USPM/16B (July 2012)

JABATAN KERJA RAYA MALAYSIA

UNIT STANDARD, PENGUJIAN & MAKMAL AKREDITASI CAWANGAN KEJURUTERAAN ELEKTRIK IBU PEJABAT JKR MALAYSIA
TECHNICAL INFORMATION ON LOW VOLTAGE SWITCHBOARD MANUFACTURER A. COMPANY A1. Name of Company A2. Address

: :

A3. Factory Address (If different to A2)

A4. Company Email Address A5. Telephone No. A6. Fax No. A7. Registration with Local Authority :

: : :
(for JKR use)

Yes

No

(Note: To attached a copy of Local Authority Registration/License) 7.1. Registration/License No. : 7.2. Registration Due Date :

A8. Suruhanjaya Tenaga Registration (Note: To attached a copy of ST Registration Certificate) 8.1. 8.2. 8.3. Registration No. Registration Due Date Voltage Restriction : : :

A9. Type Test/Partial Type Test/Verification Test (If Any) (If yes, please complete Section C2) A10. ISO Certified Company? (Note: To attached a copy of Company ISO certificate) If Yes, Certification No Standard No. If Yes, Scope of Certification Certification Due Date : : : :

Yes

No

Yes

No

Page 1 of 8

USPM/16B (July 2012)

B. B1.

COMPETENT PERSONNEL (Note: To attached copy of competency certificate) Designer : : :

(for JKR use)

Yes

No

B1.1. Name B1.2. Qualification B1.3. BEM Reg. No. (If Any)

B1.4. Copy of Competency Certificate:Attached? B2. Chargeman : : :

Yes Yes

No No

B2.1. Name B2.2. Restriction B2.3. Competency Certificate No.

B2.4. Competency Certificate Copy: Attached? B3. Wireman : : :

Yes Yes

No No

B3.1. Name B2.2. Restriction B2.3. Competency Certificate No.

B2.4. Competency Certificate Copy: Attached? C. C1. SWITCHBOARDS COMPLIANCE

Yes

No

C1.1. SURUHANJAYA TENAGA C1.2. MS IEC 60439-1 C1.3. IEC 60439-1 C1.4. MS IEC 61439-1 and 2 C1.5. IEC 61439-1 and 2 C1.6. IEC 60439-5 C1.7. Others (please state) C2. :

Yes Yes Yes Yes Yes Yes

No No No No No No

TYPE TESTED/VERIFICATION TEST (Note: i) New Application - To enclosed copy of Certificate and Complete Test Report ; ii) Renewal Application - To enclosed Certificate and front page of Test Report ) Yes No

C2.1. Type Test / Partial Type Test (If yes, please complete section C2.7) C2.2. Verification Test (If yes, please complete section C2.8) C2.3. Name of Testing Lab : Page 2 of 8

Yes

No

USPM/16B (July 2012)

C2.4. Certificate No

C2.5. Reference Standard

C2.6. Clause/Clauses

C2.7. For Type Test/Partial Type Test Report of Switchboard only, as per MS IEC 60439, please complete table below. Current Rating (A) >600 and >2000 and <3150 <2000 Yes / No Yes / No Yes / No Yes / No

Clause

Verification Of:

<600 Yes / No Yes / No

>3150 Yes / No Yes / No

8.2.1 8.2.2 8.2.3

Temperature Rise Limit Dielectric Properties Short Circuit Withstand Strength: a. 50kA for 1sec b. 30kA for 1sec

Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No

Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No

Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No

Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No

8.2.4 8.2.5 8.2.6 8.2.7 8.2.8

Continuity of Protective Circuit Clearance and Creepage Distance Mechanical Operation Degree Of Protection Electromagnetic Compatibility (EMC) Test

Yes / No

Yes / No

Yes / No

Yes / No

8.2.9

Resistance of Insulating Materials to Abnormal Heat and Fire

Yes / No

Yes / No

Yes / No

Yes / No

(Note: Circle Yes/No where applicable)

Page 3 of 8

USPM/16B (July 2012)

C2.8. For Verification Test Report of Switchboard by testing only, as per MS IEC 61439, please complete table below.
Clauses or Subclauses Characteristic to be verified: <600 Current Rating (A) >600 and <2000 >2000 and <3150 >3150

10.2 10.2.2 10.2.3 10.2.3.1 10.2.3.2 10.2.3.3 10.2.4 10.2.5 10.2.6 10.2.7 10.3 10.4 10.4 10.5 10.5.2

Strength of material and parts: Resistance to corrosion Properties of insulating materials: Thermal stability Resistance of insulating materials to normal heat Resitance to abnormal heat and fire due to internal electric effects Resistance to ultra-violet(UV) radiation Lifting Mechanical impact Marking Degree of protection of enclosures Clearances Creepage distances Protection against electric shock and integrity of protective circuits: Effective continuity between the exposed parts of the ASSEMBLY and the protective circuit. Effectiveness of the assembly for external faults Incorporation of switching devices and components(verification by design rules) Internal electrical circuits and connection (verification by design rules) Terminals for external conductors (verification by design rules) Dielectric properties: Power-frequency withstand voltage Impulse withstand voltage Temperature-rise Short-circuit withstand strength Electromagnetic compatibility (EMC) Mechanical operation Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No

10.5.3 10.6

10.7 10.8 10.9 10.9.2 10.9.3 10.10 10.11 10.12 10.13

Yes / No Yes / No

Yes / No Yes / No

Yes / No Yes / No

Yes / No Yes / No

Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No

Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No

Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No

Yes / No Yes / No Yes / No Yes / No Yes / No Yes / No

(Note: Circle Yes/No where applicable) Page 4 of 8

USPM/16B (July 2012)

D.

TESTING EQUIPMENT AND MACHINERY (Note: To attached proof of ownership for New Application) D1. TESTING EQUIPMENT (Note: i) To attached calibration certificate; ii) Testing Equipment shall be calibrated yearly)
(for JKR use)

D1.1. PRESSURE TEST EQUIPMENT/ WITHSTANDING VOLTAGE TESTER i) ii) iii) iv) v) vi) Brand Model Serial No. Max. of AC Testing Voltage Name of Calibration Lab Calibration Due Date : : : : : :

Yes

No

Vac

D1.2. INSULATION RESISTANCE TESTER i) ii) iii) iv) v) vi) D2. Brand Model Serial No. Max. of DC Testing Voltage Name of Calibration Lab Calibration Due Date : : : : : :

Yes

No

Vdc

MACHINERY Yes : : : Yes : : : Yes : : : No No No

D2.1. CUTTING MACHINE i) ii) iii) Brand Model Serial No.

D2.2. PUNCHING MACHINE i) ii) iii) Brand Model Serial No.

D2.3. BENDING MACHINE i) ii) iii) Brand Model Serial No.

Page 5 of 8

USPM/16B (July 2012)

E. E1.

SWITCHBOARD CONSTRUCTION REQUIREMENTS/SPECIFICATION Please fill form CKE.ITP.01.35.(00).2012 - FACTORY ACCEPTANCE TEST - CHECKLIST FOR VISUAL INSPECTION OF LOW VOLTAGE SWITCHBOARDS: (for JKR use) Form CKE.ITP.01.35.(00).2012 completed and attached? Yes No To attached Busbar Mill Certificate. PARTS LIST FOR SWITCHBOARD Yes Yes No No

E2. F.

Manufacturer shall only use material approved by Cawangan Kejuruteraan Elektrik IPJKR Malaysia as follows: a. Circuit Breaker b. Protection Relay c. Fuse Switch d. Surge Protective Device e. Capacitor for P.F Correction f. Power Factor Regulator g. Residual Current Device h. Isolator i. Switching Contactor j. Cable (Note : This list of mandatory items is not limited to this as it will be upgrading from time to time.) The list of approved material can be access via EMAL website: i. http://www.jkr.gov.my (click EMAL (Electrical Material Approval List) at column 'For The Public') or ii. http://ict01.jkr.gov.my/emal G. G1. SWITCHBOARD TEST CERTIFICATE Does Every Switchboard Produced has a Switchboard Certificate?

Yes

No

G2.

Sample of Switchboard Test Certificate attached: Yes No ( Note :Routine Test : 1) The main and the auxilliary circuits shall be tested to verify dielectric properties with power frequency test voltage of 2500Vac for 1 minute and insulation resistance under test voltage of 1000Vdc; 2) Wiring, operational performance and function.) FACTORY AND QUALITY CONTROL.

H. H1. H2. H3.

Name of person in-charge of factory and QA/QC

: Yes Yes Yes No No No

To enclosed floor layout of the factory/assembly line To enclosed flow chart c/w colour picture of the whole manufacturing process All process is done at factory as per declared address?

H4.

H4.1. If No, please list and attached agreement with particular third party. Name of Process Agreement attached? H5. Routine Test and Acceptance Criteria Page 6 of 8 : Yes Yes No No

USPM/16B (July 2012)

I.

SWITCHBOARD DRAWING (Note : Switchboard shall be designed to meet JKR specification) I1. To enclosed detail drawings as per JKR specification and best practice (including side view, top view, details view,etc) which clearly state the dimension and detail construction of the switchboard on A3 size.

(for JKR use)

Yes

No

J.

Any other information need to be highlighted by manufacturer? Please state below:

K.

MANUFACTURER'S DECLARATION I .. hereby declare that all information in (name) this form given by me regarding my company and my product is true, nothing false except all of them is true. I also declare that I will design and construct my product as per JKR specification and best practice as request by S.O's Representative. If I, in any condition have been found given false information or declaration, an action can be taken by JKR including denying my application or withdrawing my registration. Company Official Stamp: Signature Name Position Date : : : :

Note: This checklist is developed from L-S1, SPECIFICATION FOR LOW VOLTAGE INTERNAL INSTALLATION - Revision No.2 May 2011 - Section 2.0 as per attachment. Also attached is form CKE.ITP.01.35.(00).2012 (to be completed by applicant, stamped company and initial on every page).

Page 7 of 8

USPM/16B (July 2012)

JKR'S COMMENT:

JKR Officer's Signature

(JKR Officer's official stamp here)

Date

For JKR processing officer, to be filled as follows:

Comply

Not Comply

Page 8 of 8

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION (L-S1) SECTION: 2.0

CKE.LS.01.01.(02).2011

Date: April 1999 Revision: 2

SWITCHBOARDS Date: May 2011 Page: S2 - 1 of 10

2.1 TYPES OF SWITCHBOARD 2.1.1 The types of switchboard shall be as specified in the Bill of Quantities and/or Drawings and shall be of the following types: 2.1.1.1.1 Self-contained, floor mounted, flush fronted, metalclad cubicle type suitable for front and rear access; Self-contained, floor mounted, flush fronted, metalclad cubicle type suitable for front access; Wall mounted metalclad type suitable for front access.

2.1.1.1.2

2.1.1.1.3

2.1.2

The switchboards shall house their air circuit breakers, moulded case circuit breakers, fuse switches, switch fuses, isolators, contactors, busbars, meters, protective relays, selector switches, indicating lamps, current transformers, cable terminating boxes, cable glands, anti-condensation heaters complete with automatic thermostats and isolators and all other necessary items of equipment whether specified hereinafter or in the Drawings or not, suitable for operation on a 240/415V, 3 phase, 4 wire, 50Hz. system with solidly earthed neutral. Unless otherwise specified elsewhere, the switchboards shall be capable of withstanding fault condition of not less than 50kA at 415V for 1 second as defined in MS IEC 60439-1. The switchboards shall comply with MS IEC 604391 and the degree of protection shall be IP41 in accordance to MS IEC 60529.

2.1.3

Outdoor switchboards shall also comply with MS IEC 60439-5 with protection degree of IP54 in accordance to MS IEC 60529.

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION (L-S1) SECTION: 2.0

CKE.LS.01.01.(02).2011

Date: April 1999 Revision: 2

SWITCHBOARDS Date: May 2011 Page: S2 - 2 of 10

2.1.4 Type testing for switchboard as per categorization shall be as per Table 2A below: Category I II Current Rating I 600A 600A < I 2000A Registration & Type Test Report Suruhanjaya Tenaga Suruhanjaya Tenaga & Partial Type Test accordance with MS IEC 60439-1 (i) Short Circuit Test (Clause:8.2.3) (ii) Temperature Rise Test (Clause:8.2.1) Suruhanjaya Tenaga & Full Type Test accordance with MS IEC 60439-1

III

I > 2000A

Table 2A : Type testing for switchboard as per categorization 2.1.5 Routine tests on the switchboard shall be carried out before delivery to site. The main circuits and the auxiliary circuits shall be tested to verify dielectric properties with power-frequency test voltage of 2500Vac for 1 minute and insulation resistance under test voltage of 1000V. Routine tests shall include inspection and checking of wiring, electrical continuity of the protective circuits, connections and effectiveness of mechanical actuating elements and interlock. Test Results or Certificate duly certified by Competent Person as in Electricity Regulations 1994 shall be issued for every switchboard supplied and installed.

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION (L-S1) SECTION: 2.0

CKE.LS.01.01.(02).2011

Date: April 1999 Revision: 2

SWITCHBOARDS Date: May 2011 Page: S2 - 3 of 10

2.2 2.2.1

ENCLOSURES SELF-CONTAINED FLOOR MOUNTED CUBICLE SWITCHBOARDS

2.2.1.1 The framework of the switchboard shall be fabricated from rolled steel sections of thickness not less than 2.5mm and shall be self-supporting when assembled, uniform in height and depth from front to back. The rigid construction shall be designed to withstand without any sag, deformation or warping, the loads likely to be experienced during normal operating, maintenance or maximum fault condition. 2.2.1.2 The front shall be provided with covers/doors of box formation. The rear shall be provided with hinged removable doors of box formation. The rear doors shall be of double-leaf type with rebated edges and each leaf should preferably not be wider than 450mm. Each leaf of door shall have two (2) pairs of approved hinges. The door shall be fitted with approved type of surface-mounted espagnolette or cremone bolts complete with approved locking device operated by a satin chrome lever handle at the centre fixing. The top and sides shall be of removable panels. 2.2.1.3 Cover plates with openings for cable entry shall be provided at the base of the switchboard. All panels, covers and doors shall be fabricated from sheet steel of thickness not less than 2.0mm and so constructed as to provide a clear, flush and pleasing appearance. The panels, covers and front doors shall be secured to the enclosure by means of chromed type of screws with cylindrical knurled head complete with retaining clips. Welded cross struts shall not be used. 2.2.1.4 The switchboard shall be dust and vermin proof. All covers and doors shall be provided with grommets and dust seals to exclude dust and dirt. Louvres or ventilation vent with filter shall be provided at the sides and back for adequate ventilation. Precaution shall be taken to prevent overheating due to hysteresis and eddy current using non ferrous plate (for single core cable). All edges shall be rounded. Serrated star washers shall be fitted to ensure satisfactory earthing of the front cover.

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION (L-S1) SECTION: 2.0

CKE.LS.01.01.(02).2011

Date: April 1999 Revision: 2

SWITCHBOARDS Date: May 2011 Page: S2 - 4 of 10

2.2.1.5 The switchboards shall be of Form 2b and comply with MS IEC 60439-1. The busbars shall be separated from the switchgears/functional units and the incoming and outgoing terminals. The form of separation shall be achieved by metallic or non-metallic rigid barriers/partitions. All switchgears shall be mounted so as to give adequate clearance for cable and busbar connections. 2.2.1.6 Switchgears shall be mounted on insulation runners where connected to busbars and on steel supports where cable connection are made. The insulation runners shall be of minimum 10mm thickness and mounted on steel support or back panel of the enclosure whichever is more appropriate. 2.2.1.7 Cables connection between the busbars and the switchgears shall be neatly arranged and mounted on cable runner. The terminals of the switchgears for external cable connections shall be at least 200mm above the base of the switchboards and, moreover, so placed that the cables can be easily connected to them. Withdrawable type of switchgears shall be mounted on the framework assembly, including the runner rails and fixed rear isolation contacts, which shall be supplied as a part of the switchgear assembly. Each withdrawable switchgear shall be housed in its own compartment with rear connected busbars. 2.2.1.8 All indicating instrument which need to be read by the operator shall not be located higher than 2m above the base of the switchboard. All operating devices such as handle, push buttons, etc., shall be located at such a height that they can easily be operated, and in general, the centerline shall not be higher than 2m above the base of the switchboard. In the case where building automation devices, transducers and relays are provided, they shall be separately housed in a compartment of the section of the switchboard. All wiring from the devices, transducers and relays shall be neatly arranged and connected to the terminal blocks with removal links mounted on rail. Terminals shall be identified and labelled in accordance with IEC 60445.

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION (L-S1) SECTION: 2.0

CKE.LS.01.01.(02).2011

Date: April 1999 Revision: 2

SWITCHBOARDS Date: May 2011 Page: S2 5 of 10

2.2.1.9

Where surge protective device is specified, the device and its associate equipment shall be totally compartmentalized with clear transparent cover at immediate lower subsection where the incoming switchgear is connected. A lockable tool compartment with keys and opening handle shall be provided at the lowest subsection of the switchboard. The switchboard shall undergo derusting treatment, anti-rust treatment with the exterior finished with epoxy drypowder and oven baked semi-gloss beige colour and interior finished matt white. The switchboard shall be bolted to mild steel channel base or over concrete trench. The channel shall be anti-rusted and painted with a primer. There shall be a readily installed cable tray on the interior of both side panels for outgoing cable. All cables shall be rigidly secured using cable support bracket of non rotting material, before termination.

2.2.1.10 Where top entry is specified or required, there shall be a readily installed cable box for top entry cable. 2.2.1.11 Where the incoming feeder circuit breaker in the switchboard is 2500A and above, the switchboard shall be equipped with an arc protection system. The arc protection shall be installed against the internal arc in the switchboard in order to improve personnel safety to minimize damage to the switchgears in case of internal arc faults, thus improving the availability of the electricity service. The arc protection shall be integrated with protection relays or of stand alone type. The relays shall be in accordance to the requirements in Section 5.0. Only a simultaneous occurrence of over-current and arc incidence(s) shall activate the trip signal in the relay.

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION (L-S1) SECTION: 2.0

CKE.LS.01.01.(02).2011

Date: April 1999 Revision: 2

SWITCHBOARDS Date: May 2011 Page: S2 6 of 10

2.2.1.12 Arc sensors shall be mounted in the switchboard. The arc sensors for detecting the arc shall be of photo transistor or lens sensors. The arc sensors shall in practice be installed within the cable compartment of the outgoing feeder, main incoming circuit breaker and busbar compartment. The arc protection system shall include a self-supervision function covering all equipment, including the arc sensors. All internal faults shall be indicated on the arc protection unit and an alarm contact shall be activated. The arcmonitoring unit shall contain a display capable of indicating the exact compartment of the fault after the tripping. 2.2.1.13 All outgoing MCCBs in the switchboard where the incoming feeder circuit breaker is rated 400A and above shall be provided with panel mounting external operating handle with padlocking facilities.

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION (L-S1) SECTION: 2.0

CKE.LS.01.01.(02).2011

Date: April 1999 Revision: 2

SWITCHBOARDS Date: May 2011 Page: S2 - 7 of 10

2.2.2

WALL MOUNTED SWITCHBOARDS

2.2.2.1 The switchboard shall be fabricated from sheet steel of thickness not less than 2.0mm. The enclosure shall be of all welded construction with sheets bent where possible so as to minimise the number of welded joints. The four sides of the enclosure shall be returned at the front to facilitate fixing of front cover plates. The front cover plates or doors shall be of box formation and flanged to facilitate fixing to the enclosure. 2.2.2.2 The front cover of the switchboard shall be provided with grummets and dust seal to exclude dust and dirt. Meshed louvre or ventilation vent with filter shall be provided at both sides for ventilation. All edges shall be rounded. Serrated star washers shall be fitted to ensure satisfactory earthing of the front cover. The switchboard shall undergo de-rusting treatment, anti-rust treatment and be finished with epoxy dry-powder and oven baked semi-gloss beige colour. 2.2.2.3 The switchboard shall not be mounted directly to the wall or structure. It shall be firmly bolted/welded on to galvanised C-channel brackets which in turn shall be bolted to the wall or structure by means of bolts and nuts. The top of the switchboard shall not be higher than 2100mm and the bottom shall not be lower than 900mm from the floor.

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION (L-S1) SECTION: 2.0

CKE.LS.01.01.(02).2011

Date: April 1999 Revision: 2

SWITCHBOARDS Date: May 2011 Page: S2 - 8 of 10

2.3 2.3.1

BUSBARS Busbars shall conform to BS EN 13601 and shall be tinned hard drawn high conductivity copper with an adequate uniform rectangular cross section to carry continuously their rated current without overheating. They shall be rigidly mounted on non-hygroscopic insulators so as to withstand any mechanical stresses to which they may be subjected under maximum fault condition. Busbar sizes must not be less than that specified in the Drawings. However if the busbar sizes are not specified, then the busbar rating shall be based on a current density of not more than 1.5 A/sq. mm. In any case, the main busbars rating shall not be less than the rating of the incoming switchgear (In). All busbars whether horizontal or vertical, shall be of the same size. The main busbars shall be run for the full length of the switchboard without reduction in size. Neutral busbar shall be of full size and full length as the phase busbars. Connections shall be made up with bronze or other copper alloy bolts and nuts utilising tension washers on both outer faces. Where multiple parallel bars are used, they shall be separated by tinned copper spacers at spacing equal to the busbar thickness. The main busbar shall be arranged in a horizontal plane in the order neutralblue-yellow-red, viewed from the rear of the switchboard. Busbars shall be painted at appropriate points with colours red, yellow, blue and black to denote the phases. Tinned copper earthing bar of cross sectional area not less than 50mm x 6mm shall run along the switchboard for its entire length. This switchboard earthing bar shall be fastened and bonded at the base to each vertical frame member of the switchboard. At least one earthing bar of similar cross sectional area shall run the full height of the switchboard and connected to the main earthing bar. All earthing bars shall be identified with green and yellow (twin-coloured) colour.

2.3.2

2.3.3

2.3.4

2.3.5

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION (L-S1) SECTION: 2.0

CKE.LS.01.01.(02).2011

Date: April 1999 Revision: 2

SWITCHBOARDS Date: May 2011 Page: S2 - 9 of 10

2.3.6

Distribution busbars shall be sized in accordance with the maximum outgoing switchgear rating. Connections from busbars to the switchgears shall be effected by means of copper conductors securely clamped to the busbars and colour coded to identify the phase and neutral conductors. Copper conductor either bare tinned busbars or insulated cable shall be rated in accordance with the current rating of the switchgear. Neutral conductor shall be of full size as phase conductor. Coloured cable sleeve shall be shrouded for cable end termination. METER PANELS The metalclad, mild steel or other approved material (with thickness not less than 1.5mm) meter panel of box formation shall be installed adjacent to, but physically separated from the main switchboard. Suitable flexible and/or rigid galvanised steel conduit with approved adaptors shall be supplied and fitted between the main switchboard and the meter panel. The design, construction and method of installation of the meter panel shall be to the requirement of Supply Authority or Licensee.

2.4 2.4.1

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION (L-S1) SECTION: 2.0

CKE.LS.01.01.(02).2011

Date: April 1999 Revision: 2

SWITCHBOARDS Date: May 2011 Page: S2 - 10 of 10

2.5 2.5.1

OTHERS All secondary wiring shall be of not less than 1.5 sq. mm. section insulated with PVC and shall be fixed securely without strain by cleats of the compression type. All screws, locknuts, washers, bolts etc. shall be of copper alloy type. Indicating lights shall be long life coloured LED type. All indicating lights shall be adequately ventilated and easily be replaced from the front of the panel without the use of extractors. Instruments, meters, relays, protective fuses etc. located on the front of the switchboard shall be so positioned that as far as possible, each instrument, meter, relay, protective fuse etc. is adjacent to the unit which it is associated. All relays shall be of heavy duty type, unaffected by external vibration and capable of operation in any position. All instruments, meters, relays, equipment etc. shall be fully tropicalised. One number approved anti-condensation heater shall be installed for every two sections at the switchboards. Each heater shall be complete with automatic thermostat control, ON-OFF switch and indicating lamp. Engraved labels with white lettering on a black background shall be fastened or riveted on the front panels of each switchgear and item of equipment. The wording shall be approved by the S.O.'s Representative. Engraved name plate showing the relevant earth fault setting, overcurrent setting, currenttransformer ratio, fuse rating, name of the circuit to which it is connected, etc. shall be fixed to switchgear panels to which it refers.

2.5.2

2.5.3

2.5.4

2.5.5

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION (L-S1) SECTION: 3.0

CKE.LS.01.01.(02).2011

Date: April 1999 Revision: 2

DISTRIBUTION BOARDS AND CONSUMER UNITS

Date:

May 2011

Page: S3 - 1 of 2 3.0 3.1 DISTRIBUTION BOARDS All Distribution Boards (metalclad and all insulated) shall be installed at locations indicated in the Drawings or as directed by the S.O.'s Representative. The Distribution Boards shall be assembled by licensed switchboard manufacturer, registered with Suruhanjaya Tenaga (ST) and Jabatan Kerja Raya. They shall comply with MS IEC 60439-3 and unless otherwise specified, shall be surface mounted metalclad type. The sheet steel shall have minimum thickness of 1.2mm. They shall have hinged cover, rust-proof and finished with oven baked epoxy powder coating. Knockouts or other approved form of cable entries and suitable brass earthing bolt and nut shall be provided. The Distribution Boards shall be equipped with HRC fuses or Miniature Circuit Breakers (MCB) of rating as specified in the Drawings. HRC fuses shall comply with relevant parts of IEC 60269. MCB shall have rupturing capacity not less than that indicated on Drawings and/or Bill of Quantities and shall comply with MS IEC 60898. The busbars shall be hard drawn high conductivity copper. The current rating of the busbars shall not be less than the incoming switchgear rating. The neutral and earth connection for each circuit shall be individually connected to the neutral and brass earth bar/terminal respectively. The sequence of termination of the neutral and earth wires shall correspond to that of phase circuit. For all-insulated Distribution Boards, the main switch shall be double pole MCB (Miniature Circuit Breaker) provided with a clear indication of 'ON-OFF' positions. The main switch shall comply with MS IEC 60947-3 and have fully shrouded incoming cable terminals. The contacts shall be of long switching life type.

3.2

3.3

3.4

3.5

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION (L-S1) SECTION: 3.0

CKE.LS.01.01.(02).2011

Date: April 1999 Revision: 2

DISTRIBUTION BOARDS AND CONSUMER UNITS

Date:

May 2011

Page: S3 - 2 of 2 3.6 Where surge protective device is specified, the device and its associated equipment shall be housed in separate compartment immediately after where the incoming switchgear is connected. All outgoing cables shall have alphanumeric circuits number labels. The labels of the neutral and earth shall correspond to that of the phase circuit. Engraved labels with white lettering on a black background shall be fitted externally (using rivet) on the front cover of the distribution board/consumer unit describing its usage and with a suitable designation for identification. Each Distribution Board shall be provided with a laminated schematic diagram and paste on the inside cover of the Distribution Board. The details shall include fuse rating/MCB rating, cable size, number and type of loads etc. The description of each circuit printed thereon shall include the corresponding circuit number in the as installed schematic diagram. All Distribution Boards shall be provided with top and bottom entry/exit with minimum 50mm x 50mm pre-cut hole. The opening shall be fitted with flat, removable gland plate to cover the hole.

3.7

3.8

3.9

3.10

SPECIFICATION FOR LOW VOLTAGE INTERNAL ELECTRICAL INSTALLATION Hak Cipta: 1999 Cawangan Kejuruteraan Elektrik, JKR Malaysia

CKE.ITP.01.35.(00).2012 FACTORY ACCEPTANCE TEST

CHECKLIST FOR VISUAL INSPECTION OF LOW VOLTAGE ELECTRICAL BOARDS

Date Issued Revision Revision Date Page

: : : :

16th January 2012 1/5

PROJECT NAME MANUFACTURER NAME

: :

Notes: 1. This form is to be used as a checklist for visual inspection acceptance only. Other acceptance criteria such as dielectric properties test, insulation resistance test and functional test shall use the forms provided by the manufacturer. S.O Rep is advised to begin the FAT with the visual inspection test ahead. 2. Prior departure to the factory, SO Representatives (SORs) are recommended to bring together: Documents : Approved Shop Drawing of Switchboard, BQ & Material List as per contract Tools : Digital Caliper, Measuring Tape, Torchlight, Digital Camera 3. Upon arrival and prior of any testing, SO Representatives are required to check/ensure: a. Date of calibration status of the instruments to be used for testing. (Calibration validity: 2 years) b. Certificate of the manufacturers competent person who will in charge for the testing. (Min. AO) c. Brand & Model of the material installed had been approved during construction stage as referred to material approval list (comply to J-MAL and material list as per contract). d. Inspect thoroughly compliance of the manufactured switchboard with the approved shop drawing particularly on the following criteria: Rating, Number of Poles & Arrangement of EACH Switchgear and terminals SPECIFICATION/JKR REQUIREMENT Board Name: COMPLIANCE
[: Yes, X : No, - : Not Applicable]

NO.

DESCRIPTION

REMARKS

A) Self-Contained Floor Mounted Cubicle Switchboard

Also applicable to PFC Board and GSC Board

1 2 3 4 5 6 7 8 9 10 11

Form of Separation Frame Thickness Panels, Covers & Doors Thickness Panel (Top & Sides) Panels, Covers & Front Doors Serrated Star Washer Material for Frame Anti Rust Treatment Color Base Cover Plates Door

Form 2B Switchboard 2.5 mm 2.0 mm Removable Cylindrical knurled head (chromed type) c/w retaining clip At front cover Rolled Steel Epoxy dry powder Enamel Grey (Exterior) Matt White (Interior) Provided Espagnolette/cremone bolt, locking device & satin chrome lever handle at the center fixing Hinged removable & double-leaf type < 450 mm Sides & back Own compartment with rear connected busbars 2000 mm (above the base) Separately housed in a compartment Separate compartment at immediate lower subsection & totally compartmentalize Located at the lowest subsection c/w lockable with key Neat Properly labelled with number sleeves

Minimum Requirement.

12 13 14 15 16 17

Rear Door 12.1 Width of Each Leaf Louvers with filter Withdrawable switchgear Height of indicating instrument Building automation devices, transducers, relays SPD

18 19

Tool Compartment All secondary wiring

Cawangan Kejuruteraan Elektrik, JKR Malaysia.

CKE.ITP.01.35.(00).2012 FACTORY ACCEPTANCE TEST

CHECKLIST FOR VISUAL INSPECTION OF LOW VOLTAGE ELECTRICAL BOARDS

Date Issued Revision Revision Date Page COMPLIANCE

[: Yes, X : No, - : Not Applicable]

: : : :

16th January 2012 2/5

NO.

DESCRIPTION

SPECIFICATION/JKR REQUIREMENT Sheet steel 2.0 mm Fibre type 5.0 mm Both sides At front cover Epoxy dry powder Enamel Grey Cylindrical knurled head (chromed type) c/w retaining clip Properly labelled with number sleeves Non-hygroscopic insulator Tinned hard drawn high conductivity copper Drawing requirement:
Tender (mm) R Y B N Working (mm)

REMARKS

B) Wall Mounted Switchboard 1 2 3 Material Thickness Portion of the Front Cover (cut-out & meter) 3.1 Thickness Louvers with filter Serrated Star Washer Anti Rust Treatment Color Panels, Covers & Front Doors All secondary wiring Mounting Busbar Horizontal Busbar & Vertical Busbar Size (at main incoming supply) Size

4 5 6 7 8 9 1 2 3

C) Busbars

Compliance:

Horizontal & Vertical Busbar Size (at main incoming supply) should be the same. Size as installed is similar or more than as in the approved shop drawing. Size at each Distribution Busbar shall be less than or equal to the maximum size of outgoing circuit breakers connected to it.
Spacing=busbar thickness

Distrubution Busbar Size similar as approved shop drawing (Vertical at each outgoing)

Drawing requirement:
Tender (mm) R Y B N Working (mm)

Compliance:

5 6 7 8

Multiple Parallel Busbars Main Busbar Arrangement Phase Indication/ Identification Switchboard Earthing Bar 8.1 Size Earthing Bar Identification Sizes Cabling Coloured Cable Cable End Termination

Separated by tinned copper spacers (at spacing equal to the busbar thickness) R-Y-B-N (from back to front) Painted with colour at appropriate points to denote the phase Tinned copper 50 mm x 6 mm Or else otherwise specified Painted with green at appropriate points As per approved drawing Neat and tighten For < 25mm2 cable: shall be colour coded to identify the phase &neutral conductors Coloured cable sleeve to identify the phase and neutral conductors Easily be replaced from the front of the panel. LED type Installed for every 2 sections, excluding busbar compartment. Heater c/w enclosure c/w automatic thermostat control, ONOFF switch & indicating lamp. Engraved with white lettering,black background & fastened or riveted

Front Back R - Y - B - N

9 1 2 3 4

D) Conductors

E) Others 1 2 Indicating Lamps Anti Condensation Heater

2.1 Heater 3 Labels

Cawangan Kejuruteraan Elektrik, JKR Malaysia.

CKE.ITP.01.35.(00).2012 FACTORY ACCEPTANCE TEST

CHECKLIST FOR VISUAL INSPECTION OF LOW VOLTAGE ELECTRICAL BOARDS

Date Issued Revision Revision Date Page COMPLIANCE

[: Yes, X : No, - : Not Applicable]

: : : :

16th January 2012 3/5

NO.

DESCRIPTION

SPECIFICATION/JKR REQUIREMENT Current rating are accordance with drawing and/or BQ Withdrawable metal clad, flush mounted & horizontal drawout isolation, c/w shutter 3 or 4 Minimum 50 kA at 415V for 1 sec. or otherwise specified Tinned copper

REMARKS

F) Switchgears 1 2 Switchgears ACBs

2.1 No. of poles 2.2 Icw 2.3 Copper tape/bar from frame (metal) of ACB to SEB 2.4 Used as Bus-coupler MCCBs 3.1 Icu 3.2 Incoming Feeder Circuit Breaker 400A G) Current Transformers 1 2 3 4 1 2 Secondary Rating Rating Accuracy (for measuring & metering) Accuracy (for protection) Connecting Leads 2.1 Isolation of SPD : MCCB / Fuse 2.2 Isolation of SPD : Compartment Transparent Window for viewing the SPD indicator Label Amaran at SPD compartment Material Thickness Serrated Star Washer Anti Rust Treatment Color Panels, Covers & Front Doors Comb / Fork Busbar

4 pole No. of poles are accordance with drawing and/or BQ Minimum 50 kA at 415V for 1 sec. or otherwise specified Provided with panel mounting external operating handle with padlocking facilities and door interlocking facilities 5A 15 VA Class 1.0 or otherwise specified Class 10P10 or otherwise specified as short as possible 4 pole MCCB or fuses or otherwise specified Separate compartment for SPD At front cover of the SPDs compartment for viewing the SPD indicator Sentences as in L-S1 with red lettering on a white background Sheet steel 1.2mm to 1.5 mm At front cover Epoxy dry powder Enamel Grey Cylindrical knurled head (chromed type) c/w retaining clip Insulated type

If required

H) Surge Protection Device

Preferably not exceeding 0.5m for the total length.

3 4

I ) Distribution Board 1 2 3 4 5 6 7

Cawangan Kejuruteraan Elektrik, JKR Malaysia.

CKE.ITP.01.35.(00).2012 FACTORY ACCEPTANCE TEST

CHECKLIST FOR VISUAL INSPECTION OF LOW VOLTAGE ELECTRICAL BOARDS

Date Issued Revision Revision Date Page

: : : :

16th January 2012 4/5

NO.

DESCRIPTION

SPECIFICATION/JKR REQUIREMENT

COMPLIANCE
[: Yes, X : No, - : Not Applicable]

REMARKS

Note : For item J, K & L, the compliance of specification & JKR requirement for item Self-Contained Floor Mounted Cubicle Switchboard and item Busbar are similar as LV Switchboard above. i.e: Thickness, size, material, etc.

J) Power Factor Correction Board (PFCB) 1 Enclosure Not form part of the switchboard it is connected to (independent) but match the height and depth. 1.1 Icu of MCCB / ACB Minimum 50 kA at 415V for 1 sec. or otherwise specified 1.2 Access Front & rear 2 Capacitor 2.1 Category C (min. 40oC) 2.2 Rated Voltage 525V, 50Hz 2.3 Housing/Container Heavy metal sheet steel 2.4 Separation between Min. 80mm capacitors 3 Reactor Installed in separate compartment of PFCB c/w rubber pad to reduce noise due to vibration etc. 3.1 Class H 3.2 kVAR Rating Min. 6% (Reactance) 3.3 Rated Voltage 440V 4 MCCB 4.1 Icu of MCCB / ACB Minimum 50 kA at 415V for 1 sec. or otherwise specified. Ics = 100% Icu 4.2 Minimum Continuous Min. 155% of rated capacitor currents Current Ratings 5 Switching Contactor 5.1 Utilization Category AC-6B 5.2 Minimum Continuous Min. 135% of rated capacitors currents Current Rating 5.3 Ventilation Van Heavy duty type* c/w filter and automatic shutter 6 All secondary wiring Properly labelled with number sleeves

Icu: Ics:

Icu: Ics:

*Air Exchange : Min.200 cubic meter perhour

K) Generator Set Switchboard [Essential Board] 1 Enclosure Not form part of the switchboard it is connected to (independent) but match the height and depth. 2 Automatic Transfer Transparent protection screen of full Switching Equipment compartment size shall be provided in front (ATSE) of automatic changeover contactors / ATSE 2.1 Contactor Utilization AC-33B Category 2.2 MCCB / ACB type 4 pole 3 Tinned Copper Earthing 25mm x 6mm Bar 4 All secondary wiring Properly labelled with number sleeves L) Generator Set Control Board (GSCB) [AMF Board] 1 Enclosure Not form part of the switchboard it is connected to (independent) but match the height and depth. 2 Emergency Stop PushProvided and c/w self-latching mushroom Button head type 3 Alarm Bell Min.250mm diameter 4 All secondary wiring Properly labelled with number sleeves

Cawangan Kejuruteraan Elektrik, JKR Malaysia.

CKE.ITP.01.35.(00).2012 FACTORY ACCEPTANCE TEST

CHECKLIST FOR VISUAL INSPECTION OF LOW VOLTAGE ELECTRICAL BOARDS

Date Issued Revision Revision Date Page

: : : :

16th January 2012 5/5

COMMENTS (IF ANY)

CHECKED BY [S.O. Representative) Signature Name (CAPITALS) On behalf of : : Position Date : :

WITNESSED BY [JKR] *if applicable Signature Name (CAPITALS) On behalf of : : Position Date : :

ELECTRICAL CONTRACTOR Signature Name (CAPITALS) On behalf of : : Position Date : :

MANUFACTURER Signature Name (CAPITALS) On behalf of : : Position Date : :

Cawangan Kejuruteraan Elektrik, JKR Malaysia.