TS6 - Electrical Services

Technical Specification TS6 – Electrical Services

CBH Engineering Pty Ltd P | (08) 9236 5350 F | (08) 9236 5370 www.cbh.com.au

TS6 – Electrical Services

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

Descripton of amendments

A

30/04/2009

T. Tyler

Reformatting, CBH changed to BWE, updating reference codes and Standards

B

20/07/2009

T. Tyler

Previously TS 19

C

12/01/2010

T. Tyler

Pg.14 - 5.3 Change wiring from 1.0mm² to 0.75mm². Remove highlighting.

D

30/04/2010

T. Tyler

Re-branding

E

04/05/2010

T. Tyler

Changes made to: 5.11, Appendix A item 10 & Appendix A item 11

F

08/06/2010

T. TYLER

Changes made to page 29 point 13

5

11/11/2010

John Howard

Cable colour changes page 14

6

24/03/2011

7

28/03/2011

John Howard

Cable Ladder and tray update. Cable ties. components and equipment update. Cable colours and use of Ferrules (Boot pins) Other changes in Blue. Items to check in yellow

8

31/08/2011

John Howard

REPOL and Fibre Optic Communication conduit changed to 50mm.

9

5/01/2012

John Howard

Minor detail changes to Appendix “A”. Motor circuit breakers. Minor detail changes to Section 5.15 REPOL AND Fibre conduit installation. 5.13.8 Soft Starters. 5.13.10 Motor Protection.

10

10/01/2012

John Howard Jason Zuglian

Lighting part number update

11

19/01/2012

Jason Zuglian

Emergency Stop Button Update

12

12/02/2012

John Howard

Cat 5 cable upgraded to Cat 6

13

13/02/2012

John Howard

Minor mod to text.

14

27/02/2012

John Howard

Modified Appendix “A” Layout. Added Indicators, Photoelectric Cell, 24vdc Power supplies, Traffic Lights and Inch Motor Local Isolator, Relays, Cable tray covers.

15

28/03/2012

John Howard

Updated Cable ladder installation details. Added comments to Flexible conduit. Added Adhesive Heat shrink.

16

11/04/2012

John Howard

Added high level sensors, Weatherproof flood lights, light poles and sensors

17

07/05/2012

John Howard

Appendix “A” update. Updated Finder relay types. Added Weidmuller power supplies and STAHL DIP limit switches.

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General

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TS6 – Electrical Services 18

24/05/2012

John Howard

Circuit Breaker updates

19

13/07/2012

Jason Zuglian

Schneider circuit breaker and contactor update. Lanyard update. 240vac panel wiring change from Red to White. Added Terasaki DIN-T DIN- SAFE circuit breakers.

20

16/07/2012

Jason Zuglian

Emergency Stop Button Addition & Area Flood Lights up date.

21

17/10/2012

John Howard

Added strobe lights. Changed Light Pole type.

22

26/11/2012

John Howard

Updated light fittings

23

20/12/2012

John Howard

Bird proofing added and document clean up.

24

22/01/2013

John Howard

03/04/2013

Runi Sugiharti

Added timers, changed cables colours, see item 5.3.3. Corrected part number of Low Level Sensor. Minor document clean up. Added headers, fixed lay out of front page as per other Technical Specifications. Added file name field in footer after updating save as “New Version”. Go to Footer and place cursor on the filename and press F9, this will update the version number.

25

23/8/2013

John Howard

Update Fibre Optic Cable Type & connector type

26

15/01/2014

John Howard

Appendix “A” Changed Lanyard type

27

06/02/2014

John Howard

Appendix “A” Changed LED indication

28

28/03/2014

John Howard

Appendix “A” Changed Cable details.

29

3/06/2014

John Howard

Updated Strobe and traffic lights.

30

13/11/2014

J. McMiles

Update styling and formatting.

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TS6 – Electrical Services

Contents 1.

Scope

5

2.

Definitions

5

3.

Standards

6

4.

General requirements

7

5.

Technical requirements

12

6.

Appendix A - Electrical Equipment List

28

7.

Appendix B - Electrical Commissioning List

28

8.

Appendix C - Motor Inspection and Test Record

28

9.

Appendix D - Test Procedure for Dual REPOL Installation

28

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TS6 – Electrical Services 1. Scope This technical specification defines the general requirements for electrical services installation, testing and commissioning of grain handling equipment for Co-operative Bulk Handling Limited. 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 : 2005 Switch-rooms shall not be built within these “Hazardous Areas” unless they are pressurized and comply with AS/NZS 61241.4 : 2002

2.2 Competency standards AS/NZS 4761 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 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 61241.10 :2005, Dust Ignition Protected (DIP) electrical equipment shall be selected and installed in accordance with the current edition of AS/NZS 61241.14 : 2005 practice ‘A’. The maximum surface temperature of this equipment shall be Class T4 - 135°C. Consideration shall be given to apparatus installed in an area where the local ambient temperature is likely to be outside the specified range 20°C to +40°C. 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.

2.5 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 : 2005.

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TS6 – Electrical Services 2.6 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 and AS/NZS 61421. 14 : 2005. The maximum surface temperature of equipment selected for use within the hazardous areas, zones 20, 21 and 22 shall be Class T4 - 135°C. Consideration shall be given to apparatus installed in an area where the local ambient temperature is likely to be outside the specified range -20°C to +40°C. Test result documentation shall be provided to support this requirement.

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 3000:2007

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 0. General requirements. Part 1. Protection by enclosures “tD” Part 4. Type of protection “pD” Part 10. Classification of areas where combustible dusts are or may be present. Part 14. Selection and installation. Part 11. Protection by intrinsic safety “iD” Part 18. Protection by encapsulation “mD”

AS 1939

Classification of Degrees of Protection Provided by Enclosures for Electrical Equipment (IP Code).

AS 3947

Low Voltage Switchgear and control gear, Switchgear, Dis-connectors, Switch-Dis-connectors, and Fuse Combination units.

AS 3008

Cables for Alternating Voltages up to and including 0.6/1kV.

AS 5000.1

Approval and test specifications - Electric Cables - Thermoplastic insulated for working voltages up to and including 0.6/1kV.

AS 3439

Low Voltage Fuses - Fuses with enclosed fuse-links.

AS 2053

Non Metallic Conduits and Fittings

AS 1554.1

Structural Steel Welding Code.

AS 1795

Sheets and boards for electrical purposes.

AS 1755

Conveyors - Design, construction, installation and operation - Safety

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TS6 – Electrical Services Requirements. AS 1202

AC Motor Starters (up to and including 1000 Volts).

ACA TS 009

Installation requirements for Customer Cabling (Wiring Rules).

AS/NZS 3080

Telecommunications installations – Integrated telecommunications cabling systems for commercial premises.

CBHE TS20

CBH Engineering Technical Specification – Enclosures

CBHE TS21

CBH Engineering Technical Specification – Electric Motors

Where no Australian Standards exist, the relevant IEC Standards shall apply. The installation shall also conform to the requirements of the Office of Energy WA and the Supply Authority.

4. General requirements 4.1 Enclosures Enclosures and equipment installed in Hazardous Areas shall comply with the applicable requirements of AS/NZS 61241.1 For areas not covered by the requirements of AS/NZS 61241.1 the minimum 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. DIP standards have been specified for some non- hazardous areas, this is done for standardisation and alternative standards shall not be accepted. All glands and packing used for sealing enclosures shall be non-deteriorating neoprene rubber.

4.2 Temperature rise All equipment and materials shall be suitable for continuous full load operation in an ambient temperature range of -20°C to +40°C without exceeding allowable temperature rise.

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.

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TS6 – Electrical Services 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 detailed in Appendix A 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 installation, 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.

4.6 Welding All welding shall conform to the applicable section of AS 1554. The Contractor shall not carry out any welding without the Principal’s approval.

4.7 Fixing, brackets and supports Any fixings to woodworks shall be by steel screws, coach bolts or bolts nuts and washers. Fixings to steelwork shall be by approved explosive cartridge type fasteners (Hilti), or tapped or drilled holes with bolts or clamps, nuts and lock-washers. Explosive cartridge type fasteners shall only be used after obtaining written approval from the Principal. Equipment mounted within steel boot pits shall NOT be fixed to the outer walls of the boot pit structure. Fixings to concrete shall be steel screws or bolts into “Loxin” type fixings installed in accordance with manufacturers’ instructions. All nuts shall be locked. This clause shall be rigidly enforced. Accessories, including light fittings, power outlets, welding outlets, lighting switches, control stations, etc, shall be mounted on a minimum 3mm mild steel equipment mounting plate machine cut, fully dressed and of adequate size for the relevant accessory AND label, and shall have tapped holes for accessory mounting. Alternatively equipment may be mounted directly on to structural members, providing the member is not structurally weakened and the equipment does not overhang the member. Brackets, racks, struts, supports, etc, shall be of adequately sized structural steel members, and shall be installed in a manner which minimises dust accumulation.

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TS6 – Electrical Services Structural steel supports shall be minimum 6.5mm thick for angles and bars and 10mm diameter for rods. All ferrous metalwork shall be robust, machine cut, fully dressed with welds ground to a smooth finish and provided with an anti-corrosive finish as specified in the enclosed Technical Specification TS8.

4.8 Penetrations and making good The Contractor shall make all penetrations, holes, openings, chases, etc, necessary for the Contract work, which shall on completion be dustproof and weatherproof sealed to match surrounding finishes, and to the requirements of the Principal. Any conduits or cables which penetrate walls shall be weatherproofed with silicone rubber sealant.

4.9 Finishes All ferrous metalwork and equipment installed shall be anti-corrosive treated and finished in accordance with the enclosed Technical Specification No. TS8. 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.

4.10 Labeling and identification All labeling shall be in accordance with all of the following: AS/NZS 3000: 2000 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 to the following requirements:

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TS6 – Electrical Services

EQUIPMENT

TYPE OF LABEL

Relays/Pushbuttons/

White Traffolyte, Black Lettering

Switches Wire Numbering

White bands, Black Lettering. Clip on or adhesive types shall not be accepted

Control Panels

White Traffolyte, Black Lettering

Fuses, Links and Circuit

White Traffolyte, Black Lettering indicating circuit identification and

Breakers

rating

Instruments

White Traffolyte, Black Lettering indicating function.

Intrinsically safe barriers.

Blue Traffolyte / White Lettering indicating function and sensor location.

Cable Tags

Stamped aluminum or Granolas type cable sheath and core straps indicating cable number as per cable schedule.

Colors 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. 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. Individual items of electrical apparatus installed within hazardous areas shall also be marked in accordance with AS/NZS 61241. 0.

4.11 Documentation Prior to the time of commissioning of the installation, the Contractor shall complete the following requirements... The site hazardous area verification dossier shall be completed by the responsible designer and /or installer: 4.11.1

Confirming the location of equipment within the hazardous areas.

4.11.2

Confirming cable and wiring routes and cable and wiring details.

4.11.3

Include the certification documentation of all electrical equipment installed.

4.11.4

As constructed wiring diagrams, schematics, MCC layouts (basic) and IS system drawings.

4.11.5

Details of the accredited and responsible designer and / or installer(s).

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TS6 – Electrical Services 4.11.6

This document shall be verified and signed off by the appropriate competent and accredited responsible person by or on behalf of the designer and / or contractor.

For “Supply and Construct” contracts the Contractor shall neatly mark up, to the Principal’s approval, two sets of prints in red for any alteration made during the contract period. One set of prints shall be returned to the Principal so that the original contract drawings may be altered to the “As Installed” state. The other shall be left on site for maintenance purposes. For “Design and Construct” contracts the Contractor shall neatly mark up, to the Principal’s approval, one (1) set of prints in red for any alteration made during the contract period which shall be left on site for maintenance purposes. The Contractor shall provide the Principal with an electronic copy, on compact disc, of the “As Constructed” drawings within 14 days of practical completion of the works. These drawings shall be in AutoCAD (.dwg). The drawings are intended to be a final record of the installation and shall contain at least the following information: a)

Site layout showing all underground cable routes not included in the dossier complete with dimensioned locations.

b)

Final location of all equipment supplied under this Contract not included in the dossier.

c)

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

d)

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

e)

Conductor ferrule numbers and conductor colour codes.

f)

Schedule of all cables showing: Lengths, core numbers, designations.

g)

Terminal layouts with wire numbers for all terminations.

h)

The drawing contents shall be in accordance with the “Documentation” clause of Generic Electrical Scope of Works.

4.12. Dimensions and Locations. Verify the location of all fittings, limit switches, motors, switchgear, etc, with the Principal before proceeding. The Principal may relocate any power outlet, light switch, limit switch or similar small device up to two metres without altering the cost of the works. Check all relevant dimensions on site before proceeding with the work. Dimensions shall not be scaled from the drawings.

4.13. Redundant Plant. All redundant Co-operative Bulk Handling Limited equipment removed from sites under this contract shall be carefully and securely packaged, clearly and indelibly labeled (including site from which it was removed) and returned to Co-operative Bulk Handling Limited as directed by DOCS 826980v30

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TS6 – Electrical Services the Principal. Any redundant metering equipment which is Western Power Corporation property shall be similarly packaged and returned to the respective Western Power District Office, or at any alternative point which Western Power may require, and the Contractor shall notify the Principal in writing of all equipment so returned.

4.14. Co-ordination. Equipment to be supplied under this Contract that forms part of a composite scheme the Contractor will be required to co-operate fully with the supplier of associated equipment to ensure correct operation of the installation. This shall include close liaison between Civil and Mechanical sub-contractors, the Supply Authority and local CBH Engineering District Managers as required ensuring timely completion of the works.

5. Technical requirements 5.1. Electricity supply 5.1.1. General The supply shall be 415/240 volts, 3 phase, 4 wire, 50 hertz and derived as shown on the drawings.

5.1.2. Western Power Corporation connections For installations connected to the Western Power Corporation system, the Contractor shall be responsible for all liaisons with that organisation regarding the connection. The Contract shall cover the supply, installation and connection of the power supply except for work carried out by the Western Power. The Contractor shall supply and install all necessary poles, cross arms, pole back stays, point of attachment - fuses, etc, required for the incoming aerials. Clearance over roadways shall not be less than seven (7) metres. Where points of attachments are made direct onto building structures they shall comprise hardwood battens to Western Power Corporation acceptance. Three (3) spare service fuses shall also be supplied and fitted within the main cubicle to the Principal’s acceptance.

5.1.3. Diesel alternator connections Where shown on the drawings the Principal will provide a diesel alternator set for connection to the electrical control cubicle. Allowance shall be made for this connection to be made, prior to the commissioning date.

5.1.4. Existing switchboard connections Where shown on the drawings the electrical supply shall be derived from the existing switchboards. The existing switchgear shall be modified to accommodate the cables and switchgear nominated on the drawings.

5.2. Earth system The installation shall be earthed in accordance with the M E N System as described in AS/NZS 3000 Section 5 including telephone system and lightning protection earths. Provide DOCS 826980v30

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TS6 – Electrical Services all necessary connections and earth electrodes. The main protective earth electrode shall be copper clad steel and be driven into the ground in an approved location adjacent to the site main switch / metering board. The electrode shall be a copper sheathed steel cored rod approximately 20mm diameter and 3 metres long, driven into the earth at a perpendicular depth of not less than 3.1 metres. The main earth conductor shall be terminated to the electrode within a 600mm long, 225mm diameter VITREOUS clay pipe installed flush with finished ground level and fitted with a galvanised chequered plate cap or an approved main earth connection pit. Where the earth pit is not labeled, as part of the design, provide a brass label adjacent to the earth electrode termination engraved as follows: DANGER MAIN EARTH DO NOT DISCONNECT On completion of the installation the earth loop impedance shall be measured and shall be in accordance with the requirements of AS/NZS 3000 Appendix B. The results of this test shall be submitted to the Principal.

5.2.1. Earth bonding All structural steelwork shall be equipotentially bonded to earth as AS/NZS 3000 regardless of sheathed conductors being used.

5.3. Cables general Unless otherwise specified within Australian Standards, site specific Scope of Works or shown on the drawings, all wiring shall be carried out with standard copper conductor with PVC insulated or PVC insulated PVC sheathed cable. All conductors shall be of multi-strand construction. Three phase outlets shall be wired red, white, blue in a clockwise direction from the earth or neutral pin when facing the front of the outlet.

5.3.1. Bird damage protection Bird damage protection is required above two metre’s on all external structures, galleries and light poles. Cable ladder with removable covers is required as cable supports. PVC covered flexible steel conduit is required where the cables exit the ladder. Check the Electrical Scope of Works or the site specific Scope of Works for any site specific requirements. All conductors shall be colour coded as follows:

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TS6 – Electrical Services 5.3.2. Power circuits (hard wired) Phase/Line 1: Red. Phase/Line 2: White. Phase/Line 3: Blue. Neutral, Black. Earth, Green/Yellow.

5.3.3. Three Phase 3c+E (flexible cables). Phase/Line 1: Brown. Phase/Line 2: Black. Phase/Line 3: Blue. Earth, Green/Yellow. Three Phase 4c+E (Flexible Cables). Phase/Line 1: Brown. Phase/Line 2: Black. Phase/Line 3: Grey. Neutral: Blue Earth: Green/Yellow.

5.3.4. Control circuits – 110vac & 240vac. Panel wiring 0.75mm² or 1mm² unless nominated. 110vac Actives - Grey. 110vac Neutrals - Black. 240vac Actives - White 240vac Neutrals - Black.

5.3.5. Control & indication circuits - extra low voltage (24v & below) Panel wiring 0.75 mm² or 1 mm² unless nominated. Positive - Orange. Negative – Purple (Violet).

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TS6 – Electrical Services 5.3.6. Voltage free circuits. Pink

5.3.7. Flexible wiring Flexible wiring requires “ferrules” (Boot lace pins) fitted at the termination points. When looping wiring using use TWO CABLE type “ferrules”. See Appendix A: “Flexible Wiring” for details.

5.3.8. Intrinsically safe circuits Control cables for intrinsically safe circuits shall have a blue sheath and be electrically and mechanically segregated from other power and control cables.

5.3.9. Light and power circuits Minimum sizes shall be 1.5mm² for Lighting and 2.5mm² for power. Where more than one cable is to be routed cable tray or ladder shall be used. Cables shall only be installed when construction in the area is completed to ensure that the cables are not damaged.

5.4. General cable installation methods All cables shall be routed in the most economical manner and be parallel with the building or structural lines in a horizontal or vertical plane. Each run of cable shall be installed between conductor terminal points, with no joints in any part of the run unless specified on the drawings. Cables shall be neatly dressed to the Principal’s acceptance and any modifications deemed necessary by the Principal shall be at the Contractor’s expense. Cables shall be supplied on the cable manufacturers recommended drums and shall be delivered to site with labels showing their origin, specification and date of manufacture. The labels shall be retained by the Contractor and may be inspected by the Principal. Where single core cables are installed, they shall be installed such that the circulating currents in gland plates, etc cannot be generated. Gland plates shall be of non-ferrous material. On completion of installation all cables, conduits, ducts, etc that pass through walls, floors or in floors shall be sealed. The method of sealing shall be to the Principal’s acceptance. Cables shall be handled with all due care and at no time will twists or kinks be acceptable in the cable installation. Any twisted or kinked cable shall be removed and replaced with a new cable at the Contractor’s expense. No plastic insulated or sheathed cables shall be allowed to come into contact with petroleum products such as grease, oil etc. The method of terminating Steel Wire Armoured cable shall be to the Principal’s acceptance DOCS 826980v30

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TS6 – Electrical Services and shall be such that a metal gland securely anchors all the strands of armouring. No cutting out of armouring strands shall be permitted. The Steel Wire Armouring shall be continuous and earthed at each termination unless specified otherwise. Any cables and conductors, which have been disconnected from the supply, shall be suitably terminated, enclosed and labeled at both ends to the Principal’s acceptance.

5.5. Underground cables Underground cables - and marked as such - shall be installed as per AS 3000 Underground Wiring System Category B - Buried direct with Polymeric cable cover strip to AS 2053, unless specified otherwise. Where cable routes call for a change of direction the pull shall be made by blocks and rollers without exceeding the manufacturers recommended radii and tension limits. Where cables are pulled by mechanical methods then a stocking grip or other method acceptable to the Principal shall be used. All underground cable routes shall be indicated by use of Principal approved cable route markers: (a) at ends of each cable; (b) two markers required at change of direction; (c) not more than 50 metre intervals.

In general the methods employed shall be as specified in AS 3000 covering the installation of underground cables. The contractor shall take the utmost care to prevent any damage to existing underground services. All necessary information in regard to existing underground services shall be obtained by the contractor from the appropriate sources, e.g. Telstra, Water Authority, Local Shire etc, before the commencement of any site works. Electronic cable locators or similar shall be employed to locate existing underground cables. It shall be the responsibility of the contractor to ensure that any damage to underground services are immediately being repaired and the appropriate CBH Engineering District Superintendent and the CBH Engineering Project Supervisor are informed about the extent of the damage and the progress of the repairs. All costs relating to the repair or replacement of damaged underground services shall be to the expense of the contractor, unless the contractor can provide sufficient proof to the satisfaction of the Principal that all reasonable steps were taken to avoid such damage. Cables being installed in trenches and or ducts shall be protected from excessive temperature rise due to solar radiation and vandalism, when stored on site prior to installation. The Contractor shall allow for all excavation, backfilling and reinstatement (not including bitumen works) costs for this part of the installation to the Principal’s acceptance.

5.5.1. General trenching works specifications The contractor shall inform the Principal three days before the start of any trenching works in DOCS 826980v30

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TS6 – Electrical Services order that the works can be monitored, tested and commissioned by the Principal’s Electrical Section or nominated supervisor. Before laying cables, provide a sand base layer, after all sharp objects have been removed from the trench base. Trenches shall be free of pooled water prior to backfilling and compaction. The method of backfilling and compacting trenches shall be in accordance with the table below, each layer being well compacted by a mechanical compactor. The first layer of backfill (150mm) shall be with no stones left on a 25mm sieve. General fill above first layer to below 450mm shall be with no stones left on a 50mm sieve. The final 450mm (3 layers) shall be clean gravel as nominated by the Principal or nominated supervisor. Any backfill material that is insufficiently compacted, shall be excavated as directed by the Principal or nominated supervisor, re-spread and re-compacted in accordance with the specification. All costs involved with the repair of defective trench backfilling shall be to the Contractor’s expense. The disposal of excess excavated material shall be, subject to the Principal’s approval, removed from site. All open earth drains shall be kept free of construction materials during the contract where practical.

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TS6 – Electrical Services 5.5.2. Special trench works specifications The following additional Specifications in regard to trenching works in particular at road crossings, compacted areas, concreted surfaces or any area subject to vehicular traffic shall apply to the contract and the appropriate costs shall be included in the tender price by the contractor. All cable trenches shall have the initial 300mm of backfill material placed over the cable(s) and/or wiring enclosure(s) and be compacted in accordance with the compaction table below. Standard Perth Penetrometer reading in cohesionless soils (sand and gravel type soils) should read a minimum of 7 blows/300mm or for cohesive soils (clay type soils) obtaining a minimum Clegg Hammer reading of 25. The upper 450mm layer shall be comprised of clean gravel and be free from organic impurities. The upper fill materials shall also be placed in layers not exceeding 150mm loose thickness and compacted in accordance with the compaction table below, obtaining a minimum Clegg Hammer reading of 37. Trenches shall be free of pooled water prior to backfilling and compaction. Wet trenches shall be backfilled stabilised gravel in the following mix ratio. One (1) cubic metre of gravel plus three (3) bags of General Purpose cement plus two and one half (2.5) bags of hydrated lime. The surface level of the trench shall be crowned with a minimum 50mm rise above the existing finished surface level. The contractor shall inform the Principal three days before the contractor intends to start the trenching works in order that this particular work can be monitored, tested and commissioned by the Principal’s Civil Works Section or nominated supervisor. Compaction Table Recommended maximum layer thicknesses and minimum number of passes to achieve required standards of compaction, ensure required compaction as specified above. If compaction levels are readily achievable the Contractor shall advise the Principal or nominated supervisor immediately.

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TS6 – Electrical Services

Equipment

Hand Tamper

Min No. Passes

Cohesionless

Cohesionless

Cohesive

Materials (1)

Materials (2)

Materials

3

150mm

100mm

100mm

3

300mm

250mm

200mm

4

150mm

Not Suitable

Not Suitable

4

200mm

100mm

Not Suitable

Min 15 kg Mechanical Tamper Min 50 kg (3) Vibrating Plate Min 50 kg Vibrating Plate Min 100 kg

Notes: 1. Free draining materials. 2. Non free draining materials. 3. “Wacker Packer” or similar compactor.

5.6. Underground conduits The size of each conduit shall be as shown on the drawings and comply with the recommended conduit sizes as specified in AS 3000. Prior to installing cables in conduits, they shall be cleaned by means of a scraper and/or cylindrical brush to avoid damage to the cable during installation. Where the tensions are required that exceed those recommended by the manufacturer of the cable then a bond pull shall be used. In these installations the tension of the pull shall be taken by the steel wire rope (or substitute). Where cables have protective screens care should be taken to avoid damage to the over-sheath. On completion of the cable installation each conduit end shall be sealed between cable and conduit to avoid the entry of foreign bodies. Where conduits are used to provide a cable entry into a building, then the conduit shall be installed with a slope to prevent the natural flow of water into the building. This requirement is in addition to the sealing of the duct as specified elsewhere.

5.7. Conduits general Conduits and fittings shall be screwed galvanised steel to AS 2052 or HD rigid and HD flexible PVC to AS 2053. Screwed galvanised steel conduits and fittings shall be used throughout unless specified otherwise. Draw in boxes shall be provided as necessary to enable cables to be pulled in at a future date. DOCS 826980v30

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TS6 – Electrical Services All cables entering conduits, pipes and ducts shall be protected by means of a bush, to avoid damage due to abrasion. Conduit shall be supported by spacer bar saddles of the same material as the conduit. To minimise the collection of dust, conduit supports shall be installed vertically where possible. Inspection type tees and elbows shall not be used. All conduit and wiring shall be installed in the ‘loop in’ and ‘draw in’ system with no conductors installed until the conduit installation is completed and permanently fixed. Light switches, socket outlets, light fittings and the like shall not be used as wiring enclosures for non-associated circuits. Running threads shall not be permitted. Where conduits cross expansion joints, flexible cable shall be installed in that section. Conduits shall not interfere with movement or operation of equipment nor limit the access to equipment or access ways. Conduits shall be kept a minimum of 75mm from any non-electrical pipe work. Where potentially hazardous services such as high temperature pipes etc, are present the clearance shall be increased to permit the safe operation of the electrical installation. The conduit system shall be designed to minimise the number of parallel runs by grouping the cables where possible. All conduit runs shall be installed as straight as possible and parallel with the building or structural lines in a horizontal or vertical plane, unless otherwise approved by the Principal. All conduits shall be secured with two fixing type saddles, manufactured from the same material as the conduit being secured. Conduit installations shall be fully assembled and secured prior to the drawing in of cables. The conduit shall not be bent in a manner which appreciably distorts the walls of the conduit from their original section or split open the conduit. The radius of any bend or set shall be not less than the conduit manufacturer’s recommendation.

5.8. Flexible conduit Flexible steel reinforced PVC sheathed liquid tight and/or DIP (as required) conduit shall be provided between the ends of fixed installations and equipment, such as motors, limit switches, etc liable to movement or subject to vibration. Where rigid PVC conduit is used for the fixed installation then the conduit manufacturers’ recommended flexible PVC conduit shall be used to connect equipment, such as motors, limit switches, etc liable to movement or subject to vibration. The lengths of flexible conduit shall be kept to a minimum as dictated by the equipment being connected and accepted by the Principal.

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TS6 – Electrical Services 5.9. Cable tray or ladder 5.9.1 General Cable tray or ladder shall be galvanised steel and be complete with factory fabricated joints, bends, mounting brackets and fittings approved by the manufacturer. All external cable supports installed two metres above the ground shall Cable Ladder (not tray). Cable ladder shall be mounted only on a horizontal plane (on its back).

5.9.2 Cable ladder (external) All external Cable Ladder above two metres from the ground shall be continuous and complete with covers. Horizontally mounted ladder shall have Peak Covers. (the covers are for bird damage protection).

5.9.3 Cable ladder (mounted on galleries) Where cable ladder is installed on a gallery it shall be installed on the outside of the hand rails close to the top so that cables can exit through the bottom.

5.9.4 Cable tray Cable tray shall be mounted only on a vertical plane. All cable trays shall be installed such that the dust accumulation is minimised.

5.9.5 Cable ties exposed to ultra violet light Cables on a vertical plane of vertical or horizontal mounted cable ladder or tray shall be secured with stainless steel ties. Cables on a horizontal plane shall be secured with heavy duty Ultra Violet rated cable ties.

5.9.6. Cable ties not exposed to ultra violet light All heavy duty rated cable ties.

5.9.7. Cable tie spacing The fixing intervals of cable ties shall not be more than 300mm for cables mounted on vertical plane and 600mm for cables mounted on a horizontal plane.

5.9.8 Cable ladder or tray capacity A minimum of 30% spare area must be allowed for.

5.9.9 Cable ladder earth bonding All CLS cable ladders must be effectively earthed for personal protection. The ladder used on CLS systems is not secured to the conveyor frame. Cable ladder earthing shall consist of 16mm2 lugged earth cable link installed between the earth terminal in each of the stacker loader outlet boxes (ever 36metres) and the conveyor frame leg. Use an 8mm bolt minimum.

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TS6 – Electrical Services Install a 16mm2 lugged earth cable links between the conveyor leg earth bolt and the Cable Ladder. Use an 8mm bolt minimum. Install a 16mm2 lugged earth cable links between each length of Cable Ladder. Use an 8mm bolt minimum.

5.10. Marshalling and junction boxes All marshalling and junction boxes shall have welded or integrally cast in gland sockets for bottom entry, and shall be of robust design, fabricated from a minimum of 2mm sheet metal. Painting shall be carried out in accordance with Technical Specification TS8. All paints used shall be compatible with the anticipated working environment. All exterior marshalling and junction boxes shall be aluminum construction with a brushed exterior finish. The Contractor shall submit drawings of proposed marshalling and junction boxes for written approval of the Principal before including them in the installation. All terminations shall be made using terminals of the type shown in the Equipment Schedule. The ports shall accommodate 2.5mm square with mounting rail, end sections, jumper bars and all necessary standard accessories, in strict accordance with the relevant termination diagram. Each terminal port shall accommodate not more than one conductor, jumper bars are to be provided where multiple conductors are to be terminated together. Top entry to marshalling and junction boxes shall not be permitted in weather exposed locations.

5.11. Glands All cable glands and associated fittings shall be supplied and fitted by the contractor. All cable glands shall be DIP certified for installation within Zone 20 and Zone 21 classified areas as required. All cables shall be terminated using the cable manufacturers recommended cable glands sizes. The cable gland and locking nuts and rings shall be metal construction and shall be compatible with the termination gland plate or terminating box material. All glands shall be securely fixed to the gland plate and where locknuts are used as a method of fixing, then a locking ring shall be installed in addition to the normal locknut. Cable glands shall be terminated at a position such that the conductors can easily be worked into their final termination position without damaging the conductor insulation. Cable glands not meeting these requirements shall be replaced at the contractor’s expense.

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TS6 – Electrical Services 5.12. Power installation 5.12.1 General Supply and install power outlets and wiring to electrical equipment as shown on the drawings. Refer to electrical drawings for wiring details. Final connection to all equipment shall be made through suitable isolators where required by AS 3000. Where equipment is supplied and fitted by others and connected under this contract, check wiring details with equipment suppliers BEFORE beginning the installation. If documented details are incorrect notify the Principal and obtain instructions regarding the necessary changes.

All conductors shall be fitted with the appropriate crimped cable lugs.

5.12.2. Motors. All motors regardless of location in any area of grain handling equipment shall be a minimum IP65 DIP. All motors shall be site tested with a 1000 volt Insulation Resistance tester and the results including all Motor Nameplate data submitted in writing to the Principal – refer Appendix C. Unless otherwise specified all electric motors will be supplied and fitted by others. Provide electrical connection to these motors. Before commissioning each motor liaise with the Mechanical Contractor to verify the required motor rotation and verify that the overload settings are correct.

5.13. Control Gear and Accessories. 5.13.1 General This equipment shall be rated for the anticipated working environment and be in accordance with the equipment schedule of the Scope of Works.

5.13.2 Fuses and links Fuse links of the HRC cartridge type complying with AS 3135 shall be supplied. 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.

5.13.3. 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. DOCS 826980v30

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TS6 – Electrical Services 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. Secondary cables greater than 2 metres in length shall be 6 mm². The Contractor shall state the accuracy, capacity and ratio of the 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.

5.13.4. 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 270º, and shall be of the flush mounting type with square bezels. All instruments and apparatus shall be capable of carrying their full load currents without undue heating. They shall not be damaged due to the passage of 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. Ammeters shall be checked against actual primary current and adjusted to suit. 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.

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TS6 – Electrical Services Ammeter scaling shall be such that normal full load current gives approximately ¾ full scale deflection.

5.13.5. Limit and proximity switches Supply and install limit and proximity switches complete with all necessary base plates, striker arms, cams and brackets as required for the correct operation of the plant. Liaise with the Mechanical Contractor to ensure the limit and proximity switches are correctly located. The Electrical Services Contractor is responsible for the correct operation of all limit and proximity switches. Limit switches shall be of metal construction, plastic body types shall not be permitted. Proximity switches used for level monitoring or for detecting grain shall be fitted into a steel flange to allow for easy testing of the unit.

5.13.6. Lanyard systems The Contractor shall install and commission lanyard operated emergency stop system as shown on the drawings and complying with AS 1755. Each lanyard system shall be complete with lanyard wires, heavy duty compensating springs, eye bolts, turnbuckles and all fixings to commission the system. The Contractor shall also install “Conveyor Stop” signs at intervals of not more than 30 metres in accordance with AS 1755 clause 3.15.5.2. Lanyard wires shall be PVC sheathed covered, flexible galvanised steel wire rope, 6 x 19 construction, minimum 3.5mm diameter where 5mm is not available. The wires shall extend to within 1 metre of the end of the conveyor structure and shall be no longer than 120 metres. The end of each lanyard cable, adjacent to the switch shall be anchored to a rope thimble with clips and a galvanised turnbuckle. The turnbuckle shall be complete with an adjustable screw eye bolt and locknut. Where the lanyard cables changes direction a durable pulley block shall be supplied and fitted under this contract. Where two or more lanyard pull switches are installed on one side of equipment, the lanyards shall not be connected in series through the switches, but each switch lanyard shall have separate anchor points.

5.13.7. Auto transformers Where specified, these units shall be installed such that the heat dissipation does not adversely effect other electrical equipment. All auto transformers shall be manufactured in accordance with AS 1202 and have class ‘A’ insulation. Taps shall be provided at 50, 65 and 80%. The duty classification shall not be less than 0.1; i.e. 12 starts per hour. Thermistors shall be incorporated in the windings to provide thermal protection of the auto transformer.

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TS6 – Electrical Services 5.13.8. Soft starters Where specified shall be of those listed in Appendix A or an approved equivalent if not available. Soft starters shall have external bypass contactors installed where required. The soft starter shall be set as per drawing “Soft Starter Parameter Settings”. This may be varied during commissioning depending on equipment connected. Fine tuning of the current limit start shall ensure that the motor reaches full speed within 15 seconds. If this is not achieved other parameters may be varied.

5.13.9 Ultrasonic level switches The Contractor shall install all ultrasonic level switches as specified in the Scope of Work to the satisfaction of the Principal. The ultrasonic transducer shall be mounted to minimise dust build up. The level switch shall be calibrated by the Contractor.

5.13.9. Motor protection All Areas Thermal Magnetic Motor Circuit Breakers (see Appendix “A” for details). Motors fitted with a Soft starter to have a Control Panel mounted manual reset push button. General Motor overloads shall be rated 10% greater than the manufacturers stated full load current of the motor.

5.13.10. Year 2000 Compliance Warranty The Contractor warrants that where the functioning of any aspect of the Works relies on, incorporates or otherwise utilises a date code the Works have been specifically designed and tested, where applicable, in conjunction with associated software and/or hardware, to accommodate and implement the transition from the Year 1999 to the Year 2000. John Cairns to confirm. This Year 2000 Warranty will survive termination of this Contract and will continue for the life of the Works. TBC.

5.14 Modification of existing switchgear Where modifications to existing switchgear or cubicles in non hazardous areas are specified, the Contractor shall install indicating lamps, push buttons and similar accessories that match the existing equipment. The requirements of this clause supersede the information detailed in the schedule of equipment. Where existing Mimic Panels are to be modified, the contractor shall remove the existing Panel and have it engraved as shown on the drawings. The contractor shall nominate in his Tender the Engraving sub-contractor.

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TS6 – Electrical Services Where modifications to existing switchgear or cubicles in hazardous areas are specified, the Contractor shall treat the upgrade as a new installation and such shall comply with all current standards and industry requirements as specified in Clause 2.0 - Definitions and Clause 3.0 – Standards, of this document.

5.15 Fibre, and REPOLS installation 5.15.1 Fibre cable The contractor shall install cable (see drawings for number of pairs) in an unbroken (no joints) section between the weighbridge and the sample platform. The cable shall be installed in separate, continuous and glued 50mm communication conduits in all cases. Install draw-in pits every 100 metres and or change of direction. If the pits are likely to be damaged by vehicles and or machinery the contractor shall install trafficable pits and lids. Terminate using SC connectors. Minimum cable radius: During installation, the cable bends no greater than 20 times the diameter. After installation, the cable bends no greater than 10 times the diameter. Storage loops, the cable bends no greater than 30 times the diameter. See Appendix “A” for cable type.

5.15.2 REPOL cable The contractor shall install 20 pair cable (or as nominated) in an unbroken (no joints) section between the weighbridge and the sample platform MDF’s. The cable shall be installed in separate, continuous and glued 50mm communication conduits in all cases. Install draw-in pits every 100 metres and or change of direction. If the pits are likely to be damaged by vehicles and or machinery the contractor shall install trafficable pits and lids. See Appendix “A” for cable type. The REPOLS system shall be tested in accordance with Appendix D of this specification.

5.16 Lightning protection The Contractor shall install a lightning protection system that will prevent damage or injury which may be caused by a lightning discharge. The protection system shall be in strict accordance with AS 1768.

5.17 Testing & commissioning Testing and commissioning shall be in accordance with the Scope of Works. Appendices B, C and D shall be completed as applicable.

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TS6 – Electrical Services 6. 7. 8. 9.

Appendix A - Electrical Equipment List Appendix B - Electrical Commissioning List Appendix C - Motor Inspection and Test Record Appendix D - Test Procedure for Dual REPOL Installation

Equipment & Component short list: CBH_DMS_PROD-#1307892-Elect Equipment & Component list

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TS6 – Electrical Services

Circuit breakerControl & General

Cable Ladder

Cable Ladder

Cable Tray

Cable Cat 6 Socket

Cable-Cat 6

Cable Pits

CableOptic Fibre

CableCommunic ation (REPOL)

CablePower & Control

Appendix A: Electrical Equipment List (CBH preferred equipment and components) Cable Olex, V70, V90, XLPE.

Cable – Communication (REPOL) 20 Pair Poly/Poly Nylon 1/0.64 (OLEX)

Cable - Optic Fibre Cable 12 core Single Mode type 12F SM 9um OS1 UF SERIES YELLOW Code AFCUF112F. Available from “Australian Fibreoptic Communications” (AFC) Belmont WA, 6253 2200. Use “SC” type connectors. PVC with a concrete lid 705mm long x 455mm wide x 800mm deep

Cat 6 Communication cable Blue flexible installed in 50mm White conduit. Segregate from power cables.

CAT 6 Termination socket Weidmuller Code IE-XM-RJ45/IDC part number 8808360000. DIN rail mount 18mm wide.

Cable Tray (Internal and below two metres) Kounis Metal Industries. Type Light duty complete with rolled edges, Code L. Cable Ladder Kounis Metal Industries. Type 3/50 (NEMA 16A)

Cable Ladder (External and installed two metres above the ground). Kounis Metal Industries. Type 3/50 (NEMA 16A), complete with covers.

Circuit Breakers - Control and General. NHP “Terasaki” – DIN-T or DIN SAFE each complete with removable padlocking device type LOCKDOG DTLLA

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TS6 – Electrical Services

Circuit breakerDistribution Boards

Distribution Circuit Breakers - Merlin Gerin Type NSX TM-D Amps Type Over load Type / Rating 11-16amp NSX100N TM16D

17-25amp 22-32amp 28-40amp 35-50amp 44-63amp 56-80amp

NSX100N NSX100N NSX100N NSX100N NSX100N NSX100N

70-100amp 87-125amp 112-160amp 175-250 amp

NSX100N NSX160N NSX160N NSX250N

TM25D TM32D TM40D TM50D TM63D TM80D TM100D (Suit Stacker Loader 90amp outlets, Set on 85 amps). TM125D TM160D TM250D

Circuit breakerMain Switch

Circuit breakerMain Switch

Note. If the final sub-circuit supplied via an outlet a 100ma RCD (ELCB) is required.

Main Isolator – Distribution Board etc. “Schneider” (Merlin Gerin) - Interpact INS series.

Circuit Breakers – Distribution Board Main Switch. Schneider (Merlin Gerin) – Compact NSX400/630NA, non auto.

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TS6 – Electrical Services

Circuit breakerMotor 0.37 > 15kw

Circuit Breakers - Motors 0.37kw > 15kw 3Ø: DOL. “Schneider” GV2ME Thermal Magnetic Motor Circuit Breaker. Supply with side and or front mounted auxiliary contacts as required. Supply complete with locking device GV2V03 (1 locking device each for 50% or greater of the number of GV2ME circuit breakers).

Motor Size

Current setting

Breaking capacity

Type

0.37kw

0.63-1.0 amp

100kA

GV2ME05

0.55kw

1.0-1.6 amp

100kA

GV2ME06

0.75kw

1.6-2.5 amp

100kA

GV2ME07

1.1kw

2.5-4.0 amp

100kA

GV2ME08

2.2kw

4.0-6.3 amp

100kA

GV2ME10

4kw

6-10amp

100kA

GV2ME14

5.5kw

9-14 amp

15kA

GV2ME16

7.5kw

13-16 amp

15kA

GV2ME20

9kw

17-23 amp

15kA

GV2ME21

11kw

20-25 amp

15kA

GV2ME22

15kw

24-32 amp

10kA

GV2ME32

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TS6 – Electrical Services Circuit Breakers - Motors 18.5kw > 90kw See listing below. “Schneider” (Merlin Gerin) - Compact NSX series, Type N or a Fault Current calculated kA rating. Complete with TMD range of overloads, auxiliary contacts.

Motor size

Set thermal on Type

Over load Type / Rating

Set magnetic on

Circuit breakerMotor 18.5kw > 75kw

35 amp 18.5kw

NSX100N

TM50D, 35-50amp

0.8 38 amp

22kw

NSX100N

TM50D, 35-50amp

0.8 53 amp

30kw

NSX100N

TM63D, 44-63amp

0.9 61 amp

37kw

NSX100N

TM80D, 56-80amp

1 73 amp

45kw

NSX100N

TM100D, 70-100amp

1 81 amp

55kw

NSX160N

TM100D, 70-100amp

1 115 amp

75kw

NSX160N

TM160D, 112-160amp

1 141 amp

Horn

Heat Shrink

EnclosuresNon DIP

Contactor

Conduit

90kw

NSX250N

TM200D, 140-200amp

0.9

Flexible - PVC covered metal Thomas & Betts. Conduit type HIFLEX HLT, Fittings (glands) must include Nylon Gland Ring type VJ-… Use ferrules type 02-….on ends that don’t require Fittings (Gland) Available from Thomas & Betts 1300 666 595. Contactors Motor Starting AC 4 rating. (also see section Circuit breakers - Motor) st 1 Choice - Schneider. nd 2 Choice - NHP Sprecher Schuh. With approval from principle. Enclosures B&R Universal NI General Purpose Enclosures – IP66.

Adhesive Heavy Wall Tubing Type CJS-HWT. Available from Cable Jointing Supplies, Unit1, 45 Burlington St, Naval Base WA 6165 (08) 9437 9355

Horns & Warning Sounder (Non DIP) “Klaxon” Nexus 105 part # PNS--0009 (110/240vac). Connect a 6 watt 12k ohm ceramic bleed resistor at the Sounder.

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LanyardDIP

J BoxNon DIP

J BoxDIP

Indicator

Horn

TS6 – Electrical Services Horns & Warning Sounder (Non DIP) “Klaxon” Nexus (110/240vac). Connect a 6 watt 12k ohm ceramic bleed resistor at the Sounder. Indicators - Switchboards and Control Panels. RED Ultra Bright, Black Bezel, 14mm& RS203-975 YELLOW Ultra Bright, Black Bezel, 14mm& RS203-868 GREEN Ultra Bright, Black Bezel, 14mm& RS203-852 (RS means “RS Components)” Junction / Marshalling Boxes DIP Govan / Crouse Hinds / CCG.

Junction / Marshalling Boxes Non DIP Govan / Crouse Hinds / Clipsal.56 series.

Lanyard Switches DIP (1st preference) NHP EX55.4.00GWNBB. Lanyards to include matching heavy duty thermal compensation springs.

LightingBoot Pit & Cell DIP

LightingHand Rail Staunching mounted Non DIP

LightingHand Rail Staunching mounted DIP

Lanyard DIP

nd

Lanyard Switches DIP (2 preference) NHP EX55.4.00NBB. Lanyards to include matching heavy duty thermal compensation springs. DIP Lighting – Hand Rail staunching mounted Lighting. Mount bracket and lights are available from Pacific Automation. DIP 18w Double Fluorescent Light Fittings: Light. FNB-218-BKSA. Emergency Light. FNB-218-BUSAE. Long Life Tube. Osram: OSRL18W/840XXT. Mount Bracket. SP-W-AU-LMK-CBHCATWALK-HG-KIT c/w mounts bolts and washers. Non DIP Lighting – Hand Rail staunching mounted Lighting. Mount bracket and lights are available from Pacific Automation. Non DIP 18w Double Fluorescent Light Fittings: Light. FHDB-218-BKSUS. Emergency Light. FHDB-218-BKSUE. Long Life Tube. Osram: OSRL18W/840XXT. Mount Bracket. SP-W-AU-LMK-CBHCATWALK-HG-KIT c/w mounts bolts and washers. DIP Lighting – Internal Storage DIP Zones 21 & 22 Application – Boot Pit and Cell Lighting. PLEASE NOTE: Ex tD T4 IP65 for use in hazardous areas with a maximum surface temperature 175 degrees Centigrade if not T4. DIP 18w Double Fluorescent Light Fittings: Light. FNB-218-BKSA. Emergency Light “None Maintained” FNB-218-BUSAE. Long Life Tube. Osram: OSRL18W/840XXT. Pacific EX: HDL-CM (Surface Mount Bracket) DIP 36w Double Fluorescent Light Fittings: Light. FNB-236-BKSA. Emergency Light “None Maintained” FNB-236-BUSAE. Long Life Tube. Osram: OSRL36W/840XXT Pacific EX: HDL-CM (Surface Mount Bracket)

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LightingCat Walk (swivel Pole ) & Surface Mount Non DIP

LightingCat Walk (swivel Pole ) & Surface Mount DIP

TS6 – Electrical Services DIP Lighting – Internal Storage DIP Zones 21 & 22 Application – Cat Walk (swivel Pole ) & Surface Mount PLEASE NOTE: Ex tD T4 IP65 for use in hazardous areas with a maximum surface temperature 175 degrees Centigrade if not T4. DIP 36w Double Fluorescent Light Fitting: Pacific EX: FNB-236-BKSA (Light Fitting) Osram: OSRL36W/840XXT (36w Tube “Long Life”) Pacific EX: SP-LMK3304-40-HG-ATXKIT (Custom Head Frame) ROB Swivel Pole: S11-2400-PS-HG (Pole Mount 2.4mt) OR Pacific EX: HDL-CM (Surface Mount Bracket) DIP 18w Double Fluorescent Light Fitting: Pacific EX: FNB-218-BKSA (Light Fitting) Osram: OSRL18W/840XXT (18w Tube “Long Life”) Pacific EX: SP-LMK3304-40-HG-ATXKIT (Custom Head Frame) ROB Swivel Pole: S11-2400-PS-HG (Pole Mount 2.4mt) OR Pacific EX: HDL-CM (Surface Mount Bracket) Non DIP Lighting – External Area NON DIP Zone Application – Cat Walk (swivel Pole ) & Surface Mount Non DIP 36w Double Fluorescent Standard Light Fitting: Pacific EX: FHDB-236-BKSUS (Light Fitting). Osram: OSRL36W/840XXT (36w Tube “Long Life”) Pacific EX: SP-LMK3304-40-HG-ATXKIT (Custom Head Frame) ROB Swivel Pole: S11-2400-PS-HG (Pole Mount 2.4mt) OR Pacific EX: HDL-CM (Surface Mount Bracket) Non DIP 18w Double Fluorescent Standard Light Fitting: Pacific EX: FHDB-218-BKSUS (Light Fitting) Osram: OSRL18W/840XXT (18w Tube “Long Life”) Pacific EX: SP-LMK3304-40-HG-ATXKIT (Custom Head Frame) ROB Swivel Pole: S11-2400-PS-HG (Pole Mount 2.4mt) OR Pacific EX: HDL-CM (Surface Mount Bracket) METRO FITTING: “Details to be added”

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LightingEmergency Cat Walk (swivel Pole ) & Surface Mount, Non DIP

LightingEmergency Cat Walk (swivel Pole ) & Surface Mount DIP

TS6 – Electrical Services DIP Lighting – Internal Storage DIP Zones 21 & 22 Application – Cat Walk (swivel Pole) & Surface Mount Emergency Lighting. PLEASE NOTE: Ex tD T4 IP65 for use in hazardous areas with a maximum surface temperature 175 degrees Centigrade if not T4. DIP 36w Double Fluorescent Emergency Light Fitting “Non Maintained”: Pacific EX: FNB-236-BUSAE (Light Fitting) Osram: OSRL36W/840XXT (36w Tube “Long Life”) Pacific EX: SP-LMK3304-40-HG-ATXKIT (Custom Head Frame) ROB Swivel Pole: S11-2400-PS-HG (Pole Mount 2.4mt) OR Pacific EX: HDL-CM (Surface Mount Bracket) DIP 18w Double Fluorescent Emergency Light Fitting “Non Maintained”: Pacific EX: FNB-218-BUSAE (Light Fitting) Osram: OSRL18W/840XXT (18w Tube “Long Life”) Pacific EX: SP-LMK3304-40-HG-ATXKIT (Custom Head Frame) ROB Swivel Pole: S11-2400-PS-HG (Pole Mount 2.4mt) OR Pacific EX: HDL-CM (Surface Mount Bracket) Non DIP Lighting – External Area NON DIP Zone Application – Emergency Cat Walk (swivel Pole) & Surface Mount. Non DIP 36w Double Fluorescent Emergency Light Fitting “Non Maintained”: Pacific EX: FHDB-236-BKSUE (Light Fitting). Osram: OSRL36W/840XXT (36w Tube “Long Life”) Pacific EX: SP-LMK3304-40-HG-ATXKIT (Custom Head Frame) ROB Swivel Pole: S11-2400-PS-HG (Pole Mount 2.4mt) OR Pacific EX: HDL-CM (Surface Mount Bracket) Non DIP 18w Double Fluorescent Emergency Light Fitting “Non Maintained”: Pacific EX: FHDB-218-BKSUE (Light Fitting). Osram: OSRL18W/840XXT (18w Tube “Long Life”) Pacific EX: SP-LMK3304-40-HG-ATXKIT (Custom Head Frame) ROB Swivel Pole: S11-2400-PS-HG (Pole Mount 2.4mt) OR Pacific EX: HDL-CM (Surface Mount Bracket)

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TS6 – Electrical Services

Pendant Light Fitting & Globe: Pacific EX: HDL-114S24500400E (400w HPS Light Fitting) Pacific EX: HDL-AL10174 (Reflector) Osram: OSRNAVT400WSUPER (400W HPS Tubular)

LightingFlood Lighting, Non DIP

Lighting – External Area Flood Lights Non DIP Zone Application – Mounted at high level on structures or as nominated. Weatherproof IP65 with integral ballast. Sylvania: 2000w, 415v, MH, BLS2000/2000 Thorn: 2000w, 415v, MH, MUNC2000DEGMDKITWP Poles Suit “E” & “V” Pits G & S Industries, 6 metres type F6BM. Cage Bolts to suit above - G & S Industries, 890614, CR16/4/282. Cross arm for two flood lights to suit above – 890213, CA1200T3.

LightsStrobe Lights , Non DIP

Lighti ngPhoto Electr ic Cell

Lighting – External Area Flood Lights Non DIP Zone Application – Under garner bins & over road / rail grids Weatherproof IP65 with integral ballast. Philips: Con TEMPO L 400w HPS, RVP350SON-T400S. Thorn: 400w HPS, AP2400HST

LightingFlood Lighting, Non DIP

Pendant Light Pole & Isolator: Pacific EX: F11-H-001-P-HG-AU-NS (Custom Swivel Pole) ROB Swivel Pole: MBK2-2-50HG (Vertical Mounting Bracket) OR Pacific EX: ASP-U-BOLT-CBH-310UB (Custom ‘H’ Iron Mount) Pacific EX: SP-TEF-150-001-AU-NS (Teflon Swivel Washer) Pacific EX: SP-JBPK1110-HG-AU-NS (Isolator/Enclosure Bracket) Pacific EX: GO-ES1511-A201 (Isolator & Enclosure)

LightingFlood Lighting Poles

LightingFlood Lighting, DIP

Lighting – Internal Storage DIP Zones 21 & 22 Application – Flood Lighting / Pendant Lighting. PLEASE NOTE: Ex tD T4 IP65 for use in hazardous areas with a maximum surface temperature 175 degrees Centigrade if not T4. Flood Light Fitting & Globe: TBC

Photo Electric Cell Clipsal 56PEDD3 Strobe Lights – Stacker Loader Run Lights, High Level & Fire Alarm Indicator Lights. RED, LED 10-30vdc, Daylight visible, Vibration proof, IP67, type 155R-LED24V-CBH. AMBER, LED 10-30vdc, Daylight visible, Vibration proof, IP67, type 155Y-LED24V-CBH. GREEN, LED 10-30vdc, Daylight visible, Vibration proof, IP67, type 155G-LED24V-CBH. RED, LED 240vac, Daylight visible, Vibration proof, IP67, type 155R-LED240V-CBH. This unit is mounted on a power supply (240vac to 24vdc) enclosure c/w sun shield and adapting base plate. AMBER, LED 240vac, Daylight visible, Vibration proof, IP67, type 155Y-LED240V-CBH. This unit is mounted on a power supply (240vac to 24vdc) enclosure c/w sun shield and adapting base plate. GREEN, LED 240vac, Daylight visible, Vibration proof, IP67, type 155G-LED240V-CBH. This unit is mounted on a power supply (240vac to 24vdc) enclosure c/w sun shield and adapting base plate.

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Power OutletNon DIP

Power OutletNon DIP phase 10amp

Overload

Limit Switch HOLD

Limit SwitchInductive Proximity, DIP

Limit Switch

Limit Switch

LightsTraffic Lights

LightsTraffic Lights

LightsTraffic Lights

TS6 – Electrical Services 24vdc LED, 100mm diameter Traffic Lights - Suit Sample Platforms etc. RED/GREEN Type NBB100RG, (IP65). Available from EX Engineering 0408 221 337.

24vdc LED, 200mm diameter Traffic Lights - Suit Sample Platforms etc. RED/GREEN Type STL-200-RG-24, Available from EX Engineering 0408 221 337. Replacement RED module SRM-200-R-24. Replacement GREEN module SRM-200-G-24.

240vac LED, 200mm diameter Traffic Lights - Suit Sample Platforms etc. RED/GREEN Type STL-200-RG-240, Available from EX Engineering 0408 221 337. Replacement RED module SRM-200-R-240. Replacement GREEN module SRM-200-G-240.

Limit Switch Honeywell - SPDT, LS4A1A-DIP and DPDT, LS4A2A-DIP. Adjustable arm to suit above LSZ52C. Note…has the same fixings and shaft size as Cutler Hammer E50.

Limit Switch STAHL. DIP. 8070/1-1-HV. 1NC + 1NO, C/W ADUSTABLE ARM.

Proximities Switches – Speed Monitor (inductive) “Synatel” 30mm range sensors inductive 1D1TZ (A) normally open complete with P2 and M2 shrouds. Speed monitor PU1TZ (A) normally open.

Limit Switch HOLD. CERTIFICATE OF CONFORMITY HAS EXPIRED AS OF JUNE 2011 “Cutler Hammer” E50 AR1-DIP. Note…has the same fixings and shaft size as Honeywell LS4.

Motor Starting – Motor Protection overloads ≤ 11kw DOL “Schneider” Type TeSys Model D. (MAN/AUTO reset, set on Auto). NHP Sprecher Schuh suit CA4, CA6 & CA7.

Power Outlets (Non DIP) Single Phase General Areas “Clipsal”” 10amp 56C310HD.

Power Outlets & Plug (Non DIP) Three Phase & N 150amp 3P+N+E “Marechal” 150amp Socket Outlet c/w self-returning lid DS9 31-98-017R. Plus Wall Box 399A-053. Or equivalent. “Marechal” 150amp Inlet (Plug Top) DS9 31-98-017. Plus handle 65-9A-013-D45 (E).

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Power Outlets (DIP/IECEx) Single Phase 16amp single phase outlet Marechal TBC

HOLD Power Outlets (DIP/IECEx) Three Phase ????????? Marechal???

Power Outlets & Plug (Non DIP) Three Phase 30amp 3P+E “Marechal” 30amp Socket Outlet c/w self-returning lid DS1 31-14-013R. Plus Wall Box 311A-053. Or equivalent. “Marechal” 30amp Inlet (Plug Top) DS1 31-18-013. Plus handle 31-1A-013.

Power Outlets & Plug (Non DIP) Three Phase 50amp 3P+E “Marechal” 50amp Socket Outlet c/w self-returning lid DS3 31-34-013R. Plus Wall Box 313A-053. Or equivalent. “Marechal” 50amp Inlet (Plug Top) DS3 31-38-013. Plus handle 31-3A-013. Power Outlets & Plug (Non DIP) Three Phase 90amp 3P+E “Marechal” 90amp Socket Outlet c/w self-returning lid DS6 31-64-013R. Plus Wall Box 316A-053. Or equivalent. “Marechal” 90amp Inlet (Plug Top) DS6 31-68-013. Plus handle 31-6A-013.

Proximity SensorCapacitive

Proximity SensorCapacitive

Power Supply24vdc

Power OutletNon DIP

Power Outlets (Non DIP) Three Phase General Areas “Clipsal” 5 pin 32 amp 56C532

Power OutletNon DIP

Power OutletNon DIP

Power OutletNon DIP

Power OutletDIP

Power OutletDIP

TS6 – Electrical Services

Power Supply 96-264vac/24vdc. Weidmuller. 3 amp, CP M SNT 70W 24vdc 3amp. 5 amp, CP M SNT 120W 24vdc 5amp. 7.5 amp, CP M SNT 180W 24vdc 7.5amp. 10 amp, CP M SNT 250W 24vdc 10amp. High and Alarm Level - for within Grain Storages – Capacitive Proximities Intrinsically Safe Sensor - Pacific EX” Rechner RH-KA0030, 30mm Ø, c/w 6 metres of cable. IS Barrier - Pacific EX” Rechner Single channel 120-240vac N00012. IS Barrier - Pacific EX” Rechner Duel channel 120-240vac N00015. Extra cable (blue) to suit above Pacific EX” 2 core 0.75mm2 (6.4 dia) part # RH66200300. Level Monitors for Pits and side walls of Grain Storages and Garners DIP/IECeEx, Capacitive Proximities Sensor - Pacific EX” Rechner part number RH-KA0278, description KAS-80-A24-A-StExN, 24vdc, 5 wire, n/o & n/c, 30mm Ø, c/w 5 metres of cable. Mechanical Protection Kit (Mounting Kit) to suit above: “Pacific EX” part No RH-PMI-000101, description M30 TF-fm-fit Includes Teflon shroud, s/s flange & 20mm conduit adaptor.

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RelayControl

TS6 – Electrical Services Relays Control - Miniature 4 pole plug in. (for general purpose control e.g. Ready, Run, Interlock / Manual etc) NHP Finder 55 series 4 pole c/o. See plug-in base details below. 24vdc.55.34.9. 024.0074. 24vdc, 7amp, 4 pole, c/w LED & built in diode suppression. 110vac.55.34.8.110.0054.110vac, 7amp, 4 pole, c/w LED & built in diode suppression. 240vac. 55.34.8.240.0054.240vac, 7amp, 4 pole, c/w LED & built in diode suppression.

Relay timers Schneider. NHP Sprecher Schuh. Or as specified.

SwitchEmergency

SwitchEmergency

Soft Starter

RelayControl RelayPower

Relays Control – Slimline single pole (for general purpose control). NHP Finder 38 series 1 pole c/o with LED & diode. 24vdc. 38.51.7.024.0050. 24vdc, 6amp, 1 pole, c/w LED & built in diode suppression. 110vac. 38.51.0.110.0060. 110vac, 6amp, 1 pole, c/w LED & built in diode suppression. 240vac. 38.51.0.240.0060. 240vac, 6amp, 1 pole, c/w LED & built in diode suppression. Note. No base required. Relays Power Schneider. NHP Sprecher Schuh. Or as specified.

RelayTimer

Base to suit all above: Type Screw terminal 94.04.

Motor Starting - Soft Starters 15kW-75kW 3Ø Refer Clause 5.13.10 this document. NHP Aucom EMX3 c/w inbuilt by-pass contactor, see list below. Use heavy duty (4xFLC) soft starter of all drives 11kw and above as listed below or specified. (B* denotes inbuilt by-pass contactor) Current Main Contactor (or as kw (amps) Aucom EMX3 specified) 11kw 22 EMX3-0043B-V4-C1 (31amp) Schneider LC1D25 15kw 28 EMX3-0043B-V4-C1 (31amp) Schneider LC1D32 18.5kw 38 EMX3-0053B-V4-C1 (46amp) Schneider LC1D38 22kw 44 EMX3-0076B-V4-C1 (55amp) Schneider LC1D50 22kw (Augers) 44 EMX3-0076B-V4-C1 (55amp) Schneider LC1D65 30kw 56 EMX3-0097B-V4-C1 (69amp) Schneider LC1D65 37kw 68 EMX3-0100B-V4-C1 (74amp) Schneider LC1D80 45kw 80 EMX3-0105B-V4-C1 (95amp) Schneider LC1D115 55kw 100 EMX3-0145B-V4-C1 (106amp) Schneider LC1D115 75kw 140 EMX3-0200B-V4-C1 (160amp) Schneider LC1F185 90kw 151 EMX3-0200B-V4-C1 (160amp) Schneider LC1F185 Switches –Emergency Stop Station (DIP/IECEx) CSE: DMPB1-4PL Pacific EX: DS1511-3-PLKC

Switches –Emergency Stop Station (NON DIP) Pacific EX: ???????

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Page 39

SwitchLocal Control

SwitchIsolator

TS6 – Electrical Services 3 Phase Isolator 20amp (Red & Yellow) Suit Inch drives local isolation etc. Clipsal 56SW320RY

Switches-Local Control Stations (DIP/IECEx) Conveyors & Elevators: Pacific EX: DS1511-CA10A178M003DIP. Reversing Conveyors & 2 way valves Pacific EX: CA10-AU00271P.

Timer-Ondelay

Timer ON-DELAY & INSTA NTANEOUS

TimerDouble on --delay

Terminals BlockPower connections

TerminalsControl wiring

SwitchLocal Control

SwitchLocal Control

SwitchLocal Control

Switches-Push Buttons DIP??

Switches-Local Control Stations (NON DIP) Conveyors & Elevators: Pacific EX: ????????? Reversing Conveyors & 2 way valves Pacific EX: ???? Switches-Push Buttons NON DIP?? “Schneider” 22mm XB2 booted (green – start or open; red – stop or close). NHP Sprecher Schuh D7 Metal body.

Terminals “Schneider” AB1

Terminals Blocks - Power Phoenix Contacts type UHV …, or similar. Separating Plate UHV-TP…. or similar.

SCHNEIDER Zelio. RE7YA12BU. DOUBLE ON-DELAY, Type/Function “Qt”, 2 C/O (8amp), 24vdc & 110-240vac) CBH use: For Soft Starter Horn/Start up delay.

SCHNEIDER Zelio. RE7TP13BU. 1 x ON-DELAY contact & 1 x INSTANTANEOUS contact. Type/Function “A”, 2 C/O (8amp), R1 = ON-DELAY, R2 = INSTANTANEOUS, 24vdc & 110240vac) CBH use: For Stacker Loader Horn/Start up delay.

SCHNEIDER Zelio. RE7TL11BU. ON-DELAY, Type/Function “A”, 1 C/O (8amp), 24vdc & 110-240vac) CBH use: Hydraulic Sample spears.

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Page 40

WiringPanel wiring Ferrules

VSD

TimerOff delay

Timer-Ondelay

TS6 – Electrical Services SCHNEIDER Zelio. RE7TM11BU. ON-DELAY with remote potentiometer, Type/Function “A”, 1 C/O (8amp), 24vdc & 110-240vac) CBH use: Pit Valves.

SCHNEIDER Zelio. RE7RA11BU. OFF DELAY, Type/Function “C”, 24vdc & 110-240vac) CBH use: Hydraulic Sample Spear (Load Timer).

1 C/O (8amp),

Motor Starting - VSD start motors (only where specified) Protection inbuilt with VSD.

Wiring - Flexible Wiring Flexible wiring requires “ferrules” (Boot lace pins) fitted at the termination points. When looping wiring using Use TWO CABLE type “ferrules”. Type Grey 2x0.75mm2 RS184-9654. Or similar. Type Red 2x1mm2 RS184-9660. Or similar. Type Black 2x1.5mm2 RS184-9676. Or similar. Type Blue 2x2.5mm2 RS184-9682. Or similar.

NOTE:

No changes to the Equipment Schedule shall apply without prior approval by the Principal.

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Page 41

TS6 – Electrical Services ELEVATORS Plant Elevator Drive

Cubicle

Equipment

Initials

Comments

Motor

Refer Data Sheets

Interlock

Start and stop as required

Manual

Start, stop and override interlock as required

Cabling

Neat, tidy and glanded, terminations tightened

Local Isolators

At head and in boot pit

Protection

Circuit breakers - TM-D trips adjusted Overloads correct and set to auto reset Fluid coupling over temperature switch

Indicator Lights

Elevator running

Ammeter

Operating - red ‘Chinagraph’ mark to indicate FLC

Motor

Refer Data Sheets

Interlock

Start and stop as required

Manual

Start, stop and override interlock as required

Cabling

Neat, tidy and glanded, terminations tightened

Limit Switches

Operation and mounting

Valve Motor

Refer Data Sheets

Interlock

With CLS or conveyor system

Manual

Open, close and override interlock as required

Cabling

Neat, tidy and glanded

Timing

Adjusted at wet commissioning

Cabling

Neat, tidy and glanded, terminations tightened

Limit Switches

Operation and mounting

Grain Sensors

Operation and mounting

Cubicle

Indicator Lights

Valve open, Valve closed, Grain in pit

Head Valve

Motor

Refer Data Sheets

Interlock

With CLS or conveyor system

Manual

Change over and override interlock as required

Cabling

Neat, tidy and glanded, terminations tightened

Limit Switches

Operation and mounting

Cubicle

Indicator Lights

Indicate correct feed direction

Labelling

Fitted

As per drawings and specification

Inching Drive

Road Hopper

Located where visible Engraved and legible

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Page 42

TS6 – Electrical Services E-PITS Equipment Auger motors

Operation Electrical

Refer Data Sheets

Interlock

Start and stop as required

Manual

Start, stop and override interlock as required

Cabling

Neat, tidy and glanded, terminations tightened

Cubicle Protection Indicator Lights

Initials

Comments

Circuit breakers, o/loads. And over temp. switches Augers running

GROUND CONVEYORS Equipment Drive motor

Cubicle

Isolating Switches

Operation Electrical

Refer Data Sheets

Interlock

Start and stop as required

Manual

Start, stop and override interlock as required

Cabling

Neat, tidy and glanded, terminations tightened

Protection

Circuit breakers, overloads. And over temp. switches

Indicator Lights

Ready, Forward, Reverse

Head and Tail

Fitted as per drawings

Warning sirens Lanyard switches

Initials

Comments

Fitted as per drawings Lanyards

120m maximum length

Set correctly

Manufacturers specification

Operation

Stacker Outlets

Cabling

Neat, tidy and glanded, terminations tightened

Space from ends

9m maximum

Spaces between

36m maximum

Accessibility

Cubicle

Labelling

Cabling

Neat, tidy, glanded, clear of ground, termination

Protection

Circuit breakers, overloads. and current sensing

Indicator Lights

Stacker running

Fitted

As per drawings and specification Located where visible Engraved and legible

Cable Ladder

Mounting

Joints within 300 of trestles or end of ladder Overhead – 2700 AFL

Fixing

Around drive - clear of tripper access and guards On elevators – tool removable e.g. on Unistrut

DOCS 826980v30 of 50

Cable spacing

6mm minimum all round to allow grain through

Cable fixing

Flat on tray - 1000mm: Vert. on tray – each rung

Page 43

TS6 – Electrical Services OTHER CONVEYORS Equipment Drive motor

Cubicle

Operation Electrical

Refer Data Sheets

Interlock

Start and stop as required

Manual

Start and stop as required

Cabling

Neat, tidy and glanded, terminations tightened

Protection

Circuit breakers, o/loads. And over temp. switches

Indicator Lights

Ready and running

Lanyard switches Lanyards

Initials

Comments

120m max length compensating springs fitted

Set correctly Operation Cabling Cable Ladder

Mounting

Joints within 300 of trestles or end of ladder Overhead – 2700 AFL

Fixing

Around drive - clear of tripper access and guards On elevators – tool removable e.g. on Unistrut

Labelling

Cable spacing

6mm minimum all round to allow grain to fall through

Cable fixing

Flat on tray - 1000mm: Vert. on tray – each rung

Cable bends

Within manufactures specifications

Fitted

As per drawings and specification Located where visible Engraved and legible

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Page 44

TS6 – Electrical Services CONTROL CUBICLE Equipment

Operation

Initials

Comments

Main switch

Rating

Circuit breakers

Rating

Trip settings on motor supplies

Labelling

Fitted

As per drawings and specification Not on removable covers Located where visible Engraved and legible

Control Panel

Indicators

Layout

As per drawings

System Interlock

Start and stop as required

Manual

Start and stop as required

Wiring

Neat, tidy with spare capacity in ducts, terminations tightened

Lamps

Working and visible

General

Engraving / labels fixed

Switches Pushbuttons Rotary General

Engraving / labels fixed

Valve

Adjusted at wet commissioning

Sirens

Siren to sound seven (7) seconds before belt start

(1) Time range

Set on 1.5 – 30s

(2) Time

Three (3) second delay

(3) Hysteresis

Set at 25% of current threshold

(4) Current

10 amps on stacker circuit

(5) Contact

Set to undercurrent (UI)

Motor overloads

Settings

Set to auto reset

Cabling / Wiring

Incoming

Clamping and cable glands

Internal

Neat and spare capacity in ducts

Terminations

Check for loose terminations

Protection

‘Grommet’ strips on metal edges

Timers

Current Sensors

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Page 45

TS6 – Electrical Services

Site:

………………………………………………………

Contractor:

………………………………………………………

Plant Area:

………………………………………………………

Equipment:

………………………………………………………

Make:

…………………………………… Rated RPM:

……………………………………

Type:

…………………………………… Rated kW:

……………………………………

Serial No.:

…………………………………… Rated Voltage: ……………………………………

Frame:

…………………………………… Rated IFL:

Bearing Types:

Drive End ………………………

Insulation Test: A to E

Non D E

…………………………………… ……………………………………

Use 1000V Insulation Resistance tester, test duration 60s reading - infinity not valid

……….. Megohms B to E

C to E

………… Megohms

Provide actual

………… Megohms

Rotor shaft free to rotate: Rotation direction correct: Circuit breaker Magnetic setting:

………… Amps

Circuit breaker Thermal setting:

………… Amps

Motor Overload setting:

………… Amps

Start timer setting:

………… Seconds

Transformer tap setting:

………… %

Transformer duty classification:

………… Starts/hour

Actual supply voltage:

RW…….. RB…….WB…… Volts

Actual no grain current:

………… Amps

Actual load current:

………… Amps

Remarks: ………………………………………………………………………………………………………………… ………………………………………………………………………………………………………………… ………………………………………………………………………………………………………………… ………………………………………………………………………………………………………………… …………………………………………………………………………………………………………………

Tested By:

…………………………

Signed:

…………………………

DOCS 826980v30 of 50

Date:

…../……/……

Page 46

TS6 – Electrical Services TEST EQUIPMENT REQUIRED 1. MOD TAP TESTER 2. RAD LBT BIT ERROR RATE TESTER 3. 1 SET OF TWO WAY RADIOS

PROCEDURE FOR TESTING AS FOLLOWS: a) Visual inspection of fly and patch leads. b) Test all fly and patch leads for correct operations with Mod Tap Tester. c) Test all wall socket outlets in Sample Platform No’s 1 to 6 and Patch Panel No’s 1 to 6 with Mod Tap Tester for correct numbering and pairs, i.e. Wall Socket outlet 1 corresponding with Patch Panel Socket 1. d) Connect fly lead to Patch Panel in Sampling Platform on Infra 1 and place one half of the Mod Tap Tester on the end of the fly lead. Place the other half of the Mod Tap Tester on Infra 1 in the Weighbridge and test for correct pairs correct labeling and that the pairs are reversed. Do the same procedure for the remaining area Infra 2, Balance 1 & 2 and Term 1 & 2. NOTE: If only single Repols installation required, Infra 2, Balance 2 and Term 3 are not required. e) f)

When all Mod Tap Testing is completed, record your results on the test sheets. Install RAD Line Drivers on the last point of the installation at the Sampling Platform, wall socket’s No’s 1 to 6, then at the Weighbridge on Infra 1 & 2, Balance 1 & 2 and Term 1 & 2, making sure that all Patch Leads are connected in the Patch Panel in Sampling Platform in the correct positions. g) Set all RAD Line Drivers to DCE at all locations and connect one of the RAD LBT Testers to Infra 1 at the Sampling Platform and the other RAD LBT Tester on Infra 1 at the weighbridge. Do the same procedure for the remaining area Infra 2, Balance 1 & 2 and Term 1 & 2. NOTE: If only single Repols installation required, Infra 2, Balance 2 and Term 3 are not required. h)

Set both testers to: ASYNC PATTERN 511 19-2KB BLK512B. ASYNC PARITY : EVEN 8 BIT BLK512B. FULL DUPLEX CTS AND CD NOT USED. Both testers must be started simultaneously. Ensure sync loss at start up is zero (0). Restart if required.

i)

The first test should be run for a minimum of 3 minutes. After 3 minutes you should have approximately 6,000 blocks received. There should be no block errors or sync errors with this test. Test No. 2 should be run for a minimum of 5 minutes, during this time you should inject no less than 5 error bits into the system. After 5 minutes you should have received more than 11,000 blocks and not have a block error rate of more than .0650%. Record all your results on the test sheet. After all tests are completed, make sure RAD Line Drivers are set back to the settings as per the information on the Repols drawing. Submit all tabulated results to Co-operative Bulk Handling Limited with As-Built Drawings.

j)

k)

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Page 47

TS6 – Electrical Services RAD LBT BIT ERROR RATE TEST SHEET Without injected errors RUN TIME 5 minutes minimum

BLOCK ERROR

% RATE

RECEIVE D

BLOCKS CONTAINI NG

BLOCKS

ERRORS

SYNC LOSS

LINE DRIVER SERIAL No. WEIGHBR IDGE

LINE DRIVER SERIAL No. SAMPLE HUT

INITIALS

INFRA 1 TERM 1 BALANCE 1 INFRA 2 TERM 2 BALANCE 2

RAD LBT BIT ERROR RATE TEST SHEET With injecting 5 errors RUN TIME INITIALS

5 minutes minimum

BLOCK ERROR

RECEIVED

BLOCKS CONTAINING

% RATE

BLOCKS

ERRORS

SYNC LOSS

No. OF ERRORS

INITIALS

INJECTED

INFRA 1 TERM 1 BALANCE 1 INFRA 2 TERM 2 BALANCE 2

RECIEVAL POINT :

DATE:

CONTRACTOR :

NAME OF TECHNICIAN :

TEST COMPLETED :

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YES

/

NO

Page 48

TS6 – Electrical Services MOD TAP TEST SHEET FLY AND PATCH LEAD VISUAL CHECK

No OF PAIRS SHOWING ON TESTER

CORRECT LABELLING & WIRING OF STANDARD 568A TERMINATION

INITIALS

FLY LEAD 1 FLY LEAD 2 FLY LEAD 3 FLY LEAD 4 FLY LEAD 5 FLY LEAD 6

PATCH LEAD 1 PATCH LEAD 2 PATCH LEAD 3 PATCH LEAD 4 PATCH LEAD 5 PATCH LEAD 6

MOD TAP TEST SHEET SAMPLE PLATFORM INSTALLATION TEST VISUAL CHECK

No OF PAIRS SHOWING ON TESTER

CORRECT WIRING OF STANDARD 568A TERMINATION

CORRECT LABELLING OF INSTALLATION

INITIALS

SOCKET 1 SOCKET 2 SOCKET 3 SOCKET 4 SOCKET 5 SOCKET 6

RECIEVAL POINT :

DATE:

CONTRACTOR :

NAME OF TECHNICIAN :

TEST COMPLETED :

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YES

/

NO

Page 49

TS6 – Electrical Services MOD TAP TEST SHEET SAMPLE PLATFORM TO WEIGHBRIDGE VISUAL CHECK

No OF THE PAIRS SHOWING ON TESTER

CORRECT LABELLING & WIRING OF STANDARD 568A TERMINATION

INITIALS

INFRA 1 TERM 1 BALANCE 1 INFRA 2 TERM 2 BALANCE 2

RECIEVAL POINT :

DATE:

CONTRACTOR :

NAME OF TECHNICIAN :

TEST COMPLETED :

DOCS 826980v30 of 50

YES

/

NO

Page 50