TS6 - Electrical Services PDF

Technical Specification
TS6 Electrical Services
CBH Engineering Pty Ltd

P | (08) 9236 5350
F | (08) 9236 5370
www.cbh.com.au
Document Control
Document owner: Principal Engineer
Change Control Policy
Any amendment to this standard must be recorded in the table below.
If substantial changes are made a new version of the document shall be created to preserve an
audit trail.
Review Date Author Descripton of amendments

A 30/04/2009 T. Tyler Reformatting, CBH changed to BWE, updating reference
codes and Standards
B 20/07/2009 T. Tyler Previously TS 19
C 12/01/2010 T. Tyler Pg.14 - 5.3 Change wiring from 1.0mm to 0.75mm.
Remove highlighting.
D 30/04/2010 T. Tyler Re-branding
E 04/05/2010 T. Tyler Changes made to: 5.11, Appendix A item 10 & Appendix A
item 11
F 08/06/2010 T. TYLER Changes made to page 29 point 13
5 11/11/2010 John Howard Cable colour changes page 14
6 24/03/2011
7 28/03/2011 John Howard Cable Ladder and tray update. Cable ties. General
components and equipment update.
Cable colours and use of Ferrules (Boot pins)
Other changes in Blue.
Items to check in yellow
8 31/08/2011 John Howard REPOL and Fibre Optic Communication conduit changed to
50mm.
9 5/01/2012 John Howard Minor detail changes to Appendix A. Motor circuit breakers.
Minor detail changes to Section 5.15 REPOL AND Fibre
conduit installation. 5.13.8 Soft Starters. 5.13.10 Motor
Protection.
10 10/01/2012 John Howard Lighting part number update
Jason Zuglian
11 19/01/2012 Jason Zuglian Emergency Stop Button Update
12 12/02/2012 John Howard Cat 5 cable upgraded to Cat 6
13 13/02/2012 John Howard Minor mod to text.
14 27/02/2012 John Howard Modified Appendix A Layout. Added Indicators,
Photoelectric Cell, 24vdc Power supplies, Traffic Lights and
Inch Motor Local Isolator, Relays, Cable tray covers.
15 28/03/2012 John Howard Updated Cable ladder installation details. Added comments
to Flexible conduit. Added Adhesive Heat shrink.
16 11/04/2012 John Howard Added high level sensors, Weatherproof flood lights, light
poles and sensors
17 07/05/2012 John Howard Appendix A update. Updated Finder relay types. Added
Weidmuller power supplies and STAHL DIP limit switches.
DOCS 826980v30 Page 2 of 50

18 24/05/2012 John Howard Circuit Breaker updates
19 13/07/2012 Jason Zuglian Schneider circuit breaker and contactor update. Lanyard
update. 240vac panel wiring change from Red to White.
Added Terasaki DIN-T DIN- SAFE circuit breakers.
20 16/07/2012 Jason Zuglian Emergency Stop Button Addition & Area Flood Lights up
date.
21 17/10/2012 John Howard Added strobe lights. Changed Light Pole type.
22 26/11/2012 John Howard Updated light fittings
23 20/12/2012 John Howard Bird proofing added and document clean up.
24 22/01/2013 John Howard Added timers, changed cables colours, see item 5.3.3.
Corrected part number of Low Level Sensor. Minor
document clean up.
03/04/2013 Runi Sugiharti Added headers, fixed lay out of front page as per other
Technical Specifications. Added file name field in footer -
after updating save as New Version. Go to Footer and place
cursor on the filename and press F9, this will update the
version number.
25 23/8/2013 John Howard Update Fibre Optic Cable Type & connector type
26 15/01/2014 John Howard Appendix A Changed Lanyard type
27 06/02/2014 John Howard Appendix A Changed LED indication
28 28/03/2014 John Howard Appendix A Changed Cable details.
29 3/06/2014 John Howard Updated Strobe and traffic lights.
30 13/11/2014 J. McMiles Update styling and formatting.

Contents
1. Scope 5
2. Definitions 5
3. Standards 6
4. General requirements 7
5. Technical requirements 12
6. Appendix A - Electrical Equipment List 28
7. Appendix B - Electrical Commissioning List 28
8. Appendix C - Motor Inspection and Test Record 28
9. Appendix D - Test Procedure for Dual REPOL Installation 28

1. Scope
This technical specification defines the general requirements for electrical services installation,
testing and commissioning of grain handling equipment for Co-operative Bulk Handling
Limited.
The enclosed Scope of Work Exhibit C, details the electrical details relating to the particular
project.
2. Definitions
2.1 Hazardous areas
A hazardous area is defined as an area in which an explosive atmosphere is present, or may

be expected to be present, in sufficient quantities to require the installation of specialised
equipment to reduce the risk of fire or explosion.
The areas within and in proximity of grain storage facilities, including elevator towers and
workhouses, boot pits, road and rail discharge grids, conveyor galleries etc, shall be regarded
as HAZARDOUS AREAS. These areas shall be zoned as 20, 21 or 22 in accordance with
AS/NZS 61241.10 : 2005
Switch-rooms shall not be built within these Hazardous Areas unless they are pressurized
and comply with AS/NZS 61241.4 : 2002
2.2 Competency standards
AS/NZS 4761 prescribes a level of competency is required for personnel involved in the
design, construction, maintenance, testing and inspection of equipment within hazardous
areas. It is mandatory that any personnel engaged in such work shall be both competent and
accredited prior to commencement.
The design consultant and electrical construction contractor shall provide documented
evidence of the required competencies.
2.3 Apparatus for combustible dusts
In areas zoned as 20, 21 or 22 in accordance with AS/NZS 61241.10 :2005, Dust Ignition
Protected (DIP) electrical equipment shall be selected and installed in accordance with the
current edition of AS/NZS 61241.14 : 2005 practice A. The maximum surface temperature of
this equipment shall be Class T4 - 135C. Consideration shall be given to apparatus installed
in an area where the local ambient temperature is likely to be outside the specified range -
20C to +40C.
All equipment shall be tested and certified under the AUS Ex or IEC Ex schemes.
Alternative suitable electrical equipment shall only be installed after the written approval of the
Principal.
2.5 Hazardous area verification dossier
A site Hazardous Area Verification Dossier shall be commenced by the responsible

designer(s) showing all areas zoned hazardous, and, the relevant zoning. It shall include
justification of the various zones. This document shall be updated as design and / or
construction progresses. The dossier shall be in accordance with AS/NZS 61241.14 : 2005.

2.6 Hazardous area equipment
All electrical equipment and / or apparatus installed within classified hazardous areas shall
comply with either AUS Ex or IEC Ex certification requirements for the classification zone into
which it will be installed in accordance with and AS/NZS 61421. 14 : 2005.
The maximum surface temperature of equipment selected for use within the hazardous areas,
zones 20, 21 and 22 shall be Class T4 - 135C. Consideration shall be given to apparatus
installed in an area where the local ambient temperature is likely to be outside the specified
range -20C to +40C.
Test result documentation shall be provided to support this requirement.

3. Standards
The principal codes and specifications applicable to this work shall include but not be limited to
the current editions, including all amendments and applicable cross references, of all relevant
Australian Standards as follows:
AS/NZS 4761 Competencies for working with electrical equipment for hazardous
areas. (EEHA) Part 1 Competency Standards.
AS/NZS 3000:2007 Electrical Installations (known as the Australian and New Zealand Wiring
Rules)
AS/NZS 61241 Electrical Apparatus for use in the presence of combustible dust.
Part 0. General requirements.
Part 1. Protection by enclosures tD
Part 4. Type of protection pD
Part 10. Classification of areas where combustible dusts are or may be present.
Part 14. Selection and installation.
Part 11. Protection by intrinsic safety iD
Part 18. Protection by encapsulation mD
AS 1939 Classification of Degrees of Protection Provided by Enclosures for

Electrical Equipment (IP Code).
AS 3947 Low Voltage Switchgear and control gear, Switchgear, Dis-connectors,

Switch-Dis-connectors, and Fuse Combination units.
AS 3008 Cables for Alternating Voltages up to and including 0.6/1kV.
AS 5000.1 Approval and test specifications - Electric Cables - Thermoplastic

insulated for working voltages up to and including 0.6/1kV.
AS 3439 Low Voltage Fuses - Fuses with enclosed fuse-links.
AS 2053 Non Metallic Conduits and Fittings
AS 1554.1 Structural Steel Welding Code.
AS 1795 Sheets and boards for electrical purposes.
AS 1755 Conveyors - Design, construction, installation and operation - Safety

Requirements.
AS 1202 AC Motor Starters (up to and including 1000 Volts).
ACA TS 009 Installation requirements for Customer Cabling (Wiring Rules).
AS/NZS 3080 Telecommunications installations Integrated telecommunications

cabling systems for commercial premises.
CBHE TS20 CBH Engineering Technical Specification Enclosures
CBHE TS21 CBH Engineering Technical Specification Electric Motors
Where no Australian Standards exist, the relevant IEC Standards shall apply.
The installation shall also conform to the requirements of the Office of Energy WA and the
Supply Authority.
4. General requirements
4.1 Enclosures
Enclosures and equipment installed in Hazardous Areas shall comply with the applicable
requirements of AS/NZS 61241.1
For areas not covered by the requirements of AS/NZS 61241.1 the minimum enclosure ratings
shall be IP 52 for internal locations and IP 65 for external positions, as defined in AS 1939.
All enclosures shall be of the type detailed in the equipment schedule or accepted equal. DIP
standards have been specified for some non- hazardous areas, this is done for standardisation
and alternative standards shall not be accepted.
All glands and packing used for sealing enclosures shall be non-deteriorating neoprene
rubber.
4.2 Temperature rise
All equipment and materials shall be suitable for continuous full load operation in an ambient
temperature range of -20C to +40C without exceeding allowable temperature rise.
4.3 Standardisation
All similar equipment, brackets, accessories, etc, shall be of the same make and pattern, and
all similar parts shall be jig drilled and interchangeable. Preference shall be given to items of
Australian manufacture, particularly in respect of ready availability of replacement parts and
maintenance.

4.4 Approved equipment
All equipment, accessories, etc used in the work specified herein shall be of the makes and
types specified in the Equipment Schedule detailed in Appendix A or on the relevant drawings.
Where alternatives are offered that fully comply with the specification complete technical
details shall be submitted with the price variation of each alternative.
Before any alternative is used in the installation, written approval shall be obtained from the
Principal.
4.5 Quality of materials and workmanship
All materials shall be new. Materials and workmanship shall be of the latest and best of their
respective kinds. Second hand or previously used materials shall not be accepted. If
required, samples of the materials shall be submitted for the inspection and approval of the
Principal before being used on the work. Only first class tradesmen are to be employed on the
work of their respective trades. Any workman who in the opinion of the Principal is
incompetent or who is careless in the execution of his work must be removed at the request of
the Principal. Where work has been badly or incorrectly constructed it shall be replaced or
otherwise made good without charge by the Contractor and to the satisfaction of the Principal.
4.6 Welding
All welding shall conform to the applicable section of AS 1554.
The Contractor shall not carry out any welding without the Principals approval.
4.7 Fixing, brackets and supports
Any fixings to woodworks shall be by steel screws, coach bolts or bolts nuts and washers.
Fixings to steelwork shall be by approved explosive cartridge type fasteners (Hilti), or tapped
or drilled holes with bolts or clamps, nuts and lock-washers. Explosive cartridge type
fasteners shall only be used after obtaining written approval from the Principal.
Equipment mounted within steel boot pits shall NOT be fixed to the outer walls of the boot pit
structure.
Fixings to concrete shall be steel screws or bolts into Loxin type fixings installed in
accordance with manufacturers instructions.
All nuts shall be locked. This clause shall be rigidly enforced.
Accessories, including light fittings, power outlets, welding outlets, lighting switches, control
stations, etc, shall be mounted on a minimum 3mm mild steel equipment mounting plate
machine cut, fully dressed and of adequate size for the relevant accessory AND label, and
shall have tapped holes for accessory mounting. Alternatively equipment may be mounted
directly on to structural members, providing the member is not structurally weakened and the
equipment does not overhang the member.
Brackets, racks, struts, supports, etc, shall be of adequately sized structural steel members,
and shall be installed in a manner which minimises dust accumulation.

Structural steel supports shall be minimum 6.5mm thick for angles and bars and 10mm
diameter for rods.
All ferrous metalwork shall be robust, machine cut, fully dressed with welds ground to a
smooth finish and provided with an anti-corrosive finish as specified in the enclosed Technical
Specification TS8.
4.8 Penetrations and making good
The Contractor shall make all penetrations, holes, openings, chases, etc, necessary for the
Contract work, which shall on completion be dustproof and weatherproof sealed to match
surrounding finishes, and to the requirements of the Principal. Any conduits or cables which
penetrate walls shall be weatherproofed with silicone rubber sealant.
4.9 Finishes
All ferrous metalwork and equipment installed shall be anti-corrosive treated and finished in
accordance with the enclosed Technical Specification No. TS8.
All brackets, racks and stays shall be finished in a colour to match surrounding steelwork
unless specified otherwise.
Any damage to anti-corrosive finishes on structural steelwork or paintwork on equipment

resulting from application of fastenings, brackets, etc, shall be made good to the satisfaction of
the Principal.
4.10 Labeling and identification
All labeling shall be in accordance with all of the following:
AS/NZS 3000: 2000
Conveyor Code AS 1755
Service and Installation Rules of the Supply Authority
Generally, all apparatus shall have fitted to non-detachable parts of equipment, conspicuous
labels to the acceptance of the Principal and conforming to the following requirements:

EQUIPMENT TYPE OF LABEL
Relays/Pushbuttons/ White Traffolyte, Black Lettering

Switches
Wire Numbering White bands, Black Lettering. Clip on or adhesive types shall not be
accepted
Control Panels White Traffolyte, Black Lettering

Fuses, Links and Circuit White Traffolyte, Black Lettering indicating circuit identification and
Breakers rating
Instruments White Traffolyte, Black Lettering indicating function.
Intrinsically safe barriers. Blue Traffolyte / White Lettering indicating function and sensor
location.
Cable Tags Stamped aluminum or Granolas type cable sheath and core straps
indicating cable number as per cable schedule.
Colors shall be permanent and free from fading. Unless otherwise accepted by the Principal,
all designation labels shall be engraved with black lettering on a white background.
Labels shall be securely fixed to the equipment using not less than two fastenings. Label
fixings shall be such as to allow ready replacement without damage to the label or equipment.
Danger or similar warning labels shall have red lettering on a white background.
Individual items of electrical apparatus installed within hazardous areas shall also be marked
in accordance with AS/NZS 61241. 0.
4.11 Documentation
Prior to the time of commissioning of the installation, the Contractor shall complete the
following requirements...
The site hazardous area verification dossier shall be completed by the responsible designer
and /or installer:
4.11.1 Confirming the location of equipment within the hazardous areas.
4.11.2 Confirming cable and wiring routes and cable and wiring details.
4.11.3 Include the certification documentation of all electrical equipment installed.
4.11.4 As constructed wiring diagrams, schematics, MCC layouts (basic) and IS system
drawings.
4.11.5 Details of the accredited and responsible designer and / or installer(s).
DOCS 826980v30 Page 10 of 50

4.11.6 This document shall be verified and signed off by the appropriate competent and
accredited responsible person by or on behalf of the designer and / or contractor.
For Supply and Construct contracts the Contractor shall neatly mark up, to the Principals
approval, two sets of prints in red for any alteration made during the contract period.
One set of prints shall be returned to the Principal so that the original contract drawings may
be altered to the As Installed state. The other shall be left on site for maintenance purposes.
For Design and Construct contracts the Contractor shall neatly mark up, to the Principals
approval, one (1) set of prints in red for any alteration made during the contract period which
shall be left on site for maintenance purposes.
The Contractor shall provide the Principal with an electronic copy, on compact disc, of the As
Constructed drawings within 14 days of practical completion of the works. These drawings
shall be in AutoCAD (.dwg).
The drawings are intended to be a final record of the installation and shall contain at least the
following information:
a) Site layout showing all underground cable routes not included in the dossier
complete with dimensioned locations.
b) Final location of all equipment supplied under this Contract not included in the
dossier.
c) The actual designation of all equipment as engraved on the labels.
d) Size of all fuses, circuit breakers, conductors, cables, etc, for every circuit installed.
e) Conductor ferrule numbers and conductor colour codes.
f) Schedule of all cables showing: Lengths, core numbers, designations.
g) Terminal layouts with wire numbers for all terminations.
h) The drawing contents shall be in accordance with the Documentation clause of

Generic Electrical Scope of Works.
4.12. Dimensions and Locations.
Verify the location of all fittings, limit switches, motors, switchgear, etc, with the Principal
before proceeding.
The Principal may relocate any power outlet, light switch, limit switch or similar small device up
to two metres without altering the cost of the works.
Check all relevant dimensions on site before proceeding with the work. Dimensions shall not
be scaled from the drawings.
4.13. Redundant Plant.
All redundant Co-operative Bulk Handling Limited equipment removed from sites under this
contract shall be carefully and securely packaged, clearly and indelibly labeled (including site
from which it was removed) and returned to Co-operative Bulk Handling Limited as directed by
DOCS 826980v30 Page 11 of 50
the Principal. Any redundant metering equipment which is Western Power Corporation
property shall be similarly packaged and returned to the respective Western Power District
Office, or at any alternative point which Western Power may require, and the Contractor shall
notify the Principal in writing of all equipment so returned.
4.14. Co-ordination.
Equipment to be supplied under this Contract that forms part of a composite scheme the
Contractor will be required to co-operate fully with the supplier of associated equipment to
ensure correct operation of the installation. This shall include close liaison between Civil and
Mechanical sub-contractors, the Supply Authority and local CBH Engineering District
Managers as required ensuring timely completion of the works.
5. Technical requirements
5.1. Electricity supply
5.1.1. General
The supply shall be 415/240 volts, 3 phase, 4 wire, 50 hertz and derived as shown on the
drawings.
5.1.2. Western Power Corporation connections
For installations connected to the Western Power Corporation system, the Contractor shall be
responsible for all liaisons with that organisation regarding the connection. The Contract shall
cover the supply, installation and connection of the power supply except for work carried out
by the Western Power.
The Contractor shall supply and install all necessary poles, cross arms, pole back stays, point
of attachment - fuses, etc, required for the incoming aerials.
Clearance over roadways shall not be less than seven (7) metres.
Where points of attachments are made direct onto building structures they shall comprise
hardwood battens to Western Power Corporation acceptance.
Three (3) spare service fuses shall also be supplied and fitted within the main cubicle to the
Principals acceptance.
5.1.3. Diesel alternator connections
Where shown on the drawings the Principal will provide a diesel alternator set for connection
to the electrical control cubicle. Allowance shall be made for this connection to be made, prior
to the commissioning date.
5.1.4. Existing switchboard connections
Where shown on the drawings the electrical supply shall be derived from the existing
switchboards. The existing switchgear shall be modified to accommodate the cables and
switchgear nominated on the drawings.
5.2. Earth system
The installation shall be earthed in accordance with the M E N System as described in

AS/NZS 3000 Section 5 including telephone system and lightning protection earths. Provide
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all necessary connections and earth electrodes.
The main protective earth electrode shall be copper clad steel and be driven into the ground in
an approved location adjacent to the site main switch / metering board.
The electrode shall be a copper sheathed steel cored rod approximately 20mm diameter and 3
metres long, driven into the earth at a perpendicular depth of not less than 3.1 metres.
The main earth conductor shall be terminated to the electrode within a 600mm long, 225mm
diameter VITREOUS clay pipe installed flush with finished ground level and fitted with a
galvanised chequered plate cap or an approved main earth connection pit.
Where the earth pit is not labeled, as part of the design, provide a brass label adjacent to the
earth electrode termination engraved as follows:
DANGER MAIN EARTH
DO NOT DISCONNECT
On completion of the installation the earth loop impedance shall be measured and shall be in
accordance with the requirements of AS/NZS 3000 Appendix B. The results of this test shall
be submitted to the Principal.
5.2.1. Earth bonding
All structural steelwork shall be equipotentially bonded to earth as AS/NZS 3000 regardless of
sheathed conductors being used.
5.3. Cables general
Unless otherwise specified within Australian Standards, site specific Scope of Works or shown
on the drawings, all wiring shall be carried out with standard copper conductor with PVC
insulated or PVC insulated PVC sheathed cable.
All conductors shall be of multi-strand construction.
Three phase outlets shall be wired red, white, blue in a clockwise direction from the earth or
neutral pin when facing the front of the outlet.
5.3.1. Bird damage protection
Bird damage protection is required above two metres on all external structures, galleries and
light poles.
Cable ladder with removable covers is required as cable supports.
PVC covered flexible steel conduit is required where the cables exit the ladder.
Check the Electrical Scope of Works or the site specific Scope of Works for any site specific
requirements.
All conductors shall be colour coded as follows:
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5.3.2. Power circuits (hard wired)
Phase/Line 1: Red.
Phase/Line 2: White.
Phase/Line 3: Blue.
Neutral, Black.
Earth, Green/Yellow.
5.3.3. Three Phase 3c+E (flexible cables).
Phase/Line 1: Brown.
Phase/Line 2: Black.
Phase/Line 3: Blue.
Earth, Green/Yellow.
Three Phase 4c+E (Flexible Cables).
Phase/Line 1: Brown.
Phase/Line 2: Black.
Phase/Line 3: Grey.
Neutral: Blue
Earth: Green/Yellow.
5.3.4. Control circuits 110vac & 240vac.
Panel wiring 0.75mm or 1mm unless nominated.
110vac Actives - Grey.
110vac Neutrals - Black.
240vac Actives - White
240vac Neutrals - Black.
5.3.5. Control & indication circuits - extra low voltage (24v & below)
Panel wiring 0.75 mm or 1 mm unless nominated.
Positive - Orange.
Negative Purple (Violet).
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5.3.6. Voltage free circuits.
Pink
5.3.7. Flexible wiring
Flexible wiring requires ferrules (Boot lace pins) fitted at the termination points.
When looping wiring using use TWO CABLE type ferrules.
See Appendix A: Flexible Wiring for details.
5.3.8. Intrinsically safe circuits
Control cables for intrinsically safe circuits shall have a blue sheath and be electrically and
mechanically segregated from other power and control cables.
5.3.9. Light and power circuits
Minimum sizes shall be 1.5mm for Lighting and 2.5mm for power. Where more than one
cable is to be routed cable tray or ladder shall be used.
Cables shall only be installed when construction in the area is completed to ensure that the
cables are not damaged.
5.4. General cable installation methods
All cables shall be routed in the most economical manner and be parallel with the building or
structural lines in a horizontal or vertical plane.
Each run of cable shall be installed between conductor terminal points, with no joints in any
part of the run unless specified on the drawings.
Cables shall be neatly dressed to the Principals acceptance and any modifications deemed
necessary by the Principal shall be at the Contractors expense.
Cables shall be supplied on the cable manufacturers recommended drums and shall be
delivered to site with labels showing their origin, specification and date of manufacture.
The labels shall be retained by the Contractor and may be inspected by the Principal.
Where single core cables are installed, they shall be installed such that the circulating currents
in gland plates, etc cannot be generated. Gland plates shall be of non-ferrous material.
On completion of installation all cables, conduits, ducts, etc that pass through walls, floors or in
floors shall be sealed. The method of sealing shall be to the Principals acceptance.
Cables shall be handled with all due care and at no time will twists or kinks be acceptable in
the cable installation. Any twisted or kinked cable shall be removed and replaced with a new
cable at the Contractors expense.
No plastic insulated or sheathed cables shall be allowed to come into contact with petroleum
products such as grease, oil etc.
The method of terminating Steel Wire Armoured cable shall be to the Principals acceptance
DOCS 826980v30 Page 15 of 50

and shall be such that a metal gland securely anchors all the strands of armouring. No cutting
out of armouring strands shall be permitted.
The Steel Wire Armouring shall be continuous and earthed at each termination unless
specified otherwise.
Any cables and conductors, which have been disconnected from the supply, shall be suitably
terminated, enclosed and labeled at both ends to the Principals acceptance.
5.5. Underground cables
Underground cables - and marked as such - shall be installed as per AS 3000 Underground
Wiring System Category B - Buried direct with Polymeric cable cover strip to AS 2053, unless
specified otherwise.
Where cable routes call for a change of direction the pull shall be made by blocks and rollers
without exceeding the manufacturers recommended radii and tension limits.
Where cables are pulled by mechanical methods then a stocking grip or other method
acceptable to the Principal shall be used.
All underground cable routes shall be indicated by use of Principal approved cable route
markers:
(a) at ends of each cable;
(b) two markers required at change of direction;
(c) not more than 50 metre intervals.
In general the methods employed shall be as specified in AS 3000 covering the installation of
underground cables.
The contractor shall take the utmost care to prevent any damage to existing underground
services.
All necessary information in regard to existing underground services shall be obtained by the
contractor from the appropriate sources, e.g. Telstra, Water Authority, Local Shire etc, before
the commencement of any site works. Electronic cable locators or similar shall be employed to
locate existing underground cables. It shall be the responsibility of the contractor to ensure
that any damage to underground services are immediately being repaired and the appropriate
CBH Engineering District Superintendent and the CBH Engineering Project Supervisor are
informed about the extent of the damage and the progress of the repairs.
All costs relating to the repair or replacement of damaged underground services shall be to the
expense of the contractor, unless the contractor can provide sufficient proof to the satisfaction
of the Principal that all reasonable steps were taken to avoid such damage.
Cables being installed in trenches and or ducts shall be protected from excessive temperature
rise due to solar radiation and vandalism, when stored on site prior to installation.
The Contractor shall allow for all excavation, backfilling and reinstatement (not including
bitumen works) costs for this part of the installation to the Principals acceptance.
5.5.1. General trenching works specifications
The contractor shall inform the Principal three days before the start of any trenching works in
DOCS 826980v30 Page 16 of 50

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

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

required standards of compaction, ensure required compaction as specified above. If
compaction levels are readily achievable the Contractor shall advise the Principal or
nominated supervisor immediately.
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Equipment Min No. Cohesionless Cohesionless Cohesive

Passes
Materials (1) Materials (2) Materials
Hand Tamper 3 150mm 100mm 100mm

Min 15 kg
Mechanical 3 300mm 250mm 200mm

Tamper
Min 50 kg (3)
Vibrating Plate 4 150mm Not Suitable Not Suitable

Min 50 kg
Vibrating Plate 4 200mm 100mm Not Suitable

Min 100 kg
Notes:
1. Free draining materials.
2. Non free draining materials.
3. Wacker Packer or similar compactor.
5.6. Underground conduits
The size of each conduit shall be as shown on the drawings and comply with the
recommended conduit sizes as specified in AS 3000.
Prior to installing cables in conduits, they shall be cleaned by means of a scraper and/or
cylindrical brush to avoid damage to the cable during installation.
Where the tensions are required that exceed those recommended by the manufacturer of the
cable then a bond pull shall be used. In these installations the tension of the pull shall be
taken by the steel wire rope (or substitute). Where cables have protective screens care should
be taken to avoid damage to the over-sheath.
On completion of the cable installation each conduit end shall be sealed between cable and
conduit to avoid the entry of foreign bodies.
Where conduits are used to provide a cable entry into a building, then the conduit shall be
installed with a slope to prevent the natural flow of water into the building. This requirement is
in addition to the sealing of the duct as specified elsewhere.
5.7. Conduits general
Conduits and fittings shall be screwed galvanised steel to AS 2052 or HD rigid and HD flexible
PVC to AS 2053.
Screwed galvanised steel conduits and fittings shall be used throughout unless specified
otherwise.
Draw in boxes shall be provided as necessary to enable cables to be pulled in at a future date.
DOCS 826980v30 Page 19 of 50

All cables entering conduits, pipes and ducts shall be protected by means of a bush, to avoid
damage due to abrasion.
Conduit shall be supported by spacer bar saddles of the same material as the conduit.
To minimise the collection of dust, conduit supports shall be installed vertically where possible.
Inspection type tees and elbows shall not be used.
All conduit and wiring shall be installed in the loop in and draw in system with no conductors
installed until the conduit installation is completed and permanently fixed.
Light switches, socket outlets, light fittings and the like shall not be used as wiring enclosures
for non-associated circuits.
Running threads shall not be permitted.
Where conduits cross expansion joints, flexible cable shall be installed in that section.
Conduits shall not interfere with movement or operation of equipment nor limit the access to
equipment or access ways.
Conduits shall be kept a minimum of 75mm from any non-electrical pipe work. Where
potentially hazardous services such as high temperature pipes etc, are present the clearance
shall be increased to permit the safe operation of the electrical installation.
The conduit system shall be designed to minimise the number of parallel runs by grouping the
cables where possible.
All conduit runs shall be installed as straight as possible and parallel with the building or
structural lines in a horizontal or vertical plane, unless otherwise approved by the Principal.
All conduits shall be secured with two fixing type saddles, manufactured from the same
material as the conduit being secured.
Conduit installations shall be fully assembled and secured prior to the drawing in of cables.
The conduit shall not be bent in a manner which appreciably distorts the walls of the conduit
from their original section or split open the conduit. The radius of any bend or set shall be not
less than the conduit manufacturers recommendation.
5.8. Flexible conduit
Flexible steel reinforced PVC sheathed liquid tight and/or DIP (as required) conduit shall be
provided between the ends of fixed installations and equipment, such as motors, limit
switches, etc liable to movement or subject to vibration.
Where rigid PVC conduit is used for the fixed installation then the conduit manufacturers
recommended flexible PVC conduit shall be used to connect equipment, such as motors, limit
switches, etc liable to movement or subject to vibration.
The lengths of flexible conduit shall be kept to a minimum as dictated by the equipment being
connected and accepted by the Principal.
DOCS 826980v30 Page 20 of 50

5.9. Cable tray or ladder
5.9.1 General
Cable tray or ladder shall be galvanised steel and be complete with factory fabricated joints,
bends, mounting brackets and fittings approved by the manufacturer.
All external cable supports installed two metres above the ground shall Cable Ladder (not
tray).
Cable ladder shall be mounted only on a horizontal plane (on its back).
5.9.2 Cable ladder (external)
All external Cable Ladder above two metres from the ground shall be continuous and complete
with covers. Horizontally mounted ladder shall have Peak Covers. (the covers are for bird
damage protection).
5.9.3 Cable ladder (mounted on galleries)
Where cable ladder is installed on a gallery it shall be installed on the outside of the hand rails
close to the top so that cables can exit through the bottom.
5.9.4 Cable tray
Cable tray shall be mounted only on a vertical plane. All cable trays shall be installed such that
the dust accumulation is minimised.
5.9.5 Cable ties exposed to ultra violet light
Cables on a vertical plane of vertical or horizontal mounted cable ladder or tray shall be
secured with stainless steel ties.
Cables on a horizontal plane shall be secured with heavy duty Ultra Violet rated cable ties.
5.9.6. Cable ties not exposed to ultra violet light
All heavy duty rated cable ties.
5.9.7. Cable tie spacing
The fixing intervals of cable ties shall not be more than 300mm for cables mounted on vertical
plane and 600mm for cables mounted on a horizontal plane.
5.9.8 Cable ladder or tray capacity
A minimum of 30% spare area must be allowed for.
5.9.9 Cable ladder earth bonding
All CLS cable ladders must be effectively earthed for personal protection. The ladder used on
CLS systems is not secured to the conveyor frame. Cable ladder earthing shall consist of
16mm2 lugged earth cable link installed between the earth terminal in each of the stacker
loader outlet boxes (ever 36metres) and the conveyor frame leg. Use an 8mm bolt minimum.
DOCS 826980v30 Page 21 of 50

Install a 16mm2 lugged earth cable links between the conveyor leg earth bolt and the Cable
Ladder. Use an 8mm bolt minimum.
Install a 16mm2 lugged earth cable links between each length of Cable Ladder. Use an 8mm
bolt minimum.
5.10. Marshalling and junction boxes
All marshalling and junction boxes shall have welded or integrally cast in gland sockets for
bottom entry, and shall be of robust design, fabricated from a minimum of 2mm sheet metal.
Painting shall be carried out in accordance with Technical Specification TS8.
All paints used shall be compatible with the anticipated working environment.
All exterior marshalling and junction boxes shall be aluminum construction with a brushed
exterior finish.
The Contractor shall submit drawings of proposed marshalling and junction boxes for written
approval of the Principal before including them in the installation.
All terminations shall be made using terminals of the type shown in the Equipment Schedule.
The ports shall accommodate 2.5mm square with mounting rail, end sections, jumper bars and
all necessary standard accessories, in strict accordance with the relevant termination diagram.
Each terminal port shall accommodate not more than one conductor, jumper bars are to be
provided where multiple conductors are to be terminated together.
Top entry to marshalling and junction boxes shall not be permitted in weather exposed
locations.
5.11. Glands
All cable glands and associated fittings shall be supplied and fitted by the contractor.
All cable glands shall be DIP certified for installation within Zone 20 and Zone 21 classified
areas as required.
All cables shall be terminated using the cable manufacturers recommended cable glands
sizes.
The cable gland and locking nuts and rings shall be metal construction and shall be
compatible with the termination gland plate or terminating box material.
All glands shall be securely fixed to the gland plate and where locknuts are used as a method
of fixing, then a locking ring shall be installed in addition to the normal locknut.
Cable glands shall be terminated at a position such that the conductors can easily be worked
into their final termination position without damaging the conductor insulation.
Cable glands not meeting these requirements shall be replaced at the contractors expense.
DOCS 826980v30 Page 22 of 50

5.12. Power installation
5.12.1 General
Supply and install power outlets and wiring to electrical equipment as shown on the drawings.
Refer to electrical drawings for wiring details.
Final connection to all equipment shall be made through suitable isolators where required by
AS 3000.
Where equipment is supplied and fitted by others and connected under this contract, check
wiring details with equipment suppliers BEFORE beginning the installation. If documented details are
incorrect notify the Principal and obtain instructions regarding the necessary changes.
All conductors shall be fitted with the appropriate crimped cable lugs.
5.12.2. Motors.
All motors regardless of location in any area of grain handling equipment shall be a minimum
IP65 DIP.
All motors shall be site tested with a 1000 volt Insulation Resistance tester and the results
including all Motor Nameplate data submitted in writing to the Principal refer Appendix C.
Unless otherwise specified all electric motors will be supplied and fitted by others. Provide
electrical connection to these motors.
Before commissioning each motor liaise with the Mechanical Contractor to verify the required
motor rotation and verify that the overload settings are correct.
5.13. Control Gear and Accessories.
5.13.1 General
This equipment shall be rated for the anticipated working environment and be in accordance
with the equipment schedule of the Scope of Works.
5.13.2 Fuses and links
Fuse links of the HRC cartridge type complying with AS 3135 shall be supplied.
Carriers and bases shall be of good quality moulded insulating material with fuses of black
material and links of white. Painted bases and/or carriers will not be accepted.
AC control circuits shall have a fuse in the live side and link in the earthed side.
Descriptive labels shall be fitted adjacent to all fuses and links.
5.13.3. Current transformers
Current transformers for the operation of instruments and metering equipment shall comply
with the requirements of AS 1243 and AS 1675. Current transformers for the operation of
protective equipment shall be suited to the characteristics of the apparatus with which they are
associated.
DOCS 826980v30 Page 23 of 50

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

thermal stresses set up by a short circuit equal to the full short circuit rating of the associated
switchgear.
The method of securing current transformers in position shall be such that no undue pressure
is exerted on the windings.
All connections from secondary windings shall be brought out and connected by means of
separate insulated leads to a terminal board, and each shall be securely braced and so
arranged as to prevent accidental contact with main connections due to displacement or
breaking of the leads. Secondary cables greater than 2 metres in length shall be 6 mm.
The Contractor shall state the accuracy, capacity and ratio of the transformers are suitable for
the particular duty with which they are associated.
Protective current transformers shall maintain their ratio to ensure stability of protective
systems under fault conditions.
Magnetisation curves and type test certificates shall be submitted when requested by the
Principal.
The polarity of the primary and secondary windings of each transformer shall be clearly
indicated in an acceptable manner and labels shall be fitted, in an accessible position, to
indicate the duty of each transformer.
5.13.4. Instruments and meters
All indicating instruments shall be to AS 1042 accuracy class 1.5 and have scales in
accordance with BS 3693. They shall have a scale length of not less than 100mm and a scale
movement of approximately 270, and shall be of the flush mounting type with square bezels.
All instruments and apparatus shall be capable of carrying their full load currents without
undue heating. They shall not be damaged due to the passage of fault currents up to the
maximum fault current of the switchgear. All instruments and apparatus shall be back
connected. Accepted means shall be provided for zero adjustment of instrument without
dismantling.
All indicating instrument scales shall be clearly divided and indelibly marked, and the points
shall be of clean outline. Unless otherwise accepted the marking of the main area of the dials
shall be restricted to the scale marking; instrument transformer ratios, makers name, accuracy
grades etc shall not appear on the dials, but shall be marked in an accepted position,
preferably below the bezel.
Instrument glasses shall be coated with anti-reflective material.
Ammeters may be directly connected in circuits having a rated full load current not exceeding
25 amp. Ammeters in circuits having a rated full load current above 25 amp shall be current
transformer operated. Ammeters shall be checked against actual primary current and
adjusted to suit.
Ammeters shall be capable of carrying rated currents continuously without undue heating, be
suitable for operation without damage when carrying direct on-line starting currents of motors
and shall withstand the passage of fault currents until operation of the main circuit protective
device.
DOCS 826980v30 Page 24 of 50

Ammeter scaling shall be such that normal full load current gives approximately full scale
deflection.
5.13.5. Limit and proximity switches
Supply and install limit and proximity switches complete with all necessary base plates, striker
arms, cams and brackets as required for the correct operation of the plant. Liaise with the
Mechanical Contractor to ensure the limit and proximity switches are correctly located. The
Electrical Services Contractor is responsible for the correct operation of all limit and proximity
switches.
Limit switches shall be of metal construction, plastic body types shall not be permitted.
Proximity switches used for level monitoring or for detecting grain shall be fitted into a steel
flange to allow for easy testing of the unit.
5.13.6. Lanyard systems
The Contractor shall install and commission lanyard operated emergency stop system as
shown on the drawings and complying with AS 1755. Each lanyard system shall be complete
with lanyard wires, heavy duty compensating springs, eye bolts, turnbuckles and all fixings to
commission the system. The Contractor shall also install Conveyor Stop signs at intervals of
not more than 30 metres in accordance with AS 1755 clause 3.15.5.2.
Lanyard wires shall be PVC sheathed covered, flexible galvanised steel wire rope, 6 x 19
construction, minimum 3.5mm diameter where 5mm is not available. The wires shall extend to
within 1 metre of the end of the conveyor structure and shall be no longer than 120 metres.
The end of each lanyard cable, adjacent to the switch shall be anchored to a rope thimble with
clips and a galvanised turnbuckle. The turnbuckle shall be complete with an adjustable screw
eye bolt and locknut.
Where the lanyard cables changes direction a durable pulley block shall be supplied and fitted
under this contract.
Where two or more lanyard pull switches are installed on one side of equipment, the lanyards
shall not be connected in series through the switches, but each switch lanyard shall have
separate anchor points.
5.13.7. Auto transformers
Where specified, these units shall be installed such that the heat dissipation does not
adversely effect other electrical equipment.
All auto transformers shall be manufactured in accordance with AS 1202 and have class A
insulation. Taps shall be provided at 50, 65 and 80%.
The duty classification shall not be less than 0.1; i.e. 12 starts per hour.
Thermistors shall be incorporated in the windings to provide thermal protection of the auto
transformer.
DOCS 826980v30 Page 25 of 50

5.13.8. Soft starters
Where specified shall be of those listed in Appendix A or an approved equivalent if not

available.
Soft starters shall have external bypass contactors installed where required. The soft starter
shall be set as per drawing Soft Starter Parameter Settings. This may be varied during
commissioning depending on equipment connected. Fine tuning of the current limit start shall
ensure that the motor reaches full speed within 15 seconds. If this is not achieved other
parameters may be varied.
5.13.9 Ultrasonic level switches

The Contractor shall install all ultrasonic level switches as specified in the Scope of Work to
the satisfaction of the Principal. The ultrasonic transducer shall be mounted to minimise dust
build up. The level switch shall be calibrated by the Contractor.
5.13.9. Motor protection
All Areas
Thermal Magnetic Motor Circuit Breakers (see Appendix A for details).
Motors fitted with a Soft starter to have a Control Panel mounted manual reset push button.
General
Motor overloads shall be rated 10% greater than the manufacturers stated full load current of
the motor.
5.13.10. Year 2000 Compliance Warranty
The Contractor warrants that where the functioning of any aspect of the Works relies on,
incorporates or otherwise utilises a date code the Works have been specifically designed and
tested, where applicable, in conjunction with associated software and/or hardware, to
accommodate and implement the transition from the Year 1999 to the Year 2000. John Cairns
to confirm.
This Year 2000 Warranty will survive termination of this Contract and will continue for the life
of the Works. TBC.
5.14 Modification of existing switchgear
Where modifications to existing switchgear or cubicles in non hazardous areas are specified,
the Contractor shall install indicating lamps, push buttons and similar accessories that match
the existing equipment. The requirements of this clause supersede the information detailed in
the schedule of equipment.
Where existing Mimic Panels are to be modified, the contractor shall remove the existing
Panel and have it engraved as shown on the drawings. The contractor shall nominate in his
Tender the Engraving sub-contractor.
DOCS 826980v30 Page 26 of 50

Where modifications to existing switchgear or cubicles in hazardous areas are specified, the
Contractor shall treat the upgrade as a new installation and such shall comply with all current
standards and industry requirements as specified in Clause 2.0 - Definitions and Clause 3.0
Standards, of this document.
5.15 Fibre, and REPOLS installation
5.15.1 Fibre cable
The contractor shall install cable (see drawings for number of pairs) in an unbroken (no joints)
section between the weighbridge and the sample platform. The cable shall be installed in
separate, continuous and glued 50mm communication conduits in all cases. Install draw-in pits
every 100 metres and or change of direction. If the pits are likely to be damaged by vehicles
and or machinery the contractor shall install trafficable pits and lids. Terminate using SC
connectors.
Minimum cable radius:
During installation, the cable bends no greater than 20 times the diameter.
After installation, the cable bends no greater than 10 times the diameter.
Storage loops, the cable bends no greater than 30 times the diameter.
See Appendix A for cable type.
5.15.2 REPOL cable
The contractor shall install 20 pair cable (or as nominated) in an unbroken (no joints) section
between the weighbridge and the sample platform MDFs. The cable shall be installed in
separate, continuous and glued 50mm communication conduits in all cases. Install draw-in pits
every 100 metres and or change of direction. If the pits are likely to be damaged by vehicles
and or machinery the contractor shall install trafficable pits and lids. See Appendix A for
cable type.
The REPOLS system shall be tested in accordance with Appendix D of this specification.
5.16 Lightning protection
The Contractor shall install a lightning protection system that will prevent damage or injury
which may be caused by a lightning discharge. The protection system shall be in strict
accordance with AS 1768.
5.17 Testing & commissioning
Testing and commissioning shall be in accordance with the Scope of Works. Appendices B, C
and D shall be completed as applicable.
DOCS 826980v30 Page 27 of 50

6. Appendix A - Electrical Equipment List

7. Appendix B - Electrical Commissioning List
8. Appendix C - Motor Inspection and Test Record
9. Appendix D - Test Procedure for Dual REPOL Installation
Equipment & Component short list:
CBH_DMS_PROD-#1307892-Elect Equipment & Component list
DOCS 826980v30 Page 28 of 50

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

Control
Cable-
Cable Communication (REPOL)

Communic
(REPOL)
20 Pair Poly/Poly Nylon 1/0.64 (OLEX)

Cable-
ation
Cable - Optic Fibre Cable

Optic Fibre
12 core Single Mode type 12F SM 9um OS1 UF SERIES YELLOW Code AFCUF112F.
Cable-
Available from Australian Fibreoptic Communications (AFC) Belmont WA, 6253 2200.
Use SC type connectors.
PVC with a concrete lid 705mm long x 455mm wide x 800mm deep
Cable Pits
Cat 6 Communication cable

Cable-Cat 6
Blue flexible installed in 50mm White conduit. Segregate from power cables.
CAT 6 Termination socket

Cable Cat 6
Weidmuller Code IE-XM-RJ45/IDC part number 8808360000. DIN rail mount 18mm wide.
Socket
Cable Tray (Internal and below two metres)

Cable Tray
Kounis Metal Industries. Type Light duty complete with rolled edges,
Code L.
Cable Ladder
Kounis Metal Industries. Type 3/50 (NEMA 16A)
Ladder
Cable
Cable Ladder (External and installed two metres above the ground).
Kounis Metal Industries. Type 3/50 (NEMA 16A), complete with covers.
Ladder
Cable
Circuit Breakers - Control and General.

Control &
NHP Terasaki DIN-T or DIN SAFE each complete with removable padlocking device
breaker-
General
Circuit
type LOCKDOG DTLLA
DOCS 826980v30 Page 29

of 50
Distribution Circuit Breakers - Merlin Gerin Type NSX TM-D
Amps Type Over load Type / Rating
11-16amp NSX100N TM16D

Distribution Boards

Circuit breaker-

TM100D (Suit Stacker Loader 90amp outlets,
70-100amp NSX100N Set on 85 amps).
175-250 amp NSX250N TM250D
Note. If the final sub-circuit supplied via an outlet a 100ma RCD (ELCB) is required.
Main Isolator Distribution Board etc.

breaker-
Schneider (Merlin Gerin) - Interpact INS series.

Switch
Circuit
Main
Circuit Breakers Distribution Board Main Switch.

breaker-
Schneider (Merlin Gerin) Compact NSX400/630NA, non auto.

Switch
Circuit
Main

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

capacity
0.37kw 0.63-1.0 amp 100kA GV2ME05

0.55kw 1.0-1.6 amp 100kA GV2ME06
Motor 0.37 > 15kw
Circuit breaker-
0.75kw 1.6-2.5 amp 100kA GV2ME07

1.1kw 2.5-4.0 amp 100kA GV2ME08
2.2kw 4.0-6.3 amp 100kA GV2ME10
4kw 6-10amp 100kA GV2ME14
5.5kw 9-14 amp 15kA GV2ME16
7.5kw 13-16 amp 15kA GV2ME20
9kw 17-23 amp 15kA GV2ME21

of 50
Circuit Breakers - Motors 18.5kw > 90kw See listing below.
Schneider (Merlin Gerin) - Compact NSX series, Type N or a Fault Current calculated kA
rating. Complete with TMD range of overloads, auxiliary contacts.
Motor Set thermal on Set magnetic

size Type Over load Type / Rating on
35 amp
18.5kw NSX100N TM50D, 35-50amp 0.8
Motor 18.5kw > 75kw
38 amp
Circuit breaker-
22kw NSX100N TM50D, 35-50amp 0.8

53 amp
30kw NSX100N TM63D, 44-63amp 0.9
61 amp
37kw NSX100N TM80D, 56-80amp 1
73 amp
45kw NSX100N TM100D, 70-100amp 1
81 amp
55kw NSX160N TM100D, 70-100amp 1
115 amp
75kw NSX160N TM160D, 112-160amp 1
141 amp
90kw NSX250N TM200D, 140-200amp 0.9
Flexible - PVC covered metal

Thomas & Betts. Conduit type HIFLEX HLT, Fittings (glands) must include Nylon Gland
Conduit
Ring type VJ-

Use ferrules type 02-.on ends that dont require Fittings (Gland)
Available from Thomas & Betts 1300 666 595.
Contactors
Contactor
Motor Starting AC 4 rating. (also see section Circuit breakers - Motor)

st
1 Choice - Schneider.
nd
2 Choice - NHP Sprecher Schuh. With approval from principle.
Enclosures
B&R Universal NI General Purpose Enclosures IP66.
Enclosures-
Non DIP
Adhesive Heavy Wall Tubing

Type CJS-HWT. Available from Cable Jointing Supplies, Unit1, 45 Burlington St, Naval Base
Heat Shrink
WA 6165
(08) 9437 9355
Horns & Warning Sounder (Non DIP)

Klaxon Nexus 105 part # PNS--0009 (110/240vac). Connect a 6 watt 12k ohm ceramic
Horn
bleed resistor at the Sounder.

of 50
Horns & Warning Sounder (Non DIP)
Klaxon Nexus (110/240vac). Connect a 6 watt 12k ohm ceramic bleed resistor at the
Horn
Sounder.
Indicators - Switchboards and Control Panels.

Indicator
RED Ultra Bright, Black Bezel, 14mm& RS203-975

YELLOW Ultra Bright, Black Bezel, 14mm& RS203-868
GREEN Ultra Bright, Black Bezel, 14mm& RS203-852
(RS means RS Components)
Junction / Marshalling Boxes DIP
Govan / Crouse Hinds / CCG.
J Box-
DIP
Junction / Marshalling Boxes Non DIP

Non DIP
J Box-
Govan / Crouse Hinds / Clipsal.56 series.
Lanyard Switches DIP (1st preference)

Lanyard-
NHP EX55.4.00GWNBB. Lanyards to include matching heavy duty thermal compensation

DIP
springs.
nd
Lanyard Switches DIP (2 preference)
Lanyard
NHP EX55.4.00NBB. Lanyards to include matching heavy duty thermal compensation

DIP
springs.
DIP Lighting Hand Rail staunching mounted Lighting.

Mount bracket and lights are available from Pacific Automation.
mounted DIP
Staunching
Hand Rail
Lighting-
DIP 18w Double Fluorescent Light Fittings:

Light. FNB-218-BKSA.
Emergency Light. FNB-218-BUSAE.
Long Life Tube. Osram: OSRL18W/840XXT.
Mount Bracket. SP-W-AU-LMK-CBHCATWALK-HG-KIT c/w mounts bolts and washers.
Non DIP Lighting Hand Rail staunching mounted Lighting.
mounted Non DIP
Mount bracket and lights are available from Pacific Automation.

Staunching
Hand Rail
Lighting-
Non DIP 18w Double Fluorescent Light Fittings:

Light. FHDB-218-BKSUS.
Emergency Light. FHDB-218-BKSUE.
Mount Bracket. SP-W-AU-LMK-CBHCATWALK-HG-KIT c/w mounts bolts and washers.
DIP Lighting Internal Storage DIP Zones 21 & 22 Application Boot Pit and Cell
Lighting.
PLEASE NOTE:
Ex tD T4 IP65 for use in hazardous areas with a maximum surface temperature 175
degrees Centigrade if not T4.
Boot Pit & Cell DIP

Lighting-
Emergency Light None Maintained FNB-218-BUSAE.

Pacific EX: HDL-CM (Surface Mount Bracket)

Emergency Light None Maintained FNB-236-BUSAE.
Long Life Tube. Osram: OSRL36W/840XXT

of 50
DIP Lighting Internal Storage DIP Zones 21 & 22 Application Cat Walk (swivel Pole
) & Surface Mount
PLEASE NOTE:
Cat Walk (swivel Pole ) & Surface Mount DIP

DIP 36w Double Fluorescent Light Fitting:
Pacific EX: FNB-236-BKSA (Light Fitting)
Osram: OSRL36W/840XXT (36w Tube Long Life)
Pacific EX: SP-LMK3304-40-HG-ATXKIT (Custom Head Frame)
Lighting-
ROB Swivel Pole: S11-2400-PS-HG (Pole Mount 2.4mt)

OR
DIP 18w Double Fluorescent Light Fitting:

Pacific EX: FNB-218-BKSA (Light Fitting)
OR
Non DIP Lighting External Area NON DIP Zone Application Cat Walk (swivel Pole )
& Surface Mount
Cat Walk (swivel Pole ) & Surface Mount Non DIP
Non DIP 36w Double Fluorescent Standard Light Fitting:

Pacific EX: FHDB-236-BKSUS (Light Fitting).
OR
Lighting-
Non DIP 18w Double Fluorescent Standard Light Fitting:

Pacific EX: FHDB-218-BKSUS (Light Fitting)
OR
METRO FITTING: Details to be added

of 50
DIP Lighting Internal Storage DIP Zones 21 & 22 Application Cat Walk (swivel
Pole) & Surface Mount Emergency Lighting.
Emergency Cat Walk (swivel Pole ) & Surface Mount DIP
PLEASE NOTE:
DIP 36w Double Fluorescent Emergency Light Fitting Non Maintained:

Pacific EX: FNB-236-BUSAE (Light Fitting)
Lighting-

OR
DIP 18w Double Fluorescent Emergency Light Fitting Non Maintained:

Pacific EX: FNB-218-BUSAE (Light Fitting)
OR
Non DIP Lighting External Area NON DIP Zone Application Emergency Cat Walk
(swivel Pole) & Surface Mount.
Emergency Cat Walk (swivel Pole ) & Surface
Non DIP 36w Double Fluorescent Emergency Light Fitting Non Maintained:
Pacific EX: FHDB-236-BKSUE (Light Fitting).
Mount, Non DIP

Lighting-
OR
Non DIP 18w Double Fluorescent Emergency Light Fitting Non Maintained:
Pacific EX: FHDB-218-BKSUE (Light Fitting).
OR

of 50
Lighting Internal Storage DIP Zones 21 & 22 Application Flood Lighting / Pendant
Lighting.
PLEASE NOTE:
Flood Light Fitting & Globe:
TBC
Flood Lighting, DIP
Pendant Light Fitting & Globe:

Pacific EX: HDL-114S24500400E (400w HPS Light Fitting)
Lighting-
Pacific EX: HDL-AL10174 (Reflector)

Osram: OSRNAVT400WSUPER (400W HPS Tubular)
Pendant Light Pole & Isolator:

Pacific EX: F11-H-001-P-HG-AU-NS (Custom Swivel Pole)
ROB Swivel Pole: MBK2-2-50HG (Vertical Mounting Bracket)
OR
Pacific EX: ASP-U-BOLT-CBH-310UB (Custom H Iron Mount)
Pacific EX: SP-TEF-150-001-AU-NS (Teflon Swivel Washer)
Pacific EX: SP-JBPK1110-HG-AU-NS (Isolator/Enclosure Bracket)
Pacific EX: GO-ES1511-A201 (Isolator & Enclosure)
Lighting External Area Flood Lights Non DIP Zone Application Under garner bins
Lighting, Non
& over road / rail grids

Lighting-
Flood
Weatherproof IP65 with integral ballast.

DIP
Philips: Con TEMPO L 400w HPS, RVP350SON-T400S.

Thorn: 400w HPS, AP2400HST
Lighting External Area Flood Lights Non DIP Zone Application Mounted at high
Lighting, Non
level on structures or as nominated.

Lighting-
Flood
Weatherproof IP65 with integral ballast.

DIP
Sylvania: 2000w, 415v, MH, BLS2000/2000

Thorn: 2000w, 415v, MH, MUNC2000DEGMDKITWP
Poles Suit E & V Pits

Lighting-
Lighting
G & S Industries, 6 metres type F6BM.

Flood
Poles
Cage Bolts to suit above - G & S Industries, 890614, CR16/4/282.

Cross arm for two flood lights to suit above 890213, CA1200T3.
Photo Electric Cell

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

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24vdc LED, 100mm diameter Traffic Lights - Suit Sample Platforms etc.
Traffic Lights
RED/GREEN Type NBB100RG, (IP65). Available from EX Engineering 0408 221 337.
Lights-
24vdc LED, 200mm diameter Traffic Lights - Suit Sample Platforms etc.
Traffic Lights
RED/GREEN Type STL-200-RG-24, Available from EX Engineering 0408 221 337.

Lights-
Replacement RED module SRM-200-R-24.

Replacement GREEN module SRM-200-G-24.
240vac LED, 200mm diameter Traffic Lights - Suit Sample Platforms etc.
Traffic Lights
RED/GREEN Type STL-200-RG-240, Available from EX Engineering 0408 221 337.

Lights-
Replacement RED module SRM-200-R-240.

Replacement GREEN module SRM-200-G-240.
Limit Switch
Limit Switch
Honeywell - SPDT, LS4A1A-DIP and DPDT, LS4A2A-DIP.

Adjustable arm to suit above LSZ52C.
Notehas the same fixings and shaft size as Cutler Hammer E50.
Limit Switch
STAHL. DIP.
Limit Switch
8070/1-1-HV. 1NC + 1NO, C/W ADUSTABLE ARM.
Proximities Switches Speed Monitor (inductive)

Proximity,
Inductive
Synatel 30mm range sensors inductive 1D1TZ (A) normally open complete with P2 and
Switch-
Limit
DIP
M2 shrouds. Speed monitor PU1TZ (A) normally open.
Limit Switch HOLD. CERTIFICATE OF CONFORMITY HAS EXPIRED AS OF JUNE 2011

Limit Switch
Cutler Hammer E50 AR1-DIP.

HOLD
Notehas the same fixings and shaft size as Honeywell LS4.
Motor Starting Motor Protection overloads 11kw DOL

Overload
Schneider Type TeSys Model D. (MAN/AUTO reset, set on Auto).

NHP Sprecher Schuh suit CA4, CA6 & CA7.
Power Outlets (Non DIP) Single Phase

General Areas Clipsal 10amp 56C310HD.
Non DIP
Outlet-
10amp
Power
phase
Power Outlets & Plug (Non DIP) Three Phase & N 150amp 3P+N+E
Marechal 150amp Socket Outlet c/w self-returning lid DS9 31-98-017R. Plus Wall Box 39-
Non DIP
Outlet-
Power
9A-053. Or equivalent.
Marechal 150amp Inlet (Plug Top) DS9 31-98-017. Plus handle 65-9A-013-D45 (E).

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

????????? Marechal???
Outlet-
Power
DIP
Power Outlets & Plug (Non DIP) Three Phase 30amp 3P+E
Non DIP
Outlet-
Power
Marechal 30amp Inlet (Plug Top) DS1 31-18-013. Plus handle 31-1A-013.
Power Outlets (Non DIP) Three Phase

General Areas Clipsal 5 pin 32 amp 56C532
Non DIP
Outlet-
Power
Non DIP
Outlet-
Power
Non DIP
Outlet-
Power
Power Supply 96-264vac/24vdc.

Power Supply-
Weidmuller.
3 amp, CP M SNT 70W 24vdc 3amp.
24vdc

7.5 amp, CP M SNT 180W 24vdc 7.5amp.
High and Alarm Level - for within Grain Storages Capacitive Proximities Intrinsically
Proximity Sensor-
Safe
Capacitive
Sensor - Pacific EX Rechner RH-KA0030, 30mm , c/w 6 metres of cable.

IS Barrier - Pacific EX Rechner Single channel 120-240vac N00012.
IS Barrier - Pacific EX Rechner Duel channel 120-240vac N00015.
Extra cable (blue) to suit above Pacific EX 2 core 0.75mm2 (6.4 dia) part # RH-
66200300.
Level Monitors for Pits and side walls of Grain Storages and Garners DIP/IECeEx,
Capacitive Proximities
Capacitive
Proximity
Sensor-
Sensor - Pacific EX Rechner part number RH-KA0278, description KAS-80-A24-A-StEx-

N, 24vdc, 5 wire, n/o & n/c, 30mm , c/w 5 metres of cable.
Mechanical Protection Kit (Mounting Kit) to suit above: Pacific EX part No RH-PMI-0001-
01, description M30 TF-fm-fit Includes Teflon shroud, s/s flange & 20mm conduit adaptor.

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

240vac. 55.34.8.240.0054.240vac, 7amp, 4 pole, c/w LED & built in diode suppression.
Base to suit all above: Type Screw terminal 94.04.
Relays Control Slimline single pole (for general purpose control).

NHP Finder 38 series 1 pole c/o with LED & diode.
Control
Relay-
24vdc. 38.51.7.024.0050. 24vdc, 6amp, 1 pole, c/w LED & built in diode suppression.
110vac. 38.51.0.110.0060. 110vac, 6amp, 1 pole, c/w LED & built in diode suppression.
240vac. 38.51.0.240.0060. 240vac, 6amp, 1 pole, c/w LED & built in diode suppression.
Note. No base required.
Relays Power
Schneider.
Power
Relay-
NHP Sprecher Schuh.

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

Or as specified.
Motor Starting - Soft Starters 15kW-75kW 3

Refer Clause 5.13.10 this document.
NHP Aucom EMX3 c/w inbuilt by-pass contactor, see list below.
Use heavy duty (4xFLC) soft starter of all drives 11kw and above as listed below or specified.
(B* denotes inbuilt by-pass contactor)
Current Main Contactor (or as
kw (amps) Aucom EMX3 specified)
11kw 22 EMX3-0043B-V4-C1 (31amp) Schneider LC1D25
Soft Starter
18.5kw 38 EMX3-0053B-V4-C1 (46amp) Schneider LC1D38

22kw
(Augers) 44 EMX3-0076B-V4-C1 (55amp) Schneider LC1D65
75kw 140 EMX3-0200B-V4-C1 (160amp) Schneider LC1F185
90kw 151 EMX3-0200B-V4-C1 (160amp) Schneider LC1F185
Switches Emergency Stop Station (DIP/IECEx)
Emergency
CSE: DMPB1-4PL
Switch-
Pacific EX: DS1511-3-PLKC
Switches Emergency Stop Station (NON DIP)

Emergency
Pacific EX: ???????

Switch-

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3 Phase Isolator 20amp (Red & Yellow) Suit Inch drives local isolation etc.
Isolator
Switch-
Clipsal 56SW320RY
Switches-Local Control Stations (DIP/IECEx)

Conveyors & Elevators:
Switch-
Control
Local
Pacific EX: DS1511-CA10A178M003DIP.

Reversing Conveyors & 2 way valves
Pacific EX: CA10-AU00271P.
Switches-Push Buttons DIP??
Switch-
Control
Local
Switches-Local Control Stations (NON DIP)

Conveyors & Elevators:
Local Control
Pacific EX: ?????????

Switch-
Reversing Conveyors & 2 way valves

Pacific EX: ????
Switches-Push Buttons NON DIP??

Schneider 22mm XB2 booted (green start or open; red stop or close).
Switch-
Control
Local
NHP Sprecher Schuh D7 Metal body.
Terminals
Control wiring
Schneider AB1
Terminals-
Terminals Blocks - Power

connections
Terminals
Phoenix Contacts type UHV , or similar.

Block-
Power
Separating Plate UHV-TP. or similar.
SCHNEIDER Zelio. RE7YA12BU. DOUBLE ON-DELAY,

Double on --delay
Type/Function Qt, 2 C/O (8amp), 24vdc & 110-240vac)

CBH use: For Soft Starter Horn/Start up delay.
Timer-
SCHNEIDER Zelio. RE7TP13BU. 1 x ON-DELAY contact & 1 x INSTANTANEOUS contact.

INSTA NTANEOUS
Timer ON-DELAY
Type/Function A, 2 C/O (8amp), R1 = ON-DELAY, R2 = INSTANTANEOUS, 24vdc & 110-

240vac)
CBH use: For Stacker Loader Horn/Start up delay.
&
SCHNEIDER Zelio. RE7TL11BU. ON-DELAY,

Type/Function A, 1 C/O (8amp), 24vdc & 110-240vac)
Timer-On-
delay
CBH use: Hydraulic Sample spears.

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Timer-On- SCHNEIDER Zelio. RE7TM11BU. ON-DELAY with remote potentiometer,
Type/Function A, 1 C/O (8amp), 24vdc & 110-240vac)
delay
CBH use: Pit Valves.
SCHNEIDER Zelio. RE7RA11BU. OFF DELAY, Type/Function C, 1 C/O (8amp),

Off delay
24vdc & 110-240vac)

Timer-
CBH use: Hydraulic Sample Spear (Load Timer).
Motor Starting - VSD start motors (only where specified)

Protection inbuilt with VSD.
VSD
Wiring - Flexible Wiring

Flexible wiring requires ferrules (Boot lace pins) fitted at the termination points.
Panel wiring
When looping wiring using Use TWO CABLE type ferrules.

Ferrules
Wiring-
Type Grey 2x0.75mm2 RS184-9654. Or similar.

Type Red 2x1mm2 RS184-9660. Or similar.
Type Black 2x1.5mm2 RS184-9676. Or similar.
Type Blue 2x2.5mm2 RS184-9682. Or similar.
NOTE:
No changes to the Equipment Schedule shall apply without prior approval by the
Principal.

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ELEVATORS
Plant Equipment Comments Initials
Elevator Drive Motor Refer Data Sheets

Interlock Start and stop as required
Manual Start, stop and override interlock as required
Cabling Neat, tidy and glanded, terminations tightened
Local Isolators At head and in boot pit
Cubicle Protection Circuit breakers - TM-D trips adjusted
Overloads correct and set to auto reset
Fluid coupling over temperature switch
Indicator Lights Elevator running
Ammeter Operating - red Chinagraph mark to indicate FLC
Inching Drive Motor Refer Data Sheets
Limit Switches Operation and mounting
Road Hopper Valve Motor Refer Data Sheets
Interlock With CLS or conveyor system
Manual Open, close and override interlock as required
Cabling Neat, tidy and glanded
Timing Adjusted at wet commissioning
Grain Sensors Operation and mounting
Cubicle Indicator Lights Valve open, Valve closed, Grain in pit
Head Valve Motor Refer Data Sheets
Interlock With CLS or conveyor system
Manual Change over and override interlock as required
Cubicle Indicator Lights Indicate correct feed direction
Labelling Fitted As per drawings and specification
Located where visible
Engraved and legible

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E-PITS
Equipment Operation Comments Initials
Auger motors Electrical Refer Data Sheets

Cubicle Protection Circuit breakers, o/loads. And over temp. switches
Indicator Lights Augers running
GROUND CONVEYORS
Drive motor Electrical Refer Data Sheets

Cubicle Protection Circuit breakers, overloads. And over temp.
switches
Indicator Lights Ready, Forward, Reverse
Isolating Switches Head and Tail Fitted as per drawings
Warning sirens Fitted as per drawings
Lanyard switches Lanyards 120m maximum length
Set correctly Manufacturers specification
Operation
Stacker Outlets Space from ends 9m maximum
Spaces between 36m maximum
Accessibility
Cabling Neat, tidy, glanded, clear of ground, termination
Cubicle Protection Circuit breakers, overloads. and current sensing
Indicator Lights Stacker running
Cable Ladder Mounting Joints within 300 of trestles or end of ladder
Overhead 2700 AFL
Fixing Around drive - clear of tripper access and guards
On elevators tool removable e.g. on Unistrut
Cable spacing 6mm minimum all round to allow grain through
Cable fixing Flat on tray - 1000mm: Vert. on tray each rung

of 50
OTHER CONVEYORS
Drive motor Electrical Refer Data Sheets

Manual Start and stop as required
Cabling Neat, tidy and glanded, terminations
tightened
Cubicle Protection Circuit breakers, o/loads. And over temp.
switches
Indicator Lights Ready and running
Lanyard switches Lanyards 120m max length compensating springs fitted
Set correctly
Operation
Cabling
Cable Ladder Mounting Joints within 300 of trestles or end of ladder
Overhead 2700 AFL
Fixing Around drive - clear of tripper access and
guards
On elevators tool removable e.g. on
Unistrut
Cable spacing 6mm minimum all round to allow grain to fall
through
Cable fixing Flat on tray - 1000mm: Vert. on tray each
rung
Cable bends Within manufactures specifications

of 50
CONTROL CUBICLE
Main switch Rating

Circuit breakers Rating Trip settings on motor supplies
Not on removable covers
Control Panel Layout As per drawings
System Start and stop as required
Interlock
Manual Start and stop as required
Wiring Neat, tidy with spare capacity in ducts,
terminations tightened
Indicators Lamps Working and visible
General Engraving / labels fixed
Switches Pushbuttons
Rotary
General Engraving / labels fixed
Timers Valve Adjusted at wet commissioning
Sirens Siren to sound seven (7) seconds before belt
start
Current Sensors (1) Time range Set on 1.5 30s
(2) Time Three (3) second delay
(3) Hysteresis Set at 25% of current threshold
(4) Current 10 amps on stacker circuit
(5) Contact Set to undercurrent (UI)
Motor overloads Settings Set to auto reset
Cabling / Wiring Incoming Clamping and cable glands
Internal Neat and spare capacity in ducts
Terminations Check for loose terminations
Protection Grommet strips on metal edges

of 50
Site:
Contractor:
Plant Area:
Equipment:
Make: Rated RPM:

Type: Rated kW:
Serial No.: Rated Voltage:
Frame: Rated IFL:
Bearing Drive End Non D E
Types:
Insulation Use 1000V Insulation Resistance tester, test duration 60s Provide actual
Test: reading - infinity not valid
A to E .. Megohms B to E Megohms C to E Megohms
Rotor shaft free to rotate:

Rotation direction correct:
Circuit breaker Magnetic setting: Amps
Circuit breaker Thermal setting: Amps
Motor Overload setting: Amps
Start timer setting: Seconds
Transformer tap setting: %
Transformer duty classification: Starts/hour
Actual supply voltage: RW.. RB.WB Volts
Actual no grain current: Amps
Actual load current: Amps
Remarks:

Tested By:
Signed: Date: ..//

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TEST EQUIPMENT REQUIRED
1. MOD TAP TESTER
2. RAD LBT BIT ERROR RATE TESTER
3. 1 SET OF TWO WAY RADIOS
PROCEDURE FOR TESTING AS FOLLOWS:

a) Visual inspection of fly and patch leads.
b) Test all fly and patch leads for correct operations with Mod Tap Tester.
c) Test all wall socket outlets in Sample Platform Nos 1 to 6 and Patch Panel Nos 1
to 6 with Mod Tap Tester for correct numbering and pairs, i.e. Wall Socket outlet 1
corresponding with Patch Panel Socket 1.
d) Connect fly lead to Patch Panel in Sampling Platform on Infra 1 and place one half
of the Mod Tap Tester on the end of the fly lead. Place the other half of the Mod
Tap Tester on Infra 1 in the Weighbridge and test for correct pairs correct labeling
and that the pairs are reversed. Do the same procedure for the remaining area
Infra 2, Balance 1 & 2 and Term 1 & 2.
NOTE: If only single Repols installation required, Infra 2, Balance 2 and Term 3 are not
required.
e) When all Mod Tap Testing is completed, record your results on the test sheets.
f) Install RAD Line Drivers on the last point of the installation at the Sampling
Platform, wall sockets Nos 1 to 6, then at the Weighbridge on Infra 1 & 2, Balance
1 & 2 and Term 1 & 2, making sure that all Patch Leads are connected in the
Patch Panel in Sampling Platform in the correct positions.
g) Set all RAD Line Drivers to DCE at all locations and connect one of the RAD LBT
Testers to Infra 1 at the Sampling Platform and the other RAD LBT Tester on Infra
1 at the weighbridge. Do the same procedure for the remaining area Infra 2,
Balance 1 & 2 and Term 1 & 2.
NOTE: If only single Repols installation required, Infra 2, Balance 2 and Term 3 are not
required.
h) Set both testers to:
ASYNC PATTERN 511 19-2KB BLK512B.
ASYNC PARITY : EVEN 8 BIT BLK512B.
FULL DUPLEX CTS AND CD NOT USED.
Both testers must be started simultaneously. Ensure sync loss at start up is zero
(0). Restart if required.
i) The first test should be run for a minimum of 3 minutes. After 3 minutes you
should have approximately 6,000 blocks received. There should be no block
errors or sync errors with this test.
j) Test No. 2 should be run for a minimum of 5 minutes, during this time you should
inject no less than 5 error bits into the system. After 5 minutes you should have
received more than 11,000 blocks and not have a block error rate of more than
.0650%. Record all your results on the test sheet.
k) After all tests are completed, make sure RAD Line Drivers are set back to the
settings as per the information on the Repols drawing. Submit all tabulated results
to Co-operative Bulk Handling Limited with As-Built Drawings.

of 50
RAD LBT BIT ERROR RATE TEST SHEET

Without injected errors
RUN TIME BLOCK BLOCKS SYNC LINE LINE

5 minutes ERROR RECEIVE CONTAINI LOSS DRIVER DRIVER INITIALS
minimum D NG SERIAL SERIAL
No. No.
WEIGHBR SAMPLE
% RATE BLOCKS ERRORS
IDGE HUT
INFRA 1
TERM 1
BALANCE 1
INFRA 2
TERM 2
BALANCE 2
RAD LBT BIT ERROR RATE TEST SHEET

With injecting 5 errors
RUN TIME BLOCK BLOCKS SYNC No. OF
INITIALS 5 minutes ERROR RECEIVED CONTAINING LOSS ERRORS INITIALS
minimum
% RATE BLOCKS ERRORS INJECTED
INFRA 1
TERM 1
BALANCE 1
INFRA 2
TERM 2
BALANCE 2
RECIEVAL POINT : DATE:
CONTRACTOR :
NAME OF TECHNICIAN :
TEST COMPLETED : YES / NO

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MOD TAP TEST SHEET
FLY AND PATCH LEAD
VISUAL CHECK No OF PAIRS CORRECT LABELLING INITIALS

SHOWING ON & WIRING OF
TESTER STANDARD 568A
TERMINATION
FLY LEAD 1
FLY LEAD 2
FLY LEAD 3
FLY LEAD 4
FLY LEAD 5
FLY LEAD 6
PATCH LEAD 1
PATCH LEAD 2
PATCH LEAD 3
PATCH LEAD 4
PATCH LEAD 5
PATCH LEAD 6
MOD TAP TEST SHEET
SAMPLE PLATFORM INSTALLATION TEST

VISUAL No OF PAIRS CORRECT WIRING CORRECT
CHECK SHOWING ON OF STANDARD LABELLING OF INITIALS
TESTER 568A INSTALLATION
TERMINATION
SOCKET 1
SOCKET 2
SOCKET 3
SOCKET 4
SOCKET 5
SOCKET 6
CONTRACTOR :

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MOD TAP TEST SHEET
SAMPLE PLATFORM TO WEIGHBRIDGE
VISUAL No OF THE PAIRS CORRECT LABELLING & WIRING OF

CHECK SHOWING ON STANDARD 568A TERMINATION INITIALS
TESTER
INFRA 1
TERM 1
BALANCE 1
INFRA 2
TERM 2
BALANCE 2
CONTRACTOR :

of 50

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Technical Specification

TS6 Electrical Services

CBH Engineering Pty Ltd

Change Control Policy

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

Review Date Author Descripton of amendments

DOCS 826980v30 Page 2 of 50

18 24/05/2012 John Howard Circuit Breaker updates

DOCS 826980v30 Page 3 of 50

6. Appendix A - Electrical Equipment List 28

7. Appendix B - Electrical Commissioning List 28

8. Appendix C - Motor Inspection and Test Record 28

9. Appendix D - Test Procedure for Dual REPOL Installation 28

DOCS 826980v30 Page 4 of 50

2.1 Hazardous areas

A hazardous area is defined as an area in which an explosive atmosphere is present, or may

2.2 Competency standards

2.3 Apparatus for combustible dusts

2.5 Hazardous area verification dossier

A site Hazardous Area Verification Dossier shall be commenced by the responsible

DOCS 826980v30 Page 5 of 50

2.6 Hazardous area equipment

Test result documentation shall be provided to support this requirement.

AS 1939 Classification of Degrees of Protection Provided by Enclosures for

AS 3947 Low Voltage Switchgear and control gear, Switchgear, Dis-connectors,

AS 3008 Cables for Alternating Voltages up to and including 0.6/1kV.

AS 5000.1 Approval and test specifications - Electric Cables - Thermoplastic

AS 3439 Low Voltage Fuses - Fuses with enclosed fuse-links.

AS 2053 Non Metallic Conduits and Fittings

AS 1554.1 Structural Steel Welding Code.

AS 1795 Sheets and boards for electrical purposes.

AS 1755 Conveyors - Design, construction, installation and operation - Safety

DOCS 826980v30 Page 6 of 50

AS 1202 AC Motor Starters (up to and including 1000 Volts).

ACA TS 009 Installation requirements for Customer Cabling (Wiring Rules).

AS/NZS 3080 Telecommunications installations Integrated telecommunications

CBHE TS20 CBH Engineering Technical Specification Enclosures

CBHE TS21 CBH Engineering Technical Specification Electric Motors

4.2 Temperature rise

DOCS 826980v30 Page 7 of 50

4.4 Approved equipment

4.5 Quality of materials and workmanship

All welding shall conform to the applicable section of AS 1554.

4.7 Fixing, brackets and supports

All nuts shall be locked. This clause shall be rigidly enforced.

DOCS 826980v30 Page 8 of 50

4.8 Penetrations and making good

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

4.10 Labeling and identification

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

AS/NZS 3000: 2000

Conveyor Code AS 1755

Service and Installation Rules of the Supply Authority

DOCS 826980v30 Page 9 of 50

EQUIPMENT TYPE OF LABEL

Relays/Pushbuttons/ White Traffolyte, Black Lettering

Control Panels White Traffolyte, Black Lettering

Instruments White Traffolyte, Black Lettering indicating function.

4.11.1 Confirming the location of equipment within the hazardous areas.

4.11.3 Include the certification documentation of all electrical equipment installed.

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

DOCS 826980v30 Page 10 of 50

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