EP 23 10 00 01 SP
LV TUNNEL SERVICES BOARD
Version 2.1
Issued April 2013
Owner:
Chief Engineer, Electrical
Approved
by:
Neal Hook
Chief Engineer
Electrical
Authorised
by:
Neal Hook
Chief Engineer
Electrical
Disclaimer
This document was prepared for use on the RailCorp Network only.
RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be
sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the
copy of the document it is viewing is the current version of the document as in use by RailCorp.
RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes
any liability which arises in any manner by the use of this document.
Copyright
The information in this document is protected by Copyright and no part of this document may be reproduced, altered,
stored or transmitted by any person without the prior consent of RailCorp.
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Page 1 of 14
Engineering Specification
Engineering Specification
Electrical
RailCorp Engineering Specification — Electrical
LV Tunnel Services Board
EP 23 10 00 01 SP
Document control
Version
2.0
2.1
© RailCorp
Issued April 2013
Date
May 2008
May 2010
April 2013
Summary of change
Last Technical Review
Application of TMA 400 format.
Template update
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Version 2.1
RailCorp Engineering Specification — Electrical
LV Tunnel Services Board
EP 23 10 00 01 SP
Contents
1
Introduction .............................................................................................................................4
2
2.1
2.2
Scope and Application ...........................................................................................................4
General......................................................................................................................................4
Application.................................................................................................................................4
3
3.1
3.2
3.3
References...............................................................................................................................4
Australian Standards.................................................................................................................4
RailCorp Standards...................................................................................................................5
RailCorp Drawings ....................................................................................................................5
4
Background .............................................................................................................................5
5
Functional Characteristics .....................................................................................................6
6
6.1
6.2
6.3
6.4
6.6
Technical Requirements.........................................................................................................6
General......................................................................................................................................6
Incomer and Automatic Transfer Switch ...................................................................................7
Distribution Section ...................................................................................................................7
Lighting Control and Monitoring Section ...................................................................................7
6.4.1
Normal lighting Controls ............................................................................................8
6.4.2
Emergency Lighting Controls ....................................................................................8
6.4.3
Local indication ..........................................................................................................8
6.4.4
Selector Switches ......................................................................................................8
6.4.5
Pushbuttons...............................................................................................................8
6.4.6
Contactors .................................................................................................................9
6.4.7
System Monitoring .....................................................................................................9
PLC Requirements....................................................................................................................9
6.5.1
Hardware ...................................................................................................................9
6.5.2
Software.....................................................................................................................9
6.5.3
Functional requirements ............................................................................................9
6.5.3.1 Normal lighting .........................................................................................10
6.5.3.2 Emergency lighting...................................................................................10
SCADA Interface.....................................................................................................................11
7
Maintenance ..........................................................................................................................11
8
Testing....................................................................................................................................11
9
Data Set Associated with the Equipment ...........................................................................11
6.5
Appendix A
Technical Schedule ...............................................................................................12
Appendix B
RFT Checklist.........................................................................................................13
Appendix C
Requirements for Technical Aspects of Tender Evaluation .............................14
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Version 2.1
RailCorp Engineering Specification — Electrical
LV Tunnel Services Board
1
EP 23 10 00 01 SP
Introduction
This document describes the whole of life performance requirements for the purchase
and maintenance of low voltage tunnel services distribution boards. The document covers
design the minimum design, manufacturing, documentation and maintenance
requirements and practices
2
Scope and Application
2.1
General
This document sets out the minimum requirements for design and manufacture of Tunnel
Services Boards deployed in RailCorp’s infrastructure. It includes requirements relating to
the equipment as a whole and components used in the equipment.
A Tunnel Services Board provides protection and power distribution to normal and
emergency lighting and miscellaneous small power within the tunnel. The board is
configured to connect to two independent incoming supplies and includes an automatic
transfer switch. The board also interfaces with push button control stations for control of
normal lighting and provides indication of the mode and status of tunnel lighting, including
individual battery maintained emergency light fittings.
Tunnel Services Boards do not supply sump pumps or vent fans within the tunnel. These
are supplied separately.
2.2
Application
The requirements of this document apply when a new tunnel services board is purchased
or installed in the RailCorp network from the date of issue that this specification is
approved.
The requirements of this document apply when an existing tunnel services board is
modified or refurbished.
The requirements of this document are not applicable to the configuration of existing
tunnel services boards currently in service in the RailCorp network.
3
References
The following documents contain provisions which, through reference in this text,
constitute provisions of this Standard.
At the time of publication, the editions indicated were valid.
3.1
Australian Standards
The following Australian Standards are either referenced in this document or can provide
further information.
AS 1102
AS 1627.4
AS 1939:1990
© RailCorp
Issued April 2013
Graphical Symbols for Electrotechnical Documentation
Metal finishing – Preparation and pre-treatment of surffaces –
Abrasive blast cleaning
Degree of Protection provided by Enclosures for Electrical Equipment
(IP code)
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RailCorp Engineering Specification — Electrical
LV Tunnel Services Board
EP 23 10 00 01 SP
AS 2700
Colour Standards for General Purposes
AS/NZS 3000:2007
Electrical installations – known as the Australian/New Zealand
wiring rules
AS/NZS 3439.1
Low Voltage Switchgear and Controlgear Assemblies – Type
tested and partially type tested assemblies
AS/NZS 3100
Approval and test specification – General requirements for electrical
systems
AS 60898.1
Electrical accessories – Circuit Breakers for Overcurrent Protection for
household and similar installations
AS60947
Low Voltage Switchgear and Controlgear
3.2
RailCorp Standards
Key RailCorp Standards:
Several significant sets of requirements applicable to tunnel services boards are common
to other classes of equipment and are set out in the following RailCorp standards. The
equipment shall comply with the relevant requirements set out therein.
EP 00 00 00 12 SP Electrical Power Equipment – Integrated Support Requirements
EP 00 00 00 13 SP Electrical Power Equipment – Design Ranges of Ambient Conditions
EP 00 00 00 15 SP Common Requirements for Electrical Power Equipment
The following RailCorp documents are either referenced in this document or can provide
further information.
EP 00 00 00 00 MP Electric Power Technical Maintenance Plan
EP 17 00 00 06 SP Installation Inspections
ESC 340 Tunnels
3.3
RailCorp Drawings
The following drawings form part of this specification:
EL 0413476 Tunnel Services Board Tunnel Lighting Panel Schematic Diagram
EL 0413477 Tunnel Services Board Lighting Control Panel Schematic Diagram
EL 0413478 Tunnel Services Board Change Over Power DB Schematic Diagram
EL 0413479 Tunnel Services Board Change Over Control Circuit DB Schematic Diagram
4
Background
The RailCorp network includes a significant length of tunnels, in some cases connecting
underground stations in underground railways and on other cases discrete tunnels
connecting sections of surface rail lines. RailCorp’s rail Tunnels are both single and
double track configurations. The majority of the rail lines in RailCorp’s rail tunnels are
electrified. The overhead electric traction system operates at 1500V DC with negative
return via the rails. The rails are near earth potential but are not earthed.
Tunnel services boards are usually located in stations for underground railways and
outside tunnel portals for discrete tunnels. In longer tunnels or sections of underground
railway, the services within the tunnel will be supplied from two tunnel services boards,
one at each end. In such cases there is no connection between the services supplied
from one end and those supplied from the other end.
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RailCorp Engineering Specification — Electrical
LV Tunnel Services Board
EP 23 10 00 01 SP
In underground railways, the Tunnel Services Board will be installed within a room or an
enclosure with a minimum fire rating of two hours.
Power supplies to tunnel services boards will normally be derived from two independent
RailCorp supplies or from one RailCorp supply and one supply from the local electricity
distributor. The tunnel services boards should be connected to distribution main
switchboards and not to a railway station installation main switchboard or a sub-board
within a railway station installation.
The RailCorp supply is normally derived from a RailCorp 11kV feeder which in turn is
derived from a RailCorp sub-transmission (traction supply) feeder. The traction rectifier
loads result in significant harmonic distortion on some parts of the RailCorp HV network
and this is may be see on the LV supply connected to the tunnel services board.
In order to prevent traction leakage current from the rails from flowing in the earth
conductor the RailCorp LV distribution systems are generally earthed at one point only
and an insulated earth conductor is reticulated with the phase and neutral conductors.
5
Functional Characteristics
Tunnel Services Boards covered by this standard shall:
• Provide separate isolators for each of two incoming supplies.
• Provide an automatic transfer switch to automatically select between the two
incoming supplies.
• Provide for distribution and circuit protection for:
–
–
–
–
–
–
Normal tunnel lighting
Emergency tunnel lighting
Power outlets
Marker lights for refuges equipped with phones
Provide controls for normal tunnel lighting
Provide controls for emergency tunnel lighting
• Provide monitoring for individual battery maintained emergency tunnel light fittings.
The monitoring unit will be a free issue item.
• Provide local indication of system status.
• Provide interface to the electrical SCADA for indication of status.
6
Technical Requirements
6.1
General
The Tunnel Services Board shall be a 3 ph. +N +E board of Form 1 construction to
AS3439.1 and shall have a degree of environmental protection of IP65 to AS1939.
The Tunnel Services Board shall be suitable for both top and bottom entry cables.
The Tunnel Services Board shall be supplied complete with all internal wiring
A document pocket shall be provided on the door of the cubicle.
The Tunnel Services Board shall consist of the following segregated sections:
•
•
•
•
© RailCorp
Issued April 2013
Incomers and changeover switch
Distribution Section
Controls, PLC, indications and alarms
SCADA interface
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LV Tunnel Services Board
6.2
EP 23 10 00 01 SP
Incomer and Automatic Transfer Switch
An automatic transfer switch shall switch to the backup supply on failure of the normal
supply. Phase failure relays shall be installed on both incoming supplies and on the load
side of the transfer switch.
The Transfer Switch shall be Schneider BTS or RailCorp approved equivalent. By means
of a selector switch on the front of the panel, it shall be possible to bias the supply to
select either of the incomers as the Normal Supply.
Note:
As it is more important to maintain supply to the lights than ensuring power quality, phase
failure relays with a voltage tolerance of a minimum of 75% to 125% of nominal voltage
shall be selected. The effect of possible harmonic distortion on the phase failure relays
shall also be considered and appropriate units selected.
6.3
Distribution Section
The power distribution section shall be based on a standard, commercially available
distribution board. The distribution board shall have provision for a minimum of 25%
spare circuit breakers and contactors. Pole fillers shall be fitted to all spare poles.
Distribution board shall be one of the following types:
DB Type
1
2
3
4
Number of 1 phase poles
24
36
48
60
Number of poles fitted with RCD’s for
GPO’s
3
6
9
9
Main Switch Rating – Amps
250
250
250
250
Busbar Rating – Amps
250
250
250
250
32/16
32/16
64/32
64/32
Minimum number of PLC inputs/ outputs
Circuit breaker ratings shall be rated at 16A. GPO circuit breakers shall be equipped with
Residual Current Devices rated at 30mA. Circuit breakers shall meet the requirements of
AS 60898.1.
The distribution board shall be rated for a fault current of 30kA for 0.1 seconds.
6.4
Lighting Control and Monitoring Section
The control functionality shall be in accordance with the Schematic Diagrams listed in
Section 3.3 above.
The control section shall include all relays, contactors, indicating lights, switches,
pushbuttons and terminals associated with tunnel services.
The required functionality shall be achieved by means of a Programmable Logic
Controller.
Power supplies to the control section shall be from a dedicated circuit breaker sourced
downstream of the Automatic Transfer Switch.
Control functionality shall conform with Sections 6.4.1 to 6.4.3 below.
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RailCorp Engineering Specification — Electrical
LV Tunnel Services Board
6.4.1
EP 23 10 00 01 SP
Normal lighting Controls
Power to normal tunnel lighting shall be supplied by means of a number of single-phase
circuit breakers. Each tunnel or portion of a tunnel shall be supplied by a group of three
circuit breakers spread across the three phases.
Under normal operating conditions only one phase within a group will be energised and
every third light in the tunnel will be switched on. The set of active lights will rotate
between the three phases at regular intervals, nominally one week.
Outputs to the lights shall be wired to terminals in the tunnel services board via a
normally closed contactor contact which will be controlled by the PLC. For 2 out of every
3 lights, the contactor will be energised and the tunnel lights will be off. An external input,
initiated by pushbuttons at the tunnel entrances shall cause the contactor to de-energise
and turn all groups on, nominally for two hours.
Bypass selector switches, one per tunnel shall be installed on the front of the Tunnel
Services Board. When selected bypass the circuit breakers will connect directly to the
output terminals turning on the lights.
6.4.2
Emergency Lighting Controls
Controls shall be implemented in PLC logic.
All emergency lighting circuits shall be wired in series with a normally closed contactor
contact. Test pushbuttons (one per 3 circuits) shall be provided to test the test the
emergency lighting batteries. On operation of the test button the PLC shall open the
contactor supplying the emergency lights and cause the batteries to commence
discharging. After 4 hours the PLC will cause the contactor to de-energise and the
batteries will re-commence charging.
A reset pushbutton shall be installed which will end the timing cycle when operated.
6.4.3
Local indication
Indicating lights shall be installed for the following
•
•
•
•
•
•
•
Normal supply available
Emergency supply available
Normal supply ON
Emergency supply ON
Output ON
Normal lights on full i.e. all lights within a group turned on
Emergency lights on test (per group of 3 emergency lighting circuits)
Indicator lights shall be LEDs, 22mm diameter.
6.4.4
Selector Switches
Selector switches shall be provided for:
• Bypass ON-OFF
6.4.5
Pushbuttons
The following pushbuttons shall be installed on the front of the panel:
• All normal lights ON pushbutton
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LV Tunnel Services Board
EP 23 10 00 01 SP
• Lights OFF pushbutton.
• TEST emergency lighting
• RESET emergency lighting test
Pushbuttons shall be to 22mm diameter to AS 60947.5.1.
6.4.6
Contactors
Contactor shall be single phase and rated at 240V 40A for normal lights and 415V 40A
three phase for emergency lights.
6.4.7
System Monitoring
Space shall be provided to install an approved emergency light monitoring unit.
Approximate dimensions are 315mm long x 55mm high x 125 mm deep. Ducting shall be
provided on two sides of the unit to enable running of wiring connections. The emergency
light monitoring unit will be a free issue item. Allowance shall be made to wire 2 potential
free contacts to suitably labelled terminals for future external use.
A suitable mounting plate shall be installed for mounting the monitoring unit into the
switchboard without drilling into the switchboard.
6.5
PLC Requirements
6.5.1
Hardware
The PLC shall be a standard commercially available product. The PLC shall be of
modular design, and shall be capable of expansion by the insertion of additional cards in
spare I/O slots. The PLC shall operate from a single phase 240V 50Hz supply. Other
voltages required for the operation of the PLC and I/O shall be derived from the 240V
single phase supply.
Inputs shall operate from a 24V dc. supply generated internally by the PLC.
PLC outputs shall be voltage free contact outputs and shall be sized to operate the inrush
current of the contactors but shall in any event be capable of switching 2A at 240Volts. If
required, outputs shall be equipped with interface relays to achieve the required current
rating. PLC outputs shall be fail safe. i.e if the power supply or the PLC fails, the output
shall revert to an OFF state (output contact open).
6.5.2
Software
The PLC programme shall be supplied with the PLC in accordance with the functional
requirements set out below. A full listing of the programme shall be supplied. By plugging
in a laptop into a suitable port of the PLC it shall be possible to download the PLC
programme to the laptop and modify the programme as dictated by requirements (e.g.
upon installing additional lights). The necessary software required to perform the
modification shall be supplied. All software shall become the property of RailCorp.
A watchdog timer alarm output shall provide visual indication of PLC operational status.
The alarm shall also be wired to a set of terminals for external use
6.5.3
Functional requirements
PLC functionality shall fulfill the requirements as set out below.
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RailCorp Engineering Specification — Electrical
LV Tunnel Services Board
6.5.3.1
EP 23 10 00 01 SP
Normal lighting
Each group of 3 normal lighting circuits shall be equipped with the following inputs and
outputs
• Lights ON (input from a pushbutton on front of panel). Initiates the normal
operating mode by switching on the first set of lights, E.g. lights connected to the
red phase. After a period of nominally 1 week and adjustable from 0.5 to 4 weeks
the operating circuits will change over to the white phase, and a week later to the
blue phase. The cycle is then repeated. Note: It shall be possible to adjust the
cycle time without stopping the PLC. Suppliers shall provide details of the
proposed method of achieving this. i.e. HMI panel, potentiometer etc.
• Lights ON (Momentary external input from pushbutton station in tunnel). This is a
maintenance requirement. All the normal lights in that tunnel or section of the
tunnel will be switched ON and remain ON for a period of 2 hours, or until RESET.
At the end of the two hour period the system shall revert to the Normal mode of
operation, (Refer to bullet point 1 above).
• OFF/RESET (input from pushbutton on front of panel). Terminates the
maintenance mode and reverts back to the normal mode of operation.
• Contactor output. Operates the relevant contactor associated with each set of
lights
Active circuits shall as far as possible be spread across the three phases. Active circuits
shall rotate at periodic time intervals of nominally one week.
The table depicts the desired switching sequence.
1st GROUP OF
LIGHTS
2ND GROUP OF
LIGHTS
3rd GROUP OF
LIGHTS
PHASE
R
W
B
R
W
B
R
W
B
WEEK 1
ON
OFF
OFF
OFF
ON
OFF
OFF
OFF
ON
WEEK 2
OFF
ON
OFF
OFF
OFF
ON
ON
OFF
OFF
WEEK 3
OFF
OFF
ON
ON
OFF
OFF
OFF
ON
OFF
Switching for the fourth group of lights will be as per the first group etc.
After week 3, the cycle is repeated
The above sequence shall be automatically advance to the next period when the input
power supply to the PLC is switched off and on.
6.5.3.2
Emergency lighting
Each set of 3 emergency lighting circuits shall be equipped with the following inputs and
outputs. Note that normally all emergency lights will be left on continuously.
• Lights TEST (Input from pushbutton on front of panel). Switches off the output to
the lights and initiates the 4 hour backup battery test. At the end of 4 hours normal
operation is resumed.
• RESET (Input from pushbutton on front of panel). Terminates the battery test and
resumes normal operation.
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LV Tunnel Services Board
6.6
EP 23 10 00 01 SP
SCADA Interface
Status and alarms monitored by the SCADA system shall have one normally open and
one normally closed voltage free contact wired to a set of terminals for external use. The
contacts shall have a minimum rating of 1 Amp at 120V d.c.
The following condition shall be monitored:
•
•
•
•
7
Phase failure relay for normal supply
Phase failure relay for alternate supply
Emergency lights on test
Luminaire failure (output from lighting monitoring system)
Maintenance
The equipment must be suitable for operation with only limited periodic routine
maintenance comprising tasks falling into the following categories:
•
•
•
•
•
Testing of functionality
Cleaning
Lubrication of locks and hinges
Replacement of Circuit Breakers
Replacement of control circuit components including relays, contactors,
pushbuttons and indicating lights
• Replacement of distribution board.
8
Testing
Factory tests shall include the following:
•
•
•
•
•
•
•
•
9
Inspection in accordance with AS3439.1 Section 8.3.1
Insulation resistance test
Continuity (point to point) testing of all wiring.
Function test of all logic and interlocks
Phasing of power circuits
PLC logic functionality shall be demonstrated
The Tunnel Services Board shall be energised and tested prior to delivery.
Copies of final inspection and equipment test reports shall be provided and comply
with EP 00 00 00 12 SP
Data Set Associated with the Equipment
Drawings and documentation shall be supplied in accordance with the requirements of
EP 00 00 00 15 SP “Common Requirements for Electrical Power Equipment”.
The PLC programme shall be supplied in ladder logic format.
Detailed documentation relating to the Maintenance tasks shall be supplied for inclusion
in RailCorp’s Electrical Technical Maintenance Plan.
All documentation shall remain the property of RailCorp.
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RailCorp Engineering Specification — Electrical
LV Tunnel Services Board
Appendix A
EP 23 10 00 01 SP
Technical Schedule
The supplier shall complete the following data sheets:
Distribution board dimensions Height
− Length
.………………............
mm
− width
.………………............
mm
− depth
.………………............
mm
Distribution board fault level
.………………............
kA
Busbar rating
.………………............
Amps
Main switch rating
.………………............
Amps
Number of poles supplied
.………………............
Main switch manufacturer/type number
.………………............
Circuit breakers make/type
.………………............
Contactors make/type
.………………............
Selector switch make/catalogue number
.………………............
PLC manufacturer/model
.………………............
Number/ of inputs supplied
.………………............
Number of outputs supplied
.………………............
Maximum number of I/O that the PLC can be expanded
.………………............
Input card type/catalogue number
.………………............
Output card type/catalogue number
.………………............
Communication protocol
.………………............
General Arrangement and equipment mounting
.………………............
Recommended spares
.………………............
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RailCorp Engineering Specification — Electrical
LV Tunnel Services Board
Appendix B
EP 23 10 00 01 SP
RFT Checklist
Application
The following material is for guidance in the preparation of a Request for Tender for this
type of equipment. This checklist itself is not intended to directly form part of any
contract.
This section is to be read in conjunction with the RFT Checklist in specification EP 00 00
00 15 SP, Common Requirement for Electrical Power Equipment.
Information to be supplied to the Tenderer
Where this document is used as the basis for procurement of equipment for a particular
location, in addition to the general requirements in this specification the following
information related to the particular site will need to be supplied.
•
•
•
•
Distribution board type (as defined in Section 6.3 above)
Incoming feeder cable size
Site location
Number of sets of documentation required
Information to be Sought from the Tenderer
• Integrated Support information as per RailCorp Standard
• Tenders to complete and submit Appendix A
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RailCorp Engineering Specification — Electrical
LV Tunnel Services Board
Appendix C
EP 23 10 00 01 SP
Requirements for Technical Aspects of Tender
Evaluation
Evaluation of tenders
Tender submissions will be evaluated based on a number of criteria. One constant
criterion is compliance with this specification. The Chief Engineer Electrical requires that
persons evaluating the technical aspects of this tender have sufficient technical
competence for the task.
Tender evaluation committees shall forward details of persons evaluating the technical
aspects of the tender to the Chief Engineer Electrical for concurrence. This will normally
be in the form of an email and is to include sufficient detail of the tender and the person to
enable the Chief Engineer Electrical to satisfy themself of the merits of the evaluating
person. A minimum of 4 weeks notice is required prior to the evaluation of the Tenders.
The Chief Engineer Electrical will advise within 5 working days only if the person is
considered technically unsuitable for the technical evaluation.
Acceptance of product
A number of the specifications require acceptance of product at both the factory and at
site. The purchaser is to advise the Chief Engineer Electrical the details of the person
carrying out the acceptance testing for the concurrence of the Chief Engineer Electrical. A
minimum of 4 weeks notice is required prior to the evaluation of the acceptance testing.
The Chief Engineer Electrical will advise only if the person is considered unsuitable for
the acceptance testing.
The Chief Engineer Electrical reserves the right to nominate a representative to review
and/or attend such acceptance.
Record Keeping
Where product is purchased against this specification, the Chief Engineer Electrical
requires that relevant detail be provided so that it can be logged against this specification.
For RailCorp purchases, all records are recorded in Ariba.
Where this specification is utilised by parties external to RailCorp (Alliance parties, etc)
then copies of all relevant technical information and evaluation shall be forwarded to the
Chief Engineer Electrical for filing against the specification. In addition copies of selected
commercial information pertaining to the ongoing support of the product as follows is also
required.
• Warranty details
• Spare parts and associated availability
• Product support information.
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