technical specification for main 415v switchboard 1. general · en 60439-1. d) the degree of...

Annex B1 – Technical Specifications

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Technical Specification for Main 415V Switchboard 1. GENERAL

a) The switchboards shall be of the indoor, metal clad, modular type suitable for

operation in the switch room as indicated on the drawings. It shall be capable of operating in tropical and humid conditions.

b) The switchboards shall be totally enclosed and constructed as described below. They shall comply with the requirements of the latest edition of EN 60439-1.

c) The design of the switchboard shall comply fully with A.S.T.A. Full type test requirements.

d) The switchboards shall be suitable for operation on 415 Volts, 3-Phase, 4-Wire, 50Hz system with solidly earthed neutral.

1.1 Fault Rating The switchboards shall be designed to withstand a prospective fault level of 75 kA at 415 Volts 3 phase (symmetrical) for 3 seconds in accordance with the test procedures laid down in the EN standards.

1.2 Construction

a) The switchboards shall be naturally cooled, self-contained, metal-enclosed type, floor mounted, flush-fronted and suitable for front and rear access, bottom and top cable entry.

b) All structural works shall be adequately protected against corrosion. The basic materials shall be properly pre-treated before the final coats of resistant finishing paint are applied.

c) Construction of the switchboards shall be minimally Form 3B separation as per EN 60439-1.

d) The degree of protection for the switchboards shall be minimally IP 30 as per EN 60529. The floor shall not be considered as part of the enclosure.

e) The partitions or barriers for internal separation of assemblies shall designed to obtain Form 3B separation of compartments shall comply to degree of protection IP 20 as per EN 60529.

f) The switchboards shall provide complete with all ACB, MCCB and other electrical components necessary for the correct operation and protection of the installation as described in this specification and shown on the drawings.

g) All operating devices shall be mounted for operation at the front of the switchboard.


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h) The enclosure shall be fabricated from electro galvanized steel sheet with epoxy powder coating. The sheet steel thickness shall not be less than 2.0mm for structural member and 1.5mm for doors.

i) The front and rear covers of the switchboard shall be hinged door type. Doors

shall be effectively earthed to the fixed enclosure. All doors to be arranged to open through a minimum of 120 degrees, it must be possible to easily remove the door without disturbing other doors in the module.

j) Compartment doors or cover shall be interlocked to prevent opening when the isolating device is in the "ON" position. The isolating device shall only be operable when the door is fully closed. It must be possible to defeat the interlock for testing purposes once the door is open.

1.3 Busbars and Connections

a) The busbars shall be of plain hard-drawn, high conductivity, electrolytic copper bars in accordance with BS EN 13601 and of adequate rectangular cross-section to carry continuously the specified current without overheating and shall be rigidly mounted on non-hygroscopic glass fibre reinforced polyester so as to withstand any mechanical force to which they may be subjected under maximum fault condition.

b) All busbars shall be tinned and coloured red, yellow, blue, black and green at appropriate points to distinguish the phases, neutral and earth. No tapes shall be used. The main busbars should be located at the front upper lever in a horizontal plane and equally paced as specified in EN. All busbars system shall have short circuit rating of not less than 75 kA at 415 volts for 3 seconds.

c) The busbar system shall be readily accessible for inspection, construction and maintenance duties without the requirement of additional equipment. In case of a busbar short circuit, it shall be possible to clean or to replace the busbars and support system without stripping the assembly.

d) In the busbar compartment the phase busbars may not be fully insulated. However, each phase busbar shall be able to withstand at least an applied AC test voltage of 2.5 kV for a period of 60 seconds.

e) The neutral busbar shall be the same size as that of the phase busbar.

f) The earth busbar shall be provided internally throughout the full length of each switchboard and shall be not less than 50mm X 6mm.

1.4 Secondary Wiring, Core Identification and Termination

a) The conductor size shall be minimum 1.5mm² with minimum 300V, PVC insulation.

b) All control wiring shall be colour coded, carried out in neat, systematic manner and securely fixed by insulated cleats or approved method and arranged such that


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access to any apparatus or connection point is not impeded. Where inter-panel wiring passes through panel side sheets etc., the access hole shall be fitted with a suitable grommet.

c) Sleeve type identification ferrules shall be fitted on all wires at both ends. The sleeve or ferrules shall be of insulating material, which, except where otherwise specified, shall be white with black lettering and shall have a glossy finish. The sleeve or ferrules shall be unaffected by oil or damp.

d) All control wire shall be separately terminated with tinned crimped lugs of approved type suitable for the terminal and wire use.

e) Colour coding of secondary wiring shall be in accordance with IEC 446. Earth wires shall be green/yellow striped. Wiring between two terminals shall be continuous. Joints or interconnections are not allowed and no more than two wires shall be connected under one terminal connection.

f) Terminal studs or blocks shall be adequately rated for the duty. Terminals shall be identified using an approved marking and numbering system.

1.5 Switchboard Components

1.5.1. Air Circuit Breakers

a) All Air Circuit Breakers shall be manufactured and tested to comply fully with EN 60947-2 and shall have integral with built-in micrologic control unit. The Air Circuit Breakers shall be rated to carry continuously, the full load current currents of their respective circuits. The minimum rated short time fault capacity shall not be less than 75 kA for 1 second to EN 60947-2. The main contacts shall be of the double break type. Contacts shall be replaceable and of the silver-plated type. Individual arc chutes shall be provided on each pole of the breaker and so designed that any arc caused by the opening of breaker under maximum fault condition shall be contained completely in the chute.

b) All operating mechanisms shall have mechanical 'ON' and 'OFF' indicators and whether they are in the 'Connected', 'Test' or 'Disconnected' positions. Hand charged spring mechanisms shall have mechanical indicators to show 'SPRING CHARGED' and 'SPRING DISCHARGED'.

c) All incoming & outgoing Air Circuit Breaker shall be draw out type.

d) If indicated on drawings, Air Circuit Breaker used for bus coupler shall be 4 pole fixed or draw out type.

e) Mechanical & electrical interlocks shall be provided in cases where multiple incoming supplies are not to be paralleled.

1.5.2. Moulded Case Circuit Breakers

a) Moulded Case Circuit Breakers shall comply with EN 60947-1 and EN 60947-2 and shall have adjustable thermal-magnetic or electronic tripping devices. They shall be fully tropicalised and suitable to be used up to an ambient temperature of


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40°C, enclosed in glass-reinforced polyester moulded case and suitable for use on 240/415V, 50Hz A. C. supply system.

b) They shall be of the quick-make, quick-break type having manually operable

toggle type handle. Permanent position indicators shall be provided to show status of the breaker. They shall have trip-free feature to prevent the breaker from being closed against fault conditions. Multi pole shall have common trip operating mechanism for simultaneous operation of all poles.

c) Unless otherwise specified in the drawing and or Bill of Quantities, the minimum A.C. Interrupting capacity of the breakers shall be 75 kA rms(symmetrical) at 415 volts for switchboards connected to transformer. The rated service short circuit breaking capacity (Ics) shall be 100% of the rated ultimate short circuit breaking capacity (Icu) at 415 volts.

d) They shall have facilities for shunt trip, auxiliary contacts accessories for externally connected tripping, alarm & indication purposes if necessary.

e) All breakers where the incoming or outgoing feeder shall provide with panel mounted external operating handle with padlocking facilities and door interlocking facilities to prevent the panel door from being opened to access to the breakers in closed position.

f) All breakers shall provide a bolted type solid neutral link fitted in the same compartment together with the phase poles.

1.5.3. Protection Relays

a) Protection relays shall comply with EN 60255-8 and EN 60255-23. The protection relays shall operate as rapidly as reasonably practicable.

b) Protection system shall be designed and applied to provide the maximum discrimination between faulty and healthy circuits. All protection equipment shall remain inoperative during transient, which may arise during switching or other disturbances to the system. Where contacts of protective relays are unable to deal directly with the tripping currents, approved auxiliary contactors or relays shall be provided.

c) All protection relays shall be microprocessor base, 2 elements with 4 setting points & setting range as low as 10% of CT ratio discrimination flexibility.

d) It shall be capable of logging and communicating with remote station and shall be integrated with Building control system.

1.5.4. Instruments

a) The instruments for incomers shall be digital power meter capable to monitoring all the important electrical parameters including 3 phase current, voltage, power factor, kWhr, kVARhr, harmonics and maximum demand.

b) It shall be capable of logging and communicating with remote station and shall be integrated with Building control system. It shall be of microprocessor type.


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1.5.5. Current Transformers

Current transformers shall be designed, manufactured and tested to EN 60044-1. They shall have 5A secondary & 15 VA burdens. Current transformers used for :

a) Supply authority metering - Class 0.5

b) Instrument - Class 1

c) Protection - Class 5P10

1.5.6. Indicating Lights Indicating lights shall be of transformer type with connected lamps rated at 6.3 volts 1 watt filament. The indication must be clearly visible from front at a distance of 15 meters in a normally illuminated room. The bodies of indicating lights shall be ventilated to ensure efficient heat dissipation. Connection to lights shall be by screw to clamp terminals, soldered termination are unacceptable.

1.5.7. Anti Condensation Heater Anti condensation heaters shall be provided at both ends of each main switchboards. The heaters shall be suitable for operation on 240 volts 50Hz AC. Heater element wattage shall be a minimum of 80 watts. Supply with local 'ON / OFF' switch, thermostat sensor & indication light.

1.5.8. Labeling All switchgears, apparatus and control shall be labeled in accordance with the requirements.

1.5.9. Automatic Power Factor Correction Equipment

a) The power factor correction equipment shall comply with EN 60871-1. They

shall comprise all necessary capacitors, steps controllers, MCCBs and contactors.

b) The capacitors shall comply with EN 60831 Part 1 and Part 2 rated at 525 volts for 415volts and 480volts system, 230volts from 208 volts system, 50 Hz.

c) Power factor capacitor bank shall complete with 7% detuned reactor. The origin

shall be from Germany.

d) The power factor regulator controllers shall be microprocessor based.

e) The switching MCCBs Interrupting capacity shall not less than 75 kA meeting the voltage rating of the main switchboard and shall comply with EN 60947-2.

f) The switching contactors shall comply with EN 60947-3 and shall be of utilization categories AC-3 rated, 70 % higher than rated current.


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Technical Specification for Reticulation Mains And Submains 1. GENERAL It is the intent of this section to specify each cable and conductor type, their relevant

British Standards, the required fixing accessories and methods of installation. 2. PVC CABLES 2.1. Where PVC insulated (and / or sheathed) cables are specified, they shall be manufactured

to M.S. 136, 600V/1000V grade, and operating at maximum 70oC conductor temperature. Unless otherwise specified conductor shall be of annealed copper.

2.2. Where PVC cables are installed in trunking, a space factor of 45% shall be allowed. 2.3. PVC submains from different supply source (transformers, generator, main switchboards)

shall not be drawn into common trunking or conduit. In other cases where two or more sets of submains are to be enclosed in common trunking, each set of submains shall be properly and neatly bound using approved cable ties.

2.4. Cables shall not be drawn into conduits until all burrs at conduit ends and all foreign

matter inside the conduit are removed. 2.5. Unless otherwise approved by the Architect \ Engineer, copper alloy cable lugs shall be

used for termination of PVC cable. Fixing of cable lugs may be by means of soldering or compression type crimping tool.

2.6. Where PVC cables are installed as rising main, the cables must be properly supported and

spaced at regular interval. 2.7. Where PVC cable tap-off system is specified, line taps with insulated shrouds shall be

used for tapping off from the main cables and house in metalclad enclosures shall be provided.

2.8. Where PVC cables are installed on cable tray, cable ladder or in r.c. trenches, they must

be properly spaced, clipped and bound using approved cable ties or cable cleats whichever applicable.


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2.9. Unless otherwise specified, PVC cable mains and submains shall have full-sized neutral

conductor. 2.10. Protective conductor [earth continuity conductor] accompanying each PVC cable mains

and submains shall be sized according to the recommendations I.E.E. Regulations, 16th Edition.

3. PVC ARMOURED CABLE 3.1. PVC armoured cables (abbreviated PVC/SWA/PVC) shall be manufactured to M.S. 274,

of 600V/1000V grade, 70oC conductor [copper] temperature. Conductor shall be of annealed copper.

3.2. Jointing of PVC armoured cables shall be carried out by accredited and fully experienced

jointers and evidence of this shall be produced to the satisfaction of the Architect \ Engineer before jointing commence.

3.3. Terminations of PVC armoured cables shall be by means of appropriate cable glands to

manufacturer’s recommendations. 3.4. Provision shall be made for earthing the wire armour at terminations by means of a

metallic bond of adequate conductance, and the bonding connection should be as short and straight as possible. The wire armouring shall be maintained electrically continuous, and careful attention shall be paid to the design of all bonding clamps in joints and terminations to ensure that the resistance across a clamp is not higher than that of the equivalent length of the complete wire armour of the cable.

3.5. Up to 25mm² conductor size cable, armouring of the cable may be used as earth

condinuity conductor [e.c.c.] but for larger cables, additional copper e.c.c. shall be provided according to the recommendations as stipulated in I.E.E. Regulation, 16th Edition.

4. CROSS-LINKED POLYETHYLENE (XLPE) INSULATED CABLES 4.1. Paper insulated cables [with or without armourings] shall be manufactured to IEC60502-

1, 600V/1000V grade, and of copper conductor complying with IEC 228. 4.2. Jointing and termination of XLPE cables shall be undertaken by accredited and fully

experienced jointers and evidence of these shall be produced to the satisfaction of the Architect / Engineer before jointing commence.


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4.3. Bends in cables shall be of a radius not less than twelve times the diameter of the cable, measured from the inside of the bend.

4.4. Jointings XLPE cables shall only be made in an approved joint box with the conductors

properly insulated and the box sealed with an impervious compound. 4.5. XLPE cable shall be installed in ground, open concrete trenches and cable trays or ladder

as per drawings. 4.6 Where XLPE cables are installed as rising mains, along walls or as specified in drawings,

the cables must be properly supported and spaced at regular interval. The cables shall be held in position by means of non corrodible metal saddles of appropriate size and mechanical strength. All bolts, nuts and washers used for this installation shall be non corrodible type.

5. FLEXIBLE MINERAL INSULATED FIRE RESISTANT (FR) CABLES 5.1. FR cables shall be 300/500 volt and 500/1000 volt and suitable for wiring installation in

conduits, trunkings, cable trays and ladders. 5.2. FR cables shall conform to the following approved standards. a) Fire and Mechanical Test – BS 6387 Category C.W.Z. and IEC 60331 Fire

resistance Test ‘C’ – Resistance to Fire Alone :- Tests are carried out at 950°C for 3

hours. ‘W’ – Resistance to Fire with Water

‘Z’ – Resistance to Fire with Mechanical shock :- Tests are carried out at 950°C.

b) Flame Propagation Test – IEC 332 Category A.B.C. c) Smoke Emission Tests – IEC 1034 d) Circuit Integrity Test – IEC 331 e) Halogen Content Test – IEC 754 f) Fire Performance of Electric Cable System – DIN VDE 4102 Par 12. 5.3. Test Certificate shall be submitted to substantiate the compliance of the specifications. 5.4. FR cables shall be made of stranded, soft annealed copper conductor to IEC 228.


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5.5. FR cables shall be suitable for installation in wet or dry conditions. 5.6. FR cables shall have the copper conductors wrapped with glass mica composite tape

flame barrier (complete with special resin bonding material) and be insulated with non melt cross-linked flexible mineral insulation and mineral sheath.

5.7. Where metal armouring is specified for FR cables for the purpose of stronger mechanical

protection, harmonics / EMC screening and rodent / termite resistant, the amour shall :-

a) consist of two overlapping steel tapes for multicore cables and copper or aluminium tape armour for single core cables.

b) be designed to total enclose the cable maintaining 30% overlapping. c) not consist of toxic materials.

5.8. The installation of FR cables shall be suitable by conventional methods without requiring special tools, seals or terminations. The accessories shall be non-hygrosopic, maintenance free and insensitive to vibrations. When FR cables install on cable trays or ladder, the spacing of saddles and the cable arrangement shall be in accordance with the relevant BS or IEC standards. Minimum bending radius of not less than 8 times of the cable outer diameter for single core cables and 6 times for multicore cables.

5.9. The cables shall comply fully with the requirements of BOMBA (Fire Department of

Malaysia) and relevant approval letters shall be submitted to the Engineer. 6. PACKAGING AND LABEL All cables system must be properly packed or coiled on drums as appropriate with

manufacturer’s labels remain intact when delivered to site. Any length of cable and bus-duct with kinks or abrasions shall be rejected.

7. DERATING FACTORS All cables shall be rated according to the recommendation of IEE Regulations, 16th

Edition. Derating factors due to temperature, grouping [or bunching], method of installation, nature of usage, protective short circuits, etc. shall be taken into consideration.

8. PHASE IDENTIFICATION It shall be possible to identify at both ends of each cable the phase of the supply.

Coloured PVC sleeves may be used. 9. BENDING RADIUS When installing larger sized cable, the recommended bending radius for each type and

size of cable must be observed.


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10. FIRE BARRIERS Where cables pass through fire rated walls and floors, all opening must be sealed with

approved fire barriers. In the case where cables are enclosed in ducting or trunking, internal fire barrier shall additionally be provided.

11. UNDERGROUND CABLE INSTALLATION 11.1 The exact location of each cable route shall be verified on site before commencement of

excavation work. Trenches shall be kept as straight as possible and shall be excavated to approved

formation and dimension, and shall generally be 850mm deep. Trenches shall have vertical side and are to be timbered and shored where necessary to prevent subsidence. Trenches shall be cleared of all rocks, stones and other hard or sharp objects.

11.2. Underground cables shall be installed at a minimum depth of 750mm. 11.3. Underground cable shall rest on a layer of sand or sifted soil of not less than 75mm (3

inches) thick and another 75mm layer of sand or sifted soil shall fill on top of the cable. Protective covers shall be provided. The protective covers may be of good quality red

clay bricks or other approved materials and shall be laid over and across the entire length of each underground cable with no gap between the covers.

11.4. Trenches shall be backfilled on top of the cable protective covers using fine sifted soil.

The filling shall be well rammed and consolidated. The consolidation process shall be repeated in stages where necessary.

11.5. The surface of refilled trenches shall be temporarily reinstalled and maintained in a

thoroughly safe condition until full consolidation of the soil is achieved. 11.6. Beneath concrete pavement and tarmac surfaces, underground cable shall be drawn in

galvanised pipe, or abestos cement pipe or other approved type of cable duct. In such cases, the cable shall be laid at a minimum depth of 600 mm deep.

11.7. Approved cable markers shall be planted at strategic locations including at every bend

and change in cable direction. For straight runs cable markers shall be provided and spaced at maximum interval of 80 meters.

Where cable markers are set in footpath, roadways, taxiways, etc., they shall be installed

recessed into finished surface. 12. CABLE LAID IN CONCRETE TRENCHES 12.1. Where cables are installed in concrete trenches, they shall be properly spaced and neatly

supported according to I.E.E. Regulations, 16th Edition. Only approved cable cleats, cable ties and support shall be used.


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13. BUSBAR TRUNKING SYSTEM 13.1. Busbar trunking system [Buss Duct System] shall be manufactured to B.S. 5486 and IEC-

439. 13.2. The system shall be of proprietary make type totally enclosed in galvanised sheet steel

trunking finished with approved paint. 13.3. All conductors must be hard drawn high conductivity copper suitable for 3 phase 4 wire,

415 volt system with full size neutral. A separate protective conductor [e.c.c.] shall accompany each length of busbar.

13.4. Busbar shall be insulated with material of good mechanical, thermal and dieletric

properties. Air insulated type shall not be acceptable. 13.5. Flexible busbar joint shall be provided at interval according to manufacturer’s

recommendation. 13.6. Where tap-off units are specified, they shall be plug-in type with metalclad enclosure

suitable for mounting of moulded case circuit breakers. Door handle of the tap-off unit shall be mechanically interlocked with MCCB so that door can only be opened when the MCCB is in the `OFF’ position. Mechanical interlock must also be incorporated so that the plug-in type tap-off unit cannot be withdrawn while the breaker in the “ON” position. Tap-off units shall be suitably earthed and the earthed contact shall be made before active contact.

Trip free mechanism shall be provided for preventing breaker being maintained in the

closed position during overload or short circuit fault even if the handle is held “ON”. Position of the operating level shall indicate either ON-OFF or tripped in the centre position.

13.7. Where busbar trunking system passes through fire-rated walls and floors, factory built

fire-barrier must be provided, unless the busbar trunking system is itself fire-rate. 13.8. Short circuit rating of the busbar trunking must be coordinated with the protective device

but shall not be less than 30 kA, 1 second, symmetrical in any case. 13.9. The current carrying capacity of the busbar shall be rated at 30°C ambient. 13.10. Mounting brackets and other accessories must be proprietary make and any special tool

required for installation of the busbar trunking system must be provided.


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Technical Specification for Distribution Board 1 GENERAL REQUIREMENTS

Distribution Boards for lighting and power shall be supplied and installed where specified on the drawings. Distribution Boards shall be of the totally enclosed type suitable for wall surface and/or recessed mounting with neat appearance. They shall be of a standardised design and comply with IEC 60439-3. The circuit breakers, HRC fuses, busbars and the construction of the boards shall be as specified herein. The rating and types of circuit breakers to be supplied with each distribution board, together with the number of poles, the circuits to which the number of lighting and power outlets are to be connected and the required number of spares shall be as shown in the Drawings.

2. CONSTRUCTION

Distribution board shall either be of metalclad construction or of polycarbonate construction as specified in drawings. 2.0 Where polycarbonate boards are specified they shall be of approved proprietry

make.


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2.1 Metalclad distribution board shall be manufactured from cold rolled commercial bright mild steel. The steel sheets shall be supplied for manufacture of these boards flat, free from dents, rust, scale and other blemishes. Knockouts shall be provided at both top, bottom and sides of the enclosure. Suitable type escutcheon plate shall be provided for each distribution board hinged to the main cabinet. Edges of the escutcheon plate shall be lipped, returned or welded on an angle frame. Raw edges of metal will not be accepted. Escutcheon shall be fastened to the cabinet on the free side by either captive screws or suitable spring clips. Each distribution board shall be provided with a lockable door and fitted to the cabinet with concealed type hinges. Metalclad board shall be first coated with an etch type rust inhibiting primer and then finished with baked powder paint or other type of paint as approved by the Engineer. Construction of the Distribution Boards shall be minimally Form 2B separation.

3. BUSBAR AND CABLE DUCTS

3.0 The busbars and current carrying parts shall be sized and supported in compliance

with British Standard B.S. 159. The busbar sizes and support spacing shall be installed to withstand fault conditions as required for safe operation.

3.1 Current carrying parts of busbars shall be of electro-tinned high conductivity, hard drawn copper, with a maximum current density of 1000 amps per sq. in.

3.2 The busbars shall have a current carrying capacity appropriate for the maximum demand current for the distribution board. The minimum demand current for the distribution board. The minimum busbar size shall not be less than 0.5 in x 0.125 in rectangular or equivalent cross sectional area. Where the cross sectional area is reduced by drilling to take brass or copper tongues of fixings for take off lugs, the tongues or lugs shall be brazed or satisfactorily fastened in position so as to maintain the conductivity of the busbar. Short circuit rating of the busbars must be coordinated with the upstream protection device.

3.3 The busbar arrangement shall be such that a double or triple pole circuit breaker can be replaced with three single pole breakers an vice versa, without alternations to busbar connections or breaker mounting fixtures.

3.4 For three-phase board of more than 20 way per phase plastic duct with removable cover shall be provided next to each row of circuit breakers for outgoing circuit wiring. The plastic duct shall extend over full width of the cabinet. Ducts shall have entries punched or drilled to match the equipment mounted on the panel. Cross sectional area of the plastic duct shall be sufficient to accommodate all outgoing circuit cables in accordance with Wiring Regulations. Load side of circuit breakers shall be a maximum ¼ inch from plastic duct. The whole distribution board shall be so arranged that all conductors immediately accessible when the cabinet door is opened are fully insulated. All connections to switchgear


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shall either be sheathed with PVC to approval and shall be made behind a removable cover plate.

3.5 A neutral link and earth bar of adequate size shall be provided in each distribution board. Neutral bars shall have at each entry two pinch grip screws for connection of neutral wires.

4. MINIATURE CIRCUIT BREAKER [MCB]

4.0 The design, manufacture, ratings, and testing of the circuit breakers shall comply

with BS EN 60898 or BS EN 60947-2 Part I.

4.1 Circuit breakers shall be of the thermal and magnetic type with quick break toggle action, and shall have constant characteristics irrespective of the physical plane in which they are mounted. The fixed and moving contacts of the circuit breakers shall be of high conductivity non-welding alloys.

Multi-pole circuit breakers shall have a common trip device so that tripping and opening of one pole will cause the remaining poles to open simultaneously. Trip-free mechanism shall also be incorporated on all circuit breakers.

4.2 The interrupting capacity of the circuit breaker must not be less than the

prospective fault level at the point of installation.

NOTES: Down-stream breakers with lower interruption capacity may be allowed provided these breakers are protected by an up-stream protective devices of adequate interrupting capacities and that the tripping characteristics or the up-stream (back-up) device and down-stream breakers are properly coordinated to ensure good discrimination and full protection up to the prospective fault level. Technical information and type test reports from the breaker manufacturer, together with calculations to ascertain the prospective fault levels at point of installation must be submitted these calculations when demanded by the Engineer.

Under certain circumstances as decided by the Engineer HRC fuses may be used to provide back-up protection.

4.3 Where circuit breakers are for protection of cables feeding motor or inductive load,

the circuit breakers shall have a delayed characteristic to meet with the transient rise of current in starting or switching on of the circuit.

4.4 Circuit breakers shall be firmly mounted to the cabinet by fixings independent of terminal studs. They shall be connected to the supply by copper busbar with cross connected take-off lugs of minimum size 0.5 in x 0.64 in. The take off-lugs shall be brazed or suitably pressure riveted to the busbar. The exposed terminal lugs shall be insulated with phenolis fibre to prevent accidental contacts with live terminals.


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5. HRC FUSES Fuses shall be HRC type with matching fuse holder and base. Fuses for general purpose power circuits shall be English Electric Type “T”, HRC Fuse - Links, or approved equivalent complying with IEC 60269-1 Fuses for motor circuit protection shall be English Electric or approved equivalent complying with IEC 60269-2.

6. ON - LOAD ISOLATOR

On-Load isolators shall be provided for each distribution board and shall be of be the quick make and break mechanism with fixed, shrouded contacts. Suitably sized lugs or copper tongues shall be used for the connection between the isolator and the main busbars. Clip connections shall not be permitted. Each isolation shall be capable of load breaking at minimum three (3) times the rated current at 0.85 power factor, and shall comply to IEC 60947-3 suitable for operating under stalled rotor conditions. An interlocking mechanism shall be provided such that access to inside of enclosure cannot be made unless isolator is in “OFF” position.

7. BALANCING OF LOAD

The electrical loadings connected to each three-phase distribution board shall, as far as practicably possible, evenly distributed over the three phase. Where necessary, the connected loads shall be rearranged to achieve the said balancing of load.

8. IDENTIFICATION

Metal anodised, self-adhesive lables shall be fitted to identify circuit breakers on each distribution board. Card holders made of durable material shall be supplied and mounted inside the door of each distribution for the circuit identification schedules. The circuit identification schedule shall contain tabulation of circuits Wire, fuse or circuit breaker sizes and equipment connected to the circuits. The schedule shall be neatly typed and enclosed in a clear plastic envelope and fitted in the card holder in each distribution board. The distribution board shall be properly designated by labels of plastic material with reversed engraving.

9. CONTACTORS

9.0 Contactors shall be of robust design complying to BS EN 755 Part I.

The basic contactor shall be 2, 4, 6 or 8 pole design. Contacts shall be of the double break renewable butt type with each moving contact being individually spring loaded. Both the moving and fixed contacts are to be of silver cadmium oxide. The contacts shall be free from contact bounce and sticking of the fixed and moving contacts. Other features required shall be: -

a) Vacuum impregnated contactor and magnet coil.


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b) Minimum switching frequency per hour required is 30 operations per hour.

c) Minimum service life 13 million mechanical operations.

d) Selected according to [AC1 to AC4] utilization category.

e) The number of auxiliary contacts shall be as required.

Selection of protective devices for contactor shall be to manufacturer’s recommendation.

9.1 Contactor coils shall be vacuum inpregnated on moulded formers, the coil operating voltage shall be 240V AC 50 Hz. The coil shall be designed to operate satisfactorily from –15% to + 10% of the nominal voltage [ie 85% - 110% respectively] for continuous operation.

10. SURGE PROTECTOR

11. 1. The surge protector shall conform to: a) IEEE C62.41-1991 for Recommended practice on surge voltages in low voltage

AC power circuits. b) BS 6651:1992 for Protection of structures against lightning. c) BS2914:1972 for Specification for surge diverters for alternating current power

circuits.

11.2. The surge protector must not interfere with or restrict the system's normal operation. It should not:

11.2.1. Corrupt the normal mains suppl.y 11.2.2. Break or shutdown the power supply during operation. 11.2.3. Have an excessive earth leakage current.

11.3. The protector shall be rated for a peak discharge current of no less than 10kA

(8/20 microsecond waveform).

11.4. The protector shall limit the transient voltage to below equipment susceptibility levels. Unless otherwise stated, the peak transient let-through voltage shall not exceed 600 volts, for protectors with a nominal working voltage of 230 or 240 volts.

11.5. The peak transient let-through voltage shall not be exceeded for all combinations

of conductors: 11.5.1. Phase to neutral 11.5.2. phase to earth 11.5.3. neutral to earth

11.6. The protector should have continuous indication of its protection status. Status

indication should clearly show: 11.6.1. Full protection present. 11.6.2. Reduced protection-replacement required. 11.6.3. No protection-failure of protector.


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Technical Specification for General Lighting and Power

1. SCOPE

a. This part of the specification is relevant to the final sub-circuit wirings from

distribution boards to lighting and power services, and includes final sub-circuit wirings to equipment which are provided by others.

2. WIRING METHODS

a. Unless otherwise specified, PVC insulated cables with or without sheath shall be of 450/750V grade manufactured to BS 6004, copper conductor, with 70°C conductor temperature.

b. Before installation verification must be made to ensure that voltage drops are within allowable limits in accordance to the current I.E.E. Wiring Regulation.

c. Minimum sized cables for lighting shall be 1.5mm2 and for small power shall be

2.5 mm2 cables.

d. For lighting and small power outlets applications, wirings shall be installed according to the loop-in & loop-out principle with no connectors being used except at termination points.

e. Where PVC cables are protected in metal trunking or drawn in metal conduits the

cables may not be sheathed. Where no such protection is afforded PVC cables shall be sheathed.

f. Cables shall be colour coded throughout either by means of coloured insulation or

coloured sleevings at terminations. Essential circuits shall be coded white with each ends having phase-colour coded sleeves.

g. The terminations of cables with copper conductors up to 2.5mm2 shall generally

be made in tunnel type connectors. Terminations of copper conductors above 2.5mm2 shall always be made with suitable size copper lugs or ferrules, sweated, welded or crimped using proprietary lugs and approved crimping tool.

3. CONCEALED WIRINGS PREFERRED

a. Wirings shall as far as possible be unexposed to sight by concealing in walls, floor slabs, in partitions, behind false ceilings, or concealed in other building works wherever practical and appropriate.

b. Exposed wirings may be allowed in plantrooms and switchrooms and at other

areas approved by the Architect / Engineer.


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4. CONDUIT WIRING

a. Circuit of different voltages and/or different functions and of different supply sources (e.g. different transformers & standby generator), shall not be drawn in common conduits.

b. Conduits and fittings shall be Class “B” steel screwed conduits. They shall be of

adequate size to permit easy drawing in or removal of the conductors. Size and capacity of conduits shall be in accordance to current I.E.E. Wiring Regulations.

c. Conduits terminations shall be provided with smooth bore brass, gun-metal or

plastic bush and couplers. Conduits in contact with steel work shall have an efficient and permanent metallic bond made between them. Exposed conduit openings shall be plugged effectively to avoid the ingress of moisture and dirt until wiring is drawn. At terminations and joints a coat of anti-rust paint shall be applied and on completion of the installation, exposed conduits shall be painted with two coats of good quality approved paint to match adjacent walls and ceilings if so instructed by the Architect / Engineer.

d. Conduit installation shall be electrically and mechanically continuous so that

cables are fully protected and the system near water tight. Resistance across joint shall not be more than 0.5 ohm prior to pouring of concrete. Provision shall also be made to drain condensed moisture and/or accummulated water.

e. All conduits shall be installed continuous between termination points with

minimum number of bends. Conduits shall run in a vertical or horizontal direction. Diagonal runs shall not be. Conduit boxes with metal covers shall be provided at every straight conduit run of 12 metre maximum or every two 90 degrees bends.

f. Exposed conduit shall be installed in a neat manner and run parallel to building

edge and wall.

g. Conduit wiring for general power outlet, equipment outlets, shall be installed from ceiling down the walls/partitions. Wirings from floor slab up the walls/partitions will only permitted under specific circumstances.

h. Concealed conduits shall be fixed securely before casting of concrete, floating of

plaster and final partition works. Conduits open ends shall be temporarily plugged by means of corks or stoppers to prevent ingress of foreign matter. Conduit boxes shall be similarly protected. Conduits shall not be concealed in upper surface of floor slabs unless otherwise approved by the Architect / Engineer.

i. Exposed conduits including conduits installed within false ceiling space, shall be

fixed by means of spacer bar saddles. On straight runs, 20mm and 25mmØ conduits shall be supported at not more than 1200mm interval. Conduits with diameter above 25mm shall be supported by at not more than 1500mm interval. Each bend shall be supported by two saddles fitted as near as practicable to either side of the bend.


Page 19 of 38

j. Where a number of exposed conduits run parallel with one another, they shall be

grouped and supported by brackets or trapezo hangers. Hanger rods shall be fastened to structural steel members with suitable beam clamps or to concrete inserts set flush with the concrete surface.

5. WIRING IN CABLE TRUNKING

a. For ease of wiring from same electrical source, [eg. same transformer without standby supply] the final sub-circuit of lighting, general power outlet, small equipment power cables may be grouped and run in metal trunking provided the followings are complied with:

i. a space factor of 45% is maintained throughout;

ii. The wirings are neatly bunched and shall be identifiable at its termination

and throughout its length at every 5 metre run with coded sleeves.

b. Final sub-circuit wirings from different electrical sources, including circuits with back-up standby supply, shall not be grouped into common trunkings under any circumstances.

c. Trunking shall be manufactured from mild sheet steel and galvanised on both

internal and external surfaces. Unless otherwise stated trunking with its larger width measuring less than 100mm may be fabricated from m.s. sheet of 20 s.w.g. Larger size trunkings shall be fabricated from m.s. sheet of thicker gauge commensurating with trunking width but up to maximum thickness of 16 s.w.g.

d. All edges of trunking shall be smooth and provision shall be made to prevent

abrasion at ends.

e. Factory fabricated couplings or other approved fittings shall be used for jointing of trunkings. Earth continuity must be maintained throughout the length. Unless otherwise required by the authority such earth continuity may be effected by providing across each joint a copper bonding link.

f. Individual lengths of trunking shall be adequately supported and rigidly fixed

throughout its length. Where it is suspended, the suspension shall be rigid and the suspension point of the trunking reinforced where necessary. Under no circumstances shall visible sag be observed when loaded with cables.

g. Trunking and fittings shall have removable lids extending over their entire length.

The lids shall be of same material, thickness, and finish as that of trunking. Bends and tee junctions shall be factory fabricated and fitted with removable flat cover.

h. The trunking and supporting brackets shall be treat with an etch type rust-inhibitor

and finishes with two coats of approved paint of selected colour.

i. Trunking shall run neatly on the surface of the building vertically or horizontally. Diagonal run shall not be permitted.


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j. Trunking installations shall be mechanically and electrically continuous.

k. Connection between trunking and appratus shall be by means of screwed coupler and bush, or a standard flange coupling or an adaptor neck, fabricated or cast. When cable penetrates through holes in the trunking, the holes shall be fitted with rubber grommets or insulated bushes.

l. Cables installed in trunking that rises vertically shall be supported by cable ties or

other approved types of supports.

m. Metered and unmetered circuits shall run in a separate trunking.

6. FINAL POSITION OF OUTLETS AND LIGHTING POINTS

a. Location of lighting points, power outlets and equipment switchboards shown on drawings are only approximate. Their final positions shall be ascertained after taking into considerations the latest drawings including architectural drawings and also the site conditions.

b. Changes of outlet/switchboard position within a specified room or within 5 metre

of indicated position, whichever is greater, shall not constitute a variation

c. Switches, receptacles and light fixtures shall be installed and placed symetrically and squarely, taking into considerations wall and ceiling finishes.

d. Light switches and power outlets connected to essential supply circuits shall be

identified accordingly with suitable engraving on the switch plates and the outlets.

7. LIGHT FIXTURE INSTALLATION

a. Fluorescent fittings not exceeding 15mm in width shall be fixed with one fixing at each end. At least two fixings at each end shall be provided for fittings exceeding 15mm in width.

b. Incandescent fittings shall be provided with at least two fixings supports.

c. All light fittings shall be earthed to comply with the I.E.E. Wiring Regulations.

d. All final lighting points shall be terminated to a ceiling rose or connector box

where the connector block shall be capable of withstanding the maximum temperature rise. At each terminating connector box, flexible steel conduit or screwed steel conduit shall connect to the light fitting.

e. Heat resistant cable shall be used to connect the lamp holder of incandescent light

fitting to the fitting’s connector box.

8. LIGHT SWITCHES


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a. Light switches shall be of the single pole, quick-make and silent action type, installed flush or surface as required and manufactured to MS 616, BS EN 60669-1 with at least 5 ampere rating, and shall be wired for one way or two way operation as required.

b. Unless otherwise directed, switches shall be mounted at a height of 1.5 metre

above finished floor level. Except where surface mounted switches are specified they shall be recessed into conduit boxes.

c. Flush mounted ivory white moulded plateswitches similar to MK make and in

combination with metal boxes shall be installed in public area, apartment units, stores, corridors, etc,. Surface or flush mounted metalclad switches shall be installed in all plantrooms such as pumproom, electrical switchrooms, riser rooms, etc.

d. Where switches are exposed to weather, switches shall be or weatherproof type.

e. Positions of door swings, cupboards and other built-in fitments shall be

ascertained before installing any wiring or switches.

f. Where adjacent switches are connected to different phases of supply in a location, they shall be installed in separate switch boxes otherwise the necessary phase barriers shall be provided. A “DANGER 415V” label shall be provided in any case.

g. Where more than one switches of are required to be installed at common location

multi-gang switches may be provided. Suitable engraving shall be provided on the multi-circuit switch plate to identify the lighting circuits.

9. POWER OUTLETS

a. 13A switched socket outlets shall be manufactured to B.S. 1363-2, 2A, 5A and 15A switch socket outlets [two pole and earthing pin] shall be manufactured to MS 589. Industrial type plug and sockets shall be manufactured to IEC 60309-2.

b. Flush mounted ivory white moulded type 13A switched socket outlets similar to

MK make and in combination with metal boxes shall be installed in public areas, apartment units, stores, corridors, verandahs, etc.

c. Surface or flush mounted metalclad type socket outlets shall be installed in all

plantrooms such as pump room, electrical switchroom, riser rooms, etc.

d. Kitchen and other service areas shall have surface or flush mounted ivory white moulded type socket outlets.

e. Outlets exposed to weather shall be of weatherproof type and be provided

complete with plug tops.

f. Socket outlets shall generally be mounted at 0.3 metre above finished floor level, except in the kitchen [and other similar wet service areas] and plantroom areas where the mounting height may be 1.5 metre above finished floor level.


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g. No outlet shall be installed behind wall cabinet and other built in fitments where

these fitments and furniture.

h. No outlet shall be located at the joint or junction of any wall tiling, demountable partition and different finishes.

10. WIRING FOR EMERGENCY LIGHTING

a. Wiring for battery-backed emergency lighting shall be drawn into separate

conduit system and not share with other circuit wirings.

b. The circuit breakers protecting emergency lighting circuits shall be clearly labelled and a notice shall be provided at each distribution board to advise that these circuit breakers should not be switched off normally.

11. FINAL SUB-CIRCUIT TO FIXED EQUIPMENT

a. The location of isolator points as indicated on the drawings are approximate only. Their exact locations shall be ascertained after counter checking with other relevant services contractor and latest drawings including architectural drawings. Mounting height and means of cable entry and termination shall be similarly ascertained.

12. TIME SWITCHES

a. Where specified time switches shall be provided and run on 240V 50Hz supply and shall have a 24 hour spring reserve.

13. FIREMEN SWITCH

a. Where specified, firemen switch shall be provided and installed at every staircase enclosure to permit the disconnection of normal electrical power supply to the relevant floor or zone served. This shall be achieved by the use of a remote shunt trip type MCCB or magnetic contactor as indicated on drawing. The switch shall be a type similar to the firemen’s switch as specified in the I.E.E. Wiring Regulations. Necessary control and interposing relays shall be incorporated.

b. A distintive label shall be affixed on the front of the switch with the letterings

“FIREMEN SWITCH”.

14. CONTROL WIRING

a. Control wirings, DC or AC at or below 240 volts shall use 2.5mm2 PVC cables concealed in G.I. conduit.

15. SEGREGATION OF CIRCUITS


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a. The following shall run in separate conduit or trunking for the purpose of

segregation of services.

i. Lighting final sub-circuits from one supply source.

ii. Power final sub-circuits from one supply source.

iii. Emergency lighting circuits

iv. Emergency power circuits

v. DC low voltage control wiring for each voltage rating

vi. AC low voltage control wiring for each voltage rating

Technical Specification for Light Fittings

1. SCOPE

a. Light fittings shall be supplied and installed complete with lamps, diffusers, control, gear, power factor correction equipment and suitably sized connectors.

b. The materials used and quality of finish of all light fittings shall comply with the general requirements as specified below

2. GENERAL REQUIREMENTS

a. Fixtures shall be wired and constructed to comply with this specification, with

local codes, IEC 60598-2 lighting fixture standards, the requirements of the Chief Electrical Inspectorate and shall also bear the “SIRIM” label where applicable.

3. TEMPERATURE RISE

a. Fixtures shall be adequately ventilated so that the permissible temperature rise for

each lamp type is not exceeded during continuous operations.

4. PHOTOMETRIC DATA

a. Photometric data of light fitting shall be furnished when requested by the Architect / Engineer

5. FLUORESCENT FITTINGS

a. Fluorescent fittings shall be designed and suitable for the operation of unmodified

standard switched-start tubular fluorescent lamps unless otherwise specified.


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b. The carcase of the light fitting shall be manufactured from cold-rolled mild steel sheet of minimum 22 s.w.g. thickness, electrolytically zinc coated and phosphortised. The adjoining edges shall be welded and the exposed faces ground flush to present a neat appearance. The whole carcase shall be stiffened by the use of returned edges to flange and by rigid box construction, and provision shall be made for the removal of gear tray with accessories, by the removal of wing nuts.

i. Fittings shall have separate compartments or enclosure for lamps and control gear.

ii. Starter switches shall be mounted between the tubes in multi-lamp fittings

and on the underside above the tubes in single tube fittings. Other arrangement shall be to the approval of the Architect / Engineer.

iii. Design of diffuser fittings and trims shall be such that no light leak are visible. Particular care in this regard shall be paid to joints in the trim and to the fixing of the trim to the fitting particularly at the ends.

c. Fittings shall be supplied with necessary wiring completed between lamp holder

and components in 105ºC PVC covered flexible conductors of an adequate rating suitable for their purpose, neatly clipped into position at intervals not more than 35mm and clear of other components.

i. Terminations for connection shall be by means of “quick connect” type terminals. Wiring shall be brought to a 3 way insulated terminal block for the connection of external active, neutral and earth conductor. A cartridge type fuse of appropriate rating and fuse holder shall be provided and installed in each fitting.

ii. Flexible steel conduit shall be used for the external connection from the

lighting fixture to a steel junction box fixed adjacent to the fitting.

d. The reflector for fluorescent fitting shall be of anodized polished aluminium.

e. In all light fittings (unless constructed of aluminium which has been etched and anodised) all surfaces shall be thoroughly degreased by an approved process and cleaned free from dust, moisture, oil and corrosion products. The fitting shall then be finished with oven-baked powder paint.

f. Ballast for shall be of polyester type and with total loss not exceeding 5 watt for a standard switch-start 40w/36w lamp circuit.

g. For multi-lamp fitting each lamp circuit shall be so arranged that its operation is independent of the other.

h. Fluorescent starter switch shall be provided with r.f. suppression capacitor.

6. INCANDESCENT FITTINGS

a. All incandescent fitting shall be provided with porcelain lamp holders suitable for bayonet or Edision screw lamp cap as appropriate.


Page 25 of 38

b. Light fittings using lamp of 60W and over shall be provided with an approved junction box and heat resistant cable leads to the lamp holder.

c. The heat resistant cable shall be asbestos or glass fibre insulated. Where it is not

possible to have a junction box fixed to the fitting, the junction box shall be installed adjacent to the fitting.

7. HIGH INTENSITY DISCHARGE LAMPS (H.I.D)

a. Ballast – shall be of the reactor type with polyester varnish impregnation, ballast

to suit each type of discharge lamp as recommended by the manufacturer.

b. Capacitor – Adequate size capacitor shall be provided to correct the power factor to a minimum of 0.85 lagging.

c. Ignitor – to be provided as per manufacturer’s requirements.

d. Control Gear Box – IP44 rated for indoor application and IP56 degree of protection for outdoor operation.

e. Each fitting shall be provided with porcelain lamp-holders, porcelain terminal blocks and pre wired with heat resistant glass fibre insulated cables.

8. EXTERIOR LIGHT FITTINGS

a. Fixtures for outdoor applications shall have degree of protection better than IP55.

9. CAPACITORS

a. Capacitor shall be provided for each fluorescent and other discharge lamp circuit to correct overall power factor of the circuit to better than 0.85 lagging.

10. DIFFUSERS

a. Unless otherwise stated, diffusers shall be edge moulded. The diffuser shall have

only minimum discolouration due to usage.

b. The plastic diffusers shall be of the slow burning or self-extinguishing type with low smoke density rating and low heat distortion temperature.

11. LIGHTING FIXTURE INSTALLATION

a. All fixtures irrespective of whether surface, pendant or recessed mounted shall be

independently supported from the building structure except for the lightest incandescent fixtures where direct fixing to ceiling work may be allowed.

b. Fixtures installed in wet plaster board ceilings shall be supported by plaster frames installed for that purpose.


Page 26 of 38

c. Fixtures must not be used as means to carry cables of other circuits except specifically so designed.

12. PACKING

a. Prior to installation all fittings shall be individually packed in substantial,

reinforced cardboard cartons adequate to prevent damage during normal handling. A label shall be affixed to the outside of each carton clearly defining its contents. Each carton shall contain all the components of a complete fitting except that fluorescent tubes and diffusers for recessed fittings may be packaged separately.

13. SAMPLES

a. Sample of fixture shall be submitted at the earliest opportunity to allow time for

manufacture and delivery.

14. POWER SUPPLY

a. Unless otherwise specified fixtures shall be suitable for 240V 50Hz operation. 15. HIGH BAY LIGHT FITTING.

a. Die-cast aluminium ballast housing, with polyester powder paint finish

with threaded hub for easy mounting and sliding disconnect between optical assembly and ballast housing.

b. The optical assembly shall be IP20 and the ballast assembly shall be

IP54 rated.

c. The faceted shall be of anodized polished aluminium.

16. EMERGENCY LIGHT a. The design and operational needs shall meet

i. MS 619 and MS 983 standards. ii. JKR Approval Class 1

iii. IP20 Luminaire fitting.

b. The light shall be dual powered where the normal supply shall be used as charging facilities whereby it will maintain the charge of the battery.

c. Upon power failure, the battery shall power up the light to have at least 3 hours of backup.

d. There shall also be an LED indicator showing the status of battery power.

e. The construction shall be electro-galvanised Steel casing of high reflectance finished with corrosion resistant epoxy spray coating.

17. KELUAR SIGN

a. The design and operational needs shall meet


iii. IP20 Luminaires fitting.


Page 27 of 38

b. The light shall be dual powered where the normal supply shall be used as charging facilities whereby it will maintain the charge of the battery and light up the signage.


d. There shall also be an LED indicator showing the status of battery power and push test switch to simulate power failure.


Technical Specification for Light Fittings

1. SCOPE

a. Light fittings shall be supplied and installed complete with lamps, diffusers, control, gear, power factor correction equipment and suitably sized connectors.

b. The materials used and quality of finish of all light fittings shall comply with the general requirements as specified below

2. GENERAL REQUIREMENTS

a. Fixtures shall be wired and constructed to comply with this specification, with

local codes, IEC 60598-2 lighting fixture standards, the requirements of the Chief Electrical Inspectorate and shall also bear the “SIRIM” label where applicable.

3. TEMPERATURE RISE

a. Fixtures shall be adequately ventilated so that the permissible temperature rise for

each lamp type is not exceeded during continuous operations.

4. PHOTOMETRIC DATA

a. Photometric data of light fitting shall be furnished when requested by the Architect / Engineer

5. FLUORESCENT FITTINGS

a. Fluorescent fittings shall be designed and suitable for the operation of unmodified

standard switched-start tubular fluorescent lamps unless otherwise specified.

b. The carcase of the light fitting shall be manufactured from cold-rolled mild steel sheet of minimum 22 s.w.g. thickness, electrolytically zinc coated and phosphortised. The adjoining edges shall be welded and the exposed faces ground flush to present a neat appearance. The whole carcase shall be stiffened by the use of returned edges to flange and by rigid box construction, and provision shall be made for the removal of gear tray with accessories, by the removal of wing nuts.


Page 28 of 38

i. Fittings shall have separate compartments or enclosure for lamps and control gear.

ii. Starter switches shall be mounted between the tubes in multi-lamp fittings

and on the underside above the tubes in single tube fittings. Other arrangement shall be to the approval of the Architect / Engineer.

iii. Design of diffuser fittings and trims shall be such that no light leak are visible. Particular care in this regard shall be paid to joints in the trim and to the fixing of the trim to the fitting particularly at the ends.

c. Fittings shall be supplied with necessary wiring completed between lamp holder

and components in 105ºC PVC covered flexible conductors of an adequate rating suitable for their purpose, neatly clipped into position at intervals not more than 35mm and clear of other components.

i. Terminations for connection shall be by means of “quick connect” type terminals. Wiring shall be brought to a 3 way insulated terminal block for the connection of external active, neutral and earth conductor. A cartridge type fuse of appropriate rating and fuse holder shall be provided and installed in each fitting.

ii. Flexible steel conduit shall be used for the external connection from the

lighting fixture to a steel junction box fixed adjacent to the fitting.

d. The reflector for fluorescent fitting shall be of anodized polished aluminium.

e. In all light fittings (unless constructed of aluminium which has been etched and anodised) all surfaces shall be thoroughly degreased by an approved process and cleaned free from dust, moisture, oil and corrosion products. The fitting shall then be finished with oven-baked powder paint.

f. Ballast for shall be of polyester type and with total loss not exceeding 5 watt for a standard switch-start 40w/36w lamp circuit.

g. For multi-lamp fitting each lamp circuit shall be so arranged that its operation is independent of the other.

h. Fluorescent starter switch shall be provided with r.f. suppression capacitor.

6. INCANDESCENT FITTINGS

a. All incandescent fitting shall be provided with porcelain lamp holders suitable for bayonet or Edision screw lamp cap as appropriate.

b. Light fittings using lamp of 60W and over shall be provided with an approved

junction box and heat resistant cable leads to the lamp holder.

c. The heat resistant cable shall be asbestos or glass fibre insulated. Where it is not possible to have a junction box fixed to the fitting, the junction box shall be installed adjacent to the fitting.

7. HIGH INTENSITY DISCHARGE LAMPS (H.I.D)


Page 29 of 38

a. Ballast – shall be of the reactor type with polyester varnish impregnation, ballast

to suit each type of discharge lamp as recommended by the manufacturer.

b. Capacitor – Adequate size capacitor shall be provided to correct the power factor to a minimum of 0.85 lagging.

c. Ignitor – to be provided as per manufacturer’s requirements.

d. Control Gear Box – IP44 rated for indoor application and IP56 degree of protection for outdoor operation.

e. Each fitting shall be provided with porcelain lamp-holders, porcelain terminal blocks and pre wired with heat resistant glass fibre insulated cables.

8. EXTERIOR LIGHT FITTINGS

a. Fixtures for outdoor applications shall have degree of protection better than IP55.

9. CAPACITORS

a. Capacitor shall be provided for each fluorescent and other discharge lamp circuit to correct overall power factor of the circuit to better than 0.85 lagging.

10. DIFFUSERS

a. Unless otherwise stated, diffusers shall be edge moulded. The diffuser shall have

only minimum discolouration due to usage.

b. The plastic diffusers shall be of the slow burning or self-extinguishing type with low smoke density rating and low heat distortion temperature.

11. LIGHTING FIXTURE INSTALLATION

a. All fixtures irrespective of whether surface, pendant or recessed mounted shall be

independently supported from the building structure except for the lightest incandescent fixtures where direct fixing to ceiling work may be allowed.

b. Fixtures installed in wet plaster board ceilings shall be supported by plaster frames installed for that purpose.

c. Fixtures must not be used as means to carry cables of other circuits except specifically so designed.

12. PACKING

a. Prior to installation all fittings shall be individually packed in substantial,

reinforced cardboard cartons adequate to prevent damage during normal handling. A label shall be affixed to the outside of each carton clearly defining its contents.


Page 30 of 38

Each carton shall contain all the components of a complete fitting except that fluorescent tubes and diffusers for recessed fittings may be packaged separately.

13. SAMPLES

a. Sample of fixture shall be submitted at the earliest opportunity to allow time for

manufacture and delivery.

14. POWER SUPPLY

a. Unless otherwise specified fixtures shall be suitable for 240V 50Hz operation. 15. HIGH BAY LIGHT FITTING.

a. Die-cast aluminium ballast housing, with polyester powder paint finish

with threaded hub for easy mounting and sliding disconnect between optical assembly and ballast housing.

b. The optical assembly shall be IP20 and the ballast assembly shall be

IP54 rated.

c. The faceted shall be of anodized polished aluminium.

16. EMERGENCY LIGHT a. The design and operational needs shall meet


iii. IP20 Luminaire fitting.

b. The light shall be dual powered where the normal supply shall be used as charging facilities whereby it will maintain the charge of the battery.


d. There shall also be an LED indicator showing the status of battery power.


17. KELUAR SIGN

a. The design and operational needs shall meet


iii. IP20 Luminaires fitting.

b. The light shall be dual powered where the normal supply shall be used as charging facilities whereby it will maintain the charge of the battery and light up the signage.



Page 31 of 38

d. There shall also be an LED indicator showing the status of battery power and push test switch to simulate power failure.


Technical Specification for Lightning Protection System LIGHTNING

1. GENERAL

a. All lightning protection materials should conform to EN50164-1 and EN 50164-2 Lightning Protection Components requirements. The exceptions to these requirements are non-current carrying devices such as down-conductor fixings (clips), anti-vandal guards and mechanical supports.

b. The requirements for protection of a structure against physical damage by means

of a lightning protection system (LPS) shall conform to IEC 62305 Protection Against Lightning

c. This section of the specification describe and specifies requirements for the

supply, delivery, installation, testing, commissioning, handing over in approved working order and maintenance during the Defects Liability Period of the whole lightning protection system in accordance with MS IEC 62305, the Specification, Supplementary Notes, Bills of Quantities, Conditions of Contracts, Drawings etc.

d. The lightning protection system shall use the integrated system, i.e. making use of

the building structure and other building metallic components.

2. AIR TERMINATIONS

a. If the roof components are not made of metallic component or not to the required thickness the conventional method of designing air termination system shall be employed. To ensure the structure is entirely protected the design using protective angle method, rolling sphere method and mesh sizing method as mentioned in MS IEC 62305-3 shall be used. The design method used, shall be based on the Lightning Protection Level III or IV (for region with less than


Page 32 of 38

d. If portions of structure vary considerably in heights, any necessary air termination

or air termination network of the lower portions should, in addition to their own down conductors, be bonded to the down conductors of the taller portions. This shall also be applicable if the metallic roofing is used as an air termination.

3. DOWN CONDUCTORS

a. The reinforce rod of walls and concrete columns and steel structural frames may be used as a natural down conductor, refer to MS IEC 62305-3. The steel structure of the column shall be interconnected by the minimum 50mm2 MARSA bare GI cable to ensure continuity. The MARSA bare GI cable shall be bonded to steel structural column at interval of not more than 2m or based on drawing. The MARSA bare GI cable shall become the enhancement conductor from earthing point to roof conductor.

b. At each floor in the rises the MARSA bare GI cable shall be taken out for the

connection to Main Earthing Bar. This will form as additional conductors as per MS IEC 62305-3 unless otherwise objected by the structure engineer.

c. Spacing of down conductor shall be based on table below:

LPL SPACING (m) I 10 II 10 III 15 IV 20

d. Down conductors shall use the column steel structure with a tapping point to each floor as per drawing. The conductor shall ensure the continuity of the steel structure to ground and connected to ground and floor beam. To ensure the continuity the steel structure shall be bonded together using minimum 50mm2 MARSA bare GI cable using proper MARSA G-clamp with 50mm touching area throughout the column. (U bolt not allowed as does not satisfy touching area)

4. EQUIPOTENTIAL BONDING

a. In order to ensure the floors are at equipotential, ground beams and floor shall be bonded using minimum 50mm2 MARSA bare GI cable as per drawing. The bonding method shall be as per item 5.0 in this specification.

5. JOINTS AND BONDS

a. The lightning protection system shall ensure continuity and therefore: -

b. Joints and bonds should be mechanically and electrically effective. MARSA G-clamp with a contact length of 50mm shall be used to provide strength and overlapping contact between the steel structure and MARSA bare GI cable. Copper and steel shall not be bonded together.

c. Contact surfaces should first be cleaned then inhibited from oxidation with a

suitable non-corrosive compound.


Page 33 of 38

d. The resistance from any part of the lightning protection system to earth

termination point should not exceed 10Ω.

6. TESTING JOINTS

a. Whenever necessary the down conductor shall be provided with a testing joint along the route of the down conductor. The testing joints shall be purpose made copper clamp. A bimetallic connection shall be used to joint the galvanised steel stay cable and the copper tape. Unless otherwise specified, each testing joint shall be installed at 2m above the ground level.

7. EARTH TERMINATIONS

a. An earth termination shall be connected to columns structure and piles structure. Earth termination shall be by 25mm x 3mm copper tapes connecting the down conductor at the testing joint to the earth electrodes. The portion of the earth termination between testing joint and ground shall be enclosed in a PVC conduit of suitable size.

b. The whole of the lightning protective system shall have a combined earth

resistance of not exceeding 10 ohms.

8. EARTH ELECTRODES

a. Building reinforcement (pile column) shall be used as an earth electrode by proper bonding of the earthing system. Failing which earth electrodes shall be of copper-jacketed steel core rods with 16mm diameter and supplied in 1.8m length and shall have provision for screw coupling with another standard length. The copper jacket shall be of minimum thickness 0.25 mm and shall be metallically bonded to the steel core to ensure that the copper jacket and steel core are electrically connected.

b. Where the desired earth resistance values cannot be achieved after the set of earth

electrodes have been driven, sufficient number of sets of earth electrodes shall be

installed outside the resistance area until required value is reached.

Interconnection between different sets of earth electrodes shall be by means of

25mm x 3mm annealed copper tape. Each set of earth electrodes shall be provided

with brass connecting clamp and approved type of precast heavy-duty concrete

inspection chamber and removable cover. Each earthing point shall be identified

by permanent.

c. Label legibly marked with words “Lightning Earth” permanently fixed at the point of connection of every earthing conductor to an earth electrode.

9. TESTING

a. After the installation work has been completed, the whole lightning protection system shall be tested in accordance with MS IEC 62305, in the presence and to be the satisfaction of the S.O.’s Representative.


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b. Within the calendar months after the practical completion of the project, four sets

of prints for each of the following drawings shall be submitted: -

c. Layout plan of the lightning protection system incorporating earthing points with reference to easily recognisable buildings and structure

d. Elevations views of the lightning protection system

e. These drawings shall be in AutoCAD format and complete with four sets hard

copies and shall have at the lower right hand corner the Electrical Contractor’s name, and address, date of commissioning, scale, drawing number (the drawing number to be obtained from the S.O’s Representative), and client address.

f. If the drawings submitted are not acceptable by the S.O.’s Representative, The

Electrical Contractor shall amend and re-submit the drawings within two weeks from the date of return of the drawings.

EARTHING

1. GENERAL

a. All non-current carrying metal parts, including metal parts liable to transmit a potential including earth potential but not forming part of the electrical installation, shall be earthed in accordance to the recommendation of the I.E.E. Regulation, 16th Edition.

2. MAIN EARTHING TERMINAL

a. Main earthing terminal shall be provided for each main switchboard and a suitably sized green PVC cable shall be installed as the earthing conductor connecting each main earth terminal to the earthing electrodes. A label, “SAFETY EARTH, DO NOT DISCONNECT” shall be provided adjacent to each main earthing terminal

3. EARTHING ELECTRODES

a. Earthing electrodes shall be 16mm diameter hard drawn copper rods. Number of electrodes and depth to be driven shall commensurate with the earth resistivity and prospective earth fault current.

b. Each electrode shall be provided with an earth chamber and a steel cover plate.

Where located in area subjected to vehicle traffic the chamber and its cover shall be of robust construction to withstand vehicle traffic.

c. Bonding between electrodes shall be by means of 25mm x 3mm annealed copper

tapes. Tinned brass earth clamps shall be used for terminations at electrodes. Where electrodes are inaccessible after completion, the copper tapes shall be welded to the electrodes to ensure a permanent and reliable termination.


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d. NOTE : Foundation steel structures may be permitted to be used as earthing

electrodes, subject to the approval of the Architect / Engineer and Local Supply Authority.

4. BONDING OF OTHER SERVICES

a. All metal pipes of other services such as gas, fire fighting, and water pipings shall be effectively bonded at or near the respectively incoming section to the main earthing bar.

5. SWITCHBOARD EARTHING

a. Earthing conductors for main switchboards shall be by means of copper strips measuring 25mm x 3mm cross-section and secured at maximum 800mm intervals.

6. INSTALLATION OF EARTHING CONDUCTORS

a. Earthing conductors shall be so located, installed and protected that they are not likely to be displaced, damaged or cut. Fixing shall be by means of clamps, clips, saddles, staples or cleats all of which shall be so installed that the earthing conductor would not be damaged. Earthing conductors from the main earthing panel shall be connected to main building earthing network with cadweld joint.

Technical Specification for Surge Protection Device

1. The selection of surge protective device (SPD) must be accordance to the Treasury Circular (Surat Pekeliling Perbendaharaan bil 7. Tahun 2002) with regards to the use of local products and listed in JKR EMAL. The use of imported products is allowed only if local product for the intended use is not available.

2. The surge protective devices (SPDs) shall be one-port type compatible with the 240/415

V, 3 phase, 4 wire, 50Hz with solidly earthed neutral supply system it it’s protecting. Unless otherwise specified, SPD shall be of the type complying with MS IEC 61643.

3. The SPDs is said to have full mode protection if it has each phase-to-neutral, each

phase-to-earth and neutral-to-earth for either single phase or three phase supply system. For 3+1 mode, it has no direct protection between phase-to-earth and these shall not be used for Malaysian condition.

4. SPDs used for three phase or single phase supply system installation shall be of

Monoblock type i.e permanent termination of the switching and or voltage limiting devices. Modular type or without a solid termination (replaceable) type of the switching and or voltage limiting devises shall not be used.


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5. The SPDs shall be of voltage limiting type with metal oxide varistors (MOVs) only they shall be test to Class III, MS IEC 61643-1.

6. The maximum continuous operating voltage (Uc) of SPDs shall be maximum 275 V for

SPDs connected between each phase-to-neutral and each phase-to-earth. When SPDs connected between neutral-to-earth, the rating of Uc shall be minimum 240 V. The continuous operating current (Ic) for each mode of protection shall not exceed 3 mA. In the case where MOVs are used, the SPDs shall be provided with integrated thermal protection to avoid thermal runaway due to degradation.

7. The kA rating of the SPD shall be based on per phase (Line-to-Neutral) or (Line-to-

Earth) or (Neutral-to-Earth) whichever is the lowest or the weakest link. Parallel MOVs of each phase shall not sum up as a total kA rating of MOV.

8. The SPDs shall be equipped with LED indicator showing the protection status of the

SPDs. A durable label with red lettering on a white background with words as stated below shall be fastened externally on the front cover of the SPDs compartment.

AMARAN Pemasangan ini dilindungi oleh Surge Protective Device (SPD).

SPD tidak lagi berfungsi apabila lampu petunjuk tidak bernyala / bertukar warna.

Sila buat pemeriksaan pada SPD secara bulanan. Sila hubungi 1. “orang kompeten” untuk penggantian SPD.

Pastikan juga “circuit breaker” ke SPD sentiasa berada dalam keadaan ON(I)

9. The size of connecting conductors shall be as recommended by the SPD manufacturer. The connecting conductors shall be as possible (preferably) not exceeding 25cm for the total length) and shall be tightly bound together throughout the whole length with cable-ties or other approved means. Either four-pole Moulded Case Circuit Breaker (MCCB) or a fuse rating as recommended by the SPD manufacturer shall be provided for disconnecting the SPDs from the system in the event of SPDs failure or for maintenance. In the case where an MCCB is used, the breaking capacity of the MCCB shall comply with the a.c interrupting capacity of the switchboard or distribution board.

10. The Recommended Rating of the SPD and its Zone of protection is as shown in Table

below.

11. 12. Switch

Socket 13. Distrib

ution 14. Sub Switch

15. Main Switch

16. 17. Outlet/Equ

ipment 18. Boar

d 19. Boa

rd 20. Boa

rd 21. kA

Rating 22. 10 kA 23. 20 kA 24. 40 kA 25. 80 kA 26. Let –

Through 27.


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Us 46. Closed

cct Test 47. 1 kA 48. 3 kA 49. 5 kA 50. 10 kA 51. @ 8/20 Us 52. 53. 54. 55.

Technical Specification for Defect Liability Period SERVICE AND MAINTENANCE DURING DEFECT LIABILITY PERIOD 1. Service and maintenance shall be carried out for the completed installations as and when

necessary during the contract defects liability period following the date of practical completion. The service and maintenance shall include but not limited to : a) Replacement for fluorescent tubes, discharge lamps and any other lamps and

ballast which burnt out before the associated life span.

b) Replacement of defective items of electrical switchgear, transformer and associated equipment and accessories;

c) Replacement and repair of any faulty part;

d) For special or proprietary equipment (such as generating set, uninterruptible

supply system) the service and maintenance shall be carried out in accordance to manufacturer’s recommendations.

Technical Specification for Testing And Commissioning TESTING, BALANCING AND COMMISSIONING 1. GENERAL

After completion of the installation the Contractor shall carry out as many tests as necessary to assure the Engineer that the plant performance is as specified. The Engineer shall be notified a notified a minimum of forty – eight [48] hours prior to commencement of such tests and shall be given the option of witnessing all such tests.

The works of the Contract will not be considered as having reached a Stage of Practical Completion until all commissioning, balancing and testing as required under this section of the Specification has been carried out.

All testing, balancing and commissioning shall be carried out in accordance with the methods outlined in this Section of the Specification except where written approval has been received from the Engineer confirming acceptance of an alternative method. Should an alternative method of testing and approved, the Contractor shall be responsible for ensuring that any other items necessary for satisfactory completion of the testing, are installed or provided at no additional cost to the Employer.


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2. TEST INSTRUMENTS

All instruments and appliances required for testing shall be furnished by the Contractor for the duration of the tests. Other instruments specified as a permanent part of the installation may be used for testing purposed. Test instruments shall be tested for accuracy by an approved laboratory and recent test certificates shall be made available to the Engineer prior to site testing.

3. TEST REPORT FORMS

The result of all testing and balancing as required under this Section of the Specification shall be submitted to the Engineers in a neat and legible manner.

Typical test rep

technical specification for main 415v switchboard 1. general · en 60439-1. d) the degree of...

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