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LOGAN WATER ALLIANCE

STANDARD ELECTRICAL SPECIFICATION FOR WATER & SEWER PUMP STATIONS

TASK NUMBER: 90-10-05(C)

OCTOBER 2010

Standard Electrical Specification for Water & Sewer Pump Stations Document Number: 7600-000-PL-REP-P-8046

90-10-05(C) Date issued: 31.07.2013 Page 2 of 61 Final V1.1

Approval Register

Date

Project Manager Submitted 19.08.2010

Planning & Project Manager Reviewed 13.09.2010

Program Review

Controlled Document – Change Register

Revision Section

Changed Change Description Initial Date

A All Draft – Issue for Review RC/TK 03.08.10

B All Issue for Review RC/TK 19.08.10

C All Updated to reflect LWA comment TK 20.08.10

D 8.4, 10.2 Update for minor changes TK 27.08.10

Final All Final report formatted AH 28.09.2010

V1.1 All Rebrand from Allconnex to LCC logo SS 31.07.2013



TABLE OF CONTENTS

1. SCOPE ................................................................................................................................................. 9

1.1 General ............................................................................................................................................ 9

1.2 Preferred Telemetry Provider .......................................................................................................... 9

1.3 Proposed Variations ...................................................................................................................... 10

2. DEFINITIONS ..................................................................................................................................... 11

3. STANDARDS AND REFERENCED DOCUMENTS ........................................................................... 11

3.1 General .......................................................................................................................................... 11

3.2 Two-Pump Standard Reference Design ........................................................................................ 11

3.3 Applicable Standards ..................................................................................................................... 12

3.4 Statutory Codes ............................................................................................................................. 13

4. TECHNICAL SCHEDULES ................................................................................................................ 14

5. PREFERRED LIST OF SUPPLIERS ................................................................................................. 14

6. SERVICE CONDITIONS..................................................................................................................... 14

6.1 General .......................................................................................................................................... 14

6.1.1 Additional Considerations on Operating Conditions .................................................................. 15

6.2 PLC & Telemetry Equipment Operating Environment ................................................................... 15

6.3 Supply System Conditions ............................................................................................................. 15

7. METAL CLAD SWITCHBOARDS AND ENCLOSURES ................................................................... 16

7.1 Scope ............................................................................................................................................. 16

7.2 Measurements of Performance ..................................................................................................... 16

7.2.1 Inspections ................................................................................................................................. 16

7.2.2 Electrical Testing ....................................................................................................................... 16

7.2.3 Functional Checking .................................................................................................................. 16

7.3 Switchboard Design Criteria .......................................................................................................... 17

7.3.1 Service Conditions ..................................................................................................................... 17

7.3.2 Service Climatic Conditions ....................................................................................................... 17

7.3.3 Operating Requirements ............................................................................................................ 18

7.3.4 Supply System Conditions ......................................................................................................... 18

7.4 Switchboard Performance and Rating ........................................................................................... 18

7.4.1 General ...................................................................................................................................... 18

7.4.2 Short Circuit Performance ......................................................................................................... 18

7.4.3 Arc Containment Performance .................................................................................................. 18

7.4.4 Main Busbar Rating and Temperature Rise .............................................................................. 19

7.4.5 Equipment and Fault Co-ordination ........................................................................................... 19



7.5 Switchboard Construction Details .................................................................................................. 19

7.5.1 Type of Switchboard .................................................................................................................. 19

7.5.2 Switchboard Layout ................................................................................................................... 19

7.5.3 Busbar ........................................................................................................................................ 20

7.5.4 Metal Work ................................................................................................................................. 20

7.5.5 Doors, Escutcheons and Cable Zone Covers ........................................................................... 21

7.5.6 Removable Access Covers/Panels............................................................................................ 22

7.5.7 Gland Plate Openings ................................................................................................................ 22

7.5.8 Plinth .......................................................................................................................................... 22

7.5.9 Paint Treatment ......................................................................................................................... 22

7.5.10 Cable Zones........................................................................................................................... 23

7.5.11 Switchboard Compartments .................................................................................................. 23

7.5.12 Switchboard Modules ............................................................................................................ 23

7.5.13 Distribution Boards ................................................................................................................ 23

7.5.14 Soft Starters ........................................................................................................................... 23

7.5.15 RTU and Instrument Enclosures............................................................................................ 24

7.5.16 Sealing ................................................................................................................................... 24

7.5.17 Shrouding ............................................................................................................................... 25

7.5.18 Incoming Feeder .................................................................................................................... 25

7.5.19 Gland Plates .......................................................................................................................... 25

7.5.20 Equipment Mounting .............................................................................................................. 25

7.5.21 Spare Capacity ...................................................................................................................... 26

7.5.22 Switchboard Internal Wiring ................................................................................................... 26

7.5.23 Wiring Duct and Strapping ..................................................................................................... 27

7.5.24 Arrangement of Wiring Duct and Looms ............................................................................... 27

7.5.25 Terminations and Connections .............................................................................................. 28

7.5.26 Power Circuit Connections .................................................................................................... 29

7.5.27 Numbering of Wires ............................................................................................................... 29

7.5.28 Labelling ................................................................................................................................. 30

7.5.29 Warning Labels ...................................................................................................................... 31

7.5.30 Current Transformer (CT) Wiring ........................................................................................... 31

7.5.31 Drawing holder ....................................................................................................................... 31

7.6 Switchboard Equipment ................................................................................................................. 32

7.6.1 General ...................................................................................................................................... 32

7.6.2 Moulded Case Circuit Breakers (MCCB’s) ................................................................................ 32

7.6.3 Motor Starters ............................................................................................................................ 33



7.6.4 Current Transformers (CTs) ...................................................................................................... 33

7.6.5 Indicating Lights ......................................................................................................................... 34

7.6.6 Panel Meters .............................................................................................................................. 34

7.6.7 Tools .......................................................................................................................................... 34

7.6.8 Testing and Resetting Facilities ................................................................................................. 34

7.7 Documentation ............................................................................................................................... 35

7.7.1 Switchboard Construction Drawings .......................................................................................... 35

7.7.2 Equipment Lists ......................................................................................................................... 35

7.7.3 Label Lists .................................................................................................................................. 35

8. RTU AND TELEMETRY ..................................................................................................................... 36

8.1 General .......................................................................................................................................... 36

8.2 Operational Conditions .................................................................................................................. 36

8.3 Instrumentation .............................................................................................................................. 36

8.4 SCADA ........................................................................................................................................... 37

9. ELECTRICAL INSTALLATION .......................................................................................................... 38

9.1 Scope ............................................................................................................................................. 38

9.2 General .......................................................................................................................................... 38

9.3 Equipment Location ....................................................................................................................... 38

9.4 MCC Installation ............................................................................................................................ 38

9.5 Cables ............................................................................................................................................ 38

9.5.1 Motor Cables.............................................................................................................................. 39

9.6 Cable Installation ........................................................................................................................... 39

9.6.1 Cables on Cable Ladder ............................................................................................................ 40

9.7 Cable Trenches ............................................................................................................................. 40

9.8 Cable Ladder ................................................................................................................................. 40

9.8.1 Cable Ladder Types .................................................................................................................. 40

9.8.2 Cable Ladder Installation ........................................................................................................... 41

9.8.3 Cable Ladder Earthing ............................................................................................................... 41

9.8.4 Cable Ladder Covers ................................................................................................................. 41

9.9 Conduit Systems ............................................................................................................................ 42

9.9.1 Conduits for Unarmoured Cable ................................................................................................ 42

9.9.2 Conduits for Underground (buried) Cables ................................................................................ 42

9.9.3 Flexible Conduits ....................................................................................................................... 43

9.10 Cable Terminations ........................................................................................................................ 43

9.10.1 Terminals ............................................................................................................................... 43

9.10.2 Cable Glands ......................................................................................................................... 43



9.10.3 Cable Lugs ............................................................................................................................. 44

9.10.4 LV Cable Terminations .......................................................................................................... 44

9.10.5 Termination of Control and Instrument Cables ...................................................................... 44

9.10.6 Termination at Switchboards and Enclosures ....................................................................... 45

9.10.7 Termination of Earth Cables .................................................................................................. 45

9.11 Cable Identification ........................................................................................................................ 45

9.11.1 Cable Number Tags ............................................................................................................... 45

9.12 Cable Penetration .......................................................................................................................... 46

9.13 Power Phasing ............................................................................................................................... 46

9.14 Enclosures ..................................................................................................................................... 46

9.14.1 Junction Boxes....................................................................................................................... 46

9.14.2 Local Control Stations ............................................................................................................ 47

9.15 Lighting and Small Power .............................................................................................................. 47

9.15.1 Operating Conditions ............................................................................................................. 47

9.15.2 Supply System ....................................................................................................................... 47

9.15.3 Light Fittings ........................................................................................................................... 47

9.15.4 Mounting of Lighting Fittings .................................................................................................. 47

9.15.5 Lighting Switches ................................................................................................................... 48

9.15.6 Remote Control of Lighting Fittings ....................................................................................... 48

9.15.7 General Purpose and Welding Outlets .................................................................................. 48

9.15.8 Wiring of Lighting and General Power ................................................................................... 48

9.15.9 Lighting and Power Distribution Boards ................................................................................ 49

9.16 Instrumentation .............................................................................................................................. 49

9.17 Fixing to Structural Steelwork ........................................................................................................ 49

9.18 Signs .............................................................................................................................................. 49

9.19 Labels ............................................................................................................................................ 49

9.20 Earthing .......................................................................................................................................... 50

9.20.1 Protective Earth Connections ................................................................................................ 51

9.20.2 Equipotential bonding ............................................................................................................ 51

9.21 Painting .......................................................................................................................................... 51

10. TESTING AND COMMISSIONING .................................................................................................... 52

10.1 Scope ............................................................................................................................................. 52

10.2 Works Inspection and Testing ....................................................................................................... 52

10.2.1 Works Testing ........................................................................................................................ 52

10.2.2 Factory Inspection and Testing of MCCs and Switchboards ................................................. 52



APPENDICES

Appendix A Technical Schedule – Metal Clad MCC

Appendix B Technical Schedule - RTU

Appendix C Standard SPS Drawings (including Preferred Equipment List)



ABBREVIATIONS

AC Alternate Current

AS Australian Standards

CPU Central Processing Unit

CT Current Transformer

DOL Direct On Line

ELV Extra Low Voltage

EMC Electromagnetic Compatibility

EMI Electromagnetic Interference

ESAA Energy Supply Association of Australia

FAT Factory Acceptance Test

FLC Full Load Current

HRC High Rupture Current

HV High Voltage

IEC International Electro technical Commission

IP Ingress Protection

LCS Local Control Station

LED Light Emitting Diode

LV Low Voltage

MCC Motor Control Centre

MCCB Moulded Case Circuit Breaker

MEN Multiple Earth Neutral

NATA National Association of Testing Authorities

NEMA National Electrical Manufacturers Association

OS Operating System

PE Photoelectric

PFC Parallel Flange Channel

PLC Programmable Logic Controller – Note in this document the function of the PLC is performed by the RTU and the terms are interchangeable.

PVC Polyvinyl Chloride

RCD Residual Current Device

RFI Radio Frequency Interference

RTU Remote Telemetry Unit – Note in this document the function of the PLC is performed by the RTU and the terms are interchangeable.

SAA Standard Association of Australia

SCADA Supervisory Control and Data Acquisition

SPS Sewage Pump Station

SS Soft Starter

UPVC Unplasticized Polyvinyl Chloride

UV Ultra Violet

VSD Variable Speed Drive

WPS Water Pump Station



1. SCOPE

1.1 General

This document is the standard electrical specification for Allconnex Water water/sewer pump stations

(WPS/SPS) located within the Logan District of Allconnex Water. The pump station configuration covered in

this standard specification is for a soft starter (SS) based two-pump arrangement. This arrangement is

typically expected to be wholly applicable in the majority of new or upgraded SPS and in principle shall apply

to WPS.

This document shall be read in conjunction with the Standard Specification for Sewer Pump Station (7690-

005-S-SPE-PM-9001) and Standard Specification for Water Pump Station (7690-005-W-SPE-PM-9001).

This specification details the minimum standards and requirements for the design, supply, manufacture,

transportation to site, installation, testing and commissioning of the following electrical (inclusive of control)

equipment and services that are required to operate a WPS/SPS:

a) Metal clad switchboards and motor control centres (MCC’s);

b) Electrical conduit, cabling, equipment, and connections;

c) Motor soft starters;

d) Instrumentation;

e) Control and monitoring circuitry; &

f) RTU and telemetry equipment.

The technical schedules and the equipment standard design drawings and details listed in the Appendices

shall be read with this specification.

Electrical equipment shall comply with the preferred equipment list as shown in the drawings and listed in

Appendix F of Logan Water Alliance Standard Specification. Any deviation from this list shall be approved in

writing by Allconnex Water or their approved representative prior to purchase. All approved deviations will

require an additional two units to be supplied as spares parts.

Equipment shall be designed, manufactured or specified to meet the minimum requirement of service

conditions specified under the service conditions set out in this specification.

This specification does not cover specific requirements of voltage systems over 1000 volts.

1.2 Preferred Telemetry Provider

For the following items, as a minimum, Allconnex Water’s Preferred Telemetry Contractor must be used:

a) Programming, configuration, supply, and testing of the Kingfisher RTU;

b) Site radio path survey;

c) SCADA updates for the new WPS/SPS; &



d) Assistance with the acceptance testing of the RTU operation and the remote telemetry from the

SCADA system.

1.3 Proposed Variations

Any proposed variation to the standard requirements shall be consulted with Allconnex Water engineers

including, but not limited to the following:

a) WPS/SPS two-pump arrangement that may require VSDs;

b) SPS flow approaching to 200L/s where a three-pump arrangement may be considered; &

c) WPS/SPS small pumps less than 2.5kW may be DOL and single phase arrangement.



2. DEFINITIONS

Terms used in this specification have their usual meaning with the following terms given the following

meaning throughout this document.

Preferred Telemetry Provider shall mean Allconnex Water preferred provider of the telemetry and SCADA associated with the WPS/SPS, and shall be nominated by Allconnex Water Senior Telemetry Officer.

Principal shall mean Allconnex Water.

Developer/Consultant shall mean the party responsible for development and delivery of a WPS/SPS as part of a development in the Logan District.

3. STANDARDS AND REFERENCED DOCUMENTS

This document shall be read in conjunction with the Standard Specification for Sewer Pump Station (7690-

005-S-SPE-PM-9001) and Standard Specification for Water Pump Station (7690-005-W-SPE-PM-9001).

3.1 General

The design, supply, manufacture, installation, testing and commissioning of equipment and components

detailed in this specification shall comply with the requirements of all relevant Australian standards. If an

applicable Australian Standard does not exist an equivalent current British Standard shall be used.

Equipment and components shall also comply with all codes and/or acts that are enforced by Government

Authorities having jurisdiction over the work or the area where the equipment and/or components will be

used.

All works shall comply with the requirements of the most recent releases of the regulations and standards

noted herein. In the event of a conflict between different Codes, Standards or Regulations, the highest

requirement shall apply. Provisions of the relevant standard shall not be deviated from without first obtaining

agreement in writing from Allconnex Water or their approved representative.

3.2 Two-Pump Standard Reference Design

Allconnex Water have developed a standard SPS two-pump soft-starter based design that shall be

implemented as set out in the standard detailed design. This standard design shall be followed as closely as

possible for SPS and shall in principle be followed for WPS. Any deviation from the standard design shall be

approved in writing by Allconnex Water prior to completion of the detailed design for the site.

The standard drawings provided are listed as follows:

Drawing Title Drawing Reference

Standard Single Tier Front & Rear Access General Arrangement 7690-05-S-DWG-EL-6001

Standard 2 Tier Front Access General Arrangement 7690-05-S-DWG-EL-6002

Standard Schematic Wiring Diagram 7690-05-S-DWG-EL-6010



Standard Backup Control 7690-05-S-DWG-EL-6011

Standard Schematic Wiring Diagram 7690-05-S-DWG-EL-6012

Standard 2 Pump Telemetry 7690-05-S-DWG-EL-6013

Standard 2 Pump Equipment Schedule 7690-05-S-DWG-EL-6014

Standard 2 Pump Equipment Schedule 7690-05-S-DWG-EL-6015

Standard 2 Pump Backup Float Schematic 7690-05-S-DWG-EL-6016

Standard SPS 2 Pump RTU Electrical Assembly 7690-05-S-DWG-EL-6101

Standard SPS 2 Pump RTU Module Assembly 7690-05-S-DWG-EL-6102

Standard SPS 2 Pump RTU Module 7690-05-S-DWG-EL-6103

The functional philosophy set out in the document “Allconnex Water (Logan District) Sewer Pump Station

Telemetry Specification” shall be followed when designing, installing, testing, and commissioning the

WPS/SPS. This document is available on request from the Allconnex Water Senior Telemetry Officer.

Regardless of any deviation or not from the standard detailed drawing set, a site specific electrical detailed

drawing set shall be produced and approved prior to construction. An as-constructed electrical drawing set

shall be produced and approved, with a laminated set of drawings left inside the drawing holder on site

following approval.

Sites that require any combination of three-pump arrangement, DOL, and VSD shall be designed in close

consultation with Allconnex Water. The requirements of this specification and the general arrangements of

the two-pump standard detailed design should be followed as closely as possible.

If there are any ambiguities between this specification and the standard design drawings or the control

philosophy then the drawings and control philosophy shall take precedence.

3.3 Applicable Standards

AS 1000 International System of Units (S.I.) and its applications.

AS 1102 Graphical symbols for electrotechnical documentation

AS 1243 Voltage transformers for measurement and protection.

AS 1284 Electricity meters.

AS 1307 Surge Arresters (Diverters)

AS 1319 Safety signs for the occupational environment.

AS 1930 Circuit Breakers for Distribution Circuits

AS 2184 Moulded Case Circuit Breakers.



AS 2312 Guide to the protection of structural steel against atmospheric corrosion by the use

of protective coatings

AS 2700 Colours standards for general purposes.

AS 3000 Wiring rules.

AS 3008 Electrical installations – Selection of cables (Low Voltage).

AS 3017 Electrical installations – Testing guidelines.

AS 3100 Approval and test specification - General requirements for electrical equipment

AS 3111 Approval and Test Certification for Miniature over current Circuit Breakers.

AS 3439 Low voltage switchgear and control gear assemblies.

AS/NZS 3760 In-service safety inspection and testing of electrical equipment

AS 3947 Low-voltage switchgear and controlgear - Switches, disconnectors, switch-

disconnectors and fuse-combination units

AS/NZS 4024 Safety of machinery

AS 4070 Recommended Practices for the Protection of Low Voltage Electrical Installations

and Equipment in MEN Systems from transient Overvoltages

AS 5000 Electric Cables.

AS 60044 Instrument Transformer – Current Transformers

AS 60227 PVC Insulated Cables and Flexible Cords

AS 60269 Low Voltage Fuses.

AS 60529 Degrees of protection provided by enclosures of electrical equipment.

AS 60947 Low Voltage Switchgear and Control Gear

AS 61508 Functional safety of electrical / electronic / programmable electronic safety related

systems.

AS IEC 61551 Functional safety – Safety instrumented systems for the process industry sector.

AS/NZS 62026 Low-voltage switchgear and control gear – Controller-device interfaces

AS 62061 Safety of Machinery – Functional safety of safety related electrical, electronic, and

programmable electronic control systems

3.4 Statutory Codes

Equipment and workmanship shall conform to the requirements of relevant statutory Local, State, and

Commonwealth Authorities Legislative Acts, and Regulations including:



Queensland

a) Queensland Electrical Safety Act (2002);

b) Queensland Electrical Safety Regulation (2002);

c) Electricity Legislation Amendment and Repeal Act (2001);

d) Queensland Workplace Health and Safety Act (1995);

e) Queensland Workplace Health and Safety Regulation (2008);

f) Local Electrical Authority Conditions of Supply and Consumer Metering; &

g) Allconnex Water requirements.

4. TECHNICAL SCHEDULES

The following schedules shall be completed and submitted by the Developer for approval by Allconnex

Water. The Developer shall state the hardware and software offered to satisfy the requirements specified.

Technical schedule listed in this part of the document are as follow:

a) Appendix A Technical Schedule – Metal Clad MCC

b) Appendix B Technical Schedule – PLC & RTU System

5. PREFERRED LIST OF SUPPLIERS

Appendix F of the document “Standard Specification for Sewer Pump Station” details the preferred list of

suppliers/contractors for Allconnex Water.

Where ratings and values are included, these shall verify these against the technical schedules as calculated

as part of the detailed design.

6. SERVICE CONDITIONS

6.1 General

This section details typical values for Allconnex Water general site conditions.

The values are typical operating conditions for electrical equipment. All electrical equipment shall be

designed to operate in the described conditions, as a minimum however, in many applications equipment

must operate in conditions that are worse than detailed within this specification.

In all instances it is the designer’s responsibility to ensure that the equipment is suitably specified for the

operating environment.

Wind loading shall be based on AS1170 Part 2 – Minimum design load on structures (also known as the

SAA Loading Code).



6.1.1 Additional Considerations on Operating Conditions

Moisture laden air may exists in some areas where the equipment will operate, causing severe corrosion to

most metals.

The environment may be highly dusty at times due to the nature of the site surface. (Pollution Level 3).

Unless specified otherwise, all electrical equipment shall be designed to operate at an ambient temperature

of 45˚ C. This includes equipment located in air conditioned buildings on the surface (switch rooms, control

rooms etc) regardless of air conditioning.

Equipment installed outdoors where it is exposed to the sun, shall be designed to withstand Black Body

Temperature. Provision of solar shields may be necessary.

6.2 PLC & Telemetry Equipment Operating Environment

PLC, telemetry, equipment and the like shall be designed to operate under the environmental conditions

specified below:

a) Maximum ambient temperature: 45˚ C;

b) Minimum ambient temperature: 0˚ C; &

c) Humidity from 5% to 95%, non-condensing.

6.3 Supply System Conditions

Supply System Conditions

Low Voltage 415 V +10% -6%, 3 ph, 4 wire

Frequency 50 Hz ± 2%

Voltage Unbalance < 5%

LV Supply star point Neutral solidly earthed

Single Phase Power Supplies 240 Vac

Control Power Supplies 240 Vac or 24Vdc, Neutral earthed



7. METAL CLAD SWITCHBOARDS AND ENCLOSURES

7.1 Scope

This section details the technical requirements for the design and construction of metal clad switchboards

and enclosures, including low voltage Motor Control Centres (MCC’s) and Switchboards.

For the purpose of this document, the term MCC and switchboard are interchangeable.

7.2 Measurements of Performance

Inspections and routine testing shall be conducted in accordance with AS 3439.1 – Switchgear and Control

Assemblies.

Written notice shall be provided to Allconnex Water and/or their approved representative seven (7) days prior

to commencement of testing so that testing may be witnessed.

7.2.1 Inspections

Equipment shall be checked against the detailed design to ensure the correct type, rating and number of

circuits has been installed. The Single Line Diagram shall be marked up to properly reflect the finished

switchboard.

At a minimum, the following items shall be checked:

a) Busbar configuration and support system for consistency with Type Test Certificates;

b) Sealing of fully welded seams;

c) Equipment mounting and cable supports to ensure adequate fixing and bracing;

d) Operating handles and interlocks for correct functioning;

e) Withdrawable equipment for free movement, operation of shutters and interlocks;

f) Clearance and creepage distances and degrees of protection;

g) Doors and access covers for sealing;

h) Bolted and screwed connections for tightness and adequate contact; &

i) Label wording and annunciator window engraving against relevant schedules.

7.2.2 Electrical Testing

Power circuits insulation shall be tested to a dielectric test voltage of 2500V as per AS 3439.1. Control wiring

shall be tested at 500V only. Semiconductor equipment such as soft starters and their associated data

connections, programmable controllers and instruments shall not be voltage tested.

7.2.3 Functional Checking

Each and every control wire shall be checked for correct function and marked off on the schematic drawings.

These drawings shall be amended to reflect the final connections of the switchboard as dispatched from the



workshop. Copies of these marked schematics (dated and signed) shall be submitted to Allconnex Water or

their approved representative, within two (2) weeks of testing.

If spot checks carried out on the completed switchboards discover inconsistencies with the drawings

provided, then the Switchboard Manufacturer shall retest the whole switchboard in the presence of Allconnex

Water or their approved representative.

All control circuits shall be energised at the operating voltage with pushbuttons, indicating lights and switches

installed to fully simulate all field devices. Each feature of the circuit shall then be checked by operation of

the switches and pushbuttons.

Protective relays shall be tested at three points on their protection curve by secondary injection.

Current transformers and direct connected metering and protection equipment shall be tested by primary

injection to prove correct polarity and C.T. ratios.

Each analogue loop shall be injected with a variable input signal equivalent to its specified input and the

signal shall be varied over its entire range to test the operation of associated indicators, controllers and

recorders. In the case of controllers, outputs shall be monitored and set points checked for correct operation

including the operation of any associated process alarms.

Marked up drawings and test sheets detailing the results and extent of the above tests shall be provided to

Allconnex Water or their approved representative within two (2) weeks of testing.

7.3 Switchboard Design Criteria

7.3.1 Service Conditions

The switchboard and all components will be required to operate continuously at full load for 24 hours per

day, 365 days per year as specified under the section Service Conditions.

All equipment shall be designed to perform this duty safely and without being attended.

The following minimum fault levels are recommended for main switchboards:

a) For switchboards supplied from the local supply authority LV network and rated at less than 100A –

not less than 15kA for 1 second;

b) For switchboards supplied from the local supply authority LV network and rated at greater than 100A

up to and including 250A – not less than 25kA for 1 second; &

c) Switchboards supplied from a dedicated transformer or substation or with a current carrying capacity

greater than 250A– 36kA for 1 second (e.g. large pump stations).

7.3.2 Service Climatic Conditions

The site climatic conditions shall be as defined for an outdoor location in AS 3439.1, except as noted

otherwise in this specification.



7.3.3 Operating Requirements

Equipment ratings shown on drawings are the required ratings after all derating factors have been applied.

Switchboard components shall be selected and installed so that all circuits can operate simultaneously at the

full load rating based on the worst climatic condition.

The full load rating for motor circuits shall be taken as the motor full load current while the rating for other

circuits shall be the circuit breaker rating unless specified otherwise.

The rated diversity factors detailed in Clause 4.7 of AS 3439.1 shall not apply.

7.3.4 Supply System Conditions

The electrical system shall have the voltage levels as specified in the MCC Technical Schedule.

7.4 Switchboard Performance and Rating

7.4.1 General

Switchboards supplied shall be Type Tested Low Voltage Switchgear and Control gear Assemblies in

accordance with AS 3439.1.

The switchboard design shall have been successfully type tested in accordance with AS 3439.1 by a

recognised testing authority. The design tested shall be applicable to the switchboard being supplied; i.e. it

shall include feeders if these are being supplied.

Type Test certificates shall be held in the name of the company manufacturing the switchboards.

7.4.2 Short Circuit Performance

Switchboards shall be constructed to withstand, without thermal or mechanical damage, the short circuit

stresses generated by the fault level where stated on the drawings or specified in the technical schedule.

The switchboard being supplied shall be in no way inferior to the type tested switchboard, for example:

a) Busbar ratings shall not be less than those type tested;

b) Busbar supports shall be identical in material and mounting method to those type tested;

c) Busbar support spacing shall not be greater than those type tested;

d) Phase centres shall not be less than those type tested;

e) Creepage and clearance distances shall not be less than those type tested; &

f) The feeder and motor starting equipment (circuit breakers, switch fuses, contactors, and overloads)

shall preferably be the same equipment and in the same combination as that used in the type test

(however, not every rating need have been tested).

7.4.3 Arc Containment Performance

If the fault level specified is 10 kA or greater, then the switchboard supplied shall be of the arc containment

type in accordance with this clause.



Arc containment switchboards, including motor starting and feeder equipment shall provide ‘acceptable

protection’ for operators in the event of an internal arcing fault occurring on the load side of a protective

device in any switchboard compartment. The construction methods used in the tested switchboard (e.g.

venting, door bracing and door mounted equipment shrouding) shall be the same as in the production

switchboard(s) being supplied.

Protective devices (circuit breakers and fault limiting fuses) shall preferably be the same as those tested in

accordance with AS 3439.1, although not every protective device rating need have been tested.

7.4.4 Main Busbar Rating and Temperature Rise

The main busbar rating required shall be as specified in the MCC Technical Schedule or otherwise

determined by the Switchboard Manufacturer. The main busbar shall provide this rating with a busbar

temperature rise of not more than 300C above ambient and within the temperature rise limits detailed in AS

3439.1.

The busbar size shall be determined using a derating factor of 0.62.

Regardless of busbar sizes, the temperature rise limits specified above shall not be exceeded.

Cables shall not be used as main busbars and shall only be used as distribution busbars as permitted by

clause 7.5.5.1.2 of AS 3439.1. When cables are used as distribution busbars, they shall be double insulated.

7.4.5 Equipment and Fault Co-ordination

It shall be the Manufacturers’ responsibility to ensure that every item of equipment in the switchboard is

suitable for operation at the fault level calculated by the Switchboard Manufacturer’s Professional Engineer

or is protected by upstream fault limiting or coordinating devices supplied within the switchboard.

Protective equipment shall be coordinated as specified in the MCC Technical Schedule. The equipment

shall be protected so that no item is called upon to break fault current in excess of its fault rating. This shall

include control circuit breakers.

Power and control cable and switchboard wiring protection shall be such that the energy let through by the

protective device does not exceed the level permitted for that cable or wiring by AS 3008.

7.5 Switchboard Construction Details

7.5.1 Type of Switchboard

Switchboards shall have the characteristics as specified in the MCC Technical Schedule.

7.5.2 Switchboard Layout

The Manufacturer shall maintain the layout and dimensions specified, but shall be responsible for the

detailed design of the switchboard within these requirements.



The Switchboard Manufacturer shall be responsible for laying out the switchboard in accordance with this

specification and for the detailed design of the switchboard.

7.5.3 Busbar

Busbars shall be formed from hard drawn, high conductivity, solid round-edged rectangular copper bar.

The current carrying surfaces of busbar joints shall be thoroughly cleaned to remove all traces of dirt and

grease, and shall be coated with a layer of corrosion-inhibiting jelly immediately prior to jointing. Connections

shall be secured with high-tensile steel bolts and belville washers tensioned in accordance with

manufacturer’s instructions.

Phase busbars shall be treated to improve emissivity however this improvement shall not be considered

when sizing busbars.

Dust and vermin proofing of the busbar chamber shall not be dependent on a seal between the cubicle walls

and the floor, but shall be by a complete metal enclosure. If ventilation is required in the bus chamber, then

the openings shall be covered with bronze insect and vermin proof screens.

Full length removable busbar access covers shall be provided to allow ready access for removal and

inspection. Horizontal busbars in the top of switchboards shall have covers on the top and at the back or

front of the switchboard. Horizontal busbars in the bottom of switchboards shall have covers at the back and

front of the switchboard. Vertical busbars shall have full length covers at the back of the switchboard. These

rear access covers may be omitted if the rear access to the switchboard is not available. Covers shall be

sealed and fastened in accordance with the requirements for removable covers detailed in this specification.

A full capacity neutral busbar shall extend the full length of the switchboard and shall have take off points

sufficiently separated from live conductors to allow safe connection of circuit neutrals. The neutral bar shall

be colour-coded using black heat shrink tubing at 300 mm intervals.

A suitably sized earth bar shall extend the full length of the switchboard adjacent to the outgoing cable gland

plates. The earth bar shall be colour-coded with green/yellow heat shrink tubing at 300 mm intervals. The

earth bar shall be tapped and fitted with bolts, washers and spring washers to accommodate the earth

connections for all incoming and outgoing cables, with 20% spare connections. For termination of field earth

cables 2.5 mm² and smaller, an earth link bar with at least ten terminals shall be mounted on the earth

busbar adjacent to each cable zone. Only one earth cable shall be terminated at each earth terminal.

All parts of the switchboard which are required to be earthed shall be effectively connected to the earth

busbar. Provision shall be made for the entry and termination of an earth cable at each end of the board, and

for suitable terminals for connection to an earth core and/or steel armouring on all other incoming and

outgoing cables.

7.5.4 Metal Work

Enclosure



The switchboard shall be a completely self-supporting fully welded rigid structure constructed from:

a) Folded 3mm thick marine grade aluminium;

b) Folded 2mm thick powder coated zinc annealed mild steel; &

c) Folded 2mm thick stainless steel.

Free from rust, dents and any surface defects. The Manufacturer shall construct the switchboard from the

materials as specified in the MCC Technical Schedule.

The construction shall be such that the switchboard is a dust and vermin proof enclosure.

Equipment mounting plates shall be minimum 3 mm thick marine grade aluminium supported by four welded

stainless steel studs and secured with minimum of four stainless steel nuts. Large equipment plates

exceeding 1000 mm in any dimension shall be 3.2 mm thick and secured with six welded stainless steel

studs and nuts.

Welds shall be full fillet welds ground and machined smooth and free from splatter.

Heavy equipment shall be supported by separate independent framework and shall not rely on the enclosure

sheeting.

All nuts, bolts and studs shall be stainless steel.

The switchboard shall be provided with suitable lifting lugs that shall be designed to prevent distortion during

lifting.

All ventilation ports shall be vermin proofed with non corrosive material.

7.5.5 Doors, Escutcheons and Cable Zone Covers

All compartments other than Supply Authority metering cubicles, busbar chambers and horizontal cable

zones shall have hinged doors.

Doors shall be constructed from the same material as the rest of the switchboard and have a minimum return

of 15 mm on all four (4) sides. Door sealing shall be achieved with a 12 mm x 6 mm neoprene gasket glued

or cemented around the inside edge of the door and held by a retainer to the inside of the door. The

switchboard opening shall have 120 degree return which seals against the gasket on the door. Foam rubber

or foam plastic sealing strip shall not be used.

Doors shall have a minimum opening of 100 degrees for equipment access and shall be equipped with

retainers to hold the door in the open position.

Doors with dimensions in excess of 1000 mm high and 450 mm wide shall have a broad “U” stiffening

channel down the centre of the door for the entire length.

All doors shall be held closed with chrome plated ‘L’ handles. Doors over 400 mm high shall have Emka

stainless steel three point locking system. Handles on doors which are interlocked with the module supply, or



on doors which cover escutcheons shall be non lockable, while door handles on non interlocked

compartments shall be lockable. Locks shall be to Allconnex Water standard key structure.

Doors and escutcheons shall have a minimum of 2 lift off chrome plated pintle type hinges. Doors over 1000

mm shall have three hinges.

Escutcheons shall be held closed with two stainless steel acorn head nuts. Escutcheons over 1000 mm high

shall have three such nuts.

Hinged doors shall have two 6 mm earthing studs, one welded to the door and one to the cubicle body. A

flexible earth connection, not smaller than 4 mm², shall be made between the studs. For doors enclosing the

switchboard power modules (incomer, distribution board, feeder, motor starter, etc.) and for doors carrying

wiring, the earth connection shall be sized for the prospective fault current in accordance with the

requirements of AS 3439.1.

A fold down shelf is to be provided on the inside of the door of the RTU compartment for mounting a laptop

computer.

7.5.6 Removable Access Covers/Panels

Compartments which are not equipped with hinged doors shall have removable covers. Removable covers

shall not be used where hinged doors can be used.

Removable covers shall have a return lip and sealing arrangement similar to that for door and shall be

fastened by four stainless steel acorn head nuts or by six such nuts if over 1000 mm in any direction.

7.5.7 Gland Plate Openings

Gland plate openings shall be reinforced with 25 mm x 6 mm flat aluminium strips drilled and tapped with 6

mm holes.

Fixing holes for gland plates shall be spaced a maximum of 150 mm apart.

Openings shall be sealed with 25 mm wide neoprene gaskets glued to the switchboard.

7.5.8 Plinth

The switchboard shall have a 300 mm high plinth, constructed of 75 mm x 45 mm x 6 mm marine grade

aluminium angle that shall be securely bolted to the switchboard. All welds shall be ground smooth prior to

painting.

The plinth shall have external lugs for bolting to the floor and holes for inserting lifting bars.

7.5.9 Paint Treatment

Switchboard metalwork shall be degreased and cleaned with solvent prior to painting. Bare metal surfaces

exposed after welding or drilling shall be smoothed and treated with an iron phosphate coating.



The switchboard shall be coated with electro-statically applied polyester powder coating applied in

accordance with the paint manufacturer’s recommendations. The coating shall be uniformly applied with no

uneven build up or accumulation evident.

External and internal colours, unless specified otherwise, shall be as nominated in the schedule in the MCC

Technical Schedule. Equipment mounting plates shall be gloss white.

7.5.10 Cable Zones

Motor control centres shall be supplied with vertical cable zones adjacent to each tier, and with a horizontal

wiring enclosure running the length of the board. Adequate access shall be provided from each vertical zone

to the wiring enclosure.

Cable zones shall be adequately sized, of minimum internal width 450 mm, and shall be designed for ease of

installation and maintenance of cables. Where the MCC is top wired, cable tray shall be mounted over the

full length of all cable zones to allow fastening of cables.

7.5.11 Switchboard Compartments

Switchboard compartments shall have standardised width and depth and an interchangeable standardised

set of heights. Compartments shall be designed and sized for ease of access for maintenance.

7.5.12 Switchboard Modules

Module doors covering low voltage equipment shall have door interlocks which allow the door to be opened

only when the isolating switch/circuit breaker is in the off position. The isolating switch shall be padlockable

in the off position.

7.5.13 Distribution Boards

Compartments enclosing circuit breakers and distribution boards shall be fitted with a hinged metal

escutcheon mounted behind the compartment door, and the operating handles of the devices shall protrude

through holes in the escutcheon. The escutcheons shall be latched with acorn nuts, and the overall door

shall be equipped with non-lockable ‘T’ type handles.

Circuit breakers and isolators shall be padlockable in the off position. The padlock facilities shall not be

dependent on the position of the escutcheon, which shall be able to be opened with padlocks present.

Where the distribution board incoming circuit breaker or switch fuse is mounted on the escutcheon, the

escutcheon shall be interlocked so that it cannot be opened unless the incomer is in the off position.

7.5.14 Soft Starters

Soft Starters shall be capable of controlling the start and stop ramp rates to reduce the starting current and

prevent damage to the driven plant during starting and stopping.

The Soft Starter shall include a By-Pass contactor that switches the motor direct online when running at

rated speed, while retaining the motor protection on-line.



Supply, interconnection drawings and Soft-Starter setting lists, both of which shall be specific to the

application described in the technical schedule, shall be included. Note that generic copies of instruction

manuals do not meet this requirement.

Soft starter compartments shall provide the clearances around the equipment recommended by the supplier.

Cooling fans shall be provided to maintain 20% more than the suppliers required air flow through the

compartment.

Where soft starter has the facility for external heat sinks, then these shall be provided and shall protrude

through the rear of the compartment into a separate cooling vent. Cooling fans shall maintain airflow through

the vent.

Where soft starter does not have external heat sinks but requires cooling fans, then these shall draw air from

outside the switchboard and shall vent to the rear or top of the board. Cooling fans shall be mounted at the

inlet vent. Inlet and outlet vents shall not be in the module doors.

All inlet vents shall be filtered and filters shall be accessible for cleaning or replacement. Outlet vents shall

be bronze screened and louvered to direct air upwards.

7.5.15 RTU and Instrument Enclosures

Programmable Controllers and Instruments shall be located in a separate compartment.

Cooling fans shall be provided to maintain the manufacturer’s required air flow through the compartment if

required.

All cabinets containing RTU equipment shall have all terminations wired out to terminal strips located in the

panel below the equipment. Terminals shall be arranged in separate groups according to the I/O card

terminations with sufficient space provided between terminal strips to accommodate field wiring.

The proposed layout shall be as per layout drawings, where provided, or shall be shown on layout drawings

provided by the Switchboard Manufacturer for approval by Allconnex Water or their approved representative.

RTU connections shall be wired to the left side, or top side, of terminals with the right side, or bottom side, of

terminals being reserved for field or panel wiring. All installed I/O shall be wired out to the terminals.

The panel shall have sufficient spare space to accommodate a future backplane of similar size and

terminals.

Terminals shall be provided for Power Earths with separate terminals for Insulated instrument earths.

7.5.16 Sealing

Switchboards installed inside buildings shall be rated IP54 to AS60529. Switchboards installed external to

buildings shall be rated IP56 to AS60529 where possible. Switchboard modules shall be sealed to restrict arc

transmission in the event of a fault. Each phase of the connections between the busbars and the line side of

functional unit protective devices shall be individually supported and sealed to achieve better sealing, i.e. the



three phases shall not be brought through the same hole into the module. In addition, provision shall be

made for sealing switchboard modules after the installation of field cabling. Module cable entry points shall

be bushed to prevent cable damage.

7.5.17 Shrouding

All live parts (including terminals, busbars, and control devices and meters mounted on the doors) which are

behind hinged non interlocked doors or escutcheons and which carry a voltage higher than 110 V shall be

shrouded to IP20 with 5mm thick Lexan or equivalent clear rigid plastic covers to protect against accidental

contact when the enclosure doors or escutcheons are open.

The safety shield shall be attached using acorn nuts or approved equivalent. The shield shall have a label

attached warning of the hazardous voltages.

Where the safety shield dimensions exceed 610 mm x 610 mm the thickness shall be increased to 6 mm.

The standard test finger, as specified in AS 3100, shall be used to determine whether live metal can be

contacted by personnel.

7.5.18 Incoming Feeder

Where the size of the incoming feeder is specified, the Switchboard Manufacturer shall install busbar flags,

cable lugs and cable glands suitable for these cables in the incoming termination area. Otherwise the

Manufacturer’s Professional Engineer shall determine the cable sizes to suit the rated current carrying

capacity. Cable glands (including those for neutral and earth cable) shall be mounted on the incoming gland

plate suitable for the incoming circuit. The distance from cable lugs to the gland plate shall be a minimum of

300 mm.

7.5.19 Gland Plates

Removable single piece 6 mm thick aluminium gland plates of adequate dimension to accept glands for all

power and control circuits shall be provided for all incoming and outgoing cables. No single gland plate shall

be longer than 1000 mm. A 25% allowance for future cabling shall be made when sizing gland plates. Gland

plates shall be separately earthed with cable sized in accordance with AS 3439.1.

7.5.20 Equipment Mounting

No piece of equipment which is to be operated or viewed by an operator (i.e. pushbuttons, switches, meters)

shall be mounted more than 1800 mm or less than 500 mm above floor level. It shall not be necessary to

open any door, unless outer doors are provided to satisfy IP rating, or remove any cover to operate or reset

any piece of equipment.

No piece of equipment shall be mounted behind other equipment or in any manner denying free access for

removal or maintenance. All equipment within modules shall be mounted on equipment panels. Equipment

within small modules (less than 250 mm high opening) shall be mounted within 200 mm of the front of the

MCC to allow better access to terminals.



Control terminals shall be mounted so that the wire numbers on both sides of the terminal are readable from

the front of the switchboard with covers or doors open. Control terminals in Form 4 switchboards shall be

mounted in cable zones (not within the modules), within 150 mm of the front of the switchboard for easy

access.

Items of equipment or terminals shall be no closer than 300 mm measured vertically from outgoing gland

plates.

The manufacturer shall ensure that the equipment and devices are installed in such a manner that all

necessary electrical clearances are observed and that the rating accuracy of devices is not impaired either

thermally or electro-magnetically by the proximity of other devices or cables.

7.5.21 Spare Capacity

Spare space shall be provided in the MCC equivalent to 20% of the total space allocated to starter and

supply equipment/modules (excluding cable zones). This space shall be placed at one end of the MCC and

provision for future expansion, where specified, shall be allowed from this end of the MCC.

7.5.22 Switchboard Internal Wiring

The wiring of the switchboard shall be done in accordance with the construction details. Wiring shall comply

with AS 3000. All wiring shall be carried out in a neat and workmanlike manner.

Power and control schematics, general arrangements, equipment schedules, control system schematics,

interface wiring and wire numbering shall be as shown on the standard drawings, where available. The

Manufacturer may request these drawings where they have not been included. Where standard drawings are

not available the Manufacturer shall propose standard drawings for approval.

Wiring for protection and metering circuits within enclosures, and to equipment mounted externally on the

enclosure, shall be in phase coloured cables, PVC V75 0.6/1 kV grade copper cable, minimum size of 4.0

mm2, (50/0.25mm).

Control and Instrumentation wiring shall be minimum 1.5 mm2 (30/0.25) tinned flexible copper conductors.

Equipment with terminals that won’t take 1.5mm2 conductors may utilise 1.0mm2 copper to suit the capacity

of the equipment terminals.

Wires shall be colour coded as shown:

a) Phase Wiring (A, B & C) Red, White and Blue

b) Earth Green-Yellow

c) Voltmeter and Current transformer connections Red, White, Blue and Black

d) 240 V Control Active Grey

e) 240 V Control Active (isolated elsewhere) Orange

f) 240 V Neutral Black



g) ELV Positive Blue-Red

h) ELV Negative Blue-White

i) ELV Devices (e.g. thermistor) Brown

j) Instrumentation twisted pair positive White

k) Instrumentation twisted pair negative Black

l) Telemetry Violet

7.5.23 Wiring Duct and Strapping

Where wiring is not run on cable tray in cable zones, wires shall be run in slotted insulated wiring duct fitted

with a snap-on lid. The slots shall be of the “open” type so that it is possible to install or remove a wire

without threading it through a slot.

Ducts shall not to be filled to more than 75% of their full wiring capacity to allow additional wiring to be

accommodated in the future.

The arrangement of wiring in ducts shall comply with the segregation requirements of AS3000 i.e. low

voltage wiring such as the conductors within ‘Dekeron’ cable shall not be in the same wiring enclosure with

cables carrying a voltage higher than that for which the insulation is rated.

Where ducts are mounted upside down, wiring shall be tied/supported to prevent the duct lid being forced

open by the weight of wiring upon it.

Plastic duct or cable trays shall also be provided to accommodate incoming cable cores from the point of

cable entry, to the unit terminal block.

Where it is not practicable to run the wiring in ducts, wires shall be run in groups using cable wrap and

supported by cable ties at suitable intervals. It shall be possible for wiring to be added and withdrawn from

any portion of the group without disturbing the remainder.

Wiring looms shall be supported adequately by a suitable approved means.

7.5.24 Arrangement of Wiring Duct and Looms

Ducts shall be arranged to allow wiring passing through the slots to be taken as directly to the terminals as

possible. Access to terminal studs shall not be impeded by the ducts.

Ducts shall not interfere with the mounting of equipment on any surface and vice versa. Duct fixings shall not

have sharp projections inside the duct which could damage cable insulation. Nylon set screws or nylon dome

nut duct fixings are preferred.

The weight of wiring looms shall not cause any undue strain on the conductor strands or insulation. In

particular, where a wiring loom crosses a door joint, the loom shall be arranged so that flexing across the

hinge point is reduced to a minimum, and the wiring is firmly anchored on both sides.



All groups and bunches of wires shall be run on sections of the cubicle that are free from projections such as

small studs, etc., that may damage the conductor insulation. Where wires pass through holes in panels,

suitable bushes or plastic grommets shall be used.

7.5.25 Terminations and Connections

Control wiring terminations

Connections to external wiring, cables and auxiliaries shall be via designated terminals. Terminals shall be

large enough to accept 6 mm² cables as a minimum except as specified elsewhere.

All Analogue signal cables shall be terminated into proprietary type isolating link terminals (2.5 mm2

minimum size).

Control and instrument cable cores connected to tunnel-type terminals shall be terminated using a pre-

insulated pin lug and Grafoplast ‘TRASP’ (or equivalent) label carrier, of the correct size for the conductor.

The lug shall be crimped using a ratchet crimping tool prior to insertion into the terminal. Crimping shall not

be effected using the terminal screw alone.

Crimping lugs or pins shall be applied using an approved tool with a ratchet action. Separate lugs or pins

shall be used for each conductor. The size of the lug or pin shall be suited to the size of the conductor to be

terminated.

Lugs shall be of the type most suited to the device terminal e.g. fork tongue for stud terminals, and wire pin

type for tunnel type terminals. Only one wire shall be crimped in each terminal lug or pin.

All conductor strands shall be effectively crimped in the terminal lug. If strands are broken or separated

during conductor preparation, the termination shall be re-made. Conductor insulation shall end well inside

the lug insulation.

The Switchboard Manufacturer shall apply a pull test to each core of each cable (including terminated spare

cores) to verify that the core is properly crimped and is firmly held by the terminal.

There shall be no jointing or teeing of wires between terminals.

Not more than two wires shall be connected to any terminal. Not more than one wire shall be connected on

one side of any tunnel type terminal. Where multiple connections are required on tunnel terminals, multiple

terminals linked with proprietary terminal link bars shall be used. Only when more than one link is required,

will wire bridges be permitted.

Terminals shall be spade compression type. Screws shall not directly contact the conductors.

Terminals shall be generously spaced to provide easy access to the terminals of any circuit, and to prevent

accidental contact with live circuits in the same compartment. Terminals shall be numbered consecutively

from top to bottom and left to right.



7.5.26 Power Circuit Connections

All wiring shall be ferruled at both ends and on both sides of any terminals. The wire number shall

correspond to the relevant schematic diagram. GPO’s and lighting circuits shall be ferruled with their

respective circuit number. All neutrals shall also be ferruled with their respective circuit number.

Pump motor and power circuitry wiring from circuit breakers to external cabling terminals shall be 2.5 mm²

(7/0.67) nominal for 0-6 kW drives, and 10 mm² (7/1.35) nominal for 6-30 kW drives.

For pump motor cables larger than 10 mm2, the cables are to be connected direct to the thermal/electronic

overload.

The motor power cables shall be ferruled with cable numbers that identify the pump tag number and cable

function. Each phase on both the switchboard wiring at the terminals or isolating switches and on the pump

motor cable itself shall be labelled.

Mains cabling shall maintain double insulation for the entire length inside the switchboard until entry into the

metering section. The switchboard shall be designed so that ducting and routing of the mains cables are

segregated from other wiring in the cubicle.

Power cables within the switchboard shall be connected with a suitably sized lug unless the equipment

(circuit breaker or contactor) has tunnel type terminals.

Power circuit connections shall be made with high-tensile, electroplated steel or phosphor bronze bolts, with

a large flat washer and spring locking washer under the bolt head.

It shall be possible to check the tightness of all connections, by removing covers if necessary, when the

switchboard is completely assembled.

Provision shall be made in the termination area to allow circuits to be checked with clip-on type ammeters.

7.5.27 Numbering of Wires

‘Grafoplast’ ferrules as described above shall be fitted to each end of all separate lengths of control wire.

Ferrules shall have black letters on a background of white insulating material. Circular type, clip-on ferrules,

or saddle type clip-on numbers shall not be used.

The same ferrule number shall be used on wires forming connections directly in series or parallel in the same

panel.

Wires shall be numbered in accordance with the detailed design drawings. Wire numbers on wires which

leave the equipment module or cell, shall be prefixed with the equipment number.

Ferrules shall be arranged to read from left to right and from top to bottom.

Multi-core control cables shall not be used as combined power and control cable.



Wire numbers shall be fitted so that they can be changed without the need to remove the crimp lug. Ferrules

shall be used in accordance with the Preferred Equipment list.

All wire numbers, when in location shall read left to right, and or top to bottom, depending upon the

orientation of the termination.

7.5.28 Labelling

The switchboard and all modules shall be labelled with equipment number and title in accordance with the

Single Line Diagrams.

In addition every exterior and interior device, including terminals, terminal strips, fuses, switches, test blocks,

indication lamps, relays and other equipment, shall be identified by a label fixed near the device and oriented

so that it is readable from the appropriate access door. The label shall give both the device title or function

and a unique alphanumeric identification code.

All device labels, other than proprietary legend and escutcheon plates on devices, shall be engraved from

white/black/white formica laminated engraving material. The edges of the labels shall be bevelled. Labels

shall be fastened to the metalwork by threaded screws. External labelling is to be fixed by stainless steel

threaded. Labels shall be attached with a minimum of two stainless steel screws or stainless steel bolts.

Double sided adhesive tapes shall not be used. The use of dedicated adhesives will be considered provided

that approval is obtained in writing from Allconnex Water or their approved representative. Labels longer

than 30 mm shall have clearance fixing holes and shall have some freedom of movement, to allow

differential expansion of label and mounting. Where labels are mounted on standoffs they shall be suitably

backed to prevent breakage.

Label letter height shall be as follows:

a) Switchboard equipment number : 30mm

b) Switchboard title : 20 mm

c) Module labels : 10 mm

d) Equipment labels : 3.5 mm

Labels shall be designed to allow replacement without damage to the label or fixing.

A label list shall be submitted for approval prior to manufacture.

A main label shall be provided on the outside or door of each enclosure identifying the equipment.

A label shall be fitted to the external surface of the door that has the drawing holder for the schematics on

the inside stating that “Electrical Schematics Are Behind This Door”.



7.5.29 Warning Labels

Where specified or required by codes and/or acts that are enforced by Government Authorities having

jurisdiction over the work or the area where the equipment and/or components will be used, warning labels,

shall be fitted.

Warning labels shall be the standard material and format applicable to the location and industry.

Warning labels shall be fitted as a minimum in the following locations:

a) On safety shields;

b) On bolted covers; &

c) On hinged doors.

These labels shall:

a) Warn of voltages present;

b) State “Isolate before removing cover”;

c) Be warning signs; &

d) Be signs as required by the statutory legislation.

All removable covers and protective shrouds which give access to exposed busbars or live terminals shall be

labelled with red/white/red labels marked ‘DANGER 415V ISOLATE ELSEWHERE’.

Equipment connected to the line side of a switchboard incoming switch (e.g. Voltmeters, fire pumps) shall be

marked “DANGER - LINE SIDE CONNECTION - ISOLATE ELSEWHERE”.

7.5.30 Current Transformer (CT) Wiring

All CT secondary wiring, except motor CT wiring for motors under 30 kW, shall be connected to test links

which allow testing with banana plugs.

CTs for tariff metering on switchboard incoming supplies shall be connected to an ESAA test block as

detailed by the relevant electricity supply authority. The voltage connections shall also be made.

7.5.31 Drawing holder

With the exception of distribution boards, there shall be a drawing holder installed on the inside of one of the

doors of each enclosure. The holder shall be suitable to hold a full set of laminated A3 schematics.

Distribution boards shall have a removable circuit description label on the inside of the door. Where control

circuits are incorporated in the distribution board a drawing holder sized to accommodate A3 laminated

schematics shall be installed on the rear of the door. If there is insufficient space the circuit description label

and drawing holder may be incorporated.



7.6 Switchboard Equipment

7.6.1 General

The electrical equipment installed in the switchboard shall be new equipment complying with relevant

Australian Standards and be suitable for the duty indicated on the Approved for Construction drawings.

The equipment shall be installed so that it has the rating shown on the drawings when the switchboard is in

its fully operational and fully loaded condition i.e.: all covers and doors are closed, all circuits are at full load,

and ambient temperature is at maximum.

The equipment shall be installed strictly in accordance with the manufacturer’s instructions in all regards,

particularly concerning clearances, derating and enclosure sizes.

Equipment shall be securely mounted and braced so that movement cannot occur during operation under

normal or fault conditions and so that adjacent equipment is unaffected and personnel operating the

equipment are not endangered.

Equipment offered shall satisfy the following requirements:

a) The equipment shall meet the requirements of this specification;

b) Equipment selection shall be consistent i.e. all moulded case circuit breakers shall be from the one

manufacturer and all contactors shall be from the one manufacturer; &

c) Equipment co-ordination shall satisfy the requirements of this specification.

7.6.2 Moulded Case Circuit Breakers (MCCB’s)

Moulded case circuit breakers shall be tested by a recognised testing authority for compliance with AS 2184.

If this testing was not carried out within Australia, then a Certificate of Approval shall be provided from an

approved Australian Electrical Distribution Authority.

MCCBs shall have classification characteristics in accordance with AS 2184 and as detailed in the MCC

Technical Schedule.

Auxiliary contacts shall be provided to suit the requirements of the control circuitry.

MCCB’s used in motor power circuits shall be selected in accordance with the MCCB manufacturer’s

recommendations for the motor size. Instantaneous, magnetic only trip units may be used for motor power

circuits.

MCCB contacts shall have high resistance to welding with action designed to reduce wear.

MCCB switch mechanisms shall have a positive making/breaking action independent of the operating

handle.

MCCB poles shall operate simultaneously.



7.6.3 Motor Starters

Motor starters shall have been tested by a recognised testing authority for compliance with AS 60947 and

AS 3439. If this testing was not carried out within Australia, then a Certificate of Approval shall be provided

from an approved Australian Electrical Distribution Authority.

Motor starters shall have the following classification characteristics in:

a) Rated Frequency : 50 Hz

b) Rated Operating Voltage : 415 V ac

c) No. of Poles : 3

d) No. of Phases : 3

e) Interrupting Medium : Air

f) Control Method : Electrical

g) Type of Release : Thermal or electronic Overload

h) Rated Duty : Uninterrupted

i) Rated Operational Current : Motor FLC plus 20%

j) Utilisation Category : AC3

k) Mechanical Endurance : 10 Million operations

l) Electrical Endurance : 1 Million operations

m) Co-ordination with protective device : As per the MCC Technical Schedule

n) Rated Control Supply : As Per the MC Technical Schedule

o) Auxiliary Contacts : Minimum 1 N/O & 1 N/C

Contactors shall be of the block type with modular design suitable for vertical mounting. Mounting screws

shall be accessible from the front. The coil shall be easily removable and magnet surfaces accessible for

inspection and cleaning.

Thermal overload relays shall provide protection against single phasing.

7.6.4 Current Transformers (CTs)

Current transformers shall comply with the requirements of AS 60044 and shall have the following

characteristics in accordance with this standard:

a) Construction : Window

b) Number of Primary Turns : 1

c) System Voltage : 415 V

d) Rated Frequency : 50 Hz

e) Rated Primary Currents : Refer drawings



f) Rated Secondary Currents : 5 A

Additional Information - Measurement CTs:

a) Type : M

b) Accuracy Class : 1

c) Rated Burden : 0.6 ohms

d) Rated Output : 15 VA

Additional Information – Protection CTs:

Classification : P

Accuracy Limit Factor : 10

Composite Error : 2.5

Secondary Reference Voltage : 10

Polarity markings shall be marked on each CT along with other information as required by AS60044.

7.6.5 Indicating Lights

Indicating lights shall be low voltage transformer operated LED cluster type.

Colours shall be as indicated on the detailed design drawings.

7.6.6 Panel Meters

All meters shall be Q96 format, with 2% reading accuracy.

Ammeters for motors less than 22 kW may be Q72 format.

All ammeters shall be CT driven 5 A units.

7.6.7 Tools

The Switchboard Manufacturer shall supply any special tools necessary for the maintenance or operation of

the switchboard equipment.

If the switchboard includes air circuit breakers, then a lifting trolley for removing and transporting the circuit

breaker shall be supplied.

7.6.8 Testing and Resetting Facilities

Provision shall be made for the testing and resetting of protective devices where these devices are routinely

tested as required by the standards or the requirements of the applicable legislation.



Circuit breakers shall be able to be reset without opening an interlocked cover.

Adjustments or calibration to protection systems shall be accessible without exposure to live components.

7.7 Documentation

Switchboard manufacture shall not commence until the submitted items have been approved by Allconnex


7.7.1 Switchboard Construction Drawings

The Switchboard Manufacturer shall submit documentation which shows that switchboard construction

requirements are being met. This shall include:

a) Full construction drawings of the switchboards and MCCs being supplied. For switchboards, these

shall include busbar sizes, busbar support materials, spacing and centres, and phase centres as well

as sealing, hinging and fixing details for metalwork fabrication;

b) Full busbar and module construction drawings of the type tested switchboard; &

c) Switchboard layout drawings showing locations of all power and control equipment shown in the

schematic drawings as well as cabling and glanding areas.

Where switchboard general arrangement drawings are issued with this specification, the Switchboard

Manufacturer shall remain responsible for the design of the switchboard and shall produce the above

drawings.

The power and control circuit schematics shall be presented in A3 format, and shall conform in form and

symbols to Australian Standards and shall include equipment identification schedules.

7.7.2 Equipment Lists

Equipment lists shall detail the equipment type of every item of equipment installed in the switchboard. This

shall include all minor equipment such as control relays, lamps and terminals.

7.7.3 Label Lists

Label lists shall be provided for all labels and annunciation window engraving.



8. RTU AND TELEMETRY

8.1 General

This section covers the requirements for the provision of the instrumentation, control, monitoring, remote

telemetry unit (RTU), and the associated communications with the central SCADA system.

All necessary enclosures, mountings, antenna support structures, power supplies, batteries, hardware,

cabling, termination, RTU, radio, antenna, SCADA updates shall be provided to enable correct operation of

the WPS/SPS.

For a standard two-pump SPS, the RTU controls the pump operations via the soft starters when the site is in

Auto mode. The site can be placed in Manual mode for local pump operation. An analogue level transmitter

is the primary sensor for determining the well level and operating the pumps when in Auto mode.

For a standard two-pump SPS, a secondary level sensing arrangement, consisting of a back-up float switch

and Multitrode probe and relays, operates in the event the primary sensor and or the RTU fail while in Auto

mode.

The RTU transmits and receives control and monitoring data from the central SCADA system via the LCC

radio network. Operators are able to remotely monitor and control the site via the SCADA.

For a full description of the operational aspects of a standard WPS/SPS site refer to the “Allconnex Water

(Logan District) Sewer Pump Station Telemetry Specification”.

WPS are generally unique to each specific sites requirement and shall be designed as such. The intent of

the control philosophy for a standard SPS including pump control, instrumentation, indications, alarms,

telemetry, and SCADA mimics shall be followed as far as is practically possible. During the detailed design

consideration should be given to the WPS already installed in the Logan District area and use these as a

guide. As-constructed drawings of existing WPS sites are available on request from, and at the discretion of,

Allconnex Water.

8.2 Operational Conditions

The equipment supplied shall be rated to operate 24 hours a day, 365 days per year. The equipment should

be selected to provide a design life of 10 years minimum.

The equipment shall be designed to operate in the ambient and site conditions as specified in the service

conditions.

For thermal design purposes, still air conditions at the specified ambient temperature range and equipment and

cabling operating under maximum continuous load conditions shall be assumed. All switchboard openings shall

be dust proofed.

8.3 Instrumentation

The instrumentation shall be provided as required by the standard drawings. In summary the instrumentation

consists of:



a) Pressure based level transducer;

b) Multitrode probe;

c) Float switch; &

d) Panel indicators.

RTU & Radio

The RTU equipment and other associated equipment shall be suitable for interfacing to the soft starter where

specified. The extent of RTU equipment supplied shall be:

a) RTU modules including CPU;

b) Remote I/O modules;

c) Power supplies and backup batteries;

d) Radio; &

e) Antenna.

The RTU shall be provided via engagement of the Preferred Telemetry Contractor. A standard code set has

been produced by Allconnex and this is available for use via the Preferred Telemetry Contractor.

Any approved deviations from the two-pump standard design and operation that requires an alteration to the

standard RTU code shall be developed and provided as part of the detailed design.

The RTU shall be designed to communicate with the specified radio and soft starter and maintain a duplex

radio communication link with the remote site using the specified radio.

The radio survey shall be performed by the Preferred Telemetry Contractor. The antenna mounting shall be

designed and installed such that a fade margin of at least 20dB is achieved or as stipulated by the Preferred

Telemetry Contractor. The antenna mounting arrangement shall in general be in keeping with existing

Allconnex Water (Logan District) WPS/SPS sites.

Where a local antenna arrangement cannot be installed that meets the required fade margin a suitable

alternative arrangement shall be developed and implemented.

The RTU shall be designed to perform an orderly shutdown in the event of loss of supply. On return of

supply normal operation shall resume without manual intervention. Power supply to the RTU shall be as

specified on the standard WPS/SPS drawings.

8.4 SCADA

The site shall be incorporated into the central SCADA system. This work must be wholly undertaken by the

Preferred Telemetry Contractor.



9. ELECTRICAL INSTALLATION

9.1 Scope

This section details the minimum standards and requirements for the installation of electrical equipment and

instruments.

Prior to the transferring of assets to Allconnex Water, the Developer/Consultant shall provide Allconnex

Water or their approved representative all the necessary statutory compliance certificates for all major

electrical equipment and any machinery thereof (e.g. cranes, auxiliary hoist).

9.2 General

All materials supplied shall be new.

Cables, conduits, fittings and accessories shall be of approved type and manufacture.

All materials forming part of the electrical installation shall be carefully selected. Bare ferrous metal and

unprotected non-marine grade aluminium materials will not be accepted on any portion of the electrical

installation exposed to the environment.

The Electrical Installers attention is drawn to the possibility of galvanic action between dissimilar metals in

the specified environment. Where the use of the dissimilar metals exposed to the environment cannot be

avoided safeguards employed to minimise galvanic action shall be submitted for approval by Allconnex


The use of explosive powered fasteners in structural steel is not acceptable as a method of fixing unless

agreed to in writing by Allconnex Water.

9.3 Equipment Location

All equipment shall be installed in accordance with the Drawings and the Specifications. The position of

equipment installed and not accurately located on dimensioned drawings shall be subject to prior approval of

Allconnex Water.

9.4 MCC Installation

All MCC equipment and associated relay and control panels shall be installed strictly in accordance with the

Manufacturer’s recommendations and instructions.

Following final assembly, any minor damage to paintwork shall be restored to the satisfaction of Allconnex


9.5 Cables

Cables shall be specified in a cable schedule as part of the design drawings.

Power and control cables shall be circular, 0.6/1kV, copper conductor, PVC sheathed, PVC insulated, V75

type cables manufactured in accordance with the requirements of AS 3147, unless otherwise noted in the

cable schedule.



Cables for outdoor use shall be designed to prevent the effects of UV radiation. Cables that are subject to

the effects of UV radiation may be used provided that they are installed to prevent exposure of the cable

sheath to UV radiation.

9.5.1 Motor Cables

Motor cables shall be shielded and specially designed for variable speed drives with EMC cable glands

which provide 360 degrees (full circle) contact.

The Installer shall compensate for capacitive currents caused by the motor cable which shall include 20%

extra cable length to compensate for future changes in motor cable length.

Cabling must be carried out to prevent disturbance of sensitive circuits by EMC or RFI.

EMC and RFI noise testing shall be undertaken and checked against supplier Data Sheets. Where excessive

noise is detected, circuits shall be insulated by RFI filters.

9.6 Cable Installation

Cables shall be installed to manufacturer’s specifications. In particular, minimum bending radius shall be

adhered to.

Cables shall be installed as continuous lengths, without joints, unless prior permission is sought from

Allconnex Water their approved representative in writing. Approved cable joints shall be carried out using

two-part epoxy termination kits or heat shrink termination kits, and shall be weatherproof.

Cable ends shall be sealed in an approved manner on completion of laying or installation.

Unless prior approval is sought, large cables shall be run on vertical and horizontal rollers while drawn into

place. Sufficient rollers shall be employed to keep the cable clear of the ground or other obstructions.

Any damage to cables (including the sheathing) shall be reported immediately to the Site Supervisor before

work on the cable installation continues.

Cables shall be routed and terminated in such a manner that allows sufficient length for a re-termination.

Where cable winches are used they shall have automatic tension control. Steel mesh stocking grips shall be

used to attach cables to winch ropes. No cable shall be subjected to tension which exceeds the limit

specified by the manufacturer.

No cable shall be exposed to substances or chemicals that could or will damage the cable.

Plastic cables shall not be allowed to come into contact with grease, oil, petrol or any other petroleum-based

substance. Only lubricants that do not damage cable sheathing shall be employed, and then only when

approved by Allconnex Water or their approved representative. Materials data safety sheets shall be

supplied and approved for all lubricants.



9.6.1 Cables on Cable Ladder

Cables shall be fixed to every rung of vertical runs and to at least every fourth rung on horizontal runs. Fixing

of cables shall be by 100% UV retardant nylon cable ties.

Minimum cable tie width shall be 6.5mm. Ties shall not be series connected to increase length - appropriate

length ties shall be used.

Cable clamps shall be installed every 20 metres of vertical run to relieve tension on the cables. Clamps shall

be installed in a manner that does not allow a magnetic circuit to be maintained thorough the supporting

steelwork forming part of the clamp.

Power cables shall be spaced to achieve maximum rating. Single core cables shall be installed in a trefoil

formation and spaced one cable diameter apart from other cables or groups of trefoils.

9.7 Cable Trenches

Where cable trenches are required, the Installer shall provide all equipment, material and labour to carry out

trenching.

The Installer shall obtain excavation permits as required under site procedures prior to commencement of

any excavations. Particular care shall be taken to avoid disturbing existing services during excavation.

Unless noted otherwise in the documentation, low voltage cables shall be provided with a minimum cover of

600mm.

The trench shall incorporate protective covers and warning strip. Warning strip shall be laid at a depth no

greater than 300mm. In areas subject to vehicular traffic, trenches shall be backfilled in 150mm layers to

achieve sufficient compaction

The Installer shall not backfill any trench until Allconnex Water or their approved representative has

approved the installation.

9.8 Cable Ladder

The Installer shall supply and install all cable ladder, cable tray and conduit needed to support cables

installed.

The Installer shall supply all necessary items required for the construction of the cable ladder (i.e. fishplates,

bends, tee-pieces, nuts and bolts, etc).

The Installer shall supply all scaffolding necessary for the installation and shall ensure that the installation

does not interfere with other equipment or services.

9.8.1 Cable Ladder Types

Cable ladders shall be heavy-duty construction to NEMA 20 standard with rungs welded to the sidewalls.

Rungs shall be spaced at 300mm intervals.



Sufficient supports shall be provided for the ladder such that a deflection no greater than 1/300 of the span

length exists when the ladder is fully loaded with cables.

Where aluminium cable ladder is specified, all ladders, tray and fittings shall be constructed from marine

grade (6061) aluminium. Nuts and bolts shall be stainless steel grade 316, and shall be separated from

aluminium components by insulating spacers to prevent electrochemical corrosion.

9.8.2 Cable Ladder Installation

Cable ladder shall be installed so that it is electrically, mechanically and structurally continuous. Piecemeal

ladder installation shall not be installed unless approved by Allconnex Water or their approved

representative.

Unless specified otherwise, cable ladder supports shall be fabricated from mild steel and hot-dip galvanised,

and shall be bolted or welded to building structures. Electroplated fasteners shall not be used.

Damage to galvanised coatings is to be repaired using an approved zinc-rich protective paint.

9.8.3 Cable Ladder Earthing

All metallic equipment shall be bonded to earth with a 120mm² copper PVC sheathed earth cable at

substation exit points. Where NEMA 20C cable ladder is installed, the cable ladder shall act as the earthing

conductor and a separate 120mm² earth cable is not required. Wherever discontinuous cable ladder runs are

permitted, a 120mm² earth cable shall be installed between the cable ladder sections to continue the

earthing system.

At least one end of each cable ladder system shall be connected to the earth grid at the nearest available

substation or MCC earth bar via 120mm2 green/yellow PVC covered cable.

The Installer shall supply and install 50mm² PVC earth cable ladder earth continuity bonds at all splice plate

connections along cable ladder routes. Expansion joints shall be treated as discontinuous cable ladder and

hence a 120mm2 earth cable shall be installed between the cable ladder sections.

Following installation, each cable ladder shall be tested to ensure the total earth resistance at any point is

below 2 ohms to the nearest substation.

Consideration must be given to the possibility of induction from unshielded HV conductors running parallel to

any cable tray.

9.8.4 Cable Ladder Covers

Covers shall be installed on cable ladder where cables are exposed to sunlight or mechanical damage.

Where ladder is run vertically, the cover shall be attached to the side where cables are most exposed to

sunlight or likely mechanical damage.

Covers on horizontal cable ladder runs shall be peaked. Vertical runs may have flat covers.



Horizontal cable ladder runs susceptible to mechanical or liquid/chemical damage or to filling with dust shall

be fitted with heavy-duty (2.5 mm thick) hot dipped galvanised steel covers.

9.9 Conduit Systems

Conduit system for cable support and protection shall be supplied and installed.

Conduit systems shall equal or exceed the IP rating of any enclosure(s) they penetrate and if necessary shall

employ a cable gland where the cable exits the conduit systems.

All ends and joints in steel conduits shall be finished in accordance with AS3000, using the correct fittings

and bushes for cable protection. All threads shall be coated with an anti-seize compound prior to assembly.

Cut ends of conduit shall be filed smooth before installation of cable and shall be PVC bushed.

Rigid steel and PVC conduits shall be supported by double sided saddles fixed with hot dipped galvanised or

stainless steel fasteners. Electroplated fasteners shall not be used. Double sided saddles, exposed to the

weather or located in harsh environments shall be manufactured form stainless steel or galvanised.

Damage to galvanised coatings shall be repaired using an approved zinc rich protective paint. (Refer to

Painting Section).

9.9.1 Conduits for Unarmoured Cable

Conduits exposed to direct sunlight or possible mechanical damage shall be manufactured from heavy-duty

hot-dip galvanised steel complying with AS2052.

All other conduits may be manufactured from heavy-duty rigid orange PVC complying with AS2053. PVC

conduits shall only be used above ground with Allconnex Water or their representative’s approval.

A standard weatherproof cable gland termination shall be installed in the end of the conduit, and a shroud

shall be installed over the conduit and cable gland and secured with cable ties. A flexible armoured steel

conduit (‘Anaconda’ or approved equivalent) shall be used between local control stations and motors.

Unarmoured fragile cables, such as instrumentation and coaxial cables, shall be enclosed in a continuous

run of steel or flexible armoured conduit throughout their length. Final connection to the field device shall be

made using flexible armoured conduit.

9.9.2 Conduits for Underground (buried) Cables

Conduits buried directly, laid under or in concrete shall be deemed underground conduits.

Low voltage underground conduits shall be heavy-duty rigid UPVC conduits to AS2053 installed as a

Category A system in accordance with AS3000.

All conduit bends shall be large radius type.

All PVC conduit joints shall be made with a compatible waterproof PVC adhesive.



The ends of all conduits shall be sealed with PVC or steel end caps to prevent the ingress of concrete, water

or other foreign material during the ensuing period prior to cables being installed.

Conduits installed in concrete shall be positioned such that the conduits are not damaged during the

placement of the concrete or by settlement or movement during or after curing of the concrete.

Conduits cast in or penetrating through concrete floor slabs shall terminate at least 100mm above the

finished concrete level.

Flexible conduits shall not be installed as underground conduits.

Two appropriately sized draw cords shall be installed in all unfilled conduits.

9.9.3 Flexible Conduits

Flexible conduit shall be used for conduit runs from cable ladders or fixed conduits to items of equipment.

Flexible conduits shall be of PVC sheathed, spiral wound, galvanised steel, or plastic construction (e.g.

‘Anaconda’ or ‘Rhinoflex’).

Corrugated conduit may only be considered where installation of conduits are to be in concrete.

Terminators shall be manufactured from galvanised steel or nickel-plated brass with captive O-ring seals,

metric conduit threads and plastic bushings.

The flexible conduit system shall provide a degree of protection to at least IP56.

9.10 Cable Terminations

All cables installed shall be terminated using cable glands, lugs and fittings of the correct size and type. The

Installer shall supply all glands, lugs and fittings.

9.10.1 Terminals

All conductors shall be terminated in terminals suitably sized for the cross sectional area of the conductors.

Terminals shall be as per the Preferred Equipment List.

Terminals shall be designed for conductors of nominal size 4mm2. Terminals designed for smaller

conductors shall only be used with Allconnex Water or their approved representative’s written approval.

Symmetrical or asymmetrical mounting rail types may be used. If symmetrical terminals are used, the open

side of the terminal block shall be on the left or the top.

Terminals shall be marked with proprietary numbering systems.

End plates, dividers and end blocks shall be provided and selected to match the terminal type.

9.10.2 Cable Glands

All cable entries to equipment shall be made through cable glands that maintain the IP rating of the

equipment entered. Cable glands shall be of V75 PVC, nylon or nickel-plated brass construction as



appropriate to the environmental conditions specified in the Service Conditions and the cable type installed

specified in the cable schedule.

Glands used in outdoors locations shall be fitted with a shroud of the correct size. The shroud shall be

attached to the gland with cable ties. All gland threads shall be coated with anti-seize compound before

assembly.

9.10.3 Cable Lugs

All lugs shall be made from tinned copper. The Installer shall only use compression tools that are approved

by manufacturer of the lugs. Indent type crimping devices shall not be used.

Where compression tools are used, hexagonal crimping dyes shall be employed on all cables of 16 mm2

cross-section and above.

Suitably sized lugs shall be used to connect all power cables to equipment such as circuit breakers,

contactors, etc., unless the device has tunnel type terminals and the conductor size is greater than 2.5mm2.

Lugs shall be of the type most suited to the device terminal e.g. fork tongue for stud terminals, and wire pin

type for tunnel type terminals. Only one wire shall be crimped in each terminal lug or pin.

The Installer shall apply a pull test to each core of each cable (including terminated spare cores) to verify

that the core is properly crimped and is firmly held by the terminal.

9.10.4 LV Cable Terminations

Low voltage power cable terminations and joints shall employ crimp type cable lugs or links suitable for

bolting connections.

Lugged power circuit connections shall be made with high-tensile, electroplated steel or stainless steel bolts,

with a large flat washer and spring locking washer under the nut.

Power connections shall be tested for tightness, once all connections have been made.

Allowance shall be made at the termination to facilitate the attachment of a clip-on ammeter.

9.10.5 Termination of Control and Instrument Cables

Where the cable is to be connected to tunnel-type terminals, one-piece pin lugs shall be used to terminate

control and instruments cables.

Where the terminal requires ring or fork lugs, pre-insulated lugs and full circle (not clip-on) label carriers shall

be applied.

The Installer shall terminate every core in every control and instrument cable in switchboards and local

control stations, unless specifically indicated otherwise on termination drawings.



The Installer shall ensure that all instrument cables are terminated correctly by crimping a single core into the

pin connector, with an approved ratchet crimp tool, terminating the pin, and then applying tension between

the cable and termination to confirm the integrity of the connection.

Signal screens shall be made continuous from the instrument destination back to the origin of the signal

cable. One end of signal screens shall be terminated to earth by the site preferred method at a common

point at the supply source.

In addition, the requirements from Terminations and Connections shall apply.

9.10.6 Termination at Switchboards and Enclosures

Where cables are terminated in switchboards and other similar enclosures, the Installer shall ensure that the

arrangement of wiring in ducts within the switchboards complies with the segregation requirements of AS

3000. For example, low voltage wiring shall not be installed in the same enclosure as a cable or cables rated

a voltage lower than 110VAC.

The Electrical Installer shall supply the necessary barriers to provide segregation.

9.10.7 Termination of Earth Cables

All earth cables shall be terminated on a copper bus bar, a rail mount terminal connected to the earthed rail

or an equipment earth terminal.

Only one earth cable shall be terminated on any one terminal.

9.11 Cable Identification

All control and instrument cables shall be ferruled with wire numbers that correspond with the relevant

termination diagrams and drawings.

Where two wires to different devices with the same number terminate in the same location, the Installer shall

distinguish between the two by attaching a prefix to each ferrule. This prefix shall be the equipment number

of the device to which the wire runs to. This prefix shall be used whether or not it is shown on the drawings.

Ferrules shall be visible without disturbing the wiring.

9.11.1 Cable Number Tags

All cables shall be identified at both ends and in cable pits with allocated cable numbers. Cable number

markers shall be stainless steel cable markers attached to carrier strips fastened to the cable with 100% UV

retardant nylon cable ties or with stainless steel cable ties as appropriate to the environment conditions

specified.

At switchboards and other places where both sides of a cable gland plate cannot be viewed from the one

location, cable number tags shall be fitted to cables both above and below the gland plate.



9.12 Cable Penetration

On completion of the installation, all holes in floors and walls and all cable pipes through which cables,

conduits or cableways pass shall be sealed to prevent entry of moisture and corrosive gases.

Cable penetrations into buildings, equipment enclosures and cable sumps (except by cable gland) shall be

sealed from both sides at the completion of cable installation with an approved sealing compound to

maintain the integrity of the dust and water IP rating of the enclosure penetrated. The compound shall be of

a type that is easily drilled and tooled to enable cable additions with minimal repairs to existing sealing.

Expanding foam shall not be used.

Cable conduits shall be sealed from both ends at the completion of cable installation with an approved

sealing compound to exclude water.

9.13 Power Phasing

Single core power cables shall be colour-coded red, white and blue with approved sleeving to represent

phase colours.

Power cables shall be connected so that colour marked phases in switchboards, motor control centres,

distribution boards and cables are in R, W, B clockwise phase throughout the plant.

Phase reversal for direction changing of motors shall only be performed at the motor terminal box.

9.14 Enclosures

Enclosures include panels, cabinets, switchboards, MCCs, distribution boards and the like, whether

constructed of metal, plastic or fibre glass, which contain electrical, instrumentation or data cables and/or

equipment.

Enclosures shall be installed in the locations shown on the drawings.

Where enclosures are installed over cable trenches or floor slots and do not completely cover the opening,

the Electrical Installer shall supply approved covers cut into convenient lengths and incorporating lifting slots.

Enclosures installed in outdoor locations shall be bottom entry unless otherwise approved by Allconnex

Water.

9.14.1 Junction Boxes

Junction boxes shall be heavy duty and weatherproof, and shall be constructed from grade 316 stainless

steel.

Lids of all junction boxes shall be heavy duty and fitted with gaskets. All boxes shall have a minimum degree

of protection of IP56.



9.14.2 Local Control Stations

Local Control Stations (LCS's) where shown on drawing shall be installed as close to the motor as

practicable. In no case shall the distance from the LCS to the motor exceed five metres unless specifically

stated on layout drawings attached to this specification. In all cases, the LCS shall be visible from the motor.

Where LCS's require pedestal mounting, the support column shall be manufactured from 75x25mm PFC and

have a 250x250mm base plate with four mounting holes. The column shall be hot dipped galvanised. The

height of the column shall be such that the base of the LCS is approximately 1200mm from the base plate

level. The column shall be raised by 50mm of grout to prevent the collection of water around the base plate.

9.15 Lighting and Small Power

All lighting fittings, switches, general purpose outlets and three phase outlets shall be installed generally in

the positions shown on the relevant drawings or as directed by Allconnex Water or their approved

representative.

9.15.1 Operating Conditions

Field equipment shall be of dust and hose-proof construction to IP56 classification installed to withstand the

ingress of weather and dust.

9.15.2 Supply System

Lighting fittings and power outlets shall be suitable for connection on a 240 volt or 415 volt 50 Hz supply.

9.15.3 Light Fittings

Lighting fittings shall be of robust construction to ensure adequate strength and rigidity. The fitting shall be of

polycarbonate, stainless steel or marine grade aluminium construction.

Each fitting shall have an individual ballast and power factor correction capacitor in a weatherproof/dustproof

housing and each control unit shall be individually protected by a HRC fuse or circuit breaker.

Light fittings shall be of the type specified.

Where installed emergency fluorescent fittings shall be fitted with integral emergency battery packs.

9.15.4 Mounting of Lighting Fittings

The exact location of the light fittings shall be subject to variation from the positions shown on the drawings

prior to the actual installation of the fittings.

The Installer shall confirm final locations with respect to structures, plant and equipment and ensure that

adequate access is available for operation and maintenance without affecting personnel safety. The Installer

shall also ensure that the location is free from plant vibration, or take steps to provide anti-vibration mounts.



Light fittings shall be erected and fixed in such a manner that the whole lighting unit can be readily

unscrewed and replaced. The fittings shall be jig positioned so that similar fittings and their fixings may be

interchanged.

Where required, galvanised steel mounting plates, suspension supports, frames, brackets, etc., shall be

supplied and erected by the Installer.

The Installer shall thoroughly clean all light fittings, reflectors and associated glassware and be responsible

for the replacement of all faulty lamps, tubes, ballasts, starter switches, broken fittings etc. before hand over

of the completed electrical installation.

9.15.5 Lighting Switches

Each switch or group of switches shall bear an engraved stainless steel label, fixed by screws, and detailing

the distribution board circuit to which it is connected.

9.15.6 Remote Control of Lighting Fittings

Where lighting fittings are to be from a “controlled circuit” they shall be switched by contactors. The

contactors shall operate from a 240 volts 50 Hz supply. They shall be rated to switch 125% of the starting

current of the connected lighting load. Contactors shall be operated from a PE cell with an

“Auto/Off/Override” selector switch.

9.15.7 General Purpose and Welding Outlets

General purpose and welding outlets shall be supplied and installed as required by the detailed design.

General purpose outlets shall be mounted at a height of 400mm above finished floor level unless noted

otherwise on drawings.

Welding outlets shall be mounted at a height of 1200mm above finished floor level unless noted otherwise on

drawings.

Each external general purpose and welding outlet shall bear an engraved stainless steel label, fixed by

screws, and detailing the distribution board circuit to which it is connected. Internal outlets shall bear an

engraved W-B-W laminated plastic label.

All outlets shall be heavy duty, high impact polycarbonate weatherproof industrial type. General purpose

outlets shall be switch plug receptacles. Welding outlets shall be high impact switch plug receptacles.

9.15.8 Wiring of Lighting and General Power

Wiring shall be via multicore cable utilising minimum conductor size of 2.5 mm2.

Where necessary, small junction boxes may be used for connection to light fittings and outlets. Junction

boxes so used shall incorporate tunnel terminals as appropriate for the application. Floating or blue point

connectors shall not be used.



Light fittings shall not be used as a cable way i.e. the removal of one light fitting shall not necessitate the

removal of supply to subsequent fittings.

9.15.9 Lighting and Power Distribution Boards

Distribution boards shall be metal clad, suitable for wall mounting or floor mounting depending on size in

accordance with the requirements of this document.

Each board shall be complete with a suitably rated isolating switch, together with the required number of

poles plus 20% spare spaces. Isolating switches shall be interlocked to the escutcheon so as to allow the

escutcheon to be opened only in the "Off" position or by use of a tool.

Each outgoing circuit shall be labelled.

Each circuit breaker shall be padlockable in the off position.

9.16 Instrumentation

Instruments shall be handled with the utmost care at all times and only installed in the manner specified by

the manufacturer.

Calibration and configuration of instruments shall only be carried out in strict accordance to the

manufacturer’s instructions. Thorough checks shall be made to ensure all shipping fasteners and foreign

materials are removed prior to operation of the instrument.

Mounting brackets and fasteners shall be manufactured from 316 stainless steel. Where necessary, the

Installer shall provide guards or protective barriers to prevent physical damage to field instruments and

devices.

9.17 Fixing to Structural Steelwork

Structural members shall not be cut, drilled, welded or otherwise modified without the written permission of

Allconnex Water or their approved representative prior to the start of work.

Installers shall ensure that any process shall not reduce the mechanical strength of any structural member.

9.18 Signs

The Electrical Installer shall mount all signs listed in the particular Specification and/or required by Statutory

Authorities, Acts and Regulations.

In general, signs will be located on main earth connections, transformers, fences and gates, service routes

and large items of equipment.

Signs shall be mounted with a 6mm nickel plated bolt, washer, lockwasher and nut at each corner.

9.19 Labels

All equipment installed shall have a high visibility label attached to a non-detachable part. Colours shall be

permanent and free from fading.



All designation labels shall be engraved with black lettering on a white background and each shall be of an

approved size and material.

Labels used in outdoor locations shall be non-fading and of a weather resistant material.

Labels shall be affixed to equipment as detailed in this specification.

All apparatus shall have fitted to non-detachable parts of equipment conspicuous labels conforming with the

following requirements:

Equipment Type of label Function

Pushbutton Engraved W-B-W laminated plastic

Circuit and identification

Junction boxes distribution boards and miscellaneous components

Engraved W-B-W laminated plastic

Component and circuit identification as applicable

Power, Control and instrumentation cable cores

Ferrules with black lettering on white background

Core number on connection diagrams

Cable number tags Stainless Steel Cable number as on cable schedule

General Purpose Outlets light switches

Engraved: W-B-W laminated plastic, if indoors. Stainless Steel, if outdoors.

Board of origin, fuse or circuit breaker number

Fuses / MCB's Engraved W-B-W laminated plastic

Circuit and rating

9.20 Earthing

All portions of the installation shall be considered an “Earthed Situation” as defined in AS 3000. Earth

conductor size shall be as specified in AS3000, and in the applicable regulations.

All electrical equipment shall be earthed by copper conductor connections to the local earth bar. The

Electrical Installer shall connect frames of switchgear and equipment supplied by others to the earth system.

Unless specified otherwise, a separate earthing system shall be installed for instrumentation.

The Electrical Installer shall be responsible for the earthing of all equipment supplied and installed and for

the bonding and earthing of cable armour and sheaths, metallic switchyard enclosure fencing and gates,

exposed steelwork, steel tanks, concrete reinforcing bars and all other equipment.

Earthing of structural metalwork shall be by terminating the earth conductor to suitable flags welded to the

metalwork. Exposed connections between earthing conductors and structural metalwork shall be painted.

The paint shall be the same as adjacent paintwork. Structural metalwork shall not be drilled for the

termination of earthing conductors without Allconnex Water or their approved representative’s written

approval.



9.20.1 Protective Earth Connections

Earth connections to items of electrical equipment shall be made via either the earthing conductor of the

power supply cable or by a separately installed earthing conductor. This earth conductor shall be connected

to the local panel earth.

Earthing conductors shall be insulated and coloured yellow/green.

Removable or hinged metal parts of electrical equipment that carry wired electrical items shall be bonded

using a suitable flexible earth wire or braid. Where gaskets are installed, care must be taken to ensure that

all metal sections are earthed.

9.20.2 Equipotential bonding

In addition to the protective earthing conductor connections, large items of electrical equipment shall be

equipotentially bonded to adjacent structural steelwork.

When installing equipment, make good electrical connection between each chassis, back-panel and

enclosure through each mounting bolt or stud. Wherever contact is made, unpainted galvanised metal shall

be used. Paint or other non-conductive finish shall be removed from around studs or tapped holes. Bond

metal parts of chassis, assemblies, frames, shields and enclosures to reduce the effects of EMI and ground

noise. When connecting metal parts, large surface area conductors such as wide braided straps shall be

used. Observe any additional bonding conductors specified by the manufacturer. The door of the enclosure

shall be bonded to the enclosure by suitable means - for example, by wide braided bonding straps (minimum

3x per door).

9.21 Painting

All steelwork supplied, installed or modified by the Installer shall be thoroughly cleaned (free of rust and

grease) and painted with a self-etching, anti-corrosive primer undercoat and one coat of high-grade enamel

exterior paint.

The Electrical Installer shall ensure any paintwork damaged during installation is restored to its original

condition, with surface finishes of the approved colours.

All areas of galvanising damaged (by welding, penetration or other means) during installation shall be

repaired by ‘Galmet’ or approved equivalent paint applied strictly in accordance with the manufacturer’s

instructions and over coated with silver sheen enamel.



10. TESTING AND COMMISSIONING

10.1 Scope

Testing and commissioning shall be in accordance with the requirements of documents Standard

Specification for Sewer Pump Station (7690-005-S-SPE-PM-9001) and Standard Specification for Water

Pump Station (7690-005-W-SPE-PM-9001). The tests described in this section are in addition.

10.2 Works Inspection and Testing

10.2.1 Works Testing

Witnessed works testing is required for measuring equipment and electrical switchboards, control panels and

soft starters. Allconnex Water and/or their approved representative reserves the right not to witness the

testing of any of this equipment and request in its place calibration certificates and/or test results.

Certified test reports and test certificates must be forwarded to Allconnex Water or their approved

representative. All MCCs, electrical switchboards and control panels must be tested in Australia. Provide

type test certificates for the Main Switchboards and motor control centres. The switchboards must be type

tested to AS3439.1 or AS1136 by an NATA accredited equivalent.

A NATA accredited testing facility must be used to carry out all flow meter and other measuring instrument

tests and calibration and provide test and certification for each item of instrumentation.

10.2.2 Factory Inspection and Testing of MCCs and Switchboards

Factory Inspections

Each MCC will be inspected by Allconnex Water or their approved representative during manufacture and

prior to delivery. The following are specific milestones for witnessed inspection:

a) First inspection - metalwork finished (prior to painting);

b) Second inspection - metalwork finished and painted;

c) Third inspection - all electrical equipment installed; &

d) Final inspection.

Inspections, other than the final inspection, are intended to maintain constructional standards and are not

intended, unless otherwise arranged, as functional tests, therefore the manufacture of the MCCs must not

cease during these inspections.

The Switchboard Manufacturer shall notify Allconnex Water or their approved representative at least seven

(7) working days before each inspection is required. Where additional inspections to those listed above are

requested by Allconnex Water or their approved representative, the Manufacturer shall make arrangements

to accommodate these inspections.



Factory Testing

Testing as specified shall be performed during the final inspection. All tests shall comply with the

requirements of AS3439.1. The Switchboard Manufacturer shall perform the following tests as a minimum for

each MCC as part of the final inspection:

a) Visual inspection, equipment mounting and wiring termination checks;

b) Labelling is complete and correct;

c) Insulation tests before and after power (high pot) tests, including each phase to earth, each phase to

neutral, between phases using a minimum of 1000 V Megger insulation tester;

d) Power tests (high pot) with ac voltage of 2.5 kV;

e) Operational test of all protective devices; &

f) Simulated functional tests for all soft-starters and electrical equipment in manual mode and in

automatic mode where applicable (Local and PLC control).

The following tests shall be completed by the Switchboard Manufacturer prior to final testing:

a) Point to point tests of all wiring. This must be documented, preferably in the form of a set of drawings

marked off and signed;

b) Wire colours, sizes and numbering are correct; &

c) All connections tightened as per specifications and Australian Standards.

Random tests will be undertaken by Allconnex Water or their approved representative to confirm the

accuracy and completeness the works.

Test Certificates

Following completion of all tests, a full set of test certificates and test records for each MCC and switchboard

shall be submitted to Allconnex Water or their approved representative.



Appendix A Technical Schedule – Metal Clad MCC



Revision A Date Client Allconnex Project

Switchboard and MCC Name

Criteria Specification Offered

Site Climatic Conditions

- Ambient Air Temperature : Maximum 45 º C

- Ambient Air Temperature 24 Hr Average 40 º C

- Relative Humidity 100% at 25 º C

- Pollution Degree 3

Supply System Conditions

- High Voltage State

- Low Voltage 415 V +10% -6%, 3 ph, 4 wire

- Frequency 50 Hz ± 2%

- Voltage Unbalance < 5%

- LV Supply star point Neutral solidly earthed

- Single Phase Power Supplies 240 VAC

- Control Power Supplies 240 VAC or 24VDC, Neutral earthed

Electrical Characteristics

- Type Test Certificate Required Yes

- Co-ordination State

- Rated Current State

- Short Time Current State

- Fault Protection O/C

- Motor Protection < 11kW Thermal Overload/ Soft Start

- Motor Protection >= 11kW Soft Start

Construction

- Form of Internal Separation Form 4a

- Degree of Protection IP56

- Location Outdoor



- Arc Containment Partial

- Configuration State

- Access Front only

- Cable Entry Bottom

- Extendable Bus Bars No

- Bus Tie No

- Transfer Switch State

- Free Standing Yes

- Stationary Yes

- Material of Construction Marine Grade Aluminium / 316 Stainless Steel

- Protective Finish Brushed / Powder Coated

- External Colour Mist Green

- Internal Colour White

- Dimensions (H x W X D) State

- Weight (Kg) State

- Ventilation As per standard drawings

- Heat sink access As per standard drawings

- Heat shielding As per standard drawings

- Weather proof work area (sun/rain shield) As per standard drawings



1A. MAIN CIRCUIT BREAKER

- manufacturer Refer to Preferred Equipment List

- type State

- rating State

- protection relay State

- other devices State

1B. PUMP CIRCUIT BREAKER

- manufacturer Refer to Preferred Equipment List

- type State

- rating State

- protection relay State

- other devices State

2. BUSBARS (information required for each MCC)

Rated current:

- Incomer bars A State

- main bars A State

- droppers A State

Size:

- incomer bars mm x mm State

- main bars mm x mm State

- droppers mm x mm State

3. MOTOR STARTERS

3.1.1 Type As per drawings



Appendix B Technical Schedule - RTU



Revision A Date Client Allconnex Project

RTU Name


Site climatic conditions

- Ambient Air Temperature: Maximum / Minimum

45˚ C / 0˚ C

- Ambient Air Temperature: 24 Hr Average

40˚ C

- Relative humidity 5% to 95%, non-condensing

- Altitude Sea Level

- Pollution degree 2

Electrical supply

- PLC: Voltage / Frequency 240 VAC / 50 Hz ± 2%

- RTU: Voltage / Frequency 240 VAC / 50 Hz ± 2%

RTU

- Manufacturer Refer to Preferred Equipment List

- Type State

- CPUs and Quantity State

- Remote programming software for configuration of RTU

State

- Power Supply Module State

- Power Supply Plug Pack State

- Battery State

- Battery Bracket State

- Network Communications modules

State

- RTU to SCADA communications module

State

- RTU Programming Software Licences

State




Digital input

- Type State

- No of channels per card State

- No of Input cards State

- Pre terminated cable length State

Digital output

- Type State

- No of channels per Output card State

- No of Output cards State

- Pre terminated cable length State

Communications

Digital radio

- Type Refer to Preferred Equipment List

- Antenna State

Physical installation

- Backplane for installation into switchboard

State



Appendix C Standard SPS Drawings (including Preferred Equipment List)

Documents

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