Engineering

Technical Standard

TS 0300 Supply and

Installation of Low Voltage
Equipment

Version: 4.0
Date: 26 Aug 2022
Status: FINAL

Document ID: SAWS-ENG-0300

© 2022 SA Water Corporation. All rights reserved. This document may contain
confidential information of SA Water Corporation. Disclosure or dissemination to
unauthorised individuals is strictly prohibited. Uncontrolled when printed or
downloaded.
TS 0300 Supply and Installation of Low Voltage Equipment SA Water - Technical Standard

Copyright
This Technical Standard remains intellectual property of the South Australian Water
Corporation. It is copyright and all rights are reserved by SA Water. No part may be
reproduced, copied or transmitted in any form or by any means without the express
written permission of SA Water.
The information contained in this Standard is strictly for the private use of the intended
recipient in relation to works or projects of SA Water.
This Standard has been prepared for SA Water’s own internal use and SA Water makes
no representation as to the quality, accuracy or suitability of the information for any
other purpose.

Application and Interpretation of this Document

It is the responsibility of the users of this Standard to ensure that the application of
information is appropriate and that any designs based on this Standard are fit for SA
Water’s purposes and comply with all relevant Australian Standards, Acts and
regulations.
Users of this Standard accept sole responsibility for interpretation and use of the
information contained in this Standard. Users should independently verify the accuracy,
fitness for purpose and application of information contained in this Standard.
Only the current revision of this Standard should be used which is available for
download from the SA Water website.

Significant/Major Changes Incorporated in This Edition

Technical changes described in this clause are related to TS 0300 revision 3.0, dated 23
November 2020. Clause numbers described below relate to the superseded
document.
Clause 3.3.5 – Item 4 – Requirement for sunshields on metal outdoor cubicles.
Clause 3.3.5 – Item 11 – Requirement for ELV LED lamps on metal outdoor cubicles.
Clause 3.3.6 – Item 5 – Reference to TS0340 for LV cubicles in HV switchrooms.
Clause 3.3.5 – Item 8 – Requirement for ELV lamps on metal indoor cubicles.
Clause 3.3.8 – Minor clarification.
Clause 3.3.12 – Clarification on meter location.
Clause 4.2.1 – Clarification relating to circuit breaker discrimination requirements.
Clause 4.4 – Clarification on isolating switches mounted through fixed escutcheons.
Clause 4.11 – New requirements for cubicle heaters.
Clause 4.22 – Changes to surge protection requirements encouraging SP devices to be
mounted as close as possible to the supply.
Clause 4.23.1 – Item 6 – Clarification of the provision of lightning protection for
instrumentation.
Clause 4.26 – Headings rearrangement, and the requirement for ELV fittings in panels.
Clause 6.1 – Item 15 – Clarification of requirements for vibration monitoring.
Clause 6.2 – Item 4 and 11 – minor corrections/clarifications.
Clause 7 – Major re-write on Generator Sets to cover all types of generators used by SA
Water.

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Clause 8.1 – Item 13 – Removal of exclusive use of lead-acid batteries and links to
changes from section 7.
Clause 8.4 – Application of double-pole circuit breakers for certain UPS equipment.
Clause 9.4 – Minor clarification on cable ladders/trays.
Clause 9.5 – Clarification on spares requirements for conduits in various situations.
New Clause 9.7.2 - Installation of Cables in Wastewater Treatment/Pumping Areas
Clause 9.7.9 (Now 9.7.10) – Minor clarification.
Clause 9.9 – Additional requirement details for earthing installations.
Clause 9.9.3 – Rewording of section to remove ambiguity and correct language.
Clause 10.1 – Minor update.
Clause 12.3.7 – Clarification as to testing for generator size.
Clause 13.1.3 – Minor reference changes and removal of table of mnemonics for
electrical schematic drawings.
Figures 5 and 6 – Updated to latest revision example schematics.

Document Controls
Revision History

Revision Date Author Comments

Sept. 1998 Document Issued as DS 79
May 1999 Document Issued as DS 79
01 Sept. 2001 Document Issued as DS 79
10 Jan 2007
Dec 2011
Aug 2012
1.0 31 July 2015 Carl Franz
1.0 15 Nov 2016 Tony Zelipski Document previously TS 79
2.0 24 April 2018 Justin Hamra Major review
2.1 31 January 2019 Justin Hamra Minor Review
3.0 23 Nov 2020 Justin Hamra Minor Review
4.0 26 Aug 2022 Justin Hamra Minor Review

Template: Technical Standard Version 6.00, 10/05/2016

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Approvers
Role Signature and Date
Principal Electrical Engineer
Justin Hamra
X
S ig n e r 's N a m e

Manager Engineering Quality and Innovation

Matthew Davis
X
S ig n e r 's N a m e

Senior Manager Engineering Services

Richard Gray
X
S ig n e r 's N a m e

Reviewers
Role Name Revision Review Date
Senior Electrical Engineer Troy Kennedy 4.0 17/08/22
Senior Electrical Engineer Jonathan Nicholls 4.0 17/08/22
Senior Electrical Engineer Sachin Pandey 4.0 17/08/22
Electrical Engineer Hamid Kooshanfar 4.0 17/08/22
Senior Electrical Engineer Ken Rose 4.0 17/08/22
Senior Electrical Engineer Jason White 4.0 17/08/22
Elec Inst and Controls Eng Yin Min 4.0 17/08/22
Elec Inst and Controls Eng Harmanjit Singh 4.0 17/08/22

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Contents
1 Introduction ..................................................................................................... 11
1.1 Purpose ....................................................................................................... 11
1.2 Acronyms and Abbreviations ................................................................... 11
1.3 Definitions ................................................................................................... 12
1.4 References ................................................................................................. 12
1.4.1 Australian and International Standards ............................................... 12
1.4.2 SA Water Documents ............................................................................ 16

2 Scope .............................................................................................................. 17
2.1 Approval to Deviate from This Standard .................................................. 17
2.2 Design Criteria ............................................................................................ 17

3 Switchboards and Control/Telemetry Panels ............................................... 18

3.1 General ....................................................................................................... 18
3.2 Design Verification ..................................................................................... 18
3.3 Construction ............................................................................................... 18
3.3.1 General .................................................................................................. 18
3.3.2 Form of Segregation.............................................................................. 19
3.3.3 Arrangement of Cubicles and Equipment .......................................... 20
3.3.4 Busbars ................................................................................................... 20
3.3.5 Metal Outdoor Cubicles ....................................................................... 21
3.3.6 Metal Indoor Cubicles........................................................................... 22
3.3.7 Stainless Steel Cubicles ......................................................................... 23
3.3.8 Plastic Enclosures ................................................................................... 24
3.3.9 Vandal Resistant Cubicles .................................................................... 24
3.3.10 Cable Entry ............................................................................................ 24
3.3.11 Mounting of Equipment ........................................................................ 25
3.3.12 Electricity Supplier Energy Metering..................................................... 25
3.4 Internal Wiring............................................................................................. 25
3.4.1 Type ........................................................................................................ 25
3.4.2 Colour Coding ....................................................................................... 26
3.4.3 Wiring Installation ................................................................................... 26
3.4.4 Segregation ........................................................................................... 26
3.4.5 Termination ............................................................................................ 26
3.4.6 Small Wiring Protection ......................................................................... 27
3.5 Labelling ..................................................................................................... 27
3.5.1 General .................................................................................................. 27
3.5.2 Main Titles and Subtitles ........................................................................ 27
3.5.3 Naming Convention.............................................................................. 27
3.5.4 Panel Controls and Indications ............................................................ 28
3.5.5 Switchboard Nameplates..................................................................... 28
3.5.6 Contactors, Relays and Circuit Breakers ............................................. 28
3.5.7 Instrumentation Equipment .................................................................. 29

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3.5.8 Terminals ................................................................................................. 29

3.5.9 Wiring ...................................................................................................... 29
3.5.10 Fuses ....................................................................................................... 29

4 Components ................................................................................................... 29
4.1 General ....................................................................................................... 29
4.1.1 Ratings .................................................................................................... 29
4.1.2 Degree of Protection ............................................................................ 30
4.1.3 Corrosive Environments ......................................................................... 30
4.1.4 Ambient Temperatures ......................................................................... 30
4.2 Circuit Breakers........................................................................................... 30
4.2.1 Discrimination ........................................................................................ 30
4.2.2 Air Circuit Breakers................................................................................. 30
4.2.3 Moulded Case Circuit Breakers............................................................ 31
4.2.4 Miniature Circuit Breakers ..................................................................... 32
4.3 Residual Current Devices .......................................................................... 32
4.4 Isolating Switches ....................................................................................... 32
4.5 Air Break Switches ...................................................................................... 32
4.6 Composite Fuse Switch Units ..................................................................... 33
4.7 Low-Voltage Fuses ..................................................................................... 33
4.8 Motor Contactors ...................................................................................... 33
4.9 Soft Starters ................................................................................................. 34
4.10 Variable Speed Drives ............................................................................... 34
4.11 Cubicle Heaters ......................................................................................... 36
4.12 Motor Protection Units ............................................................................... 36
4.12.1 Thermal Overload Units ......................................................................... 36
4.12.2 Electronic Motor Protection Relays ...................................................... 36
4.12.3 Thermistor Control Units ......................................................................... 37
4.13 Meters ......................................................................................................... 37
4.13.1 General .................................................................................................. 37
4.13.2 Ammeters ............................................................................................... 37
4.13.3 Voltmeters .............................................................................................. 37
4.13.4 Multi-function Meters............................................................................. 38
4.14 Current Transformers .................................................................................. 38
4.14.1 Metering Current Transformers ............................................................. 38
4.14.2 Protection Current Transformers ........................................................... 38
4.15 Control Relays ............................................................................................ 39
4.16 Timing Relays .............................................................................................. 39
4.17 Programmable Logic Controllers .............................................................. 39
4.18 Programmable Relays ............................................................................... 39
4.19 Hours Run Meters........................................................................................ 40
4.20 Undervoltage and Phase Imbalance Relays .......................................... 40
4.21 Control Switching Devices and Indicator Lights ...................................... 40
4.21.1 Motor Control Centre - Control Selector Switch ................................. 42
4.22 Surge Protection......................................................................................... 42
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4.22.1 Main and Distribution Switchboards .................................................... 42

4.22.2 Process Instrumentation Systems .......................................................... 43
4.23 Instrumentation Equipment ....................................................................... 43
4.23.1 General .................................................................................................. 44
4.23.2 Scale Indicators ..................................................................................... 44
4.23.3 Digital Indicators .................................................................................... 44
4.23.4 Flow Integrators ..................................................................................... 45
4.23.5 Signal Isolators........................................................................................ 45
4.23.6 Signal Alarm Units .................................................................................. 45
4.23.7 Lightning Protection Units ..................................................................... 45
4.23.8 Test Points and Test Injection Points ..................................................... 45
4.24 Human Machine Interfaces (HMI) ............................................................ 46
4.25 Emergency Stop Circuits ........................................................................... 46
4.26 General Lighting and Power Equipment ................................................. 47
4.26.1 Lighting Fittings (General) ..................................................................... 47
4.26.2 Fluorescent Fittings ................................................................................ 48
4.26.3 High Intensity Discharge Fittings ........................................................... 48
4.26.4 Emergency Fittings ................................................................................ 48
4.26.5 Lighting Switches ................................................................................... 48
4.26.6 Socket Outlets ........................................................................................ 49
4.27 Switchroom Air Conditioners ..................................................................... 49

5 Field Cables and Equipment ......................................................................... 51

5.1 Power Cables ............................................................................................. 51
5.2 Control Cables ........................................................................................... 51
5.3 Instrumentation Cables ............................................................................. 52
5.4 Data Cables ............................................................................................... 52
5.5 Cable Trays and Ladders .......................................................................... 52
5.6 Conduits and Fittings ................................................................................. 53

6 Motors and Electric Actuators ....................................................................... 54

6.1 Motors ......................................................................................................... 54
6.2 Electric Actuators ....................................................................................... 55

7 Generator Sets ................................................................................................ 57

7.1 General ....................................................................................................... 57
7.2 Ambient Temperatures .............................................................................. 57
7.3 Power Rating .............................................................................................. 57
7.4 Isolation ....................................................................................................... 57
7.5 Outdoor Enclosures .................................................................................... 57
7.6 Mounting Assembly Features .................................................................... 58
7.7 Guarding .................................................................................................... 58
7.8 Noise and Vibration Levels ........................................................................ 58
7.9 Engine ......................................................................................................... 58
7.10 Generator ................................................................................................... 59
7.11 Controls, Indications and Protection ........................................................ 60
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7.11.1 General .................................................................................................. 60

7.11.2 Controls .................................................................................................. 60
7.11.3 Automatic Operation ........................................................................... 61
7.11.4 Indications .............................................................................................. 61
7.11.5 Protection............................................................................................... 62
7.12 Batteries and Chargers .............................................................................. 62
7.12.1 Batteries .................................................................................................. 62
7.12.2 Chargers................................................................................................. 62
7.13 Load Banks ................................................................................................. 63

8 Uninterruptible Power Supplies ...................................................................... 64

8.1 General Requirements .............................................................................. 64
8.2 Battery and Charger.................................................................................. 65
8.3 Shutdown Operation ................................................................................. 65
8.4 Isolation ....................................................................................................... 66

9 Installation ....................................................................................................... 66
9.1 General ....................................................................................................... 66
9.2 Fixing ........................................................................................................... 66
9.3 Switchboards and Control/Telemetry Panels .......................................... 67
9.4 Cable Trays and Ladders .......................................................................... 67
9.5 Conduits...................................................................................................... 68
9.6 Cable Pits .................................................................................................... 69
9.7 Cable Installation ....................................................................................... 69
9.7.1 General .................................................................................................. 69
9.7.2 Installation of Cables in Wastewater Treatment/Pumping Areas...... 70
9.7.3 Cable Handling ..................................................................................... 70
9.7.4 Installation of Data Cable .................................................................... 70
9.7.5 Cable Termination ................................................................................. 71
9.7.6 Instrumentation Cable Screens ............................................................ 71
9.7.7 General Power and Lighting Cables ................................................... 71
9.7.8 Cable Fixing ........................................................................................... 71
9.7.9 Cable and Wire Labelling ..................................................................... 72
9.7.10 Cable Numbering System ..................................................................... 72
9.7.11 Wire Numbering System ........................................................................ 74
9.8 Lighting Systems ......................................................................................... 74
9.8.1 Lighting and Small Power Distribution Boards ..................................... 74
9.8.2 Indoor Lighting Design .......................................................................... 75
9.8.3 Outdoor Lighting Design ....................................................................... 76
9.8.4 Lighting Arrangement ........................................................................... 76
9.8.5 Lighting Control ..................................................................................... 76
9.8.6 Labelling ................................................................................................. 76
9.8.7 Wiring of Lighting Circuits ...................................................................... 77
9.9 Earthing ....................................................................................................... 77
9.9.1 Main Power Earth Bar ............................................................................ 77

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9.9.2 Earth Electrodes ..................................................................................... 77

9.9.3 Equipotential Bonding........................................................................... 77
9.9.4 Main Instrument Earth Bar ..................................................................... 78
9.9.5 Instrument Earth Bars Located in Cubicles .......................................... 78
9.10 Power Factor Correction ........................................................................... 78
9.11 Harmonics ................................................................................................... 78
9.12 Lightning and Transient Overvoltage Protection .................................... 78

10 Excavation and Backfilling of Trenches for Underground Conduits ........... 79

10.1 General ....................................................................................................... 79
10.2 Clearing ...................................................................................................... 79
10.3 Trench Width and Conduit Spacing ......................................................... 79
10.4 Fill Materials................................................................................................. 79
10.4.1 Sand ....................................................................................................... 79
10.4.2 Quarry Rubble ....................................................................................... 79
10.5 Bedding and Backfilling ............................................................................ 80
10.5.1 Bedding .................................................................................................. 80
10.5.2 Backfill Around Conduits ....................................................................... 80
10.5.3 Backfill in Roadways and Footpaths .................................................... 80
10.5.4 Backfill in Other Locations..................................................................... 80

11 Painting ............................................................................................................ 81
11.1 General ....................................................................................................... 81
11.2 Indoor Cubicles .......................................................................................... 81
11.3 Outdoor Cubicles ...................................................................................... 81
11.4 Other Equipment ....................................................................................... 82
11.5 Coating Reinstatement ............................................................................. 82

12 Inspection and Testing ................................................................................... 82

12.1 General ....................................................................................................... 82
12.2 Inspection ................................................................................................... 82
12.3 Works Tests .................................................................................................. 82
12.3.1 General .................................................................................................. 82
12.3.2 Test Results.............................................................................................. 82
12.3.3 Dispatch of Equipment ......................................................................... 83
12.3.4 Power Switchboards/MCCs .................................................................. 83
12.3.5 Control/Telemetry Panels ..................................................................... 83
12.3.6 Motors ..................................................................................................... 83
12.3.7 Generator Sets ....................................................................................... 84
12.3.8 Uninterruptible Power Supplies ............................................................. 85
12.3.9 Other Equipment ................................................................................... 85
12.4 Site Tests ...................................................................................................... 85
12.4.1 General .................................................................................................. 85
12.4.2 Test Results.............................................................................................. 85
12.4.3 Switchboards, Control/Telemetry Panels, Associated Equipment and
Cabling................................................................................................... 86
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12.4.4 Motors ..................................................................................................... 86

12.4.5 Generator Sets ....................................................................................... 86
12.4.6 Other Equipment ................................................................................... 87

13 Technical Information and Drawings ............................................................ 87

13.1 Drawings ..................................................................................................... 87
13.1.1 Tender Drawings .................................................................................... 87
13.1.2 Prior to Manufacture ............................................................................. 87
13.1.3 Drawing Details ...................................................................................... 88
13.2 Manuals ...................................................................................................... 89
13.3 Test Certificates .......................................................................................... 90
13.3.1 Information to be Submitted with Tenders .......................................... 90
13.3.2 Information to be Submitted Prior to Start of Manufacture ............... 90

List of figures
Figure 1 - Example of Switchboard and Distribution Board Naming Convention
..................................................................................................................... 28
Figure 2 – Test Points ................................................................................................ 46
Figure 3 – Test Injection Points ................................................................................. 46
Figure 4 – Example Cable Numbering ................................................................... 73
Figure 5 – Example of Electrical Drafting Quality - Drawing 1 .............................. 92
Figure 6 – Example of Electrical Drafting Quality - Drawing 2 .............................. 93

List of tables
Table 1-1 - Table of Definitions Used in this Technical Standard .......................... 12
Table 1-2 – Standards Referred to in this Technical Standard.............................. 13
Table 1-3 – Referenced Internal Standards ........................................................... 16
Table 1-4 –Standard Drawings ................................................................................ 16
Table 4-1 - Colours of Pushbuttons ......................................................................... 40
Table 4-2 - Colours of Indictor Lights ...................................................................... 41
Table 9-1 – Minimum Illumination Levels and Colour ............................................ 75
Table 10-1 – Grading of Quarry Rubble for Bedding and Backfilling .................. 80

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1 Introduction
SA Water is responsible for operation and maintenance of an extensive amount of
engineering infrastructure.
This standard has been developed to assist in the design, maintenance, construction,
and management of this infrastructure.

1.1 Purpose
The purpose of this standard is to detail minimum requirements to ensure that assets
covered by the scope of this standard are constructed and maintained to consistent
standards and attain the required asset life.

1.2 Acronyms and Abbreviations

The following acronyms and abbreviations are used in this document:

Term Description
ACB Air Circuit Breaker
AS Australian Standards
CFS Composite Fuse Switch
ELV Extra Low Voltage: Not exceeding 50 V a.c. or 120 V ripple-free d.c.
HMI Human Machine Interface – generally regarded as a ‘Touch Screen’ that shows
the graphical representation of a process or system.
HRC High Rupturing Capacity
HV High Voltage: Exceeding low voltage.
LED Light Emitting Diode
LV Low Voltage: Exceeding extra-low voltage, but not exceeding
1,000 V a.c. or 1,500 V d.c.
MCB Miniature Circuit Breaker
MCCB Moulded Case Circuit Breaker
Must Indicates a statement is mandatory
PCN Plant Control Network
PLC Programmable Logic Controller
RCD Residual Current Device
RTU Remote Telemetry Unit
SA Water South Australian Water Corporation
SAPN South Australian Power Networks
SCADA Supervisory Control and Data Acquisition
Shall Indicates a statement is mandatory
Should Indicates a recommendation
TS SA Water Technical Standard
UPS Uninterruptible Power Supply
VSD Variable speed drive

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1.3 Definitions
The following definitions are applicable to this document:
Table 1-1 - Table of Definitions Used in this Technical Standard

Term Description
Contractor A person or firm that undertakes a contract to provide materials or
labour to perform a service or do a job.
Corrosive Environments Any environment where there is a presence of destructive chemicals in
which the electrical assets are subject to deleterious effects. Examples
of destructive chemicals are:
Hydrogen Sulphide;
Ammonia;
Chlorine;
Sodium Chloride; etc.

Any installation located close (within 1 km of the ocean) or in high

ground water environments (exhibiting salinity) should be considered as
a corrosive environment for the purposes of this Technical Standard.
Critical Infrastructure Any SA Water asset that must continually operate, including those
prescribed under adverse events (i.e. natural disasters)
SA Water’s Representative The SA Water nominated representative with delegated authority under
a Contract or engagement, including (as applicable):
• Superintendent’s Representative (per AS 4300 and AS 2124,
etc.)
• SA Water Project Manager
• SA Water nominated contact person
SAPN Service and Manual no. 32 published by SA Power Networks and approved by the
Installation Rules (latest Technical Regulator, incorporating the ‘Technical Installation Rules’
revision) referred to in Regulation 76 of the Electricity (General) Regulations 2012
under the Electricity Act 1996.
Standard Reference to a SA Water Technical Standard.
Switchboard An assembly of circuit protective devices, with or without switchgear,
instruments or connecting devices, suitably arranged and mounted for
distribution to, and protection of, one or more submains or final
subcircuits or a combination of both.
Voltage (a) Extra-low voltage: Not exceeding 50 V a.c. or 120 V ripple-free d.c.
(b) Low voltage: Exceeding extra-low voltage, but not exceeding
1,000 V a.c. or 1,500 V d.c.
(c) High voltage: Exceeding low voltage.

1.4 References
1.4.1 Australian and International Standards
Any Standard referred to in this Specification shall be of the latest edition (including
amendments) of that Standard at the date of calling of tenders.
The following table identifies Australian and International standards and other similar

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documents referenced in this document:

Table 1-2 – Standards Referred to in this Technical Standard

Number Title
NFPA 70E Standard for Electrical Safety in the Workplace
AS/NZS 1158 Lighting for roads and public spaces
AS 1289 Methods of testing soils for engineering purposes
Part 5.1.1 Lightning categories
Part 5.2.1 Road Classification
AS 1307 Surge arresters
Part 2 Metal-oxide surge arresters without gaps for AC systems
AS 1359 Rotating electrical machines - General requirements
Part 102 Methods of determining losses and efficiency
Part 106 Methods of cooling (IC Code)
Part 114 Vibration measurement and limits
AS/NZS 1554 Structural steel welding
Part 1 Welding of steel structures
Part 6 Welding stainless steels for structural purposes
Part 6.2 External surface treatment
IEEE 1584 Guide for Performing Arc Flash Calculations
AS 1627 Metal finishing Preparation and pre-treatment of surfaces
Part 1 Cleaning using liquid solvents and alkaline solutions
AS 1680 Interior and Workplace Lighting
AS/NZS 1768 Lightning Protection
AS/NZS 2053 Conduits and fittings for electrical installations
Part 1 General Requirements
Part 2 Rigid plain conduits and fittings of insulating material
Part 4 Flexible plain conduits and fittings of insulating material
Part 5 Corrugated conduits and fittings of insulating material
Part 7 Rigid metal conduits and fittings
Part 8 Flexible conduits and fittings of metal or composite material
AS 2124 General Conditions of contract
AS/NZS 2293 Emergency evacuation lighting for buildings
Part 3 Emergency luminaires and exit signs
AS/NZS 2648 Underground marking tape
Part 1 Non detectable tape
AS 2700 Colour standards for general purposes
AS/NZS 3000 Wiring Rules
AS/NZS 3008 Electrical installations Selection of cables
Part 1.1 Cables for alternating voltages up to and including 0.6/1 kV
AS/NZS 3010 Electrical installations – Generating set
AS/NZS 3017 Electrical installations - Verification guidelines

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Number Title
AS/NZS 3111 Approval and test specification - Miniature overcurrent circuit breakers
AS/NZS 3112 Approval and test specification - Plugs and socket-outlets
AS/NZS 3133 Approval and test specification - Air break switches
AS/NZS 3190 Approval and test specification Residual current devices (current
operated earth leakage devices)
AS 3715 Metal Finishing – Thermoset powered coating for architectural of
aluminium and aluminium alloys.
AS/NZS 3760 In service safety inspection and testing of electrical equipment
AS/NZS 4024 Series : Safety of machinery
Part 1 Safety of machinery
AS 4070 Recommended practices for protection of low voltage electrical
installations and equipment in MEN systems from transient overvoltages
AS 4300 General Conditions of contract for design and construct
AS 4506 Metal finishing - Thermoset powder coatings
AS 4594 Internal combustion engines – Performance
AS/NZS 4680 Hot-dip galvanised (zinc) coatings on fabricated ferrous articles
AS/NZS 5000 Electric cables
Part 1 Polymeric insulated – For working voltages up to and including 0.6/1 (1.2)
kV
Part 2 Polymeric insulated - For working voltages up to and including 450/750 V
Part 3 Polymeric insulated - Multicore control cables
AS 60034 Rotating electrical machines
Part 1 Rating and performance
Part 5 Degrees of protection provided by the integral design of rotating
electrical machines (IP Code) - Classification
Part 9 Noise limits
AS 60044.1 Instrument transformer
Part 1 Current transformers
AS/NZS 60079 Explosive Atmospheres
AS 60529 Degrees of protection provided by enclosures (IP Code)
AS/NZS 60598 Luminaires
Part 1 General requirements and tests
Part 2 Particular requirements - Mains socket-outlet mounted nightlights
AS/NZS 60921 Ballasts for tubular fluorescent lamps - Performance requirements
AS/NZS 60925 DC supplied electronic ballasts for tubular fluorescent lamps -
Performance requirements
AS/NZS 60947 Low voltage switchgear and controlgear
Part 2 Circuit breakers
Part 3 Switches, disconnectors, switch-disconnectors and fuse combination units
Part 4.1 Contactors and motor-starters - Electromechanical contactors and
motor-starters
Part 4.2 Contactors and motor-starters - AC semiconductor motor controllers and
starters

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Number Title
Part 5.1 Control circuit devices and switching elements - Electromechanical
control circuit devices
Part 7.3 Ancillary equipment - Safety requirements for fuse terminal blocks
Part 8 Control units for built-in thermal protection (PTC) for rotating electrical
machines
AS/NZS 61000 Electromagnetic compatibility (EMC)
Part 3.6 Limits – Assessment of emission limits for distortion loads in MV and HV
power systems (IEC 61000.3.6:1996 MOD)
Part 6.1 Generic standards - Immunity for residential, commercial and light-
industrial environments
AS/NZS 61347 Lamp controlgear
Part 2.8 Particular requirements for ballasts for fluorescent lamps
AS/NZS 61439 Low voltage switchgear and controlgear assemblies
Part 0 Guide
Part 1 General rules
Part 2 Power switchgear and controlgear assemblies
Part 3 Distribution Boards
AS 61818 Application guide for low-voltage fuse
AS/NZS 62040 Uninterruptible power systems (UPS)
Part 2 Electromagnetic compatibility (EMC) requirements
Part 3 Method of specifying the performance and test requirements
AS/NZS CISPR 11 Industrial, scientific and medical (ISM) radio frequency equipment –
Electromagnetic disturbance characteristics – Limits and methods of
measurement
AP-S0280/1 Paint standard
BS 2869 Fuel oils for agricultural, domestic and industrial engines and boilers -
Specification
IEC 60085 Thermal evaluation and classification of electrical insulation
IEC 61131 Programmable controllers
Part 1 General Information
Part 2 Equipment requirements and tests
Part 3 Programming languages
IEC 61643 Low-voltage surge protective devices
Part 11 Surge protective devices connected to low-voltage power systems -
Requirements and test methods
ISA-S71.04 Environmental Conditions for Process Measurement and Control Systems:
Airborne Contaminants

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1.4.2 SA Water Documents

[Link] Standard Documents

The following table identifies the SA Water standards and other similar documents
referenced in this document:
Table 1-3 – Referenced Internal Standards

Number Title
TS 0100 Requirements for Technical Drawings
TS 0200 Process and Instrumentation Diagrams
TS 0132 Operating and Maintenance Manuals
TS0340 Design, Supply, Installation and Testing of High Voltage Equipment
TS 0360 PLC and HMI Systems
TS 0371 Arc Flash Hazard Assessment and Design Aspects

[Link] Standard Drawings

The following table identifies drawings that are referenced in this document:
Table 1-4 –Standard Drawings

Number Title
TYP-03-00001-25c Example of electrical drafting quality standards (1)
TYP-03-00001-40 Example of electrical drafting quality standards (2)

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2 Scope
This Technical Standard Specification covers the general requirements for the supply
and installation of low voltage electrical equipment and extra low voltage equipment
where it applies to control and instrumentation.
This Technical Standard Specification shall be read in conjunction with the associated
project specification, drawings and any documents annexed to the project
specification. The provisions of this Technical Standard Specification shall apply unless
they are specifically deleted or amended in the project specification or drawings
which shall then take precedence. The currency of these Standards should be
checked prior to use.

2.1 Approval to Deviate from This Standard

Approval may ultimately be granted by the SA Water Principal Electrical Engineer, to
deviate from the requirements as stipulated in this Standard, if the functional
requirements (e.g. asset life, ease of use, maintainability, etc.) for the asset differs from
those stated in the Standard, but is assessed as still being acceptable. Any approval to
deviate from the stated requirements of this Standard shall not be seen as creating a
precedent for future like projects. Any request to deviate from this Standard must be
carried out on a project-by-project basis, where each alternative proposal will be
individually assessed on its own merit. No action should be taken until a written reply to
such a request has been received.
SA Water encourages and welcomes suggestions as to the improvement of this
standard for future releases. These suggestions should be passed through to the SA
Water Principal Electrical Engineer.

2.2 Design Criteria

The design criteria must be ascertained and agreed with SA Water or its representative
during all stages of investigation, concept design and detailed design in order to
achieve a value-for-money installation that is fit for purpose and with minimum or
negligible risks to SA Water. The design criteria should consider the following aspects:
1. Life Cycle Costs
Designs should be innovative and incorporate the appropriate techniques and
technology, in conjunction with the selection of appropriate equipment, to minimize
the life cycle costs, while satisfying operation and maintenance requirements. Energy
consumption must be given particular attention in this respect.
2. Security of Operation
Designs should take into account the failure of a single item of equipment or a fault in
a particular area of an installation is confined to the associated part of the installation
and does not affect the continuous operation of the remaining parts of the installation,
where possible.
3. Reliability
The installations are to be designed to minimize the likelihood of a failure, taking into
consideration the electricity supply characteristics, ambient conditions, load
characteristics and operation and maintenance requirements.
4. Upgradability
The installations are to be designed to facilitate future upgrades where applicable.

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5. Interchangeability
The installations are to be designed to maximize the interchangeability of components
and assemblies as far as practical to improve flexibility and reduce the spare parts
inventory.
6. Operation, Maintenance and Fault-Finding Facilities
The installations are to be provided with suitable and adequate facilities to allow ease
of operation, maintenance and fault finding.
7. Environmental Considerations
The installations are to be designed and suitable equipment selected to avoid or
minimize unacceptable impact on the environment as far as possible.
8. Safety Considerations
The installations are to be designed with the safety and welfare of construction,
operation and maintenance personnel and the general public in mind, complying with
statutory regulations. Wherever possible, electrical equipment and wiring should not be
located in areas classified as hazardous.

3 Switchboards and Control/Telemetry Panels

3.1 General
Switchboards, control/telemetry panels and cubicles housing electrical equipment
shall be constructed in accordance with this Technical Standard and AS/NZS 3000.
Individual components shall comply with the relevant standards.
All work shall comply with the requirements of the electricity supply authority and shall
be suitable and approved for connection to a 400/230 V AC, 50 Hz earthed neutral
(MEN) supply.
Enclosures that are tendered in variance to these requirements shall have information
submitted with full details, for subsequent approval.

3.2 Design Verification

Testing certificates shall be provided for Design Verification and Routine Verification to
AS/NZS 61439 in accordance with 13.3.

3.3 Construction
Switchboards that have a rated current of greater than 250 A per phase shall follow
the design, construction and installation principles and be provided with an arc flash
assessment provided in accordance with TS 0371 Arc Flash Hazard Assessment and
Design Aspects.

3.3.1 General
Switchboards and control/telemetry panels shall comply with the following general
requirements:
1. Assemblies shall conform to the forms of construction, as defined in AS/NZS
61439.1.
2. Adequate derating of equipment and/or ventilation of the cubicles shall be
provided to protect the equipment against the effects of excessive temperature
rises within the cubicles. Any ventilation shall not compromise the IP rating and
form of segregation of the cubicles.

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3. All components which are mounted on the outside of any Switchboard or

control/telemetry panel shall be selected and installed so that the degree of
protection specified for that panel is maintained.
4. In-service accessibility for inspection and maintenance shall be provided in
accordance with clause [Link] of AS/NZS 61439.1.
5. Locks shall be keyed alike to the Lenlock key code 320, except for vandal
resistant cubicles, which shall be in accordance with clause 3.3.9. The exception
to this is for indoor radio /RTU telemetry cabinets, where:
a. If the cabinet is accessible by third parties (e.g. shared site/building) the locks
shall be in accordance with clause 3.3.9; or
b. If the panel is in a secure location within a building, not accessible by third
parties, a cam lock insert will be suitable.
6. Cubicle doors shall be 3-point locking for all doors of height greater than 1000
mm.
7. All outdoor cubicles shall be provided with rigid stays of robust construction to
hold all doors in a not less than 100° open position. The same requirement shall
apply for indoor cubicle doors with combined dimensions greater than 500mm in
width and 900mm in height. It shall be possible to open all doors simultaneously.
8. With the doors open, all accessible internal live parts shall be protected against
accidental contact to not less than IP2X.
9. Proprietary, off-the-shelf, Soft Starter and VSD panels may be granted exception
to this Technical Standard on a project-specific basis, subject to approval by the
SA Water Principal Electrical Engineer. All custom-built Soft Starter and VSD panels
are categorized as falling under Switchboards and control/telemetry panels as
they contain switchgear and control gear, and must be constructed and
supplied to this Standard.
10. Low Voltage shall not be wired directly to a door panel or escutcheon. The
exceptions to this are for multi-function meters (which need to meet the
requirements of section 4.13.4 and 230 V door-mounted cooling fans, which need
to have interlocks to cease operation on door opening).

3.3.2 Form of Segregation

The form of segregation shall be in accordance with the following:
1. Switchboards and control/telemetry panels which have a rated current less than
or equal to 250 A per phase shall be, as a minimum, Form 1 assemblies in
accordance with AS/NZS 61439.2.
2. Switchboards and control/telemetry panels which have a rated current of
greater than 250 A per phase shall be, as a minimum, Form 3b or 3bi assemblies in
accordance with AS/NZS 61439.2, with segregated compartments for each of
the following:
a. Incoming functional unit (main switch),
b. Busbars,
c. External cable terminals,
d. Outgoing functional units,
e. General power and lighting distribution panel,
f. Common control/telemetry panel.
In addition, Switchboards that have a rated current of greater than 250A per phase
shall be provided with increased security against the occurrence or the effects of
internal arcing faults in accordance with Appendix ZC of AS/NZS 61439.1. For

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switchboards that require arc fault containment, testing to Appendix ZD of AS/NZS

61439.1 shall be applied. The alternative Form 3bih segregation indicated in Appendix
ZB of AS/NZS 61439.2 is precluded.

3.3.3 Arrangement of Cubicles and Equipment

The cubicles and equipment comprising the switchboard or control/telemetry panel
shall be arranged in accordance with the following:
1. The incomer cubicle shall be located on the left-hand end of the assembly.
2. Busbar location shall be located at the top of the assembly.
3. Cubicles and compartments housing switchgear and control gear for the plant
equipment shall be grouped into functional groups, or arranged in the same
order as the process sequence of the plant equipment, as far as practical.
Similarly, control and indication devices on the front of individual cubicles and
compartments shall be arranged to correspond with the physical layout or
process sequence, wherever practical.
4. Switchboards shall be designed such that they can be readily extendable at
either end.
5. Provision of power circuits in Switchboards shall include a minimum of 20% spare
power circuits, or as specified in the project specification, whichever results in the
greater spares requirement.
6. Adequate spare space shall be provided in the cubicles or compartments to
accommodate all future equipment associated with the spare circuits, including
circuit protective devices, motor starters, control equipment, terminals and
control and indicating devices.
7. All controls, operating handles, meters and indicators shall be mounted not less
than 500 mm and not greater than 2000 mm above ground or floor level.
8. All touch-screen HMIs shall be mounted with a vertical centre between 1500 mm
and 1600 mm from floor level.
9. Switchboard assemblies shall be designed to be able to be split for ease of
transportation, installation, removal, replacement and demolition.
10. In control/telemetry panels where a PLC is installed, a portable tray to rest a
laptop shall be incorporated into the enclosure.

3.3.4 Busbars
Busbars shall be air insulated and constructed from high conductivity copper.
For Corrosive Environments, all busbars shall be tin coated according to clause 4.1.3.
The order of phasing of the busbars shall be red, white, blue from top to bottom, left to
right and back to front, all relative to the front of the panel. The neutral conductor shall
occupy an outer position.
Each individual busbar section shall be colour coded to correspond with the phase to
which it is connected.
Mechanical joints between busbars shall be by means of properly made bolted or
clamped joints. Bolted joints shall use high tensile steel bolts with plain washers, nuts and
lock nuts used to complete the joint. Care shall be taken to ensure that all contact
surfaces are clean and flat, and that adequate pressure is obtained to ensure that a
low resistance, trouble free joint is obtained. Torque verification of all joints shall be
indicated with a suitable marking pen across all busbar nut/bolt assemblies.

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3.3.5 Metal Outdoor Cubicles

Metal outdoor cubicles for Switchboards and control/telemetry panels shall be in
accordance with the following additional requirements:
1. Constructed either of Aluminium or mild steel with a minimum galvanised coating
of Z275, or 316 stainless steel, in accordance with clause 3.3.7.
2. Steel cubicle construction shall have a minimum body thickness of 1.5 mm for all
floor mounted cubicles. Small wall or post-mounted cubicles not exceeding 400
mm high x 400 mm wide may have a minimum body thickness of 1.0 mm. The
minimum body thickness for all Aluminium cubicles shall be 2 mm.
Doors greater than 800 mm in width, or doors where the total combined cut-outs
exceed 25% of the door area, shall have additional thickness or shall have
stiffeners added to ensure rigidity. An exemption to this thickness specification
may be granted for fully type-tested enclosures. However, to obtain an
exemption, type-test certificates must be provided for pre-approval on each
occasion.
3. Front access for all outdoor control/telemetry panels shall be provided with
hinged lockable doors. Opening the doors shall give access to a dead front
panel on which controls and indications are mounted. Locks and hinges shall be
in accordance with clause 3.3.1.
4. Installed with sunshields in non-sheltered aspects, and have a minimum of 50 mm
air gap between the enclosure and sunshield.
5. Rain hoods, where specified for non-wall mounted cubicles, shall be constructed
such that the top surface shall slope to prevent accumulation of water. The slope
shall be such as to direct water away from the front of the cubicle.
6. On externally located control/telemetry panels where there is an HMI mounted
on an escutcheon, there shall be coloured matte black area on the inside
surface (back of) door opposite the HMI so as to minimise reflections when the
HMI screen is being viewed.
7. With doors and covers in position, a degree of protection in accordance with
AS 60529, of not less than IP56 is required.
8. Equipment which is installed within outdoor cubicles shall be protected against
the effects of excessive temperature through a combination of:
a. the equipment being de-rated to accommodate the higher ambient
temperatures which are to be expected within the cubicles,
b. the cubicles being ventilated/cooled/arranged to ensure that the cubicle
internal temperatures do not exceed the temperature ratings of the
equipment. Any ventilation shall not decrease the IP rating of the
enclosure,
c. the fitting of a metal sun shield of appropriate design,
d. panel mounting orientation/location when installed.
9. Ground and floor mounted cubicles shall be provided with a bolt-on, hot-dip
galvanised (to AS/NZS 4680) rolled steel channel plinth, 100 mm high. Stainless
steel plinths should be used for stainless steel constructed cubicles and Aluminium
plinths should be used for Aluminium constructed cubicles. Insulation of dissimilar
metals needs to be considered in all cases. The toes of the plinth shall turn
outwards at each end with two, minimum 12 mm diameter, holes to facilitate the
bolting of the plinth to the floor or concrete pad using a minimum size of M10
bolts, depending on expected structural loading. A sheet of bitumen
impregnated felt or other approved moisture barrier shall be placed under the
plinth.

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10. Where 50 mm diameter holes have been provided in the plinth for lifting of
panels, metallic plugs of compatible material need to be provided with holes or
mesh to allow for air circulation beneath the panel, whilst excluding vermin.
11. Switchboards and floor mounted control/telemetry panels shall be provided with
interior switchable ELV LED lamp(s) and a switched socket outlet, accessible
when the front door is open.
12. The control/telemetry sections of cubicles shall be provided with thermostatically
controlled anti- condensation heaters, in accordance with clause 4.11.
13. Where specified, applied with paint finish as per section 11.3.
14. The maximum dimension of a control/telemetry panel intended to be wall-
mounted shall be no greater than 1200 mm(H) x 1200 mm(W). All cubicles
required to be larger than these dimensions shall be ground mounted.

3.3.6 Metal Indoor Cubicles

Metal indoor cubicles for Switchboards and control/telemetry panels shall be in
accordance with the following additional requirements:
1. Painted Zincseal sheet steel construction or Aluminium, both with paint finish as
per section 11.2, or constructed of 316 stainless steel in accordance with clause
3.3.7.
2. The sheet steel shall have a minimum thickness of 1.5 mm for all floor mounted
cubicles. Small wall mounted cubicles not exceeding 400 mm high x 400 mm
wide shall have a minimum thickness of 1.0 mm.
3. Doors greater than 800 mm in width, or doors where the total combined cut-outs
exceed 25% of the door area, shall have additional thickness or shall have
stiffeners added to ensure rigidity.
4. The maximum dimension of a control/telemetry panel intended to be wall-
mounted shall be no greater than 1200 mm(H) x 1200 mm(W). All cubicles
required to be larger than these dimensions shall be floor mounted.
5. Indoor cubicles shall provide a degree of protection in accordance with AS
60529 as follows:
a. Not less than IP51 in areas where the ingress of water is excluded,
b. Not less than IP54 in areas where the ingress of water is likely (e.g. due to
possible hosing down operations or the close proximity of pumps or
pipework),
c. Not less than IP56 for 316/316L stainless steel cubicles,
For LV cubicles in high voltage switchrooms, refer to the requirements stipulated
in TS0340
6. All floor mounted cubicles shall be provided with a bolt-on, hot-dip galvanised
(to AS/NZS 4680) rolled steel channel plinth not less than 75 mm high. Stainless
steel plinths should be used for stainless steel constructed cubicles and Aluminium
plinths should be used for Aluminium constructed cubicles. Insulation of dissimilar
metals needs to be considered in all cases.
Where the cubicles are mounted directly onto a floor without a concrete plinth
and which may be subjected to dampness (e.g. due to possible hosing down
operations or the close proximity of pumps or pipework) a sheet of bitumen
impregnated felt or other approved moisture barrier shall be placed under the
plinths.
The toes of the plinth shall turn outwards at each end with 2, minimum 12 mm
diameter, holes to facilitate the bolting of the plinth to the floor or concrete pad
using a minimum size of M10 bolts, depending on expected structural loading.

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7. Where 50 mm diameter holes have been provided in the plinth for lifting of
Switchboards, metallic plugs of compatible material need to be provided with
holes or mesh to allow for air circulation beneath the Switchboard, whilst
excluding vermin.
8. Switchboards and floor-mounted control/telemetry panels shall be provided with
interior switchable ELV fluorescent or ELV LED lamp(s) and a switched socket
outlet, accessible when the front door is open.
9. The control/telemetry section of panels shall be provided with thermostatically
controlled anti- condensation heaters, in accordance with clause 4.11.

3.3.7 Stainless Steel Cubicles

[Link] Required Application
316/316L stainless steel cubicles shall be provided:
1. For installations (indoor and outdoor) in Corrosive Environments (refer to
Definitions section);
2. For indoor installations located in the same room as chlorination equipment; or
3. Where required by the project specification.

[Link] General
Cubicles shall be manufactured from grade 316 or 316L stainless steel.
Cubicles, doors and escutcheons shall be fabricated from a stainless steel sheet with a
minimum thickness of 1.5 mm. Bracing, stiffening, internal brackets, plinths and other
structural components shall also be manufactured from type 316/316L stainless steel of
minimum 2.0 mm thickness.
Internal components, such as mounting plates (gear trays), may be constructed of mild
steel, treated and painted as per section 11.2.

[Link] Welding
Any welding shall be carried out in accordance with AS 1554 Part 6. The weld quality
and surface finish for the welds shall be:
1. Internal welds 2B, II (a),
2. External welds 2B, I (120#).

[Link] Surface Treatment

The external surface finish for the cabinets shall be a No. 4 finish with a final surface
polish of 120 to 150 grit in accordance with AS/NZS 1554.6. The cabinets shall be
manufactured with the polish directionality in the vertical direction.
Where the original machine polishing lines are parallel to the line of a weld, the weld
bead shall be dressed down by grinding and then finished by polishing with 120 grit
polishing wheel driven by a portable machine. The traversing of the wheel should be
kept in line with the run of the weld bead so that its cut lines are kept parallel to those
of the of the original machine polished surface. Care shall be taken to bring the metal
joint flush with that of the base metal in order to avoid residual ridges or grooves.
Where the machine polished lines are not parallel to the lines of the weld, the final
manual polishing shall be conducted in the original direction of the machine polishing.
Where the original polished lines on the two sides of a joint are not parallel, the final
manual polishing shall be in the direction which has the least visual impact on the
component.

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Any heat tint on the external surfaces as a result of internal welding shall be removed
and the original external surface finish reinstated.
The internal surfaces of the cubicles require no special surface finish other than
cleaning, as specified above, for the internal welds.

[Link] Fasteners
All fasteners shall be type 316 stainless steel.

[Link] Hardware
All hinges shall be type 316 stainless steel.
Locks and handles shall be type 316 stainless steel.

3.3.8 Plastic Enclosures

Plastic enclosures shall only be installed in pre-approved situations, and preferably out
of direct sunlight. Plastic enclosures shall be in accordance with following:
1. Made from high impact-resistant, flame-retardant material,
2. Totally electrically insulated,
3. Degree of protection not less than IP56 to AS 60529 when the covers are in
position,
4. Covers which, when removed, give access to live equipment shall require the use
of a tool in the removal of the covers.

3.3.9 Vandal Resistant Cubicles

Vandal resistant cubicles shall be manufactured from sheet steel in accordance with
clause 3.3.5.
Additional design and construction features to improve the security of the cubicles
from theft and vandalism shall include the following:
1. No switches, indicators, etc. on the outside of the cubicle unless required by the
project specification,
2. Concealed or vandal resistant hinges,
3. Doors and covers designed to eliminate, as far as is practicable, leverage points
which would enable the doors or covers to be forced open,
4. Doors to be provided with high security swing-type handles (Emka 1107 type or
approved equivalent) with locking facilities for SA Water approved security
padlocks. All padlocks to be keyed alike, as per SA Water security requirements.
5. Fixing bolts, screws, etc. shall, as far as practicable, be concealed to prevent
unauthorised removal. Fastener heads, which are accessible from the outside of
the cubicle, shall be of a type which will not allow the unscrewing of the fastener
from the outside of the cubicle.

3.3.10 Cable Entry

Cable entry to all switchboards and control/telemetry panels shall be bottom entry,
where possible. If bottom entry is impractical, top/side/back entry is permitted, but only
indoors or undercover, not outdoors where water can settle.
Cable entry facilities shall be suitable for the number and size of cables specified, or
alternatively, if sizes are not specified, for cables rated for the full load current of the
connected load. Appropriate deratings for temperature and grouping of cables shall
be allowed for when determining cable sizes, as per AS/NZS 3008.

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Cubicles shall be protected from the entry of vermin through suitable glanding of
cables and sealing of any ducts beneath cubicles.

3.3.11 Mounting of Equipment

All equipment within a Switchboard or control/telemetry panel shall be installed on
mounting plates affixed to the interior rear of the panel (i.e. not on top, side or bottom
panels), except for batteries, anti-condensation heaters and vent fans, which shall be
as per project specifications.
All equipment within a Switchboard or control/telemetry panel, with the exception of
cable ducts and batteries, shall be installed not less than 300 mm and not greater than
2000 mm above ground or floor level.

3.3.12 Electricity Supplier Energy Metering

Where energy metering is required, a meter box complying with the requirements of
clause 3.3.5 shall be provided and located preferably on an external wall of the
building. The meter configuration and location shall comply with the requirements of
SA Power Networks (SAPN) Service and Installation Rules, where connection is made to
their network.
Metering shall be upstream of all Switchboard load consuming equipment.
For main Switchboards which have a full load current rating of 100 A or more,
adequate arrangements shall be made within the Switchboard to mount the electricity
supplier’s metering current transformers in an enclosure which is capable of being
sealed by the electricity supplier. The facilities shall be acceptable to the electricity
supplier and shall allow for the on-site fixing, connecting and changing of the metering
transformers without the need to disturb the incoming cables. The metering
transformers shall be supplied and installed by the Contractor to the electricity
supplier’s requirements.
Potential wiring for the electricity supplier’s metering shall be protected by 100 A
busbar mounted fuses, or approved equivalent, in accordance with the electricity
supplier’s requirements. The fuses shall be enclosed within the sealed current
transformer enclosure and shall be located such that they do not interfere with the
installation of the main service cable or the installation and/or removal of the current
transformers.
Adequate provision shall be made for the outgoing potential and current transformer
secondary wiring to the electricity supplier’s meters.
Metering current transformers and potential fuses are generally not required on main
Switchboards rated at less than 100 A.

3.4 Internal Wiring

3.4.1 Type
Wiring shall be of PVC or XLPE insulated stranded copper conductor in accordance
with AS/NZS 5000.1, 5000.2, 5000.3.
The wiring shall be adequately sized to carry the current and the minimum conductor
size shall be as follows:
1. Signal wiring to PLCs and similar devices – 0.5 mm2,
2. Control relays and timers – 0.50 mm2,
3. Current transformers – minimum of 4.0 mm2 and sized in accordance with AS/NZS
3008,
4. Contactors and other power circuits – Conductor sized in accordance with
AS/NZS 3008.
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3.4.2 Colour Coding

The insulation of cables and wires shall be used to provide colour coding as follows:
1. Low voltage three phase AC power circuits and CT wiring to be colour coded in
accordance with the phase to which they are connected, i.e. RED, WHITE, BLUE
with neutrals coloured BLACK,
2. Low voltage single phase AC power circuits and control cables to be colour
coded in accordance with the phase to which they are connected, until they
terminate into a protection device (e.g. circuit breaker, fuse, etc.) at which point
the active colour will change to WHITE with BLACK neutral,
Note: Control supplies shall be derived from the white phase, unless otherwise
indicated.
3. Low voltage DC and extra low voltage DC circuits to be colour coded GREY (+)
and PINK (0 V),
Note: For three wire DC systems a green wire shall be used for the earth wire and
a grey or pale pink conductor used for the supply wire, depending if the supply is
positive or negative with respect to earth,
4. Extra low voltage AC circuits to be BROWN for the active conductor and BLACK
for the neutral conductor,
5. All analog signals (e.g. 4~20 mA DC, 0~10 V DC) to be colour coded VIOLET
where not included within screened cables. Core colours within screened cables
may be to the manufacturer's standard,
6. Critical digital signals to be colour coded ORANGE. The critical signal wire colour
shall apply for cubicle wiring between the terminal and the device on the
mounting plate,
7. All earth cables shall be GREEN/YELLOW.

3.4.3 Wiring Installation

Wiring of size 1.5 mm2 or less shall be run, wherever possible, inside slotted PVC ducts
with snap on covers. Ducts shall be adequately sized to accommodate the wiring, plus
at least an additional 20% spare capacity. Where ducting is impractical, wiring may be
loomed using proprietary looming or sleeving.
Where applicable, wiring shall be arranged so that the equipment can be removed
without disconnection of the plug from the equipment. (i.e. the plug can fit through
any conduits, or restrictions along its path).

3.4.4 Segregation
Low voltage circuit and extra low voltage circuit cables may be enclosed in the same
wiring system provided that compliance to AS/NZS 3000 is maintained.

3.4.5 Termination
The boundary between internal and outgoing wiring shall be a DIN rail mounted clip on
type terminal strip within the control/telemetry panel or switchboard.
Outgoing low voltage circuits with conductors 25 mm2 or above and general-purpose
power and lighting circuits may terminate directly on the switchgear, provided that the
cable selected can be accommodated by the terminal arrangement of the
equipment.
Terminals for control and instrumentation signals shall be grouped in a logical manner
according to the signal types (i.e. digital inputs, digital outputs, pulse inputs, analog
inputs and analog outputs). The following spare terminals shall be provided for each
group of signals as a minimum:
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1. 20% for total installed I/Os of up to 100,

2. 10% for total installed I/Os exceeding 100.
Extra low voltage terminals shall be segregated from low voltage terminals. AC
voltages shall be segregated from DC voltages. All low voltage terminals shall be
adequately shrouded to prevent accidental contact, with hazardous voltage labelling
included on the shroud.

3.4.6 Small Wiring Protection

Small wiring which feeds directly from the busbars (e.g. voltmeter wiring, wiring to
voltage operated protection relays) shall be protected by means of fuses which shall
be in accordance with clause 4.7. The fuses shall be located as closely as is
practicable to the point of tee-off from the busbar system, but shall be located in a
position which allows access for maintenance.

3.5 Labelling
3.5.1 General
Labels shall be made of engraved multi-layered Phenolic plastic sheet, such as
Gravoply, Rowmark, or approved equivalent, giving white lettering on a red
background for warning labels, and black lettering on a white background for all other
labels. Embossing tape shall not be used. Labels for outdoor equipment shall be
resistant to corrosion and sunlight.
Labels shall be fixed by pins, screws or an approved adhesive. Labels which are fixed
to the outside surfaces of outdoor Switchboards, control/telemetry panels and other
equipment shall be fixed with corrosion resistant (preferably stainless steel) pins or
screws. Adhesives shall not be used for fixing outdoor labels.
Labels shall not be affixed to removable covers, such as cable ducting lids.
Where applicable, the location of the main switchroom shall be clearly identified by a
permanent sign at the entrance or at the fire indicator board, in accordance with
AS/NZS 3000.

3.5.2 Main Titles and Subtitles

Switchboards, control/telemetry panels and their sub sections shall be labelled with the
titles provided in the project specification and drawings or, where these are not
specified, titles which adequately and accurately describe the units.
Minimum lettering height shall be as follows:
1. Main Titles 20 mm,
2. Sub Sections 10 mm.
Nameplates for Switchboards and control/telemetry panels shall be in accordance
with clause 3.5.5.

3.5.3 Naming Convention

In the absence of any other site convention, the Main Switchboard shall be labelled as
MSB, followed by a unique number (where location numbers are assigned, they should
be used as the unique number) to differentiate the Switchboard from other
Switchboards on site.
Distribution boards shall be labelled as DB, followed by the Main Switchboard or
Distribution board number from which the distribution board is fed, followed by a
unique number to differentiate the distribution board from other distribution boards
within that supply circuit. (For an example, refer to Figure 1).

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MSB.1 MSB.2

DB.1.1 DB.1.2 DB.2.1 DB.2.2

DB.1.1.1 DB.1.1.2 DB.1.2.1 DB.1.2.2

Figure 1 - Example of Switchboard and Distribution Board Naming Convention

3.5.4 Panel Controls and Indications

Panel controls, indications and features shall be labelled with the titles provided in the
project specification and drawings or, where these are not specified, titles which
adequately and accurately describe their function.
The manufacturer's standard escutcheon plates may be used for panel control and
indicator items.
The minimum lettering height for purpose-made labels shall be 4 mm.

3.5.5 Switchboard Nameplates

In addition to the requirements of AS/NZS 61439.1, low voltage Switchboards and
control/telemetry panels which have a rated current of 100 A or more per phase, or a
rated prospective short circuit current of 5 kA or more, shall have a label(s) fitted which
includes the following information, if not already provided on other labels:
1. The number of the Standard (including country of origin) with which the
equipment complies,
2. Manufacturer's name or trademark/logo,
3. Identification of the assembly, e.g. model, type, catalogue number, etc.
4. Assembler's name or trademark/logo, if different from that of the manufacturer,
5. Degree of protection in accordance with AS 60529,
6. Form of segregation,
7. Rated operational voltage,
8. Rated frequency,
9. Rated current,
10. Type-tested short circuit rating,
11. Any other information required to be marked on the equipment by the Standard
with which the equipment is purported to comply,
The nameplate shall be manufactured from laminated plastic or other approved
material and shall be attached to the front structure of the Switchboard in compliance
with clause 3.5.1.

3.5.6 Contactors, Relays and Circuit Breakers

Contactors, relays, circuit breakers and other components shall be labelled with the
designations or label names used in the control circuits. Labels shall be affixed

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adjacent to each individually mounted circuit breaker to designate the circuit. If room
does not permit a description of the function of the device, then this may be omitted.
A printed (not hand-written) legend shall be included in the general LV power
distribution section of every Switchboard and Control/Telemetry panel.
Where plug-in relays are used, the labels shall be fixed on, or adjacent to, the
associated sockets and not on the relays or other removable parts, such as cable duct
covers.
The minimum lettering height shall be 4 mm.

3.5.7 Instrumentation Equipment

Instrumentation equipment shall be labelled with the P&ID mnemonic, plus loop
number and loop description, in accordance with the instrumentation loop diagrams.
Panel displays shall be labelled with the variable description and engineering units.
The minimum lettering height shall be 4 mm.

3.5.8 Terminals
Terminal blocks shall be labelled as per termination schedules using the manufacturer’s
label systems, where possible.

3.5.9 Wiring
Wiring shall be labelled by means of slip-on ferrules or similar, numbered to correspond
with wire numbers generated from schematic diagrams, in accordance with clause
13.1.3. Jumper wires of less than 50 mm length and which are visible for their entire
length need only be labelled once, but other wiring shall be labelled at each end.
Where equipment terminal strips accommodate high density wiring, or in the case of
pre-wired looms, such as PLC I/O cards and the like, where it is not physically possible
to fit wire labels, these may be dispensed with.

3.5.10 Fuses
Labels shall be fitted on, or immediately adjacent to, each fuse base or each 3-phase
set of bases to identify (where possible) the function and designation of the fuses, and
to specify the current ratings of the fuse links. If room does not permit a description of
the function of the fuse, then this may be omitted.

4 Components
4.1 General
4.1.1 Ratings
Electrical equipment shall be adequately rated for the specified duty and operating
conditions. Adequate derating shall be applied where the operating conditions
exceed those for which the equipment is designed (e.g. high ambient temperatures).
Where current and/or voltage ratings for components are specified and/or shown on
the specification drawings, components shall have ratings not less than those specified
or shown.
Where current and/or voltage ratings are not specified or shown, then components
shall have current and voltage ratings adequate for the duty to which they are to
perform.
When determining the ratings, allowance shall be made for:
1. frequency of usage,

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2. making and breaking currents,

3. power factor (where applicable),
4. prospective fault current, and
5. ambient temperatures which will occur at the point of installation.
Components which are not characterised by current ratings (e.g. multi-function meters,
programmable logic controllers, protection relays, instrumentation equipment) shall
have temperature ratings suitable for the point of installation.

4.1.2 Degree of Protection

Unless otherwise specified, the degree of protection of components shall be suitable
for the location and application.

4.1.3 Corrosive Environments

Unless otherwise specified, equipment in corrosive environments shall be designed and
installed in accordance with the following:
1. A risk assessment shall be completed at each site to determine areas of plant
most at risk of a Corrosive Environment. The risk assessment shall include
determination of the air quality as guided by ISA-S71.04;
2. Determine specific requirements for any equipment in those risk areas (e.g.
conformal coating of electronic equipment, tin plating of busbars and wiring
conductors, stainless steel or corrosion resistant non-metallic cable supports),
including mitigation measures for electrical enclosures and switch rooms.

4.1.4 Ambient Temperatures

Where not otherwise specified, the Contractor shall design and install equipment in
accordance with the following:
1. All equipment in an outdoor environment shall be suitable for continuous
operation with an ambient temperature range of -5 °C ~ 50 °C. Outdoor
enclosures shall be adequately ventilated/cooled to ensure that the maximum
temperature will not exceed the equipment design temperature,
2. All equipment in an indoor environment shall be suitable for continuous operation
with an ambient temperature range of 0 °C ~ 40 °C. Indoor environments and
electrical enclosures shall be ventilated/cooled to ensure that the maximum
temperature will not exceed the equipment design temperature,
3. Equipment housed in outdoor enclosures shall be adequately de-rated to allow
for the increase in ambient temperature inside the enclosure.

4.2 Circuit Breakers

4.2.1 Discrimination
Where circuit breakers are installed in series, every effort should be made to provide
discrimination for tripping currents up to the maximum prospective fault current for the
installation. If full discrimination cannot be achieved between protective devices,
options need to be explored with the SA Water Principal Electrical Engineer or a
dispensation sought.

4.2.2 Air Circuit Breakers

Air circuit breakers (ACBs) shall be in accordance with AS 60947.2 and the following:
1. Three pole air insulated,

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2. Suitable for 400 volt 3 phase 50 Hz operation,

3. Withdrawable with service, test and isolated positions being available and clearly
indicated,
4. Provided with pad-lockable automatic shutters over both the live and load side
connections,
5. Provided with interlocks to:
a. prevent movement of the unit to or from the service position whilst the
breaker is closed, and
b. prevent the compartment door from being opened whilst the breaker is in
the service position and the breaker is closed,
6. Manual closing,
7. Trip free,
8. Manual and overcurrent opening,
9. Provided with mechanical indication of status, i.e. open, closed and fault,
10. Lockable in the open position,
11. Pad-lockable in the test and isolated positions,
12. Designed to be maintained,
13. Suitable for uninterrupted duty,
14. Rated for the full load current,
15. Have an interrupting capacity of not less than the prospective fault current of the
supply,
16. Provided with adjustable instantaneous and adjustable inverse time delay
tripping,
17. Provided with auxiliary contacts for indication of circuit breaker open, closed and
tripped status.

4.2.3 Moulded Case Circuit Breakers

Moulded case circuit breakers (MCCBs) shall be in accordance with AS 60947.2 and
the following:
1. Three pole,
2. Suitable for 400 V AC, 3 phase 50 Hz operation,
3. Quick make manual closing,
4. Quick break manual opening,
5. Trip free,
6. Automatic opening on overcurrent and short circuit,
7. Provided with mechanical status indication, i.e. open, closed and fault,
8. Lockable in the open position,
9. For Form 3 switchboards, provided with safety interlocks to prevent the
compartment door from being opened with the breaker in the closed position
and to prevent the breaker from being closed with the compartment door
opened,
10. Suitable for uninterrupted duty,
11. Rated for the full load current of the circuit,

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12. Have a rated short circuit making capacity not less than the prospective short
circuit current of the supply,
13. Have a rated service short circuit breaking capacity not less than the prospective
short circuit current of the supply,
14. Provided with instantaneous tripping,
15. Provided with inverse time delay tripping.

4.2.4 Miniature Circuit Breakers

Single pole and multi-pole miniature circuit breakers (MCBs) shall be in accordance
with AS/NZS 3111 and the following:
1. Shall have a current interrupting capacity suitable for the prospective fault
current and not less than 5 kA symmetrical,
2. Lockable in the open position via permanently fixed locking device (except for
Extra Low Voltage applications where the lockable requirement to be as per
project specification).

4.3 Residual Current Devices

Residual current devices shall be in accordance with AS/NZS 3190 and the following:
1. Shall be type II devices unless otherwise specified,
2. Site tested in accordance with clause 12.4.3 before being placed into service,
3. Either one of the following configurations shall be provided:
a. Combined miniature circuit breakers/residual current devices which shall
be in accordance with the requirements of AS/NZS 3111 and clause 4.2.4,
b. Protected on the supply side against overcurrent and short circuit by
miniature circuit breakers or fuses, which shall be in accordance with
clause 4.2.4 or 4.7 respectively.

4.4 Isolating Switches

Isolating switches shall be in accordance with AS/NZS 3133. Any switch which is used to
directly isolate its associated electric motor by switching the phase conductors shall be
a motor control switch as defined in the Standard and shall, in addition, be provided
with facilities to padlock the switch in the OPEN or OFF position.
Isolators mounted through hinged escutcheons or doors shall be mechanically
interlocked with the power supply isolators such that the door cannot be open with the
isolator closed and the isolator cannot be closed with the door open. For modules less
than 160A, mechanical interlocking of escutcheons may only be excluded in the case
where the escutcheon is fixed in place entirely with bolts that requires a tool to remove
it.
The requirement for locking facilities detailed above shall also apply to crane isolator
switches.
All single-phase isolating switches rated at 20A and above and all multiphase isolating
switches shall include a positive status indication. The indication shall include the words
‘ON’ and ‘OFF’ or the symbols ‘I’ and ‘O’ for the respective positions of the switch.

4.5 Air Break Switches

Air break switches shall be in accordance with AS/NZS 60947.3 and the following:
1. Fast make/fast break, independent manual operation preferably with double
break contacts on each pole of the switch,

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2. Fitted with a positive indication of the position of the switch which shall include
the words ‘ON’ and ‘OFF’ or the symbols ‘I’ and ‘O’ to indicate the switch
position,
3. Provided with facilities to padlock the switch in the OPEN or OFF position,
4. Equipment used for the direct switching of an associated electric motor shall
have a utilisation category AC-23. Other equipment shall have a minimum
utilisation category of AC-22.

4.6 Composite Fuse Switch Units

Composite Fuse Switch (CFS) units shall be in accordance with clause 4.5 and the
following:
1. Accommodate HRC fuses in accordance with clause 4.7,
2. Triple pole units,
3. Individual contacts to be separately and fully shrouded,
4. Barriers included between fuse cartridges to reduce the possibility of a phase-to-
phase or phase-to-earth fault occurring,
5. Shrouds, barriers and the complete moving contact assembly shall be removable
from the CFS enclosure for maintenance purposes,
6. Provided with facilities to padlock the unit in the OPEN or OFF position,
7. Provided with safety interlocks to prevent the compartment door from being
opened with the CFS unit in the closed position and to prevent the CFS unit from
being closed with the compartment door opened.

4.7 Low-Voltage Fuses

Low voltage fuses shall be in accordance with the general requirements of AS 61818,
applicable requirements of AS/NZS 60947 part 7.3 and the following:
1. Suitable for use on a 400/230 V AC, 50 Hz supply,
2. Fuse links shall:
a. have a rated breaking capacity of not less than 50 kA at 400 V AC, 50 Hz or
the prospective fault level at the point of installation, whichever is higher,
and
b. be of the 'gG' or 'gM' type,
3. Fuse holders shall:
a. have a protection rating of not less than IP2X in accordance with AS 60529
with the fuse carriers removed,

4.8 Motor Contactors

Motor contactors shall be in accordance with the following:
1. Air break, electromechanical type with short-circuit protective devices in
accordance with AS 60947.4.1,
2. Provided with Type 2 co-ordination in accordance with AS 60947.4.1,
3. Utilisation category AC-3 and intermittent duty not less than Class 12 as defined in
AS 60947.4.1, or a higher category and/or duty class to suit the specified
operation requirements, if required,
4. A mechanical endurance of not less than 1 million operating cycles,
5. Operating coils shall operate at either 24 V DC or 230 V AC.

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4.9 Soft Starters

Soft starters shall be AC type in accordance with the following:
1. Stepless variable voltage output, adequately rated for the maximum
temperature which will occur inside the cubicle,
2. Adjustable start and stop ramp times and ranges in accordance with the project
specification,
3. In-built fault indications with diagnostics and a changeover voltage-free contact
for remote fault indication,
4. Provided with a bypass contactor facility,
5. Protection against short-circuit faults with fast acting semi-conductor fuses for
starters rated above 22 kW, in accordance with manufacturer’s
recommendation,
6. Provided with overload protection of the connected motors with Type 2 co-
ordination, with the short-circuit protective devices in accordance with AS
60947.4.2,
7. Electromagnetic compatibility in accordance with clause 8.3 of AS 60947.4.2,
8. Utilisation category AC-53a as defined in AS 60947.4.2, or AC-53b where bypass
contactors are provided,
9. Intermittent duty as defined in AS 60947.4.2 with the number of operating cycles
per hour (S value) of not less than 10 or to suit the specified duty, whichever is
higher. The ratio of the on-load period to the total period (F value) shall be not
less than 70%, or to suit the specified duty, whichever is higher.
10. Communications port to interface with other devices such as PLCs (i.e. Ethernet),
where specified.

4.10 Variable Speed Drives

Where space and installation environment/methodology allow, VSDs shall be IP54,
mounted external to the switchboard i.e. mounted on the switchroom building internal
wall.
Variable speed drives (VSDs) shall comply with the following requirements:
1. Variable voltage variable frequency type, rated for continuous operation at full
load, under the specified maximum ambient temperature,
2. Electromagnetic and Harmonic disturbances shall comply with the requirements
of AS/NZS CISPR11 and AS/NZS 61000 and SAPN Service and Installation rules,
Harmonic calculations shall be provided during design, and verification
measurements taken during commissioning to validate the compliance of the
mitigation technique,
3. Electromagnetic immunity in accordance with AS/NZS 61000.6.1,
4. Capable of sustaining not less than 110% rated output current for a minimum
duration of 1 minute,
5. Infinitely variable speed control over the required speed range, directly
proportional to a 4~20 mA DC setpoint control signal,
6. Adjustable minimum and maximum speed limits,
7. Adjustable current limits,
8. Soft start with adjustable acceleration and deceleration ramp rates,
9. In-built PID controller for closed-loop control, where specified by the project,

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10. Power loss ride-through to allow continued operation of a rotating motor after a
short power interruption,
11. Where an emergency stop is required by the project specification, a risk
assessment of a ramp-to-stop arrangement or coast-to-stop arrangement shall
be documented,
12. Galvanic isolation between remote and internal circuits to not less than 1 kV DC,
13. Provided with the following minimum controls and indications available on the
front of the VSD unit:
a. Running,
b. Fault,
c. Output current,
d. Output voltage,
e. Output frequency (or speed),
f. Power,
g. Adjustment of all drive parameters,
14. Provided with the following minimum protection, with indications available on the
front of the VSD unit:
a. Lightning and voltage transients,
b. Overvoltage,
c. Undervoltage,
d. Overcurrent,
e. Short circuit,
f. Earth fault,
g. Input phase failure,
h. Output phase failure,
i. Overtemperature,
j. Motor overload,
k. Motor winding overtemperature (where applicable),
l. Loss of 4~20 mA DC control signal,
15. if required in accordance with the manufacturer’s recommendation, additional
protection against short-circuit for drives rated at 22 kW and above,
16. Provided with the following minimum remote interfaces:

Digital Inputs

a. Local/ Remote selection,

b. Start/Stop (or Run) control,
c. Preset speed selection (where applicable).

Digital Outputs

a. VSD Running,
b. VSD Fault (incorporating all the protection in (14) above).

Analog Input

a. 4~20 mA DC speed control signal.

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Analog Outputs (only where specified)

a. Not less than two programmable 4~20 mA DC outputs to enable any two
parameters to be selected (e.g. power, current, frequency or speed). Each
analog output shall be capable of driving a load of not less than 600 .

Network Interface (where required)

a. Communications port to interface with other devices, such as PLCs. Where

this facility is utilised, the minimum requirement of analog outputs can be
incorporated into the network interface communications.

4.11 Cubicle Heaters

Cubicle anti-condensation heaters shall be provided for all outdoor control/telemetry
cubicles, or where the internal cubicle temperature is expected to drop to 10 °C or
below, or in locations where condensation could form inside the cubicle. The
exception to this rule is for standalone solar or battery-powered panels. Justification
must be provided for not providing cubicle heaters, otherwise heaters shall be installed
in all control/telemetry cubicles in accordance with the following:
1. Black heat strip heaters rated at approximately 20 watts per square metre of
cubicle surface area and suitable for operation at 230 V AC. Heaters powered
with 230 V AC shall be protected with an RCD;
2. Shall be of a number and installed so that heat from the heaters can readily
circulate throughout the cubicles without damage to materials or components;
3. Provided with a thermostat in each section of a cubicle where there are heaters
fitted that will energise the heaters when the air temperature inside the cubicle is
below 10 °C. The thermostat can be either built-in or separate and shall
preferably be adjustable. For long cubicles, additional thermostatically controlled
heaters shall be supplied and installed to ensure adequate temperature control
within the control/telemetry cubicle;
4. Heater and thermostat terminals shall be IP2X in accordance with clause 3.3.1
(8); and
5. Provided with a label, adjacent to the heater indicating the origin of the supply.

4.12 Motor Protection Units

4.12.1 Thermal Overload Units
Thermal overload units shall be provided for the protection of motors rated at less than
15 kW. Thermal overload units shall be in accordance with AS 60947.4.1 and the
following:
1. Triple pole, differential action to enhance the performance of protection against
phase imbalance or phase failure,
2. Incorporate ambient temperature compensation,
3. Include provision to allow the trip setting to be adjusted,
4. Suitable for alternative manual or automatic reset and initially set to automatic
reset if the control circuit has a separate lockout facility and RESET pushbutton.

4.12.2 Electronic Motor Protection Relays

Electronic motor protection relays shall be provided for the protection of motors rated
at 15 kW and above. Protection relays shall be in accordance with the following:
1. Provide protection and separate indication for each of the following:
a. Overload,
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b. Winding over-temperature by means of thermistors,

c. Single phasing and asymmetry.
2. Have selectable current and trip time settings,
3. Have a test feature,
4. Suitable for operation from a 230 V AC supply,
5. Provide finger protection for the terminals (IP2X) other than the main
connections,
6. Unaffected by the passage of short circuit currents through the unit.
Directly connected units (i.e. without the need for external current transformers) are
preferred.

4.12.3 Thermistor Control Units

Thermistor control units shall be used to monitor the operation of thermistors built into
motors and auto-transformers unless the thermistors are monitored by an electronic
motor protection relay.
The control units shall be in accordance with AS 60947.8 and the following:
1. Suitable for a 230 V AC supply voltage,
2. Provide a visual indication that a trip has occurred,
3. Match the type of thermistor, i.e. positive or negative coefficient type.

4.13 Meters
4.13.1 General
Ammeters and voltmeters shall be provided where required by the project
specification and drawings. These may be square bezel pattern type, of nominal size
96 mm with an approximate 120o movement. Alternatively, a multi-function meter
digital display or HMI may be used to measure and display the required parameters in
a single unit.

4.13.2 Ammeters
Ammeters shall be in accordance with the following:
1. Where used for measuring 3 phases, provided with a selector switch to allow
selection of individual phase currents. An OFF position shall be provided,
2. Accuracy of ±2.5% or better,
3. Scaled to correspond to the rated primary current,
4. Where used for measuring motor current, be over-scaled to approximately six
times the rated current of the associated motor. Full load current shall occur
between 60% and 90% of full scale,
5. Where used for other than measuring motor current, be over-scaled to
approximately two times the rated current of the circuit.
6. Provided with insulating shrouds on exposed terminals.

4.13.3 Voltmeters
Voltmeters shall be in accordance with the following:
1. Provided with a voltmeter selector switch and potential fuses to allow selection of
individual phase to phase voltages. No OFF position shall be provided,

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2. Accuracy of ±2.5% or better,

3. Scaled to read between 0 and 500 V,
4. Provided with insulating shrouds on exposed terminals.

4.13.4 Multi-function Meters

Multi-function meters shall be in accordance with the following:
1. Measure and display voltage, current and power in a single integral unit at not
less than ±1% accuracy,
Additional parameters (energy, power factor, individual and total harmonic
distortions etc.) shall be included as required by the project specification and/or
drawings. The display shall be retained during power failure where used for
energy measurement.
The multi-function meter shall be capable of measuring, storing and displaying
maximum load.
2. Panel mounting facilities,
3. Suitable for monitoring a 3-phase unbalanced supply and load,
4. Operation from a 230V AC auxiliary supply,
5. Provided with insulating shrouds on exposed terminals,
6. Provided with the following remote interfaces, where required by the project
specification:
a. Digital and analog inputs/outputs, programmable to represent the
selected parameters,
b. A communications port with industry standard protocol (e.g. Ethernet).

4.14 Current Transformers

4.14.1 Metering Current Transformers
Metering current transformers shall be in accordance with AS 60044.1 and the
following:
1. Accuracy not lower than Class 1M or, where used with test sockets, kW meters,
kWh meters or multi-function meters, not lower than Class 0.5M,
2. Rated secondary current of 5A,
3. Rated burden sufficient to cover the burden imposed by the connected
equipment, including cables. Where a test socket is required, in accordance with
clause 4.23.8, an additional burden of 5 VA shall be allowed for external
equipment which may be plugged into the socket.

4.14.2 Protection Current Transformers

Protection current transformers shall be in accordance with AS 60044.1 and the
following:
1. Designated as 10P150F20 unless otherwise specified or required to suit the
protection relay,
2. Rated secondary current of preferably 1A,
3. Transformer ratio shall be determined for correct operation of the associated
relay under fault condition, taking into consideration the rated accuracy limit
factor of the transformer and the burden of the connected circuit,

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4. Provided with test taps, where required, to be used in conjunction with a test
socket.

4.15 Control Relays

All control, interposing, latching and auxiliary relays shall be in accordance with AS
60947.5.1 and the following:
1. If no voltage is specified, then 24V DC shall be used.
2. Relays shall be suitable for the voltage and type of duty required, and shall have
a current rating adequate for the load and, in any case, not less than 1A,
3. The operational life shall be not less than 10,000,000 cycles,
4. Finger protection for terminals (IP2X in accordance with AS 60529),
5. Provided with a LED status indicator.

4.16 Timing Relays

Timing relays shall be in accordance with the following:
1. Electronic type with an adjustable range,
2. If no voltage is specified, then 24V DC shall be used,
3. Relays shall be suitable for the voltage and type of duty required, and shall have
a current rating adequate for the load and, in any case, not less than 1A,
4. Accuracy Class 1.5 or better,
5. The operational life shall be not less than 10,000,000 cycles,
6. Finger protection for terminals (IP2X in accordance with AS 60529),
7. Provided with LED status indicators.

4.17 Programmable Logic Controllers

Programmable logic controllers (PLCs) shall comply with the requirements of TS 0360 -
PLC and HMI Systems.

4.18 Programmable Relays

Programmable relays (also referred to as intelligent or smart relays) may be used for
basic control applications and shall comply with the following requirements:
1. Programmable with a personal computer,
2. Programming software and hardware shall be supplied for the programmable
relay and shall provide full editing, debugging, monitoring, testing and
documentation functions,
3. Display screen to facilitate basic monitoring, fault finding and diagnostics,
4. Minimum of 1 year program backup time (including all timer/counter values) in
the event of a power failure,
5. System clock (where applicable),
6. Shall operate from 24 V DC unless otherwise approved,
7. Provided with minimum 20% spare inputs and outputs of each type installed,
8. Digital inputs and outputs shall be in accordance with the following:
a. Digital input signals to the programmable relay shall be failsafe for fault
indications,

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b. Digital outputs shall be protected from short-circuit faults through provision

of a fuse or other means. The type of output selected shall be chosen in
accordance with the voltage, current and the type of load.

4.19 Hours Run Meters

Hours run meters shall have a display capable of registering not less than 9999 hours
and shall not be resettable on the unit itself. Where the project specification calls for
provision of HMIs, hours run data should be calculated in the relevant PLC and
displayed on the relevant HMI, if possible. 230/400 V supplies running to these meters
when they are escutcheon/door mounted is discouraged. (Consider the use of
interposing relays.)

4.20 Undervoltage and Phase Imbalance Relays

The three-phase relay shall be a combined phase imbalance and undervoltage type
with a contact opening for the following:
1. Voltage below 80% of rated site voltage,
2. Phase imbalance greater than value set. This value shall be adjustable from 5-
15% and initially set at 10%.
For single phase installations a similar relay designed for single phase monitoring shall
be used for monitoring of voltages below 80% of rated site voltage.

4.21 Control Switching Devices and Indicator Lights

Pushbuttons, rotary switches and indicator lights shall be in accordance with AS
60947.5.1.
Indicator lights shall be clearly visible under all indoor and outdoor ambient light
conditions. Suitable sunshields or other means shall be provided for outdoor situations
to improve visibility, if necessary. Indicator lights shall be high intensity LEDs. Where only
one or two lamps exist on a panel, the LAMP TEST pushbutton may be replaced with
lamps that have an integral lamp test function. Ensure these lamps are clearly labelled
as ‘push to test’.
The colours of pushbuttons and indicator lights shall be in accordance with Table 4-1
and Table 4-2, respectively.
Table 4-1 - Colours of Pushbuttons

Colour Application
RED Action in case of EMERGENCY STOP, STOP or OFF
• Emergency stop (mushroom head)
• Emergency close a valve (mushroom head)
• Stop or Off
• Combined stop and reset
• Open a circuit breaker or switch (only on the switchgear panel)
YELLOW Intervention (e.g. to avoid danger or unwarranted change)
• Sound a horn
• Interrupt an automatic sequence
• Bypass an inhibit
GREEN START or ON
• Start
• Close a circuit breaker or electrical switch (only on the switchgear panel)
BLUE Not used unless required by the project specification.

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BLACK No specific meaning. To be used for all other applications, e.g.:

• Reset • Raise
• Acknowledge • Lower
• Lamp Test
• Open (a valve)
• Close (a valve)
• Forward
• Reverse

Table 4-2 - Colours of Indictor Lights

Colour Application
RED Danger or alarm
• Chlorine extraction fan not running
• Fire alarm
• High fluoride dose rate alarm
• Alarms which automatically shut down the plant or process. For example:
• Motor winding over-temperature
• Pump discharge failure
• Tank overflow
• Circuit breaker or switch closed (only on the switchgear panel)
YELLOW Caution
• Stage 1 alarm (Stage 2 being shutdown)
• Alarm which allows operation in an abnormal mode (e.g.: non vital fault
which allows a variable speed controller to operate in fixed speed as backup)
• Machinery with exposed moving parts operating
GREEN Safety or authorised to proceed
• Circuit breaker or switch open (only on the switchgear panel)
• Earth switch closed
BLUE The following have been assigned:
• Off
• Stopped
• Valve Closed
• Remote
• Local
• Automatic
• Manual
• Normal
• Standby
• Circuit breaker or switch open (remote from the switchgear panel)
WHITE The following have been assigned:
• On
• Available (illuminated when power available, and in remote (or auto) mode
and no faults, and no E-Stop)
• Running
• Valve Open
• Electrical supply available
• Circuit breaker or switch closed (remote from the switchgear panel)

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4.21.1 Motor Control Centre - Control Selector Switch

Unless otherwise specified, MCCs, as a minimum, shall have 3-way selector switches for
selecting the motor control operating mode. These 3-way selector switches shall be
configured as:

• AUTO/OFF/MANUAL for equipment which does not have automatic or manual

control from SCADA (this typically applies to small wastewater pump stations
and valve sites).
• REMOTE/OFF/LOCAL for equipment which has automatic and manual control
from SCADA (this typically applies to treatment plant equipment).

3-way control operating mode selector switches shall not be lockable.

Control operating mode selector switches requiring more than 3-ways shall be
determined and approved during the design phase of a project.

4.22 Surge Protection

Surge arresters for limiting voltage surges on AC power circuits shall be in accordance
with the following:
1. Comply with the requirements of AS/NZS 1768 and IEC 61643-11,
2. Non-linear metal-oxide type in accordance with AS 1307.2,
3. Shall operate at a nominal system voltage of (Vrms) 230/400V, 50Hz,
4. Provided with failure indication,
5. Indicators visible without opening the escutcheon/enclosure door, unless remote
indication is provided (for example, on the HMI).
6. Surge Protection Devices are to be mounted as close as practicable to the
Neutral/Earth bar of the supply, with wiring run as straight and direct as possible.
Where cables are connected to output equipment with a potentially damaging high
current output under short circuit conditions, the cables and output equipment shall be
protected against short circuit unless the output equipment is inherently current-limited
or short-circuit proof.

4.22.1 Main and Distribution Switchboards

Low Voltage surge arrester devices for Main and Distribution Switchboards shall also
comply with the following minimum design, construction and performance
requirements:
1. Voltage limiting (L-N), voltage switching (N-PE) topology with a redundant
segment arrangement for L-N voltage limiting components;
2. Suitable for locations Category B, C1, C2, C3 as per AS/NZS 1768;
3. Degree of protection: IP20;
4. External back up HRC fuses or purpose-specific Circuit Breaker;
5. External alarm contacts: Voltage free SPST shall indicate status;
6. Main terminal size: suitable for maximum 16mm2 stranded cable;
7. External alarm terminal: suitable for maximum 2.5mm2 stranded cable;
8. Temporary over voltage withstand mode: 340 volts for 5 sec;
9. Temporary over voltage fail mode: 440 volts for 120 sec;
10. Nominal discharge current (15 impulses 8/20 µs wave shape):

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a. Main Switchboard: ≥ 40 kA per phase. ≥ 80kA N-PE.

b. Distribution Switchboard: ≥ 20 kA per phase. ≥ 40kA N-PE.
11. Maximum discharge current (1 impulse 8/20 µs wave shape):
a. Main Switchboard: ≥ 100 kA per phase. ≥ 100kA N-PE.
b. Distribution Switchboard: ≥ 50 kA per phase. ≥ 50kA N-PE.
12. Back up fuse: HRC type - purpose-specific CB Type:
a. Main Switchboard: 63A (HRC) or 3A purpose-specific CB, 25kA 10/350
b. Distribution Switchboard: 32A (HRC) or 3A purpose-specific CB, 80kA 8/20
13. Voltage protection level: As defined in IEC61643-11 shall be less than 850V at 3kA
8/20µs
14. The Maximum Continuous Operating Voltage, Uc as defined in AS1768 and
IEC61643-11, shall be 275 V,
15. Shall incorporate built-in short circuit protection,
16. Failure mode: Priority to continued operation. Back up fuse must be coordinated
with supply fuse or circuit breaker; and
17. Short circuit power frequency withstand current: 25 kA.

4.22.2 Process Instrumentation Systems

Low Voltage and Extra Low Voltage surge arrester devices for Process Instrumentation
Systems shall also comply with the following minimum design, construction and
performance requirements:
1. Gas Discharge Tube and Transzorb type construction;
2. Suitable for Category A locations as per AS/NZS 1768;
3. Degree of protection: IP20;
4. External back up HRC fuses or purpose-specific Circuit Breaker;
5. Internal thermal fuses on individual MOVs, if parallel segments per phase;
6. Status display: Internal alarm shall indicate device failure, visible without opening
the escutcheon /enclosure door;
7. External alarm contacts: Voltage free SPDT shall indicate status;
8. Main terminal size: suitable for maximum 2.5mm2 stranded cable;
9. External alarm terminal: suitable for maximum 2.5mm2 stranded cable;
10. Nominal discharge current: ≥ 10kA per line to line and ≥ 5kA per line to earth;
11. Maximum discharge current: (1 impulse 8/20 µs wave shape) ≥ 20kA per line to
line and ≥ 10kA per line to earth;
12. Voltage protection level shall be no more than double the continuous operating
voltage;
13. Failure mode: Priority to continued operation with local indication and switched
output for condition monitoring; and
14. Communication surge protection (say, for Profibus or DeviceNet) shall
incorporate high speed switching.

4.23 Instrumentation Equipment

This Technical Standard does not provide specific direction on the specification of
particular instruments. Each project or location will give direction as to the selection

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requirements or preferences of instrumentation. The sections below provide general

information as to the integration of instrumentation.

4.23.1 General
Instrumentation loops shall comply with the following:
1. Signals shall be linear with respect to the measured variables and shall be 4~20
mA DC,
2. For Critical Infrastructure and for control and instrument loops that, if interrupted,
would cause a significant incident, provided with a test injection facility, per
section 4.23.8, in each primary loop for plant testing or maintenance purposes.
For all other instrumentation loops, a purpose-made disconnect terminal will
suffice;
3. Equipment which is of the plug-in type shall be capable of being unplugged
without open-circuiting the instrumentation loop;
4. Where a primary loop is required to drive a number of secondary loops, a signal
isolator shall be provided for each secondary loop to maintain the integrity of the
primary loop so that a fault in a secondary loop does not affect the primary loop
and other secondary loops. (Ensure the primary loop is monitored for ‘out-of-
range’ condition (in PLC/RTU), or any secondary loop that performs a control
function is also monitored.);
5. Where it forms a control loop with other equipment (e.g. RTU, PLC, VSD, SCADA)
the loop shall be electrically isolated from other loops, power supply and earth
and be capable of driving the total loop impedance;
6. Provided with lightning protection at the control panel side of cables where the
equipment is installed in separate buildings or structures, or where the field
transducer is located outdoors at a distance of 50 m or greater from the Control
panel; and
7. Where a communication protocol (ie MODBUS, HART, Ethernet) is used in the
transmission of instrument signals, an additional 4-20mA hardwired signal must be
used for any control signal functions.
The requirement for lightning protection shall be determined in consultation with the
Regional Maintenance representative.

4.23.2 Scale Indicators

Scale indicators shall be in accordance with the following:
1. Accuracy of ±1.5% or better,
2. Dial type indicators shall be square bezel pattern of 96 mm nominal size and
having a concentric scale with an approximately 90o movement,
3. Scaled in engineering units,
4. Suitable for use with a 4~20 mA DC signal.

4.23.3 Digital Indicators

Digital indicators shall be in accordance with the following:
1. Number of digits to suit the appropriate displays,
2. Accuracy not less than ±0.2% ±1 count,
3. Height of digits not less than 12.5 mm,
4. Suitable for panel mounting,
5. Zero suppression or elevation capability not less than full scale,

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6. Readout in percent or engineering units as appropriate,

7. Suitable for 4~20 mA DC input,
8. Voltage drop in current loop shall not exceed 2.5 V,
9. Shall not earth the instrument loop at either input.

4.23.4 Flow Integrators

Flow integrators shall be in accordance with the following:
1. Direct reading digital type with 7 digits,
2. Calibrated to display total flow in the specified units,
3. Inhibited from operation when the flow rate is below 0~15% (adjustable) of the
maximum flow,
4. Reading shall be retained during a power failure,
5. Shall not earth the instrument loop at either input,
6. Provide a signal from the flow transmitter integrator over Modbus, HART or similar
connection, for totaliser flows through to SCADA.

4.23.5 Signal Isolators

Signal isolators shall be in accordance with the following:
1. Complete electrical isolation between the input, output and power supply,
2. Provide a boosting capacity to suit the load requirements,
3. Provide a 4~20 mA DC output proportional to a 4~20 mA DC input with an
accuracy of ±0.25% of span or better,
4. Shall not earth the instrument loop at either input or output.

4.23.6 Signal Alarm Units

Signal alarm units shall be in accordance with the following:
1. Adjustable differential over the full range,
2. Repeatability of alarm operation shall be ±0.5% or better,
3. Shall not earth the instrument loop at either input or output.

4.23.7 Lightning Protection Units

Lightning protection units shall be in accordance with the following:
1. Discharge current rating of not less than 20 kA for surges with a characteristic
corresponding to a standard as defined in AS/NZS 1768,
2. Protection against both differential and common mode transients extending from
the power supply input,
3. Include both voltage limiting devices and overcurrent fuses.

4.23.8 Test Points and Test Injection Points

For Critical Infrastructure and for control and instrument loops that, if interrupted, would
cause a significant incident, test points for instrumentation loops shall be of Type A, B or
C in accordance with Figure 2, or as specified in the project specification. Test injection
points shall be provided with a NORMAL-TEST selector switch in accordance with Figure
3. Test points and test injection points shall be located inside the cubicles.

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Figure 2 – Test Points

+ N
+
4~20 mA 4~20 mA N T
4~20 mA from
TIP
transmitter 4~20 mA to
T 100  Red secondary
¼ W 1% instruments
- N

-
T

Black

Figure 3 – Test Injection Points

4.24 Human Machine Interfaces (HMI)

Human machine interfaces (or touch screen displays) shall comply with the
requirements of TS 0360 - PLC and HMI Systems.

4.25 Emergency Stop Circuits

An Emergency Stop circuit is a facility that is initiated by a human action and is
intended to shut down equipment in the case of an emergency. A Process Stop circuit
is a facility that commands equipment or a process plant to come to a controlled stop.
This clause prescribes the requirements for an emergency stop circuit.
Emergency stop circuits shall comply with the requirements of AS/NZS 4024 series and
AS/NZS 3000. A risk assessment (as a part of the Safety in Design process) shall dictate
the requirements of Emergency Stop circuits and type (Category 0 or Category 1 as
per AS/NZS 4024.1604 section 4.1.4) on a project-by-project basis.
Emergency Stop pushbuttons shall be:
1. Red, palm or mushroom headed with a push to operate motion and a twist to
release action, in order to release it from its operated position,

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2. Mounted on a yellow backing plate and clearly labelled, identifying its function
and what equipment it relates to, e.g. “EMERGENCY STOP AERATOR No 1”,
3. IP rated to at least that of the panel/enclosure to which the Emergency Stop is
installed,
4. Mounted in a position that will not impede its use (to be approved on site by SA
Water Operations personnel),
5. Hard wired directly into a relay used for the contactor control circuit (for AS/NZS
4024 series Category 0 installations only) or into a safety relay (for installations
other than Category 0).
Emergency Stop lanyards shall be:
1. Pull to operate motion and a pushbutton to release action, in order to release it
from its operated position,
2. Clearly labelled, identifying its function and what equipment it relates to, e.g.
“EMERGENCY STOP AERATOR No 1”,
3. A minimum IP 56 rated,
4. Mounted in a position that will not impede its use (to be approved on site by SA
Water Operations personnel),
5. Hard wired directly into a contactor control circuit (for AS/NZS 4024 series
Category 0 installations only) or into a safety relay (for installations other than
Category 0).
Emergency stops circuits shall be:
1. Designed such that releasing an Emergency Stop button will not cause any
equipment to move/restart,
2. Only capable of being reset by pressing a dedicated Emergency Stop reset
button. The reset function shall be provided by either hardwired panel mount
button or via local HMI. For certain remote applications with no battery backup
the Emergency Stop circuit may be reset using a power-up pulse, only if it is
deemed low risk, following a risk assessment,
3. Provide local visual indication that the Emergency Stop circuit has been tripped.
This indication shall be either hardwired panel mount or via local HMI. If installed,
the AVAILABLE indicator lamp shall not be illuminated when the Emergency Stop
circuit is tripped,
4. Provide a signal(s) to the control system, indicating the status of the Emergency
stop/Emergency stop circuit. The status signal(s) shall be displayed/alarmed in
SCADA.
Emergency Stop Installations:
1. A risk assessment shall be performed to determine whether more than one
Emergency stop pushbutton is required (e.g. for large equipment or equipment
where access may be restricted). The risk assessment shall also include
consideration of field cable types and routes.

4.26 General Lighting and Power Equipment

4.26.1 Lighting Fittings (General)
Where applicable, all lighting fittings shall be in accordance with AS/NZS 60598.1 and
AS/NZS 60598.2, with a preference for energy-efficient fittings (i.e. LED type) to be
installed.

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Lighting fittings shall be of high efficiency and high power factor and require minimum
maintenance. All materials forming part of the lighting installation shall be suitable for
the duty and environment of operation.
Materials used in lighting installations shall be selected in order to minimize the effect of
galvanic corrosion between dissimilar metals using appropriate safeguards.
Lighting fittings in the following locations shall have a degree of protection of not less
than IP56 in accordance with AS 60529:
1. Indoor locations which are subject to dampness, high humidity or ingress of
water,
2. Corrosive environments,
3. All outdoor locations.
Lighting fittings in hazardous areas shall be certified for the appropriate classification of
the hazardous areas in accordance with AS/NZS 60079.
Lighting fittings in corrosive environments shall be constructed of a material suitable for
that environment.
Lighting fittings in ELV sections of Switchboard and Control/Telemetry panels shall be
ELV powered, rather than LV powered.

4.26.2 Fluorescent Fittings

Fluorescent lighting fittings shall be supplied and installed complete with all necessary
auxiliary equipment, including reflectors, louvres or diffusers (if specified). Each
fluorescent tube shall be provided with a separate electronic ballast which shall be in
accordance with AS/NZS 61347.2.8, AS/NZS 60921 and AS/NZS 60925.
The internal wiring of fluorescent fittings shall have a temperature rating of not less than
105 °C. Each terminal in the connector block shall be suitable for the connection of not
less than 3 x 1.5 mm2 PVC insulated conductors.

4.26.3 High Intensity Discharge Fittings

High intensity discharge lighting fittings shall be power factor corrected so that the
power factor is not less than 0.8 lagging. Capacitors shall be located so as not to be
affected by heat generated by the lamp or ballast.
The internal wiring of the fittings shall have a temperature rating of not less than 105 °C.
Each terminal in the connector block shall be suitable for the connection of not less
than 3 x 1.5 mm2 PVC insulated conductors.

4.26.4 Emergency Fittings

Emergency luminaires and exit signs shall be type-tested self-contained fittings in
accordance with AS/NZS 2293.3. Emergency luminaires shall preferably be non-
maintained type, integrated within normal fluorescent lighting fittings.

4.26.5 Lighting Switches

Lighting switches shall be in accordance with AS/NZS 3133 and the following:
1. Switches in office areas shall be white and flush mounted with concealed wiring,
2. In other areas, switches may be either flush mounted or surface mounted and
shall be either white with white mounting blocks or shall match the colour of the
associated wiring conduit,
3. Lighting switches in the following locations shall have a degree of protection of
not less than IP56 in accordance with AS 60529:
a. Indoor locations which are subject to dampness or ingress of water,
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b. Indoor locations where additional mechanical protection is required,

c. Corrosive environments,
d. All outdoor locations,
4. Lighting switches in hazardous areas shall be certified for the appropriate
classification of the hazardous areas in accordance with AS/NZS 60079,
5. Lighting switches in corrosive environments shall be constructed of a material
suitable for that environment.

4.26.6 Socket Outlets

Socket outlets shall be in accordance with AS/NZS 3112, AS/NZS 3190 and the following:
1. Socket outlets shall be switched,
2. Outlets in office areas shall be white and flush mounted with concealed wiring,
3. In other areas outlets may be either flush mounted or surface mounted and shall
be either white with white mounting blocks or shall match the colour of the
associated wiring conduit,
4. Socket outlets supplied by UPS shall be colour-coded blue and/or appropriately
labelled,
5. Socket outlets in the following locations shall have a degree of protection of not
less than IP56 in accordance with AS 60529:
a. Indoor locations which are subject to dampness or ingress of water,
b. Indoor locations where additional mechanical protection is required,
c. Corrosive environments,
d. All outdoor locations,
6. Plugs and socket outlets in hazardous areas shall be certified for the appropriate
classification of the hazardous areas in accordance with AS/NZS 60079,
7. Plugs and socket outlets in corrosive environments shall be constructed of a
material suitable for that environment,
8. Socket outlets shall be clearly labelled to indicate the associated circuit breaker
feeding the outlet,
9. Wiring to three phase outlets shall be such that, when viewing the socket from
the front and reading the phases clockwise from the earth pin, the phases shall
be red, white and blue. The neutral pin, where fitted shall be the central pin.

4.27 Switchroom Air Conditioners

Unless detailed in project specifications, the minimum requirements for the installation
of air conditioners in electrical control/switch rooms shall be as per this clause.
Depending on the configuration and size of room to be temperature controlled, one or
more reverse cycle air conditioners shall be installed that are capable of maintaining
the room temperature at 23°C dry bulb, with an efficiency of greater than 95%. They
shall be set up for cool-mode only. The dry bulb temperature requirement shall be met
with the room equipment heat loading allowing for the heat generated by the ultimate
equipment capacity of the building and a maximum external temperature of 40°C.
Where more than one unit is specified, each air conditioner shall have the BTU (British
Thermal Unit) capacity, plus 30%, to maintain the temperature of the entire
environmentally controlled space at no more than 30°C in the event of failure of one of
the units.
All air conditioners shall be auto restart after a power outage and self-defrosting in the
event of icing up. No drip trays or plumbing joints shall be installed above switchgear.
Ducted air conditioning systems are not preferred.
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Air conditioners shall be fitted with monitoring alarm contacts for air-conditioner failure
and over temperature. A separate room temperature sensor shall be provided to allow
for connection to a local PLC for monitoring of the room internal temperature. Air
conditioner controls shall be hardwired rather than wireless ‘remote’ type control units.
Dust filters shall be used on any ventilators or grilles to the exterior of the building. The
cable entry points to the building are to be sealed off with a removable seal upon
completion of installing the cables to prevent ingress of dust and vermin.
All steelwork required to support the external compressor unit shall be galvanized and
firmly secured. An external pad-lockable and labelled isolating switch shall be fitted
adjacent to the air conditioning units. In public spaces, a suitably applied galvanised
cage is to be fitted to ensure the security of the outdoor unit.
A minimum 20 mm diameter PVC condensate drain to each air conditioning unit shall
be installed. Drains shall extend vertically down the walls of the building (with a
minimum of three fixings to each drain) to a suitable drainage point such as a roof
guttering down pipe.
The system shall be installed by qualified gas fitters.
Where applicable, a clean set of changeover contacts rated at a minimum of 230 V
AC shall be installed and wired to a suitably labelled terminal block within the FIP (Fire
Indicator Panel) for each of the following functions:
• One clean 230 V AC changeover contact to disconnect AC supply from the air
conditioners via a contactor; and
• One spare clean 230 V AC changeover contact.

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5 Field Cables and Equipment

5.1 Power Cables
Power cables shall be in accordance with AS/NZS 5000.1. Sheathed cables shall have a
PVC sheath, unless otherwise specified, and shall be suitable for use underground.
Power cables shall be screened in the following situations:
1. Where required to comply with the specified electromagnetic emission limits or as
required by the manufacturer of the connected equipment (e.g. variable speed
drives),
2. Where the power cables are installed in close proximity to data or signal cables
and it is not possible to provide adequate separation between the power cables
and data or signal cables to prevent interference in the data or signal cables.
All cables shall be of multi-strand construction and of copper conductor unless
otherwise specified.
The minimum cross-sectional area of any cable core shall be 2.5 mm2 except for:
• current transformer wiring which shall be a minimum of 4 mm2; and
• Lighting circuits, which may be a minimum of 1.5 mm2.
The Contractor shall be responsible for selecting cable sizes, where not shown on the
specification drawings, in accordance with AS/NZS 3008.1.1.
Where not otherwise specified, the Contractor shall select required cables in
accordance with the following:
1. For sizes between 1.5~6 mm2 they shall be minimum Cu 450/750 V, V-90 PVC/PVC
insulated and sheathed,
2. For sizes 10~16 mm2 they shall be Cu 0.6/1 kV, V-90 PVC/PVC insulated and
sheathed,
3. LV Power Cables with cross sectional area greater than 16 mm2 shall be Cu 0.6/1
kV, X-90 XLPE/PVC insulated and sheathed,
4. VSD Motor Cables shall be min 2.5 mm2 Cu 0.6/1 kV, X-90 insulated, 3C+3E, PVC
bedded, Cu tape screened, PVC sheathed (Olex ‘Varolex’ or approved
equivalent).

5.2 Control Cables

Control cables which are required to operate at low voltages shall be stranded PVC
insulated PVC sheathed copper conductor cables manufactured in accordance with
AS/NZS 5000 and having a minimum conductor cross sectional area of 1.0 mm2.
Control cables which are required to operate at extra low voltage shall be rated for
the voltages and currents with which they have to carry. Conductor cross sectional
area shall be not less than 0.50 mm2.
Multi-core cables shall be provided with a number of spare cores, not less than two, or
20% of the total number of installed cores, rounded to the next higher whole number,
whichever is the greater. The application of mixed voltages (LV and ELV) within the
same multi-core cable is not permitted.
Control cables shall be screened, where required by the manufacturer of the
connected equipment (e.g. variable speed drives).
In all situations, voltage drop needs to be considered in the selection of cable size with
regards to the final installation.

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A minimum of 20% of spare cores for control cables shall be terminated in terminals on
DIN rail. Excess cores shall be insulated and secured to avoid accidental contact with
conducting parts. For PLC/RTU I/O, at least 20% of spare/unused I/O shall be wired for
each I/O type installed.

5.3 Instrumentation Cables

Instrumentation cables shall consist of either single pair or multiple pairs, with each pair
being of twisted PVC insulated stranded copper conductors in either case.
Each instrumentation cable shall have an overall screen with a stranded tinned copper
drain wire and PVC sheath.
The conductors of each pair shall have a minimum conductor area of 0.5 mm2.
Multi-pair cables shall be provided with a number of spare pairs not less than 20% of the
total number of installed pairs, rounded to the next higher whole number.
A minimum of 20% of spare cores for control cables shall be terminated in terminals on
DIN rail. Excess cores shall be insulated and secured to avoid accidental contact with
conducting parts. For PLC/RTU I/O, at least 20% of spare/unused I/O shall be wired for
each I/O type installed.

5.4 Data Cables

Cables used for data transmission shall be suitable for the transmission rate, route
length and installation conditions and as specified by the equipment suppliers (i.e. Cat
6 Shielded Twisted Pair designed for use in industrial environments). The outer sheath
colour will be dependent on the tier of network being connected to, as defined in TS
0360 [Link] Topology, and shall follow the below convention:
The outer sheath colour convention that shall be adopted for data transmission cables
is as such:
• Blue - Business network cabling/OSN
• Green - Plant Control Network communications (PCN) (site Ethernet network –
also covers PLC to RTU)
• Red - Device level communications (Remote IO Networks as defined in TS
0360)
• Yellow - Non-Ethernet (e.g. RS485) communications (note: Proprietary cables
do not need to conform to this colour.)
Notes:
In small sites such as water/sewer pump stations and tank sites, unless there is a
separate remote I/O network, then the local network shall be deemed to be the PCN.
Coloured sleeve is acceptable if outer sheath colour is incorrect.

5.5 Cable Trays and Ladders

Cable trays, ladders and fittings (e.g. brackets and supports) shall be in accordance
with following:
1. General indoor and outdoor locations - Hot-dip galvanised to AS/NZS 4680,
2. Corrosive environments (e.g. marine, sewage pumping stations and sewage
treatment plants) - Marine grade aluminium, fibreglass, insulating (non-metallic) in
thermoplastic raw material (PVC), GRP or Grade 316 stainless steel,
Where aluminium is in contact with concrete surfaces less than 12 months old, a
suitable material (e.g. bituminous sheet) shall be used to isolate the contact areas.
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5.6 Conduits and Fittings

Electrical conduits and conduit fittings shall comply with one or more of the following:
1. Heavy duty rigid UPVC conduits and fittings in accordance with AS/NZS 2053.2,
2. Flexible PVC conduits and fittings in accordance with AS/NZS 2053.4,
3. Corrugated conduits and fittings in accordance with AS/NZS 2053.5,
4. Rigid screwed steel conduits and fittings in accordance with AS/NZS 2053.7,
5. Flexible steel conduits and fittings in accordance with AS/NZS 2053.8.,
UPVC conduits and fittings installed in locations which are subject to direct sunlight shall
be protected by one of the following methods:
1. Complying with high protection classification against solar radiation in
accordance with AS/NZS 2053.1,
2. Painted with an exterior gloss acrylic paint complying with APAS specification AP-
S0280/1. The surface shall be degreased and lightly sanded prior to application,
3. Provided with sun shields.
Steel conduits and fittings shall have the following protection classifications against
corrosive or polluting substances in accordance with AS/NZS 2053.1 as follows:
1. Medium Protection or higher, for indoor locations,
2. High Protection for outdoor locations.
Generally, conduit runs shall be rigid steel or rigid UPVC, with flexible or corrugated
conduits used for special or difficult points in the installation (e.g. connection to
vibrating or moveable equipment). Alternative materials/systems appropriate for the
application may be proposed with prior approval.

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6 Motors and Electric Actuators

6.1 Motors
Three phase motors in all power ratings are preferred. Single phase motors should only
be used where a three-phase supply cannot be economically provided.
Electric motors shall comply with the following:
1. Three phase motors shall be high efficiency squirrel cage induction motors
generally in accordance with AS/NZS 1359. Single phase motors can only be used
for applications of 1.5 kW or less,
2. Three phase motors shall be rated for connection to a 400 V AC, 3 phase 50 Hz
supply. Single phase motors shall be rated for connection to a 230 V AC single
phase 50 Hz supply,
3. Constructed to withstand direct-on-line starting forces,
4. Adequately de-rated for the effects of ambient temperature, harmonics and
unbalanced supply,
5. After the appropriate derating in accordance with (4) above, have a maximum
continuous rating of not less than 110% of the maximum load, in accordance with
the S1 duty rating provisions of AS 1359.101 rounded to the next larger size,
6. Provide adequate accelerating torque to the load, under worst conditions of
load and electricity supply,
7. Totally enclosed air cooled as defined by IC411 to AS 1359.106 with a degree of
protection to AS 60034.5 as follows:
a. Indoor motors - Not less than IP54,
b. Indoor motors which are subject to ingress of water and all outdoor motors -
Not less than IP56,
8. Provided with winding insulation Class F or higher in accordance with IEC 60085,
9. Provided with anti-condensation heaters for all (non-submersible) indoor and
outdoor motors rated at 15 kW and above,
A warning label shall be provided at the Switchboard or control panel and at the
motor with the wording 'MOTOR HEATERS ON WHEN MOTOR STOPPED'. In
addition, an appropriately labelled isolating switch shall be provided at the
Switchboard or control panel.
10. Provided with positive temperature coefficient thermistors, RTDs or thermostats
embedded in each phase winding to protect the motor windings from the
effects of overload and, if possible, stalling for motors rated at 15 kW and above
in accordance with AS 60947.8. The over-temperature detectors shall be wired to
the motor auxiliary terminal box,
11. Provided with a terminal box for stator power cables with all 6 winding terminals
available at the motor and a separate terminal box for auxiliaries (e.g. motor
heaters, thermistors). Cable entries shall be from below unless otherwise specified.
Consideration should be given to the position of the terminal boxes.
12. Motors which are directly coupled to loads shall be provided with grease
lubricated steel caged ball bearings at both the drive and non-drive ends. Roller
bearings shall be used at the drive ends where the motors are coupled to the
loads via gears or belts, due to the high radial loads. Each bearing housing shall
be fitted with a grease nipple and with a pressure relief system to prevent
overfilling of the bearing with grease. Bearings shall be designed for an L 10 life of
not less than 60,000 hours,

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13. Rating plates shall show the direction of rotation and bearing identification and
grease type, in addition to the details specified in AS 1359.101. Rating plates shall
be made of stainless steel for outdoor motors and corrosive environments,
14. The limits of vibration severity shall be in accordance with AS 1359.114 Table 1
Vibration N for both transverse and axial vibrations,
15. Provided with vibration measurement points at both drive-end and non-drive-
end bearing housings for motors rated at 110 kW and above. If the non-drive-end
bearing housing is not accessible, then the vibration measurement point shall be
located on the motor casing as near as practical to the bearing housing,
Each vibration measurement point shall consist of three machined pads of 25
mm diameter with a centrally located spot drill point nominally 6 mm in diameter.
The machined pads shall be located such that a studded accelerometer with its
wiring can be easily screwed into a hole tapped into the pad at a later date (i.e.
sufficiently clear of guards) and to allow measurement points to be positioned in
the horizontal-radial, vertical-radial and axial directions. However, the radial
measurement points need not necessarily be horizontal and vertical, provided
that they are perpendicular to each other and to the motor axis.
Where specifically stated, continuous vibration monitoring compatible with SA
Water’s existing vibration monitoring platform shall be provided. This will typically
be the case for a motor, and the associated pump, larger than 300kW or where
the site is considered of high operational criticality. SA Water’s Representative
should be consulted as to the requirements in this respect.
16. Provided with a lifting facility. The weight of the motor shall be clearly visible on
the nameplate,
17. Motors installed outdoors in direct sunlight shall be adequately de-rated for the
maximum external ambient temperature or provided with a removable sun
shield.

6.2 Electric Actuators

Electric actuators shall be of adequate capacity to open and close the associated
equipment under all operating conditions and consideration shall be given to the
protection of the final mechanical configuration, in terms of shear-pin or other over-
torque protection. In general, electric actuators shall incorporate the following
features:
1. Electric motor operation from a 400 V AC, 3 phase, 3 wire 50 Hz electricity supply
unless otherwise specified in the project specification. The actuator internal
control circuit shall operate at 24 V DC,
2. Either a phase rotation discriminator operating such that the actuator motor can
only operate when the electricity supply is connected with the correct phase
rotation or an actuator which is insensitive to the direction of phase rotation,
3. Motor winding insulation shall be not less than Class 130 to IEC 60085,
4. Inbuilt reversing starter for the actuator motor. The starter shall incorporate
thermal overload protection for the actuator motor, preferably on all three
phases. The starter shall have a utilization category AC4 and an intermittent duty
appropriate for the application,
5. Inherently self-locking,
6. A LOCAL-OFF-REMOTE selector switch,
7. Local control by means of integral controls providing OPEN, STOP and CLOSE
functions,
8. Remote controls to suit the specified control systems,

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9. In-built over-travel and over-torque protection. It shall be possible to drive the

actuator out of the over-torque limit,
10. Local OPEN, CLOSED and FAULT indications. A separate voltage free changeover
contact for each of the open and closed positions operated from adjustable
travel limit switches shall be provided for remote indications and controls,
11. Anti-condensation heater, if specified,
12. Enclosure with a degree of protection of not less than IP56 in accordance with AS
60529,
13. Cable entries from below,
14. Fully numbered wiring terminals or sleeves for all control wiring,
15. An auxiliary manual hand wheel mechanically independent of the electric drive
for emergency operation, incorporating automatic disconnection if the actuator
is energised electrically. The hand wheel shall operate clockwise to close the
valve/gate,
16. An integral position indicator which gives continuous indication of position, in
addition to OPEN and CLOSED indications. This indicator shall be visible while
operating the manual hand wheel,
17. 4~20 mA DC valve position input/output signals for controls and indications
where relevant.
The preference is for actuators to be arranged such that in the final arrangement, the
motor resides above the gearbox.

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7 Generator Sets
Unless otherwise noted, this section covers all types and sizes of generator sets including
transportable with standalone electrical connection, transportable with a permanent
switchboard connection, and permanent installations.

7.1 General
Generator sets shall be in accordance with AS/NZS 3010 and shall comprise a diesel
engine and a generator mounted on a common skid base, complete with engine
cooling radiator, automatic starting system, control equipment, battery and charger,
fuel storage tank and lifting facility as specified in the following clauses.
The weight of the complete generator set (including sound-proofing casing, etc) shall
be clearly visible on the nameplate or a separate permanently applied label.

7.2 Ambient Temperatures

Generator sets shall be suitable for continuous operation over the following ambient
temperature ranges, unless otherwise specified in the project specification:
1. Indoor: 0 ~ 40 °C,
2. Outdoor: -5 ~ 50 °C.
Equipment housed in outdoor enclosures shall be adequately de-rated to allow for an
increase in ambient temperature inside the enclosures.

7.3 Power Rating

Where power rating and load characteristics for an application is not specified, the
Contractor shall determine the required power rating for the application, based on the
following criteria:
1. Duty Cycle (Standby, Prime or Continuous),
2. Maximum ambient temperature, as specified in clause 7.2,
3. The ability to run at 10% overload for 1 hour,
4. The ability to start the motor with the highest starting kVA, (DOL, soft starter or
VSD) when this motor is the last load added to achieve full load, with a voltage
dip not exceeding 20%.
A load bank in accordance with clause 7.13 shall be provided, if recommended by the
manufacturer, to avoid problems associated with running the engine on light loads
over long periods of time.

7.4 Isolation
A lockable isolating switch shall be provided at a readily accessible location within 10
metres to isolate the generator supply. This isolating switch shall disconnect all live
conductors (including the neutral conductor) as per AS/NZS 3010. The generator
protection circuit breaker may be used for isolation, provided it is readily accessible.

7.5 Outdoor Enclosures

Where permanent generator sets are installed outdoors, they shall be enclosed in a
weatherproof enclosure with a degree of protection of not less than IP46 in
accordance with AS 60529. The enclosure shall be vandal resistant and shall provide
sound proofing to comply with the requirement of clause 7.8. Lifting points shall be
provided to allow the complete removal of the enclosure.

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Generators rated below 25kVA used in outdoor locations may forego the requirements
of this clause, provided the enclosure for the electrical components is rated not less
than IP56 in accordance with AS 60529.
Easy access shall be provided for viewing all instruments and indicator lights. Access for
operation shall be available by opening key-lockable hinged doors/panels only.
Access for all adjustments and routine service and maintenance shall be available by
opening doors or hand removal of covers by one person, the doors or covers being
lockable or requiring the use of special tools for opening or removal. In areas open to
the public, these doors need to be pad-lockable. Removable doors or covers shall be
ergonomically designed for manual handling and hinge doors shall be fitted with stays.
Acoustic louvred air vents shall be provided to allow air circulation through the
enclosure. Any opening in the enclosure shall not reduce the enclosure IP rating and
shall be protected against the ingress of birds and vermin.

7.6 Mounting Assembly Features

The generator mounting assembly shall be in accordance with the following:
1. Robust steel construction protected against corrosion by fuel and oils. In corrosive
environments (as per the definition outlined in Table 1-1) special consideration of
materials of construction shall be taken into account to ensure the longevity of
the plant. The SA Water representative shall be consulted in such situations.
2. Possess lifting points located such that generator remains horizontal when being
lifted.
3. Permanently-mounted generators shall be capable of being resiliently fixed on a
concrete plinth with anti-vibration mountings selected to minimize noise and
vibration transmission. There shall be a clearance between the underside of the
base frame and the concrete base to give access for handling equipment.
Where anti-vibration mounts are provided between the base frame and the
engine/generator as an alternative, the base frame shall be levelled on the
concrete base with grout. Details of the lifting method shall be provided with this
alternative.

7.7 Guarding
The internal operations of the generator set shall be protected by machine guarding in
accordance with AS 4024.1 in addition to the guarding provided by the acoustic
enclosure.

7.8 Noise and Vibration Levels

The maximum sound pressure level of permanently installed generator sets shall not
exceed 85 dB(A) at a distance of 1 metre from the generator set when operating at
the full rated load. The noise level limit at the plant property boundary shall be in
accordance with the Environment Protection Act 1993. An acoustic enclosure shall be
provided, if necessary, to meet the requirements of the Act.
The generator set shall not suffer from excessive internal vibrations. The out-of-balance,
torsional vibrations and critical operating speeds are the manufacturer’s responsibilities
and shall be subject to guarantee by the Contractor. Factory performance vibration
tests shall be provided for permanently-mounted generator sets in accordance with
clause 12.3.7.

7.9 Engine
The engine shall be in accordance with AS 4594 and the following:

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1. Water cooled, turbocharged or after-cooled compression-ignition (diesel) type

and a rated speed of 1500 rpm.
2. For generators of size 25 kVA and over, provided with a thermostatically
controlled 230 V AC water jacket heater with a labelled isolating switch on the
set. The Supplier shall recommend the coolant treatment (anti-freeze/corrosion
inhibitor) required to suit the specified ambient temperature range without the
jacket heater on, and any water conditioning required to minimize scale
formation and corrosion. Coolant filling and draining facilities shall be secured
within the acoustic enclosure (where provided) and shall be accessible without
removing the enclosure. Ready but secured access for checking the coolant
level shall also be provided without the need to remove any equipment or
covers.
3. The fuel tank shall provide a minimum storage capacity of 8 hours continuous
operation at full rated load, or longer. Tank filling and draining facilities shall be
secured within the acoustic enclosure (where provided) and shall be accessible
without removing the enclosure. Suitable bunding arrangements are required for
permanently installed generator sets.
4. Speed governor of accuracy Class M3 in accordance with AS 4594.4.
5. Replaceable dry type air cleaner, fuel filter and oil filter, which shall be secured
within the acoustic enclosure (where provided) and shall be accessible without
removing the enclosure.
6. The exhaust system shall be fitted with a spark arrestor. For fixed indoor units, the
exhaust pipe shall be routed to the outside of the enclosure or building,
terminating in a weatherproof cap. The connection between the exhaust pipe
and engine shall be made by a suitable stainless steel flexible connector and
shall be oil tight. The full length of the exhaust pipe and silencer (if fitted) shall be
lagged to minimize heat and noise transmission.
7. For generators of size 25 kVA and over, provided with the following instruments
and sensors, as a minimum:
a. Coolant temperature gauge,
b. High coolant temperature sensor,
c. Coolant low level sensor,
d. Fuel level gauge, and
e. Oil pressure gauge.

7.10 Generator
The generator shall be in accordance with AZ/NZS 3010 and the following:
1. For three-phase generators: Verified, 4 pole 400 V AC, 50 Hz, 4 wire star
connected, horizontal, self-exciting and brushless type. For single phase
generators: Verified, 230 V AC, 50 Hz, self-exciting and brushless type.
2. For permanent and portable installations the neutral star point shall have no
earth connection at the generator set.
3. Ingress protection of not less than IP22 to AS 60529.
4. Winding insulation not less than Class 180 in accordance with IEC 60085. All
windings shall be impregnated with moisture proofing varnish or epoxy resin and,
for permanently connected units, provided with anti-condensation heaters.
5. Solid state voltage regulator with the following functions:
a. Automatic voltage regulation in accordance with the following criteria:
• Voltage regulation under steady-state conditions:
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Voltage variation max (per unit): + 0.025

Voltage restoration after transient change (seconds): 10
• Voltage regulation under transient conditions:
Load Current (per unit): 0.60
Recovery voltage: 0.97
Maximum recovery time (seconds): 0.50
Transient voltage rise after rejection of rated kVA at 0.8 power factor
lagging (per unit) 0.26
b. Short circuit field forcing to at least 300% of rated output current,
c. Under frequency protection,
d. Manual voltage adjustment of ±10% of nominal voltage,
6. For generators of size 25 kVA and over, limits of electromagnetic interference
shall not exceed those specified in AS/NZS 61000.6.1,
7. For generators of size 25 kVA and over, total harmonic distortion of the output
voltage waveform shall not exceed 3.5% at no load and 5% at balanced linear
load.

7.11 Controls, Indications and Protection

7.11.1 General
Control cubicles not integrated with the generator assembly shall be constructed in
accordance with clause 3.3 and shall house all the electrical equipment required for
the control, indication and protection of the engine, generator and ancillary
equipment.
All control switches, indicator lights, instruments and meters shall be mounted on the
front of the cubicle and shall be readily accessible, clearly labelled and visible.

7.11.2 Controls
The following minimum control facilities shall be provided on the front of a remotely
located control cubicle, either through a key-operated five-position switch, or
preferably through the facility of an HMI. Mode selection needs to be communicated
to the site PLC, preferably through a MODBUS connection, to ensure continuity of
supply to the plant is maintained at all times.
Mode selection:
a. OFF,
b. AUTO,
c. TEST WITH NO CHANGEOVER,
d. TEST WITH CHANGEOVER,
e. MANUAL.
With the OFF mode selected, the starting circuit shall be isolated so that the generator
set cannot be started. In addition, the generator set shall stop, if running, when the OFF
mode is selected.
With the AUTO mode selected, the generator set shall be on automatic standby and
shall be under the control of the automatic transfer sequence. An AUTO ENABLED
indicator light shall be illuminated on the front panel.

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The TEST WITH NO CHANGEOVER mode shall start the generator set and enable the
complete automatic operation to be tested without transferring electrical load to the
generator.
The TEST WITH CHANGEOVER mode shall start the generator set and enable the
complete automatic operation, including the automatic transfer sequence to be
tested by simulating a mains power failure. The electrical load shall be automatically
transferred to the generator set in this mode.
The MANUAL mode shall be used in an emergency to bypass all automatic control
functions and incorporate a spring return contact (or separate start button) to start the
generator set manually. The load transfer contactors shall be controlled manually in this
position.
In addition, the following control facilities are to be provided, such that only authorized
and trained personnel can activate them:
1. EMERGENCY STOP pushbutton (Latched OFF),
2. RESET pushbutton.

7.11.3 Automatic Operation

At sites where permanent generator facilities exist, external control equipment shall be
provided for the automatic start and stop of the generator set, and the automatic
transfer between the mains and standby supplies. Electrical and mechanical interlocks
shall be provided to ensure that feedback cannot occur between the two supplies.
Where the generator sets are required to operate in parallel with the mains supply, all
necessary control, metering and protection equipment shall be provided to enable the
generator supply to be connected to, and synchronised with, the mains supply in
accordance with the requirements of the electricity supplier.
A minimum ‘run-on’ timer shall be provided to run the generator after restoration of the
mains supply. If the mains supply fails again while the set is in run-on mode or stopping,
the generator shall, after the pre-set mains failure time delay, immediately be re-
started. All time delays in the automatic sequence shall be readily adjustable.

7.11.4 Indications
For sites with permanently connected generators of size 25 kVA and over, the following
minimum indications shall be provided on the front of the generator set control cubicle
and be made available to the site PLC/RTU through contacts brought out to terminals
or signals available through a serial link, such as MODBUS:
1. GENERATOR ON,
2. AUTO ENABLED,
3. Generator Synchronised to Mains (where applicable),
4. Emergency Stop activated,
5. Individual fault indicator lights (where provided),
6. Load bank fault indicator light (where provided),
7. Fuel level LOW,
8. Hours run.
The following items may be provided by a digital multivariable meter:
a. Voltage
b. Current
c. kW
d. kWh
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e. Frequency
Generator Circuit Breaker status (tripped/off) shall be provided on an external (remote)
switchboard.

7.11.5 Protection
For sites with permanently connected generators of size 25 kVA and over, the
generator set shall be provided with automatic protection against:
1. Failure to start,
2. Engine oil pressure low,
3. Engine coolant temperature high,
4. Engine overspeed/underspeed,
5. Generator armature overcurrent,
6. Generator field overcurrent,
7. Generator over voltage/under voltage.
Each fault shall open the generator contactor control contact, stop the set, illuminate
a fault indicator light and operate a changeover common fault contact for remote
indication. A manual fault reset shall be provided. Alarms made available to the site
PLC/RTU through a serial link, such as MODBUS, is preferred.
Protective devices shall be fitted with suitable time delays to prevent them from
operating during acceptable transient conditions in normal service.
In addition, short circuit and sustained overload protection of the generator output
shall be provided by means of a suitably rated automatic circuit breaker. Reference to
the overcurrent and alternator data is required for the correct selection of a suitable
overcurrent protective device. The circuit breaker shall be located in a readily
accessible position.
The circuit breaker shall be in accordance with clause 4.2.3.

7.12 Batteries and Chargers

7.12.1 Batteries
For sites with permanently connected generators of size 25 kVA and over, separate
batteries for control and engine starting purposes shall preferably be provided.
The batteries shall be in accordance with the following:
1. Starting battery adequately sized to provide at least three successive 10 second
cranking periods with a cold engine, and then capable of a further two cranks
for 10 seconds not more than two hours later. (After three cranks, if the engine
has not started, an alarm shall be raised),
2. Installed on the generator set (not in the charger cubicle) protected from the
weather, ventilated and readily accessible for inspection and maintenance,
3. Electrolyte level indicator for each cell (if applicable),
4. Provided with terminal insulators,
5. Provided with explosion-proof vent plugs (if applicable).

7.12.2 Chargers
For sites with permanently connected generators of size 25 kVA and over, either a
common charger with two separate outputs, or two separate chargers shall be

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provided for the batteries, in addition to the integral generator-driven battery charger,
to maintain battery charge when the generator set is not being used for extended
periods.
The battery charger(s) shall be in accordance with the following:
1. Constant voltage, current limited type, providing automatic boost and float
charge facilities,
2. Adequately rated for the ambient conditions,
3. Capable of fully recharging the battery within 24 hours, following a full discharge,
4. Ensure battery is fully charged at all times,
5. Suitable for operation from a 230 V AC +10% - 6%, 50 Hz single phase supply,
6. Provided with the following indications at the charger cubicle:
a. Group alarm “Charger Fail” output,
7. Provided with a common voltage-free changeover fault contact for remote
indication,
8. Provided with a battery tester to indicate the battery condition,
9. Provided with the following protection:
a. Input overcurrent,
b. Output overcurrent and short circuit,
c. Lightning and transient over-voltages,
10. Charger cubicle shall be generator set mounted or wall mounted in the building
and may be integral with the generator set control panel.
11. As a minimum, an indication of CHARGER FAILURE shall be made available to the
site PLC/RTU through contacts brought out to terminals or signals available
through a serial link, such as MODBUS.

7.13 Load Banks

Load banks, if required, shall be in accordance with the following:
1. Multi-stage or continuously adjustable to provide a minimum load, to avoid
engine glazing, as recommended by the manufacturer, taking into consideration
the operation of the plant loads,
2. Automatic controls to maintain the minimum load in response to the varying
plant loads,
3. Adjustable set points for both minimum and maximum loads,
4. Resistance elements shall be made of a durable material and shall be
individually replaceable,
5. Located so as not to obstruct the removal or maintenance of the generator set
and to comply with requirements of AS 4024.1.
6. Enclosure shall be constructed in accordance with clause 3.3. External covers
shall be removable to provide maintenance access and shall be secured with
locks keyed alike to the generator set enclosure,
7. Adequate heat dissipation to prevent excessive temperature rise within the
enclosure. All accessible external surfaces shall be insulated, if necessary, to
ensure that they are safe to touch. The temperature of the discharge air and the
manner it is discharged shall not create a safety hazard,
8. All equipment and wiring shall be adequately rated for the maximum
temperature within the enclosure,
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9. Over-temperature protection, with the appropriate status and fault indications,

shall be provided on the generator set control panel.

8 Uninterruptible Power Supplies

This section includes requirements of Uninterruptible Power Supplies (both battery-
backed 24VDC and 230V/400VAC power supplies.

8.1 General Requirements

Uninterruptible/Battery-Backed power supply units shall be in general accordance with
the following:
1. Uninterruptible Power Supplies shall comply with AS 62040,
2. In general, battery backup times should be calculated on the diversified
maximum demand of the applicable loads, rather than the demand plus the
spare capacity,
3. Provide an on-line, no-break supply in the event of a mains supply failure for a
continuous period of eight hours, or greater, if specified in the project
specification,
4. Provide “seamless” output voltage transition when operation changes from
battery power to mains power, when mains power is restored,
5. For PLC and Control systems, be suitability designed, sized and installed to ensure
that local controls and indications continue to operate in the event of a power
failure,
6. For RTU's, be suitability designed, sized and installed to ensure that the
communications system will continue to operate in the event of a power failure,
7. The power supply shall be provided via a dedicated final sub-circuit protected
by a miniature circuit breaker in the distribution board,
8. Automatic static bypass upon a rectifier or inverter failure,
9. Manual bypass to allow maintenance to be carried out without disconnecting
the loads,
10. Connected load shall not exceed 80% of the full load capacity (i.e. 20% spare
capacity),
11. Sealed batteries with integral automatic battery charger in accordance with
clause 8.2,
12. Automatic preservation of battery charge in the case of a prolonged power
outage, in accordance with clause 8.3,
13. Be fitted with a 12 V DC or 24 V DC (or 2 x 12 V DC) battery with a capacity of
not less than 1.2 Ah and a minimum design life of 5 years under the conditions in
which it will operate. The battery shall be rated to supply the backed-up system
for a continuous period of eight (8) hours for standard outstations and sixteen (16)
hours for SCADA and Control link repeater sites, or greater, if specified. In cases
where a permanently connected on-site generator is in use, SA Water
representatives may be approached to determine if the back-up time may be
reduced,
14. Where applicable, suitable for continuous operation from an input voltage of 230
V AC single phase or 400 V AC, 3 phase (as specified in the project specification)
with an input voltage fluctuation of +10% - 15% and an input frequency variation
of ±5%,
15. Where applicable, output voltage shall be 230 V AC single phase or 400/230 V
AC three phase in accordance with the project specification. Output voltage

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regulation shall be not greater than ±3% and output frequency variation shall be
not greater than ±0.5%,
16. Where applicable, output power factor within the range of 0.8 lagging to 0.8
leading,
17. Harmonics in the mains supply caused by a UPS shall not exceed the limits
specified in AS/NZS 61000.3.6 and the radio frequency interference caused by
the UPS shall not exceed the limits specified in AS 62040.2,
18. Overload capacity of 103% full load for 10 minutes continuous, 125% full load for
more than 30 seconds and 150% full load for more than 10 seconds,
19. Capable of performing a cold start, i.e. starting in the absence of AC mains
supply,
20. Non-encased battery terminals shall be provided with insulating covers,
21. The following alarms shall be indicated on the front panel of the UPS :
a. LOW BATTERY VOLTAGE,
b. UPS FAULT.
A voltage-free common alarm contact or MODBUS/Ethernet interface shall be
provided for remote alarm monitoring.
22. The following instruments shall be provided on the front panel of the UPS:
a. Input voltmeter,
b. Input ammeter,
c. Output voltmeter,
d. Output ammeter,
e. Output frequency meter,
f. Battery voltmeter,
g. Battery ammeter.
The meters shall be appropriately scaled to accommodate the normal operating
conditions and the specified one hour overload capacity.

8.2 Battery and Charger

The UPS shall be provided complete with an integral battery charger and battery
capable of continuous operation at the full rated load (not the connected load) of the
UPS for the specified duration.
The charger shall be of adequate capacity to supply the full rated load and to
simultaneously charge a fully discharged battery to at least 95% fully charged state
within a period of 12 hours. The output voltage and current characteristics of the
charger shall be suitable for the type of battery used and for the UPS inverter. The
charger shall be capable of both float and boost charge operation with changeover
between the two modes being automatic with manual override. Both float and boost
operating characteristics shall be in accordance with the battery manufacturer's
recommendations.
The UPS charging and monitoring circuit shall not be plugged into the output of the
UPS.

8.3 Shutdown Operation

During prolonged power outages exceeding the UPS backup time, the UPS shall
automatically disconnect the supplied load before its output drops below that required
by the load.
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After shedding its connected load, the UPS shall disconnect the battery, if necessary, to
prevent permanent damage to the battery.

8.4 Isolation
Where the UPS output is reticulated, an isolating switch shall be provided at a readily
accessible location to isolate the UPS supply.
Where a floating neutral exists for supplies broken out from a UPS, then double-pole
circuit breakers shall be used for subcircuits. Appropriate labelling shall be applied to
the equipment, highlighting the potential hazard.

9 Installation
9.1 General
All electrical work shall be in accordance with AS/NZS 3000, this document, project
specification, statutory requirements and the electricity supplier’s service and
installation rules and applicable technical standards. The installation shall be suitable
for and approved for connection to the electricity supply network.
All electrical works shall be carried out by Registered Electrical Workers and a
competent person in accordance with AS/NZS 3000 and Certificates of Compliance
shall be provided, where required, in accordance with the Electricity Act and
Regulations.

9.2 Fixing
Items of electrical equipment shall be rigidly secured in their respective positions using
fixtures provided with the equipment, or as otherwise specified. Electrical equipment
mounted on concrete surfaces shall be secured by means of approved anchors.
Uncoated steel bolts, screws etc. shall not be used to affix electrical equipment in the
following areas:
1. Outdoor areas,
2. Damp environments,
3. Corrosive environments.
Materials which may be satisfactory depending on the environment include
Aluminium, hot-dip galvanised steel, brass or stainless steel.
Electrical equipment, tray, conduit, etc., shall not, as a practice, be attached to
structural steelwork and shall be separate from, and not attached to, any pipework.
If approval for welding to structural steelwork is given, such welding shall be in
accordance with AS 1554.1.
For galvanised and zinc coated steelwork, the mounting brackets and weld areas shall
be cleaned by abrading till bright steel is exposed. Two coats of zinc rich paint type
B14, complying with AS/NZS 2311 shall be applied. For all other coated steelwork, the
coating system shall be the same as, and match that, as originally applied.
Conduit saddles which are attached to steelwork shall be fixed in the approved
locations only and shall be fixed by means of metal thread screws either screwed into
drilled and tapped holes in the steelwork or fitted to drilled clearance holes in the
steelwork and fitted with nuts and lock washers.

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9.3 Switchboards and Control/Telemetry Panels

Switchboards, control/telemetry panels and cubicles housing electrical equipment
shall be installed in accordance with this document, the project specification and
AS/NZS 3000.
The following clearances shall be provided around Switchboards and control/telemetry
panels:
1. Horizontal clearances shall be in accordance with AS/NZS 3000,
2. A vertical clearance from the ground, platform or other walked-on surfaces to a
height of 2 m or not less than the height of the Switchboards and
control/telemetry panels, whichever is the greater.
Openings, doorways and emergency exits and paths shall be in accordance with
AS/NZS 3000.
Where provision has been made on the cubicle for lifting purposes, the Contractor shall
use this provision whenever lifting is required.
The cubicles shall be fastened to the floor or wall as appropriate by means of bolts
screwed into masonry anchors, and made of a compatible material to that of the
cubicle material.
The Contractor shall level the cubicles and shall then grout underneath all floor and
ground mounted cubicles.
Cubicles which are mounted directly on a concrete plinth shall be provided with a
sheet of bitumen impregnated felt or other approved moisture barrier between the
underside of the cubicle and the plinth. This requirement shall also apply to cubicles on
metal plinths located in areas which are damp or likely to be damp (e.g. due to
leakage or hosing down operation) and in all outdoor locations.
Outdoor cubicles shall be positioned such that no openings are facing the prevailing
weather.
At the completion of the mechanical installation of the cubicles and prior to any field
electrical connections being made, all mechanical and all electrical connections shall
be checked for tightness. Mechanical checks shall include for tightness of bolts holding
sections of the cubicle together, tightness of busbar supports and tightness of
mountings of circuit breakers, composite fuse switch units, isolators and switches, fuse
bases, contactors and relays. Electrical checks shall include joints in busbars and all
wiring terminations. Covers shall be removed as required for these checks and shall be
replaced and secured immediately after checking of connections is completed.
Any damage to painted surfaces at the completion of installation shall be reinstated in
accordance with clause 11.5. Damaged or scratched surfaces on stainless steel
cubicles shall be repaired or replaced to the satisfaction of SA Water’s Representative.
The Contractor shall maintain the degree of vermin proofing as required to achieve the
IP rating as per Clause 3.3 of this document.

9.4 Cable Trays and Ladders

Final locations and fastenings of cable trays, ladders and supports shall be determined
on site in cooperation with SA Water’s Representative.
Cables ladders/trays shall, where possible, be of ample width and support strength to
accommodate the cables specified with a 30 % allowance for future cabling.
The cable trays and ladders shall be supported at not greater than the manufacturer's
recommended intervals and there shall be no discernible deflection of the trays or
ladders evident to the naked eye.
Cover plates shall be provided in situations as follows:

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1. Providing cable protection to:

a. Protect cables against mechanical damage where cable trays or ladders
are installed across areas in which personnel or machinery access or the
like is probable,
b. Protect cables against damage by sunlight,
c. Reduce the effect of heat gain from solar radiation, which may affect the
cable current rating,
2. Where specified or shown on the drawings.
Where galvanised cable trays or ladders are installed outdoors, any damaged surfaces
shall be reinstated using zinc rich primer type B14 complying with AS/NZS 2311. Two
coats shall be applied to clean, rust-free surfaces.
Electrically conductive cable trays and ladders shall be bonded to the earthing system
in accordance with AS/NZS 3000 and equipment manufacturer installation
requirements and the following:
1. Cable ladder shall be earthed back to the main earthing system via two main
earth conductors, or via one earth conductor with a bonding loop installed to
each side rail,
2. Where bonding between cable ladder sections is provided with fixed multi-
bolted splice plates, no additional earth wire conductors are required,
3. Where cable ladder sections are separated and are not joined via splice plates,
two off earth conductors shall be provided to maintain a continuous earth,
4. Where expansion gaps or sliding expansion joints are used, a bonding earth wire
shall be installed to maintain a continuous earth,
5. Where adjustable splice plates are used, these shall include an earth bonding
conductor.

9.5 Conduits
Conduits shall be sized in accordance with AS/NZS 3000 for the number and size of
cables to be installed within each conduit and the additional requirements of this
clause. Conduits shall be a minimum size of 20 mm diameter.
Conduits shall be saddled either side of every bend and elbow. Conduit saddles and
clips shall be secured using purpose-made fasteners. In outdoor locations, fasteners
and fixings shall be made of brass, stainless steel, hot-dip galvanised or other approved
corrosion resistant materials. Electroplated zinc fasteners and fixings may be used for
indoor locations only.
Approval shall be obtained from SA Water’s Representative before any holes are
drilled in any structural steelwork.
Conduit shall, wherever possible, be run in horizontal or vertical planes, shall be
grouped and generally be as inconspicuous as possible. Where conduits are required
to run adjacent to non-planar surfaces, the conduits shall be shaped to closely follow
the surface on which they are to run.
If there is an open point of entry of cables into conduits that may admit water or
vermin, then openings shall be filled with a non-degrading sealant. The type of sealant
used should be easily removable to allow for future installation of cables.
Pull boxes shall be provided in long runs of conduit to facilitate installation of cables.
Junction boxes shall be provided at all tee-offs in conduit runs. All conduits shall be
installed with a polypropylene draw wire in place to facilitate the drawing in of cables.
A draw wire shall also be left in place for future use after the cables have been drawn
in and be suitably restrained to prevent accidental withdrawal into or out of the
conduit.

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In above ground situations, adequate provision shall be made to allow the conduits to
expand and contract with temperature, either at bends or by the use of expansion
couplings.
Rigid conduits shall not connect directly to vibrating equipment. A short length of
flexible conduit shall be provided for such connections.
Underground conduits shall be installed in accordance with AS/NZS 3000 and clause
10. Cable route markers and cable pits shall be provided for underground conduits in
accordance with clauses 9.7.3 and 9.6 respectively.
Buried conduits shall generally be laid in straight lines and to even falls. Nominally level
conduit runs shall be laid with falls to create a high point midway in each run to allow
moisture to run back to the cable pits. Conduits entering buildings should be installed
to stop liquid from draining into the building.
Where conduits are required to be cast into concrete foundations, the conduits shall
be provided with a minimum of 60% spare cross-sectional capacity inside each conduit
after all cables are installed, and a minimum of one spare conduit for each of LV and
ELV/telecommunications conduits, where present. All spare conduit ends shall
terminate into a pit, cable void space, or cabinet base.
Where conduits pass under roads, footpaths, and foundations, the conduits shall be
provided with a minimum of 60% spare cross-sectional capacity inside each conduit
after all cables are installed, and a minimum of one spare conduit for each of LV and
ELV/telecommunications conduits, where present. All spare conduit ends shall
terminate into a pit, cable void space, or cabinet base.

9.6 Cable Pits

Cable pits shall be provided for all underground conduit runs where the conduits
change direction and at intervals not exceeding 50 m in straight runs. Cable pits shall
be constructed to avoid the ingress of groundwater and provided with drainage
facilities. A drainage point should be connected from the base of the pit to a suitable
soak-away. For landscaped applications, where only foot traffic is anticipated, it is
recommended that at least 150mm of a gravel base is laid at the bottom of the pit to
act as a drain and help prevent the enclosure from sinking.
Cable pits in footpaths or where there is no vehicle traffic shall be provided with covers
equivalent to ‘Gatic style’ light duty category.
Cable pits located where there is vehicle traffic (or loading) shall be provided with
covers equivalent to ‘Gatic style’ heavy duty category.
Cable pits shall be sized to accommodate the bending radius of cables and so as to
allow physical access to install cables.
All cabling within cable pits shall be individually identified with appropriate labelling in
accordance with clause 9.7.9.

9.7 Cable Installation

9.7.1 General
Power, instrumentation and control cables shall be installed in accordance with AS/NZS
3000 and this Specification. Data and communication cables shall be installed in
accordance with ACMA Technical Standards.
Different wiring systems shall be segregated in accordance with clause [Link] of
AS/NZS 3000 (e.g. by installing power cables in separate conduits from control,
instrumentation and data cables).
Cables shall not be installed on suspended ceilings unless the ceilings are designed to
support the weight of the cables.
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Intermediate joints in cables are not permitted.

9.7.2 Installation of Cables in Wastewater Treatment/Pumping

Areas
The following guidelines shall be adopted within designated areas of wastewater
treatment/wastewater pumping installations. SA Water Asset Owners/Plant Operations
must be consulted when determining the designated areas which require rodent-
proofing of cables and cabling systems.
In general, the following guidelines are to be adhered to, understanding that each
situation is unique and an approach of ‘best endeavours’ is to be applied:
The use of vertically installed cable tray is preferred. Above ground cable installation is
preferred over underground cable installations. When cables require replacement,
then the principles outlined below are to be followed.
Underground Cables
All cables which are installed in an underground ducting/conduit system are to use
rodent-proof rated conduit sealing systems and, where available for the application,
rodent-proof cable (e.g. steel wire armoured or wound steel tape cables).
Above Ground Cables or Cable Tunnels
All cables installed on an outdoor or indoor horizontal cable tray/ladder are to use
rodent-proof cable (e.g. steel wire armoured or wound steel tape cables).
All cables installed in an outdoor or indoor vertical cable tray/ladder do not need to
use rodent-proof cable (e.g. steel wire armoured or similar) unless the plant area has
been designated by the Asset Owner/Plant Operations to be prone to cable damage
caused by rodents.
Use of vertically installed cable tray is preferred. Cables that are installed on a vertical
cable tray need to be clipped from the top of the tray downwards.
Fibre Backbone Communication Cables
All fibre backbone communications cables shall use rodent-proof cable (e.g. steel wire
armoured or wound steel tape).
Cable System Sealing
All conduits shall be sealed with a rodent-proof rated sealant.
All switchboards and control/telemetry panels shall be sealed to prevent vermin
ingress.

9.7.3 Cable Handling

Cables shall be installed in a manner which is not inferior to the manufacturer's
instructions.
Care shall be taken during installation of cables such that cables are not cut, abraded,
kinked or otherwise damaged, or subject to a bending radius greater than that
specified by the cable manufacturer.
Any cables that are damaged during installation shall be repaired or replaced by the
Contractor to the satisfaction of SA Water’s Representative at the Contractor's
expense.

9.7.4 Installation of Data Cable

Each run of an Ethernet ring shall be mounted in separate conduit or on separate
ladder, to ensure a redundant path is achieved. Field network cables shall be colour
coded in accordance with clause 5.4 and shall be labelled in accordance with the
numbering system in clause 9.7.10.
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9.7.5 Cable Termination

Cables shall be supported at all points of termination to prevent undue mechanical
strain on the terminations. Support may be by means of fittings supplied with the various
items of equipment or, if these are inadequate or insufficient, additional supports.
All spare cores shall be terminated in terminals.
Compression lugs shall be properly sized in accordance with the size of cable to be
terminated and which shall be applied using approved compression tools in
accordance with the manufacturer's written recommendations. Compression lugs used
on control cables, instrumentation cables or small power cables shall be of the pre
insulated type, and when fitted, shall support the cable insulation.
All bolted connections shall be made with cadmium plated high tensile bolts and nuts
fitted with lock nuts.

9.7.6 Instrumentation Cable Screens

Screens on instrument cables shall be isolated from each other and metal components
of cubicles, and earthed at one point only, (namely the instrument earth bar).
At field equipment, cable screens shall generally be cut back and isolated from earth
(depending on the instrument manufacturer’s recommendations).
At junction boxes and control/telemetry panels, where the cable screen breaks out
from the cable tray, the screen shall be isolated from all other cable screens and earth.
The screen drain wire shall then be insulated using green or clear sleeving and
terminated onto a unique terminal provided for the screen. This terminal is to be
connected to the instrument earth bar.
Note that it is permissible to connect the cable screen directly onto the instrument
earth bar if this is adjacent to the point where the cable is to be terminated.
Where a multi-pair cable with an overall cable screen only is connected via a junction
box to numerous single cables, each having a screen, the terminals containing the
screen connections shall be linked together. In this way the multi-pair overall screen will
provide the connection to the instrument earth bar for all the single cable screens.
Where a multi-pair cable with individual and overall screens is connected via a
junction box to numerous single cables, each having a screen, the terminals containing
the screen connections shall NOT be linked together. Each individual screen on the
multi-pair cable shall only be connected to the screen of the associated single cable.
In this way each screen will be provided with a single path to the instrument earth bar,
thus ensuring circulating earth currents cannot be formed.

9.7.7 General Power and Lighting Cables

Wiring for the general power and lighting installation shall commence at the
appropriate general power and lighting distribution boards. For non-office areas, the
cables for general power and lighting shall be run along ducts, trays or in surface
mounted rigid conduits. In office areas, cables for general power and lighting shall be
concealed and shall utilise wall cavities, where available.
Wiring connection to light fittings shall be arranged such that a fitting can be readily
disconnected and/or removed without having to disconnect or remove other fittings.

9.7.8 Cable Fixing

Cables which run on cable trays shall be fixed to the tray and such fixings shall be in
accordance with AS/NZS 3000.
Cables which are run in cable ducts or on cable trays shall run parallel to the sides of
the duct or tray. Where such cables must negotiate a bend, the centre of curvature

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shall generally be common for all cables and shall be determined by the largest cable
of the group, so that a neat installation is obtained.
Single core cables which form part of one multiphase circuit shall be run in proximity to
each other.
Control and instrumentation cables may be bunched. A clearance of not less than 25
mm shall be maintained between power and control or instrumentation cables.

9.7.9 Cable and Wire Labelling

Cables shall be identified at the ends by a durable corrosion-resistant tag printed with
the cable identification used on circuit diagrams.
Cables shall be identified at both ends both inside and outside of panel/gland plates.
Labels installed in the horizontal plane shall be read left to right. Labels installed in the
vertical plane shall be read bottom to top. In addition to this, cables passing through
cable pits shall also be labelled.
Individual wires (cores) of control or instrumentation cables shall be labelled with
printed slip on type full circle ferrules.

9.7.10 Cable Numbering System

All cable numbers shall be unique in an installation. Cables connecting equipment
external to Switchboards or control/telemetry panels shall be labelled as follows:
TT-XXXX-YYYY-ZZ-zz where:
TT = Cable Type
PH High Voltage Power
PL Low Voltage Power
DC DC Power
PV* PV Solar Power
PE Power Earth
CC Control
CE Control Earth
IA Instrumentation Analog
ID Instrumentation Digital
IX Instrumentation Mixed Analog and Digital
IP Instrumentation Power
IE Instrumentation Earth
DD Data
XXXX, YYYY = Equipment Identification at the Points of Connection
Internal to switchboard data cables shall be identified using XXXX-YYYY-ZZ (i.e. no need
for the DD prefix).
Equipment identification shall be the tag name as assigned to the plant.
XXXX shall precede YYYY generally in accordance with the following descending
order:
PV* This may also be used with additional identifiers as such:
PV/T PV Tail (*P1 and *N1)
PV/S PV String (*P1 and *N1)

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PV/R PV String Tracker Column Jumper Cable (*P1 and *N1)

PV/M PV String Tracker Motor Jumper Cable (*P1 and *N1)
PV/X PV String Extender Cable (*P1 and *N1)
PV/H PV String Harness Cable (*P1 and *N1)

1. Generator/Transformer/Power Supply/Instrument Transducer,

2. Main Switchboard,
3. Area Switchboard/Motor Control Centre,
4. Local Control cubicle,
5. RTU,
6. Field Equipment (pumps, valves etc).
Where the order of precedence cannot be distinguished (e.g. interlocks between two
Switchboards or cables carrying bi-directional signals between two locations of the
same order), the tag names shall be arranged in an alphabetical/numerical order.
XXXX is optional where all the cables originate from a single source in the same area,
e.g. in a simple installation consisting of a single Switchboard only.
ZZ = Cable Sequential Number
A 2-digit number to differentiate two or more cables of the same type and
identification.
zz = Wire Sequential Number
A 2-digit suffix number to identify individual wires (cores) of a cable, where required.

TFR1
PL-MCC1-P1-01
PH-MSB-TFR1-01 PL-TFR1-MCC1-01
11 kV P1
MSB MCC1 CC-MCC1-P1-01
11/0.4 kV

CC-MCC1-MCC2-01
PL-TFR1-MCC2-01

LX123
IA-LX123-MCC2-01
MCC2

IA-MCC2-RTU-01 IX-MCC2-RTU-01

RTU

Figure 4 – Example Cable Numbering

PH-MSB-TFR1-01 11 kV feeder cable from main Switchboard MSB to transformer

TFR1
PL-TFR1-MCC1-01 400 V supply cable from transformer TFR1 to motor control centre
MCC1
PL-TFR1-MCC2-01 400 V supply cable from transformer TFR1 to motor control centre
MCC2
PL-MCC1-P1-01 400 V motor power cable from motor control centre MCC1 to
pump P1
CC-MCC1-P1-01 Control cable from motor control centre MCC1 to pump P1

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CC-MCC1-MCC2-01 Interlock control cable between motor control centres MCC1

and MCC2
IA-MCC2-LX123-01 4~20 mA DC instrumentation cable between loop powered level
transducer LX123 and MCC2
IA-MCC2-RTU-01 4~20 mA DC instrumentation cable between MCC2 and RTU
IX-MCC2-RTU-01 Instrumentation cable carrying mixed analog and digital signals
between MCC2 and RTU

9.7.11 Wire Numbering System

No two wire numbers in interconnected wiring systems shall be the same, unless the
wires are physically linked.
All wire numbers shall be generated from Schematic Diagrams in accordance with
clause 13.1.3 (2) such that the wire number references back to the drawing of origin
and a cross reference location of the wire on that drawing.
Wire numbers shall be prefixed with the drawing number, or part thereof, or in the case
where a drawing set has only one drawing number with many sheets, shall be prefixed
with the sheet number, or a combination of drawing number and sheet number, as
required, such that every wire number in an interconnected wiring system is unique.
The remaining identifier of the wire number shall be a cross reference to where the wire
is located on the drawing. The cross reference shall be made at the point of
origin/source. (For example, a PLC output wire number shall be generated at the PLC
output end of the wire, not the field end. Whereas a PLC input wire number shall be
generated from the point of source, being the field device, rather than the PLC input
card.)
For LV systems, the neutral wire number should be prefixed with the respective active
supply wire number. i.e. Supply wire number 25100, the neutral should be labelled
25100-N. This label should then follow through for all circuits that share the common
neutral rail.
For ELV systems, the 0 V DC wire number should be prefixed with the respective positive
supply wire number. i.e. Supply wire number 25100, the 0 V DC should be labelled
25100-0 V. Thus, different labels will apply for different discrete power supplies.
Wire numbers on each side of test links and inject terminals shall be labelled the same.

9.8 Lighting Systems

Lighting fittings shall be provided in accordance with clauses 4.26.1 and this
Specification.
After completion of the installation, any fittings which are considered excessively noisy
by SA Water’s Representative shall either be repaired or replaced by the Contractor.
All equipment which forms part of the general power and lighting installation and
which, under the requirements of AS/NZS 3000, is required to be earthed, shall be
earthed by means of earthing conductors to the earthing bar of the relevant general
power and lighting cubicle.

9.8.1 Lighting and Small Power Distribution Boards

Lighting distribution boards shall be constructed with integral wiring, and where
required, include relays to achieve compliance with this Technical Standard. In facilities
such as pumping stations, the light and small power distribution board shall be
incorporated into the LV switchboards. In smaller facilities, such as valve houses, the
light and small power distribution board shall be a separate distribution board.

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Each distribution board shall be fitted with a main incoming isolating load break isolator
which supplies a proprietary chassis. The line side of the main isolator shall be shrouded
to IP4X as a minimum.
The Contractor shall provide and fix, inside each distribution board, an ‘As Built’
schedule clearly indicating the circuits controlled. This schedule shall be on material of
permanence, suitably protected by a transparent cover.
Circuit breakers supplying lighting circuits shall incorporate earth leakage protection
units, set to operate at not more than 30 mA. For hazardous areas, single phase circuits
shall be protected by two pole circuit breakers. Three phase circuits shall be protected
by four pole circuit breakers.

9.8.2 Indoor Lighting Design

Lighting systems shall be designed in accordance with AS/NZS 1680 and the Building
Code of Australia. Lighting design shall be for end-of-life lighting levels.
The design shall aim to minimise energy consumption. Design shall also consider and
minimise light overspill to nearby properties and roads.
The levels of “maintained illuminance” as defined in AS/NZS 1680.1 shall be determined
using the following criteria:
1. The contribution of daylight shall be excluded from any illuminance calculations,
2. The ‘uniformity of illuminance’ shall not be less than 0.6,
3. The minimum levels shall not be reached until after 24 months of lighting
operation (for conventional lighting) or 5 years (for LED lighting) with an
acceptable level of failure rate,
4. A suitable value of reflectance shall be considered for the purpose of any
illuminance calculations.

[Link] Illumination Levels

The lighting design shall ensure uniform light distribution and shall provide lighting levels
as specified in Table 9-1 in accordance with the AS/NZS 1680 series. The design of the
lighting installation for facilities such as pumping stations and valve houses shall allow
for switching to be arranged into multiple banks of lights.
Table 9-1 – Minimum Illumination Levels and Colour

Lighting Bank Area Maintained Lamp Colour Lamp Rendering Maximum Glare
Illuminance Appearance Index (Ra) Index
(Minimum) [Lux] Group Range
Indoor Plant Area – 120 1, 2 60 to 80 25
General
Indoor Plant Area – 400 1, 2 80 to 90 22
Supplementary Task
Lighting
Plant Area – 160 1, 2 80 to 90 -
Control/Telemetry
panels
Electrical Switchrooms 240 1, 2 80 to 90 -

[Link] Emergency Lighting and Exit Signs

Emergency lighting in accordance with AS 2293 shall be provided to enable the safe
movement of persons from all areas of the facility if the normal lighting system fails.
Emergency lighting, exit signs and warning systems shall be provided in accordance
with the Building Code of Australia.

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Emergency and exit lighting shall be provided at strategic positions to enable

personnel to safely move around and evacuate the facility, in the case of a power
failure. All switchrooms shall have emergency lighting. Emergency lighting shall be
arranged on dedicated circuits to ensure batteries are kept charged and for ease of
testing and maintenance.

9.8.3 Outdoor Lighting Design

If not defined in the project specification, outdoor lighting requirements and design
shall be determined in accordance with the AS 1158 series.
The design shall aim to minimise energy consumption. Design shall also consider and
minimise light overspill to nearby properties and roads.
Outdoor area lighting is generally not required for unattended automatic installations,
however, local lighting shall be provided for safe entry and exit to buildings/structures
to comply with statutory requirements.

9.8.4 Lighting Arrangement

The arrangement of lighting needs to be such that adequate access is available for
operation and maintenance without affecting personnel safety and that the location is
minimised in the effects of vibration.
The completed installation shall have a neat and pleasing appearance.
Light fittings that are mounted within reach distance, 2.5 m, from a designated
walkway or platform shall be guarded against contact with hot surfaces.
Suspending of light fittings from the ceiling in some facilities is not possible due to
overhead travelling cranes.
Care shall be taken to ensure that light is correctly directed towards the areas
intended. In particular, lighting a lower level through floor grating, from a level above
will not be acceptable.
Where light fittings are arranged in rows, they shall be mounted so that they are
aligned both horizontally and vertically.

9.8.5 Lighting Control

Lighting switches shall be provided and switching arranged so that all lights in the
building can be switched from a switching panel adjacent to each access door. The
lights shall be switched in a logical manner, i.e. per room or per section if the room is
deemed to be reasonably large.
The lighting circuits shall be divided into logical groups such that the failure of any
individual group will not result in total darkness in any one area. Two-way switching
should be provided for galleries, tunnels, etc. Consider the use of illuminated light
switches in locations where these switches may be hard to see in low light conditions.
In plant areas where rotating machinery is present, lighting shall be supplied from at
least two different phases.

9.8.6 Labelling
All lighting distribution boards shall be labelled according to the board name,
equipment number and point of supply.
All luminaires shall be labelled with their supply point distribution board and circuit
number.
Labels shall be fixed in positions where they can be easily seen and read.

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9.8.7 Wiring of Lighting Circuits

All wiring of lighting circuits shall be in accordance with AS/NZS 3000 and shall be wired
with minimum Cu 450/750V, V-90 PVC/PVC insulated and sheathed multi core cable
with a minimum conductor size of 1.5 mm2. Lighting and small power loads shall be
phase balanced.
Junction boxes may be used for connection to light fittings, where necessary. Junction
boxes used shall incorporate tunnel terminals as appropriate for the application.

9.9 Earthing
The installation shall be earthed in accordance with the requirements of AS/NZS 3000
and in particular the multiple earthed neutral (MEN) provisions of the rules.
Bare earth conductors and earth connections shall be protected against damage and
corrosion, especially in areas where H2S is likely to be present, through suitable sealing
systems.

9.9.1 Main Power Earth Bar

All low voltage Switchboards shall be provided with a suitably rated earth bar. The
earth bar shall be connected to the installation main earthing system. All cables
connecting to the main earth bar shall be labelled according to their function.
The earth bar should be located to allow easy access for cables leaving the
switchroom or equipment, and be adequately sized for the prospective fault current
and the number of connections required.

9.9.2 Earth Electrodes

The choice of earth electrode system shall be governed by the following factors:
1. System voltage,
2. Fault ratings,
3. Whether a combined or separate earth system is adopted,
4. The pH, resistivity and conductivity of the soil, the terrain and difficulty of
installation.
A minimum of one copper clad, mild steel earthing rod of minimum diameter 15 mm
and minimum length 2400 mm shall be fully driven into the ground at a distance of not
less than 5 m from any supply transformer installation and shall be connected to the
main earth bar of the installation. The main connections at the earth rods shall be
protected against damage and corrosion, through suitable termination in an
inspection pit, in accordance with AS/NZS 3000.
The use of ground enhancing materials may be used with prior approval of SA Water.

9.9.3 Equipotential Bonding

All exposed conductive parts or extraneous conductive parts of a site’s electrical
infrastructure shall be protected against potentially dangerous differential voltages in
accordance with AS/NZS 3000 ‘Equipotential Bonding’.
The floor slab reinforcement of new infrastructure shall be provided with equipotential
bonding.
All electrical enclosure doors shall be provided with an equipotential bonding earth
conductor.
In situations where metallic pipework is accessible, both suction and delivery pipework
shall be individually connected to the installation main earth bar for the purpose of
equipotential bonding.

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9.9.4 Main Instrument Earth Bar

A high integrity instrument earth bar shall be established at a suitable location, usually
in the equipment room or switchroom. This instrument earth bar shall be mounted on
insulating blocks providing a minimum clearance of 30 mm to surrounding structures.
Whenever possible, the instrument earth bar shall be connected to the main earth bar
of the installation. Two connections shall be made between the instrument earth bar
and the main earth bar, each being a minimum of 6 mm² copper cable. The
instrument earth system shall have a resistance of less than 1  to the main earth bar,
with each of the connections to the main earth bar disconnected in turn.
All earth bars shall be appropriately labelled and shall identify their function.

9.9.5 Instrument Earth Bars Located in Cubicles

Instrument earth bars located in cubicle shall be of hard-drawn copper and mounted
on insulating blocks, providing a minimum spacing of 10 mm to the cubicle frame.
All the instrument system earth bars may be connected in a daisy chain arrangement
to form a ring or as a star, and shall be appropriately labelled and shall identify the
function of the earth bar.
The earth connections shall be provided with identification labels at both ends of the
cable.

9.10 Power Factor Correction

The power factor of a completed electrical installation shall not exceed the limits
specified in the electricity supplier’s service and installation rules. Power factor
correction equipment shall be provided, if required, to comply with the specified limits.

9.11 Harmonics
Total Harmonic Distortion of an electrical installation shall be in accordance with the
electricity supply authority’s regulations.
Harmonic mitigation techniques shall be required when the harmonic levels do not
comply with the supply authority’s regulations, Australian Standards and IEEE standards.
The Contractor is required to provide calculations to indicate that either the existing
installation does not need additional mitigation techniques, or that the mitigation
complies appropriately.

9.12 Lightning and Transient Overvoltage Protection

Where lightning protection for an installation is required, a risk assessment shall be
completed. The risk assessment and lightning protection of persons and buildings shall
be provided in accordance with AS/NZS 1768.
Irrespective of the requirements of lightning protection of persons and buildings, all
voltage sensitive equipment shall be provided with secondary protection against
damage by transient and lightning induced overvoltages in accordance with AS/NZS
1768.
Instrumentation equipment shall be provided with lightning protection in accordance
with clause 4.23.1.

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10 Excavation and Backfilling of Trenches for

Underground Conduits
10.1 General
The Contractor shall supply all labour, materials etc. for the excavation and backfilling
of trenches for the laying of electrical conduits. All underground cables shall be in
conduits, unless otherwise specified.
The Contractor shall be responsible for the location of existing buried services and shall
hand dig (‘pot hole’) in the vicinity of those services. BYDA (Before You Dig Australia)
services should be used.

10.2 Clearing
The Contractor shall not damage any trees or shrubs which are required to remain
inside or outside the working area.
In open ground, organic topsoil shall be stripped to a minimum depth of 150 mm and
stockpiled for use in reinstating the surface of the trench.

10.3 Trench Width and Conduit Spacing

Trench width shall be adequate to accommodate all the conduits with a minimum
spacing of 50 mm between the outside conduits and trench wall and the space shall
be filled with sand.
The spacing of conduits shall be in accordance with the design specification and
drawings. Cables shall be de-rated in accordance with AS/NZS 3008.

10.4 Fill Materials

10.4.1 Sand
Bedding sand shall consist of clean coarse sand of such grading that no more than
10% shall be coarser than 2.36mm mesh sieve, and fines shall have a linear shrinkage of
not more than 2%.
The sand used for bedding and backfilling around conduits shall be free from
dangerous and noxious weeds as proclaimed in South Australia by regulations under
the Weeds Act with amendments. The sand shall be free from rocks and lumps and
shall be non-plastic.

10.4.2 Quarry Rubble

Quarry rubble shall be of a nominal size of 20mm. Quarry rubble shall be clean, sound,
hard and durable, free from adherent coating and other foreign matter, and graded
in accordance with Table 10-1.

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Table 10-1 – Grading of Quarry Rubble for Bedding and Backfilling

Sieve Size mm Percentage Passing

26.5 100
19.0 90 ~ 100
13.2 74 ~ 96
9.5 61 ~ 85
4.75 42 ~ 66
2.36 28 ~ 50
0.425 11 ~ 27
0.075 4 ~ 14

10.5 Bedding and Backfilling

10.5.1 Bedding
All pipes and fittings laid underground shall be bedded over the full trench width on 75
mm thickness of clean sand or an approved equivalent crushed fine granular material.
Bedding shall be compacted to a density not less than 95% of the maximum standard
dry density of the material, as determined by AS 1289.5.1.1.

10.5.2 Backfill Around Conduits

Sand shall be placed around the conduits and shall extend to not less than 75 mm
above the conduits. The sand backfill shall be compacted to not less than 95% of the
standard maximum dry density of the sand in accordance with AS 1289.5.1.1.
An orange marker tape shall be installed above the sand fill in accordance with
AS/NZS 2648.1.

10.5.3 Backfill in Roadways and Footpaths

In roadways, road shoulders and footpaths, quarry rubble shall be placed from 75 mm
above the conduit to the underside of the base course. Compaction shall be to 95% of
its modified maximum dry density (AS 1289.5.2.1) for roadways and to 90% of its
modified maximum dry density for footpaths. Unless specified or directed otherwise, the
formed pavement shall then be reinstated to the original condition.

10.5.4 Backfill in Other Locations

In verges, open ground etc., the trench fill shall be inorganic fill material with a
maximum stone size of 75 mm, either imported or obtained from the trench
excavation. The trench fill shall be brought up to within 150 mm of the finished surface
level. The trench fill shall be placed in layers not exceeding 300 mm compacted
thickness and each layer given nominal compaction (e.g. with an excavator bucket)
sufficient to eliminate long-term settlement.
The top 150 mm of the trench shall be reinstated using stockpiled topsoil or imported
soil similar to that in the vicinity of the trench.

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11 Painting
11.1 General
All steel or other surfaces of items of electrical equipment which would normally be
painted or are specified as requiring painting shall be protected by painting in
accordance with this Section.

11.2 Indoor Cubicles

Following fabrication of the cubicles, all surfaces shall be degreased in accordance
with AS 1627.1. All welds and bare steel areas shall be ground to remove all surface
rust, scale and weld spatter.
Bare steel and Zincseal surfaces where the phosphate coating has been damaged,
shall be coated with etch primer applied in accordance with the manufacturer’s data
sheets.
Custom built and modified cubicles and enclosures must be painted as per the
requirements of this clause. Exterior and interior surfaces (excluding any internal
removable panels) shall be finished in high gloss air dry spraying enamel, stoving
enamel or polyester powdercoat to colour Opaline G32 to AS 2700, and applied
according to AS 4506 or AS 3715. Internal removable panels (e.g. bolt-in panels to
which electrical equipment will be mounted) shall be gloss white in colour. The coating
shall be applied in accordance with the manufacturer’s data sheets and shall include
any primers or undercoats, if recommended by the manufacturer.
Off-the-shelf cubicles and enclosures that do not require any modification prior to
installation, other than fitting out with electrical equipment, do not require additional
coating and may remain as per the manufacturer’s factory supplied colour, except
where there is a requirement to colour match with existing cubicles.
Where the cubicles are required to match the existing cubicles, as specified in the
project specification, the finish colour shall match the existing colour as closely as
possible.
Stainless cubicles and enclosures shall not be painted.

11.3 Outdoor Cubicles

Following fabrication of the cubicles, all surfaces shall be degreased in accordance
with AS 1627.1. All welds and bare steel areas shall be ground to remove all surface
rust, scale and weld spatter. Edges shall be rounded to a minimum 3 mm radius. All
surfaces shall be treated with an acid etch pre-treatment solution or two pack etch
primer approved by the coating supplier.
The coating system shall consist of 125 microns of epoxy followed by 50 microns of two
pack polyurethane complying with APAS 2911.
Custom built and modified cubicles and enclosures must be painted as per the
requirements of this clause. Colour shall be Opaline G32 to AS 2700, or Rivergum G62 to
AS 2700 if the cubicles are located in a natural environment, and applied according to
AS 4506 or AS 3715.
Internal removable panels (e.g. bolt-in panels to which electrical equipment will be
mounted) may be coated in accordance with clause 11.2 or this clause and shall be
gloss white in colour.
Where approved for use on a project-by-project basis, commercial ’off-the-shelf’
cubicles and enclosures that do not require any modification prior to installation, other
than fitting out with electrical equipment, do not require additional coating and may
remain as per the manufacturer’s factory supplied colour, except where there is a
project specified requirement.
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Where the cubicles are required to match the existing cubicles, as specified in the
project specification, the finish colour shall match the existing colour as closely as
possible.
Stainless cubicles and enclosures shall not be painted, unless specified.

11.4 Other Equipment

Equipment other than custom-built Switchboards and control cubicles may be finished
in the manufacturers’ standard colours unless otherwise specified.

11.5 Coating Reinstatement

Following installation, any damaged paintwork shall be prepared by using abrasive
paper to prepare the surface and feather back edges. Coatings shall be applied in
accordance with the original requirements to match the original coating system.

12 Inspection and Testing

12.1 General
Reference shall be made to the project specification for requirements associated with
the inspection, testing, commissioning and running-in of the equipment and installation.

12.2 Inspection
The manufacture of equipment under the Contract shall be subject to inspection by SA
Water’s Representative at the manufacturer's works.

12.3 Works Tests

12.3.1 General
All equipment manufactured under the Contract may be tested at the manufacturer's
works to ensure that the equipment complies with the project specification.
Witness tests shall be carried out in the presence of and to the satisfaction of SA
Water’s Representative.
All test instruments shall have current calibration certificates, if applicable, and all
certificates shall be made available for checking by the Inspecting Officer before
testing commences.
The Contractor shall give SA Water’s Representative a minimum of ten working days’
notice of the manufacturer's intention to conduct tests.
At the same time, or earlier, the Contractor shall:
1. Submit a copy of the latest certified drawings of the Switchboards, cubicles and
control/telemetry panels.
2. Submit for approval by SA Water’s Representative, a copy of the proposed
testing procedure and test sheets. Testing shall not commence until SA Water’s
Representative has approved the testing procedure and test sheets.
3. Submit pre-test results. Testing shall not commence until SA Water’s
Representative has reviewed the pre-test results.

12.3.2 Test Results

The following test results shall be submitted to SA Water’s Representative for approval:
1. Certificates of design verification or unwitnessed routine verified equipment,

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2. Results of all witnessed tests recorded during the progress of the tests on the
approved test sheets. A copy of the test sheets co-signed by the manufacturer
and the Inspecting Officer shall be handed to the Inspecting Officer on
completion of the tests,
3. A copy of formalised test sheets upon which all test results shall have been typed,
within ten days of the equipment successfully completing the tests.

12.3.3 Dispatch of Equipment

The equipment shall not be dispatched from the manufacturer's works until authorised
by SA Water’s Representative. Dispatch will be authorised only after each item has
been shown to comply with the specified test requirements and guaranteed
performance.

12.3.4 Power Switchboards/MCCs

Witness testing and inspection of power Switchboards shall be carried out for routine
verification as per AS/NZS 61439 series. All motor circuits (including VSDs and soft
starters) shall be powered-up in the Contractor’s/manufacturer's works and tested in
‘automatic’ and ‘manual’ modes.

12.3.5 Control/Telemetry Panels

Control/telemetry panels shall be subjected to witnessed routine tests in accordance
with AS/NZS 61439.
Each cubicle shall be put through a series of witness tests to thoroughly test all functions
of control, including alarm, indication, pushbutton and contactor operations. External
contact operations shall be simulated by application or removal of jumper links at
appropriate terminals on the outgoing terminal blocks. Outputs shall be indicated on a
suitable lamp or meter across respective output terminals.

12.3.6 Motors
Motors shall be works tested generally as part of performance testing of pumping units
or other coupled equipment.
For motors rated up to and including 22 kW, work tests are not required.
For motors rated at 30 kW to 90 kW inclusive, work tests are required but need not be
witnessed. Results of unwitnessed work tests shall be provided to SA Water’s
Representative in accordance with clause 12.3.2.
For motors rated at 110 kW and above, witnessed works tests shall be carried out in
accordance with the following:
1. One of each type of motor shall be performance tested in accordance with the
relevant parts of AS 1359. The remaining motors shall be routine tested. Should a
motor fail a performance test, the remaining motors of that type shall be
performance tested,
2. Performance tests shall include temperature rise, momentary overload, dielectric,
winding insulation resistance, efficiency, power factor, locked rotor current,
locked rotor power factor, locked rotor torque, noise and vibration. Tests shall be
carried out with the motor connected direct-on-line. Measurement of voltage,
current and power shall be made for all tests,
Efficiency and power factor shall be measured at 50%, 75% and 100% loads.
The methods of measurement and test conditions for noise tests shall be in
accordance with AS 1359.109. Vibration measurements shall be in accordance
with AS 1359.114 and clause 6.1.

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3. The performance test certificate shall include all information necessary to allow
the calculations to be checked and shall include motor serial numbers, normal
winding configuration and winding configuration during resistance
measurements,
4. Declared efficiencies shall be determined by the summation of losses method in
accordance with AS 1359.102. The guaranteed efficiencies shall not include the
negative tolerances specified in AS 1359.101. The declared efficiencies shall be
achieved,
5. The performance tested motors shall be delivered to the pump manufacturer’s
works to test the relevant pumps or coupled equipment in accordance with the
project specification,
6. All data required for setting of electronic motor protection relays shall be
provided, including:
a. Maximum overload current,
b. Earth fault current including recommended maximum time delay to
overcome CT phase imbalance during motor starting inrush,
c. Motor thermal capacity in seconds,
d. Run-up time for the starting method proposed.

12.3.7 Generator Sets

The tests outlined in this clause apply to generators of size 25 kVA and over, or when
called for by the project specification.
Generator sets shall be fully run-in and ready for the specified duty before the specified
tests are performed at the manufacturer’s works. Running-in shall consist of not less
than 8 hours of running at loads of 80 ~ 100% of the continuous rating, or such running
as the manufacturer recommends to run the engine in.
Each complete set shall be tested for correct assembly and to prove satisfactory
operation, including starting, stopping, rated output, governing, voltage regulation,
transient performance, overload, short circuit current, and all control, indication,
protection and alarm functions including the batteries and chargers.
The noise level of each complete set shall be measured across the range of expected
loads during the test. The radiator fan shall be running for the noise level measurement.
The sound power level shall not exceed the Contractor’s designed sound power level
required to ensure that the specified noise levels are not exceeded.
In addition, vibration tests shall be carried out on each complete set in accordance
with AS 1359 part 114. Test certificates shall be provided to prove compliance with the
Standard.
The engine shall be tested for torque, power output and fuel consumption at 1500 rpm
in accordance with AS 4594.
The generator shall be performance tested in accordance with AS 1359.101.
Tests shall be carried out to check for correct assembly and sound mechanical and
electrical operation.
Performance tests shall also be carried out and shall include the following:
1. Short-circuit withstand (not required if a verified design certificate is provided),
2. Overload,
3. Temperature rise,
4. High voltage,
5. Functional tests of all safety and protection devices.

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Where facilities for a temporary generator set are provided, system performance tests
shall be carried out using a hired generator set.

12.3.8 Uninterruptible Power Supplies

Each UPS shall be routine tested in accordance with AS 62040.3 and the tests shall
include but not be limited to the following:
1. All control, indication and protection functions,
2. Operation of the static bypass and maintenance bypass,
3. Verification of the backup duration with the UPS operating at full load current
from the batteries without mains supply input. The battery protection system shall
be checked during this test.

12.3.9 Other Equipment

Works testing of other equipment shall be in accordance with the project specification,
where applicable.

12.4 Site Tests

12.4.1 General
At the completion of the installation or at the completion of agreed subsections of the
work, the Contractor shall, in the presence of SA Water’s Representative (or his
nominated Inspecting Officer) conduct site acceptance tests on all equipment which
has been supplied and/or installed as part of the Contract. The tests shall demonstrate
to the satisfaction of SA Water’s Representative that the installation is in accordance
with the specified requirements and that the installation operates correctly.
Unless otherwise specified, equipment which has been satisfactorily performance
tested or witness tested in the manufacturer's works need not be site tested except for
the following:
1. Check the installation and interconnections,
2. Check for any damage or deterioration which may have occurred since the
works tests,
3. Demonstrate that the system functions in accordance with the project
specification.
The Contractor shall give SA Water’s Representative not less than ten working days’
notice of intention to undertake the tests.
At the same time or earlier the Contractor shall:
1. Make available the latest drawings and PLC program listings for the equipment
to be tested, and
2. Submit for approval by SA Water’s Representative a copy of the proposed testing
procedure and test sheets. Testing shall not commence until SA Water’s
Representative has approved the testing procedure and test sheets.
The provision of all necessary equipment for testing shall be the responsibility of the
Contractor. All test instruments shall have current calibration certificates, if applicable,
and all certificates shall be made available for checking by the Inspecting Officer
before testing commences.

12.4.2 Test Results

Test results shall be supplied in the SA Water Operations and Maintenance Manual. The
results of all witnessed site tests shall be neatly and legibly recorded during the progress
of the tests on the approved test sheets. A copy of the test sheets, co-signed by the
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Contractor and the Inspecting Officer, shall be handed to the Inspecting Officer on
completion of the tests.

12.4.3 Switchboards, Control/Telemetry Panels, Associated

Equipment and Cabling
The following site tests shall be carried out (where applicable) to demonstrate the
integrity and correct operation of the system in accordance with AS/NZS 3017 and any
other relevant Standards:
1. insulation resistance,
2. earth resistance,
3. earth fault loop impedance,
4. continuity,
5. polarity,
6. calibration checks,
7. control sequencing,
8. functional tests.
Such testing shall include protective devices, manual operations, remote operations,
indications and controls, as a minimum.
The sequencing of control circuits etc. shall be checked against the control schematic
drawings and not against the formalised test sheets. The test sheets shall state that the
circuits were tested against the drawings and list any defects.
All adjustable parameters shall be properly setup and recorded for each equipment
item or device and the record submitted to SA Water’s Representative at the
completion of the tests.
Devices which cannot be adjusted (e.g. miniature circuit breakers) shall not have
calibration tests performed. However, fixed residual current devices shall be tested
before being placed into service to ensure that:
1. The tripping current is set to the appropriate value, and
2. The unit trips in less than 40 milliseconds at a test current of 10 mA for a Type I
device or in less than 300 milliseconds at a test current of 30 mA for a Type II
device.
Protective units, relays etc. which allow current injection or similar to check their settings
shall, during testing, have each function tested and calibrated.
Units which may be adjusted (e.g. thermal overload relays) shall be adjusted to the
appropriate settings in accordance with the manufacturer's written instructions prior to
being placed in service.
Equipment which is connected via a flexible power supply cord and plug and comes
under the scope of AS/NZS 3760 shall be inspected and tested in accordance with
AS/NZS 3760.

12.4.4 Motors
Site tests shall be conducted in accordance with the project specification to verify the
system performance under site conditions.

12.4.5 Generator Sets

Site tests for generator sets shall include the following as a minimum:

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1. Running of each set over the full load range to establish that the installation is
satisfactory and complies with guaranteed performance,
2. Continuous running at a power output equivalent to the continuous engine
rating for a period as agreed by the Principal’s Representative or project
specification to prove the onsite engine cooling system,
3. Multiple actual power failure start-ups to investigate various power failure
scenarios, as agreed with the Principal’s Representative or project specification,
4. Noise measurements shall be taken at the generator set and at the property
boundary at the specified times when the generator set is running at full rated
load.
Fuel for the site acceptance tests shall be supplied by the Contractor.
The plant loads and load bank (where provided under the Contract) may be used for
site tests. Any additional test load or equipment required shall be the responsibility of
the Contractor.
The generator set shall be run-in according to the run-in period specified by the
manufacturer.

12.4.6 Other Equipment

Site testing of other equipment shall be in accordance with the project specification,
where applicable.

13 Technical Information and Drawings

13.1 Drawings
13.1.1 Tender Drawings
Drawings which shall clearly explain the proposed construction, layout and physical
size of the electrical Switchboards, control/telemetry panels etc. shall be submitted
with the tender.

13.1.2 Prior to Manufacture

The Contractor shall provide a copy of detailed drawings, at the earliest practical date
but not later than four weeks prior to:
• The construction of any relevant portion of the works, or;
• The commencement of manufacture of equipment, or;
• Placing firm orders for any components.
The detailed drawings shall contain all necessary information for the manufacture and
installation of the equipment including the following, where applicable:
1. Dimensioned general arrangement drawings including critical tolerances,
2. Equipment layout drawings,
3. Single line diagrams,
4. Control circuit schematic drawings,
5. Layouts for Switchboards, control/telemetry panels and other cubicles,
6. Cable block diagrams,
7. Termination drawings,
8. Materials and parts listings.

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The details required in clause 13.1.3 shall be shown on the appropriate drawings.
These drawings will be examined to determine general compliance with the specified
requirements, but this shall not absolve the Contractor from the responsibility to
achieve a fully workable installation. Work shall not proceed on the manufacture or
supply of equipment, components or structure until the relevant drawings have been
approved by SA Water’s Representative. If manufacture or assembly is commenced
prior to the approval of the drawings, any restoration or modification work shall be at
the Contractor's expense.
Should SA Water’s Representative require additional information and/or drawings, or
any amendments to the previously submitted drawings, then the Contractor shall
supply the additional information and/or drawings or amended drawings within two (2)
weeks from the date of request. The cost of providing the additional information,
drawings and amendments shall be borne by the Contractor.
The Contractor shall allow a period of at least one (1) day per drawing or ten (10)
working days following each submission, whichever is the longer, for the examination or
re-examination of the information or drawings, unless otherwise agreed.
The drawings shall be prepared in accordance with TS 0100, as they will form the basis
of drawings to be submitted as final contract drawings. In particular, the fourth line of
the drawing title block should describe the drawing type 'sub-category'.

13.1.3 Drawing Details

Final contract drawings shall include the following details where applicable:
1. Single line diagrams detailing the following:
a. Current rating and fault rating of main busbars
b. Current ratings of all major incoming and outgoing switchgear (circuit
breakers, fuses, isolating switches, etc)
c. Type and sizes of all major incoming and outgoing cables
d. Voltmeters, ammeters, kW meters, kWh meters
e. Current transformer ratios
f. Protection relays
g. Motor starters
h. Others as appropriate to the installation (e.g. voltage transformers, auxiliary
supply transformers, earth switches, interlocks etc).
If necessary, the following additional drawings should also be provided to define the
requirements more clearly where applicable:
a. Control system block diagrams
b. Typical control schematics
c. Process and instrumentation diagrams
d. Earthing system
e. General arrangements.
2. Full schematic diagrams of control circuits including terminal, wire and cable
numbers.
A system of mnemonics shall be used in the labelling of contacts and coils. The
system shall follow the guidelines laid down on Drawing TYP-03-00001_40 in Figure
6 and as outlined below:
a. Schematics shall be drawn as vertical ladders with each line (rung)
numbered referencing the drawing sheet number and sequential line (rung)
number,

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b. Each wire shall be numbered with the sheet/line number suffixed by a

sequential number indicating the horizontal position of the wire. The wire
adjacent to the coil shall have the suffix number 9,
c. Components shall be numbered by device type, sheet/line number (e.g.
K2514, 25 represents sheet 25, 14 represents the line number,
d. Cross referencing of remote contacts etc. shall be shown using sheet/line
numbers and other drawing numbers as appropriate,
e. Spare cores of field cables shall be identified by their respective cable, core
and terminal numbers, where applicable,
f. PLC/RTU digital input/output label conventions to be enunciated such that
they include a description of the device and the status of the input/output
when in the ‘ON’ or ‘HIGH’ state. The I/O description shall match the SCADA
tag description as close as possible. This may mean that a fault state is
inverted to describe the I/O in the high state. e.g. ‘AC Power Supply Not
Faulted’.
g. Suitable mnemonics shall be placed adjacent to indicator lamp and
pushbutton symbols on schematics to clearly indicate their colour.

NOTE: TYP-03-00001_40 in Figure 6 is included for information and as a means of

establishing quality standards only. The circuitry shown shall not be taken as an
indication of the facilities required, or as an indication of the methods to be
adopted to achieve any specified requirements.
3. Instrument loop diagrams shall be drawn using the standard symbols,
Preferably one loop per A3 drawing sheet shall be provided,
4. Instrumentation and control equipment shall be shown on P&ID drawings in
accordance with TS 0200,
5. Layouts for Switchboards and control/telemetry panels,
6. Network drawings including:
a. A drawing sheet describing the overall network ring, where applicable;
b. Drawing sheet(s) detailing the connection of all devices to each switch, PLC,
etc in the network;
c. Details to be included:
➢ All network cable numbers;
➢ IP addresses of all devices;
➢ Label names of all devices,
7. Any other details specified in the project specification to be provided (either
tender, acceptance or final contract),
8. All final drawings shall include the ‘as constructed’ information.

13.2 Manuals
Unless otherwise specified, the Contractor shall supply all manuals in accordance with
TS 0132 Operating and Maintenance Manuals.

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13.3 Test Certificates

13.3.1 Information to be Submitted with Tenders
Where this clause requires the submission by the Tenderer of certificates from a
recognised Testing Authority, Tenderers need not provide additional copies of any
certificates which they have previously lodged in the central file of test certificates held
by the South Australian Water Corporation. However, reference shall be made, by
number, in the Tender to the certificate(s) that apply to the Switchboards covered by
the Tender. Submission of certificates with previous Tenders does NOT constitute
lodgement in the central file. The other requirements of this clause shall still apply.
Information to be submitted with Tenders shall include the following:
1. Certificate(s) from a recognised Testing Authority to verify the short circuit
capacity of the Switchboard,
The certificate(s) shall be complete and show all details of the tests undertaken.
Only limited sections of untested busbar will be allowed (e.g. the connection
from the main incoming unit to the main busbar) provided that short circuit
capacity is extrapolated from verified designs. The Contractor will be required to
provide calculations or written justification to support any such extrapolation prior
to manufacture in accordance with clause 13.3.2 (1).
The following details shall be provided:
a. Which components or sections of the Switchboard are covered by the
certificates;
b. Which parts of the various certificates apply to specific components or
sections of the Switchboard;
c. Which components or sections of the Switchboard are not covered by the
certificates and will be subject to extrapolation;
d. Drawings and sketches which show the proposed busbar arrangement and
detail which certificate(s) apply to individual sections of busbar,
2. Either:
a. Full copies of relevant certificates from a recognised Testing Authority to
verify the temperature rise of the Switchboard busbars, or
b. A guarantee shall be provided that the busbars are adequately rated for
the specified full load currents without exceeding the specified maximum
temperatures. The Contractor will be required to justify any such guarantee
prior to manufacture in accordance with clause 13.3.2 (2),
3. A guaranteed maximum temperature rise above ambient at full load of the
incoming and outgoing power conductor termination facilities. The Contractor
will be required to justify any such guarantee in accordance with clause 13.3.2
(3).

13.3.2 Information to be Submitted Prior to Start of Manufacture

The Contractor shall supply a copy of the following to SA Water’s Representative (refer
also to clause 13.1.2):
1. Full calculations and/or written justification (and any associated drawings) to
prove that any extrapolation or departure from the verified design (as allowed
for in clause 13.3.1 (1)) is capable of withstanding the specified fault conditions,
2. Full calculations (and any associated drawings) to prove that the busbar
temperature rise (as allowed for in Clause 13.3.1 (2)) is within the specified range
if certificates were not provided,

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3. Full calculations (and any associated drawings) or other documented evidence

that the temperature rise of the incoming and outgoing conductor terminations
(as allowed for in clause 13.3.1 (3)) are within the limits guaranteed.
Calculations (together with any associated drawings) will be examined to determine
general compliance with the specified requirements, but this shall not absolve the
Contractor from the responsibility to achieve a fully workable installation. If
modifications are required as a result of the examination of the calculations (and
drawings), a copy of modified or further calculations or modified drawings shall be
delivered for further examination. The cost of these modifications shall be borne by the
Contractor.
The Contractor shall allow a period of at least ten (10) working days after each
submission of the calculations (and drawings) for the above examination or re-
examination.
The Contractor shall not commence manufacture until SA Water’s Representative has
given written approval to do so. If manufacture commences prior to approval then
any restoration or modification work shall be at the Contractor's expense.

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Figure 5 – Example of Electrical Drafting Quality - Drawing 1

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Figure 6 – Example of Electrical Drafting Quality - Drawing 2

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