VUL-INS-16 Electrical Equipment Inspection

Isolation & Lockout (Electrical)

A suitable lockout system is to be provided to enable physical isolation of the unit as per AS 4871.6. The isolation devices must be capable of being padlocked and clasped in the OFF position. ON and OFF positions should be clearly identified.
In circuits at Extra Low Voltage (ELV – below 50Vac or 120Vdc) potential, isolation may be achieved by switching the positive / negative conductor only. All circuits above ELV must achieve positive isolation by switching all active and neutral conductors.

Battery isolators are to be red in colour and disconnect power to all electrical loads. If fitted, Starter Motor Isolators must be yellow in colour.

Systems such as fire protection, communication (site two-way radios), GPS, or tyre monitoring systems are permitted to not be controlled by the battery isolation switch, provided they have separate isolator switches for their circuit(s)."
The isolation and lockout systems are to be tested and verified as safe and functional. Isolation process must include isolation of the jump-start receptacle.
Check that all exposed terminals are protected from arcing.
Isolation switches are not to be positioned in a potential crush zone (e.g. between position 1 or 2 wheels and chassis, or in articulation points).

Earth Continuity

Record Reading (ohms)

The resistance of the main earthing conductor must not be more than specified in AS/NZS3000. Welding power sources must be tested in accordance with AS1674.2

Earth Leakage

Record Test Results mA & Ms

All residual current devices (RCD/ELCB) must be tested for correct operation by injection testing after a initial test using suitable means.
All final circuits must possess individual earth leakage devices and must be tested individually. The testing device serial number and calibration date must be recorded on the inspection certificate. Refer to AS/ NZS3760.DC systems above ELV must have DC rated earth leakage protection.

Earthing System

Record Results

The Multiple Earth Neutral point must be accessible in a labelled box which requires tools to access the connection point. Check that earth bonds, equipotential bonding, straps, stakes and cables are in position, securely bolted and in good condition and are bonded to the steel frame with no section isolated by insulating material such as rubber liners or timber decks.
All conductive parts of equipment must be provided with an equipotential bond as per AS/NZS3000. Enclosure doors, gland plates and escutcheons on electrical apparatus must be connected to earth.

Confirm that frame of the power source is earthed, the maximum resistance between any metal part of the equipment’s frame and any hand controllers must be within the values specified within AS/NZS3000. The earth pin on the power supply plugs and the earthing system must be within the values specified within AS/NZS3000.
Generating equipment above 8kVA requires an independent earth stake.

Electrical Enclosures

All enclosures must be locked or require a tool to gain access to live parts. No panels should be damaged, compromise the IP rating or expose bare conductors.

Damaged fasteners are not acceptable (e.g. burred nut heads, deformed screwdriver slots).
Electrical equipment is required to be a minimum IP54 rating to protect equipment from water and dust ingress.
All live parts must be located within enclosures that provide protection against direct contact of at least IP2X.

Electrical - General Condition

Operational tests (including functional testing of safety devices. E.g. Deadman switches, interlocks, E stops, etc.) must be conducted on all electrical components to ensure that they are in good working condition, as well as a visual inspection to identify signs of damage or wear.

The inspector must check that all circuit breakers, RCDs and other protective devices are of the type and rating as shown on the drawings and /or labels or as stipulated in AS/ZNS3000.

If there are protective devices which are programmable or can be manually set (including timers, protection relays, pressure switches, thermostats) the inspector must check that they are set as per the drawings and/or labels. If this information is not shown on the labels and/or drawings the inspector must record all settings on the inspection report.
All electrical wiring (including colours) must comply with AS/NZS 3000 and AS/NZS 3007.

Electrical - Labelling and Signage

All electrical equipment must be clearly labelled with weather proof labels in English and complying with AS1102 symbols.
Check that Authorised personnel only and Maximum voltage notices within the enclosures are fixed to the generator, lighting plant and welding machines.

Signage on switchboards must include:
• Signage indicating maximum voltage within the enclosure “e.g. Danger 415 or 240 volts”.
• Signage on any cover or door which exposes live conductors “Isolate Elsewhere Before Removing Cover” and “Authorised Personnel Only”.
• Signage for isolation points.

Electrical Drawings

Check that all equipment/buildings has an up-to-date circuit diagram available. Drawings are to be specific to the equipment. This could be via hard copy on the machine/building or via soft copy that is easily accessible.
All wiring and terminations must be labelled and confirmed against drawings.

Electrical Protection

30mA RCD/OCB protection must be provided on all final circuits (e.g. lighting and power / welding outlet sockets). All outgoing circuits originating from an electrical enclosure must have earth leakage protection.

Each outgoing circuit must have over current protection (OC) which is equal to, or less than, the current carrying capacity of the conductors being protected. The fault withstand rating of the OC device must be a minimum of 10kA and at least equal to the prospective fault current of the generator or inverter.

If fitted with fuses the inspector must check that the correct size fuses are fitted as per the drawings and/ or labels.
The main circuit breaker must be fitted with earth fault protection.

Electrical Terminations

Check that all cables are terminated, secured correctly (not loose) and that terminals are protected from arcing risk.

Escutcheon Panel Interlocking

Before the escutcheon is opened, check that the main switch board has:
• Electrical interlocking to trip the main switch, or
• Mechanical interlocking so main switch must be in the “oﬀ “position, or
• Requires a key or tool to open the escutcheon, with warning signs applied.

General Purpose Outlets (GPO)

Generating equipment with a supply frequency greater than 50 Hz with GPOs fitted must have the GPO circuit eﬀectively isolated in such a way the GPOs cannot be operated. (GPO being of any size that will accept a plug and flexible cable).

Glands / Bushing of Cables

Check that where wiring is threaded through conduits, partition walls etc. that they are adequately glanded, bushed or protected so that wiring and cabling does not come in contact with any surfaces that may degrade the sheathing or insulation of any wiring

Hazard Reducing Device

All welders must be fitted with a Hazard Reducing Device (HRD) in accordance with AS1674.
All Voltage Reducing Devices VRD must be tested and confirmed as operating correctly in accordance with AS1674.

If fitted for dual application machines (e.g. stick/MIG/TIG), HRD bypass switches must be installed to disable the arc welding mode.
Confirm that all controls, such as current regulation, HRD/VRD indication, wire feeders, remote controller, etc. function as per the manufactures instructions. Any indicators (voltage and current) are to be tested to ensure they are within 10% of the true value.

Insulation Resistances

Resistance result recorded (Mohms)

The insulation of all live parts must comply with AS/NZS3000

Main Isolator

The Main Isolator must be clearly labelled and isolate all active power conductors of the plant being isolated from the electricity supply.

Mechanical Protection

All electrical equipment, cabling, accessories and devices must be protected from risk of mechanical damage.
Split conduit and spiral wrap on electrical cabling must not be used as a means of primary protection.

Polarity Test

Active and neutral conductors must not be transposed. Ensure socket outlets polarity is correct (e.g. lighting and power / welding outlet sockets). Refer to AS/NZS3000

Segregation of Voltage Levels

Check that diﬀerent voltage cables are installed as per AS/NZS3000

Record Output Voltages and Frequency Readings