Technical Specification

TS7 Electrical Control Cubicles

CBH Engineering Pty Ltd

P | (08) 9236 5350
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www.cbh.com.au
TS7 Electrical Control Cubicles

Document Control
Document owner: Principal Engineer

Change Control Policy

Any amendment to this standard must be recorded in the table below.

If substantial changes are made a new version of the document shall be created to preserve an
audit trail.

Review Date Author Description of amendments

A 15/06/2009 T. Tyler Reformatting, CBH changed to BWE,

B 20/07/2009 T. Tyler Previously TS 20

C 12/01/2010 T. Tyler Pg.10 5.3 Insert (Panel wiring 0.75mm unless
nominated) x2. Remove 1.00mm x2.
D 30/04/2010 T. Tyler Rebranding
4 16/04/2013 John Howard Cable colour changes.

5 13/11/2014 J. McMiles Update styling and formatting.

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Contents
1. Scope 4

2. Definitions 4

3. Standards 5

4. General requirements 6

5. Technical Requirements 9

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1. Scope
This technical specification defines the general requirements for electrical control cubicles.

The enclosed Scope of Work Exhibit "C", details the electrical details relating to the particular
project.

2. Definitions
2.1 Hazardous areas
A hazardous area is defined as an area in which an explosive atmosphere is present, or may
be expected to be present, in sufficient quantities to require the installation of specialised
equipment to reduce the risk of fire or explosion.

The areas within and in proximity of grain storage facilities, including elevator towers and
workhouses, boot pits, road and rail discharge grids, conveyor galleries etc, shall be regarded
as "HAZARDOUS AREAS". These areas shall be zoned as 20, 21 or 22 in accordance with
AS/NZS 61241.10.

Switch-rooms shall not be built within these "Hazardous Areas" unless they are pressurized
and comply with AS/NZS 61241.2.

2.2 Competency standards

AS/NZS 2381.1 prescribes a level of competency is required for personnel involved in the
design, construction, maintenance testing and inspection of equipment within hazardous
areas. It is mandatory that any personnel engaged in such work shall be both competent and
accredited prior to commencement.

The competencies shall comply with those set out in AS/NZS 4761. The design consultant and
electrical construction contractor shall provide documented evidence of the required
competencies.

2.3 Apparatus for combustible dusts

In areas zoned as 20, 21 or 22 in accordance with AS/NZS 61241.3:1999, Dust Ignition
Protected (DIP) electrical equipment shall be selected and installed in accordance with the
current edition of AS/NZS 61241.1. practice A The maximum surface temperature of this
equipment shall be 1758C.

All equipment shall be tested and certified under the AUS Ex or IEC Ex schemes.

Alternative suitable electrical equipment shall only be installed after the written approval of the
Principal.

2.4 Hazardous area verification dossier

A site Hazardous Area Verification Dossier shall be commenced by the responsible
designer(s) showing all areas zoned hazardous, and, the relevant zoning. It shall include
justification of the various zones. This document shall be updated as design and / or
construction progresses. The dossier shall be in accordance with AS/NZS 61241.14.

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2.5 Hazardous area equipment

All electrical equipment and / or apparatus installed within classified hazardous areas shall
comply with either AUS Ex or IEC Ex certification requirements for the classification zone into
which it will be installed in accordance with AS/NZS 2381 and AS/NZS 61421.

3. Standards
The principal codes and specifications applicable to this work shall include but not be limited to
the current editions, including all amendments and applicable cross references, of all relevant
Australian Standards as follows:
AS/NZS 4761 Competencies for working with electrical equipment for hazardous areas.
(EEHA) Part 1 Competency Standards.
AS/NZS 3000 Electrical Installations (known as the Australian and New Zealand Wiring
Rules)
AS/NZS 61241 Electrical Apparatus for use in the presence of combustible dust.
Part 1. Electrical apparatus protected by enclosures and surface
temperature limitation.
Part 10 Classification of areas where combustible dusts are or may be
present.
Part 2 Type of protection (pD)
AS/NZS2381 Electrical equipment for explosive atmospheres Selection, installation and
maintenance.
Part 1 General requirements
Part 7 Intrinsic safety
AS/NZS 2380 Electrical equipment for explosive atmospheres Explosion protection
techniques.
Part 1 General requirements
AS 1042 Direct acting indicating electrical measuring instruments and their
accessories.
AS 1675 Current transformers - Measurement and protection.
AS 1243 Voltage transformers for measurement and protection.
AS 1202 AC motor starters (up to and including 1000 V).
AS 1029 Low Voltage Contactors.
AS 1775 Low Voltage Switchgear and control gear - Air-break switches, isolators and
fuse combination units.
AS 2067 Switchgear assemblies and ancillary equipment for alternating voltages
above 1 kV.
AS 1136 Low Voltage Switchgear and Control gear assemblies.
AS 1795 Sheets and Boards for electrical purposes.
AS 2005 Low voltage fuses - Fuses with enclosed fuse links.
AS 2374 Power transformers.
AS 1939 Classification of degrees of protection provided by enclosures for electrical
equipment (IP Code).

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4. General requirements
4.1 Enclosures
Enclosures and equipment to be installed in Hazardous Areas shall comply with AS/NZS 2380,
AS/NZS 2381 and AS/NZS 61241.

For areas not covered by the above requirements the enclosure ratings shall be IP 52 for
internal locations and IP 65 for external positions, as defined in AS 1939.

All enclosures shall be of the type detailed in the equipment schedule or accepted equal.
Hazardous area standards have been specified for some non-hazardous areas; this is done
for standardisation and alternative standards shall not be accepted.

Hinged doors shall not exceed 850mm panel width and shall be fitted with mechanical door
stays if less than 0.33 square metres in area. Doors exceeding 0.33 square metres in area
shall be fitted with gas stays. Stays are not required on switchboard internal hinged panels.

Access doors and interior hinged panels shall be sealed against the ingress of grain and chaff
dust. All glands and packing used for sealing enclosures shall be non-deteriorating neoprene
rubber.

Access door handles and latches shall be padlockable.

Externally located enclosures shall be constructed of high quality folded aluminium and shall
have a brushed aluminium finish, or, marine grade (316) stainless steel. Stainless steel is the
preferred option for ports.

Externally located switchboards and cubicles shall be constructed from high quality folded and
welded minimum thickness 2mm aluminium, rigid, with radiussed corners and all visible joints
ground smooth and shall have a brushed aluminium finish. Free standing switchboards and
cubicles shall be mounted on min 150 legs and concrete footings to allow cable and cleaning
access under the enclosure.

Internally located switchboards may be of steel construction to industry accepted standards

and shall be anti-corrosive treated before applying a painted finish.

Each hole in the sheet metal through which wiring passes shall be bushed, using PVC
extruded channel section having a "return" not less than 10mm on each side. This bushing
shall be neatly fitted to cover the metal completely and shall be securely cemented into
position.

All external screws, latches, handles and the like shall be chrome plated suitable for external,
high use applications. Bolts, nuts and washers used inside the cubicles shall be electro-zinc
plated. All equipment shall be mounted as indicated on the drawings. All equipment located
on the equipment mounting plates shall be fixed by riveted root nuts or similar approved. Note
that nuts welded to the rear of the mounting plate are not acceptable.

Aluminium Escutcheons shall be provided which permit the equipment to protrude through
correctly shaped apertures. Chrome lift off handles and chrome captive thumbscrews shall be
provided. Where escutcheons exceed 1 square metre in area, chrome locating bolts shall be
provided.

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Insulating panels or strips for the mounting of equipment shall comply with AS 1795, cut
square with bevelled edges accurately milled and drilled with finish of clear glass duco.
Wherever practicable, all similar parts shall be jig formed and drilled to permit maximum
interchangeability. Equipment mounting plates shall be fixed in position by Unistrut channels
or accepted equal.

Separate tiers or isolated sections of tiers shall be provided for the installation of Intrinsically
Safe barriers as required.

4.2 Temperature rise

All equipment and materials shall be suitable for continuous full load operation in an ambient
temperature of 50C without exceeding allowable temperature rise.

Ventilation fans and filters shall be fitted to all tiers housing electronic starting equipment. The
ventilation fans shall have the capacity to completely change the air within the tier every two
minutes as a minimum. Filters shall prevent the ingress of dust into the tier.

4.3 Standardisation
All similar equipment, brackets, accessories, etc shall be of the same make and pattern, and
all similar parts shall be jig drilled and interchangeable. Preference shall be given to items of
Australian manufacture, particularly in respect of ready availability of replacement parts and
maintenance.

4.4 Approved equipment

All equipment, accessories, etc used in the work specified herein shall be of the makes and
types specified in the Equipment Schedule of Technical Specification TS19 Appendix C or on
the relevant drawings.

Where alternatives are offered that fully comply with the specification complete technical
details shall be submitted with the price variation of each alternative.

Before any alternative is used in the manufacture, written approval shall be obtained from the
Principal.

4.5 Quality of materials and workmanship

All materials shall be new. Materials and workmanship shall be of the latest and best of their
respective kinds. Second hand or previously used materials shall not be accepted. If
required, samples of the materials shall be submitted for the inspection and approval of the
Principal before being used on the work. Only first class tradesmen are to be employed on the
work of their respective trades. Any workman who in the opinion of the Principal is
incompetent or who is careless in the execution of his work must be removed at the request of
the Principal. Where work has been badly or incorrectly constructed it shall be replaced or
otherwise made good without charge by the Contractor and to the satisfaction of the Principal.

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4.6 Welding
All welding shall conform with the applicable section of AS 1665.

4.7 Fixing, brackets and supports

Brackets, racks, struts, supports, etc., shall be of adequately sized structural members, and
shall be installed in a manner which minimises dust accumulation.

4.8 Finishes
All ferrous metalwork and equipment installed shall be anti- corrosive treated and finished in
accordance with CBH Engineering Technical Specification TS 8 - Protective Coatings.

All brackets, racks and stays shall be finished in a colour to match surrounding steelwork
unless specified otherwise.

Any damage to anti-corrosive finishes on structural steelwork or paintwork on equipment

resulting from application of fastenings, brackets, etc., shall be made good to the satisfaction
of the Principal.

4.9 Labelling and identification

All labelling shall be in accordance with all of the following:

AS 3000

Conveyor Code AS 1755

Service and Installation Rules of the Supply Authority

Generally all apparatus shall have fitted to non-detachable parts of equipment, conspicuous
labels to the acceptance of the Principal and conforming with the following requirements:

EQUIPMENT TYPE OF LABEL

Relays/Pushbuttons/Switches White Traffolyte / Black Lettering
Wire Numbering White bands, black lettering, clip on or
adhesive types shall not be accepted
Control Panels White Traffolyte / Black Lettering
Circuit Breakers White Traffolyte / Black Lettering indicating
circuit identification and rating
Instruments White Traffolyte / Black Lettering indicating
functions
Intrinsically safe barriers. Blue Traffolyte / White Lettering indicating
function and sensor location.
Cable Tags Stamped aluminium straps indicating cable
number as per cable schedule

Colours shall be permanent and free from fading. Unless otherwise accepted by the Principal,
all designation labels shall be engraved with black lettering on a white background.

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Labels shall be securely fixed to the equipment using not less than two fastenings. Label
fixings shall be such as to allow ready replacement without damage to the label or equipment.

'Danger' or similar warning labels shall have red lettering on a white background.

4.10 "As Installed Drawings"

Prior to the time of delivery of the equipment, the Contractor shall obtain from the Principal a
complete set of prints of the Contract drawings.

The Contractor shall neatly mark up to the Principal's approval, these prints in red with any
alterations made during the Contract period.

This set of prints will be returned to the Principal so that the original contract tracing may be
altered to the "as installed" state.

The drawings are intended to be a final record of the installation and shall contain at least the
following information:

(a) Final layout of all cubicles supplied under this Contract.

(b) The actual designation of all equipment as engraved on the labels.

(c) Size of all fuses, circuit breakers, conductors, cables, etc for every circuit
installed.

(d) Conductor ferrule numbers and conductor colour codes.

(e) Terminal layouts with wire numbers for all terminations.

(f) Schedule of make and type of all equipment used within cubicles.

5. Technical requirements
5.1 Electricity supply
The supply shall be 415/240 volts, 3 phase, 4 wire, 50 hertz and derived as shown on the
drawings.

5.2 Earth system

The installation shall be earthed in accordance with the M E N System. Provide all necessary
connections.

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5.3 Cables: general

Unless otherwise specified or shown on the drawings all wiring shall be carried out with
standard copper conductor with PVC insulated or PVC/PVC sheathed cable.

All conductors shall be colour coded as follows:

Power Circuits (Hard Wired)

A phase Red
B phase White
C phase Blue
Neutral Black
Earth Green/Yellow

Control Circuits (Panel wiring 0.75mm unless nominated)

Actives 110V Grey
Neutrals 110V Black
Actives 240V Red
Neutrals 240V Black

ELV d.c. Circuits (Panel wiring 0.75mm unless nominated)

Positive Orange
Negative Purple

Voltage Free
Pink

Intrinsically Safe Circuits

Sheath Blue

Minimum sizes shall be 1.5mm for lighting and 2.5mm for power.

5.4 Switchboards and cubicles

5.4.1 General

Switchboards and cubicles shall comply with the requirements of AS 1136 and be
segregated (modular) as per contract drawings.

Submit shop drawings for approval before manufacture commences.

Western Power approval shall be obtained where necessary before drawings are submitted
to the Principal.

5.4.2 Bus bars

Bus Bars shall be copper and be designed to carry the currents nominated on the drawings
after applying the derating factors specified in AS 3000.

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Every bus bar shall be colour coded with high gloss enamel or plastic sleeving throughout
its entire length. This shall include earth bus bars which shall be coloured green.

5.4.3 Wiring and terminations

Wiring within switchboards generally shall be contained in PVC ducting. The ducts shall be
sized to accommodate 30% extra cables. Where ducting is impracticable, cables shall be
neatly trussed.

Conductors connected to stud type terminals shall be fitted with crimped cable lugs.

Each terminal port shall accommodate not more than one conductor, jumper bars are to be
provided where multiple conductors are to be terminated together.

All unused cores of control cables shall be terminated and earthed within the cubicle. Allow
sufficient terminals.

Unless specified or shown on the drawings all terminal blocks shall be arranged vertically
with left hand ports for internal wiring and right hand ports for external wiring.

Each control terminal group shall be provided with a minimum of 10% spare termination
ports.

Cable entry gland plates shall be provided with neoprene seal to ensure that the specified
enclosure rating is maintained.

5.4.4 Earthing

Provide the M E N Neutral earth link within the main switchboard where specified in a
position easily accessible when the installation has been completed.

A separate port shall be provided for each earth wire terminal on the switchboard earth bar.
Provide 20% spare ports on the earth bar.

5.5 Control gear and accessories

5.5.1 General

This equipment shall be rated for the anticipated working environment and be in
accordance with the equipment schedule of the Scope of Works.

5.5.2 Fuses and links

Fuse links of the HRC cartridge type complying with AS 3135 shall be supplied where
shown.

Carriers and bases shall be of good quality moulded insulating material with fuses of black
material and links of white. Painted bases and/or carriers will not be accepted.

AC control circuits shall have a fuse in the live side and link in the earthed side.

Descriptive labels shall be fitted adjacent to all fuses and links.

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5.5.3 Current transformers

Current transformers for the operation of instruments and metering equipment shall comply
with the requirements of AS 1243 and AS 1675. Current transformers for the operation of
protective equipment shall be suited to the characteristics of the apparatus with which they
are associated.

Current transformers shall be constructed so as to withstand safely the mechanical and

thermal stresses set up by a short circuit equal to the full short circuit rating of the
associated switchgear.

The method of securing current transformers in position shall be such that no undue
pressure is exerted on the windings.

All connections from secondary windings shall be brought out and connected by means of
separate insulated leads to a terminal board, and each shall be securely braced and so
arranged as to prevent accidental contact with main connections due to displacement or
breaking of the leads.

The Contractor shall state the accuracy, capacity and ratio of the transformers and shall
guarantee that all transformers are suitable for the particular duty with which they are
associated.

Protective current transformers shall maintain their ratio to ensure stability of protective
systems under fault conditions.

Magnetisation curves and type test certificates shall be submitted when requested by the
Principal.

The polarity of the primary and secondary windings of each transformer shall be clearly
indicated in an acceptable manner and labels shall be fitted, in an accessible position, to
indicate the duty of each transformer.

5.5.4 Instruments and meters

All indicating instruments shall be to AS 1042 accuracy class 1.5 and have scales in
accordance with BS 3693. They shall have a scale length of not less than 100mm and a
scale movement of approximately 270 degrees, and shall be of the flush mounting type with
square bezels.

All instruments and apparatus shall be capable of carrying their full load fault currents up to
the maximum fault current of the switchgear. All instruments and apparatus shall be back
connected. Accepted means shall be provided for zero adjustment of instrument without
dismantling.

All indicating instrument scales shall be clearly divided and indelibly marked, and the points
shall be of clean outline. Unless otherwise accepted the marking of the main area of the
dials shall be restricted to the scale marking; instrument transformer ratios, maker's name,
accuracy grades, etc shall not appear on the dials, but shall be marked in an accepted
position, preferably below the bezel.

Instrument glasses shall be coated with anti-reflective material.

Ammeters may be directly connected in circuits having a rated full load current not
exceeding 25 amp. Ammeters in circuits having a rated full load current above 25 amp
shall be current transformer operated.

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Ammeters shall be capable of carrying rated currents continuously without undue heating,
be suitable for operation without damage when carrying direct on-line starting currents of
motors and shall withstand the passage of fault currents until operation of the main circuit
protective device.

5.5.5 Intrinsically safe barriers

Intrinsically safe circuits and barriers shall be segregated from other power and control
circuits in accordance with AS/NZS 2380 and AS/NZS 2381and AS/NZS 61241.11

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