DOC-WKI-000090

DKIGENERALWIRINGPRACTICES

UncontrolledDocumentwhenprinted Page

PAGE

4

of

NUMPAGES

12

WORKINSTRUCTION

DKIGENERALWIRINGPRACTICES

Scope

ThisworkinstructionshallbeappliedintheDiamondKeyInternationalWorkshopsElectricalwiringonskidsorassociatedisrequired.

Allwiringtobeperformedbyqualifiedexperiencedwiringpersonnelusingappropriatetoolsforstrippinginsulation,cutting,solderingandattachingmechanicalcrimptypeterminalswiththecorrectdiesandtoolsasadvisedbytheterminalmanufacturer.

ForemostelectricalinstallationsaretobeperformedtolatestissueofwiringrulesAS/NZS3000aswellasIECdirectives

Generalinstallation:

Whenremovinginsulationfromtheconductor,wirestrandsshallnotbenickedordamaged.Properstrippingtoolsshallbeusedtoavoidsuchdamage.

Wireandcabletiesshallbesnugbutshallnotbesotightastocauseindentationandcoldflowdamagetotheinsulation.

Cabletiesshallbetensionedandtrimmedusingcabletiemanufacturerstooling.

(Useofsidecuttersfortrimming,isnotpermitted)

AllwiringwithinExe,Exiorsimilarenclosurestobeterminated.

Wherepossible,adhesiveinstalledmountingbasesshouldnotbeusedfortiesorcablesupportunlessaffixedwithamechanicalfastener.

Wireandcabledressshallallowsufficientslackforremovalandreapplicationofthewireterminations,atleasttwicewithoutexcesstension.

Allwireandcable,includingthatinductsandconduit,shallbehandledtobefreefromkinksandinsulationabrasions.

Wireinstallationshallnotbesubjecttoaccumulationofwater,oilorotherforeignmatter.

InstrumentcablesaretobefreeofOrangedrainwires.

Cabletobelaidoutneatlyandunduecrossingofcablesistobeavoided(referAppendix3).

Allwireshallbeprotectedagainstanycontactwithanysurfaceotherthanthatdesignedspecificallytosupportorprotectthewire.

Protectiveedging,Grommetsandsimilarmaterialsshallbeappliedwhereveranypossibilityexistsforawiretocontactasharpedge.

Adriploopshallbeprovidedineachwireorcablewherewatercouldotherwiserunalongthewireorcabletothepointwhereitentersaboxorenclosure.

Wire/cablesformingpartofthewiringsystemshallbebentinamannerthatwillnotcausedamageorplaceunduestressontheirsheathingorinsulation.

Wheremanufacturer’sinformationonrecommendedbendradiiisnotavailable,thefollowingradiimaybeconsideredsuitable

Unarmouredsheathedcables6timesthecablediameter

Armouredsheathedcables12timesthecablediameter

(ChangeofdirectionAS/NZS30003.9.7.)

Wirejumpersondevicesshallberunwithintheloom,soastonotbemisplacedondevicereplacement.

CableColorsandtype:

WherepossibletheDKIstandardsforcablecolorsaretobestrictlyfollowed

Powercables–110v–240v Orange

Instrumentcables–0v–24v Black

IScables- Blue

Flexiblecablesandcordsshallbe0.6/1kVor450/750Vrated,heavyduty,withmultiplestrandedtinnedcopperconductorsof1.5sqmmminimumcrosssectionandwithatinnedcopperbraidedscreen.

InsulationmaterialsmaybeeitherPVC,EPRorNBR

ScreensshallbeincludedinallZone1cables,withtheexceptionofshortlengths(not>600mm)ofinstrumentcables

WireandcabletypeusedshallbeasstatedonDKIdrawings,alternativesshallbesubmittedforDKIapproved.

Cablesusedforthetransmissionofsignalsfromtemperature,pressure,speed,flow,weight,levelandsimilarsignals,orany4-20mA,0-20mA,24VDCorsimilarextralowvoltagesignalshallcomprisetwistedscreenedpairs.

WireandcablesizestobeasstatedoragreedbyDKIcableblockdiagramandcableschedule,alternativesshallbesubmittedforDKIapproved.

Sealingmustbedoneinaccordancewiththemanufacturesinstructions

Forverticalsealingaphysicalbarriersuchassiliconmustbelaidatthelowerpointoftheconduitsealtoensurethecompoundcannotpass/drippastthesealingarea.

Forhorizontalsealingaphysicalbarriersuchassiliconmustbelaidatbothendpointsoftheconduitsealtoensurethecompoundcannotpass/drippastthesealingarea.

Allwirespassingthroughtheconduitsealmusthaveallouterinsulationandanyplasticwrappingremoved.Ensurethattheremovaloftheinsulationisvisible/traceableevenaftersealinghasbeendone(forinspectionpurposes).

Allwiresaretobestraightenedandnottwistedtogetherwhenpassingthroughthesealingarea.

Sealingcompoundistobemixedasperthemanufacturer’sinstructions,

PouringofthecompoundmustensurethatthesealingfittingiscompletelyfilledtotherequiredlevelandmustnotcoverthePlugbungthread.

Sealingfittingplugs/bungsarenottobeinstalleduntilthesealingcompoundhashardenedtoensuretheplug/bungisnotincontactwiththecompound.

Conduit-Flexible:-

FlexibleconduitshallbeofaDKIapprovedtypesuchasSealsafe.

EquivalenttypesmaybepresentedtoDKIforapproval)

ConduitandfittingsshallberatedtoIP66whenentering/exitingenclosuresorterminationjunctionboxes.

WhenaFlexibleconduithasIScableinsidebothendsoftheconduitmustbesleevedinbluecolor.

CableGlands:-

GlandsaretosuittheHazardousapplication.AndconformtoIECorASstandards

Glandsaretobeofcorrectsizeforthecablesused.

AllGlandsenteringanExdboxmustbeBarriertype

AllglandsenteringanExeboxmustberatedExetypeminimum.

Glandstobetightenedtomanufacturersrecommendations.

BarrierGlandstohavethecorrectepoxyresinapplied,tomanufacturer’sinstructions.

GlandstohavenylonwashersfittedtoEnclosureexternals.

GlandstohaveShroudsfitted,unlessrequestedbythecustomernotto.

Cableglandtypesshallbeselectedasfollows:

Cabletype

Enclosure

GlandType

Manufacturers

PVC/PVC/SWA/PVC

XLPE/PVC/SWA/PVC

Exe

CompressionglandscertifiedExeandfittedwithasealinggasket

Crouse-HindstypeTWAE

CMPE1FWseries

PVC/PVC/SWA/PVC

XLPE/PVC/SWA/PVC

Exd

SeeAS/NZS60079.14Figure2

CompressionglandcertifiedExdandfittedwithsealinggasket

CMPE1FWseries

BarriertypeglandcertifiedExd

Crouse-HindstypeTWAB

CMPPX2Kseries

PVCorEPRScreenedFlexible

ExeorExd

CMPE1FXseries

PVC/PVC

XLPE/PVC

IntrinsicallySafecircuits

Generalindustrialglands.

Crouse-HindsTUA

CMPA2series

PVC/PVC/SWA/PVC

XLPE/PVC/SWA/PVC

IntrinsicallySafecircuits

Generalindustrialglandsforarmouredcables.

Crouse-HindsTWA

CMPCWseries

PVC/PVC/SWA/PVC

XLPE/PVC/SWA/PVC

SwitchboardsinNonHazardousAreas

Compressionglandsdesignedforarmouredcables

Crouse-HindstypeTWA

CMPCWseries

Cableladders/Trays:-

AllCableTraysshallbeEzyStrut/Unistrutperforatedtrayorapprovedequivalent.

AllLadderTraysshallbeBurndyLTseriesorapprovedequivalent.

AllCableLaddershallbeNEMA16Aorapprovedequivalent.

Tobefreeofkinkssharpedgesandburrs

CableenteringthroughthesidesmusthaveGrommetprotection

PlasticDuct:-

TobeofanapprovedDKIslottedfingertype.

Ductcoverstobefitted,aftercompletionofwiring.

Nosharpfastenerstobepresentontheinsidetodamagewiring.

DuctwithblueI.S.wiringinsiderequiresabluelabelwithwhitelettering,stating“ISCIRCUIT”

CableConnectors:-D15,D25etc

Unusedconnectorcontactpositionsshallbesealedwitheitherconnectorcontactsorplasticsealingplugsdesignedforthatpurpose.

Adjacentconnectorswhereverpossiblearetohavedifferentinsertordifferentinsertorientationstopreventerroneousconnections.

Whereverpossible,connectorsaretohavemechanicalcrimpcontacts.

WheneverconnectorssuchasCannon‘D’withsolderpotconnectionsareused,thewireistohaveclearHeat-shrinktubingappliedtojoint,forstrainrelieving.

Splices:-

Slicing/Joinersofconductorsshallbeavoidedandundernocircumstanceswillsplicingofconductorsinconduitbepermitted.

Enclosures:-

EnclosuresshallbeofaDKIapprovedrangewithanIP65orbetterrating.

EnclosuresforExternalusearetobemetallictypeunlessapprovedotherwise.

AllwirebundleswithinanEnclosureshallbesupportedandfreefromtheEnclosurestructure,metaledges,boltheadsetc.

Enclosuresshallhavetheirmountingbrackets/holesexternalwhereverpossible.

Enclosures&equipmenttobeearthedusingfittedearthstudsforpreventionagainststatic,asshownonDKIStaticEarthlingwiringdiagram.

Enclosuresshallhaveearthconnectionsbetweendoorandmainchassis.

Allenclosurecoverstohavegasketsusingapprovedmaterial.

EnclosureswithIScircuitsinside,aretohavealabelmountedonthefrontdoorstating“INTRINSICALLYSAFECIRCUITSONLY” whenonlyISor“INTRINSICALLYSAFECIRCUITSINSIDE”whenamixtureofcircuits.

Labeltobewhiteletteringuponabluebackground

Enclosuredrilling/machiningswarfistobethoroughlyremovedalongwithanyburrsorsharpedgespriortoinstallation.

AllspareglandholestobeblankedoffwithsuitablezoneStoppingplugs.

Solder:-

Anon-corrosivesoldershallbeused.

Anautomatictemperaturecontrolledsolderstationshallbeused.

TerminalBlocks:-

TerminalblocksshallbeofthemoldedunittypeTensionclamporclampingyokescrewonagreedprojectsandbeDKIapproved.Inthecasewheredifferentmodelofterminalshastobeusedotherthanwhathadspecifiedinthedrawings,pleaseacquireforsign-offonthenewlyselectedmodel.

Theopensideofthelastterminalofanassemblyshallbeclosedbyanendbarrier.

Bothendsoftheassemblyshallberetainedbyanendbracket.

I.S.terminalstobecolouredblue

Whereverpossible10%sparesshallbeprovided,ifnotshown