approval of Telecom. For details on separation from, and crossing of power cables see<br />
relevant ACMA Specification.<br />
Conduits shall be sized as indicated.<br />
Draw cords shall be installed in each conduit in accordance with Clause 108.10.<br />
Before installation, approval shall be obtained from the local Telecommunication Authority<br />
Office.<br />
MEW E101 Page 19
Part 1 - Installation<br />
110 CABLE TRAY, LADDER AND TROUGHING<br />
110.1 Generally<br />
110.2 Cable Tray<br />
Cable tray, cable ladder and all accessories shall be proprietary items from a single<br />
manufacturer whose range includes splice connections, expansion splices, covers, risers,<br />
crossovers, reducers, bends and all other accessories used. Supply covers<br />
manufactured from the same material as the tray or ladder up to 2000 above finished<br />
floor level.<br />
Cable tray shall be manufactured from steel, hot dip galvanised after fabrication or from<br />
aluminium or stainless steel.<br />
Minimum thickness for cable tray shall be:<br />
1mm up to 150 wide 1.6 for aluminium<br />
1.2 mm from 150 up to 300 wide 2 for aluminium<br />
1.6 mm above 300 wide 2.6 for aluminium<br />
All cable trays shall be slotted similar to "Admiralty" pattern and shall have folded or rolled<br />
edges. The "standard" tray shall be formed with the perforations punched from outside<br />
the folded edge to avoid any sharp edges or burrs existing on the outside face. The<br />
"reverse" tray shall be perforated from the inside and shall be used in positions where<br />
cables are laid horizontally in the tray or alternatively, trays shall have the metal<br />
reinforced by folding to provide equivalent stiffness.<br />
Cable trays installed externally must be aluminium or stainless steel.<br />
110.3 Cable Ladder<br />
110.4 Installation<br />
Cable ladder shall consist of two folded steel or extruded structural grade aluminium side<br />
rails with cable support rungs between the two rails. The rungs shall be either welded or<br />
fitted to the side rails.<br />
Unless otherwise indicated rung spacing shall not exceed 300. Cables smaller than 13<br />
OD installed on cable ladder shall be run on perforated tray or ducts installed on the<br />
ladder. This <strong>requirement</strong> does not apply where the rungs of the ladder form a continuous<br />
base.<br />
Cable tray and ladder shall be installed by either:<br />
(a) surface fixing to ceilings or walls; or<br />
(b) suspending by hangers from ceilings, or by angle brackets out from walls.<br />
Fixings, hangers and angle brackets are to be spaced at a maximum distance of 1000.<br />
Joints shall be adequately supported.<br />
Where possible, cable tray and ladder shall not be mounted less than 2300 above floor<br />
level. Adequate access shall be provided to cable tray and ladder. Where supported by<br />
hangers or angle brackets, a <strong>minimum</strong> distance of 150 shall be allowed above and 600<br />
on one side of the tray or ladder.<br />
Alternative systems and supports with greater spacing may be accepted if they give equal<br />
rigidity and strength.<br />
Where cable tray or ladder span open areas they shall be capable of supporting an<br />
additional load of 70kg at mid span without permanent deformation.<br />
Cables or groups of cables shall be securely strapped to the tray or ladder using<br />
proprietary nylon cable ties or straps: for vertical runs at 1000 maximum; for horizontal<br />
runs at 2000 maximum.<br />
Cables shall leave the cable tray or ladder in such a manner that no cable shall be in<br />
contact with the side rails. In general, cable shall leave the tray or ladder in conduit,<br />
Page 20 MEW E101
Part 1 -Installation<br />
which shall be securely anchored to the tray or ladder and with the conduit end fitted with<br />
a screwed cable gland to suit the cable.<br />
110.5 Cable Troughing<br />
110.5.1 Generally<br />
Cable troughing, covers and fittings shall be of proprietary manufacture. Troughing shall<br />
have screw fixed covers, unless installed in a location not readily accessible, where clipon<br />
lids may be used. All fixing methods shall provide a smooth internal surface for the<br />
cables, for example, domed headed gutter bolts for joining sections, with the smooth<br />
head surface on the inside and nuts on the outside. Self tapping screws are prohibited.<br />
Troughing shall be installed with the cover fixing screws accessible and the covers shall<br />
be easily removable. The troughing shall be adequately supported in accordance with<br />
the Wiring Rules and, where they span open areas, they shall be capable of supporting<br />
an additional load of 70 kg at mid span without permanently deforming.<br />
Retaining clips shall be installed to retain the wiring at intervals not exceeding 1000 in all<br />
locations except where cable troughing is run horizontally with covers uppermost.<br />
Where troughing is connected to weatherproof or hoseproof (i.e. IP43 through to IP56)<br />
enclosures, the entry shall be made in such a manner as to prevent moisture entering the<br />
enclosure.<br />
Only PVC/PVC cables are permitted in troughing.<br />
110.5.2 Metal Cable Troughing<br />
Metal troughing shall be of an approved design and construction with removable covers<br />
fixed by suitably plated bolts and captive nuts. The troughing and covers shall be of<br />
galvanised sheet steel or aluminium of <strong>minimum</strong> 0.8 thickness and shall be free from<br />
rags, burrs and sharp edges.<br />
110.5.3 Plastic Cable Troughing<br />
Plastic troughing shall be of UPVC. The troughing and covers shall be robustly<br />
constructed from heavy gauge material to avoid sagging between supports and to avoid<br />
warping. All associated fittings shall be of similar material to the troughings.<br />
110.5.4 Skirting Troughing<br />
111 FIXINGS<br />
111.1 Generally<br />
Skirting troughing shall be of proprietary manufacture and shall have three channels.<br />
Where used to extend an existing installation, the skirting troughings shall match that<br />
installation. Skirting troughing used for Telecommunication Authority telephone cables<br />
shall comply with the relevant ACMA Specifications.<br />
The following <strong>minimum</strong> <strong>requirement</strong>s shall be observed.<br />
Fixings shall be secure and adequately sized to suit the weight, size, shape and location<br />
of the equipment being fixed.<br />
Fixings used in external or damp locations, or sewage treatment plants and pumping<br />
stations including exterior luminaires, shall be 316 grade stainless steel. All other fixings<br />
shall be hot dipped galvanised.<br />
Fixings shall be made to adequate firm supports and not to asbestos cement or<br />
hardboard sheeting, etc.<br />
Holes for screws shall have the correct clearances.<br />
MEW E101 Page 21
Part 1 - Installation<br />
111.2 Conduits<br />
Holes drilled for masonry anchors shall be 6 mm deeper than the plug or anchor and<br />
correctly sized to the manufacturer's recommendations. Pilot holes for timber fixing shall<br />
not be larger than the screw root diameter.<br />
Plastic or fibre plugs shall not be used.<br />
Conduits 20, 25 and 32 dia. shall be fixed as follows:<br />
(a) To masonry, concrete, cement rendered walls: Ø 6 expanding sleeve masonry<br />
anchor to accommodate an M4.5 thread. However for 20 and 25 conduits indoors<br />
nylon anchors with mushroom stainless steel expansion nail may be used.<br />
(b) To timber: where directed fixed, wood screw No. 8 x 20, round head. Where fixed<br />
through fibrous cement, plaster, plaster board, etc., the screws shall be of<br />
sufficient length to allow for the additional thickness.<br />
(c) To sheet metal: No. 8 x 13 long, galvanised binding head, self tapping screws.<br />
(d) To steel: M5 round head screws of appropriate length tapped or bolted.<br />
Conduits 40, 50, 63, 65, 80 and 100 dia. shall be fixed as follows:<br />
(a) To masonry, concrete, cement rendered walls: Ø8 expanding sleeve masonry<br />
anchor to accommodate an M8 thread.<br />
(b) To timber: where directly fixed, steel wood screw No. 12 x 35, round head. Where<br />
fixed through asbestos cement, plaster board, etc, the screws shall be of sufficient<br />
length to allow for the additional thickness.<br />
(c) To sheet metal: No. 12 x 13 long, galvanised binding head, self tapping screws.<br />
(d) To steel: M6 round head screws of appropriate length tapped or bolted.<br />
111.3 Mounting Blocks<br />
Mounting blocks shall be fixed with four screws as specified for conduits 20, 25 and 32<br />
mm diameter.<br />
111.4 Switchboards<br />
The fixing of switchboards shall be as described in Clause 112.2.<br />
111.5 Switch Panels, Boxes<br />
Switch panels and boxes shall be fixed with four screws in accordance with 112.2.<br />
Fixings shall be one of the following, to suit the surface:<br />
(a) Steel wood screw, No. 8, round head, or<br />
(b) No. 8 electro-galvanised, binding head, self tapping, or<br />
(c) M5, round head.<br />
(d) M8 masonry anchor.<br />
111.6 Surface Mounted Switches<br />
Fixings shall be as indicated in Clause 112.5.<br />
Single gang switches shall be fixed with two screws and double gang and larger with four<br />
screws.<br />
111.7 Cable Troughing, Cable Tray, Skirting Troughing<br />
Cable troughings, trays and skirting troughing wider than 100 shall be fixed at intervals of<br />
not more than 1000 with two screws per fixing. Screws shall be steel wood screws, No.<br />
12, round head, cadmium plated or cadmium plated M6 round head screws or No. 12<br />
electro-galvanised, binding head, self tapping screws.<br />
Page 22 MEW E101
111.8 Metal Channel<br />
Part 1 -Installation<br />
Metal channels shall be suspended using galvanised suspension rods with proprietary<br />
fittings.<br />
Where secured directly to timber, metal channels shall be fixed with M10 x 50,<br />
hexagonal head, coach screws.<br />
111.9 Hollow Block Locations<br />
Fixing to hollow sections shall be avoided. Where approved, it shall be by means of M5<br />
electro-galvanised, round head screws and spring loaded butterfly toggles. This fixing<br />
does not apply to ceiling fans.<br />
111.10 Fixing of Luminaires<br />
The fixing of luminaires shall be as indicated in Clause 403.<br />
111.11 Fixing of Ceiling Fans<br />
The fixing of ceiling fans shall be 2 off M6.<br />
112 INSTALLATION OF SWITCHBOARDS<br />
112.1 Generally<br />
112.2 Fixings<br />
Where a switchboard has been split for installation, it shall be reassembled on site by the<br />
switchboard manufacturer. Particular attention shall be given to busbar joints which shall<br />
be torque tightened to the manufacturer's recommended torque and shall be insulated or<br />
coated in accordance with Clause 204.6<br />
If a switchboard is stored or installed in any area where building work is incomplete, it<br />
shall be adequately protected against moisture, corrosion, dust, paint, and mechanical<br />
damage.<br />
Floor mounted switchboards shall be fixed to the floor or other structure with M12 hot<br />
dipped galvanised bolts through the mounting holes provided in the base. Alternatively, a<br />
<strong>minimum</strong> of four hot dipped galvanised clamps may be used, each secured with an M12<br />
hot dipped galvanised bolt.<br />
Wall mounted switchboards shall be installed using an adequate number of fixings.<br />
However, not less than four fixings per switchboard shall be used. Fixings shall be:<br />
(a) To timber:<br />
(i) Proprietary Assemblies - hot dipped galvanised steel No. 12 wood screws of<br />
suitable length<br />
(ii) Custom-built Assemblies - 10 diameter coach screws of suitable length with<br />
a full washer under the head.<br />
(b) To masonry and concrete:<br />
(i) Proprietary Assemblies - stainless steel 6 diameter expanding sleeve<br />
masonry anchors of the projecting stud type each fitted with a full washer<br />
and nut.<br />
(ii) Custom-built Assemblies - stainless steel 10 diameter expanding sleeve<br />
masonry anchors of the projecting stud type each fitted with a full washer<br />
and nut.<br />
112.3 Cables, Cable Enclosure and Busway Entry and Termination<br />
MEW E101 Page 23
Part 1 - Installation<br />
Where switchboards are fitted with cable-entry plates, one or more plates shall be neatly<br />
adapted to accept the incoming cable(s). Only the <strong>minimum</strong> number of plates shall be<br />
used thereby leaving spare cable entry plates for future cable entries.<br />
Cables entering a switchboard or control panel shall be glanded using non-ferrous<br />
metallic or plastic glands with neoprene compression seals conduit with suitable adaptor<br />
and locknut may be used where circuit is enclosed in conduit for its entire length. Cable<br />
entry shall only be through the detachable gland plate supplied with the switchboard.<br />
Where the sheath of a multicore cable enters either a switchboard or an <strong>electrical</strong><br />
equipment enclosure, the sheath shall be:<br />
(i) Continued unstripped up to within less than 350 of either its lug terminations if a<br />
power cable or its connecting terminal block if a control cable.<br />
(ii) Continued unstripped after either the related conduit entry or the related cable<br />
gland by at least 100 to allow for cable identification marking.<br />
(iii) Identification marked as indicated within 100 of the end of the sheath.<br />
Where multicore cables with numbered cores are installed, the same numbers shall be<br />
continued from the switchboard to the final connections. This may require stripping of the<br />
outer sheath and continuation of the cores. This may also require the use of extra earth<br />
cables where more than one final connection is made.<br />
The unused cores of a multicore cable shall be terminated in the terminals provided in a<br />
switchboard and in an insulated screwed connector in the field. The length of the unused<br />
cores shall be at least as long as the longest used cores. The unused cores shall be<br />
looped and tied so as to be easily accessible.<br />
Terminations of multicore cables shall be such as to minimise the length of the<br />
unsheathed cores, but sufficient core length in the form of a neat loop shall be left to<br />
ensure that no termination is under tension and to allow for connectors to be relocated.<br />
Cores with the same insulation colours or numbers shall not be run together.<br />
There shall be no more than one conductor per terminal and all field cables shall enter<br />
switchboards via terminals (except instrument cables where indicated).<br />
Cables enclosures shall continue to the switchboard, but each cable shall be separately<br />
glanded at the gland plate.<br />
Cable and cable cores shall be identified in accordance with Clause 205 of this<br />
document.<br />
Where more than five separate surface run cables or cable enclosures are to enter a<br />
switchboard through the top or bottom, enclose all this wiring within U-shaped metal<br />
covers or ducts run from ceiling or floor to within 150 of the switchboard. Gland all cables<br />
when they enter the switchboard. Covers shall be earthed to switchboard cubicle, fixed to<br />
walls generally in accordance with Clause 112, painted to match switchboard and shall<br />
maintain the switchboard IP rating. The metal cover or duct shall have <strong>minimum</strong> 50%<br />
spare capacity for future wiring.<br />
Cables shall not enter through the top of externally mounted switchboards.<br />
To minimise eddy current effects, where single core cables rated over 300 A pass<br />
separately through a steel cable entry plate, the entry holes shall be joined with slots and<br />
the slots brazed or epoxy filled. In addition, metal cable saddles shall not be fitted over<br />
these cables.<br />
All mains and submains shall be supported or tied within 200 of the terminations. This<br />
support or tie shall be substantial due to the stresses under short circuit conditions.<br />
Where a busway is brought into a switchboard, the insulated cable entry plate shall have<br />
a close tolerance cut-out to fit the busbars. The busway enclosure shall be flanged at the<br />
switchboard and shall be bolted and sealed to the switchboard enclosure. The busway<br />
enclosure shall be earthed to the switchboard cubicle. Busbar clearances entering the<br />
switchboard shall comply with Clause 204.8.<br />
Page 24 MEW E101
Part 1 -Installation<br />
Terminations of mains and submains shall be fully insulated or coated in accordance with<br />
Clause 204.6.<br />
112.4 Schedules and Drawings<br />
Neat and legible schedules and drawings as described below shall be installed in insectproof<br />
mounting frames having clear plastic covers and located on or adjacent to the<br />
relevant switchboard but away from direct sunlight.<br />
Schedules and drawings required are:<br />
(a) For each distribution board a type-written circuit schedule.<br />
(b) For each switchboard a copy of the relevant "as installed" lighting and power layout<br />
floor plans.<br />
(c) For each site a copy of the "as installed" drawing showing all main site reticulation<br />
including details and accurate positions of all spare conduits.<br />
(d) Drawings shall be <strong>minimum</strong> A3 size photocopies.<br />
113 WORK AS EXECUTED DRAWINGS<br />
Progressively produce Work As Executed Drawings and secure accuracy of detail for all<br />
work covered by this contact.<br />
Number Work As Executed Drawings with the suffix “X”. Provide a dated notation on<br />
Work As Executed Drawings indicating all changes that were made as modifications to<br />
exhibited drawings.<br />
All abbreviations shall be in accordance with AS 1000.<br />
Drawings shall conform to AS 1100 Drawing Practice, SAA HB7-1993-1989 Engineering<br />
Drawing Handbook, AS 1102 Graphical Symbols for Electrotechnology and AS 1103<br />
Diagrams, Charts and Tables for Electro-technology and AS3702-1989. Printing shall be<br />
<strong>minimum</strong> 2.5 high.<br />
113.1 Drawings Produced by Modification of Exhibited Drawings<br />
(Exhibited drawings are defined to be drawings which are part of the original<br />
documentation.)<br />
Drawings which are produced by modification of exhibited drawings shall be based on a<br />
clean print of the exhibited drawing which shall contain modifications and additions neatly<br />
marked up in red pen. At the completion of the commissioning, these marked up<br />
drawings shall be signed by the contractor. Five copies of these drawings shall be<br />
supplied.<br />
113.2 New Drawings Submitted by the Contractor<br />
Where new drawings are required to be produced as part of this contract to supplement<br />
the modified exhibited drawings, produce the drawings using the latest versions of<br />
Computer Aided Drafting software and print the drawings using a laser quality printer of<br />
<strong>minimum</strong> resolution 1200 x 1200 dots per inch. Use <strong>minimum</strong> 80 grams per square<br />
metre paper. Five prints of these drawings shall be supplied.<br />
114 ACCREDITATION FOR ‘CONTESTABLE WORKS”<br />
Where the <strong>NSW</strong> Office of Fair Trading of the <strong>NSW</strong> Department of Commerce requires<br />
the accreditation of Service Providers for such works as are deemed “contestable”, such<br />
accreditation shall be required to carry out the works as follows:<br />
114.1 Level 1 Accreditation<br />
Work on the electricity distributor’s distribution system (ie construction work relating to<br />
distribution network assets).<br />
MEW E101 Page 25
Part 1 - Installation<br />
114.2 Level 2 Accreditation<br />
Work associated with service lines between the distribution system and the point of<br />
supply to the premises, energising and metering <strong>services</strong>. (i.e. construction and/or<br />
installation of the service line interface between the distribution system and consumer<br />
terminals, including metering <strong>services</strong>).<br />
114.3 Level 3 Accreditation<br />
Design work associated with Levels 1 and 2 above. (i.e. design of transmission and<br />
distribution works for categories overhead and underground).<br />
Page 26 MEW E101
PART 2 - SWITCHBOARDS AND ASSOCIATED EQUIPMENT<br />
201 SCOPE<br />
Part 2 - Switchboards and Associated Equipment<br />
The section covers the design, manufacture and testing of extra low voltage and low<br />
voltage switchboards and associated equipment.<br />
202 GENERALLY<br />
All Custom-built Assemblies for one contract shall be manufactured by the one<br />
manufacturer with all equipment sourced from the same suppliers for all switchboards.<br />
All equipment shall be positioned so as to provide safe and easy access for operation<br />
and maintenance. All switchboards shall be totally enclosed and shall comply with the<br />
<strong>requirement</strong>s of AS 1939 with a <strong>minimum</strong> degree of protection as indicated in the<br />
relevant section herein or as indicated in the Specification.<br />
Switchboards shall be designed and manufactured such that they may be readily moved<br />
to, and installed at the indicated locations.<br />
If a switchboard is split for installation, all materials necessary for reassembly shall be<br />
provided.<br />
In addition to complying with the Specification, all switchboards shall comply with the<br />
special <strong>requirement</strong>s of the relevant Supply Authority.<br />
202.1 Classification of Switchboards<br />
Switchboards are classified as Custom-built Assembly Type “CT”, Custom-built<br />
Assembly Type “CU”, Custom-built Assembly Type “DT”, Custom-built Assembly Type<br />
“DU”, Custom-built Assembly Type “DUPLUS”, Custom-built Assembly Type “DTPLUS”<br />
or Proprietary Assembly.<br />
A Proprietary Assemblies is defined as a low or extra low voltage switchgear and<br />
controlgear assembly available as a catalogue item, which consist of the manufacturer’s<br />
standard layouts and equipment.<br />
A Custom-built Assemblies is defined as a low or extra low voltage switchgear and<br />
controlgear assembly manufactured to order.<br />
202.1.1 Proprietary Assemblies<br />
The following details shall apply to Proprietary Assemblies:<br />
(a) They shall be front connected, surface mounted with <strong>minimum</strong> protection IP 30.<br />
(b) Enclosures shall be metallic.<br />
(c) Circuit Breakers or switches mounted in enclosures shall have the circuit<br />
breaker/switch toggle protruding through a metallic escutcheon.<br />
(d) Space shall be provided within a proprietary assembly containing circuit<br />
breakers/switches for a <strong>minimum</strong> of 20% spare poles or 4 spare poles, whichever<br />
is the greater.<br />
(e) Lifting handles or substantial knobs shall be provided for front covers and<br />
escutcheons.<br />
(f) All edges of all covers shall rest on the cubicle body or on a mullion. Interlocked<br />
covers are not acceptable.<br />
MEW E101 Page 27
Part 2 - Switchboards and Associated Equipment<br />
202.1.2 Custom-built Assembly Type “CT”<br />
The following details shall apply to Custom-built Assemblies Type “CT”:<br />
(a) A Type “CT” assembly shall be a stationary “cubicle-type assembly” as defined in<br />
AS/NZS 3439.1:2002.<br />
(b) A Type “CT” assembly shall comply with AS/NZS 3439.1:2002 as defined by the<br />
following <strong>requirement</strong>s:<br />
(i) Form of separation shall be Form 1.<br />
(ii) The degree of protection after installation in accordance with the<br />
manufacturer’s instructions shall be IP51 for indoor installation and IP56 for<br />
outdoor installation.<br />
(iii) Assemblies shall be front access with top and/or bottom cable entry.<br />
(iv) Assemblies shall be floor mounted or wall mounted. Wall mounting is<br />
acceptable only if the frontal area of the assembly has an area less than 2<br />
square metres.<br />
(v) For outdoor switchboards containing busbars, pollution degree 3 shall apply<br />
at locations further than 1km in a direct line from the coast or at altitudes<br />
below 1000 metres. Otherwise, pollution degree 4 shall apply.<br />
For indoor switchboards, pollution degree 3 shall apply.<br />
(vi) The following safety measures against direct contact shall apply:<br />
• Requirement of a key or tool to gain entry into the switchboard. (Meet<br />
clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.)<br />
• Shielding all live parts in such a manner that they cannot be<br />
unintentionally touched when the door is opened or the cover is removed.<br />
(Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.)<br />
(vii) Assemblies shall be Partially Type Tested Assemblies or Type Tested<br />
Assemblies with type test certificates or satisfactory test reports for the type<br />
tests listed in clause 8 of AS/NZS 3439.1:2002. Documentation shall be<br />
available to demonstrate that the results of type tests were satisfactory. The<br />
testing facility shall be accredited by NATA or registered with the Association<br />
of Short-Circuit Testing Authorities.<br />
(viii) The standard Internal Arcing-Fault Test specified in Annex ZD of AS/NZS<br />
3439.1:2002 (limited arc, initiated on the load side of a protective device<br />
within the functional unit being tested) shall be met and a test certificate<br />
demonstrating that the results of the type tests were satisfactory shall be<br />
available. The testing facility shall be accredited by NATA or registered with<br />
the Association of Short-Circuit Testing Authorities.<br />
202.1.3 Custom-built Assembly Type “CU”<br />
The following details shall apply to Custom-built Assemblies Type “CU”:<br />
Note that type test certificates or satisfactory test reports for the type tests listed in<br />
clause 8 of AS/NZS 3439.1:2002 are not required.<br />
(a) A Type “CU” assembly shall be a stationary “cubicle-type assembly” as defined in<br />
AS/NZS 3439.1:2002.<br />
(b) A Type “CU” assembly shall comply with AS/NZS 3439.1:2002 as defined by the<br />
following <strong>requirement</strong>s:<br />
(i) Form of separation shall be Form 1.<br />
(ii) The degree of protection after installation in accordance with the<br />
manufacturer’s instructions shall be IP51 for indoor installation and IP56 for<br />
outdoor installation.<br />
Page 28 MEW E101
Part 2 - Switchboards and Associated Equipment<br />
(iii) Assemblies shall be front access with top and/or bottom cable entry.<br />
(iv) Assemblies shall be floor mounted or wall mounted. Wall mounting is<br />
acceptable only if the frontal area of the assembly has an area less than 2<br />
square metres<br />
(v) For outdoor switchboards containing busbars, pollution degree 3 shall apply<br />
at locations further than 1km in a direct line from the coast or at altitudes<br />
below 1000 metres. Otherwise, pollution degree 4 shall apply.<br />
For indoor switchboards, pollution degree 3 shall apply.<br />
(vi) The following safety measures against direct contact shall apply:<br />
202.1.4 Custom-built Assembly Type “DT”<br />
• Requirement of a key or tool to gain entry into the switchboard. (Meet<br />
clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.)<br />
• Shielding all live parts in such a manner that they cannot be<br />
unintentionally touched when the door is opened or the cover is removed.<br />
(Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.)<br />
The following details shall apply to Custom-built Assemblies Type “DT”:<br />
(a) A Type “DT” assembly shall be a stationary “cubicle-type assembly” or ‘multicubicle-type<br />
assembly” as defined in AS/NZS 3439.1:2002.<br />
(b) A Type “DT” assembly shall comply with AS/NZS 3439.1:2002 as defined by the<br />
following <strong>requirement</strong>s:<br />
(i) Form of separation shall be Form 3b or 4a.<br />
(ii) The degree of protection after installation in accordance with the<br />
manufacturer’s instructions shall be IP51 for indoor installation and IP56 for<br />
outdoor installation.<br />
(iii) Assemblies shall be front access with top and/or bottom cable entry.<br />
(iv) Assemblies shall be floor mounted.<br />
(v) For outdoor switchboards containing busbars, pollution degree 3 shall apply<br />
at locations further than 1km in a direct line from the coast or at altitudes<br />
below 1000 metres. Otherwise, pollution degree 4 shall apply.<br />
For indoor switchboards, pollution degree 3 shall apply.<br />
(vi) The following safety measures against direct contact shall apply:<br />
For Main Incoming Supply Compartments, Motor Starter Compartments and<br />
Distribution Feeder Compartments with one feeder in the Distribution Feeder<br />
Compartment:<br />
• Requirement of a key or tool to gain entry into the switchboard. (Meet<br />
clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.)<br />
• Disconnection of all live parts that can be unintentionally touched after<br />
the door has been opened. (Meet clause 7.4.2.2.3 b) of AS/NZS<br />
3439.1:2002.)<br />
• Shielding all live parts in such a manner that they cannot be<br />
unintentionally touched when the door is opened or the cover is removed.<br />
(Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.)<br />
MEW E101 Page 29
Part 2 - Switchboards and Associated Equipment<br />
For Common Control Compartments:<br />
• Requirement of a key or tool to gain entry into the switchboard. (Meet<br />
clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.)<br />
• Shielding all live parts in such a manner that they cannot be<br />
unintentionally touched when the door is opened or the cover is removed.<br />
(Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.)<br />
For Distribution Compartments with one main protective device plus a<br />
number of subcircuit protective devices:<br />
• Requirement of a key or tool to gain entry into the switchboard. (Meet<br />
clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) for the compartment door<br />
and for the escutcheon.<br />
(vii) Assemblies shall be Partially Type Tested Assemblies or Type Tested<br />
Assemblies with type test certificates or satisfactory test reports for the type<br />
tests listed in clause 8 of AS/NZS 3439.1:2002. Documentation shall be<br />
available to demonstrate that the results of type tests were satisfactory. The<br />
testing facility shall be accredited by NATA or registered with the Association<br />
of Short-Circuit Testing Authorities.<br />
(viii) The special Internal Arcing-Fault Test (unlimited arc, initiated on the line<br />
side of the protective device within the functional unit being tested) required<br />
by Appendix ZD.6 of AS/NZS 3439.1:2002 shall be met and a test certificate<br />
demonstrating that the results of the type tests were satisfactory shall be<br />
available. The duration of the test shall be chosen by the manufacturer<br />
according to the time response of the <strong>electrical</strong> protection devices. If details<br />
of these devices are not known, a power supply duration of at least 100<br />
milliseconds shall apply. The testing facility shall be accredited by NATA or<br />
registered with the Association of Short-Circuit Testing Authorities.<br />
202.1.5 Custom-built Assembly Type “DU”<br />
The following details shall apply to Custom-built Assemblies Type “DU”:<br />
Note that type test certificates or satisfactory test reports for the type tests listed in<br />
clause 8 of AS/NZS 3439.1:2002 are not required.<br />
(a) A Type “DU” assembly shall be a stationary “cubicle-type assembly” or ‘multicubicle-type<br />
assembly” as defined in AS/NZS 3439.1:2002.<br />
(b) A Type “DU” assembly shall comply with AS/NZS 3439.1:2002 as defined by the<br />
following <strong>requirement</strong>s:<br />
(i) Form of separation shall be Form 3b or 3bi, 3bh, 3bih, 4a, 4b, 4ah, 4ai, 4aih,<br />
4bh, 4bi, 4bih.<br />
(ii) The degree of protection after installation in accordance with the<br />
manufacturer’s instructions shall be IP51 for indoor installation and IP56 for<br />
outdoor installation.<br />
(iii) Assemblies shall be front access with top and/or bottom cable entry.<br />
(iv) Assemblies shall be floor mounted.<br />
(v) For outdoor switchboards containing busbars, pollution degree 3 shall apply<br />
at locations further than 1km in a direct line from the coast or at altitudes<br />
below 1000 metres. Otherwise, pollution degree 4 shall apply.<br />
For indoor switchboards, pollution degree 3 shall apply.<br />
(vi) The following safety measures against direct contact shall apply:<br />
For Main Incoming Supply Compartments, Motor Starter Compartments and<br />
Distribution Feeder Compartments with one feeder in the Distribution Feeder<br />
Compartment:<br />
Page 30 MEW E101
Part 2 - Switchboards and Associated Equipment<br />
• Requirement of a key or tool to gain entry into the switchboard. (Meet<br />
clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.)<br />
• Disconnection of all live parts that can be unintentionally touched after<br />
the door has been opened. (Meet clause 7.4.2.2.3 b) of AS/NZS<br />
3439.1:2002.)<br />
• Shielding all live parts in such a manner that they cannot be<br />
unintentionally touched when the door is opened or the cover is removed.<br />
(Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.)<br />
For Common Control Compartments:<br />
• Requirement of a key or tool to gain entry into the switchboard. (Meet<br />
clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.)<br />
• Shielding all live parts in such a manner that they cannot be<br />
unintentionally touched when the door is opened or the cover is removed.<br />
(Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.)<br />
For Distribution Compartments with one main protective device<br />
plus a number of subcircuit protective devices:<br />
• Requirement of a key or tool to gain entry into the switchboard. (Meet<br />
clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) for the compartment door<br />
and for the escutcheon.<br />
202.1.6 Custom-built Assembly Type “DUPLUS”<br />
The following details shall apply to Custom-built Assemblies Type “DUPLUS”:<br />
Note that type test certificates or satisfactory test reports for the type tests listed in<br />
clause 8 of AS/NZS 3439.1:2002 are not required except for the “Verification of<br />
short-circuit withstand test”, Clause 8.2.3 of AS/NZS 3439.1:2002, for the busbar<br />
system.<br />
(a) A Type “DUPLUS” assembly shall be a stationary “cubicle-type assembly” or ‘multicubicle-type<br />
assembly” as defined in AS/NZS 3439.1:2002.<br />
(b) A Type “DUPLUS” assembly shall comply with AS/NZS 3439.1:2002 as defined by<br />
the following <strong>requirement</strong>s:<br />
(i) Form of separation shall be Form 3b or 3bi, 3bh, 3bih, 4a, 4b, 4ah, 4ai, 4aih,<br />
4bh, 4bi, 4bih.<br />
(ii) The degree of protection after installation in accordance with the<br />
manufacturer’s instructions shall be IP51 for indoor installation and IP56 for<br />
outdoor installation.<br />
(iii) Assemblies shall be front access with top and/or bottom cable entry.<br />
(iv) Assemblies shall be floor mounted.<br />
(v) For outdoor switchboards containing busbars, pollution degree 3 shall apply<br />
at locations further than 1km in a direct line from the coast or at altitudes<br />
below 1000 metres. Otherwise, pollution degree 4 shall apply.<br />
For indoor switchboards, pollution degree 3 shall apply.<br />
(vi) The following safety measures against direct contact shall apply:<br />
For Main Incoming Supply Compartments, Motor Starter Compartments and<br />
Distribution Feeder Compartments with one feeder in the Distribution Feeder<br />
Compartment:<br />
• Requirement of a key or tool to gain entry into the switchboard. (Meet<br />
clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.)<br />
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Part 2 - Switchboards and Associated Equipment<br />
• Disconnection of all live parts that can be unintentionally touched after<br />
the door has been opened. (Meet clause 7.4.2.2.3 b) of AS/NZS<br />
3439.1:2002.)<br />
• Shielding all live parts in such a manner that they cannot be<br />
unintentionally touched when the door is opened or the cover is removed.<br />
(Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.)<br />
For Common Control Compartments:<br />
• Requirement of a key or tool to gain entry into the switchboard. (Meet<br />
clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.)<br />
• Shielding all live parts in such a manner that they cannot be<br />
unintentionally touched when the door is opened or the cover is removed.<br />
(Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.)<br />
For Distribution Compartments with one main protective device plus a<br />
number of subcircuit protective devices:<br />
• Requirement of a key or tool to gain entry into the switchboard. (Meet<br />
clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) for the compartment door<br />
and for the escutcheon.<br />
202.1.7 Custom-built Assembly Type “DTPLUS”<br />
The following details shall apply to Custom-built Assemblies Type “DTPLUS”:<br />
(a) A Type “DTPLUS” assembly shall be a stationary “cubicle-type assembly” or ‘multicubicle-type<br />
assembly” as defined in AS/NZS 3439.1:2002.<br />
(b) A Type “DTPLUS” assembly shall comply with AS/NZS 3439.1:2002 as defined by<br />
the following <strong>requirement</strong>s:<br />
(i) Form of separation shall be Form 4b.<br />
(ii) The degree of protection after installation in accordance with the<br />
manufacturer’s instructions shall be IP51 for indoor installation and IP56 for<br />
outdoor installation.<br />
(iii) Assemblies shall be front access with top and/or bottom cable entry.<br />
(iv) Assemblies shall be floor mounted.<br />
(v) For outdoor switchboards containing busbars, pollution degree 3 shall apply<br />
at locations further than 1km in a direct line from the coast or at altitudes<br />
below 1000 metres. Otherwise, pollution degree 4 shall apply.<br />
For indoor switchboards, pollution degree 3 shall apply.<br />
(vi) The following safety measures against direct contact shall apply:<br />
For Main Incoming Supply Compartments, Motor Starter Compartments and<br />
Distribution Feeder Compartments with one feeder in the Distribution Feeder<br />
Compartment:<br />
• Requirement of a key or tool to gain entry into the switchboard. (Meet<br />
clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.)<br />
• Disconnection of all live parts that can be unintentionally touched after<br />
the door has been opened. (Meet clause 7.4.2.2.3 b) of AS/NZS<br />
3439.1:2002.)<br />
• Shielding all live parts in such a manner that they cannot be<br />
unintentionally touched when the door is opened or the cover is removed.<br />
(Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.)<br />
Page 32 MEW E101
For Common Control Compartments:<br />
Part 2 - Switchboards and Associated Equipment<br />
• Requirement of a key or tool to gain entry into the switchboard. (Meet<br />
clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.)<br />
• Shielding all live parts in such a manner that they cannot be<br />
unintentionally touched when the door is opened or the cover is removed.<br />
(Meet clause 7.4.2.2.3 c) of AS/NZS 3439.1:2002.)<br />
For Distribution Compartments with one main protective device plus a<br />
number of subcircuit protective devices:<br />
• Requirement of a key or tool to gain entry into the switchboard. (Meet<br />
clause 7.4.2.2.3 a) of AS/NZS 3439.1:2002.) for the compartment door<br />
and for the escutcheon.<br />
(vii) Assemblies shall be Partially Type Tested Assemblies or Type Tested<br />
Assemblies with type test certificates or satisfactory test reports for the type<br />
tests listed in clause 8 of AS/NZS 3439.1:2002. Documentation shall be<br />
available to demonstrate that the results of type tests were satisfactory. The<br />
testing facility shall be accredited by NATA or registered with the Association<br />
of Short-Circuit Testing Authorities.<br />
(viii) The special Internal Arcing-Fault Test (unlimited arc, initiated on the line<br />
side of the protective device within the functional unit being tested) required<br />
by Appendix ZD.6 of AS/NZS 3439.1:2002 shall be met and a test certificate<br />
demonstrating that the results of the type tests were satisfactory shall be<br />
available. Further to Clause ZD.2 (Relevance of Tests) of AS/NZS<br />
3439.1:2002, the special internal arcing-fault test shall be applicable to all<br />
compartments. The duration of the test shall be chosen by the manufacturer<br />
according to the time response of the <strong>electrical</strong> protection devices. If details<br />
of these devices are not known, a power supply duration of at least 100<br />
milliseconds shall apply. The testing facility shall be accredited by NATA or<br />
registered with the Association of Short-Circuit Testing Authorities.<br />
202.1.8 Manufacturer of the Switchboard.<br />
(a) Custom-built Assemblies Type “DTPLUS”<br />
The firm in whose name the test certificates have been issued shall completely<br />
manufacture the switchboard at its workshop.<br />
(b) Other Custom-built Assemblies<br />
For Custom-built Assemblies, other than Type “DTPLUS”, where a proprietary<br />
modular switchboard system is offered, the switchboard builder shall have been<br />
appropriately trained and have the appropriate level of accreditation to build the<br />
switchboard from the manufacturer of the modular switchboard system.<br />
203 FAULT LEVELS AND LIMITATION<br />
203.1 Fault Levels and Time of Duration<br />
The indicated fault level shall apply. The fault level being the prospective symmetrical<br />
r.m.s. value at the switchboard input terminals. Conductors and equipment shall be<br />
suitable for a time not less than that determined in the following manner:<br />
(a) On any conductor or equipment:-<br />
one (1) second.<br />
(b) On any conductor or equipment protected by a consumer's line side fuse or fast<br />
acting circuit breaker: the actual cut-off time or trip out time at the indicated fault<br />
level where it is not less than 10 milliseconds.<br />
Where the actual cut-off time or trip out time of the consumer's line side fuse or<br />
fast acting circuit breaker is less than 10 milliseconds, then the conductors and<br />
MEW E101 Page 33
Part 2 - Switchboards and Associated Equipment<br />
equipment shall be suitable for the actual fault let through energy and peak cut-off<br />
current of the protective device corresponding to the indicated fault level.<br />
Equipment shall not be used at a higher fault level than that for which it has been tested,<br />
irrespective of fault duration.<br />
203.2 Fault Current Limiting<br />
Fault current limiting, either by fuses or suitable circuit breaker combinations shall only be<br />
used where indicated and shall be of the form indicated.<br />
Selection of fault current limiting equipment shall be in accordance with a selection table<br />
accepted by the relevant Supply Authority.<br />
203.3 Short Circuit Co-ordination<br />
Type 2 short circuit co-ordination in accordance with AS 60947.4.1 is required for the<br />
short circuit protective device, the motor contactor and the overload device if either of the<br />
following conditions apply:<br />
(a) Main busbar fault level of 31.5kA or greater at 415Volts has been specified.<br />
(b) Starter size is greater than 37kW when direct on line started.<br />
(c) Starter size is greater than 45kW when reduced voltage started.<br />
Type 1 short circuit co-ordination in accordance with AS 60947.4.1 is required for the<br />
short circuit protective device, the motor contactor and the overload device in all cases<br />
other than (a), (b), and (c) above, except for the following condition:<br />
Where ventilation fans are installed to provide a safe environment for personnel, Total<br />
Co-ordination for the short circuit protective device, the motor contactor and the overload<br />
in accordance with AS 60947.6.2 is required.<br />
204 BUSBARS<br />
204.1 Generally<br />
204.2 Material<br />
204.3 Sizes<br />
Busbars for Proprietary Assemblies may be of the manufacturer's standard.<br />
Multi-pole proprietary busbar assemblies for circuit breakers shall be of an accepted type.<br />
When busbar systems have been verified by type testing, such arrangements are<br />
acceptable in lieu of the methods specified below.<br />
Busbars shall be arranged to ensure that the phase sequence at all switchboard<br />
equipment terminals is red, white and blue from left to right and from top to bottom, when<br />
viewed from the front of the switchboard.<br />
Busbars shall be hard-drawn high-conductivity copper. Square-edged busbars shall not<br />
be used.<br />
Busbar sizes in relation to current ratings shall be to AS 3000, assuming the<br />
switchboards are of magnetic materials, located indoors in a well ventilated room and the<br />
appropriate enclosure rating shall apply. However, smaller busbars may be used in<br />
accordance with an approved Testing Authority Temperature Rise Test Certificate for a<br />
switchboard with a similar internal physical configuration.<br />
For purposes of withstanding thermal stresses due to fault currents, active busbars shall<br />
be sized in accordance with AS 3439.1, unless smaller busbars can be substantiated with<br />
Page 34 MEW E101
Part 2 - Switchboards and Associated Equipment<br />
an approved Testing Authority Type Test Report. (Busbars coated with copolymer<br />
membrane shall be regarded as insulated).<br />
Unless otherwise indicated, incoming busbar current rating to the first tee-off shall not be<br />
less than the maximum possible current rating of the frame size of the busbar protection<br />
device. However, for main switchboards with no main protection device, the incoming<br />
busbar current rating shall not be less than the current rating of the consumers mains.<br />
Tee-off busbars to other controlling devices shall have a current rating equal to the<br />
maximum frame size rating of that controlling device.<br />
In determining other than incoming and tee-off busbar sizes (eg vertical droppers etc),<br />
the actual frame size rating of the controlling devices and spare spaces shall be used and<br />
the load diversity reduction factors given in AS 3439.1 shall be applied. Busbars so sized<br />
need not exceed the size of that section's incoming busbars. Accepted proprietary<br />
busbar assemblies shall not be used at higher than the assigned ratings.<br />
Busbars connected to fault current limiters shall be rated to 100% of indicated current<br />
limiter rating.<br />
MEW E101 Page 35
Part 2 - Switchboards and Associated Equipment<br />
204.4 Jointing<br />
204.5 Supports<br />
Busbar jointing shall maximise the copper-to-copper contact area under the "shadow<br />
area" of the bolt head and nut.<br />
Bolt holes shall be round, square edged with a maximum bolt clearance of 1. Deburring<br />
shall be the <strong>minimum</strong> necessary to remove any projections.<br />
Joint surfaces shall be flat and shall be deliberately roughened by sanding or draw filing<br />
immediately prior to making the joint. Tinned or electroplated joints are an acceptable<br />
alternative.<br />
Where the fault rating of any busbar section of a switchboard does not exceed 14kA, and<br />
for all proprietary multi-pole busbar assemblies, the <strong>minimum</strong> <strong>requirement</strong>s shall be<br />
plated steel commercial bolts to AS 1111, with <strong>minimum</strong> strength grade of 4.6.<br />
Where the fault rating of any busbar section of a switchboard exceeds 14 kA, the<br />
<strong>minimum</strong> <strong>requirement</strong>s for all size busbars throughout that section shall be M10, plated<br />
steel precision bolts to AS 1110 with <strong>minimum</strong> strength grade of 8.8, which shall be<br />
confirmed by the marks "M" and "8.8" appearing on the bolt head. This applies to busbar<br />
joints and where busbars are bolted to insulators and support.<br />
For the purposes of joint inspections, a joint as nominated by the Superintendent shall be<br />
stripped of its finish coating dismantled, reassembled and re-finished during the factory<br />
inspection.<br />
Where busbars are bolted to proprietary equipment, the proprietary bolts and terminating<br />
methods supplied by the manufacturer are acceptable.<br />
The number of bolts used per joint shall be consistent with first grade jointing practice. A<br />
<strong>minimum</strong> of two bolts per joint is preferred.<br />
Busbar jointing bolts shall not be used to support the busbar.<br />
For both commercial and precision bolts, use one plated steel full flat washer on each<br />
side of the joint, and one plated steel full nut (no spring or serrated washer, or locknut).<br />
The full nuts shall be torque-tightened to the bolt manufacturer's recommended levels.<br />
For both commercial and precision bolts, use one plated steel full flat washer on each<br />
side of the joint, and one plated steel full nut (no spring or serrated washer, or locknut).<br />
The full nuts shall be torque-tightened to the bolt manufacturer's recommended levels.<br />
Written agreement shall be obtained to alternative jointing methods, before commencing<br />
manufacture.<br />
Busbar support spacings shall be determined by reference to "Copper for Busbars"<br />
issued by the Copper Development Association and to other appropriate engineering<br />
principles and data. Spacings greater than those indicated by these references shall be<br />
substantiated by an approved Testing Authority Type Test Report.<br />
Busbar supports shall be made of non-hydroscopic insulating material and shall be<br />
capable of holding busbars at a temperature of 105ºC. Supports shall be capable of<br />
withstanding thermal and magnetic stresses associated with relevant fault levels and<br />
times of duration.<br />
Supports shall be of adequate size and shall rigidly hold all busbars by being rigidly fixed<br />
to the cubicle where possible. Floating supports shall be kept to a <strong>minimum</strong>.<br />
Clamp type supports shall suit the busbar cross-sectional shape so as to minimise<br />
distortion and migration of busbar insulation or coating during normal service.<br />
Page 36 MEW E101
204.6 Prevention of Arcing Faults<br />
204.6.1 Rigid Insulation<br />
Part 2 - Switchboards and Associated Equipment<br />
Where hook-stick links, open blade type fuse links or the like are installed within a<br />
switchboard, suitable rigid, fixed insulating barriers shall be provided to prevent<br />
inadvertent <strong>electrical</strong> contact between phases by a foreign straight metallic object.<br />
Barriers shall be provided on both sides of each link or fuse link (eg four barriers for a<br />
three phase set).<br />
204.6.2 Coating of Busbars and Terminations<br />
Active busbars shall be coated with polyethylene. All joints and jointing bolts not so<br />
coated shall be either taped, insulated with air drying plastic coating or have a water<br />
based copolymer membrane coating applied.<br />
As an alternative, all active busbars including joints and jointing bolts may be coated with<br />
a water based copolymer membrane coating.<br />
Those parts of busbars which are fully encapsulated need not be coated. One system<br />
deemed to be equivalent to encapsulation is proprietary close fitting busbar insulation<br />
mouldings not less than 1.0 thick.<br />
In the case of equipment providing integral shrouding between the main active terminals,<br />
the coating shall not extend into the shrouded area.<br />
Mating surfaces of the main plugs or connections of demountable or withdrawable<br />
functional units shall not be coated.<br />
Busbar flags for the connection of future equipment shall not be coated, but shall be<br />
covered with readily removable insulating material of <strong>minimum</strong> thickness 0.4.<br />
204.6.3 Application of Busbar Coatings<br />
(a) Polyethylene<br />
Polyethylene shall be applied by a fluidised bed process in which the material is<br />
directly cured onto the bars.<br />
Preparation of the busbars and method of application shall be strictly in<br />
accordance with the supplier's recommendations.<br />
The thickness of the coating shall be not less than 0.4 and the <strong>minimum</strong> dielectric<br />
strength of the coating shall be 2 kV rms for one minute.<br />
The colours shall be either the correct phase colours or all white with phase colour<br />
bands.<br />
(b) Acrylic Copolymer Membrane Coating<br />
Before coating, all surfaces shall be cleaned down, treated with an etch cleaner<br />
and then completely dried. One substantial coat approximately 0.15 to 0.2 thick<br />
shall then be applied.<br />
The material used shall have a <strong>minimum</strong> titanium dioxide content of 10%.<br />
Coating colour shall be cream with phase colour bands.<br />
Care shall be taken to prevent the coating being applied over any insulation<br />
between phases or phase to earth at busbar barriers and supports or on any<br />
switchboard equipment.<br />
(c) Taping at Joints<br />
Taping shall be with non-adhesive stop-off half lapped to achieve a thickness not<br />
less than 0.4 and the ends shall be tied off. The colour shall match the adjoining<br />
busbar coating.<br />
(d) Air Drying Plastic Coating at Joints<br />
MEW E101 Page 37
Part 2 - Switchboards and Associated Equipment<br />
204.7 Phase Identification<br />
Plastic coating material shall achieve a tensile strength of greater than 17 MPa and<br />
have a <strong>minimum</strong> ultimate elongation of 300%.<br />
Application of air drying plastic coating shall be in accordance with the<br />
manufacturer's recommendations to achieve a thickness of not less than 0.4.<br />
Coating colour shall match the adjoining busbar coating.<br />
Busbars shall be identified by <strong>minimum</strong> 25 wide colour bands neatly and permanently<br />
applied and located at not more than 500 intervals along the active, neutral and earth<br />
busbars with a <strong>minimum</strong> of one colour band for each busbar piece. Adhesive type<br />
material is not acceptable.<br />
MEN links shall have green-yellow and black bands.<br />
Colours shall be red, white and blue respectively for the phases A, B, and C, black for<br />
neutral and green-yellow for earth.<br />
204.8 Busbar Clearances<br />
Clearance between phases and phase to earth shall be not less than that required by AS<br />
3000. All busbars shall be treated as being bare.<br />
Where busbars are connected to proprietary equipment, clearances less than that<br />
required by AS 3000 are acceptable provided the busbars are insulated.<br />
204.9 Cable Connection Flags<br />
All equipment, having main terminals inadequate for the cable size, shall be fitted with<br />
busbar flags. The size of the flags shall be appropriate for the cable lugs to be<br />
terminated and shall have a current rating of not less than the maximum frame size of the<br />
equipment. Busbar flags shall be suitably supported.<br />
204.10 Neutral and Earth Busbars<br />
The ratio of neutral to active busbars size shall be equal to that of the incoming cable<br />
cores.<br />
Earth busbar cross sectional areas shall be in accordance with AS 3000.<br />
The <strong>minimum</strong> cross sectional area of the neutral and earth busbars throughout the<br />
switchboard shall be sized in accordance with Appendix C of AS 136 to suit 50% of the<br />
indicated fault level for 100% of the time of duration (eg a fault level of 43 kA for one<br />
second requires a <strong>minimum</strong> uninsulated busbar of 124mm 2 cross-sectional area).<br />
The metal frames of switchboard cubicles and equipment (eg air break circuit breaker,<br />
FCU's etc) shall be effectively bonded to the earth busbar. To achieve a good metal-tometal<br />
contact, painted surfaces shall be stripped and given a corrosion resistant coating<br />
just prior to bolting to the earth busbar.<br />
204.11 Flexible Busbars Take Offs<br />
Notwithstanding other <strong>requirement</strong>s of this document, the conductors between the rigid<br />
busbars and the supply side of a single functional unit may consist of flexible, insulated<br />
copper woven busbars which are forged to a solid unit at both ends. In any case, comply<br />
with Clause 7.5.5.1.2 of AS/NZS 3439.1:2002.<br />
205 CABLING<br />
205.1 Generally<br />
Interconnecting cables may be used instead of busbars for all ratings and shall comply<br />
with the <strong>requirement</strong>s of this clause.<br />
Page 38 MEW E101
Part 2 - Switchboards and Associated Equipment<br />
Cables are not to be used to link adjacent circuit breakers where multi-pole busbar<br />
assembly can be used for this purpose.<br />
Except for I/O cabling, internal cabling shall be at least V75 insulated with stranded<br />
copper conductors of a size not less than that determined from AS 3008.1 for enclosed in<br />
free air conditions but shall not be less than 1.5mm 2 . Cable sizes determined shall<br />
include the principles explained in Clause 204.3 and 204.10.<br />
Digital PLC I/O wiring shall be carried out in <strong>minimum</strong> 0.5mm 2 PVC flexible cable.<br />
The current rating of cables between fault current limiting fuses and a fixed setting circuit<br />
breaker used to limit the maximum demand, need not exceed the current rating of that<br />
circuit breaker.<br />
Cables shall be adequately supported and run clear or busbars and metal edges.<br />
Adhesive supports are not permitted.<br />
Phase, neutral and earth cables shall be capable of withstanding the maximum thermal<br />
and magnetic stresses associated with the relevant fault level and time of duration.<br />
Thermal performance shall be based on AS 3008.1.<br />
All cables shall be neatly run and shall be supported and tied at maximum 150 intervals<br />
unless enclosed in a duct.<br />
Ducts shall be of a slotted type adequately sized for present and all anticipated future<br />
cables.<br />
Switchboard design shall allow wiring to be run to future equipment without removal of<br />
existing equipment.<br />
All cables shall have suitable palm type crimp lugs fitted. Crimp lugs shall be fitted with<br />
the correct tooling. Flexible cables to be terminated in tunnel terminals shall be fitted with<br />
insulated sleeved ferrules. For all sewage treatment works and sewage pumping stations,<br />
immerse the exposed conductor at the end of the flexible cables in petroleum jelly prior to<br />
termination.<br />
Looping of earth cables is not permitted, and all earth cables shall terminate at an earth<br />
link or at a <strong>minimum</strong> M6 earthing stud adjacent to the equipment.<br />
Cables shall be arranged to ensure that the phase sequence at all switchboard<br />
equipment terminals is red, white and blue from left to right and from top to bottom, when<br />
viewed from the front of the switchboard.<br />
Control wiring shall originate from white phase throughout an installation.<br />
205.2 Cable Identification<br />
Colours<br />
Cable insulation shall be coloured in accordance with the following table:<br />
Phase wiring (A, B & C) - red, white and blue<br />
Voltmeter and current transformer connections - red, white, blue and black<br />
240 V control active (controlled by isolator on the board) - grey<br />
240 V control active (not controlled by isolator on the board) - orange<br />
240 V neutral - black<br />
ELV AC active - brown-red<br />
ELV AC common - brown-white<br />
ELV devices eg thermistor - brown<br />
ELV DC positive - blue-red<br />
ELV DC negative - blue-white<br />
Telemetry - violet<br />
MEW E101 Page 39
Part 2 - Switchboards and Associated Equipment<br />
Earth - green-yellow<br />
Cables listed in two colours (eg brown-red) shall consist of a base colour (ie brown) and a<br />
spiral trace colour (ie red). Cable trace colours shall cover between 20% and 40% of the<br />
cable surface and extend the full length of the cable.<br />
As an alternative for cables above 50mm 2 , all double insulated cables, phase<br />
identification may be 25 wide heat shrink bands of the colours tabulated above applied at<br />
each end and at not more than 500 intervals along the entire run.<br />
Identification<br />
(a) Control Wires<br />
All control wires shall be individually identified at each end. All control cables shall<br />
have the same identifying number over its entire length even when it passes in and<br />
out of a terminal block.<br />
(b) Multicore Control Cables<br />
Each cable core shall be individually identified with a number in numerals and spelt<br />
out in letters. Such identification shall be in black on to the cable cores during<br />
manufacture. Cable cores shall be consecutively numbered.<br />
(c) Plastic Cable Ferrules<br />
Cable cores which do not have integral number identification shall be identified<br />
using proprietary cable ferrules. Cable ferrules shall be flexible plastic sleeve type<br />
Z type with indelible alphanumerics. The cable ferrules shall be designed for the<br />
cable core diameter. The use of Critchley Multi-Mark and Grafoplas identification<br />
systems is acceptable.<br />
(d) Cable Sheaths Identification<br />
All cable sheaths shall be identified at both ends. Identification shall include cable<br />
number prefixed by J for instrumentation, C for control and P for power, circuit<br />
name (e.g. Pump 1) and type and size of cable (e.g. 3C + E 2.5 mm²).<br />
Identification shall be neat, permanent and legible and the following will be<br />
acceptable:<br />
- Stamped aluminium tags<br />
- Proprietary write-on tags<br />
(e) Visibility<br />
Cable and core identification shall be fully legible and visible from the front of the<br />
switchboard, control panel, equipment etc. ferrules, embossed alphanumerics,<br />
tags, etc., shall be arranged such that all letters and numerals are in line and can<br />
be readily read from the front without manipulation. Alphanumerics shall be<br />
vertically upright on horizontal cables and cores, and shall be read from the right<br />
hand side on vertical cables and cores.<br />
205.3 Large Cables (Cables above 6mm²)<br />
Not more than one cable shall terminate in a tunnel terminal, and not more than two<br />
cables shall terminate at any other connection point or terminal.<br />
Active links shall comply with paragraphs (a) to (d) of Clause 206.2.<br />
Large cables shall not be run to hinged panels or doors.<br />
In addition to the cable supports described in Clause 205.1, rigid non-metallic fixings to<br />
the switchboard cubicle shall be provided within 200 of all terminations and at not more<br />
than 400 intervals along the entire run.<br />
If the cables are in a duct, the intermediate fixings shall be within the duct.<br />
To minimise eddy current effects metal cable saddles shall not be fitted over single core<br />
cables rated over 300A.<br />
Page 40 MEW E101
Part 2 - Switchboards and Associated Equipment<br />
For arcing fault prevention, large cable terminations shall be treated in accordance with<br />
Clause 204.6<br />
205.4 Small Cables (Cables up to and including 6mm ²)<br />
Each cable core shall be marked at both ends with neat fitting ring type identification<br />
ferrules and the markings shall agree with the endorsed circuit diagram. Markings shall<br />
comply with AS 1103.<br />
Marked cables to connect with external controls shall terminate in correspondingly<br />
marked terminals located within the switchboard, adjacent to the external cable route.<br />
Cables to items of equipment mounted on hinged panels or doors shall run at the hinge<br />
side in such a manner as to not impede opening of the panel or door. Spiral type<br />
sheathing shall be applied to the cables between the fixing at the switchboard cubicle and<br />
the fixing on the panel or door.<br />
206 ACTIVE, EARTH AND NEUTRAL LINKS<br />
206.1 For Proprietary Assemblies<br />
Links for Proprietary Assemblies may be the manufacturer's standard.<br />
206.2 For Custom-built Assemblies<br />
For small cables (up to and including 6mm 2 ), two screw tunnel terminals with <strong>minimum</strong><br />
M4 brass or plated steel screws shall be provided. Screw diameter shall be not less than<br />
70% of tunnel diameter.<br />
For large cables (above 6mm 2 ), one of the following is acceptable:<br />
(a) Minimum M8 brass screws, tapped and sweated into a <strong>minimum</strong> 6 thick brass or<br />
copper bar. A full nut and flat washer shall be provided for each stud.<br />
(b) Minimum M8 hexagon head plated steel or brass set screws with flat washer,<br />
tapped into a brass bar. The length of engaged thread shall be not less than the<br />
diameter of the screw.<br />
(c) Minimum M8 plated steel screws through clearance holes not more than 1.0 larger<br />
than the screw diameter, in a <strong>minimum</strong> 6 thick busbar. A plated full nut and two<br />
plated flat washers, one under the head and one under the nut, shall be provided.<br />
This method shall only be used where there is adequate spanner access to both<br />
the screw head and the nut.<br />
(d) Tunnel terminals with one Allen head grub screw per terminal of diameter not less<br />
than 90% of the tunnel diameter.<br />
(e) Approved nut tightened line-tap type clamp which securely clamps the conductors<br />
and prevents the cable strands from spreading.<br />
For aluminium cables, only methods (a), (b) and (c) are acceptable.<br />
Spring washers shall not be used at links.<br />
Each incoming and outgoing switchboard control shall be numbered with consecutive<br />
numbers starting at 1 and no number shall be repeated on the same switchboard. The<br />
same number shall appear at the corresponding neutral and earth terminals.<br />
Switchboards with 36 poles or less and where single pole circuit breakers can be fitted<br />
shall have one neutral and one earth terminal for each pole. Switchboards with more<br />
than 36 poles shall have one neutral and one earth terminal for every indicate circuit with<br />
a <strong>minimum</strong> of 36 neutral and 36 earth terminals.<br />
Where spare spaces are indicated, one neutral and one earth terminal shall be provided<br />
for each pole space or indicated future control. In determining the type of spare<br />
terminals, the ratio of small cable to large cable terminals for the indicated circuits shall<br />
MEW E101 Page 41
Part 2 - Switchboards and Associated Equipment<br />
be maintained, except that no less than two spare neutral and two spare earth large cable<br />
terminals shall be provided. Spare large cable terminals are not to be identified with a<br />
circuit number.<br />
Where the number of interchangeable circuit breaker poles in a switchboard exceeds 36,<br />
at least one neutral link and one earth link shall be provided at the top and at the bottom<br />
of the circuit breaker section. Generally, it is preferred that the links be of equal size<br />
although consideration must be given to circuit grouping and the links allocated<br />
accordingly. For example a 60 pole switchboard could have terminals 1 to 24 at the top<br />
and 25 to 60 at the bottom. The conductor linking the top and bottom neutral links shall<br />
have a current rating of not less than the active conductors on the load side of the<br />
controlling device.<br />
Neutral links shall be mounted on an insulated base.<br />
All earth links shall be bonded to the main earthing conductor with a conductor suitable<br />
for 100% of the indicated fault level for 100% of the time of duration. Bonding by means<br />
of cubicle contact is not acceptable.<br />
Control circuit neutrals and earths shall not occupy terminals designated for outgoing<br />
cables.<br />
207 EQUIPMENT<br />
207.1 Compliance with Australian Standards<br />
Proof of compliance with the relevant Australian Standard shall be provided if requested<br />
by the superintendent. Such proof shall comprise a complete Test Certificate from an<br />
accepted independent Testing Authority or a Certificate of Suitability issued by an<br />
Australian Electricity Authority.<br />
207.2 Ambient Temperature<br />
All outdoor SCA's equipment shall be rated for min 60°C. All equipment for indoor SCA's<br />
shall be rated at min 50°C.<br />
207.3 Miniature Overcurrent and Moulded Case Circuit Breakers<br />
Circuit breakers with current ratings of up to and including 100 A, and interrupting<br />
capacities up to but not including 10 KA, and/or a projected panel mounting area not<br />
exceeding 4000 sq. mm per pole, shall comply with AS 3111.<br />
This shall include Miniature Overcurrent Circuit Breakers fitted with or incorporating a<br />
current operated core balance core leakage relay or auxiliary contacts.<br />
Circuit breakers with an interrupting capacity of 10 kA and above shall comply with AS<br />
2184.<br />
The trip current rating shall be clearly visible with the switchboard covers in place.<br />
Separate labels on the switchboard cover for this purpose are not acceptable.<br />
Identification of the contact positions shall be clearly marked on the circuit breaker in a<br />
contrasting colour.<br />
Horizontally mounted circuit breakers shall be capable of successful operation under full<br />
load and short-circuit conditions in the horizontal position.<br />
Where switchboards are supplied as a group of one or more switchboards from the one<br />
manufacturer, then within that group all circuit breakers of each frame size shall be of the<br />
same manufacture. However, the selection of all circuit breakers for any project shall<br />
ensure full overload and short circuit compatibility with each other and with all existing<br />
circuit breakers. This latter <strong>requirement</strong> is particularly important where, for fault current<br />
limiting, the use of series circuit breaker combinations is indicated.<br />
Page 42 MEW E101
Part 2 - Switchboards and Associated Equipment<br />
To limit the possibility of low level short circuit arcing faults, all adjustable short circuit trip<br />
settings are to be set to the "low" position.<br />
To assist in phase balancing, circuit breakers for two phase circuits shall be either three<br />
pole circuit breakers or two pole circuit breakers that occupy two pole spaces.<br />
Where locking is indicated, circuit breakers shall be provided with the facility for locking in<br />
the "open" position.<br />
207.4 Drawout Circuit Breakers and Tripping Battery<br />
207.4.1 Drawout Circuit Breaker<br />
207.5 Fuses<br />
Drawout circuit breakers shall comply with AS 1930 and shall incorporate the following<br />
features:<br />
(a) Rated duty shall be "uninterrupted type" for a non-ventilated enclosure.<br />
(b) "Rated short circuit breaking capacity" shall be not less than the switchboard fault<br />
level<br />
(c) Closing shall be either:<br />
(i) "Independent manual closing", or<br />
(ii) "Stored energy closing" with a separate release button.<br />
(d) Drawout construction<br />
(e) Auxiliary contacts shall be rated to AC-11 <strong>requirement</strong>s with a <strong>minimum</strong> rated<br />
operational current of 6 A, 240 V. A <strong>minimum</strong> of one spare normally open contact<br />
and one spare normally closed contact shall be provided.<br />
(f) Ability to be padlocked in the "open" position.<br />
(g) Automatic main contact shutters.<br />
(h) A door interlock to prevent the compartment door being open while the circuit<br />
breaker is in the "closed" position, except where the door serves merely as a cover<br />
to the circuit breaker and its operating mechanism.<br />
(i) Racking gear shall prevent the withdrawal or engagement of the circuit<br />
breaker when its contacts are closed and shall have the following positions:<br />
(i) Connected<br />
(ii) Test/Isolate<br />
(iii) Disconnected.<br />
(j) All stored energy devices shall be automatically discharged before any racking<br />
operation.<br />
(k) Separate racking handles and all special installation, operation and servicing tools<br />
shall be supplied.<br />
(l) The protection system shall be either:<br />
(i) An integral part of the circuit breaker, either solid state protection relay type<br />
or adjustable magnetic instantaneous relay type, or<br />
(ii) externally mounted relays operating a d.c. trip coil, either adjustable<br />
induction disc type, or solid state protection relay type.<br />
(m) An earthing connection shall be provided to earth the movable carriage and<br />
mounting frame. This connection shall "make" no later than and "break" no earlier<br />
than any other connection. It shall be suitable for busbar termination.<br />
Fuses shall comply with AS 2005 (All Parts).<br />
MEW E101 Page 43
Part 2 - Switchboards and Associated Equipment<br />
Fuses shall be suitable for the fault level of the installation and shall discriminate properly<br />
with other protective equipment. Let-through energy and peak current cut-off shall suit<br />
the protected equipment.<br />
Fault current limiter fuse links shall be held in proprietary holders, and shall be mounted<br />
for withdrawal directly towards the operator. Holders for open blade type fuses shall have<br />
barriers complying with Clause 204.6.1.<br />
Where fuse extraction handles are required, they shall be clipped inside the switchboard<br />
cubicle adjacent to the fuses. Where the fuses are located behind more than one cover,<br />
one handle shall be provided behind each cover.<br />
Fuse links shall clearly state the name of the Australian manufacturer or distributor.<br />
A <strong>minimum</strong> of three spare fuse links shall be provided for every fuse size included in the<br />
switchboard, with the exception of fuses installed solely for fault current limiting. The<br />
spare fuse links shall be mounted in clips in the spare parts cabinet or space described in<br />
Clause 214, and where more than one size is provided, rating labels shall be fitted.<br />
207.6 Fuse Combination Units<br />
Fuse combination units shall comply with AS 1775 and shall incorporate the following<br />
features:<br />
(a) Be either of the totally enclosed type or constructed such that the fixed live parts of<br />
the switches and fuses are fully and directly shrouded to prevent faults developing<br />
between phases by introduction of a foreign straight metallic object. The shrouding<br />
shall be fully effective throughout the entire movement of the air break switch.<br />
(b) Switching shall be "independent manual operation".<br />
(c) Rating duty shall be "uninterrupted type".<br />
(d) Derating shall be applied, if appropriate, for units mounted in a compact formation<br />
(eg stacked formation).<br />
(e) Utilisation category shall be in general AC-21 <strong>minimum</strong>, with AC-23 for motor<br />
loads.<br />
(f) Ability to be padlocked in the open position, if indicated.<br />
(g) Contact position shall be clearly shown both with the cover in place and with the<br />
cover removed. A secondary indication independent of the handle position shall<br />
additionally be provided. Where the fuses are mounted in a withdrawable carriage<br />
which ensures isolation from the supply before access to the fuses is possible,<br />
then the secondary indication may be omitted.<br />
(h) Identification of the contact position shall be clearly marked on the F.C.U. in a<br />
contrasting colour.<br />
207.7 Main Switches<br />
This clause shall apply to main switches on main switchboards and local main switches<br />
on distribution boards.<br />
Main switches shall comply with AS 1775 and shall be suitable for fault-making/loadbreaking<br />
duties. Suitable switches are automatic circuit breakers, fused F.C.U.'s and<br />
fault-making/load-breaking switches.<br />
Non-automatic breakers, F.C.U.'s with solid links, or load-making/load-breaking style<br />
switches are not acceptable unless they have been tested for fault-making/load-breaking<br />
duties to AS 1775.<br />
The following features shall be incorporated:<br />
(a) Type of switching shall be "independent manual operation".<br />
(b) Rated duty shall be "uninterrupted type" for a non-ventilated enclosure.<br />
Page 44 MEW E101
207.8 Contactors<br />
Part 2 - Switchboards and Associated Equipment<br />
(c) "Rated short time withstand current" shall be not less than the switchboard fault<br />
level.<br />
(d) Utilisation category shall be in general AC-21 <strong>minimum</strong>, with AC-23 for motor<br />
loads.<br />
(e) Identification of contact position shall be clearly marked on the switch in a<br />
contrasting colour.<br />
AC contactors shall comply with AS 1029.<br />
The following details and <strong>minimum</strong> features shall apply:<br />
(a) Block style electromagnetic, air break type generally from the one manufacturer.<br />
(b) Quiet in operation.<br />
(c) Rated duty "intermittent class .03".<br />
(d) Utilisation category "AC-3" or "DC-3" as applicable.<br />
(e) Mechanical endurance "class 10".<br />
(f) Contact life 1 million operations at AC-3 or DC-3 as applicable.<br />
(g) Three phase contactors shall have <strong>minimum</strong> rating of 16 A, 415 V at category<br />
AC-3. For motor below 0.5 kW 8A is allowed..<br />
(h) Be designed to allow for fitting of auxiliary contacts with rating (I e ) of 4 A at 240 V<br />
a.c.<br />
(i) Series or parallel contacts shall not be used to achieve the required ratings.<br />
207.9 Control Switching Devices<br />
Control switching devices eg instantaneous relays, time delay relays, control switches<br />
and push button switches, shall comply with AS 1431. Contact arrangements and<br />
numbering to EN50011 is required.<br />
207.9.1 Instantaneous Relays<br />
Instantaneous relays shall be of the type and contact arrangement as indicated but, if not<br />
indicated, shall be Type 3 as described below. Where practical, relays shall be selected<br />
from the one manufacturer's range and must be common in regard to contact switching in<br />
any one voltage range.<br />
Where relays are used as on interposing relay between a PLC and other equipment, the<br />
relays may be Type 2.<br />
Type 2 relays shall be 11 pin round plug-in with Push to test feature. Where specified as<br />
a DC relay, they shall be complete with suppression diode and an indicator to show<br />
energisation bases shall have screw connections with scissor action contacts.<br />
Relay coils shall be capable of operating under the required duty in the surrounding<br />
ambient conditions with a supply voltage variation of ± 1-%.<br />
Where indicated a <strong>minimum</strong> of 1 N/O and 1 N/C spare contacts shall be provided within<br />
each relay.<br />
Relays shall have visual indication of contact operation. Type 3 relays shall be of the 4/8<br />
pole style and shall be of identical width in both configurations.<br />
The following details and <strong>minimum</strong> features shall apply:<br />
MEW E101 Page 45
Part 2 - Switchboards and Associated Equipment<br />
Relay<br />
Type<br />
Mech. Life<br />
x 10 6<br />
Operations<br />
Base Contact Rating Min. No.<br />
of Contact<br />
Elements<br />
Plug-In<br />
Unit<br />
Retention<br />
Clips<br />
1 5 Plug-in 1.25I L 2 Yes<br />
2 10 Plug-In 7A @ 240V @ COS Ø= 0.4 2 Yes<br />
3 10 Fixed Mounting 5A @ 240V 4 -<br />
207.9.2 Time Delay Relays<br />
Time delay relays shall be adjustable over the entire range, as indicated, and the timing<br />
range shall not exceed 400% of the indicated setting.<br />
Time delay relays shall be capable of operating under the required duty in the<br />
surrounding ambient conditions with a supply voltage variation of ± 10% and a timing<br />
repeat accuracy of ± 2.5%. The details and <strong>minimum</strong> features indicated in the table in<br />
Clause 207.9.1 excluding <strong>minimum</strong> number of contact elements, also shall apply to time<br />
delay relays.<br />
Unless otherwise indicated, time delay relays shall be electronic operation.<br />
Electronic relays shall incorporate a LED which shall indicate energisation of the output<br />
relay.<br />
207.9.3 Control Switches<br />
Control switches shall be of the rotary switch type with cam operation and switch<br />
positions arranged with a displacement of 60º and, if an "OFF" position is required, it shall<br />
be located at the "12 o'clock" position.<br />
Contacts shall have <strong>minimum</strong> rated operational current (I e ) of 6 A at 240 V a.c. to<br />
utilisation category AC-15 or AC-23.<br />
Escutcheon plates shall be rectangular and shall allow function and switch position<br />
labelling to be included on the plate. Escutcheon plates shall be silver with black<br />
lettering. Where control switches are input to a PLC the contacts shall be low resistance<br />
wiping type.<br />
207.9.4 Push Button Switches<br />
Push Button switches shall be of the oil-tight type with <strong>minimum</strong> rated operational current<br />
(I e ) of 4 A at 240 V a.c. to utilisanaln category AC-15. Buttons shall be not less than 22<br />
diameter and shall all be selected from the same size range. Each switch shall be<br />
provided with a legend plate indicating its functions. In the case of latched "STOP" or<br />
"EMERGENCY STOP" push buttons instructions for releasing the latch shall be included<br />
either on the legend plate or on the face of the button.<br />
Buttons shall be colour coded to AS 1431 Part 2, Table 5.4.1 or the Drawings.<br />
In addition, illuminated push button switches shall comply with <strong>requirement</strong>s of Clause<br />
207.20.<br />
Page 46 MEW E101
207.10 Phase Failure Relays<br />
Part 2 - Switchboards and Associated Equipment<br />
Phase failure relays shall be of the electronic type and shall detect under voltage (80% of<br />
nominal voltage), voltage or phase angle imbalance and reverse phase sequence. The<br />
sensing circuit shall reject signals of other frequencies, i.e. ripple control and spurious<br />
voltage spikes; either in the supply or induced by the protect loads.<br />
The relay shall be suitable for protecting motor loads under starting and running<br />
conditions. A LED shall indicate when the power supply is normal.<br />
Contacts shall have <strong>minimum</strong> rated operational current (I e ) of 5 A at 240 V a.c. to<br />
utilisation category AC-15.<br />
Each relay shall be individually protected by external protective devices of maximum 10 A<br />
rating.<br />
207.11 Residual Current Devices (RCD)<br />
RCD's shall be current-operated (core balance) type to AS 3190. Rated trip current shall<br />
be 30 mA unless otherwise indicated.<br />
All equipment associated with an individual earth leakage circuit section shall be grouped<br />
together in a regular and logical manner.<br />
207.12 A. C. Motor Starters<br />
207.12.1 General<br />
Unless otherwise indicated and except where limitations on starting current preclude their<br />
use, motor starters shall be of the D.O.L. type. Each starter shall be complete with<br />
overload protection incorporating at least one of the classes of motor protection<br />
described in Clause 207.12.<br />
Where indicated, further protective devices, as described by the classes of motor<br />
protection in Clause 207.12, shall be incorporated.<br />
Motor starters shall have the following <strong>minimum</strong> ratings:<br />
Rated duty : intermittent duty 0.1<br />
Utilisation category : AC3<br />
Mechanical endurance : Class 10<br />
One million on-load operating cycles<br />
Minimum 16 A current rating<br />
The voltage rating of the coil shall be such as to be compatible with other components in<br />
the control circuit and the operating voltage applicable.<br />
Contactors used in motor starters shall be designed to allow the fitting of auxiliary<br />
contacts with <strong>minimum</strong> rating (I e ) of 4 A at 240 V a.c. AC 15<br />
Motor starters shall be rated for motor full load currents and shall be suitable for<br />
operation in the enclosures used.<br />
Supply each motor starter with control field isolation terminals to disconnect power to the<br />
contactors.<br />
207.12.2 Direct-On-Line Starters<br />
These shall incorporate a direct switching electromagnetic contactor together with<br />
overload protection relay, offering overload protection in each phase of the supply,<br />
suitable for starting motors "direct-on-line" in accordance with AS 1202 Part 1.<br />
MEW E101 Page 47
Part 2 - Switchboards and Associated Equipment<br />
207.12.3 Reduced Voltage Starters<br />
Reduced voltage starters shall be of the electromagnetically operated type complying with<br />
AS 1202 Parts 2 and 3, offering overload protection in each phase of the supply or motor<br />
circuit and incorporating the following features.<br />
(a) Star Delta Starter<br />
Star-delta starters shall include:<br />
(i) One (1) main line contactor or equivalent.<br />
(ii) Star and Delta contactors mechanically and <strong>electrical</strong>ly interlocked to<br />
prevent simultaneous operation.<br />
(iii) One (1) triple pole overload relay, fitted to the line contactor. Where the<br />
star-delta starter configuration is such that the overload is connected into the<br />
motor phase winding circuit, a nameplate shall be fixed to the starter stating<br />
the full load current of the motor phase wind, i.e. 58% of the full load line<br />
current of the motor.<br />
(iv) One (1) time delay relay with nominal 0-30 second adjustable time delay<br />
period to control the star to delta switching contactors.<br />
(v) Where closed transition type starters are indicated, suitably rated stainless<br />
steel resistor banks, transition contactor and time delay relay shall be<br />
provided.<br />
(b) Auto-Transformer Starters<br />
207.12.4 Reversing Starters<br />
Auto-transformer starters shall be parallel, closed transition (Korndorfer<br />
connections) type in accordance with Diagram B1, Appendix G of AS 1202, Part 3,<br />
utilising three poles of the star contactor ("K1"), Mechanical and <strong>electrical</strong><br />
interlocking shall be employed between the star contactor ("K1") and the run<br />
contactor ("K3") to prevent simultaneous closing.<br />
Each auto-transformer starter shall include:<br />
(i) One (1) three core auto-transformer tapped at 50%, 65% and 80% and rated<br />
for enclosed operation. Provide Auto-transformers with insulation class 155<br />
to AS 2768. Provide Auto-transformers suitable for a <strong>minimum</strong> of 12 starts<br />
per hour. House each auto-transformer in its own segregated compartment.<br />
(ii) One (1) triple pole thermal overload relay.<br />
(iii) Star, auto-transformer and run contactors (K1, K2 and K3).<br />
(iv) One (1) set of three embedded thermistors, complete with manual reset,<br />
operating relays and indicators, to protect the auto-transformer.<br />
(v) One (1) time delay relay with nominal 0 to 30 second adjustable time delay<br />
period to control the start and run contactors.<br />
Reversing starters shall generally comply with Clause 207.12.1 and shall include:<br />
(i) Two (2) main line contactors, mechanically and <strong>electrical</strong>ly interlocked to prevent<br />
simultaneous closure.<br />
(ii) One (1) triple pole overload relay.<br />
(iii) One (1) time delay relay with nominal 0 to 30 second adjustable time delay period,<br />
to prevent plugging of the motor.<br />
Page 48 MEW E101
207.12.5 Electronic Soft Starter<br />
Part 2 - Switchboards and Associated Equipment<br />
Electronic soft starters shall comply with AS 1202 Part 5 and be selected from a<br />
manufacture with a range from 10A to 500A using a three wire rating.<br />
The starter shall incorporate the following features:-<br />
(i) Automatic restart in the event of failure.<br />
(ii) Breakaway torque adjustment.<br />
(iii) Motor starting current limit adjustment.<br />
(iv) Adjustable acceleration time.<br />
(v) adjustable deceleration time.<br />
The starter shall incorporate:<br />
(i) Phase loss trip.<br />
(ii) Shorted SCR trip<br />
(iii) Open circuit output trip.<br />
(iv) Motor stalled trip.<br />
The starter shall incorporate a RL snubber network for dV<br />
suppression and be capable<br />
dt<br />
of withstanding (min) 1400 VDC PIV: Temperature rating shall be 0-60°C <strong>minimum</strong>.<br />
207.13 Motor Protection Devices<br />
207.13.1 Three Phase Motor Protection<br />
Three phase motors required by AS 3000 to have overload protection shall be protected,<br />
as indicated, by one or more of the means listed in Clause 207.13.2 and shall in all cases<br />
include thermal overload protection connected on the load side of appropriate contactor.<br />
The protection equipment shall operate in the event of:<br />
(a) Overloading in continuous or intermittent service.<br />
(b) Extended acceleration times.<br />
(c) Failure of one phase resulting in single phasing.<br />
(d) Mechanical seizure of the rotor.<br />
207.13.2 Motor Protection<br />
Thermal Overloads<br />
Thermal overload relays shall comply with AS 1023, Part 2 and shall incorporate the<br />
following features:<br />
(a) An overload sensing element in each phase.<br />
(b) Ambient temperature compensation shall be such that the temperature of the air<br />
surrounding the overload relay within the starter enclosure can vary over the range<br />
from 5ºC to 50ºC without effectively altering the tripping time of the relay.<br />
(c) Single phasing detection by differential trip bar mechanism which shall operate at<br />
60% of motor full load rating under single phasing conditions.<br />
(d) An integral manual reset button.<br />
(e) One N/O and one N/C auxiliary contact with <strong>minimum</strong> operational current (I e ) of 4<br />
A at 240 V a.c.<br />
(f) Except where operated separately by C.T.'s, T.O.L.'s shall be directly connected to<br />
contactor by "proprietary" links.<br />
(g) C.T.'s used to operate T.O.L.'s shall be protection type, saturating at 10 to 15 times<br />
MEW E101 Page 49
Part 2 - Switchboards and Associated Equipment<br />
full load current, and shall comply with AS 1675, Class 10P. also refer to Clause 207.17.<br />
Note: Where used on fire-pump motors T.O.L.'s shall be used to indicate motor overload<br />
only.<br />
Thermistors<br />
Thermistors shall be installed in the motor winding as detailed in Clause 505.<br />
The thermistor protection relay shall be compatible with the thermistors installed in the<br />
motor and shall comply with AS 1023 Part 1.<br />
The relay shall have at least one (1) normally open and one (1) normally closed set of<br />
contacts rated at the starter control circuit voltage and <strong>minimum</strong> 4 A 240V ac AC 15. The<br />
contacts shall be connected to open the starter at the setting temperature. The control<br />
unit shall be of a type that does not reset following a power failure.<br />
The circuit shall be arranged so that failure of any thermistor by going very low resistance<br />
or open circuit or other component in the control system, or excessive winding<br />
temperature, results in the motor circuit being opened. In addition, on open, a circuit shall<br />
also trip. A manual reset device shall be provided to restore the motor circuit when<br />
tripped due to excessive winding temperature.<br />
A LED shall be installed on the thermistor control unit to indicate that the circuit is in<br />
normal operating mode.<br />
Electronic Motor Protection Relays<br />
Electronic motor protection relays shall incorporate the following features:<br />
(a) Single phasing protection and phase sequence protection.<br />
(b) Thermal overload protection.<br />
(c) Loss of load protection.<br />
(d) Excessive motor run-up and stall protection.<br />
(e) Earth fault protection.<br />
(f) LED indication of fault conditions.<br />
(g) Manual reset facilities.<br />
(h) Adjustable settings of protection parameters (items (b) to (e)).<br />
(i) One (1) normally open and one (1) normally closed set of auxiliary contacts with<br />
<strong>minimum</strong> current rating (I e ) of 4 A at 240 V a.c. AC 15.<br />
(j) C.T.'s used to operate these relays shall be protection type, saturating at 10 to 15<br />
times full load current complying with AS 1675 class 10P. The relay shall<br />
incorporate adjustment facilities to allow matching of C.T. characteristics. Also<br />
refer to Clause 207.17.<br />
(k) Test facilities shall be incorporated to allow testing of the relay.<br />
207.13.3 Single Phase Motor Protection<br />
Single phase motors required by AS 3000 to have overload protection shall be equipped<br />
with one of the following forms of overload protective devices:<br />
(a) Proprietary type integral overload units within the motor, sensing either motor<br />
winding temperature or motor current. Preference shall be given to overload units<br />
having manual reset facilities.<br />
Where motors incorporating integral overload units are installed in inaccessible<br />
positions, the overload devices shall be disconnected and, in lieu, one of the types<br />
referred to in (b) below shall be used.<br />
(b) Overload units generally meeting the <strong>requirement</strong>s of Clause 207.13.1 with the<br />
three individual phase overload elements wired in series..<br />
Page 50 MEW E101
207.14 Time Switches<br />
Time switches shall incorporate the following features:<br />
(a) Electronic with quartz crystal control.<br />
Part 2 - Switchboards and Associated Equipment<br />
(b) Reserve power supply to operate time switch during mains supply failure shall have<br />
<strong>minimum</strong> capacity of 24 hours and battery reserves shall have <strong>minimum</strong> initial<br />
capacity of 100 hours and 10 year battery field life.<br />
(c) Displays shall be digital with liquid crystal.<br />
(d) Minimum 16 A AC-15, 140 V contacts.<br />
207.15 Hour Run Meters<br />
Hour run meters shall incorporate the following features:<br />
(a) Minimum six digits, indicating up to 99999.9 hours.<br />
(b) Digits shall be at least 3.5 high.<br />
(c) A running indicator.<br />
(d) Non reset type<br />
207.16 Indicating Counters<br />
Indicating counters, eg number of starts counters, shall incorporate the following features:<br />
(a) Minimum 6 digits.<br />
(b) Digits shall be at least 3.5 high.<br />
(c) Continuous duty<br />
(d) Non reset type.<br />
(e) Surge diverters shall be fitted. Diverters shall be varistors min 4500A 100 joule<br />
275 Volt.<br />
207.17 Extra-Low Voltage Transformers<br />
Transformers shall comply with AS 3126.<br />
The following features shall be incorporated:<br />
(a) The primary and secondary windings shall be brought out at opposite sides of the<br />
transformer case.<br />
(b) The primary and secondary windings shall be separated by means of an earthed<br />
screen: this screen shall be brought out to an insulated terminal where the<br />
transformer is installed in a double insulated situation.<br />
(c) The output loading shall not exceed 80% of the transformer continuous rating.<br />
Note that such rating shall take account of the degree of ventilation and ambient<br />
temperature of the transformer and supplied load.<br />
207.18 Current Transformers (CTS)<br />
(Not Applicable to Supply Authority Equipment or Protection CTS)<br />
Current transformers shall be resin encapsulated window type and shall comply with AS<br />
1675.<br />
The following details shall apply:<br />
(a) Rated primary current shall have a current rating equal to the maximum current<br />
rating of the frame size of the controlling device.<br />
(b) Secondary windings of measurement current transformers shall be rated at 5 A.<br />
The burden shall be 0.4 ohms (10 VA) <strong>minimum</strong> and the accuracy shall be class 2<br />
<strong>minimum</strong>.<br />
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Part 2 - Switchboards and Associated Equipment<br />
(c) Secondary windings of protection current transformers shall be rated 5 A and shall<br />
be suitable for burden.<br />
Current transformers shall be capable of withstanding the indicated switchboard fault<br />
level for the appropriate time of duration and shall be suitable for operation in an ambient<br />
temperature of 30ºC with a temperature rise of 75ºC.<br />
Where fitted on busbar systems each C.T. shall be fitted on removable links to allow easy<br />
removal from the switchboard.<br />
Where fitted on cables C.T.'s shall be installed to allow easy removal from the<br />
switchboard.<br />
Where C.T.'s are associated with ammeters M.D.I.'s or energy meters, each C.T. shall be<br />
provided with test link terminals.<br />
207.19 Meters and Associated Controls (Not applicable to Supply Authority Equipment)<br />
207.19.1 Voltmeters, Ammeters, Maximum Demand Indicators and Associated Controls<br />
Meters shall comply with AS 1042 and the following details shall apply:<br />
(a) Flush mounting.<br />
(b) Accuracy class 1.5 (<strong>minimum</strong>).<br />
(c) Meter movements shall be jewel and pivot or taut band type, with oil damping.<br />
(d) Impact resisting anti-glare face.<br />
(e) Voltmeter transfer switches shall be seven position type with positions designated<br />
R-W/W-B/B-R/OFF/R-N/W-N/B-N and shall be mounted under or adjacent to the<br />
relevant voltmeter. Also refer to Clause 207.9.3.<br />
(f) Ammeter transfer switches shall be four position type with positions designated<br />
R/W/B/OFF and shall be mounted under or adjacent to the relevant ammeter. Also<br />
refer to Clause 207.9.3<br />
(g) Meters shall be <strong>minimum</strong> 72 square bezel with 90 degree quadrant scale.<br />
(h) Meter scales shall be direct reading.<br />
(i) Meters shall be mounted on hinged panels and wired with maximum 6mm 2 cable.<br />
Where associated exclusively with one phase, meters shall be labelled "RED",<br />
"WHITE" or "BLUE" as applicable.<br />
(j) Potential protection devices for meters shall be grouped together behind a cover or<br />
hinged door, preferably adjacent to the current transformer test links.<br />
(k) Ammeters subject to motor starting currents shall be overscaled a <strong>minimum</strong> of five<br />
times.<br />
(l) Meter scales shall be as indicated. Ammeter scales shall be selected such that<br />
running current is at 45° approx.<br />
(m) Maximum demand indicating meters shall have a 15 minute response time and<br />
provision for sealing of the reset mechanism. Where M.D.I. metering is indicated,<br />
a meter in each phase shall be provided. An accuracy of Class 3 is acceptable.<br />
207.19.2 Energy Meters<br />
These <strong>requirement</strong>s shall apply to rotating element induction type meters designed to<br />
register kWh. Meters shall be general purpose type complying the AS 1284 Part 1.<br />
Where metering is on three phases a polyphase meter shall be used. For two or one<br />
phase metering single phase meters shall be used.<br />
Meters shall be selected to suit load and probable overload conditions. Whole current<br />
meters shall be 15 to 100 A current rating and meters supplied with current transformers<br />
shall be suitable for 5 A secondary.<br />
Page 52 MEW E101
Part 2 - Switchboards and Associated Equipment<br />
Registers shall be large figure cyclometer type and shall be direct reading.<br />
Meters shall be supplied with calibration error figures and shall have the main cover<br />
sealed. Calibration error figures shall be supplied to the Superintendent together with<br />
relevant technical data and wiring diagrams.<br />
207.20 Indicating Lights<br />
Indicating lights shall be of the oil-tight type with heat resistant plastic or glass lens. Size<br />
classification shall be uniformly D30 or D22.<br />
Lamps shall be maximum 28 V incandescent type supplied from integral or separate<br />
transformer and shall be suitable for the indicating light used with maximum rating of 1.2<br />
W. Higher voltage globes shall be used where available e.g. 28 V globes for 24V.<br />
Lamps shall be changed from front of switchboard and lampholders shall remain rigidly<br />
fixed in panel during lamp changing.<br />
Lamps shall not become disconnected under conditions of vibration.<br />
Three (3) spare lamps per 10 indicating lights or part thereof and tools for removal of<br />
lamps (if applicable) shall be provided.<br />
Indicating light colours shall comply with AS 1431 Part 2, Table 5.3.1 (A) "Colours of<br />
indicating lights and their meanings" or as per the drawings.<br />
207.21 Variable Speed Drives<br />
The following clause applies to VSDs controlling 415V, 3 phase, squirrel cage induction<br />
motors:<br />
The adjustable speed <strong>electrical</strong> power drive system (PDS) shall comply with AS61800.3<br />
and shall comply with intended use sub clause 3.2.2 (second environment) and sub<br />
clause 3.2.5 (PSS of Category C3). Compliance with Australian EMC Framework C Tick<br />
is also required.<br />
The VSD shall be suitable to drive its associated motor throughout its entire speed range<br />
under all conditions of operation to achieve:<br />
• Continuous and smooth operation through all speeds<br />
• Torque speed curves which rise continuously with increasing speed with variable<br />
torque which increases with increasing speed and flat torque speed curves for<br />
constant torque loads<br />
• Correct operating and commutation characteristics<br />
• Minimum ripple current, motor heating and noise generation<br />
• Correct running and starting sequences<br />
• Ability to operate on a 3 phase input voltage of 415 V a.c. with prolonged periods<br />
of 440 V a.c.<br />
• Suitable for 3 phase, 415 V a.c. motors of the ratings specified in the contract<br />
documentation<br />
• Minimum a.c. network harmonic distortion within the limits required by the<br />
Electricity Supply Authority or as specified in AS 61000, whichever is the more<br />
onerous. As well, the maximum level of total harmonic current distortion shall be<br />
no greater than 5%.<br />
.<br />
One VSD unit shall be dedicated to each variable speed driven motor.<br />
Cabling for VSDs<br />
Control cables shall be shielded/armoured with the shield connected by means of a cable<br />
clamp at both ends to the metal enclosure.<br />
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Part 2 - Switchboards and Associated Equipment<br />
Control cables and the filtered line cable shall be installed separately to the motor cables<br />
at a distance of separation as large as possible and in accordance with the<br />
manufacturer’s recommendations.<br />
Motor cabling specifically designed to suit the <strong>requirement</strong>s of the variable speed drive<br />
shall be used. Such cables shall have features which reduce the transmission of<br />
electromagnetic interference.<br />
Air Conditioning<br />
Where installed outdoors, switchboards containing VSDs shall have one suitable air<br />
conditioning unit per VSD.<br />
Where installed indoors, the room containing the VSD(s) shall be suitably air conditioned.<br />
The level of air conditioning shall be such that the temperature at the VSD does not<br />
exceed the maximum allowable operating temperature of the VSD minus 5 degrees<br />
Celsius.<br />
Starting Limitations<br />
Each speed controller shall be capable of starting its motor from rest for all speed<br />
settings without exceeding a supply current of twice full load current of the motor and<br />
shall be able to achieve this starting current without falsely tripping or operating any<br />
protective device or overheating the motor.<br />
Motor Insulation Considerations<br />
When selecting the VSD, protection against damage to the motor windings and bearings<br />
shall be provided to meet the recommendations of IEC 60034:17 for limiting the<br />
maximum peak voltage and the rise time at the motor for up to 150 metres of screened<br />
cable. The use of soft switching of the insulated gate bipolar transistor or provision of<br />
output filters to limit the peak voltages is acceptable.<br />
Additional Filters<br />
Where indicated in the documentation, make provision for advanced harmonic filters and<br />
wave filters to ensure. Filtering equipment shall meet the manufacturer’s<br />
recommendations for the application.<br />
Single Phase Fault Response<br />
The VSD shall be capable of “Autoderating” when losing a single mains phase and<br />
recover upon the restoration from the single phase fault. Hence, the VSD shall neither trip<br />
nor require to restart upon a temporary single phase fault.<br />
Power Supply<br />
Each speed controller shall be suitable for operation from a 415V, 3 phase, 4 wire, 50 Hz<br />
supply having a prospective fault level of at least 50kA as far as thermal and magnetic<br />
overcurrent effects are concerned and a voltage tolerance of plus or minus 10% and<br />
rating to suit the motor and drive selected.<br />
Efficiency<br />
The speed controller will be required to control the speed of the unit within close tolerance<br />
of speed setting with maximum efficiency. The V/F output curve of the VSD shall match<br />
the V/F profile that the load curve of the driven mechanical item requires. This is, the load<br />
curve of the driven item shall be matched by an adjustable V/F output curve of the VSD,<br />
in order to save energy that would be wasted if the V/F ratio of the voltage output of the<br />
VSD and the V/F profile that the load curve of the driven mechanical item requires are<br />
different.<br />
Accuracies<br />
The speed controllers shall be designed such that the drive speed is independent of load<br />
conditions, motor iron losses and fluctuations in supply voltages and frequency in order to<br />
give good speed stability and accurate speed control with motor current limited to a safe<br />
Page 54 MEW E101
Part 2 - Switchboards and Associated Equipment<br />
level for all speeds. The speed shall be controlled to within plus or minus 2.5% of input<br />
speed for a range of 10% to 100% speed.<br />
Harmonics<br />
Generated harmonics shall be limited to one third of the limits set down in AS 61000 and<br />
as required by the Supply Authority through appropriate design of equipment and any<br />
devices necessary to achieve this, such as capacitors and/or inductors. For the purpose<br />
of the design of the harmonic filter components, use the current actual fault level of the<br />
installation. For the purpose of thermal and magnetic ratings against fault overcurrents,<br />
assume a fault level rating of 50kA unless otherwise specified in the documentation.<br />
Care shall be taken in the harmonic filter design to ensure that there is no interference<br />
which may cause malfunction with other electronic equipment in the switchboard.<br />
The maximum total harmonic current distortion shall be 5% or less. Filters shall not cause<br />
power system resonance nor attract harmonics from other non linear loads. Filters shall<br />
meet the <strong>requirement</strong>s of IEEE-519.<br />
As an alternative to providing dedicated harmonic filters for all drives, filtering can be<br />
provided such that the whole of the installation meets the <strong>requirement</strong>s of the Supply<br />
Authority, AS61000 and the limitation of total harmonic current distortion of less than 5%.<br />
Status and Faults<br />
Provide the following fault indication with reset provisions for each fault:<br />
• Earth fault in motor<br />
• Input undervoltage fault<br />
• Input overvoltage fault<br />
• Over temperature fault<br />
• Output overcurrent<br />
• Regeneration overcurrent<br />
Provide the following status:<br />
• Remote Trip<br />
• Power on<br />
• Unit enabled<br />
• Acceleration limit operating<br />
• Deceleration limit operating<br />
• Unit at zero speed<br />
VSDs shall be able to drive a 0-5/10 Vdc meter with a voltage signal which shall be<br />
linearly proportional to load motor frequency.<br />
Programming Aspects<br />
It shall be possible to upload/download to copy the set up program from one VSD to<br />
another. Provide an operating keypad on each VSD which is detachable so as to provide<br />
upload/download functionality which allows the copying of one set up program from one<br />
VSD to another.<br />
Electromagnetic Interference<br />
Electromagnetic interference emitted by the equipment shall be within the limits stipulated<br />
by AS 61800.3. Provide RFI filters for each of the motor drives.<br />
Converter Stage<br />
The converter stage shall include a full wave bridge rectifier and any required line side<br />
short circuit protection. The converter stage shall also include all supply line voltage surge<br />
MEW E101 Page 55
Part 2 - Switchboards and Associated Equipment<br />
filtering, RFI filtering and line side harmonic filtering. For converter stages which comprise<br />
controlled rectifier bridges include all required auxiliary control equipment and firmware.<br />
DC Link Stage<br />
The DC link stage shall comprise all control and monitoring devices required to establish<br />
DC voltage and current conditions applicable to the type of inverter used.<br />
Inverter Stage<br />
The inverter stage shall provide dc to ac inversion at the voltage and frequency<br />
appropriate to the speed setting. All control and monitoring including capacitors, inductors<br />
and components required by the methods of modulation and commutation shall be<br />
included. The inverter stage shall include the motor protection and monitoring devices<br />
including thermal overload and thermistor relays.<br />
The converter, link and inverter stages shall incorporate protection devices and circuitry<br />
to ensure maximum reliability under all operating conditions.<br />
Degree of Protection<br />
For stand alone enclosures, the degree of protection shall be IP51.<br />
Single Phase VSDs<br />
Single phase VSDs providing a three phase output are permitted up to a maximum size<br />
motor of 0.37kW.<br />
207.22 Audible Alarm Devices<br />
207.23 Terminals<br />
207.24 Locking<br />
Audible devices such as buzzers, small bells or electronic alarms shall be suitable for the<br />
application. Where several different alarms are included in one location and where<br />
distinction between alarms is required immediately, different tones or devices shall be<br />
used.<br />
Terminals shall be screw tightened, clip-on, 32 DIN rail mounted, flexible, non-flammable<br />
and, as a <strong>minimum</strong>, suitable for the insertion of blade of a screwdriver width 3mm. The<br />
cable shall be secured by a moving plate actuated by the screw. Direct contact of the<br />
screw to the wire is not permitted.<br />
For up to cable size 70mm ² , terminals shall be from the same manufacturer and shall be<br />
capable of accepting the indicated cable size plus a <strong>minimum</strong> of 10%.<br />
Above 70mm ² cable size, terminals shall be of the stud type fixed to the switchboard (not<br />
rail mounted).<br />
Terminals shall be located such as to provide easy access to outgoing terminations, with<br />
cable holes clearly visible.<br />
Mounting rails shall be riveted or screwed to the switchboard at not more than 500<br />
centres and shall be of sufficient length to accept a further 20% terminals or 3 terminals,<br />
whichever is the greater. For each type of control terminal, install on the mounting rail<br />
10% spare terminals or 3 terminals, whichever is the greater.<br />
Terminal rails may be used as earthing conductors only if they are aluminium and earthed<br />
separately to the main earth. Maximum rating of rail shall be 80A.<br />
Where lockable doors are indicated, locks shall be "keyalike" "E" type DPWS, or<br />
approved alternative.<br />
Two keys shall be provided for each switchboard.<br />
Lock handles and surrounds shall be nickel or chromium plated.<br />
207.25 Ambient Temperature<br />
Page 56 MEW E101
Part 2 - Switchboards and Associated Equipment<br />
All outdoor SCA equipment shall be rated for an external air temperature of 45°C. All<br />
indoor SCA equipment shall be rated for an external air temperature of 40°C.<br />
Relative humidity shall be 0-90% non-condensing.<br />
MEW E101 Page 57
Part 2 - Switchboards and Associated Equipment<br />
208 SWITCHBOARD CONSTRUCTION<br />
208.1 Generally<br />
For Proprietary Assemblies, manufacturer's standard construction may be accepted.<br />
Cubicles shall be sized to suite the location and purpose and shall be fitted with<br />
removable access covers.<br />
The arrangement of equipment within each section shall be such as to allow easy access,<br />
maintenance and, where applicable, adjustment. All terminations shall be visible from the<br />
front, or the rear of the cubicle for rear access switchboards.<br />
Internal equipment shall be mounted on equipment mounting panels.<br />
Suitable supports (e.g. cable trays or adequate support straps) shall be provided within<br />
switchboards for all external cabling. As far as practicable such supports shall be located<br />
along the entire cable route length.<br />
Adequate space shall be provided within each switchboard to accommodate all cables<br />
and cable terminations.<br />
Cables gland plates shall be fitted from within the cubicle with adequate room for access<br />
to the plates. Plate shall be 5mm thick aluminium.<br />
Switchboards mounted externally shall not be provided with top cable entries.<br />
To prevent the ingress of dust, ventilation louvres shall not be provided unless required to<br />
cool heat developing equipment such as ballasts and transformers. If ventilation louvres<br />
are fitted they shall be metal screened to minimise vermin entry and maintain the IP<br />
rating.<br />
Wall mounted switchboards shall be provided with an adequate number of M10 clearance<br />
fixing holes. However, not less than four fixings per switchboard shall be provided. The<br />
holes shall be clear of all switchboard equipment, readily visible and accessible from the<br />
front with the switchboard covers removed. All wall mounting switchboards shall contain<br />
additional internal reinforcing to prevent distortion of the cubicle after mounting and<br />
through which the fixing bolts shall pass.<br />
Floor mounted switchboards shall be mounted on a full perimeter <strong>minimum</strong> 75 high x 40<br />
wide x 6 thick mild steel channel base. The base shall be drilled with at least four M12<br />
clearance holes per channel base section to allow fixing of the switchboard to the floor.<br />
Fixing holes shall be positioned to allow easy access to all floor mounting bolts.<br />
Additionally, the base shall be hot dipped galvanised to AS 1650 to a <strong>minimum</strong> thickness<br />
of 85 micrometres and shall not be painted. As an alternative to using fixing holes and<br />
bolts floor mounted switchboards may be clamped in position using suitable galvanised<br />
clamps internal to the switchboard.<br />
Mechanical equipment containing fluids or steam such as pressure gauges, pressure<br />
switches, etc., shall not be installed in these switchboards. In the case of pneumatic<br />
controls they shall be located generally in a separate panel except when of a minor<br />
nature.<br />
208.2 Externally Mounted Switchboards<br />
Externally mounted switchboards shall have a <strong>minimum</strong> degree or protection IP 56.<br />
If the externally mounted switchboard contains a variable speed drive unit, air<br />
conditioning of the outdoor switchboard shall be provided.<br />
Switchboards, with an overall volume 1m³ shall be fitted with ventilation louvres located at<br />
the top and bottom of the vertical surfaces and which maintain the IP ratings.<br />
Openings in the enclosure shall be flanged to prevent the entry of water running down the<br />
vertical surfaces when any cover or door is open. Drain holes shall be provided in the<br />
bottom of the enclosure and shall be metal screened to minimise vermin entry and to<br />
maintain the IP rating.<br />
Page 58 MEW E101
Part 2 - Switchboards and Associated Equipment<br />
Where an outer roof is indicated, it shall be spaced from the top of the enclosure by a<br />
ventilated air space. The outer roof shall overhang the enclosure by 50 on all sides, shall<br />
have a <strong>minimum</strong> pitch of 5° away from all openings a nd shall be provided with a gutter at<br />
all openings.<br />
The top of the enclosure, or the outer roof where fitted, shall be free of openings, bolts,<br />
rivets or other penetrations and shall have sufficient strength to support a person without<br />
distortion.<br />
Thermostatically controlled anti-condensation heaters shall be fitted to weatherproof<br />
switchboards with an external surface area in access of 4m², and shall be on the basis of<br />
10 watts/m² of exposed surface area.<br />
Anti-condensation heaters shall be of the black heat type, shall be able to be touched<br />
without harm and shall be mechanically protected.<br />
208.3 General Cubicle Construction<br />
Cubicles, covers and doors shall be manufactured from zinc coated sheet steel not less<br />
than 1.5 thick except for exterior surfaces of weatherproof switchboards where marine<br />
grade sheet aluminium not less than 2.0 thick shall be used. Marine grade sheet<br />
aluminium shall be grade "5251 H34" with finish "MILL".<br />
Panels forming the body of the cubicle shall be straight and of sufficient rigidity to prevent<br />
warping and excessive flexing with or without covers and doors fitted.<br />
Cubicles shall be all-welded construction, with sheets bent to minimise the number of<br />
welded joints. Consideration will be given to non-welded forms of construction but written<br />
acceptance shall be obtained from the Superintendent before manufacture.<br />
Edges shall be rounded to remove sharp or irregular projections, etc.<br />
Internal equipment panel supports shall be heavy metal angles or plates bolted or welded<br />
to the cubicle sides.<br />
For earth continuity, serrated washers shall be placed under bolt heads and nuts of all<br />
painted, structural metal-to-metal contact points.<br />
Equipment mounting panels shall be <strong>minimum</strong> 2.6 thick and equipment shall be mounted<br />
by studs brazed to the panel or be set screws into proprietary threaded inserts.<br />
Alternatively, small items (e.g. relays) may be set screw fixed into tapped holes in the<br />
panel. Mounting of equipment panels shall be by <strong>minimum</strong> M6 plated steel screws.<br />
All metal in contact shall be as close as possible on the electrochemical series to<br />
minimise corrosion due to dissimilar metals in contact.<br />
208.4 Construction of Covers and Doors<br />
Covers and doors shall be manufactured with right angle welded corners, shall be straight<br />
and of sufficient rigidity to prevent warping and flexing when fitted to, or removed from,<br />
cubicle.<br />
The construction of covers and doors shall allow easy removal and replacement.<br />
Covers shall fit neatly to expose only the toggles and escutcheons of flush mounted<br />
equipment, but shall allow interchangeability of 1, 2 and 3 pole circuit breakers. All<br />
covers and doors shall be fitted with neoprene seals around openings for breakers.<br />
The <strong>minimum</strong> <strong>requirement</strong> for doors and covers shall be a single right angle return on all<br />
four sides, with adhesive U-section sealing rubber or other accepted means to prevent<br />
paint damage.<br />
For Custom-built Assemblies the seal shall be a neoprene section. Foam rubber shall<br />
not be used. The surfaces involved in forming the seal shall be at least as wide as the<br />
sealing strip, a <strong>minimum</strong> of 12, and the seal shall be effectively retained in a U-channel<br />
section.<br />
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Part 2 - Switchboards and Associated Equipment<br />
Each cover shall have a <strong>minimum</strong> of four fixings, each consisting of an M8 plated stud<br />
fixed to the cubicle and fitted with a serrated star washer and a nickel or chromium plated<br />
acorn nut.<br />
All edges of all covers shall rest on the cubicle body or on a mullion. Interlocked covers<br />
are not acceptable.<br />
All covers shall be fitted with chromium plated "D" type handles.<br />
Doors shall be fitted with chromium plated pintle hinges, and doors above 1m in height<br />
shall have three hinges. Doors which are removable shall have staggered pin lengths to<br />
achieve progressive engagement as the door is fitted. Non lift-off doors shall have the<br />
hinges opposed and shall be fitted with a restraining device to prevent damage to<br />
adjacent surfaces or equipment.<br />
The arrangement of door mounted equipment shall allow for ease or operation. All<br />
equipment and terminals on the inside of doors shall be shrouded or otherwise protected<br />
to prevent inadvertent contact with live terminals and/or wiring. An insulated panel<br />
covering the equipment is an acceptable method.<br />
Doors shall have a maximum width of 900, be hinged on a vertical side and be fitted with<br />
a stay to hold the door open at <strong>minimum</strong> angle of 120 o .<br />
208.5 Spacing and Mounting of Circuit Breakers<br />
208.5.1 Generally<br />
Circuit breakers shall be mounted in a regular and logical manner with the toggles<br />
operating in either the vertical or the horizontal plane. When operating vertically the "on"<br />
position shall be uppermost.<br />
Circuit breakers with interchangeable trip units shall be connected so that the trip units<br />
are not "live" when the circuit breaker contacts are open.<br />
208.5.2 Circuit Breakers Not Larger than 160 Amps<br />
Adequate and unimpeded space for access to external cabling is required around multipole<br />
proprietary busbar assemblies in switchboards. Clearances shall be measured from<br />
the return edges or folds of the cubicle to the busbars or circuit breakers, whichever is the<br />
lesser. The following are <strong>minimum</strong> <strong>requirement</strong>s.<br />
(a) On all sides of a busbar assembly a clearance of 100 shall be provided, except<br />
(b) where a switchboard compartment contains a total of more than 60 poles, a<br />
clearance of 150 on all sides of a busbar assembly shall be provided.<br />
208.5.3 Circuit Breakers Larger than 160 Amps<br />
Adequate uninterrupted internal air space shall be provided for the natural convection<br />
cooling of all circuit breakers.<br />
The volume of the total possible number of circuit breakers shall not exceed 25% of the<br />
volume of the compartment, unless verification in the form of an approved Testing<br />
Authority Test Report is available proving that circuit breakers can successfully operate at<br />
full load under more compact arrangements.<br />
208.5.4 Circuit Breakers of the Drawout Type<br />
Each circuit breaker shall be housed in an individual compartment in accordance with the<br />
manufacturer's recommendations.<br />
208.6 Spacing and Mounting of Fuse Combination Units<br />
FCU's shall be arranged in a regular and logical manner and connected such that the<br />
fuse links are isolated when the switch contacts are open.<br />
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Part 2 - Switchboards and Associated Equipment<br />
The extended operating handle of an FCU shall, in any position, remain clear of all other<br />
equipment and be not less than 100 from the floor.<br />
208.7 Space for Future Circuit Breakers and Fuse Combination Units<br />
Where space is provided for future circuit breakers and FCU's the switchboard shall be<br />
fitted with the necessary holes, connection studs and busbar connections to allow<br />
installation and connection.<br />
Front covers shall have all necessary cut-outs for the future equipment and individual or<br />
proprietary blanking plates shall be fitted. Blanking plates shall be installed such that<br />
when removed and the equipment fitted, no unused holes are visible. Fixing of blanking<br />
plates by adhesive material is not acceptable.<br />
208.8 Mounting Heights<br />
(a) No equipment or cable termination, other than neutral and earth links, shall be<br />
mounted less than 200 from floor level.<br />
(b) Mounting heights above floor level of fuse links and toggles of circuit breakers and<br />
fuse combination units shall be between:<br />
(i) 300 and 2000 for Custom-built Assemblies Type “CT” and ”CU”<br />
(ii) 200 and 2000 for Custom-built Assemblies Type “DT”,“DU”,“DUPLUS”&<br />
“DTPLUS”.<br />
(c) Mounting heights above floor level for control switches, indicating lights, meters<br />
and other equipment requiring operator interface or viewing shall be between:<br />
208.9 Extra Low Voltage<br />
(i) 300 and 1700 for Custom-built Assemblies Type “CT” and “CU”<br />
(ii) 200 and 1800 for Custom-built Assemblies Type “DT”,“DU”,“DUPLUS”&<br />
“DTPLUS”.<br />
Extra-low voltage control circuits shall preferably be 24 volts a.c. or 24 volts d.c.<br />
208.10 Auto-transformer Compartment<br />
Each auto-transformer of an auto-transformer motor starter shall be located in a separate<br />
ventilated compartment segregated from the remainder of the switchboard cubicle by<br />
steel partitions. This separate compartment may have a <strong>minimum</strong> degree of protection<br />
IP 41.<br />
208.11 Arrangement of Equipment<br />
(a) Switch/control gear shall be mounted on horizontal combination rail and shall be<br />
set out in a logical manner in functional groups which shall be separated by cable<br />
ducts or an equivalent space.<br />
The following <strong>minimum</strong> <strong>requirement</strong>s shall apply:<br />
180mm centre to centres spacing between rows of equipment.<br />
(b) All internal cabling shall be run in slotted ducts.<br />
(c) Readily accessible terminals grouped in conventional locations shall be provided<br />
for the connection of all external control cables and out-going power circuit cables.<br />
These terminals shall be labelled to correspond to the identification shown on<br />
switchboard workshop drawings.<br />
(d) Control switches, indicating lights, meters and other equipment requiring operator<br />
interface or viewing shall be set out in a logical manner in functional groups and<br />
shall be able to be accessible without the use of a key (to be able to be operated).<br />
MEW E101 Page 61
Part 2 - Switchboards and Associated Equipment<br />
209 PAINTING OF SWITCHBOARDS<br />
209.1 Generally<br />
Proprietary assemblies shall be painted in accordance with the manufacturer’s standard<br />
except that the external colour of the assembly shall be orange X15 and the internal<br />
colour and escutcheon colour shall be off white Y35.<br />
All metal surfaces of the switchboard cubicle and covers shall be painted. Stainless<br />
steel, electroplated, anodised or galvanised equipment mounting panels need not be<br />
painted.<br />
Insulating materials, and door and cover sealing strips shall not be painted.<br />
209.2 Paint Materials<br />
All paint and other preparations shall be of the best quality, non-poisonous, lead-free<br />
synthetic products, conforming to the relevant Australian Standards. Paint materials shall<br />
be used strictly in accordance with the manufacturer's recommendations.<br />
209.3 Surface Preparation<br />
Where the protective coating of any steel surface is removed through welding, grinding,<br />
etc., the standard of surface preparation shall be to AS 1627 with <strong>minimum</strong> power tool<br />
clean to grade "St 3", followed by the application of a cold galvanising compound.<br />
Surfaces shall be degreased using solvent or alkaline solutions.<br />
209.4 Painting and Finish<br />
One coat of etch primer having a suitable corrosion inhibiting compound shall be applied.<br />
If required, a putty sealer, rubbed back to cover major imperfections, and undercoats<br />
rubbed back to cover minor imperfections shall be applied. Undercoats shall be applied<br />
as a base for the final coats unless otherwise recommended by the paint manufacturer.<br />
The finish shall be full-gloss heat cured enamel or 2-pack polyurethane paint which shall<br />
be applied on internal and external surfaces in accordance with the manufacturer's<br />
recommendations to achieve a completely smooth finish with no noticeable<br />
imperfections. Minor paint surface ripple due to the use of galvanised sheet steel will be<br />
accepted.<br />
The <strong>minimum</strong> thickness of the finished paint coating shall be 60 micrometres for indoor<br />
switchboards and 90 micrometres for weatherproof switchboards.<br />
Minimum pencil lead hardness factor shall be "H" to AS 1580 (method 405.1).<br />
Switchboard colours shall comply with AS 2700 and shall be:<br />
(a) Indoor switchboards - X15 orange<br />
(b) Weatherproof switchboards - G52 eucalyptus<br />
(c) Removable equipment panels - Y35 off white<br />
210 LABELLING OF SWITCHBOARDS<br />
210.1 Generally<br />
Every switchboard, switchboard control, contactor, time switch, relay, indicator lamp,<br />
meter, motor starter, link and any control or protection equipment within or on a<br />
switchboard shall be clearly and accurately labelled under the equipment.<br />
Labels shall be engraved laminated plastic and shall comply with the following<br />
<strong>requirement</strong>s:-<br />
Except where otherwise required, labels shall not be on any item of equipment.<br />
Page 62 MEW E101
Part 2 - Switchboards and Associated Equipment<br />
Exterior labels associated with door mounted components (eg. indicating lights) shall be<br />
mounted directly beneath that equipment. In addition, circuit reference labels shall be<br />
fixed on the inside of the door adjacent to the equipment.<br />
Engraved lettering shall be black on a white background, except that the label for a main<br />
switch shall have red lettering on a white background, and warning and caution labels<br />
shall have white lettering on a red background.<br />
The <strong>minimum</strong> height of lettering shall be 3 and of sufficient definition to allow easy<br />
reading.<br />
210.2 Fixing of Labels<br />
Labels shall be securely fixed by:<br />
(a) Screws and adhesive, or<br />
(b) Fixed in an extruded aluminium section which shall be countersunk screw fixed or<br />
countersunk riveted to the panel.<br />
(c) Plastic drive pin and adhesive.<br />
Screws shall be tightened with nuts or into tapped holes in the switchboard. Mechanically<br />
expanded plastic rivets of <strong>minimum</strong> 6 head diameter are acceptable instead of screws.<br />
Aluminium or monel rivets may be used to fix aluminium labels only. Self-tapping screws,<br />
thread-cutting screws or other fixing are not acceptable.<br />
210.3 Labels on Exterior of Switchboards and Schedules<br />
All switchboards shall be labelled with the manufacturer's name and the manufacturer’s<br />
type designation or identification number or other means of identification making it<br />
possible to obtain relevant information from the manufacturer.<br />
Custom-built Assemblies shall be provided with a name plate containing the following<br />
<strong>minimum</strong> data to AS/NZS 3439.1:2002:<br />
• The manufacturer’s name<br />
• The manufacturer’s type designation or identification number<br />
• Rated Operational Voltages<br />
• Rated Main Busbar Current<br />
• Rated short-time withstand current of the Main Busbars<br />
• Short-circuit withstand strength of the Assembly (see 7.5.2 of AS/NZS<br />
3439.1:2002)<br />
• Degree of Protection<br />
• Form of Separation<br />
• This document’s classification of the switchboard<br />
(eg. “<strong>NSW</strong> Dept of Commerce - MEW E101-Custom-built Type “DT” ” )<br />
A switchboard designation label shall be provided (eg. “West Haven Sewage Pumping<br />
Station No. 3 - Main Switchboard”). For other than main switchboards, the designation<br />
label shall also state the source of <strong>electrical</strong> supply. Separate sections of enclosures<br />
shall be identified. The label for any section or enclosure containing Supply Authority<br />
equipment shall be to the satisfaction of the Superintendent and the Supply Authority.<br />
Every switchboard control shall be labelled and shall include:-<br />
(a) Circuit designation for all main switches, main controls and submain controls.<br />
(b) Details of consumers mains and all submains.<br />
(c) Incoming busbar or cable rating to the first tee-off.<br />
(d) Fuse link size fitted to each FCU.<br />
MEW E101 Page 63
Part 2 - Switchboards and Associated Equipment<br />
For uniformity, the labels shall agree with the following examples and be of the <strong>minimum</strong><br />
lettering height shown:<br />
ITEM ENGRAVING EXAMPLE MINIMUM HEIGHT<br />
Main Switchboard MAIN SWITCHBOARD 10<br />
Distribution Board DISTRIBUTION BOARD 3<br />
8<br />
(SUPPLIED FROM MSB)<br />
3<br />
Main Control on a Main<br />
Switchboard<br />
MAIN SWITCH 6<br />
Submain Control SUBMAIN CONTROL TO DB 3 3<br />
Main Control on a<br />
Distribution Board<br />
LOCAL MAIN SWITCH 6<br />
Control for Section of MAIN CONTROL<br />
6<br />
Switchboard<br />
SECTION NAME<br />
3<br />
ELCB Control for Section MAIN CONTROL<br />
6<br />
of Switchboard<br />
ELCB PROTECTED<br />
CIRCUITS<br />
3<br />
SECTION NAME<br />
3<br />
Copper Cu 3<br />
Aluminium<br />
Cable Designation<br />
Al<br />
8 x 1 CORE 150mm<br />
3<br />
² Cu<br />
PVC/PVC<br />
3<br />
Incoming Busbar (or INCOMING BUSBAR (or<br />
3<br />
Cable) Rating<br />
CABLE) TO FIRST TEE-OFF:<br />
800A<br />
Fault Current Limiters FAULT CURRENT LIMITERS<br />
3<br />
behind cover<br />
BEHIND<br />
F.C.U. Fuse Link Size 160A FUSES 3<br />
Spare Parts Section SPARE FUSES/PARTS<br />
BEHIND<br />
6<br />
Phases RED, WHITE & BLUE 3<br />
For identification of final subcircuits, a typed schedule, cross-referenced to the lighting<br />
and power layout plans, shall be provided. The schedule shall be protected by a plastic<br />
sheet and fixed in a suitable frame mounted on the inside of the relevant switchboard<br />
door of, if the switchboard has no door, on the wall immediately adjacent to the<br />
switchboard. Refer to Clauses 114.5 and 214.<br />
210.4 Labels on Interior of Switchboards<br />
Labels identifying equipment within a switchboard shall be located such that the item<br />
referred to is obvious and the lettering is not substantially obscured by the temporary or<br />
permanent position of any equipment or wiring.<br />
For plug-in equipment where items are physically but not functionally interchangeable, the<br />
label wording shall be expanded to clearly identify the removable section (e.g. to identify<br />
the contact configuration or timing range). Where this is not possible, a second<br />
identifying label shall be glue fixed to the removable section.<br />
The function and coding shown on the circuit diagram shall be used.<br />
The MEN link shall be labelled or stamped and infilled MEN LINK on the link.<br />
Labels for fault current limiters shall indicate the rating of the fuse links fitted, for<br />
example:<br />
FAULT CURRENT LIMITERS 160A.<br />
210.5 Warning Labels<br />
Where copolymer membrane coating is used anywhere on live conductors without further<br />
insulation, a warning label shall be provided on the front cover near the main switch or<br />
Page 64 MEW E101
Part 2 - Switchboards and Associated Equipment<br />
local main switch and in a prominent position within each section of the switchboard. The<br />
label shall have the following wording in 6 high lettering:<br />
WARNING<br />
PAINTED COATING ON BUSBARS OR<br />
TERMINATIONS IS NOT INSULATION<br />
In each section of a switchboard containing fault current limiters, a warning label as<br />
follows shall be fixed adjacent to the fault current limiters:<br />
WARNING<br />
DO NOT REPLACE FAULT CURRENT LIMITERS UNTIL<br />
SOURCE OF FAULT HAS BEEN CLEARED, REPLACE ONLY<br />
WITH IDENTICALLY RATED FUSE CARTRIDGES<br />
Should any item of equipment on a switchboard not be isolated by the main switch or<br />
local main switch (eg a relay fed from another switchboard) a warning label shall be<br />
provided adjacent to the equipment. An example of a suitable label is:<br />
WARNING<br />
ORANGE WIRING IS NOT CONTROLLED BY THE<br />
MAIN SWITCH ON THIS SWITCHBOARD<br />
If a stand-by power supply is installed, an appropriate warning label shall be fixed at the<br />
main switch or local main switch. An example of a typical label is:<br />
WARNING<br />
IN THE EVENT OF LOSS OF NORMAL SUPPLY<br />
A.C. GENERATOR SET WILL AUTOMATICALLY START<br />
AND BE CONNECTED TO THIS SWITCHBOARD<br />
When anti-condensation heaters are fitted, a label shall be provided at each heater<br />
reading:<br />
WARNING<br />
THERMOSTATICALLY CONTROLLED ANTI-CONDENSATION<br />
HEATER - DO NOT SWITCH OFF<br />
210.6 Special Label on Custom-built Assemblies<br />
Where the removal and non-replacement of any insulation or shrouding during normal<br />
switchboard maintenance could lead to the possibility of arcing faults, a label with<br />
appropriate wording shall be provided for each function unit. An example of a suitable<br />
label is:<br />
WARNING<br />
REPLACE LINE SIDE SHROUDS AND INSULATING<br />
MATERIAL BEFORE REACTIVATING<br />
These labels shall be positioned to be readily seen, adjacent to, or in impracticable, on<br />
the busbar chamber covers of functional units, and also behind the front cover of<br />
functional units.<br />
A circuit identification label shall be provided in the cabling chamber of each functional<br />
unit. This label shall be positioned adjacent to the external terminations.<br />
MEW E101 Page 65
Part 2 - Switchboards and Associated Equipment<br />
211 INSPECTION AND TESTING<br />
211.1 Generally<br />
211.2 Inspection<br />
The following clauses refer to inspection and testing which shall be performed in the<br />
factory or on site, as indicated. Final inspection and testing will be carried out on site.<br />
The provision of all required testing apparatus shall be the responsibility of the<br />
Contractor.<br />
Witnessing of any or all tests will require ten working day <strong>minimum</strong> notice of all tests.<br />
Normally Serial "A" and "B" switchboards will be inspected on site. If indicated, a factory<br />
inspection of fully assembled switchboards will be carried out at the place of manufacture.<br />
Inspection of fully assembled Custom-built Assemblies will be carried out at the place of<br />
manufacture.<br />
Ten working days <strong>minimum</strong> notice shall be given for a factory inspection.<br />
211.3 Residual Current Equipment Testing<br />
A functional check of residual current equipment on completed switchboards shall be<br />
performed before delivery to site. Suitable testing apparatus shall be used which, as a<br />
<strong>minimum</strong>, shall consist of an adjustable resistance and a.c. millimetre to produce an out<br />
of balance current adjustable between 5 mA and 40 mA through the toroid.<br />
211.4 Dielectric Tests<br />
The dielectric tests described in AS/NZS 3439.1:2002 shall be performed at the factory<br />
or, if indicated, on site, except that the duration of the application of the test voltage shall<br />
be 60 seconds. A verification of insulation resistance test in accordance with clause 8.3.4<br />
of AS 3439.1:2002 shall be carried out before and after the dielectric test. The resistance<br />
shall be recorded. The tests shall be carried out between all live parts and the frame of<br />
the SCA and also between each pole and all other poles connected to the frame of the<br />
SCA. For the tests, either close all switching devices or apply the tests successively to all<br />
parts of the circuit. Any equipment which is not rated to withstand the tests shall be<br />
nominated by the tester and either disconnected or otherwise protected during testing.<br />
With Proprietary Assemblies a 1 kV d.c. test is required and for Custom-built Assemblies<br />
both 1 kV d.c. and 2 kV r.m.s. a.c. tests are required.<br />
Tests shall be conducted with all functional unit isolators switched "on". Special care<br />
must be taken to isolate equipment which could be damaged during the tests.<br />
211.5 Functional Testing<br />
Prior to delivery to a site a check of all switchboard equipment shall be performed. This<br />
check shall include the manual operation of all switches, circuit breakers, F.C.U.'s,<br />
contactors etc.<br />
Following the above check, functional testing shall be performed to ensure satisfactory<br />
operation of all interlocking, control protection and alarms. Where necessary, appropriate<br />
input and output devices shall be used to simulate external circuit conditions.<br />
211.6 Checking of Safety Measures and Electrical Continuity of Earthing Circuit<br />
Prior to delivery to site all safety measures against direct and indirect contact with live<br />
parts shall be checked and the earthing circuit shall be checked for compliance with<br />
<strong>requirement</strong>s of AS/NZS 3439.1:2002.<br />
Page 66 MEW E101
212 DRAWINGS<br />
212.1 Generally<br />
Part 2 - Switchboards and Associated Equipment<br />
Each drawing shall have a discrete number. Resubmitted drawings shall be identified by<br />
a different suffix added to the drawing number for each re-submission, and a dated<br />
notation shall appear on the drawing indicating all changes which were made for each resubmission.<br />
All abbreviations shall be in accordance with AS 1000.<br />
Drawings shall conform to AS 1100 Drawing Practice, SAA HB7-1993-1989 Engineering<br />
Drawing Handbook, AS 1102 Graphical Symbols for Electrotechnology and AS 1103<br />
Diagrams, Charts and Tables for Electro-technology and AS3702-1989. Printing shall be<br />
<strong>minimum</strong> 2.5 high. Drawings shall be prepared on ISO standard drawing sheets size A1<br />
or A3.<br />
For Proprietary Assemblies, details may be submitted in the form of drawings,<br />
engineering schedules and/or correspondence each quoting numbers and issue<br />
identification of endorsed standard drawings.<br />
In the case of Custom-built Assemblies, all information shall be on a drawing. Equipment<br />
schedules shall be in drawing form.<br />
Proprietary Assembly drawings shall be on sheets separate from Custom-built Assembly<br />
drawings.<br />
212.2 Switchboard Drawings and Equipment Schedules<br />
Drawings and equipment schedules shall be submitted containing the following<br />
information:<br />
(a) Manufacturer's name, address, postcode and telephone number with STD code.<br />
(b) Switchboard designation (e.g. Main Switchboard) and classification (e.g. Custombuilt<br />
Type “CU”).<br />
(c) Indicated input fault level.<br />
(d) Overall dimensions of the switchboard and any separate enclosures (e.g. cable<br />
termination enclosure).<br />
(e) If surface or flush mounted.<br />
(f) If a door is fitted, and if so the hinge side of the door.<br />
(g) Confirmation of external paint colour.<br />
(h) Quantities and full details of all equipment, i.e. brand names and full catalogue<br />
numbers of equipment associated with each individual circuit and drive.<br />
(i) Proprietary circuit breaker busbar manufacturer's name, number of poles and<br />
continuous current rating.<br />
(j) Nameplate data (as per 210.3)<br />
212.3 Additional Information on Custom-built Assembly Drawings<br />
The following shall be shown in addition to that required by Clause 212.2:<br />
(a) An overall line diagram and circuit diagrams of main, auxiliary circuits, starters and<br />
control showing wire numbers, terminals, terminal numbers and all equipment.<br />
(b) One complete general arrangement and wiring diagram for each different<br />
switchboard. Typical diagrams and cross-references are not acceptable unless<br />
switchboards are identical.<br />
(c) Full details and sizes of the consumers mains and submains, and termination<br />
routes of these within the switchboard by means of dashed line.<br />
MEW E101 Page 67
Part 2 - Switchboards and Associated Equipment<br />
(d) Spacing between proprietary circuit breaker busbar assembles and spacing<br />
between these assemblies, the switchboard cubicle and other equipment, either to<br />
scale or by dimensioning.<br />
(e) Proposed numbering of all circuit breakers, F.C.U.'s and the associated neutral<br />
and earth links.<br />
(f) The trip or fuse rating of circuit breakers and F.C.U.'s, together with the actual<br />
frame ratings derated due to duty or physical arrangement (e.g. 100A fuse/130A<br />
frame).<br />
(g) Details of all busbar and internal interconnecting cable sizes, spacing and<br />
configuration.<br />
(h) Details of busbar supports including materials, sizes, spacing and fixing methods.<br />
(i) Details of all internal segregations.<br />
(j) Clearance dimensions between the switchboard surfaces and permanent<br />
obstructions including the walls, ceiling and floor. Doors and hinged covers shall<br />
be shown in the open position and withdrawable equipment shall be shown racked<br />
out.<br />
212.4 Drawings Produced by Modification of Exhibited Drawings<br />
(Exhibited drawings are defined to be drawings which are part of the original<br />
documentation.)<br />
Drawings which are produced by modification of exhibited drawings shall be based on a<br />
clean print of the exhibited drawing which shall contain modifications and additions neatly<br />
marked up in red pen. These marked up drawings shall be signed by the contractor. Five<br />
copies of these drawings shall be supplied.<br />
212.5 New Drawings Submitted by the Contractor<br />
Where new drawings are required to be produced as part of this contract to supplement<br />
the modified exhibited drawings, produce the drawings using the latest versions<br />
Computer Aided Drafting software and print the drawings using a laser quality printer of<br />
<strong>minimum</strong> resolution 1200 x 1200 dots per inch. Use <strong>minimum</strong> 80 grams per square metre<br />
paper. Five prints of these drawings shall be supplied.<br />
213 OPERATION AND MAINTENANCE INSTRUCTIONS MANUALS<br />
Where indicated, Operation and maintenance instructions manuals shall be supplied with<br />
the switchboard.<br />
Each copy shall be assembled in a suitably labelled orange A4 size ring type binder of<br />
adequate size and with durable plastic covered hard covers, containing the following:<br />
Where the number of drawings exceeds 30 the drawings shall be bound in a separate A3<br />
ring binder. Each drawing shall be separately bound and enclosed in a plastic sleeve.<br />
(a) One copy of all "work as executed" drawings, schedules and arrangements.<br />
(b) One copy of any drawing supplied by The Department of <strong>Public</strong> <strong>Works</strong> and<br />
Services not incorporated under item (a).<br />
(c) A list of the names, addresses and phone numbers of all equipment suppliers.<br />
(d) Descriptive brochures and manufacturer's maintenance instructions and<br />
recommendations for all switchboard components and equipment.<br />
(e) A software description of the PLC programme where provided as part of the<br />
contract.<br />
(f) A complete listing of any PLC programme provided as part of the Contract.<br />
(g) A copy of Australian Standard AS 2467.<br />
Page 68 MEW E101
(g) SCADA system software description and functional description.<br />
Part 2 - Switchboards and Associated Equipment<br />
(h) A schedule of "Fault Cause Action" for all faults of the plant. The "Cause" shall<br />
detail all possible causes. The action shall detail actions by both operator and<br />
electrician.<br />
(i) Any other information or instructions necessary for operation and maintenance of<br />
the switchboard.<br />
All pages and drawings shall be properly reinforced where attached to the binder.<br />
See also Clause 215<br />
Supply five copies of Operation and Maintenance Instruction Manuals.<br />
214 SWITCHBOARD ACCESSORIES<br />
Whenever fuses, racking handles, other spare parts and maintenance instruction books<br />
are to be stored, a non-lockable, labelled spare parts cabinet shall be supplied for<br />
installation adjacent to the switchboard. If space permits, this cabinet may be part of the<br />
switchboard.<br />
If the schedule holder is not mounted on the switchboard, it shall be supplied loose for<br />
installation in the switchroom. Refer to Clause 114.5.<br />
The drawout circuit breaker tripping battery with cabinet and charger shall be supplied<br />
loose for installation in the switchroom.<br />
215 HEAVY EQUIPMENT HANDLING<br />
Design objects to be handled for routine or maintenance purposes to, as far as<br />
reasonably practical, eliminate risks arising from manual handling.<br />
In particular, design switchboards, variable speed drive enclosures and other enclosures<br />
such that manual handling of equipment for routine or maintenance purposes is limited to<br />
a weight of no more than 16kg per person handling the equipment.<br />
If an object weighing more than 16kg for each person who could simultaneously, in a<br />
balanced and comfortable posture, access the object for handling purposes is required to<br />
be moved, nominate the mechanical aid to facilitate the handling of such an object.<br />
Advise the correct use of such a mechanical weight handling aid. Incorporate this data<br />
into the Operation and Maintenance Instruction Manual.<br />
Refer also to the National Standard for Manual Handling (NOHSC:1001) and the<br />
Occupational Health and Safety Regulation 2001.<br />
MEW E101 Page 69
Part 3 - Accessories<br />
PART 3 - ACCESSORIES<br />
301 ACCESSORIES GENERALLY<br />
Flush mounted light switches, isolating switches, socket outlets and other outlets shall be<br />
mounted in wall boxes.<br />
Outlets shall not be installed across the junction of different wall finishes.<br />
Installation methods are shown below:<br />
Wall Construction Installation Requirements<br />
Rendered brick partition Flush wall box - conduit chased into wall.<br />
Face brick partition Architrave switch with conduit channels cut in architrave.<br />
Flush wall box-conduit concealed in cut bricks.<br />
Face brick external Flush wall box - conduit run in cavity and tied against inner<br />
brick surface.<br />
Stud partition Flush wall box - conduit run in cavity.<br />
302 LAMPS AND LAMPHOLDERS<br />
302.1 Lamps<br />
Unless otherwise indicated:<br />
Stud mounting bracket - conduit run in cavity within 25 of<br />
the bracket.<br />
(a) All incandescent lamps shall be 250 volt grade, general service internally etched<br />
type with normal bayonet caps (B22) up to and including 100 watts, and screw<br />
caps (E40) above 100 watts.<br />
(b) Fluorescent lamps shall be straight fluorescent tubes of standard lengths, with bipin<br />
connection, hot cathodes and a phosphor colour temperature in the range 4100<br />
to 4300 degrees Kelvin.<br />
All 26 mm diameter lamps shall be switch start type.<br />
(c) Mercury vapour lamps shall be class MBF/U colour corrected mercury fluorescent<br />
lamps or class MBTF/U where self ballasted lamps are indicated and shall have<br />
E27 or E40 screw caps.<br />
(d) Sodium discharge lamps shall be high pressure sodium lamps with tubular or<br />
elliptical, frosted or clear glass envelope and shall have E27 or E40 screw caps.<br />
All screw caps shall have nickel plated contacts and ceramic insulating material between<br />
screw and button contact areas.<br />
302.2 Lampholders<br />
Bayonet-type lampholders and batten-holders shall comply with AS 3117 and generally<br />
be ceramic type although moulded type with brass lined shell may be used with lamps<br />
rated up to and including 60 watts.<br />
All screw type lampholders shall be ceramic or moulded glass filled polyester, long skirt<br />
type complying with AS 3140 and having the following features:<br />
(a) spring loaded and nickel plated contacts,<br />
(b) isolated nickel plated fixed screw shell,<br />
(c) nickel plated tunnel type terminals.<br />
Page 70 MEW E101
303 WALL MOUNTED SWITCHES<br />
303.1 Generally<br />
Part 3 - Accessories<br />
Switches shall be of approved manufacture, of <strong>minimum</strong> 10 A rating, complying with AS<br />
3133 and the following:<br />
(a) Switches shall be of the flush type, fixed in wall boxes to suit the installation located<br />
as indicated.<br />
(b) Switchplates for switches other than ironclad shall be impact resistant plastic<br />
mouldings, suitably reinforced, of selected colour and finish.<br />
(c) Ironclad switches shall have the toggle fully recessed, or protected by shrouds.<br />
(d) Switches exposed to the weather, installed in trenches, in basement areas or in<br />
locations subject to dampness or condensation shall be approved to AS 1939-<br />
degree of protection IP56, and shall have a rotary action positive contact switch.<br />
(e) Switch mechanisms, fitted to a flush plate, shall be secured to the plate with<br />
retaining screws, or constructed so that switch mechanisms cannot be displaced.<br />
(f) Isolating switches shall be selected to meet the <strong>requirement</strong>s of the location and<br />
function. A sample of the isolating switch to be used shall be submitted for<br />
approval prior to installation.<br />
(g) Where indicated, a pilot indicator comprising a neon lamp and ruby lens shall be<br />
incorporated within the switch or enclosure.<br />
303.2 Installation of Switches<br />
Switches installed adjacent to door openings shall be installed on the lock side of the<br />
door. Flush mounted wall switches shall be located vertically with a maximum of four<br />
switches to a single gang plate.<br />
Adjacent switches connected to different phases shall be shrouded.<br />
Mounting heights for switches shall be approximately 1200 to the centre of plate unless<br />
otherwise indicated.<br />
304 240 VOLT COMBINATION SWITCH SOCKETS<br />
304.1 Generally<br />
Fittings and accessories shall be of approved manufacture and rating and shall be<br />
selected to meet the <strong>requirement</strong>s of the location and function. Socket outlets shall have<br />
the earth pin located at the 6 o'clock position. Unless otherwise indicated, outlets shall<br />
have a 10 A rating. Where indicated, a pilot indicator, comprising a neon lamp and ruby<br />
lens, shall be incorporated in the enclosure.<br />
Unless otherwise indicated, flush plates for outlets other than ironclad, shall be impact<br />
resistant plastic mouldings, suitably reinforced, of selected colour and finish.<br />
Generally, power outlets shall be located in the fifth brick course above floor level or at<br />
300 above bench top height or as indicated. For walls of different construction a similar<br />
mounting height shall be used.<br />
For school projects, safety shutters shall be incorporated in 240 volt outlets.<br />
MEW E101 Page 71
Part 3 - Accessories<br />
304.2 Socket Outlets - Plastic Type<br />
Socket outlets shall comprise a combination switch and three-pin (flat pin) socket<br />
assembly. Where approved, the assembly may be installed on an impact resistant plastic<br />
moulded mounting block.<br />
304.3 Special Purpose Outlets<br />
SPO's shall comprise a combination switch and socket assembly, shall comply with AS<br />
3000 and shall be polarised as for socket outlets.<br />
305 240 VOLT COMBINATION SWITCH AND PERMANENTLY<br />
CONNECTED CORD OUTLET<br />
This outlet shall comprise an approved, three-terminal flush type switch and flex-lock<br />
insert assembly with an impact resistant plastic moulded flush plate, set flush in a single<br />
gang wall box.<br />
The flex-lock entry shall match the size and type of connected flexible cord and shall<br />
provide a secure grip for the cord.<br />
Where indicated, a pilot indicator, comprising a neon lamp and ruby lens, shall be<br />
incorporated within the switch enclosure.<br />
306 415 VOLT POWER OUTLET<br />
This outlet shall comprise an approved, heavy duty, five pin (round pin), surface mounted<br />
switch socket assembly, ironclad or of impact resistant plastic, with flap lid and complete<br />
with five pin plug top and screw ring for holding plug top in position.<br />
Outlets shall have the earth pin located at the 6 o'clock position, neutral pin in centre<br />
position and phase conductors connected such that a positive phase sequence will be<br />
indicated by a phase rotation meter connected by red, white and blue leads in a clockwise<br />
direction.<br />
Plugs shall be connected in a similar manner.<br />
The capacity of each outlet shall be suitable for the indicated load. Outlets shall be<br />
installed with a neutral conductor in all cases.<br />
307 EXTRA LOW VOLTAGE POWER OUTLET<br />
This outlet shall comprise a 2 pin socket outlet with flat pins at 90 degrees for DC, and<br />
flat parallel pins for AC, flush mounted, with flushplate to Clause 304.1, or surface<br />
mounted with ironclad or impact resistant plastic enclosures.<br />
308 CLOCK OUTLET<br />
This outlet shall comprise an approved 4 pin (round pin) receptacle complete with a plug<br />
top.<br />
When installed, the entire plug top and outlet shall be flush with the surface of the wall.<br />
Unless otherwise indicated, the mounting height shall be 2400 above finished floor level.<br />
309 LABELLING<br />
For labelling of items covered by Clauses 302 to 308 inclusive refer to Clause 603.<br />
Page 72 MEW E101
PART 4 - LUMINAIRES - SUPPLY AND INSTALLATION<br />
401 GENERAL<br />
Part 4 - Luminaires - Supply and Installation<br />
Luminaires shall be complete with incandescent lamps, fluorescent tubes, discharge<br />
lamps, and accessories necessary for their proper functioning and shall be in accordance<br />
with the provisions indicated herein.<br />
All fluorescent luminaires shall have low loss lead/lag ballasts and be switch start 26mm<br />
tubes.<br />
All discharge luminaires shall be power factor corrected to <strong>minimum</strong> of 0.85 lagging.<br />
Other blocking inductors shall be incorporated where indicated and/or where required by<br />
the Supply Authority.<br />
402 SUPPLY OF LUMINAIRES<br />
402.1 Luminaires Other than "Contract" Type<br />
These luminaires shall be purchased from a reputable supplier, and shall be<br />
manufactured in accordance with SAA Approval and Test Specification AS 3100,<br />
AS 3300 and AS 3137.<br />
The catalogue numbers or trade designations for luminaires used in the schedule of<br />
equipment are intended to indicate the required quality, style and performance of the<br />
luminaires. Where an alternative luminaire is offered, all performance data shall be<br />
submitted for approval. If requested, a sample shall be submitted for approval.<br />
403 INSTALLATION OF LUMINAIRES<br />
403.1 Generally<br />
All screws, battens, roses, noggings, trims, packing, etc., necessary for the proper fixing<br />
of luminaires shall be provided by the Contractor as part of the works. Packing pieces of<br />
approved material shall be fitted where required to level the luminaires and to prevent<br />
distortion.<br />
Noggings shall be of similar size to the timber joists, and of <strong>minimum</strong> size 75 x 50.<br />
Unless otherwise indicated, in rooms with only one luminaire, the luminaires shall be<br />
centrally placed for even illumination.<br />
Where painted surfaces are damaged, they shall be made good by painting in<br />
accordance with Clause 601 to the same standard as the original paintwork.<br />
Fittings are to be installed subject to the agreement of the Main Contractor and the<br />
approval of the Superintendent.<br />
All luminaires shall be effectively earthed.<br />
All fixings in outdoor locations shall be stainless steel.<br />
Where rod suspensions are indicated, standard rod suspension sets as supplied by the<br />
fluorescent luminaires supplier shall be used, or, alternatively, rods shall be steel water<br />
pipe with gimbal mounting from ceiling. Rod length shall be adjusted so that the<br />
luminaires hang true.<br />
Where chain suspensions are indicated, standard chain suspension sets as supplied by<br />
the fluorescent luminaires contract supplier shall be used or alternatively, electroplated<br />
welded steel link chains/<strong>minimum</strong> 3 diameter steel shall be used. Chains shall be hook<br />
mounted from ceiling and lengths adjusted so that the luminaires hang true.<br />
403.2 Fluorescent Luminaires<br />
MEW E101 Page 73
Part 4 - Luminaires - Supply and Installation<br />
Luminaires shall be supported by two fixing at each end. One fixing at each end of a<br />
narrow fitting will be accepted where a 1.6 mm thick back plate reinforces each fixing<br />
screw.<br />
End to end luminaires shall be correctly aligned using packing strips where necessary.<br />
Luminaires shall not be erected on sprayed acoustic ceilings until at least one week after<br />
the spraying of the ceilings has been completed.<br />
Luminaires shall not be supported or suspended from plastic boxes or fittings. Plastic<br />
boxes attached to luminaires for cable protection shall not be used as part of the fixing<br />
method.<br />
Where a PVC conduit enters a luminaire, a screwed PVC adaptor with circular lock nuts<br />
shall be used to secure the conduit to the luminaire. Lock nuts are not required for<br />
luminaires with screwed conduit entries.<br />
403.3 Surface Mounted Luminaires<br />
Luminaires shall be securely fixed to structural members of the ceilings or walls, or fixed<br />
by hangers or brackets which are securely fixed to structural members.<br />
403.3.1 Fixings for Surface Mounted Luminaires<br />
The <strong>minimum</strong> size of fixing for luminaires, hangers, or brackets for various surfaces shall<br />
be as follows:<br />
(a) Fixing to timber: steel wood screw No. 10 x 25, round head, cadmium plated.<br />
(b) Fixing to concrete: approved screw expanding bolts M5 x 40.<br />
(c) Fixing to hollow blocks: M5 electro galvanised, round head screws with spring<br />
loaded butterfly toggles. Where a deep cast iron junction box is provided in the<br />
centre, M5 metal screws shall be used with approved expanding fixing at each end.<br />
(d) Fixing to suspended ceilings shall be as indicated.<br />
All fixings shall be fitted with large diameter (<strong>minimum</strong> 3 x screw dia.) cadmium plated<br />
washers under the heads of each screw.<br />
403.3.2 Recessed Luminaires<br />
Recessed luminaires shall be fitted with flexible cords and 3 pin plugs. The flexible cord<br />
shall be PVC insulated, 3 core with 0.75 mm 2 conductors, and shall comply with AS<br />
3191. It shall be of suitable length not greater than 1500.<br />
A plug socket shall be located within 500 from the edge of the access aperture to allow<br />
the luminaire to be plugged-in prior to fixing.<br />
Recessed luminaires installed in timber-framed ceilings shall be fixed to the ceiling<br />
members and noggings using the proprietary fixings supplied by the luminaires<br />
manufacturer, subject to the approval of the Superintendent.<br />
Recessed luminaires using incandescent or discharge lamps and installed in a confined<br />
space (e.g. covered way, counter canopy, integrated ceiling/roof) shall be wired to a<br />
nearby junction box using cable having insulation at least rated to 200ºC maximum<br />
operating temperature.<br />
Recessed luminaires for suspended or modular ceilings shall be attached to suspended<br />
ceilings with proprietary mounting brackets supplied by the luminaire manufacturer.<br />
Page 74 MEW E101
403.4 Post Top Luminaires<br />
Post-top luminaire shall be mounted on tapered steel lighting columns.<br />
Part 4 - Luminaires - Supply and Installation<br />
Unless otherwise indicated, lighting columns shall consist of proprietary brand steel poles,<br />
hot dipped galvanised and suitable for base plate mounting on galvanised rag bolt<br />
assembly set in a concrete pad. The poles shall be adequately drained and shall be fitted<br />
with an approved weatherproof lockable enclosure to house the control gear and fuse(s),<br />
in the lower section of the pole, within 1000 of the ground.<br />
403.5 Emergency Luminaires<br />
Emergency luminaires shall be non-maintained mode. 10W halogen fittings with<br />
separate battery pack. They shall be flush mounting on the ceiling with a charged LED<br />
and a discharge push-button. Battery shall provide a <strong>minimum</strong> two hours full illumination.<br />
403.6 Bollard Luminaires<br />
Bollards shall be flange plate mounted on a 500 x 500 x 500 reinforced concrete block.<br />
The bollard shall have integral controlgear. Body of the bollard shall be manufactured<br />
from <strong>minimum</strong> 2mm aluminium 150 diameter. Bollards shall be epoxy painted eucalyptus<br />
green or similar. Unless specified otherwise, bollards shall have 18W fluorescent tubes.<br />
MEW E101 Page 75
Part 5 - Electrical Motors<br />
PART 5 - ELECTRICAL MOTORS<br />
501 GENERAL<br />
All electric motors except special purpose motors shall have dimensions and outputs to<br />
AS 1360.<br />
Motors shall be three phase. However, single phase motors will be acceptable for<br />
smaller motors (e.g. 0.37 kW and below), where three phase motors are not<br />
manufactured.<br />
Motor design, marking, rating, performance and testing shall be in accordance with the<br />
<strong>requirement</strong>s of AS 1359.<br />
Motors shall be designed to have a winding temperature rise to Class B (Class 130)<br />
<strong>requirement</strong>s and be provided with Class H (Class 180) insulation to AS 2768.<br />
The motor and drive unit torque/speed characteristics shall ensure smooth positive<br />
acceleration in conjunction with the specified starting method.<br />
Motor ratings shall be continuously rated at an ambient temperature of at least 40ºC.<br />
Where a motor is installed in a location at which an ambient temperature greater than<br />
40ºC is indicated or, where due to design, a motor is installed in an ambient temperature<br />
greater than 40ºC, the motor shall either be rated for continuous operation at or above the<br />
ambient temperature or be oversized to the extent that its continuous operating<br />
temperature in the installed ambient shall not exceed its rated operating temperature.<br />
A motor oversized as above shall be derated by fixing to the frame a suitable label which<br />
will indicate the derated full load and the correct setting of the motor protective devices.<br />
The derated full load and the current drawn by the motor at the derated full load shall be<br />
used wherever reference is made to full load or full load current respectively in later<br />
clauses.<br />
Motors shall satisfy the Electricity Supply Authority's <strong>requirement</strong>s particularly in regard to<br />
interference to other consumers and frequency injection systems.<br />
Motors shall be capable of starting direct on line and of operation within the voltage range<br />
of 370 to 440 volts, where three phase and 216 to 264 volts where single phase.<br />
Motors shall have a synchronous speed not exceeding 1500 r/min, except where higher<br />
speeds are specified.<br />
Nameplates shall be stamped or embossed, corrosion resistant, permanently fixed to the<br />
motor in a location adjacent to the terminal box and shall not be painted.<br />
Motors having pressed metal end shields are not acceptable.<br />
502 MOTOR BEARINGS<br />
Motors shall be fitted with ball or roller bearings. Bearings shall be either or the sealed<br />
type or have provision for greasing. For motors having a frame size greater than 132,<br />
provision shall be made for regular greasing of the bearings during their in-service life.<br />
(Sealed bearings are not acceptable).<br />
Where bearings require greasing, the greasing system shall permit the addition of grease<br />
whilst the motor is running, without the risk of over lubrication or injury to personnel and<br />
shall include a pressure relief grease valve to expel excess grease external to the motor.<br />
It shall allow old grease to be purged from the bearing during the regreasing operation. A<br />
name plate shall be attached to motors fitted with regreasable bearings stating the type of<br />
bearing installed and the lubrication instructions.<br />
For variable speed driven motors, which are sized at 90kW, 4 pole or greater (or an<br />
equivalent frame size for other than 4 pole motors), protect the non drive end bearings<br />
from shaft voltages using ceramic insulation material or equivalent.<br />
Page 76 MEW E101
Part 5 - Electrical Motors<br />
For variable speed driven motors, which are sized at 90kW, 4 pole or greater (or an<br />
equivalent frame size for other than 4 pole motors) and which are located in hazardous<br />
locations, do not provide earthing brushes designed to remove the effect of <strong>electrical</strong><br />
discharge through the bearings but provide drive and non drive end insulated bearings,<br />
using ceramic insulation material or equivalent.<br />
503 POWER FACTOR<br />
Single speed motors, when operating at rated full load and rated speed, shall exhibit<br />
power factors equal to or greater than those indicated in the following table:<br />
kW Rating Range<br />
Less than 0.5 kW<br />
0.5 kW<br />
to less than 1.1 kW<br />
1.1 kW<br />
to less than 5. 5 kW<br />
5.5 kW<br />
to less than 30 kW<br />
2 Pole 4 Pole 6 Pole 8 Pole<br />
p.f. p.f. p.f. p.f.<br />
0.62 0.62 0.62 0.56<br />
0.83 0.74 0.71 0.64<br />
0.84 0.77 0.72 0.65<br />
0.87 0.83 0.77 0.74<br />
30 kW to 100 kW 0.87 0.87 0.81 0.75<br />
Greater than 100 kW 0.89 0.87 0.81 0.77<br />
In selecting motors to drive the specified plant, the motors selected shall be sized to allow<br />
operation at the highest efficiencies possible, allowing for standard motor sizes and<br />
starting conditions, and shall operate at load factors between 75% and 95% of the motor<br />
full load ratings.<br />
504 MEPS COMPLIANCY<br />
Three phase squirrel cage induction motors, other than submersible motors, hazardous<br />
area motors and motors that are integral with and not separable from a driven unit or<br />
motors meeting clause 1.2 (Exclusions) of AS/NZS 1359.5:2004, shall be compliant to<br />
the Minimum Energy Performance Standard (MEPS) <strong>requirement</strong>s of AS/NZS<br />
1359.5:2004, for all motors with ratings from 0.73kW to 185kW.<br />
Such motors shall meet either Table A3 (Heff-A) Minimum High Efficiency – Test Method<br />
A or Table B3 (Heff-B) Minimum High Efficiency – Test Method B of AS/NZS<br />
1359.5:2004.<br />
Provide a stainless steel label on the motor identifying MEPS compliancy as follows:<br />
“MEPS COMPLIANT TO AS/NZS 1359.5.2004, Table A3”<br />
or<br />
“MEPS COMPLIANT TO AS/NZS 1359.5.2004, Table B3”<br />
as applicable.<br />
Use <strong>minimum</strong> size lettering of 2.5 high for the above label.<br />
MEW E101 Page 77
Part 5 - Electrical Motors<br />
505 POWER FACTOR CORRECTION<br />
When power factor correction capacitors are permitted and required they shall be<br />
supplied in three phase delta-connected units, fitted with fuses and internal discharge<br />
devices. All capacitors shall be housed in the SCA.<br />
When audio-frequency rejection is specified, the capacitors shall be fitted with frequency<br />
rejection devices tuned to the specified frequency.<br />
Power factor correction equipment is to comply with the <strong>requirement</strong>s of the Electricity<br />
Distributor.<br />
In addition to the <strong>requirement</strong>s of AS 1013 Clause 6.1 the capacitor unit rating plate shall<br />
be labelled "CAPACITOR UNIT DETAILS".<br />
506 MOTOR ENCLOSURES<br />
Enclosures for motors shall comply with the <strong>minimum</strong> <strong>requirement</strong>s of the following table:<br />
Motors operating in Enclosure<br />
Areas designated hazardous Flameproof as specified<br />
Areas subject to hosing and external area IP 56<br />
Other Areas IP 54<br />
Motor cooling <strong>requirement</strong>s shall be to IC 0141.<br />
Page 78 MEW E101
507 EMBEDDED OVERLOAD PROTECTION<br />
Part 5 - Electrical Motors<br />
Embedded overload protection shall comprise thermistors embedded in the winding of<br />
each phase and connected to fixed terminals in the motor terminal section. The<br />
thermistors shall comply with AS 1023 Part 1 and shall be Class 1. Details of the type<br />
installed shall be attached to the motor nameplate. The thermistors shall be suitable for<br />
windings having a temperature rise meeting Class B <strong>requirement</strong>s.<br />
All motors rated 15 kW and higher, and all motors used on water supply or sewerage<br />
projects rated 5.5 kW and higher, shall be fitted with thermistors unless otherwise<br />
indicated. A thermistor control unit in accordance with Clause 207.12.2 shall only be<br />
provided when indicated.<br />
508 ANTI-CONDENSATION HEATERS<br />
When indicated, two 240 volt 50 Hz anti-condensation heaters, connected in parallel,<br />
shall be fitted in the motor and connected to terminals in a separate terminal box. A<br />
nameplate on the motor shall state:<br />
(1) Heater Details<br />
(2) Number of Heaters<br />
(3) Voltage (240 V 50 Hz)<br />
(4) Power Rating.<br />
Anti-condensation heater terminal boxes shall be fitted with a sign stating:<br />
509 MOTOR TERMINAL BOX<br />
"WARNING: 240 VOLT ANTI-CONDENSATION HEATER<br />
CIRCUIT LIVE WHEN THE MOTOR IS OFF".<br />
Motor terminal boxes shall be of metallic construction, and be of adequate dimensions<br />
suitable for the entry and termination of the appropriately sized cables.<br />
All terminals shall be identified and coded in accordance with the <strong>requirement</strong>s of AS<br />
1359.3 and an earth terminal shall be provided within the terminal box.<br />
Where thermistors and/or anti-condensation heaters are provided, terminals shall be<br />
suitably segregated and identified and a separate terminal box shall be provided for the<br />
anti-condensation heaters terminals.<br />
Each end of the motor phase windings shall be terminated on separate terminals within<br />
the motor terminal box for all single speed motors 5.5 kW and larger.<br />
In addition to the <strong>requirement</strong>s of AS 1023.1 Clause 1.5 the thermistor nameplate shall<br />
be labelled.<br />
"THERMISTOR DETAILS"<br />
When specified, two 240 volt 50 Hz anti-condensation heaters, connected to terminals in<br />
a separate terminal box. A nameplate on the motor shall state:<br />
(1) "Heater Details"<br />
(2) Number of Heaters<br />
(3) Voltage (240 V 50 Hz)<br />
(4) Power Ratings<br />
Anti-condensation heater terminal boxes shall be fitted with a sign stating:<br />
"WARNING: ANTI-CONDENSATION HEATER<br />
CIRCUIT LIVE WHEN THE MOTOR IS OFF".<br />
MEW E101 Page 79
Part 5 - Electrical Motors<br />
Motor terminal boxes shall be metallic construction and shall be of adequate dimensions<br />
and suitable for the entry and crimp-lug termination of the specified cable.<br />
All terminals shall be identified and coded.<br />
An earth terminal shall be provided inside the motor terminal box.<br />
510 PART WINDING START MOTORS<br />
These motors shall have two separate windings arranged so that for starting only one<br />
winding is energised. When the motor is up to speed the second winding is connected in<br />
parallel. The time delay between energising the two windings shall be set to that<br />
specified by the motor manufacturer and sealed by the installer of the equipment.<br />
511 HERMETICALLY AND ACCESSIBLE SEALED MOTORS<br />
These shall comprise proprietary units constructed by the recognised manufacturers to<br />
comply with current industrial practice.<br />
The protection shall comprise a suitable temperature sensing method arranged to<br />
interrupt the electricity supply in the event of the winding temperature exceeding the limit<br />
of the insulation temperature rating from whatever cause. This protection shall be in<br />
addition to over current protection in the control circuit and, for air conditioning plants,<br />
preferably shall be manually reset.<br />
512 SUBMERSIBLE MOTOR REQUIREMENTS<br />
The motor and driven unit torque/speed characteristics shall ensure smooth positive<br />
acceleration in conjunction with the scheduled starting method under all specified<br />
conditions of operation. The final speed during the first step of starting shall exceed the<br />
speed of breakdown torque.<br />
All motors will be started by means of automatic starters designed to AS 1202.<br />
Motors shall satisfy the Electricity Supply Authority's <strong>requirement</strong>s particularly in regard to<br />
interference to other consumers and frequency injection systems.<br />
Motors shall be rated for type S1 duty in air, i.e. maximum continuously rated (MCR) in air<br />
using a method of cooling consistent with continuous operation with a water level at the<br />
top of the volute. The motor power required over the entire operating range, i.e. between<br />
maximum total head pipeline characteristic and 10% in excess of flow rate at flood head<br />
pipeline characteristic shall be less than the motor rating.<br />
Within the operating range the current in each phase shall be less than the MCR current<br />
for a supply voltage within the specified range, and for a voltage variation between<br />
phases which is within the tolerance that the Electricity Supply Authority permits.<br />
Motor starting, or continuous operation at MCR shall not cause a temperature rise in<br />
excess of that specified, and shall not cause nuisance operation of any protective device.<br />
Starting characteristics shall be Design B to AS1359.41.<br />
Motor winding insulation shall be Class 155, but the design of the motor shall ensure that<br />
the temperature of the windings does not exceed the limits for Class 130 insulation.<br />
All terminals shall be identified and coded to drawing E94A.<br />
Phase time sequence of the electricity supply will be red/white/blue (clockwise rotation)<br />
and the motor shall be suitable for connection of the motor cables directly to this supply<br />
sequence. Any interchanging of phases to achieve correct shaft rotation shall be within<br />
the motor terminal box.<br />
An earth terminal shall be provided inside the motor terminal box.<br />
The motor finish shall be in accordance with that indicated for the pump.<br />
Page 80 MEW E101
Part 5 - Electrical Motors<br />
Each motor shall be supplied with cables suitable for use in sewage. Conductors shall be<br />
flexible with high conductivity tinned copper wire, ethylene propylene rubber (or equal)<br />
insulated and chlorosulphinated and polyethylene (CSP) or polychloroprene (PCP)<br />
sheathed.<br />
Power cores shall be continuously coloured, continuously numbered or fitted with wire<br />
numbers using one of the identification systems shown on Drawing E94A.<br />
Each cable shall be terminated at the motor using a cable gland, in such a way that there<br />
will be no undue mechanical stress on either the conductors or the motor terminals to<br />
which the cable is connected.<br />
Further, the termination system shall be such that water cannot reach the motor windings<br />
from a cut cable under a pressure of fifteen (15) metres head of water.<br />
Cables shall include control cores for each specified and other installed protection<br />
devices. Two control cores per device shall be provided.<br />
Each motor shall have no more than three cables and the cables shall be tied together<br />
with black nylon cable ties at 300 mm centres. Control cores shall be in one cable or may<br />
be part of the power cables.<br />
When determining cable sizes, the three motor cores of motors for Direct-on-Line starting<br />
only shall be taken as each carrying a current equal to MCR current.<br />
The rating of the motor power cores and earth cores shall be suitable for the motor<br />
supplied taking into account all debating factors of AS 3008.1, as the cables are run in<br />
conduit to the switchboard with the cables for each pump in a single conduit, and with the<br />
conduits for different pumps spaced by not less than 100 mm or more.<br />
Cables shall also be sized to ensure that with the pump operating at MCR, the total<br />
voltage drop in the motor cores shall not exceed 2.5% of the supply voltage. For stardelta<br />
or auto transformer starting cables shall be sized to ensure reliable starting in star.<br />
All motors above 4.5kW shall have six (6) power conductors for star-delta starting.<br />
Suitable precautions shall be taken to ensure that signal noise of sufficient quantity to<br />
produce nuisance tripping is not induced in the thermistor, seal failure or any other control<br />
cores.<br />
Control cores shall be permanently and indelibly marked at the free end as S1 and S2 for<br />
seal failure cores, T1 and T2 for thermistor cores and TB1 and TB2 for thermostat cores.<br />
The free end of each motor cable shall be fitted with a heat shrink seal giving a degree of<br />
protection of IPX8 to AS 1939 at 15 m head of water during delivery and prior to<br />
installation.<br />
Each cable or cable group to each motor shall be provided with a means of support. This<br />
support shall be by means of a stainless steel cable support hook provided by the<br />
Contractor and suitably sized stainless steel or nylon support stockings similar to those<br />
manufactured by MACEY CABLE PTY. LTD. of Newcastle, N.S.W.<br />
MEW E101 Page 81
Part 6 - Painting, Colour Coding and Labelling<br />
PART 6 - PAINTING, COLOUR CODING AND LABELLING<br />
601 PAINTING<br />
601.1 Generally<br />
This section shall apply to "on site" painting of equipment. Unless otherwise indicated all<br />
surfaces of conduits, fittings, accessories, equipment and supports installed as part of the<br />
works shall be painted. Sheet metal enclosures shall be painted internally and externally.<br />
All equipment delivered to site already painted shall be thoroughly cleaned down and<br />
damaged or unsatisfactory painting made good. For painting of switchboards refer to<br />
Clause 209.<br />
Surface preparation and painting shall take place in a tradesman-like manner and<br />
coatings shall be applied free from runs, pinholes, misses, patchiness, non-uniform<br />
appearance or any other surface defects and all work shall be to the complete<br />
satisfaction of the Superintendent.<br />
All painter's plant, tool, gear, steps, trestles, scaffolding, dust covers, masking, etc., shall<br />
be provided by the Contractor as necessary for the completion of the work and for the<br />
protection of finished work.<br />
Painting shall not be carried out under adverse weather conditions or when work is wet<br />
with fog, mist or dew or when the work would be subject to damage by such conditions.<br />
Dust sheets, drop sheets and masking shall be used whenever necessary to protect<br />
finished work and any other surfaces or equipment from dirt or paint spotting. Paint spots<br />
and splashes shall be removed immediately from adjacent surfaces and any surface so<br />
damaged shall be restored.<br />
Under no circumstances shall paint be sprayed to surfaces unless prior approval has<br />
been given by the Superintendent in writing. Approval will be granted only in exceptional<br />
conditions he applies.<br />
The following surfaces shall not be painted:<br />
(a) Concealed conduits.<br />
(b) Chrome plated, stainless steel or anodised surfaces.<br />
(c) Bearing surfaces, slides, adjusting screws and any surface that is required to be<br />
unpainted for the correct operation or adjustment of the equipment.<br />
(d) Internal surfaces of galvanised cable troughs.<br />
(e) Galvanised steel poles, unless otherwise indicated.<br />
(f) Galvanised cable tray and ladder, unless otherwise indicated.<br />
(g) Motor and equipment nameplates.<br />
(h) Plastic or fibreglass surfaces, other than conduits, ducts and associated fittings.<br />
601.2 Paint Materials<br />
All paint products and surface preparation material shall comply with S.A.A. standards.<br />
AS 2204 Zinc rich organic primer<br />
AS 2603 2 pack epoxy<br />
Inhibitive metal primer.<br />
GPC-P-12/1 Solvent borne paint for galvanised steel.<br />
AS 2673 Alkyd micaceous iron oxide<br />
AS 2602 Full gloss exterior polyurethane<br />
AS 4025.1 Full gloss oil and petrol resistant enamel.<br />
AS 3730 Vinyl gloss exterior paint.<br />
Page 82 MEW E101
Part 6 - Painting, Colour Coding and Labelling<br />
All paint and other preparations shall be best quality, non-poisonous, lead-free, prepared<br />
synthetic products of approved brand. They shall be brought to site in their original<br />
unopened containers, bearing the manufacturer's label, batch number, instructions for<br />
application and date of expiry where applicable.<br />
All materials in any one complete coating system shall be manufactured by the same<br />
manufacturer and shall be compatible with each other.<br />
All paint shall be stored under conditions which will not lead to deterioration of the paint<br />
and no paint shall be used after expiration of its shelf life and, in the case of a multi-pack<br />
paint, after expiration of its pot life.<br />
Surfaces which shall operate at temperatures in excess of 100ºC shall be primed,<br />
undercoated and finish coated with approved heat-resisting materials suitable for the<br />
temperature to be encountered.<br />
601.3 Preparation of Surfaces<br />
All surfaces shall be thoroughly dry, cleaned down, free from weld spatter, burrs, dust,<br />
rust, cement and grease. Metal surfaces shall be thoroughly wire brushed to remove<br />
loose rust and scale. All sharp edges shall be rounded off to a radius of curvature of not<br />
less than 1. Butt welds shall be ground to a reasonably smooth surface free of sharp<br />
crests. Deposits of oil or grease shall be removed by solvent cleaning generally in<br />
accordance with AS 1627.1.<br />
Galvanised or zinc coated steel surfaces shall be cleaned by washing with potable water<br />
using nylon pads or brushes. After cleaning, the surface shall be thoroughly degreased<br />
by washing with mineral turpentine; alternatively a dispersion cleaner may be used if so<br />
recommended by the paint manufacturer. Soaps and detergents shall not be used for<br />
degreasing. The prime coat of the coating system shall be applied within 4 hours of<br />
completion of surface preparation.<br />
601.4 Application of Coating Materials<br />
601.4.1 General<br />
The paint manufacturer's printed recommendations shall be strictly observed, with<br />
particular reference to <strong>requirement</strong>s for mixing, thinning, application techniques, drying<br />
time between coats and dry film thickness of each coat.<br />
No painting shall be carried out at ambient temperatures below 10ºC or above 30ºC or if<br />
the surface to be painted is less than 3ºC above the dew point or if the relative humidity is<br />
greater than 85%.<br />
Where two coats of otherwise identical paint are to be applied consecutively, each coat<br />
shall be of a different shade in the selected colour. The final coat shall be left smooth,<br />
even and free from visible brush marks and other defects.<br />
Painting of steel surfaces shall be to AS 2312 MP4-A.<br />
601.4.2 Prime Coating<br />
Steel surfaces shall be prime coated with a zinc rich organic primer. The prime coat shall<br />
be applied to a <strong>minimum</strong> dry film thickness of 70 micrometres.<br />
Galvanised or zinc coated steel surfaces shall be prime coated with a zinc dust<br />
pigmented drying oil primer for galvanised surfaces, followed by a micaceous iron oxide<br />
long oil alkyd or phenolic modified alkyd paint. Each prime coat shall be applied to a<br />
<strong>minimum</strong> dry film thickness of 40 micrometres.<br />
Non-ferrous metal surfaces shall be lightly abraded by light whip blasting or sanding then<br />
prime coated with a non-reactive two-pack epoxy primer to a dry film thickness of not less<br />
than 20 micrometres not more than 35 micrometres.<br />
Plastic surfaces shall be etch prime coated with an automotive lacquer thinner.<br />
MEW E101 Page 83
Part 6 - Painting, Colour Coding and Labelling<br />
601.4.3 Finish Coating<br />
Steel surfaces shall be finish coated with two coats of a pigmented gloss alkyd enamel<br />
paint conforming to S.A.A. The total dry film thickness of the completed coating system<br />
shall be not less than 140 micrometres.<br />
Galvanised or zinc coated steel surfaces shall be finish coated with two coats of a<br />
pigmented gloss alkyd enamel paint. The total dry film thickness of the completed<br />
coating system shall be not less than 150 micrometres.<br />
Non-ferrous metal surfaces shall be finish-coated as for galvanised surfaces.<br />
Plastic surfaces shall be finish coated with two coats of a pigmented water borne gloss<br />
acrylic paint. The total dry film thickness of the completed coating system shall be not<br />
less than 70 micrometres.<br />
602 COLOUR CODING<br />
All exposed conduits, cable enclosures and cable troughing installed in switchrooms,<br />
boiler rooms, plant rooms, tank rooms, accessible trenches and masonry ducts shall be<br />
coloured light orange, colour X15 AS 2700.<br />
Elsewhere all such exposed material shall be coloured to match its surroundings, unless<br />
otherwise indicated.<br />
Cable enclosures, etc., within switchboard cupboards shall be considered concealed and<br />
need not be colour-coded or painted except that enclosures which form an extension of<br />
the switchboard shall be painted to match the switchboard.<br />
603 LABELLING<br />
Switches, socket outlets, SPO's, permanently connected outlets and power outlets, etc.,<br />
shall be labelled in an approved manner to provide ready identification.<br />
Hand painted, embossed plastic or metal tapes and adhesive fixed labels are not<br />
acceptable.<br />
A stamped metal tag shall be securely tied to the termination of the consumer's mains<br />
cable, giving details of the size, number and material of the conductors.<br />
A similar metal tag shall be attached to each end of all spare pipes and conduits, stating<br />
purpose and point of termination.<br />
An approved traffolyte label with 10mm high black lettering reading: "WARNING - DO<br />
NOT USE THIS ROOM FOR STORAGE" shall be supplied for each switchroom and<br />
switchboard cupboard. The label shall be installed in a prominent location on the door or<br />
switchrooms/switchboard cupboards, as directed.<br />
For labelling of switchboards refer to Clause 210.<br />
For labelling of MEPS compliant motors, refer to Clause 504.<br />
Page 84 MEW E101
Index<br />
TABLE OF CONTENTS<br />
PAGE<br />
PART Ø - GENERAL 1<br />
0.1 SCOPE 1<br />
0.2 USER GUIDELINE FOR THE SELECTION OF SWITCHBOARD<br />
CLASSIFICATION 1<br />
0.3 STANDARDS 2<br />
0.4 ABBREVIATIONS 4<br />
PART 1 - INSTALLATION 5<br />
101 SETTING OUT OF RUNS 5<br />
102 PENETRATIONS 5<br />
102.1 Generally 5<br />
102.2 Penetrations Through Waterproof Membranes 5<br />
102.3 Penetrations Through External or Existing Structures 5<br />
102.4 Unenclosed Cables Passing Through Slabs 6<br />
103 AERIAL RETICULATION (POWER) 6<br />
103.1 Attachment to Poles 6<br />
103.2 Attachment to Buildings 6<br />
103.3 Poles 6<br />
103.3.1 Generally 6<br />
103.3.2 Hardwood Poles 6<br />
103.3.3 Crossarms 6<br />
103.3.4 Service Poles 7<br />
103.4 Aerial Cables 7<br />
104. UNDERGROUND RETICULATION 7<br />
104.1 Trenching, Backfilling and Reinstatement 7<br />
Page 85 MEW E101
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INDEX<br />
104.1.1 Generally 7<br />
104.1.2 Inspection 7<br />
104.1.3 Backfilling and Reinstatement 8<br />
104.2 Underground Cable Protection 8<br />
104.3 Underground Cable Draw-In Pits 8<br />
105 MARKING PLATES FOR UNDERGROUND RETICULATION 9<br />
105.1 Generally 9<br />
105.2 Indication of Cable Entry to Buildings 9<br />
105.3 Indication of Directional Changes 9<br />
105.4 Indication of Cables Under Roads and Paths 10<br />
105.5 Indication of Terminated Conduits 10<br />
106 CABLES AND WIRING 10<br />
106.1 Generally 10<br />
106.2 Consumer's Mains and Metering 10<br />
106.3 Final Sub-Circuit Wiring 11<br />
106.3.1 Generally 11<br />
106.4 Instrumentation Cables 11<br />
106.5 Insulated Non-Armoured Cables in Enclosures (TPI) 12<br />
106.6 Underground Grade Insulated and Sheathed Non-Armoured Cables (TPS) 12<br />
106.7 Armoured and Sheathed Cables (Other than Paper Insulated) 12<br />
106.8 Aerial Cables 12<br />
106.9 Special Purpose 12<br />
106.9.1 Essential Service Cables 12<br />
106.9.2 Telephone Cables 12<br />
106.9.3 Fire Alarm Cables 13<br />
106.9.4 Security Cables 13<br />
106.10 Control Cabling 13<br />
107 EARTHING 13<br />
107.1 Generally 13
Index<br />
107.2 Earthing Conductors for Underground Cables 14<br />
107.3 Earth Electrodes 14<br />
108 CONDUITS, FITTINGS AND JOINTS 14<br />
108.1 Generally 14<br />
108.2 Heavy Duty UPVC Conduits to AS 2053 (HD-UPVC) 14<br />
108.3 Steel Conduits 15<br />
108.4 Light Duty UPVC Conduits to AS 2053 (LD-UPVC) 15<br />
108.5 Flexible Conduits 15<br />
108.6 Installation 15<br />
108.6.1 Generally 15<br />
108.6.2 Conduit Saddles 16<br />
108.6.3 Expansion Joints 16<br />
108.7 Conduits in Roof Spaces 16<br />
108.8 Conduits in Concrete 18<br />
108.8.1 Generally 18<br />
108.8.2 Conduits in Suspended Slabs 18<br />
108.8.3 Conduits in General Columns 18<br />
108.9 Draw-In Points 18<br />
108.10 Conduits and Pipes for Future Use 18<br />
108.11 Wall Boxes 19<br />
109 CONDUIT SYSTEMS FOR COMMUNICATION SERVICES 19<br />
109.1 Conduits for Telecommunication Facility Cabling 19<br />
109.2 Conduits for Telecommunication Lead-In and Block Cabling 19<br />
110 CABLE TRAY, LADDER AND TROUGHING 20<br />
110.1 Generally 20<br />
110.2 Cable Tray 20<br />
110.3 Cable Ladder 20<br />
110.4 Installation 20<br />
110.5 Cable Troughing 21<br />
110.5.1 Generally 21<br />
Page 87 MEW E101
MEW E101 Page 88<br />
INDEX<br />
110.5.2 Metal Cable Troughing 21<br />
110.5.3 Plastic Cable Troughing 21<br />
110.5.4 Skirting Troughing 21<br />
111 FIXINGS 21<br />
111.1 Generally 21<br />
111.2 Conduits 22<br />
111.3 Mounting Blocks 22<br />
111.4 Switchboards 22<br />
111.5 Switch Panels, Boxes 22<br />
111.6 Surface Mounted Switches 22<br />
111.7 Cable Troughing, Cable Tray, Skirting Troughing 22<br />
111.8 Metal Channel 23<br />
111.9 Hollow Block Locations 23<br />
111.10 Fixing of Luminaires 23<br />
111.11 Fixing of Ceiling Fans 23<br />
112 INSTALLATION OF SWITCHBOARDS 23<br />
112.1 Generally 23<br />
112.2 Fixings 23<br />
112.3 Cables, Cable Enclosure and Busway Entry and Termination 23<br />
112.4 Schedules and Drawings 25<br />
113 WORK AS EXECUTED DRAWINGS 25<br />
113.1 Drawings Produced by Modification of Exhibited Drawings 25<br />
113.2 New Drawings Submitted by the Contractor 25<br />
114 ACCREDITATION FOR ‘CONTESTABLE WORKS” 25<br />
114.1 Level 1 Accreditation 25<br />
114.2 Level 2 Accreditation 26<br />
114.3 Level 3 Accreditation 26<br />
PART 2 - SWITCHBOARDS AND ASSOCIATED EQUIPMENT 27
Index<br />
201 SCOPE 27<br />
202 GENERALLY 27<br />
202.1 Classification of Switchboards 27<br />
202.1.1 Proprietary Assemblies 27<br />
202.1.2 Custom-built Assembly Type “CT” 28<br />
202.1.3 Custom-built Assembly Type “CU” 28<br />
202.1.4 Custom-built Assembly Type “DT” 29<br />
202.1.5 Custom-built Assembly Type “DU” 30<br />
202.1.6 Custom-built Assembly Type “DUPLUS” 31<br />
202.1.7 Custom-built Assembly Type “DTPLUS” 32<br />
202.1.8 Manufacturer of the Switchboard. 33<br />
203 FAULT LEVELS AND LIMITATION 33<br />
203.1 Fault Levels and Time of Duration 33<br />
203.2 Fault Current Limiting 34<br />
203.3 Short Circuit Co-ordination 34<br />
204 BUSBARS 34<br />
204.1 Generally 34<br />
204.2 Material 34<br />
204.3 Sizes 34<br />
204.4 Jointing 36<br />
204.5 Supports 36<br />
204.6 Prevention of Arcing Faults 37<br />
204.6.1 Rigid Insulation 37<br />
204.6.2 Coating of Busbars and Terminations 37<br />
204.6.3 Application of Busbar Coatings 37<br />
204.7 Phase Identification 38<br />
204.8 Busbar Clearances 38<br />
204.9 Cable Connection Flags 38<br />
204.10 Neutral and Earth Busbars 38<br />
204.11 Flexible Busbars Take Offs 38<br />
Page 89 MEW E101
MEW E101 Page 90<br />
INDEX<br />
205 CABLING 38<br />
205.1 Generally 38<br />
205.2 Cable Identification 39<br />
205.3 Large Cables (Cables above 6mm²) 40<br />
205.4 Small Cables (Cables up to and including 6mm ²) 41<br />
206 ACTIVE, EARTH AND NEUTRAL LINKS 41<br />
206.1 For Proprietary Assemblies 41<br />
206.2 For Custom-built Assemblies 41<br />
207 EQUIPMENT 42<br />
207.1 Compliance with Australian Standards 42<br />
207.2 Ambient Temperature 42<br />
207.3 Miniature Overcurrent and Moulded Case Circuit Breakers 42<br />
207.4 Drawout Circuit Breakers and Tripping Battery 43<br />
207.4.1 Drawout Circuit Breaker 43<br />
207.5 Fuses 43<br />
207.6 Fuse Combination Units 44<br />
207.7 Main Switches 44<br />
207.8 Contactors 45<br />
207.9 Control Switching Devices 45<br />
207.9.1 Instantaneous Relays 45<br />
207.9.2 Time Delay Relays 46<br />
207.9.3 Control Switches 46<br />
207.9.4 Push Button Switches 46<br />
207.10 Phase Failure Relays 47<br />
207.11 Residual Current Devices (RCD) 47<br />
207.12 A. C. Motor Starters 47<br />
207.12.1 General 47<br />
207.12.2 Direct-On-Line Starters 47<br />
207.12.3 Reduced Voltage Starters 48<br />
207.12.4 Reversing Starters 48
Index<br />
207.12.5 Electronic Soft Starter 49<br />
207.13 Motor Protection Devices 49<br />
207.13.1 Three Phase Motor Protection 49<br />
207.13.2 Motor Protection 49<br />
207.13.3 Single Phase Motor Protection 50<br />
207.14 Time Switches 51<br />
207.15 Hour Run Meters 51<br />
207.16 Indicating Counters 51<br />
207.17 Extra-Low Voltage Transformers 51<br />
207.18 Current Transformers (CTS) (Not Applicable to Supply Authority Equipment or<br />
Protection CTS) 51<br />
207.19 Meters and Associated Controls (Not applicable to Supply Authority Equipment) 52<br />
207.19.1 Voltmeters, Ammeters, Maximum Demand Indicators and Associated Controls 52<br />
207.19.2 Energy Meters 52<br />
207.20 Indicating Lights 53<br />
207.21 Variable Speed Drives 53<br />
207.22 Audible Alarm Devices 56<br />
207.23 Terminals 56<br />
207.24 Locking 56<br />
207.25 Ambient Temperature 56<br />
208 SWITCHBOARD CONSTRUCTION 58<br />
208.1 Generally 58<br />
208.2 Externally Mounted Switchboards 58<br />
208.3 General Cubicle Construction 59<br />
208.4 Construction of Covers and Doors 59<br />
208.5 Spacing and Mounting of Circuit Breakers 60<br />
208.5.1 Generally 60<br />
208.5.2 Circuit Breakers Not Larger than 160 Amps 60<br />
208.5.3 Circuit Breakers Larger than 160 Amps 60<br />
208.5.4 Circuit Breakers of the Drawout Type 60<br />
208.6 Spacing and Mounting of Fuse Combination Units 60<br />
Page 91 MEW E101
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INDEX<br />
208.7 Space for Future Circuit Breakers and Fuse Combination Units 61<br />
208.8 Mounting Heights 61<br />
208.9 Extra Low Voltage 61<br />
208.10 Auto-transformer Compartment 61<br />
208.11 Arrangement of Equipment 61<br />
209 PAINTING OF SWITCHBOARDS 62<br />
209.1 Generally 62<br />
209.2 Paint Materials 62<br />
209.3 Surface Preparation 62<br />
209.4 Painting and Finish 62<br />
210 LABELLING OF SWITCHBOARDS 62<br />
210.1 Generally 62<br />
210.2 Fixing of Labels 63<br />
210.3 Labels on Exterior of Switchboards and Schedules 63<br />
210.4 Labels on Interior of Switchboards 64<br />
210.5 Warning Labels 64<br />
210.6 Special Label on Custom-built Assemblies 65<br />
211 INSPECTION AND TESTING 66<br />
211.1 Generally 66<br />
211.2 Inspection 66<br />
211.3 Residual Current Equipment Testing 66<br />
211.4 Dielectric Tests 66<br />
211.5 Functional Testing 66<br />
211.6 Checking of Safety Measures and Electrical Continuity of Earthing Circuit 66<br />
212 DRAWINGS 67<br />
212.1 Generally 67<br />
212.2 Switchboard Drawings and Equipment Schedules 67<br />
212.3 Additional Information on Custom-built Assembly Drawings 67<br />
212.4 Drawings Produced by Modification of Exhibited Drawings 68
Index<br />
212.5 New Drawings Submitted by the Contractor 68<br />
213 OPERATION AND MAINTENANCE INSTRUCTIONS MANUALS 68<br />
214 SWITCHBOARD ACCESSORIES 69<br />
215 HEAVY EQUIPMENT HANDLING 69<br />
PART 3 - ACCESSORIES 70<br />
301 ACCESSORIES GENERALLY 70<br />
302 LAMPS AND LAMPHOLDERS 70<br />
302.1 Lamps 70<br />
302.2 Lampholders 70<br />
303 WALL MOUNTED SWITCHES 71<br />
303.1 Generally 71<br />
303.2 Installation of Switches 71<br />
304 240 VOLT COMBINATION SWITCH SOCKETS 71<br />
304.1 Generally 71<br />
304.2 Socket Outlets - Plastic Type 72<br />
304.3 Special Purpose Outlets 72<br />
305 240 VOLT COMBINATION SWITCH AND PERMANENTLY CONNECTED<br />
CORD OUTLET 72<br />
306 415 VOLT POWER OUTLET 72<br />
307 EXTRA LOW VOLTAGE POWER OUTLET 72<br />
308 CLOCK OUTLET 72<br />
309 LABELLING 72<br />
PART 4 - LUMINAIRES - SUPPLY AND INSTALLATION 73<br />
401 GENERAL 73<br />
402 SUPPLY OF LUMINAIRES 73<br />
Page 93 MEW E101
MEW E101 Page 94<br />
INDEX<br />
402.1 Luminaires Other than "Contract" Type 73<br />
403 INSTALLATION OF LUMINAIRES 73<br />
403.1 Generally 73<br />
403.2 Fluorescent Luminaires 73<br />
403.3 Surface Mounted Luminaires 74<br />
403.3.1 Fixings for Surface Mounted Luminaires 74<br />
403.3.2 Recessed Luminaires 74<br />
403.4 Post Top Luminaires 75<br />
403.5 Emergency Luminaires 75<br />
403.6 Bollard Luminaires 75<br />
PART 5 - ELECTRICAL MOTORS 76<br />
501 GENERAL 76<br />
502 MOTOR BEARINGS 76<br />
503 POWER FACTOR 77<br />
504 MEPS COMPLIANCY 77<br />
505 POWER FACTOR CORRECTION 78<br />
506 MOTOR ENCLOSURES 78<br />
507 EMBEDDED OVERLOAD PROTECTION 79<br />
508 ANTI-CONDENSATION HEATERS 79<br />
509 MOTOR TERMINAL BOX 79<br />
510 PART WINDING START MOTORS 80<br />
511 HERMETICALLY AND ACCESSIBLE SEALED MOTORS 80<br />
512 SUBMERSIBLE MOTOR REQUIREMENTS 80<br />
PART 6 - PAINTING, COLOUR CODING AND LABELLING 82<br />
601 PAINTING 82
Index<br />
601.1 Generally 82<br />
601.2 Paint Materials 82<br />
601.3 Preparation of Surfaces 83<br />
601.4 Application of Coating Materials 83<br />
601.4.1 General 83<br />
601.4.2 Prime Coating 83<br />
601.4.3 Finish Coating 84<br />
602 COLOUR CODING 84<br />
603 LABELLING 84<br />
Page 95 MEW E101