TECHNICAL SPECIFICATIONS ACMV/TS/ELEC

MECHANICAL SERVICES
- Air Conditioning & Mechanical Ventilation Services PAGE 1 OF 22

1.0 ELECTRICAL WORKS

1.1 General

The contractor shall supply and install all electrical works necessary for the proper
functioning of all systems and items of equipment.

Wherever applicable, all electrical works, materials and equipment shall comply with
the requirements of the most recent revision of the regulations promulgated by:

(i) Tenaga Nasional Berhad (TNB)

(ii) The institution of Electrical Engineers
(iii) The British Standard Institution.
(iv) Jabatan Perkhidmatan Bomba

All items of equipment shall be of first grade with regard to design, manufacture and
safety. Uniformity of type and manufacture of switch gear, controls, fittings and
accessories shall be maintained through the whole of the installation.

The control circuits of a system shall be connected to the same phase but as far as is
possible, the electrical loads shall be balanced between the three phases of supply.

1.2 PVC Insulated Cables

Unless otherwise specified, all LV electrical wring shall be carried out with PVC
insulated cables.

PVC insulated cables shall be of 600/1000v. 75oC grade with stranded copper
conductors and comply with the requirements of BS 6004 and BS 6221. Single
conductor PVC insulated cable shall not be used.

All cables delivered to site shall have a proof of origin intact on each coil or drum.

PCV insulated cables shall be installed in galvanised Class ‘B’ conduits. Where
installed on cable trays or run buried underground in GI pipes the cable shall be PVC
insulated and PVC sheathed.

Cable shall be installed without any joints between items of equipment unless
permission has been given.

Cable terminations shall be properly carried out, using glands, lugs and other
terminating media recommended by the cable manufacturer.

1.3 Conduits

All conduits and conduit fittings shall be Class ‘B’ galvanised metallic conduits with
screwed fittings and shall comply with BS 31 and BS 731.

Conduits shall be delivered to site with ends properly sealed against the ingress of
dirt, etc. Conduits and conduit fittings bearing traces of rust or damaged shall be
rejected.
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Conduits shall be of sufficiently large section and so arranged with draw-in boxes to
allow for easy draw in/out of any one or all of the cables. The sizes and total number
of cables shall not exceed that given in Table B.5M of the IEE Regulations (18th
edition).

For conduit or G.I pipe sizes other than those provided for in Table B.% M, the number
and size of cables installed shall be such that a space factor of 30% is not exceeded.

No conduit shall be less than 20 mm (3/4 inch) outside diameter.

Each conduit shall not contain more than one motor or power circuit unless
permission has been given for deviation.

The conduit installation for each conduit shall be completely erected and inspected
by the S.O before any cable is drawn in.

Conduits shall be installed in straight runs rigidly fixed, level and parallel or at right
angles to building structure.

Conduits shall be set and bent cold without deformation to the section, using only
approved bending machines and following the recommended minimum bending radius.
“Tee” and elbow” shall not be used.

Conduits shall be cut square and threaded with the minimum number of threads to
obtain paper unions.

The ends of conduits shall be reamed to remove burrs and other projections and
terminated into threaded with copper wire or tape and screw-on clips.

Where conduits and G.I pipes are exposed to damp situations or buried underground
they shall be made completely water-tight by treating all joints with red lead or other
approved method.

1.4 CableTrays

Cable trays may only be used in the Main Plant Room to support cables at high level
from the chiller plant switchboard to the compressor motors.

Cable trays shall be fabricated with suitably formed edges at each side, and sized in
accordance with the number and sizes of cables they are required to support. In this
regard, cables shall be installed in a single formation with the exception of single core
cables, which require to be installed in a trefoil configuration with adequate space
allowed for air circulation.

Cable trays shall be of 1.6mm thick for width not exceeding 300mm (1ft). For width
exceeding 300mm the thickness shall be 2mm.

Cable trays shall be hot dip galvanised. Intersection pieces and bends shall be
factory made and hot dip galvanised finish. The cut end of the cable tray shall be
made good with a coat of zinc chromate and two coats of approved paint.

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Cable trays shall be supported using purpose made brackets and accessories and
shall be installed in straight line level runs, and in a manner to minimise the number of
bends.

The cables shall be adequately fixed on the cable tray and braced with purpose
made clips, cleats or supports recommended by the cable maker to ensure that
damage is minimised under fault conditions.

1.5 MICC Cables

Mineral insulated copper covered (MICC) cables shall be of 1000v grade sized to
specified conditions and shall be manufactured in accordance with BS 6207 with
terminations and glands manufactured to BS 608.1

All the equipment for the fire protection services (pressurisation, smoke spill, etc)
shall be wired with MICC cables. The minimum size of conductor shall be 2.5 sq mm
for power and 1.5 sq mm for control circuits. The selection of cable sizes shall be based
on exposure to touch current ratings and permissible voltage drop.

At terminations the tails entering the equipment shall not exceed 450mm in length. In
the case of switchboards where 450mm length is insufficient the cable shall enter the
enclosure through a hole secured with a gland.

All cables shall be installed with terminations suitable for the intended duties and
prevailing conditions as recommended by the cable manufacturer.

Conductors of 6 sq mm shall be terminated using appropriate cable lugs. Small

conductors shall be connected directly into the thermal ports of the equipment.

MICC cables shall be installed nice and straight, vertical and horizontally, with
bends formed by proper tools. No level shall have a radius of less than eight (8)
times the outside diameter of the cable and with at least 150 mm of straight cable
adjacent to the termination.

MICC cables shall be terminated via flexible (loop) connections at motors and
equipment, which are subject to vibration.

MICC cables shall be fixed by means of multi-way saddles where more than one
cable run along a common route and if the member exceeds four, the cable tray shall
be erected as a support medium.

All MICC cables installation shall be free of through-joints except where the cable
route exceeds the full manufacture cable length. In these circumstances joints are
permitted but the joints shall be made by the cable manufacturer.

All MICC cable installation shall, in addition to the required routine cable installation
tests, be subjected to the following tests.

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The insulation resistance tests shall be performed using a 1000v bridge megger
immediately after the seals have been applied and gain after a minimum of 48 hours
later before the final connections are made. This is to ensure “infinite” readings are
being maintained in the cables.

Installation with reading less than 100 megaohm will not be acceptable.

1.6 Earthing

All metal parts of switchboard enclosures, cable trays, trunking, conduits, equipment
and motors shall be effectively earthed.

Each free standing switchboard shall be equipped with a copper earthing strip of
adequate size installed along the whole of its length to which shall be connected all
metal parts not intended to be energised. The switch board shall be separately
earthed to IEE Wiring Regulations requirements.

The copper sheathing of the MICC cable may be used in all earthing conductor
where permitted by the Wiring Regulations.

All metal pipes and other services pipes shall be dully earthed to IEE Wiring
Regulation requirements.

1.7 Shield Cables

Shield cables shall be thermoplastic insulated, metal braided or metal meshed and
thermoplastic sheathed.

The metal shielding shall be earthed at each termination.

The type of shielded cable to be used shall be suitable for the particular control
application.

1.8 LV Electric Motors

All electrics motors shall be designed for 415V-3Ph-50Hz electric supply with ±10%
voltage fluctuation.

Unless specified or indicated otherwise the motors for all belt-driven fans, adjustable
pitch fans and variable pitch fans shall be of ratings sufficient to increase the air flow
by 10% above specified flow rate against the resistance of the system.

The type of motors, speeds and additional requirements for the use with different
equipment shall be as specified in the respective sections of the equipment.

All electric motors of 0.75kw and above shall operate with a power factor not lower
than 0.85 lagging irrespective of load variations between 10 to 100% full load. Power
factor correction equipment shall be incorporated where necessary.

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Local isolating switches installed adjacent to motors shall be rated not less than the
locked motor current of the motor.

Weather proof enclosure type switches shall be used where exposed to weather and
in damp locations, and all conduit entries shall be sealed.

1.9 Motor Starter

Unless specified in contract drawing, otherwise the electric motor starting shall
generally conform to the following:

Motor KW (HP) Phase Starting Arrangement

Up to 0.7 (1) Single Direct-on-line (DOL)

Up to 1.8 (2.5) Single DOL (Fan Coil Units)

Up to 2.2 (3) Three DOL

Above 2.2 to 7.4 Three Soft-Starter or Star-Delta or

(Above 3 to 10) Auto-Transformer

Above 7.4 (10) Three Soft-Starter or Auto-Transformer

The contractor shall however select the correct ratings and starting arrangement for the
various components to suit their equipment, subject to the approval of the S.O. All
starting arrangement must comply with SESB’s requirement.

Star-Delta Starter (Open Transition) for motors up to 15 kw shall comply with BS

4941. The time for transition (switch-over time) from star to delta connection shall not
exceed 0.1 second.

The time relay (to indicate switch-over) shall have adjustable time setting.

Mechanical interlock shall be protected between the star contactor and the delta
contactor. The star contactor shall be of adequate size.

Star-Delta Starter (Close Transition) for motor up to 30 kw shall have resistance

banks suitable for four (4) or more starts per hour. Resistance banks shall be
mounted in a well ventilated separate enclosure with over temperature protection.

Other requirements, where applicable, shall be as specified in Star-Delta Starter

(Open Transition) above.

Auto-Transformer Starter shall comply with BS 4941 and BS 5856. The core shall
have three (3) windings.

For compressor motors up to 5kw, where star-delta starting cannot be arranged, the
auto-transformer shall be used and the tapping shall be at 70% on each windings of
the transformer core.

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For larger auto-transformer starters the tappings shall be at 50%, 65% and 80% on each
winding of transformer core.

The auto-transformer starters shall be suitable for four (4) or more starts per hour
and shall be fitted with thermistors, on for each phase.

Under Voltage Protection shall be provided for all electric motors of 30 kw and larger,
irrespective of starting arrangements, if the switchboard from which the motor is
connected has not been equipped with under-voltage cut-out.

1.10 Motor Soft-Starter

The soft starter shall be suitable for operation on a 3 phase, 415 V ± 10% supply of 50
Hz ± 2Hz. It shall be suitable for operation at full load in an ambient temperature of
50°C. The soft starter must be derated for ambient operating temperatures from 40 to
60 deg.C.

The enclosures shall have a degree of protection of IP 21 up to 132 kW and IP 20 for

150kW and above.

The soft starter shall limit the amount of interference to other equipment and shall
comply with AS/NZS 2064-1997 group 1 class A. The contractor shall state whether
there are certain operating modes where compliance cannot be met under Radio
Frequency Interference Emission.

The controllers shall be immune to interference from other RFI producing equipment
and shall comply with AS/NZS 4252.1 1994.

The soft starter shall have digital inputs for 2 and 4-wire start/stop and reset controls.

Three relay outputs shall be provided for remote monitoring of the controller.

The programmable options below shall be include as a minimum:

• Bypass contactor control or Run
• Main contactor control
• Alarm
• High Current Flag
• Low Current Flag
• Output On

All digital control inputs and outputs shall be galvanically isolated from the mains
supply.

The soft starter shall be constant current control type, which is able to limit the current
100% to 550% of the motor full load current and modulate the output voltage to
maintain this current during start.

The starter shall be able to be programmed to provide a current ramp start whereby the
initial start current, maximum start current, and ramp rates are all selectable.

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The soft starter shall have the facility to provide a torque boost during start up by
providing full output voltage for a period of 5 supply cycles (100ms on a 50Hz supply)
to break away the load before going back to the current controlled start.

The soft starter shall have up to 2 sets of independently adjusted parameters to allow
starting and protecting of two speed motors. Parameter sets should selectable via a
digital input.

The soft starter can provide motor temperature read out as calculated by the internal
Motor Thermal Model protection.

The soft starter shall be able to monitor the motor current (for motor protection) in by-
pass mode without extra thermal overload devices. The soft starter bypass power
terminals must be used.

The soft starter shall be equipped with a data log menu that will allow storage of at
least the last eight faults that have occurred.

The soft starter shall test for faulty SCR’s and shut down with an alarm if a fault is
detected.

The soft starter shall include as minimum the following protection and features :
• Electronic thermal overload protection
• Excess start time delay
• Instantaneous Overload
• Undercurrent
• Motor Thermistor input
• Phase Rotation
• Serial Communication

1.11 Overload Protection

All motor starters for drives 11 kw and above shall have 240V AC motor heater
outputs which are automatically energised when the main contactor is open.

Standard features on all starters shall be:

(a) Motor rated isolator

(b) HRC (motor starting characteristics) fuses or MCB as appropriate

(c) Control supply fuses

(d) Auxiliary field devices supply fuse

(e) Main air break contactor

(a) Running indication light

(b) Starter healthy (ie main motor protection made) indication light and relay

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MECHANICAL SERVICES
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(c) Start relay (110V AC)

(d) Starter test button (only enabled and accessible in test position)

(e) Latching stop button

(f) 110V AC supply for external control wiring (common supply for whole MCC).

(g) Hours run meter

(h) Control test switch

(i) Provision for local control station with latching stop button, local/remote switch
and start button

In addition to the equipment listed above each starter shall include the following
equipment related to motor rating.

(a) 2.2 kw and Below

An in-line thermal overload with front of panel reset; phase failure relay and
direct wired ammeter shall be provided.

(b) 2.2 kw to 7.5 kw Inclusive

As for item (a) single phase protection shall be provided.

(c) 7.5 kw and above

A current transformer operate electronic protection relay with overload,

single phasing and earth fault protection with front of panel reset, CT
operate ammeter and motor heater supply shall be provided. Thermistor
protection shall be provided for motor above 90 kw.

Auxiliary contacts shall be provided for the running and ready states, for fault
conditions, local selected, and from field devices as necessary. All indication
lights shall be press to test type.

Thermistor protection shall comprise PTC Thermistor sensors embedded in

the motor stator winding (one per phase). These sensors (ie a total of at least
three per relay) shall provide an alarm by operating the thermistor relay and
thereby disconnecting supply from the motor, at a tripping temperature as
recommended by the motor manufacturer for the class of insulation used.
Under no circumstances shall any control equipment associated with a particular
motor be subject to a second source of supply exceeding 32V when the motor is
isolated by means of its isolating switch. All damage resulting from overload,
single phasing or unbalanced conditions and earth leakage current or earth fault.
All relays shall be of approved manufacture.

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MECHANICAL SERVICES
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1.12 Switchboards

The switchboards/control panel shall be manufactured by an approved company

experienced in the manufacture of control switchboards for mechanical services.
Prior to manufacture, fully detail shop drawings shall be submitted to the S.O. for
approval.

The switchboard shall be equipped with automatic power-factor regulating systems

complete with status indicators. Anti-condensation heaters shall be provided.

The switchboard shall be completed in every respect and factory tested. Type test
certificate shall be submitted.

The incoming section of the switchboard shall be compartmented and in addition, be

equipped with voltmeter with selector switch, ammeter with selector switch and
power-factor meter.

1.12.1 Construction

Switchboard fabrication shall comply with the requirements of BS 5486 part 1,

Form 2. All switchboards shall be manufactured to type tested standards set by
ASTA or similar testing authorities. Certificate of approval from testing
authority shall be provided at the time of tendering.

The switchboard shall be of free-standing design and shall have a degree of

protection not less than IP44 as defined by BS 5490.

Switchboards shall be constructed from standard components using jig

assembly. Construction shall be of 2.5mm minimum thickness for front doors
and a minimum thickness of 2mm elsewhere. All sections shall be adequately
reinforced to enable site installation by lifting from above and to permit the
use of rollers for final location.

All doors shall be fully gasketed with neoprene gaskets. Gaskets shall be firmly
held in place by continuous metal retaining strips in addition to the adhesive.

Doors shall be of rigid construction suitably stiffened and formed with

minimum 15mm lipped edges.

Door hinges shall be chrome-plated pintle type, allowing a minimum door

swing of 165 degrees. The door shall have door lock, which can be opened by a
lock knob.

Internal hinged escutcheons shall be 3mm steel or 6mm perspex sheet, hinged
on the same side as the outer door. Hinges shall be chrome-plated pintle or
piano type. Escutcheons and doors providing access to 240 Volt AC equipment
and wiring shall be secured by 6mm captive screws or such other method
acceptable to the Supply Authority.

External doors and panels higher than 700mm shall incorporate three-point
fastening.

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The switchboard shall be mounted on a base constructed of 76mm high steel

channels. The channels shall be welded flush with the front and back of the
cubicle. Blank steel plates shall be welded at the base of the cubical, to cover
the channel ends.

Welding and painting of the base shall be carried out in accordance with the
relevant clauses below.

All joints shall be continuously welded. Reinforcing, retaining and similar

sections shall be welded to the main structure using fillet welds not less than 15
mm in length. Tack and or spot welding will not be permitted. All welds shall
be ground smooth and filled prior to surface treatment.

Vermin-proof ventilation grilles shall be provided at the sides and anti-

condensation heaters controlled by thermostats shall be installed with indicator
lamps.

Rubber mats of equal lengths to that of each floor standing switchboard shall be
supplied for each switchboard and shall be a minimum of 915mm and 25mm
thick installed at the front of each switchboard (and rear for near access
switchboards).

All floor-mounted cubicles shall be suitable for installation on a 100mm high,

concrete plinth. The whole of the cubical shall be shimmed level and bolted to
the floor. All openings into the cubical shall be sealed to prevent ingress of
moisture and vermin.

1.12.2 Finish

After fabrication all welds shall be ground smooth and filled prior to prime coat
painting.

The board shall then be painted as follows:

(a) Metal thoroughly degreased and then treated with phosphoric rust
inhibitor.

(b) Prime one coat Zinc Chromate primer.

(c) Undercoat one coat of synthetic resin primer.

(d) Rub down with wet and dry paper.

(e) Apply two finishing coats of first quality baked enamel, rubbing down
between coats.

All internal surfaces and the equipment chassis shall be finished in matt white
enamel. The external surface finish colour shall be light grey. A 500 ml
container of touch-up paint shall be delivered to site with the switchboard. The
paint shall be sourced from the paint that was used on the external surfaces of
the switchboards.

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1.12.3 Busbar Systems

The Contractor shall design, manufacture, supply, install and test all busbar
system within the boards as shown on the Specification Drawings and specified
below.

The switchboard busbars shall be of the low impedance type, rated 415 volts, 3
phase with full size neutrals. Continuous current rating shall be designed to suit
individual switchboard requirements. Busbars in the main switchboard shall
have a short circuit ratings as indicated on the Specification Drawings.

The busbars shall be of copper to BS 159 of uniform cross section area with
continuous rating as indicated in the drawings arranged horizontally or
vertically through the switchboard. The markings and disposition shall be to BS
159.

Busbars shall be mounted on non-hygroscopic insulators strong enough to

withstand all stressed as a result of thermal expansion or prospective fault
currents. All busbars penetrating compartments shall be suitably bushed.

Adequate busbar links shall be provided for coupling of each section of

switchboard and for future expansion. Busbars shall be identified with red,
yellow, blue and black plastic sleeves.

All earthing busbar of appropriate cross section shall run on the full length at
the base of the switchboard.

Busbars shall be unplated and designed for a maximum temperature rise above
ambient of 65oC.

Busway joints shall be supplied pre-assembled with fully prepared contact

surfaces, which are suitably protected against contamination. Clamping bolts
shall be fitted with high capacity Belleville washers and be of sufficient number
to ensure an even contact surface pressure of not less than 5.5 MPa.

Expansion joints shall be provided at sufficient intervals to ensure that thermal

expansion of the conductor cannot cause excessive mechanical loads on the
busway or its supports. In particular consideration shall be given to the thermal
expansion of vertical runs to ensure that mountings will be provided for
adequate support and movement under all operating conditions.

1.12.4 Wiring

All switchboard internal wiring shall be carried out using PVC insulated cables
in PVC wiring ducts. Wiring shall be colour coded as follows or as otherwise
required by the Supply Authority.

• Power wiring - applicable phase colour

• All neutrals - black
• Earth conductors - green
• LV control wiring actives - brown

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• ELV control wiring actives - grey

Power wiring shall be of 0.6/1 KV grade, V75 thermal rating, PVC insulated
stranded copper conductors minimum conductor size 2.5 mm2.

Control wiring shall be of 0.6/1 KV grade, V75 thermal rating, PVC insulated
stranded copper conductors minimum conductor size 1.5 mm2 complying with
BS 6500.

Equipment mounted on doors shall be wired with flexible PVC insulated cables,
of minimum section 1.5 mm2 complying with BS 6500.

Crimp pins or lugs shall be used on all terminations. No more than two (2)
conductors shall be terminated at any one terminal.

Special care shall be taken to ensure that:

(a) No strands are cut during cable stripping and crimping; and

(b) No un-insulated conductor is exposed where the wire enters lugs.

Rail mounted, double sided, tunnel-type terminal strips manufactured from

polyamide or approval equal shall be installed at low level in the board for
incoming and outgoing power and control wiring.

A separate terminal shall be provided for each incoming and outgoing

conductor. ELV and LV terminals shall be separated by barriers.

Incoming and outgoing cables shall enter and exit the board via cable glands.
Cable glands shall be mounted on removable or brass gland plates.

Terminal strips and wiring ducts shall be sized to allow for minimum 30% spare
capacity.

1.12.5 Neutral Links and Earth Bars

Separate main neutral links and earth bars of either brass or copper shall be
provided adjacent to the incoming and outgoing terminal strips. Each bar shall
be provided with sufficient suitably-sized terminals for all internal and external
earth or neutral connections plus a minimum of twenty (20) percent spare
terminals. A separate terminal shall be provided for each connection. The earth
bar shall be solidly earthed to the switched structure. The neutral link shall be
insulated from the switchboard structure and earth.

All instrument cases, gland plates, transformer frames, panel doors (which have
equipment mounted on them), metallic escutcheons, equipment chasses and
other exposed metal parts shall be connected to the main earth bar by PVC
insulated copper earth wire of minimum size.

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1.12.6 Identification

All electrical equipment supplied under this Specification shall be identified

with labels as specified and in accordance with the identification indicated on
the drawings. Where no such identification is shown on the Drawings, the
Contractor shall seek the S.O’s approval of labelling proposals.

All switchboards and equipment mounted on or within switchboards shall be

identified with labels.

All labels shall be fitted adjacent to (preferably above, but not directly on) the
particular item of equipment to which they apply, with the working horizontal.

Labels shall not be installed on wiring duct lids.

All labels shall be fixed with at least two chrome-plated screws per 80mm label
length. Self-adhesive labels will not be acceptable.

Unless specified otherwise elsewhere, all shall be of “traffolyte” or equivalent

and of the following colours:

• Identification labels and name plates : black lettering on white

background.

• Warning labels or labels associated with emergency conditions (eg.

“danger”, “emergency stop” and the like) : white lettering on red
background.

All wording on labels shall be in capital block letters.

Door or hinged panels and escutcheons which provide immediate access to

exposed low voltage wiring or terminals shall clearly labelled “Danger – 240
volts” in white lettering on red background.

Terminals shall be numbered and shall include link bars and group marker
identification etc as shown on the connection diagrams.

Wiring shall be identified as follows:

All power connections shall be identified at each termination with the

appropriate phase colour. All other wiring shall be identified with wire numbers
and/or colour coded in accordance with the Supply Authority’s requirements.

All ends of wires including neutrals shall be identified at each termination with
Critchley type “Z” interlocking full sleeve marker ferrules or equivalent.

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1.12.7 Switchboard Equipment

The following switchboard shall be used in switchboards to be provided by the

Contractor.

Where an item of equipment shown on the Specification Drawings or is

specified and is not listed below the Contractor shall seek S.O’s approval for the
particular brand and type selected for the application.

(a) Fuse Switches and Switch Fuses

The units shall be of the totally enclosed flush mounted chases type and
shall be of the double air-break, quick make and quick break action
suitable for on-load operation.

The fixed contacts shall be fully shrouded so as to ensure complete

isolation of the cartridge fuse links when the switch is in the open
position.

The ‘ON’ and ‘OFF’ positions shall be clearly indicated. The fuse
switch shall be lockable in the ‘OFF’ position.

Access to a switch unit shall be by the hinged door, or readily removable

bolted cover on the front panel. The door shall be fitted with dust proof
resilient grommets. An interlock shall be provided so that the door
cannot be opened with the switch in the ‘ON’ position or the switch
closed with the door open.

(b) Moulded Case Circuit Breakers (MCCB)

(i) General

MCCB’s shall comply with IEC 1571 : 1973 and BS 4752 : Part 1 :
1977. The breaking capacities of the circuit breakers shall be at least
equal to the prospective fault level at the point of the distribution system
where the breakers are installed, unless the limitation capacity of an
upstream breaker allow cascading. All MCCB’s shall be designed for
horizontal or upright mounting without any adverse effect on electrical
performance.

(ii) Construction

Operating mechanism shall be of the quick make quick break type, with
the speed of operation independent of the operator, and mechanically
trip free from the operating handle so as to prevent the contacts from
being held closed against short-circuit and overload conditions. The
operating mechanism shall be constructed to operate all poles in a multi-
pole breaker simultaneously during opening, closing and tripped
conditions.

The breakers shall be operated by a toggle, which shall clearly

indicate the three fundamental position ON, OFF and TRIPPED.

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If required, rotary handles shall be supplied.

The breaking and extinction of the electrical arc shall be achieved by

means of non-welding contacts and an arc chute surrounding these
contacts.

The breakers will have a positive break indication. In addition, they will
have a double insulation of the front face allowing the installation of
auxiliaries without insulating the unit.

All accessories and electrical auxiliaries such as shunt trip or under-

voltage release, auxiliary contact, motor mechanism shall be
manufactured in such a way that they can be easily adapted on the
installation premises.

The current limiting MCCB’ with very high breaking capacity shall be
made of two parts:

(1) A standard circuit breaker to break small and medium fault

currents

(2) A current limiter block to break and limit large short-circuit

currents.

The current limiter block shall be of electromechanical type (fuse free)

and factory fitted to the standard breaker.

(iii) Operation

Each pole of the MCCB shall be provided with bi-metallic thermal

element for inverse time delay protection and magnetic element for
short-circuit protection. The thermal release shall be of the adjustable
type and could be equipped with sealing facility.

MCCB’s of 100 A size and above with thermal magnetic trip unit will
be provided with interchangeable trip unit.

Above 400 A, the trip unit could be of the solid state energised by
internally mounted current transformer. It shall not require any external
power supply to operate the tripping mechanism.

Current discrimination tables showing overload and short-circuit

discrimination shall be provided for each rating of breaker.

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Where earth leakage relay is specified, it should be a module to be

attached to the MCCB units. No auxiliary supply shall be required.
The sensitivity and total trip time, which are adjustable, shall be as
follows:

S1 S2 S3
(1) Sensitivity (A) 3 10 30

T1 T2
(2) Trip Time (mS) 170 390

(c) Contactors

Contactors shall comply with the requirements of BS 5424 and 764

except where varied in this document and supplied for the required
applications, which are:

(i) Disconnecting
(ii) Bulk Switching

Each unit shall be suitable for AC3 utilisation category with contacts
suitable for the required currents (It shall be noted that the rating of the
contacts for disconnection duties shall be such as to avoid welding under
fault conditions).

All units shall be suitable for uninterrupted duty, block type with
contacts, which may be readily replaced and accommodated within the
switchboard enclosure.

Auxiliary contacts of minimum 10A rating, of the quantity as indicated,

together with at least one set of normally open and one set of normally
closed contacts shall be provided which shall be wired to the terminal
board. If it is impracticable to equip the contactor with sufficient
auxiliary contacts, auxiliary relays shall be installed. Contactors shall
have a making capacity of 10 times the rating and have at least 1 million
operations life span.

(d) Fuses

Fuses shall be of the interchangeable cartridge type having a capacity of

not less than 31 MVA at 440 volts AC to BS 88.

The heavy duty fuse switches must be fully comply with BS 5419 with
short-circuit of 65 KA, 550V.

(e) Instruments

Instruments and meters shown on individual panels shall be flush-

mounted, square or rectangular type with moulded plastic escutcheons
complying to BS 89 and shall conform to the requirement shown on the
drawings.

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(f) Current Transformers

Current transformer necessary for protection, measuring and metering

shall comply with latest British Standard Specifications and shall have
accuracies of Class ‘1.0’ for measuring and Class 5P10 for protection.
They shall be adequately rated and shall be capable of carrying currents
of the corresponding circuit breakers and fuses. They shall be capable
of operation, without damage, with open circuit secondary and full-load
current flowing in the primary.

(g) Protective Devices

Over-current tripping device with setting adjustable between 50% to

150% of approved load and a maximum operating time of 3 seconds at
200% of the setting.

Each fault relay set at 10% CT ratio with instantaneous operation.

The overall earthing resistance should not exceed 1 ohm.

1.12.8 Cable Joints

Crimped cable lugs should be used for jointing cables. Lugs shall be affixed to
cable by means of a crimping tool as recommended by the manufacturer using
the correct pressures.

1.12.9 Earthing

All units shall be efficiently bonded and connected to the earth bar. The earth
bar shall consist of a 25mm x 3mm thick hard drawn high conducting copper
busbar running the full length of the switchboard. The earth bar shall be suitably
labelled to the satisfaction of the S.O.

1.12.10 Rating Plates

Small rating plates giving serial numbers and data in accordance with the
relevant British Standards are required on equipment supplied, namely: Circuit,
Breakers, Fuse Switches, Isolators, Current Transformers, etc.

1.12.11 Type Tests

Type tests certificates issued by recognised testing authorities shall be submitted

for all switchgears to the S.O.

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1.12.12 Factory Tests

Factory inspection and performance test shall be carried out for all
switchboards.

The test shall be witnessed by the following personnel:

• 1 representative from UEM

• 1 representative from the M&E Consultant

The Contractor shall be responsible for all cost involved for the factory
inspection and performance test as detailed above. The Contractor shall witness
the factory test together with the manufacture, UEM and Consultant.

The Contractor shall submit certified test sheets showing details of all routine
tests conducted during manufacture of switchboards and individual components
thereof.

1.12.13 Delivery Tests

After the equipment has been erected on site and before final connection to the
supply, the Contractor shall with his own instruments and at his own expense,
and to the satisfaction of the S.O., carry out all test necessary to demonstrate
that the equipment complies with the requirements of this specification.

The tests to be conducted shall be as follows:

(a) Demonstration that all equipment are installed and all wiring connected,
so that the switchboard functions as required.

(b) Tests for accuracy of all measuring instruments.

(c) Insulation resistance between phase, between each phrase and neutral,
and between each phase, neutral and earth with the circuit breaker
closed.

(d) Insulation resistance across breaks in all circuit breakers, with the
breaker open and all equipment installed.

(e) Setting of overcurrent and earth fault protection relays on circuit breaker
in accordance with the requirements of the Electricity Supply Authority.

Copies of test sheets showing the results of all tests carried out in accordance
with this section of the specification shall be submitted to the S.O.

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1.12.14 Main Single Line Diagrams

The Contractor shall provided a main single line diagram indicating details of
main switchboard, sub-mains, rising mains, tap-off units and distribution
boards. All drawings shall be framed in a glass panel and mounted at an
appropriate position acceptable to the S.O.

1.12.15 Floor Mats

The Contractor shall supply floor mats of rubber material without perforation to
be minimum 900mm wide 6mm thick extended to the full length of each
switchboard.

1.12.16 Automatic Power Factor Correction Equipment

(a) General

The Contractor shall supply and install automatic power factor

correction equipment of capacity as indicated on the drawings for the
chiller switchboard.

(b) Power Capacitors

The power capacitors shall be tropically rated type suitable for operation
in average temperature of 45 degree C and shall conform to BS 1650.

The power capacitors shall be suitable for a supply voltage of 415 volts
phase to phase and 240 volts phase to neutral at a supply frequency of 50
Hz with a tolerance of 20%.

The impregnant and filling used in the capacitors shall be non-

flammable, non-explosive liquid, possessing excellent insulation and
dielectric properties including high insulation resistance and high
dielectric constant. The material shall be chemically stable ie. it shall not
oxidise or sludge under the most severe conditions of operating
temperature.

The capacitor shall be designed to withstand at least the following

harmonic contents in the system:-

- Third Harmonics - 7%
- Fifth Harmonics - 7%
- Seventh Harmonics - 7%
- Nineth Harmonics - 4%
- Eleventh Harmonics - 3%

The electrodes shall be made of commercially pure aluminium foils free

from all rolling lubricants.

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A continuously rated, low loss discharge device shall be incorporated in

all capacitors. This shall ensure that the capacitor is discharge from peak
alternating voltage to a voltage not exceeding 50 volts, measured at the
capacitor terminals, one minute after disconnection from the supply,
Capacitors losses shall not exceed 3 watts per KVAR of capacitor rating.

(c) Capacitor Containers

The containers of power capacitors shall be fabricated from heavy

tinplate or stainless steel and shall be hermetically sealed to prevent
leakage of filling or ingress of moisture. The containers shall be coated
with a zinc chromate primer and a heavy coat of an enamel paint.
Capacitor shall be fitted with overpressure disconnector as safety
measure in case of over voltage, in rush current peak and harmonics.

(d) Control Equipment

The control equipment shall be of ASCOM Frako or equivalent. It shall

be such that the various capacitor units shall automatically step into the
load in various stages as the power factor worsen and will automatically
stop when the present value of system power factor has been reached.

The automatic Power factor correction multistage relay shall be of the

Var (reactive VA) sensitive type with power factor adjustment. The
power factor adjustment feature shall be adjustable between 0.80 lag and
unity and shall be set at voltage reset feature which prevents all the
capacitor stages being switched in up restoration of the electricity supply
after a mains failure.

Indicator lamps shall be provided to indicate the number of steps that

have stepped in. Power ‘ON’ indicator lamps shall also be provide.

Power factor correction relays shall have a minimum capacity for

switching six steps of capacitors automatically and shall have six step
indicator lights. Space provisions shall be made at switchboards to
enable installation of six capacitor units per bank.

The unit shall measure the 3rd, 5th, 7th, 9th, 11th and 13th harmonics
content on the supply voltage and current.

(e) Display

The following LED displays shall be provided for the control

equipment:

(i) Power Factor ‘ON’

(ii) Reactive Current (Ampere)
(iii) Active Current (Ampere)
(iv) Apparent Current (Ampere)
(v) Harmonic

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1.12.16 Harmonic Filter

The Contractor shall ensure that all the electrical equipment supplied in this
contract shall not be allowed to introduce any odd harmonics to the system. If
any of the harmonic content exceed five percent, the Contractor shall be
required to install harmonic filters at the nearest sub-switchboards or at the main
switchboard as determined by the S.O.

1.12.17 Testing and Commissioning

Before the switch on of power visually check all connections and equipment
then carry out the following checks:

- Check all terminations for tightness.

- Check capacitors for leaks. Replace any that are leaking.

- Operate contactors by hand to see that they are free.

- Test systems for insulation resistance.

- Check that contactors are of the latching type.

- Check that staging of power factor correction capacitors to as specified

and sufficient stages are provided.

- Check earthing complete.

- Isolate power factor correction before switch on of power.

- Check all equipment labelled and drawings provided.

After switch on of power

- set correction to a minimum.

- connect correction to power

- Increase correction gradually until each stage is operating. Check

contactors are closing and indicator lamps operating. If some stages will
not operate when connection is set to maximum prevent early stages
contactors from closing to force later stage capacitors to be connected to
the system.

- Measure and record power factor at start of test and as each stage is
connected. Include results of the tests in the Operation and Maintenance
Instruction Bulletin. Advise the M&E Engineer if with all correction in
circuit power factor does not exceed 0.86 lagging. Record load current at
each stage.

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- Measure and record current in main neutral conductor at start of test and
as each stage of correction is connected. Advise M&E Engineer of any
significant increase in neutral current as this may indicate harmonic
currents particularly third harmonics, which may cause damage to the
equipment.

- Check contactors and capacitors for signs of heat, excessive noise and
odour, which could indicate an electrical fault.

- Repeat checks of power factor staging and neutral current measurement

after one month and six months operation and record results together
with load current at each stage.

- Include results of all tests in the operation and maintenance instruction

bulletin.

Oct’ 08