household renewable energy systems - planetary power · bushlight household renewable energy...

Centre for Appropriate Technology Inc

ABN 93 080 271 156

BUSHLIGHT

Light and Life in the Bush

®

Household Renewable Energy Systems

At

Fish Hole

In the North Queensland Region

Contract N o: NQ07-0905

Invitation to Tender for the Suppl y and Installation of Household Renewable Energy Systems

October 2005

TENDERS CLOSE WITH: Bushlight, 32 Priest Street Alice Springs 0871 DATE: Tuesday 6 / 12 / 2005 TIME: 2 pm

23/09/2005 Contents of Invitation to Tender Contract: NQ07-0905 Household Renewable Energy Systems

Contents of Invitation to Tender 1. Background

2. Conditions of Tendering

3. Form of Tender and Tender Schedules

4. Annexure to the General Conditions of Contract

5. Particular Conditions of Contract

6. Technical Specification

7. Drawings

8. Site Information

9. Commissioning Documents

September 05 Section 1

Bushlight


Background for Tender

23/09/2005 Section 1- Background to Tender Page 2 Contract: NQ07-0905 Household Renewable Energy Systems

Background

1.1 The Bushlight Project

Bushlight is a 4-year project that improves livelihood choices for small and remote Indigenous communities in WA, NT, SA and Qld through improved access to sustainable renewable energy (RE) services.

Key benefits of Bushlight include: 1. An improved understanding of, and confidence in, renewable energy systems and increased

self-sufficiency of the remote communities 2. Improved reliability of renewable energy systems to enhance the quality of life in remote

communities 3. A reduction in diesel consumption freeing up funds to be used elsewhere 4. Stimulating further development of the Australian renewable energy industry and research

sector Bushlight has regional teams in Central Australia, the Northern Territory’s Top End, the Kimberley and North Qld who work closely with community members to provide energy services which will support community energy decisions affecting livelihood aspirations.

Bushlight aims to provide sustainable energy outcomes by providing highly reliable RE systems, developing improved community capacity/confidence to choose and manage RE services, and establishing a qualified technical support network to service RE systems. Bushlight also provides commercial opportunities for the supply, installation and servicing of RE systems and components.

1.2 Reliable RE Systems

Bushlight has a range of strategies to provide highly reliable RE systems. These include: 1. Constructive engagement with the RE industry through industry forums, formal and informal

consultation rounds 2. Pre-testing RE system components specified in Bushlight supply contracts 3. Rigorous system commissioning standards and 12-month defects liability period.

1.3 Developing improved community capacity/confidence

Bushlight has developed a community energy planning model to build awareness, confidence and capacity in relation to RE services choice and management. In addition to facilitating community energy planning, other community confidence building strategies include: 1. Development of Regional Energy Plans to identify existing energy infrastructure and outline

priorities and strategies for addressing energy demands 2. Application of community energy planning processes 3. Provision of Life Cycle Costing to assist in the evaluation of the relative costs of different

types power supply systems 4. Provision of training resources, system manuals and procedural posters that can be used by

community members

23/09/2005 Section 1- Background to Tender Page 3 Contract: NQ07-0905 Household Renewable Energy Systems

5. Provision of system component maintenance and demand-side management training to system users and community essential service providers

6. Provision of a telephone support service for system users and community essential service providers

7. Remote and on-line system performance monitoring

1.4 Technical Service Provider network

Bushlight is establishing a qualified Technical Service Provider network to provide system scheduled and unscheduled maintenance and servicing for Bushlight and other remote area power systems. Bushlight is establishing a legacy of regional and community energy plans, RE system and component standards, a community energy planning model and ongoing commercial opportunities for RE industry contractors.

1.5 Functional Description

Bushlight Household Renewable Energy Systems are “standalone” photovoltaic (solar) powered systems”, designed to provide 100% of the design load from renewable energy. The system shall provide 240 VAC single phase power. The Household Renewable Energy System performs the following functions: 1. Connection of solar input: The system includes either a roof or ground mounted photovoltaic

array to provide daily energy input.

2. Equipment Enclosure: Electrical equipment is housed in an equipment enclosure, and includes an inverter, charge controllers and all necessary circuit breakers, switch and control gear for the Household Renewable Energy System.

3. Battery Enclosure: The system includes a battery bank to provide energy storage. The battery bank will be housed in the battery enclosure(s).

4. Load distribution: The system provides AC load distribution from the equipment enclosure to meet the predetermined household electrical needs.

5. Monitoring of system performance: The system monitors system performance using a Bushlight pre-approved inverter and additional equipment as detailed in this Specification. The monitoring system will also be used to operate a fault light to be located on the User Interface.

6. Generator backup: Provision is made for the connection of a diesel or petrol generator backup (supplied by others) and a manual change-over switch. The system shall provide a 240VAC signal when the generator is running and meeting the load.

7. User interface: A user interface shall be provided. This shall be accessible to users upon opening of the exterior self-closing panel. Once the panel has been opened the user can view key system indicators and meters, and operate load distribution switches and circuit breakers.


Bushlight


Conditions of Tendering for the Supply and Installation of Household Renewable Energy

Systems

23/09/2005 Section 2 - Conditions of Tendering Page 2 Contract: NQ07-0905 Household Renewable Energy Systems

Basis of Tender 1.1 General

Tenderers are to satisfy themselves as to the nature of the Site of the Works and of all matters relating to the Works, including but not limited to the nature of ground, condition of the Site, and likely weather conditions.

The tenderer may carry out a site visit to further assess the works described in this document but will do so at their own expense. Access to these sites must be arranged through Bushlight and tenderers are to provide 7 days notice of a proposed site visit.

Every tenderer must not collude with, accept any commission from, offer any commission to, or inflate its tendered price for the benefit of, any other Tender or disclose any part of its Tender to any other Tenderer.

1.2 Tender Inquiries

All Tender Inquiries shall be submitted in writing to:

Bushlight Capital Works Manager

Address: 32 Priest Street, PO Box 8044, Alice Springs, NT 0871

Phone 08 8951 4341

Facsimile: 08 8951 4333

Email: [email protected]

Tenderers shall note that questions submitted to the Principal, and the answers to these inquiries may be made available to all Tenderers.

1.3 Non-Conforming Tenders

Any Tender which does not comply with the requirements of the Tender Documents or which contains provisions not required by the Tender Documents may be rejected by the Principal, at its absolute discretion.

Tenderers may submit alternative materials/components in Tenders to that specified herein. Any such exception to the Specification shall be expressly stated in the Tender and clearly identified as an exception to the Specification. Any such Tender shall be accompanied by full details of the alternative and documented evidence of its ability to achieve the specified quality and other requirements.

Any alternative systems will only be considered if submitted in conjunction with a conforming tender.

1.4 Opening of Tenders

Tenders will not be subject to a public opening.

1.5 Withdrawal of Tenders

A Tenderer may withdraw their Tender at any time after the expiration of sixty days from the date of closing of Tenders, but shall not withdraw its Tender prior to the expiration of such period.

23/09/2005 Section 2 - Conditions of Tendering Page 3 Contract: NQ07-0905 Household Renewable Energy Systems

1.6 Acceptance of Tenders

The Principal shall not be bound to accept the lowest or any tender. The Principal may accept the Tender that in view of all the circumstances appears to be the most advantageous to the Principal.

The Principal reserves the right by negotiation to confer with any or all Tenderers to reach an agreement or compromise in relation to all matters covered by the Tender. If none of the Tenders are acceptable, negotiations for an amended Tender may be conducted, in the first instance, with the initially preferred Tenderer, or the tender process may be abandoned.


Bushlight


Form of Tender and Tender Schedules

26/09/2005 Section 3 - Form of Tender and Tender Schedules Contract: NQ07-0905 Household Renewable Energy Systems

Form of Tender Name of person, firm or company tendering USE BLOCK LETTERS

Address of

hereby tender(s) to perform the work for

Description of Works Household Renewable Energy System

The Supply and Installation of Household Renewable Energy Systems for

Fish Hole

(Contract No NQ07-0905 in accordance with the following Documents:

General Conditions of Tendering

Tender Form

Schedule A – Tendered Lump Sum and Schedule of Rates

Schedule B – Day work Charges

Schedule C – Company Information

Schedule D – Program

Schedule E – Proposed work force

Schedule F – Code of Conduct

Schedule G – Declaration

AS 2124-1992 General Conditions of Contract

Annexure Parts A & B to the General Conditions of Contract

Particular Conditions of Contract

Technical Specification for Contract

Drawings as listed in the Specification

Write total tendered price here and provide amount in numerals

Note: this is the combined total of all works for all sites

For the lump sum of ............................................................................................................................ ............................................................................................................................ ($ AUS ) Including GST

If the tenderer is a firm the full names of the individual members of the firm must be stated here.

Insert date.

DATED this ................................. day of ............................. 20.......

Signature of Tenderer

26/09/2005 Section 3 - Form of Tender and Tender Schedules Contract: NQ07-0905 Household Renewable Energy Systems

Schedule A - Tendered Lump Sum

Site Name Description

A-1. Fish Hole Household Renewable Energy System

Fish Hole

Schedule A-1 Contract: NQ07-0905

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Site and Work Information

Site Details Community Name Fish Hole

Location Approximately 6km east of Kowanyama Refer to map/drawing in Section 8 of Tender

Access conditions Dirt access road. Good road conditions. Drive along the Pormpuraaw road and turn left just after the first culvet. (approx 5 kms) Impassable river crossing in wet season.

Phone 08 8951 4385 Fax 08 8951 4333 Contact person for Tender information Alison Sutherland Mobile - Email [email protected] Phone 07 4031 0505 Fax 0429 875 084 Contact person for site access information Cheryl Prestipino

Fax 07 4031 0431 Email [email protected] Toilet Shower Potable Water Shelter

Site Amenities available to contractor Y Y Y At Kowanyama there is a guest house.

System Design Details System Load Details PV Array Batteries

Average Summer 5.7 kWh/day Min. Array Output (nominal) 2.72 kWp System Voltage 24 V Average Winter 5.7 kWh/day Orientation 0 o E of N +/- 2o Min Battery Bank Capacity 1700 Ah @ C100

Peak Load 1.3 kW Tilt Angle (from horizontal) 10 o +/- 1o Number of strings 1 Surge Load 3.9 kVA

PV Charge Controller Cable Sizes/Lengths Inverter Total Design Current 102 A PV String to M. Box - Length 4 m

Continuous Capacity @40C 2.2 kW @ 40oC Capacity of Regulator 60 A PV String to M. Box – Size 6 mm2 Charge Controllers Quantity 2 M. Box to Enclosure - Length 18 m

Marshalling Box Quantity 2 M. Box to Enclosure - Size 70 mm2

Equipment Location and Installation Details

System Component Quantity Preferred Model or Size Installation Location Installation Details

Equipment Enclosure 1 BL1v3 House 1 SW exterior wall on top of battery box • Concrete pad to locate the enclosure must

be raised to at least the floor slab height

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(approximately 150-200mm) due to flooding concerns.

• Dimensions of concrete pad must allow for enclosure and sufficient standing space in front to safely access equipment.

• Skillion roof required to shelter BL enclosure from rain and all sun

• See details in Other Works below.

Battery Enclosure 1 Bushlight supplied

As above • As above

PV Array Frames

Contractor to determine

Ground mounted

Approximately 15m S of House 1 – refer to Map 3: Fish Hole Site Layout. Contractor to ensure shading from ablutions (to be completed at time of install) does not affect the PV array

• Orientation - 0.0°±2° • Array tilt angle - 10.0°±2° • Array to be mounted a minimum of

1200mm above ground level to alleviate shading issues

• The ground underneath the array shall have weed control measures carried out as per the BL1 installation specifications.

PV Modules

2.72kWp (34 * 80W or equivalent)

BP380 or pre-approved equivalent

On the above frames As per Bushlight Installation Specification and manufacturer requirements.

PV Charge Controller(s) 2 PL60 Installed in the above Equipment Enclosure As per Bushlight Installation Specification

Marshalling Box(s)

Contractor to determine

Must be large enough to allow 70mm cable bending and termination

As per Bushlight Installation Specification

Inverter

1 Selectronics SA32 - 2.2kW @ 40ºC

Installed in the above Equipment Enclosure As per Bushlight Installation Specification

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Batteries 1700Ah 1 string of 12

* 1700Ah or equivalent

Installed in the above battery enclosure(s) As per Bushlight Installation Specification and manufacturer requirements.

Remote User Interface(s) 1 Bushlight

supplied Internal SW wall of proposed kitchen refer to Map 3: Fish Hole Site Layout.

If outdoor kitchen not constructed by time of BL install, RUI to be located inside roller door of house 1

Generator Set Connection Genset CB Size (A)

16A (contractor to ensure appropriate size of circuit breaker to protect existing cable, taking into account the fault current generating capacity of the generator)

Connection Method

• Genset to be plug connected (as per current situation)

• Disconnect from existing CSB and feed to BL1 enclosure genset connection point. To be hard wired to BL1 enclosure

Earthing and lightning protection

The expected number of ‘Thunder Days’ per year for this site are 40 - 50 Days. Note: Where the number of thunder days equal to, or greater than, 40 days per year, the Bushlight generic earthing and lightning protection plan shall be implemented for this site

Lightning Protection required (Yes/No) Yes

Monitoring and Communications Monitoring type Inverter Based Monitoring Communications Not required Circuit configurations

No. Circuit Name Location Existing Connection Point CB (A) Timer Duration (Hrs)

PE Cell (Y/N) Other Details

Essential Circuits

1 K1EFF Bushlight Enclosure

New 6 N Fridge and freezer outlet located midway along SW side of outdoor kitchen.

2 H1ESD Bushlight Enclosure

New 4 N Located in the enclosed shed in a suitable location.

3 H1EXL Bushlight

Enclosure New 4 Y House 1 (enclosed shed) outdoor fluoro (SE corner),

dusk to dawn PE cell for this light. BL enclosure light (SW) and toilet lights.

4 H1EL Bushlight Enclosure

New 4 4 N SW light for proposed outdoor kitchen. SW light in House 1.

Discretionary Circuits

1 H1DL Bushlight Enclosure

New 4 4 N All other lights i.e. House 1 – eastern end, open shelter, proposed outdoor kitchen and shower

2 H1DP New 4 4 N All other GPOs existing in house 1 and shelter. Open shelter, NW and SE sides, outdoor kitchen SW side,

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Circuit configurations No. Circuit Name Location Existing Connection Point CB (A) Timer Duration

(Hrs) PE Cell (Y/N) Other Details

House 1 east and west corners

3 H1DF House 1, kitchen

New 4 N Electronic timers

4 Genset Only Circuits

1 H1GP Bushlight Enclosure

New 16 N House 1, SW interior wall (west end) double GPO.

2 KGP Bushlight Enclosure

New 16 N Outdoor kitchen double GPO, W corner

3 Note: Wiring for this site may need to be in conduit as no walls or ceilings in some of the structures.

Demand Side Management Individual Device Timers ID Location Number

required Preferred

Model Duration (Hours) Details

1. Proposed toilet 1 Clipsal

319HP or approved equivalent

0.25 • Supply and install pneumatic timer in (proposed) toilet for lighting • Feed from H1EL circuit

2. BL enclosure 1 Clipsal


0.16 • Supply and install pneumatic timer at BL enclosure for lighting • Feed from H1EXL circuit

3. Proposed shower 1 Clipsal


0.25 • Supply and install pneumatic timer in (proposed) shower for lighting • Feed from H1DL circuit

4. House 1, adjacent to fan switch

1 Clipsal 31VETR3 or approved equivalent

9 • Supply and install electronic timer • Feed from H1DF circuit

5. Outdoor kitchen, 1 Clipsal 4 • Supply and install electronic timer

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adjacent to fan switch

31VETR3 or approved equivalent

• Feed from H1DF circuit • This to be mounted in weather resistant Clipsal 255 or similar

Notes: 1. Device timers to be installed to replace or adjacent to existing switches, or as otherwise directed by the Bushlight Regional Manager. 2. For 31VETR3 timers, neutral wire connection may need to be run to these switches (if not already present). 3. With 31VETR timers, a 2-10µF capacitor (MM Electrical Part # AIMK1100060 or equivalent) may need to be installed to enable some fluorescent lights (i.e. old type ballasts) to

operate. Preference is for a 2µF capacitor. Alternatively the ballast in these lights could be replaced with electronic ballasts. Alternatively a 31VETR3 switch could be installed, if a neutral connection is available or can be installed to the switch.

PE Cells ID Location Number

required Preferred

Model Duration (hours) Details

1. House 1 1 56PEDD3

(or approved equivalent)

Dusk till dawn

• Supply and install PE cell timer • For operation of house 1 exterior light • H1EXL circuit

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Work Descriptions and Calculations

RE Enabling Equipment

Component Manufacturer Nation of manufacture Model Rating Warranty Period Quantity Supplier $ Price (ex GST)

Inverter Selectronics Australia SA32 2.2kW @

40C 1 Bushlight -----------------

Batteries Contractor Regulator 1 Plasmatronics Australia PL60 60A 1 Bushlight ----------------- Regulator 2 Plasmatronics Australia PL60 60A 1 Bushlight -----------------

Regulator Synchronizer Plasmatronics Australia PLA 1 Bushlight ----------------- Battery Enclosure Sage Australia BL1v3 1 Bushlight -----------------

Equipment Enclosure Sage Australia BL1v3 1 Bushlight ----------------- Remote User Interface Sage Australia BL1v3 1 Bushlight -----------------

Spare Parts Kit Sage Australia BL1v3 1 Bushlight ----------------- Battery Maintenance Kit Contractor

O & M Manuals Sage Australia BL1v3 1 Bushlight ----------------- Consumables Contractor

Sub-total (B)

Unless other wise stated all components must be Bushlight approved or approved alternatives as per Bushlight preferred components list http://www.bushlight.org.au/pdf/Buhslight_Component_Preapproved_List.pdf

RE Generating Equipment Component Manufacturer Nation of manufacture Model Rating Warranty Period Quantity Supplier $ Price (Ex GST)

PV Array Contractor Array Frame Contractor

Marshalling Box Contractor Array Consumables Contractor

Lightning Protection Contractor Aggregate and weed matting Contractor

Other Contractor Sub-total (A)

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Insurance & Handling charges on equipment issued by the Principal Item Insurer's Details $ Price (ex GST)

Insurance Handling Fee

Sub-total (C)

Installation Pricing

Activity Comments $Price (ex GST) Travel to and from Site Personnel travel including vehicle rates

Freight to Site Freight of equipment from contractor's depot or starting point to remote site.

Installation & Commissioning Includes all works and labour to complete installation to handover as per technical requirements Indicate estimated man hours for the install phase not including Other Works.

Maintenance Visits (2 visits required)

Include all costs to perform maintenance visit and reporting to the Principal. Time on site; 3 hours per visit.

Sub-total (D)

Demand Side Management

New or Replacement Appliances ID Location Number

required Preferred

Model Details $ Materials

$ Labour

$Amount (ex GST)

1.

House 1 1 Fisher and Paykel 160litre (145W)

• Freezer • To be supplied by community, • To be delivered to site by contractor if purchased in time for install.

Regional Manager to confirm.

2.

House 1 1 Fisher and Paykel 270litre fridge only (120W)

• Fridge • To be supplied by Bushlight, • To be delivered to site by contractor

Sub-Total (E)

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Other Works and Reticulation Other works ID#

Location Preferred Model

Details $ Materials

$ Labour

$Amount (ex GST)

1. SW side of house 1 1 * 20W weather-proof fluorescent

• Supply and install weatherproof fluorescent • To be mounted under skillion roof for BL enclosure • Feed from H1EXL via pneumatic timer

2. House 1 1 * Clipsal 755 or equivalent

• Supply and install smoke detector in house 1 in appropriate location • Feed from H1ESD circuit

3. House 1 1 * 1200mm (70W max) ceiling fan

• Supply and install ceiling fan • Down rod required to ensure 800mm drop from roof mounting point • Feed from BL enclosure H1DF circuit via electronic timer and normal fan switch

4. House 1, SE exterior wall (southern end)

1 * 20W weather-proof fluorescent 1 * weather-proof switch

• Supply and install weatherproof 20W fluorescent • To be fitted high on SE exterior wall (south end) opposite the toilet • Supply and install weatherproof switch • To be fitted adjacent to southern door on exterior wall • Feed from H1EXL via switch and PE cell

5. House 1 1 * single GPO, Clipsal 2015 (or approved equivalent)

• Supply and install standard double GPO on SW interior wall • Feed from BL enclosure H1GP (generator supply) circuit • Bushlight supplied red Traffolyte label to be secured, stating the words “Genset Supply Only”

6. House 1 • Disconnect existing GPO circuit from CSB and re-feed from H1DP circuit 7. House 1 • Disconnect existing generator supply from CSB and re-feed to (as detailed

above in “equipment location and installation details)

8. House 1 • Disconnect south eastern interior 20W fluorescent from CSB and re-feed from H1DL circuit

9. House 1 • Disconnect north western interior 20W fluorescent from CSB and re-feed from H1EL circuit

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10. Open shelter • Split existing 20W fluorescents from existing mixed circuit and re-feed from H1DL (timed) circuit

11. Open shelter • Re-feed both existing GPOs from H1DP • To be reticulated underground

12. Outdoor kitchen (proposed) 1 * 1200mm (70W max) ceiling fan 1 * Clipsal 255 or equivalent

• Supply and install ceiling fan • Down rod may be required to ensure appropriate drop from roof mounting point • Supply and install weatherproof housing for protection of electronic timer • Feed from H1DF circuit via electronic timer and normal fan switch • To be reticulated underground

13. Outdoor kitchen (proposed) 1 * weather-proof double GPO

• Supply and install weatherproof double GPO on SW interior wall • Feed from KGP (generator supply) circuit • Bushlight supplied red Traffolyte label to be secured, stating the words “Genset Supply Only” • To be reticulated underground

14. Outdoor kitchen (proposed) 1 * weather-proof standard double GPO

• Supply and install weatherproof double GPO • To be mounted on the south western interior wall • Feed from K1EFF circuit • Bushlight supplied blue Traffolyte label to be secured, stating the words “Fridge/Freezer Supply Only” • To be reticulated underground.

15. Outdoor kitchen (proposed) 1 * weather-proof double GPO

• Supply and install standard weatherproof double GPO on SW interior • Feed from H1DP circuit • To be reticulated underground

16. Outdoor kitchen (proposed) 1 * 20W weather-proof fluorescent 1 * weather-proof switch

• Supply and install 1 weatherproof 20W fluorescents on ceiling towards south western end (refer Fish Hole map) • Supply and install switch • Feed from H1EL circuit via switch

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• To be reticulated underground 17. Outdoor kitchen (proposed) 1 * 20W

weather-proof fluorescent 1 * weather-proof switch

• Supply and install 1 weatherproof 20W fluorescent on ceiling towards north eastern end (refer to Map 3: Fish Hole Site Layout) • Supply and install switch • Feed from H1DL circuit via switch • To be reticulated underground

18. Toilet (proposed) 1 * 20W weather-proof fluorescent

• Supply and install 20W weatherproof fluorescent in toilet • Feed from H1EL circuit via pneumatic timer • To be reticulated underground

19. Ablutions (proposed) 1 * 20W weather-proof fluorescent

• Supply and install 20W weatherproof fluorescent in shower • Feed from H1DL circuit via pneumatic timer • To be reticulated underground

Note: Concrete slab and skillion roof for the Bushlight enclosure and a Bushlight specification fence is to be completed by the Kowanyama Council.

Reticulation ID#

From To Length (m)

Max Current

(A)

Source CB (A)

Destination CB (A)

Min cable size (mm2)

Notes $ Materials

$ Labour

$Amount (ex GST)

1. BL enclosure Toilet/Laundry/Shower

30m Essential and discretionary circuits

2. Outdoor kitchen Outdoor kitchen 25m All kitchen circuits in this trench

Also open shelter to be fed from this trench

3. Note All underground reticulation shall be with XLPE nylon jacketed cable for the protection against termites, Singapore ants and other insects. For the Central Australian (CE) Bushlight Region this cable is not required, but it is mandatory for the three other Bushlight Regions – Kimberley (KI), Top End (TE) and North Queensland (NQ).

Sub-Total (F)

Tender Cost Summary

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RE Generating Equipment Sub-total (A) RE Enabling Equipment Sub-total (B)

Insurance & Handling Sub-total (C) Installation & Maintenance Sub-total (D) Demand Side Management Sub-total (E)

Other Works and Reticulation Sub-total (F)

Total (Ex-GST)

26/09/2005 Section 3 - Form of Tender and Tender Schedules Contract: NQ07-0905 Community Renewable Energy Systems

Schedule B – Daywork Charges These charges shall apply to time basis variations on site instructed by the Principal. For the purposes of certification of Daywork costs pursuant to Clause 41 of AS 2124 General Conditions of Contract, Tenderers shall complete the following Table of Charges for Daywork.

Charges for Constructional Plant under Clause 41(c) shall include the cost of any stall and loose tools which have an individual new value of less than one thousand dollars ($1000).

Under Clause 41(f), the tender rates shall include all overheads administration and profit.

Bushlight 2004/2005 Procurement Program Plant $ Rate/

KM $ Hourly

Rate $ Daily Rate

4WD Vehicle (including driver)

Truck (including driver)

Dingo

Backhoe

Trencher

Bobcat

Other

Personnel Travel (other than driver)

Extra Person 1

Extra Person 2

Extra Person 3

On Site Labour Electrician

RAPS Technician

Labourer

Other

Overnight Expenses Per Person

Tenderer:................................................Signature:...............................................Date:.......................................................


Schedule C – Company Information

Business Name

ABN

Type of business (partnership, public company, private company, etc.)

Type of services the business delivers

Business Address

Postal Address

Contact Person

Telephone Number

Facsimile Number

Email Address

Names of Directors or Partners

Names and positions of Authorised Signatories

Year business established

Accreditation and licences

Electrical Contractors Licence

BCSE Accreditation No.

Business Accreditation No. (CAL – NT, Register No. -WA, Gold Card – QLD)

Other Accreditations (eg ISO 9002)

Financial: Bushlight may request written advice from a chartered accountant to verity the financial ability for the contractor to undertake the tendered works. Any costs are to be borne by the Tenderer.

Referee Name and Company Contact Phone Project Description

1.

2.

3.

Tenderer: ...............................................Signature:...............................................Date:.......................................................


Schedule D – Program Ordering

Lead time required for components ……….. Weeks

Installation Shade in boxes for each task

Days of Installation Program Start Date

Finish date

TASK 1 2 3 4 5 6 7 8 9 Mobilisation

Site preparation

Enclosure install (including batteries)

PV array install

Other Works (DSM, Retic, repairs etc)

Commissioning

Handover

Site clean up

Demobilisation

Example of a 3 day task starting on Day 4 and finishing on Day 6

Other works

Tenderer:................................................Signature:...............................................Date:.......................................................


Schedule E – Proposed Workforce

1. Subcontractors Details of subcontractors to which the Supplier intends to subject portions of the work shall be listed below. In accordance with the provisions of the contract, the Supplier shall not change the nominated sub-contractors without prior approval by the Purchaser. Please al Name and address of proposed sub-contractor

Work to be sub-contracted

1. Indigenous employees

The supplier is to note in the table below whether they intend to have any Aboriginal or Torres Strait Islanders employed directly by the supplier or its nominated contractors during the life of this contract. Please note whether they are permanent or temporary employees. Number of Permanent

Indigenous employees Number of Temporary/Casual Indigenous employees

Supplier

Nominated Sub-contractors


Schedule F - Code of Conduct 1. Applicable to contractors, subcontractors, suppliers and agents (the `Contractor').

2. There shall be no direct contact or liaison by the Contractor with the community in relation to this contract unless initiated by the community, and then shall be conducted in the presence of the Superintendent's Representative.

3. No loan or gift of equipment, vehicles, food or beverages shall occur to any member of the Community (including elected representatives), unless as part of employment by the Contractor, under award or over award conditions.

4. Services not included in the Contract shall not be provided to Community (including elected Council members) without specific prior approval of the Superintendent's Representative.

5. The Contractor shall not seek employment within the Community during the entire term of the contract.

6. There shall be no initiation or maintenance of sexual or close contact relationships by the Contractor, with any community members. In the event of such an occurrence, instant dismissal and/or removal from the site and the Community will occur.

7. Any racially discriminatory behaviour by the Contractor will result in dismissal and/or removal from the site and the Community.

8. In the event of a dispute arising in relation to the requirements or application of this clause an independent Adjudicator, will consider representations from the Contractor and the Superintendent's Representative. The determination of the Adjudicator shall be adhered to by all parties.

9. The costs for removal of Contractor personnel from the site and replacement by other suitable personnel shall be borne by the Contractor.

10. No pets or animals shall be taken onto site by the contractor.

I/We have read this Code of Conduct and agree to abide by the Conditions whilst on site. PRINTED NAME: PRINTED NAME:

SIGNATURE: SIGNATURE: (Contractor’s

Representative) (Superintendent’s

Representative)

DATE: DATE:

WITNESS: WITNESS:


.

Schedule G – Declaration I/We declare that I/We have read, understood and agree to abide by all the requirements of the Tender Documents, and that all the information provided in the Tender is true and correct.

We declare that we understand and agree that the amount of security and retention to be held is as detailed in Annexure Part A to AS 2124-1992, and maybe greater than 5% of the Contract Sum.

Tenderer: ...............................................Signature: ..............................................Date: ......................................................


Bushlight

Annexure to the General Conditions of Contract


23/09/2005 Section 4 - Annexure of General Conditions of Contract Page 2 Contract: NQ06-0905 Household Renewable Energy Systems

AS 2124-1992 Annexure Part A The law applicable is that of the State or Territory of: (Clause 1) State or Territory in location of works

Payments under the Contract shall be made at: (Clause 1)

The Principal: (Clause 2) Centre of Appropriate Technology

The address of the Principal: 32 Priest Street Alice Springs 0871

The Superintendent: (Clause 2) Mr Lyndon Frearson Capital Works Manager Bushlight

The address of the Superintendent: 32 Priest Street Alice Springs 0871

Limits of accuracy applying to quantities for which the Principal accepted a rate or rates: (Clause 3.3(b))

No Limit

Bill of Quantities-the alternative applying: (Clause 4.1) Alternative 2

The time for lodgement of the priced copy of the Bill of Quantities: (Clause 4.2)

N/A

Contractor shall provide security in the amount of: (Clause 5.2) Nil

Principal shall provide security in the amount of: (Clause 5.2) Nil

The period of notice required of a party's intention to have recourse to retention moneys and/or to convert security: (Clause 5.5)

7 days

The percentage to which the entitlement to security and retention moneys is reduced: (Clause 5.7)

0%

Interest on retention moneys and security-the alternative applying: (Clause 5.9)

Alternative 2

The number of copies to be supplied by the Principal: (Clause 8.3) 2

The number of copies to be supplied by the Contractor: (Clause 8.4)

3

The time within which the Superintendent must give a direction as to the suitability and return the Contractor's copies: (Clause 8.4)

14 days

Work which cannot be subcontracted without approval: (Clause 9.2)

All work under the Contract

The percentage for profit and attendance: (Clause 11(b)) Nil

The amount or percentage for profit and attendance: (Clause 11(c))

5%

Insurance of the Works-the alternative applying: (Clause 18) Alternative 1

The assessment for insurance purposes of the costs of demolition and removal of debris: (Clause 18(ii))

Nil

The assessment for insurance purposes of consultants' fees: (Clause 18(iii))

Nil

23/09/2005 Section 4 - Annexure of General Conditions of Contract Page 3 Contract: NQ06-0905 Household Renewable Energy Systems

The value of materials to be supplied by the Principal: (Clause 18(iv))

Up to $ 30,000

The additional amount or percentage: (Clause 18(v)) 10%

Public Liability Insurance-the alternative applying: (Clause 19) 1

The amount of Public Liability Insurance shall be not less than: (Clause 19)

$5,000,000 any one occurrence

The time for giving possession of the site: (Clause 27.1) Principle shall advise upon acceptance of tender

The Date for Practical Completion: (Clause 35.2) 6 weeks from the date of awarding of contract

Liquidated Damages per day per Bushlight System Installation site: (Clause 35.6)

$100/day/site

Limit of Liquidated Damages: (Clause 35.7) 5% of contract value

Bonus per day for early Practical Completion: (Clause 35.8) Nil

Limit of bonus: (Clause 35.8) N/A

Extra costs for Delay or Disruption: (Clause 36) To be stated by Tenderer (0 if not stated)

The Defects Liability Period: (Clause 37) Twelve months

The charge for overheads, profit, etc. for Daywork: (Clause 41(f))

To be stated by Tenderer, 0% if not stated.

Times for payment claims: (Clause 42.1) Submit on Practical Completion

Unfixed plant and materials for which payment claims may be made notwithstanding that they are not incorporated in the Works: (Clause 42.1(ii))

Nil

Retention Moneys on: (Clause 42.3) $ 3,500

Unfixed Plant or Materials-the alternative applying: (Clause 42.4)

Alternative 1

The rate of interest on overdue payments: (Clause 42.9) 7% per annum

The delay in giving possession of the Site which shall be a substantial breach: (Clause 44.7)

3 months or UNLIMITED if Contractor is in breach of Clause 14.1 or 21.1

The alternative required in proceeding with dispute resolution: (Clause 47.2)

Alternative 2

The person to nominate an arbitrator: (Clause 47.3) President of Institution of Engineers, Australia

Location of arbitration: (Clause 47.3) State or Territory in location of work


Bushlight


Particular Conditions of Contract

23/09/2005 Section 5 - Particular Conditions of Contract Page 2 Contract: NQ06-0905 Household Renewable Energy Systems

Contents of Particular Conditions of Contract

1. Particular Conditions of Contract ............................................................. 3

1.1 Nature and Extent of Contract ..................................................................................3 1.2 Materials to be provided by the Principal..................................................................3 1.3 Defects Period ..........................................................................................................3 1.4 Warranties ................................................................................................................4 1.5 Occupational Health, Hygiene, Welfare and Safety..................................................4 1.6 Environmental Protection .........................................................................................4 1.7 Works Program.........................................................................................................5 1.8 Work Hours...............................................................................................................5 1.9 Publicity ....................................................................................................................5 1.10 National Code of Practice for the Construction Industry...........................................5 1.11 Site Facilities ............................................................................................................6 1.12 Public Utilities ...........................................................................................................6 1.13 Community Protocol .................................................................................................6 1.14 Operating Manuals ...................................................................................................6 1.15 System Commissioning ............................................................................................7 1.16 Handover and training ..............................................................................................7 1.17 Scheduled Maintenance ...........................................................................................7

APPENDIX 1. Statutory Declaration By Contractor .................................. 8


1. Particular Conditions of Contract

1.1 Nature and Extent of Contract

This Contract is a Lump Sum Contract. The Contract Sum shall include all applicable GST and be full compensation for the complete construction of all works under this Contract, including any items of work not specifically mentioned but necessary to complete the works of the Contract in accordance with the intention of the Drawings, Site Information and Specifications.

The Contract Sum shall be a fixed sum not subject to adjustment for rise and fall.

The Schedule of Tendered Lump Sum forms part of the Contract only to the extent that it will be used as a guide to the assessment of the progress payments and variations, if appropriate.

The work to be performed under this Contract comprises the provision of all materials, plant and labour and the performance of all operations of whatever kind necessary for the complete and proper construction of the Works associated supply and installation of the remote area power supply systems as indicated on the drawings and the specification.

No variations to the work shall be undertaken by the Contractor without a notice in writing by the Works Superintendent. The Contractor on receipt of such notice shall provide to the Works Superintendent written acknowledgment of receiving the notice. A variation shall be valued by agreement between the Contractor and the Works Superintendent prior to variations being carried out.

The contractor shall pay fees, provide notices and comply with the regulatory authorities as required in the State or Territory that the work is undertaken.

The Principle reserves the right to request a Statutory Declaration from the Contractor with each progress claim declaring all workers, sub-contractors and suppliers have been paid all monies due and payable to them up to the date of submission. An example of a Statutory Declaration is provided in Appendix A.

1.2 Materials to be provided by the Principal

Materials provided by the Principal are detailed in the Schedule A. The contractor will be required to receive theses materials at their business or nominated address and store, handle and transport them to site at the time of mobilisation. Upon receipt the Contractor shall visually inspect the materials (and packaging) for signs of damage, and confirm to the Principal in writing that the materials have been received in good condition. The contractor shall ensure that the materials are insured against damage due to any cause whatsoever from the time receipt to handover at site. Insurance and handling costs are to be included in the Tender Schedule.

1.3 Defects Period

If a fault is reported during the Defects Liability Period (and when a maintenance visit is not scheduled), Bushlight will generally investigate and determine the cause for the fault. The cost of Bushlight’s travel and inspection time will be borne by the Principal.

If the fault is determined to be due to a defect in the manufacture or installation, the Contractor will be notified and requested to rectify the defect at the Contractor’s expense. If agreed by both the Contractor and the Superintendent, Bushlight personnel may be able to complete the required rectification work during the investigation visit at the Contractors cost. Bushlight hourly rate is $50/hr. Any agreement between Bushlight and the Contractor to rectify a defect in this way would be on the condition that the work undertaken by Bushlight would not void the warranty in any way. If in rectifying a defect on behalf of the Contractor, a spare part held by Bushlight is used, the Contractor shall arrange and pay for the replacement of the spare including the associated freight.


If the Contractor attends a site at the specific request of the Principal to rectify a defect and it is subsequently determined to the satisfaction of the Principal that no manufacturing or installation defect existed (i.e. the fault was due to circumstances outside of the responsibility of the Contractor), the Contractor will be reimbursed reasonable travel and labour expenses.

1.4 Warranties

The Contractor shall register warranties with the manufacturers as necessary and complete a Warranty Schedule recording the item, manufacturer, period and type of warranty. The contractor shall retain copies of warranties delivered with components and equipment for handover to the Principal with the operation manuals. The Contractor shall ensure that all warranty entitlements arising from the works include the Principal and the Contractor as named beneficiaries. Such warranties shall be in a form approved by the Superintendent and shall be submitted to the Superintendent prior to the issue of the final payment certificate.

Warranty periods shall commence at practical completion.

1.5 Occupational Health, Hygiene, Welfare and Safety

The Contractor shall be directly responsible for safety during and associated with the performance of the work under the Contract, including the safety and protection of its own Employees, other personnel, the public and all other people and for the protection of the property of the Principal, the public and third parties.

The Contractor shall establish and operate an Occupational Health and Safety Plan (Safety Plan) which will manage safety during work under the contract in accordance with all applicable statutory requirements in force at the time. The Contractor shall ensure that all of its employees, subcontractors, agents, consultants and guests are familiar with the particular hazards and responsibilities of their jobs and have read, understood and comply with the Safety Plan.

Preparation of the Safety Plan should include, but not be limited to, consideration of the following:

1. Safety Meetings 2. Work Methods 3. Accidents and Incidents 4. First aid equipment and facilities 5. Safety Equipment 6. Personal Protection Equipment 7. Competent or licensed Employees 8. Fire Precautions 9. Emergency Response

The Contractor shall notify the Superintendent of any and all accidents within the meaning of the Workers' Compensation Acts and/or Regulations which may happen to his employees or employees of his Sub-Contractors or nominated Sub-contractors engaged on the Contract work within 24 hours of the occurrence of each such accident.

1.6 Environmental Protection

During all work under the contract, the Contractor shall take all steps necessary to prevent damage to the environment on or about the Site and to existing facilities including the adjacent public roadways. The Contractor shall manage the protection of the environment in accordance with all applicable statutory requirements in force at the time.

The Contractor shall ensure that all persons engaged in providing the Services are fully aware of, and comply with, requirements in relation to environmental protection and conservation.


The Contractor, at its own cost and to the satisfaction of the Principal, shall be solely responsible for the remediation of any environmental damage or contamination caused by the Contractor during the work under the contract.

The Contractor shall not cause or permit damage or injury to any tree, other vegetation and fauna. The written permission of the Principal must be obtained before any tree or other vegetation can be removed, destroyed or damaged.

The Contractor also must comply with the Conservation of Wildlife Act.

1.7 Works Program

The tender program, schedule D, is to be updated within two (2) weeks of the date of the Letter of Acceptance by the Contractor and submitted to the Principal.

The Works program shall take into account lead times for the supply of materials.

Before entering on private or other land for any purpose whatsoever, the Contractor shall give at least forty-eight (48) hours clear notice of intention of the installation in writing to the Superintendent. The contractor will also advise installation start date. The project plan will be updated with this starting date. The Superintendent will then, in writing, advise the contractor of the access requirements.

If, in the opinion of the Superintendent, the Contractor falls behind the program, the Contractor shall take such steps as considered necessary by the Superintendent to improve progress. The Contractor shall submit a revised program in an approved form indicating the manner in which the works shall be completed including as necessary what additional resources are to be utilised within the specified time. No additional cost shall be incurred by the Principal due to such measures.

Failure of the Contractor to comply with the requirements of the Superintendent as specified above and to improve progress to comply with the current approved program shall constitute a default by the Contractor under the terms of the General Conditions of Contract. Neither the submission of, nor the approval of a construction program by the Superintendent shall relieve the Contractor of any of its duties or responsibilities under this Contract.

1.8 Work Hours

Work hours on site will normally be restricted to 7.30 am to 6.00 pm, Monday to Saturday. These times can only be varied with the prior approval of the Superintendent. If variation to these schedule hours of work is needed the approval of the Superintendent shall be obtained, and such approval may contain conditions.

1.9 Publicity

The Works under the contract are a confidential matter between the Principal and the Contractor. The Contractor shall not make any media release or other public statement without written approval from the Principal.

1.10 National Code of Practice for the Construction Industry

The Contractor shall comply, in the performance of this Contract, with the requirements of the National Code of Practice for the Construction Industry (the code) and the Industry guidelines for the industrial relations and occupational health and safety components of the National Code of Practice for the Construction Industry (the industry guidelines), both of which are from Australian Procurement and Construction Council Inc, Unit 6 First Floor, James Darling House, 42 Geils Court, Deakin ACT 2600, Phone: 02 6285 3255.


Compliance with the code or the industry guidelines shall not relieve the contractor from responsibility to perform the contract, or from liability or any defect in the Works arising from compliance with the code or the industry guidelines.

1.11 Site Facilities

Existing power, water and shower/toilet facilities as listed in Schedule A may be available for use by the Contractor. However, the specific availability of such amenities is not guaranteed by the Principal. The location of establishment of the Contractor's site facilities shall be to the approval of the Superintendent.

The Contractor shall make all arrangements and pay all charges in connection therewith, for any temporary services that may be required for the execution of all works under this contract.

1.12 Public Utilities

The Contractor shall take care to protect facilities from damage and, in the case of any damage occurring to facilities, the matter shall be immediately reported to the owner of the plant and to the Superintendent. The cost of the necessary repairs or renewals shall be borne entirely by the Contractor.

If it is found to be necessary to alter the location or level of any existing mains or services to conform with construction under this Contract then the Contractor shall notify the Superintendent immediately.

1.13 Community Protocol

All persons intending to visit Aboriginal communities for any purpose associated with this contract must prior to visiting, obtain permission to enter from the community via the Principal. In the case of carrying out inspections and installation activities in relation to this contract the contractor shall obtain all permissions through the Principal.

All persons visiting or engaged in building activities on communities must abide by all rules, regulations and conventions laid down by the community council and shall endeavour at all times to be aware that the community has long-established traditions, language and codes of behaviour which must be respected. The community rules may include restricted access to designated areas, working hours, work on Sundays, restrictions on consumption and sale of drugs and alcohol and the like. The Code of Conduct included in Schedule E must be adhered to and must be completed before any works begin on site.

The Contractor shall ensure that local and Community regulations concerning behaviour and access are adhered to at all times. The Contractor shall contact the Community Chairperson for any further information regarding Community By-laws.

As a component of Site Establishment, the Contractor is to ensure that all workers have been briefed by a Bushlight Regional Manager or nominated representative on the customs and traditions that will impact upon their work and which must not be contravened.

All costs associated with complying with this clause shall be deemed to have been included in the lump sum tender price.

1.14 Operating Manuals

The Contractor will be provided with a Bushlight Household Renewable Energy System Operating Manual. This manual is supplied with all Bushlight equipment enclosures. The manual includes installation, operating and maintenance instructions, fault finding guidelines and commissioning forms.


It will be the Contractors responsibility to complete in full all sections of the commissioning documentation within the Operating Manual. This includes all the commissioning forms, a scaled site map and nominated site photos. A generic version of these commissioning documents is provided in this Tender for general information for the Tenderer.

The Operating Manual with the completed commissioning documentation will be left on site (in the enclosure) by the contractor. System photographs will be provided to the Principle in a digital format. A sum of $ 1 000 shall be retained until the Manuals, including the site map and photographs are completed and acceptable to the Principle.

1.15 System Commissioning

Unless otherwise specified by Bushlight, the final system commissioning will occur in the presence of a Bushlight representative. As the completion date approaches Bushlight and the Contractor will coordinate a suitable date and time for the system commissioning. As noted above, it will be the Contractors responsibility to complete in full all sections of the commissioning documentation within the Operating Manual.

1.16 Handover and training

The Contractor shall provide Bushlight at least one weeks notice prior to the commencement of the final commissioning and handover of a system. Bushlight will advise the contractor if a representative will attend to inspect the installation and witness the commissioning. The Contractor shall provide system users with basic system operation and troubleshooting training. Bushlight will provide detailed user training to the community.

1.17 Scheduled Maintenance

The Contractor shall carry out two scheduled maintenance visits to the site within 12 months of the date of commissioning in accordance with the procedures approved by Bushlight. The first would be scheduled at approximately six (6) months and the second at twelve (12) months to coincide with the end of defects period. The timing of these visits is to be determined with Bushlight. Bushlight may require additional maintenance visits as detailed in Schedule A. The Contractor shall provide Bushlight at least one weeks notice prior to a scheduled maintenance visit. Bushlight will advise the Contractor if a representative will attend the maintenance visit.


APPENDIX 1. STATUTORY DECLARATION BY CONTRACTOR

Statutory Declaration by Contractor Oaths Act 1867

To Wit

1, ……………………………………………………………….. of …………………………… do solemnly and sincerely declare that, in relation to the Contract between

……………………………………. “the Principal” and ……………………………..…… “the Contractor” for construction of ……………………………………… Contract No. …………. (the Contract).

1. I hold the position of ............................................................................................................

I am in a position to know the facts contained herein and to bind the Contractor by the terms of this declaration, and I am duly authorised by the Contractor to make this declaration on its/his behalf.

2. All the Contractor’s workers who at any time have been engaged on work under the Contract by the Contractor have been paid in full all moneys due and payable to them up to the date of submission by the contractor of Progress Claim No. ………………

3. All Subcontractors, Suppliers and Consultants of the Contractor have been paid all that is due and payable to them up to the date of submission by the Contractor of Progress Claim No. ………… in respect of their part of the work under the Contract.

And I make this solemn declaration conscientiously believing the same to be true.

.........................................................................

(Signed)

TAKEN AND DECLARED before me

(name in full) ...................................................

..........................................................................

at ......................................................................

in the State/Territory of . ..................................

this ...................................................................

day of .................................................. 20.......

.........................................................................

A Justice of the Peace


Bushlight

September 2005


Technical Specification

23/09/2005 Section 6 – Technical Specification Page 2 Contract: NQ07-0905 Community Renewable Energy Systems

CONTENTS OF TECHNICAL SPECIFICATION 1. GENERAL.................................................................................................................4

1.1 Overview of Bushlight Household Renewable Energy Systems.................................. 4 1.2 Scope of Installation..................................................................................................... 4 1.3 Standards..................................................................................................................... 5 1.4 Definitions..................................................................................................................... 6 1.5 Packing and Transit Protection .................................................................................... 6

2. MAJOR SYSTEM COMPONENTS...........................................................................7 2.1 Battery and Equipment Enclosures.............................................................................. 7

2.1.1 Supply ...................................................................................................................... 7 2.1.2 Installation................................................................................................................ 7

2.2 Inverter ......................................................................................................................... 7 2.2.1 Supply ...................................................................................................................... 7 2.2.2 Installation................................................................................................................ 7

2.3 Charge Controllers ....................................................................................................... 7 2.3.1 Supply ...................................................................................................................... 7 2.3.2 Installation................................................................................................................ 7

2.4 Monitoring system........................................................................................................ 8 2.4.1 Installation................................................................................................................ 8

2.5 Remote User Interface (RUI) ....................................................................................... 8 2.5.1 Supply ...................................................................................................................... 8 2.5.2 Installation................................................................................................................ 8

2.6 Battery Bank and Battery Maintenance Kit .................................................................. 8 2.6.1 Supply ...................................................................................................................... 8 2.6.2 Installation................................................................................................................ 9

2.7 PV Modules.................................................................................................................. 9 2.7.1 Supply ...................................................................................................................... 9 2.7.2 Installation................................................................................................................ 9

2.8 PV Array Mounting Frames.......................................................................................... 9 2.8.1 Supply ...................................................................................................................... 9 2.8.2 General requirements .............................................................................................. 9 2.8.3 Orientation, Tilt angle............................................................................................. 10 2.8.4 Array wiring............................................................................................................ 10 2.8.5 PV Marshalling boxes ............................................................................................ 10 2.8.6 Fire Protection........................................................................................................ 10

3. GENERAL INSTALLATION REQUIREMENTS......................................................11 3.1 Equipment Location ................................................................................................... 11 3.2 Equipment Protection................................................................................................. 11 3.3 Cabling ....................................................................................................................... 11

3.3.1 Cable specification................................................................................................. 11 3.3.2 Cable colour........................................................................................................... 11 3.3.3 Cable identification ................................................................................................ 11 3.3.4 Underground reticulation ....................................................................................... 12 3.3.5 Cable protection..................................................................................................... 12 3.3.6 Connectors............................................................................................................. 12

3.4 Fixings........................................................................................................................ 12 3.5 Enclosure Protection .................................................................................................. 12 3.6 Generating Set Connection........................................................................................ 13 3.7 Earthing...................................................................................................................... 13 3.8 Lightning Protection ................................................................................................... 13 3.9 Household Wiring....................................................................................................... 13 3.10 Demand Side Management (DSM) Measures ........................................................... 13 3.11 Marshalling Box and GPO Labels.............................................................................. 13

APPENDIX 1 RELEVANT STANDARDS ...................................................................15


APPENDIX 2 SYSTEM PHOTOGRAPHS ..................................................................16


1. General

1.1 Overview of Bushlight Household Renewable Energy Systems

The Bushlight Household Renewable System has been designed to provide a 100% RE power source for small to medium sized households. A generator can be either hardwired or plug connected to the system but its function is only as a standby power source. To use the generator power a manual changeover must be carried out via a switch on the front panel.

The equipment enclosure contains all of the electrical equipment. This includes the RE management equipment, inverter, load circuits and demand side management.

Significant demand side management measures have been incorporated into the system so that the energy use by the owner can be controlled in an orderly manner. The method by which this is achieved is a negotiated process between Bushlight and the communities and determined largely by community priorities.

The system has a maximum capacity to deliver 10–12 kWh/day on average, dependant on installed region and climatic conditions.

The major system components at their maximum size are:-

PV Array Output 4.5kWp

Battery bank 3500Ah @C100, 24V

Charge controller 180A @ 24V

Inverter 2.2kW Continuous

3.5kW 30min overload

7.0kVA Surge load

Monitoring Inverter based monitoring

1.2 Scope of Installation

The installation of a Bushlight Household RE System includes:

• Supply of components as per requirements set out in Tender Schedule A. Components to be supplied by the installation Contractor may include batteries, PV modules, PV array support structures, PV array marshalling boxes and lightning protection.

• Installation, electrical connection, testing and commissioning of:

o Equipment and battery enclosures,

o Inverter and charge controller(s),

o Battery bank,

o Ground and/or roof mounted PV arrays, including modules, supporting structures and footings,

o System earthing and lightning protection,

o Up to two Remote User Interface units if specified in the tender schedule,

o Data logging and monitoring equipment.


o Additional works to support the installation of the RE System as required, typically including:

o AC and DC household wiring, including the installation of appliances,

o Connections to generator set,

o Installation of circuit and appliance control devices (eg. timers),

o Minor structural additions and modifications (eg. slabs, awnings).

o Basic user training in system operation and troubleshooting.

1.3 Standards

Unless otherwise stated in this specification, all components provided by the contractor shall be in accordance with the Bushlight pre-approved components list. This list can be found at:

http://www.bushlight.org.au/pdf/Bushlight_Component_Preapproved_List.pdf

Unless otherwise stated in this specification, all equipment shall be installed and all work carried out in accordance with relevant Australian Standards, State and local government statutory requirements (including amendments). These standards include but are not limited to those listed in Appendix 2. The photographs provided in Appendix 3 provide examples of preferred and generally acceptable installation practices.

The Contractor shall also install the RE System in accordance with the requirements of the Renewable Remote Power Generation Program (RRPGP) as administered by the applicable state agency. These agencies are:

Sustainable Energy Development Office (SEDO) in Western Australia;

Department of Business, Industry and Resource Development in the Northern Territory;

Equipment Enclosure with door open revealing User Interface

Equipment Enclosure (top) and Battery Enclosure (bottom) for Bushlight Household

Renewable Energy System


Environment Protection Authority in Queensland; and

Department of Minerals and Energy in South Australia. Components and equipment shall be installed in accordance with manufacturers’ requirements to ensure that warranty conditions are met.

1.4 Definitions

The definitions in Table 1 shall apply to this document. Table 1 Standard definitions

Term Definition

Shall Indicates that a statement is mandatory.

Should Indicates a recommendation.

MOVs Metal Oxide Varistors

Nominal system life 20 years

Equipment Enclosure RE System equipment enclosure as provided to the Contractor by Bushlight

Tamper-proof fasteners Fasteners that can not be easily removed using common tools such as standard screwdrivers and spanners. Refer to drawing notes for specific details of fasteners to be used.

Provision Supply and Installation of Component

PV Photovoltaic.

RAPS Remote Area Power Supply

RUI Remote User Interface – external user control unit - optional

Shading On any given day, the exclusion of 90% of direct sunshine on the entire item being shaded and must provide full shading during 0830 to 1630 hours

Solar Used interchangeably with PV.

“Standalone” photovoltaic (solar) power system

A power system that derives 100% of its designed electrical load from photovoltaic (solar) power

1.5 Packing and Transit Protection

All system components and equipment should be packed appropriately for transportation by truck on gravel roads, and for handling by forklifts or HIAB cranes. The Bushlight Equipment Enclosure, Bushlight Battery Enclosures and the inverter will be supplied to the Contractor packed in wooden crates or other appropriate packaging, direct from the manufacturer and will be fitted with active Shockwatch labels. The charge controllers and regulator synchronizer come pre-installed within the Bushlight Equipment Enclosure

Bushlight may reject components that show signs of transportation damage or that it reasonably suspects may have been damaged in transit.


2. Major System Components

2.1 Battery and Equipment Enclosures

2.1.1 Supply The Bushlight Equipment and Battery Enclosures will be free issued to the Contractor and delivered to the Contractor’s premises once a contract has been awarded.

2.1.2 Installation The Contractor shall install the Bushlight Enclosures in accordance with Drawing BL1V2-04-03-G003-01 Bushlight Enclosure – Installation Notes and the installation instructions outlined in the Enclosure Manual provided with the Bushlight Equipment Enclosure . A generic version of the installation and commissioning sections of this manual are included in Section 9 of this Tender for reference by the contractor prior to work on site.

All wiring, to and from the Bushlight Enclosures shall conform to Drawing BL1V2-04-03-G001-01 Bushlight Enclosure – Installation Notes

The physical location of these Bushlight Enclosures will be specified in Tender Schedule A. It is required that they shall be installed on a concrete slab, either inside or adjacent to an existing building, or a under a purpose built shelter to provide environmental protection. The details will be specified in Tender Schedule A.

2.2 Inverter

2.2.1 Supply The inverter will be free issued to the Contractor and delivered to the Contractor’s premises. The inverter will be supplied pre-wired with the appropriate plug connections.

2.2.2 Installation The Contractor shall install, connect (via pre-wired plug connections and terminals) and commission the inverter within the Bushlight Equipment Enclosure once on site.

2.3 Charge Controllers

2.3.1 Supply The Bushlight Equipment Enclosure is designed to contain up to three charge controllers. The appropriate type and number of charge controllers will be pre-installed within the Bushlight Equipment Enclosure that is free issued to the Contractor.

2.3.2 Installation The Contractor shall check that the connections to the Charge Controllers are correct during the on-site commissioning of the system.

During the installation of the system on-site, the Contractor shall mount the temperature sensor for each charge controller on the battery bank in accordance with the notes on Drawing BL1V2-04-03-G001-01 Battery Layout


2.4 Monitoring system

Bushlight Household RE systems are designed with inverter based monitoring. The monitoring system will be configured, installed and tested by the contractor. The Contractor shall carry out onsite commissioning of the monitoring system in accordance with the instructions provided by Bushlight and the enclosure manufacturer.

2.4.1 Installation The contractor will be required to make the connections between the inverter and the pre-wired terminal strip supplied by the enclosure manufacturer. The battery temperature sensor used for monitoring to be installed as per the notes on Drawing BL1V2-04-03-G001-01, Section 6 – BL1V2 Battery Layout.

The inverter download cable supplied shall be fitted to the inverter and left coiled on the top of the inverter case.

2.5 Remote User Interface (RUI)

2.5.1 Supply The contractor will be free issued with any RUI(s) units called for in Tender Schedule A. This requirement is site specific and the system may be installed with the option of none or up to two units. Details of the RUI are to be found in drawing BL1V2-04-01-E005 in Section 6. Complete details will be supplied with the installation instructions from the enclosure manufacturer.

2.5.2 Installation The location of and number of RUI units to be installed will be specified in Tender Schedule A. The interconnecting cable required will be a minimum of 16 core x 0.5mm2 cross sectional area. Possible cable - Farnell 715-670 18 core 16x0.2 (0.5mm2) RS 383-086 18 core 16x0.2 (0.5mm2) both unscreened. The requirement allows the unit(s) to be located up to 50m from the BL1 enclosure. The interconnecting cable must be mechanically protected and installed with due regard to protection from LV wiring within the building and enclosure. Location: Within 50m of enclosure, preferred location kitchen (due regard to hazard or wet areas) or living room Height: Not less than 1200 above floor, not higher than 1800 Weather: Must be in sheltered location No rain, No direct sun Cabling can be from top, bottom or through the back, if existing 25mm access hole is not used a suitable blanking plug must be installed. The RUI shall be securely fixed to the wall with appropriate fixings.

2.6 Battery Bank and Battery Maintenance Kit

2.6.1 Supply The size and number of cells to be installed is specified in Tender Schedule A. Where the Contractor is required to supply batteries, one battery maintenance kit shall also be provided per system and shall contain the following:


Two appropriately sized insulated spanners;

Anti corrosion post compound or spray;

Cleaning and safety equipment; and

2 spare inter-cell links and post connectors (bolts).

The battery maintenance kits shall be stored in a suitable sealed container (eg plastic lunchbox) and left inside the Equipment Enclosure behind the escutcheon panel.

2.6.2 Installation Inter-cell connections shall be made via flexible links with double crimped lugs with heat shrink or equivalent protection. Inter-cell connections shall be of a type approved by the battery manufacturer and be such that terminals are not, under expected site conditions, subjected to mechanical strain.

Batteries, and battery interconnections, shall be installed within the enclosure(s) in accordance with manufacturer’s instructions, relevant standards, and Bushlight Drawing BL1V2-04-03-G001-01, Section 6 – BL1V2 Battery Layout.

Appropriately sized and pre-crimped cables to connect the battery to the battery isolator switch will be provided by the enclosure manufacturer.

2.7 PV Modules

2.7.1 Supply The size and number of modules required is specified in Tender Schedule A.

2.7.2 Installation The PV modules shall be installed and wired as per manufacturer’s requirements and in accordance with Drawing BL1V2-04-03-G002-01, Section 6 – BL1V2 PV Array Layout.

Note that PV modules shall be attached to the array mounting frames with tamperproof fasteners as specified on Drawing BL1V2-04-03-G002-01, Section 6 - BL1V2 PV Array Layout The tool(s) required to fit or remove the Tamper proof fittings used in the installation shall be provided and become part of the site spare parts kit.

2.8 PV Array Mounting Frames

2.8.1 Supply The type of array mounting frames (ground or roof mount) to be used is specified in Tender Schedule A.

2.8.2 General requirements All PV array mounting frames (ground or roof mount) shall meet the following requirements:

The Contractor shall provide a certified drawing of the PV array mounting frames signed by a structural engineer (NPER) certifying that the structure is suitable for use at the installation site. The certification shall include all fixings and footings.

Frames shall be designed to support the modules at the orientation and tilt angle prescribed in Tender Schedule A.

Frames shall be galvanised steel or aluminium construction with all module fixings being corrosion resistant and tamper proof. If pre-galvanised steel is used, all cuts and holes shall be painted with rust inhibiting/preventing paint.


Frames shall allow for the thermal expansion and contraction of solar modules to ensure that damage to the solar modules does not occur;

Frames shall allow for the removal of any one module in the array without having to remove more than adjacent modules.

Frames should be simplistic in design, installation and operation, minimising onsite installation work.

Refer Drawing BL1V2-04-03-G002-01, Section 6 - BL1V2 PV Array Layout for additional specific requirements

Refer Drawing 1V1B-04-02-M001-03, Section 6 – GM20_Generic_20 for examples of ground mount PV Array support structures that are generally acceptable to Bushlight.

Refer Appendix 4 for an example of roof mounting array system that are generally acceptable to Bushlight .

2.8.3 Orientation, Tilt angle The PV array shall be installed in the location, with the orientation and tilt angle specified by Bushlight in the Tender Schedule A.

2.8.4 Array wiring Configuration of array wiring and cable sizes shall be in accordance with the notes on Drawing BL1V2-04-03-G002-01, Section 6 - BL1V2 PV Array Layout and the details in Tender Schedule A.

2.8.5 PV Marshalling boxes All marshalling box construction and associated wiring is to conform to the notes and diagrams on Drawing BL1V2-04-03-G004-01, Section 6 - BL1V2 PV Array Marshalling Box.

2.8.6 Fire Protection The area beneath and around ground mount PV support structures shall be covered with weed mat and then suitable aggregate to a depth of 50mm to inhibit vegetation growth. Aggregate shall extend to a distance of 2m beyond the extent of the array structure (Note: This is to reduce the risk of faulty equipment being a source of ignition of ground fires and to minimise the risk to installed equipment from damage during a ground fire.)


3. General Installation Requirements

3.1 Equipment Location

The location of equipment on-site will be determined by Bushlight and provided to the Contractor. Contractors shall install the equipment as close as practical to the location specified. Bushlight may approve any changes prior to works being carried out. Refer to Section 8 – Photos and Site Maps for specific site information.

3.2 Equipment Protection

Ground beneath and around ground mount PV support structures shall be covered with a suitable aggregate material to a depth of 50mm (and underlay where appropriate) to inhibit vegetation growth. Ground cover shall extend to a distance of 2m beyond the extent of the structure. (Note: This is to reduce the risk of faulty equipment being a source of ignition of ground fires and to minimise the risk to installed equipment from damage during a ground fire.)

Where specified in the Tender Schedule, the ground to be covered by aggregate and cable trenches shall be pre-treated by pesticide to reduce likelihood of ant infestation.

3.3 Cabling

3.3.1 Cable specification Cabling shall be selected and installed in accordance with AS3000, AS3008 and AS4509.2.

All underground reticulated cabling shall be sized utilising a soil thermal conductivity of 4.0°C m/W and a soil temp of 35°C. Cables used for DC circuits shall be sized such that cable losses are less than 3%.

3.3.2 Cable colour Electrical wiring within the enclosure shall be colour coded in accordance with the system shown in Table 2.

Any cable not colour coded will be coded with heat-shrink adjacent to the connecting terminal with the correct colour heat-shrink. This applies in the case of orange sheathed cable use for battery and PV array connections.

Table 2 Bushlight standard electrical wiring colour codes

AC Active White

AC Neutral Black

Earth Green/yellow

DC Positive Red

DC Negative Black

Control (e.g. monitoring) Any other colour or combination of colours not listed above. Multi-coloured cables should be used to assist circuit tracing.

3.3.3 Cable identification All terminations in the enclosure shall be identified with cable identification (ID) at both ends. All terminals shall be numbered in accordance with equipment enclosure wiring diagrams.


The cable pairs from the PV marshalling box(s) shall be clearly identified with permanent markings as “PV SOLAR #1”, “PV SOLAR #2” and “PV SOLAR #3”.

3.3.4 Underground reticulation All underground reticulation shall be with XLPE nylon jacketed cable for the protection against termites, Singapore ants and other insects. For the Central Australian (CE) Bushlight Region this cable is not required, but it is mandatory for the three other Bushlight Regions – Kimberley (KI), Top End (TE) and North Queensland (NQ).

3.3.5 Cable protection In locations where buried conduit passes from below to above the ground, conduit shall be sealed to prevent the ingress of water and insects.

All above ground external cabling shall be protected by UV stabilised conduit.

3.3.6 Connectors For cable (other than within the PV marshalling box) with cross sectional area greater than 6mm2, all connections shall be made using bolt-secured crimp connections. This requirement applies to the cable connecting the PV array marshalling box to the equipment enclosure. Connections shall be double crimped with an appropriate tool and protected with heat-shrink covering. Cables with cross sectional area less than 6mm2 may be directly terminated in clinch terminals or spring loaded terminals as appropriate.

3.4 Fixings

Fixings shall include all necessary metal work, bolts, screws and washers. Fixings shall be galvanised, zinc plated, and/or stainless steel as appropriate for the use and environment. Dissimilar metals shall be separated at all times.

3.5 Enclosure Protection

In general Bushlight will specify the installation of equipment and battery enclosure(s) in areas that are not directly exposed to elements, and are naturally ventilated and shaded. A typical location would be on the veranda of a house. However, the Contractor may be required to provide (supply and install) a suitable housing or other protection for the enclosures if a suitable site is not available. Examples include the installation of an awning, veranda or skillion roof. If such work is required it will be specified in the Tender Schedule A.

Where required in coastal areas structures shall be appropriately designed and constructed for cyclonic conditions and saline environments.

Free standing structures shall be raised on gravel and concrete pads sufficiently above the natural ground level to prevent damage by water ingress.

The Contractor shall be responsible for all approvals relevant to any installed stand alone structure. This shall include the provision of required documentation and drawings to local authorities prior to and following the completion of works.


3.6 Generating Set Connection

Tender Schedule A nominates if a generating set is to be hard wired to the equipment enclosure. (Note: The generating set is a manual backup for the Bushlight Household System). The generating set shall be connected in accordance with the equipment enclosure installation instructions provided.

3.7 Earthing

Earthing of equipment shall be in accordance with AS3000 and Bushlight Drawing BL-04-07-E001-03 & Drawing BL-04-07-E002-02, Section 6 - Generic Earthing and Lightning Protection Plan. Battery enclosures shall be earthed to the system earth as per the generic earthing plan. All earthing conductors liable to be exposed to a battery fault current shall be suitably rated.

3.8 Lightning Protection

Lightning protection in accordance with AS/NZS 1768(Int.):2003 and Bushlight Drawing BL-04-07-E001-03, Drawing BL-04-07-E002-02 and BL-04-07-E003-00, Section 6 - Generic Earthing and Lightning Protection Plan. Where specific additional lightning protection requirements exist, these will be detailed in Tender Schedule A.

3.9 Household Wiring

In addition to the installation of the RE system, additional electrical reticulation or building wiring maybe required and if so will be detailed in Tender Schedule A under ‘Other Works’..

All such electrical works carried out shall comply with the relevant AS3000 requirements.

If a site visit is required to assess and calculate a fixed price for these requirements it may be arranged through the Bushlight Regional Manager.

3.10 Demand Side Management (DSM) Measures

A range of additional measures and household wiring changes maybe specified in the Tender Schedule in order to implement DSM measures. These may include:

Additional AC circuits;

Lighting, appliances and timers;

In-house metering panel (where supplied by Bushlight); and

Pay for use metering (where required).

3.11 Marshalling Box and GPO Labels

With each Bushlight Equipment Enclosure there will be a number of pre-engraved adhesive trafolyte labels provided free issue by Bushlight. The quantity, description and install location of these labels is: Quantity Text Colour Location

2 FRIDGE/FREEZER ONLY

White on Blue

On front of all fridge/freezer GPO’s. These will be specified in the Schedule A of this Tender

4 GENSET SUPPLY White on On front of all Genset Only GPO’s. These will


ONLY Red be specified in the Schedule A of this Tender

1 SOLAR ARRAY

MARSHALLING BOX ARRAY #1

Black on White

On front of the Marshalling Box that is connected to the Array 1 input circuit breaker in the Bushlight Equipment Enclosure.

1 SOLAR ARRAY


Black on White


1 SOLAR ARRAY


Black on White



Appendix 1 Relevant Standards Systems shall be designed and installed in accordance to all relevant Australian Standards and State and local government statutory requirements (including amendments), including but not limited to:

AS/NZS 1170.0:2002 Structural design actions - General principles;

AS/NZS 1170.1:2002 Structural design actions - Permanent, imposed and other actions;

AS/NZS 1170.2:2002 Structural design actions - Wind actions;

AS 1543-1985 Electrical equipment of industrial machines;

AS 1627.0-1997 Metal finishing - Preparation and pre-treatment of surfaces - Method selection guide;

AS/NZS 1768(Int.):2003 Lightning protection;

AS 1939-1990 Degrees of protection provided by enclosures for electrical equipment (IP Code);

AS 2676.2-1992 Guide to the installation, maintenance, testing and replacement of secondary batteries in buildings - Sealed cells;

AS 2700-1996 Colour Standards for general purposes;

AS/NZS 3000:2000 Electrical installations;

AS/NZS 3008.1.1:1998 Electrical installations - Selection of cables - Cables for alternating voltages up to and including 0.6/1 kV - Typical Australian installation conditions;

AS 3010.1-1987 Electrical installations - Supply by generating set - Internal combustion engine driven sets;

AS 3439.1-1993 Low-voltage switchgear and control gear assemblies - Type-tested and partially type-tested assemblies;

AS 3439.2-1994 Low-voltage switchgear and control gear assemblies - Particular requirements for busbar trunking systems (bus ways);

AS 3439.3-1995 Low-voltage switchgear and control gear assemblies - Particular requirements for low-voltage switchgear and control gear assemblies intended to be installed in places where unskilled persons have access for their use - Distribution boards;

AS 4509.1-1999 Stand-alone power systems - Safety requirements;

AS 4509.2-2002 Stand-alone power systems - System design guidelines;

AS 4509.3-1999 Stand-alone power systems - Installation and maintenance;

AS 4086.1-1993 Secondary batteries for use with stand-alone power systems - General requirements;

AS 4086.2-1997 Secondary batteries for use with stand-alone power systems - Installation and maintenance;

AS 5033:2005 Installation of photovoltaic (PV) arrays

IEC 61724 Ed. 1.0 b Photovoltaic system performance monitoring - Guidelines for measurement, data exchange and analysis.


Appendix 2 System Photographs This Appendix contains photographs of typical and generally acceptable aspects of Household RE Systems installations. Contractors should refer to the appropriate drawings for specific information relating to the correct installation of equipment.

Photograph 1 Household RE System with single Battery Enclosure

Photograph 2 Household RE System Enclosure with an additional Battery Enclosure


Photograph 3 Detail of roof mount PV support structure showing tamperproof fixing and

sealing

Photograph 4 Detail of a roof mount PV Array showing Dektite boot protection of roof penetration by conduit


Photographs 5- Remote User Interface (RUI)

Photographs 6 & 7- Preferred location of marshalling box(s) for roof mounted systems and

ground mounted systems


Bushlight


Drawings

BL1v2 Installation Drawing List

Drawing Number Description

1. BL1V2-04-01-SL01 Single Line Diagram

2. BL1V2-04-03-G001 Battery Enclosure layout and cabling

3. BL1V2-04-03-G002 PV Array layout

4. BL1V2-04-03-G003 Bushlight Enclosure Layout

5. BL1V2-04-03-G004 PV Array Marshalling Box

6. BL-04-07-E001 Generic Earthing and Lightning Plan

7. BL-04-07-E002 Generic Earthing and Lightning Plan - Graphs

8. BL-04-07-E003 Generic Earthing and Lightning Plan - Diagram

9. 1V1B-04-02-M001 Ground mount array

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BATTERY TEMP SENSOR STRING 1

BL1 BATTERY ENCLOSURE

Battery location within typical two string enclosure.

TYPICAL TWO STRING INSTALLATION (RHS) BATTERY ENCLOSURE

Both pairs of cables to be same length and physical size.

-

+

SECTIONED TOP VIEWENCLOSURE 1

6 %

CELL 1, STRING 1

SECTIONED TOP VIEWENCLOSURE 2 6 /

-

+

CELL 1, STRING 2

BATTERY TEMP SENSORSTRING 2

SMALL CELLS

Footprint

Maintain this relationship for all size cells.

Battery location within typical single string enclosure.

SECTIONED TOP VIEWENCLOSURE

TYPICAL SINGLE STRING INSTALLATION

Both pairs of cables to be same length and physical size.

BL1 BATTERY ENCLOSURE

-

CELL 1

+

LARGER CELLS Footprint extends in

this direction.

SMALL CELLS

Footprint

BATTERY TEMP SENSOR


this direction.

Maintain this relationship for all size cells.


this direction.

SMALL CELLS

Footprint

BATTERY INSTALLATION NOTES:

1. WARNING: Each cell may weight up to 120kgs. Correct manual handling and lifting techniques should be used at all times to avoid injury.2. The battery stand, the main cables (battery string(s) to enclosure) and all the required glands will be supplied by the battery enclosure manufacturer.3. The batteries shall be installed such that at least 25mm clearance is maintained from the enclosure.4. The batteries shall be spaced such that at least 10mm clearance is maintained between cells.5. Inter-cell connections shall be of a type approved by the battery manufacturer and be such that terminals are not, under expected site conditions, subjected to mechanical strain. 6. The cell interconnections shall be of equal length and size, the exception being the end of the row on each tier. These shall be of equal size and kept as short as possible.7. The cabling from the string(s) to the enclosure shall be of equal length and cross sectional area. They will exit the battery enclosure via the glands provided by the battery enclosure manufacturer.8. Where two strings of batteries are required; • The cells shall be arranged so that one string is contained in each enclosure. • The layout and connection points of the cables shall comply with this drawing. • The identical connections shall be used on each string. • The strings shall be connected to the enclosure by cables of identical cross sectional area and length.9. The cells in each string shall be numbered with 1 being the lead Positive battery.10. Batteries shall be located within the enclosure(s) in accordance with this drawing.11. The temperature sensors from the preinstalled charge controller and the inverter monitoring shall be positioned in the physical centre of the first battery bank and on the side of a battery near a Positive terminal.12. If a second Plasmatronics PL charge controller is to be fitted the position of the associated temperature sensor shall be determined by:- • Where one battery string is used the temperature sensor shal be positioned in the same position as the first - refer Item 11. • Where two battery strings are used the temperature sensor shall be positioned in the physical centre of the second battery string and on the side of a battery near a Positive terminal.13. If a third Plasmatronics PL charge controller is required the associated temperature sensor shall be located in the same position as that of Item 11.14. If MPPT charge controller(s) have been specified for the installation. The requirements of Item 11 will still apply as one Plasmatronics PL60 charge controller and inverter monitoring will always be fitted. In addition any temperature sensors used by the MPPT charge controller(s) shall be positioned in the same manner as for Items 11 and 12. 15. Corrosion inhibiting grease shall be applied to all terminals.16. All terminations to be fitted with covers or shrouds.17. Battery safety signage shall be provided and attached to the battery enclosure in accordance with AS4509.1 Sect. 3.5. 18. Battery maintenance kit to be provided as per Technical Specifications.

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INSTALLATION NOTES:

GENERAL REQUIREMENTS:1. All PV module fixings shall be corrosion resistant and tamperproof, TORX with security pin or approved equivalent.2. Each individual string shall be wired to a circuit breaker in the marshalling box.3. All Bypass diodes shall be fitted and blocking diodes to be removed.4. The module junction boxes shall have all entry points sealed to maintain the IP rating. 5. All cabling shall be single core multistrand.6. All cabling between PV modules and between PV modules and the Marshalling box must be protected by UV stabilized conduit.7. Entry and exits from all PV junction boxes and Marshalling box(s) shall be made with the appropriate conduit glands to maintain IP ratings.

ROOF MOUNT REQUIREMENTS:1. A minimum PV module clearance of 50mm shall be provided above the roof surface.2. Penetration of roof sheets to mount the array should be minimised (where possible use existing penetrations) and they shall be suitably sealed to prevent water ingress.3. It is desirable that the cabling from individual strings and physical arrays be gathered together through the use of conduit junction boxes to reduce the number of conduits needed to penetrate the roof sheeting to provide access to the Marshalling box.3. Any conduit penetrating the roof shall be protected by dektite boots or approved equivalent.

GROUND MOUNT REQUIREMENTS:1. A minimum PV module clearance of 500mm shall be provided above all footings.2. The array marshalling box shall be located under the array to minimise UV exposure.3. Underground cabling to comply with AS3000 or other requirements in the Tender Schedule A. 4. Local aggregate to be spread under array and 2 metres in all directions providing a minimum 50mm cover over weed mat.

ARRAY ORIENTATION:1. The PV module direction and tilt angle shall comply with the requirements in Tender Schedule A. CABLE SIZING REQUIREMENTS:1. Inter-module connections shall have a volt drop loss less than 1%.2. Module string connection to the marshalling box and the marshalling box to the enclosure shall have a combined volt drop loss of less than 2%.3. Required minimum cable cross sectional areas will be in Tender Schedule A

TO MARSHALLING BOX

TEN 24V SUB- ARRAYS

EXAMPLE OF GROUND MOUNT 24V ARRAY ON

20 MODULE ARRAY FRAME

CONDUIT JUNCTION BOXCONDUIT JUNCTION BOX CONDUIT JUNCTION BOX

PV MODULEJUNCTION BOX

CONDUIT

CONDUIT JUNCTION BOXCONDUIT JUNCTION BOXEXAMPLE OF WIRING

LAYOUT FOR 24V SUB-ARRAY

MODULE 2

24V TOMARSHALLING

BOX

-Ve LEAD TO BE CONTINOUSFROM FIRST MODULE TO

MARSHALLING BOX.

-

+

+ -

MODULE 1

- +

EXAMPLE OF ROOF MOUNT 24V ARRAYS ON 4 MODULE ARRAY FRAMES USING JUNCTION BOXES TO REDUCE

THE NUMBER OF ROOF PENETRATIONS

CONDUIT JUNCTION BOX

SINGLE CONDUIT TOMARSHALLING BOX

TO NEXT JUNCTION BOX

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THE ADDITION OF A SECOND BATTERY ENCLOSURE REQUIRES 1500mm (ON THE SIDE FITTED) PLUS THE CLEARANCE OF 25mm FROM THE END OF THE BATTERY ENCLOSURE TO ANY SOLID WALL.

THIS SPACING FROM SOLID WALLS MUST BE MAINTAINED TO ENABLE ACCESS TO ENCLOSURE.

THE RHS IS TO ENABLE ACCESS THROUGH THE SIDE DOOR.

INSTALLATION NOTES:

Enclosure is supplied in 2 pieces - Equipment enclosure and Battery enclosure - to be screwed together onsite with fixings supplied by enclosure manufacturer.Typical weight of each enclosure is - Equipment enclosure ~120 kg. Battery enclosure ~80 kg.

Equipment enclosure is manufactured with cable entry points on both sides.

A perforated metal tray shall be affixed to the wall on the side(s) most appropriate for wiring. This will secure all of the conduits carrying cables to and from the enclosure. It shall be covered by a metal cover (top hat or similar) to add further mechanical protection for the conduits.

Conduits shall be securely fixed to the support structure.

The cable ladder may be carried into the roof space or terminate below the ceiling as required.

All cables shall be protected by rigid or corrugated conduit.

All cable penetrations to the equipment enclosure shall be fitted with appropriately sized glands.

For a roof mount array the marshalling box(s) shall be located in close proximity to the enclosure under the same shelter. They shall not be placed in the roof space or on the roof.

The enclosure shall be positioned so that a minimum clearance from the rear of the enclosure to a wall is 75mm for ventilation of the battery enclosure.

The enclosure shall not be installed in a location where it may be subjected to direct rain or full sunshine.

FRONT VIEW

Ceiling OR Shelter roof

Preferred location of marshalling box(s) for installation using roof mounted array(s).

Perforated metal trayfixed to wall.

ENCLOSURE SHALL BE FIXED TO THE FLOOR TO COMPLY WITH THE

ENCLOSURE MANUFACTURERS INSTALLATION INSTRUCTIONS.

Metal cover

All wiring protected byconduits.

Marshalling box 1

Marshalling box 3

Marshalling box 2

SHIM UNDER SKID AS REQUIRED TO ENSURE ENCLOSURE IS LEVEL IN ALL DIRECTIONS.

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MARSHALLING BOX SHOWN WITH COVER AND LID REMOVED.

OUTPUT SIDE TO COMMONING POINTAND CHARGE CONTROLLER

FEED CABLE.

INPUT SIDE FROM STRING +VES

T35 DIN RAIL

ON ONON ON

1 ! 3

DOUBLE SCREWCONNECTOR OF APPROPRIATE SIZEUSED AS COMMON POINTAND FEED CABLE CONNECTORS

Circuit Breakers (10 max) MERLIN GERIN, Multi9, C60a, (Appropriately sized) or purchaser approved equivalent.

MOV EARTH LINK MOV EARTH LINK

ON ON ON ON ON ON

4 3

SOLAR ARRAYMARSHALLING BOX

ARRAY #1

MARSHALLING BOX LABEL

MARSHALLING BOX NOTES:

1. Marshalling box enclosure shall be a PDL-DBS enclosure. or purchaser approved equivalent : - IP56 compliant. - UV stabilised.3. One marshalling box per charge controller.4. Shall accomodate a maximum of 10 strings.5. Shall be fitted with one circuit breaker per string.6. Shall have MOV's fitted from input (i.e. before circuit breaker) +VE lead to Earth.7. MOVs shall be Farnell part no. 502-546 (56VDC,37J, 2000A) 22.5 Ø or purchaser appproved equivalent.8. The Earth link for the MOV's shall be connected to the enclosure Main Earth link by a green/yellow earth wire of at least 6mm sq.9. All entry points shall have conduit glands fitted that shall not reduce the IP rating below IP56.10. The layout shall allow string currents to be easily measured using a DC clamp ampmeter.11. A label (as per detail on this drawing) identifing the array shall be affixed to the front hinged cover with permanent adhesive. Labels will be provided by the enclosure manufacturer.

CABLE SIZING1. The voltage drop at working current shall not exceed 3 % total from PV module to enclosure terminals.2. The cable sizes will be specified in Tender Schedule A but the installer shall confirm that sizes used will meet the voltage drop requirements.

MOUNTING REQUIREMENTS1. The marshalling box shall be located in a shaded position.2. For roof mounted arrays it shall be located adjacent to the enclosure. See enclosure layout drawing for more detail.3. For ground mount arrays it shall be located under the PV array.

To ChargeController

FROM PV ARRAY STRINGS

FROM PV ARRAY STRINGS

MOV's (40V rms, 56V DC, 37J, 2000A), 22.5 Ø, FARNELL Part No. 502-546 or approved equivalent.

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MAIN NEUTRAL

LINK

MAIN EARTH

LINK

MEN LINK

SERVICE EARTH

Protective earthing conductorto inverter housing. (2.5mm sq.)

Protective earthing conductors associatedwith final subcircuits.

Protective earthing conductor to metallic switchboard enclosure. (16mm sq.)

Equipotential (EP) Bonding metallic structure of house.

EP Bonding water reticulation.

EP Bonding Ground mount array.

EP Bonding communications.

Protective earthing electrodeto AS3000. ( Existing )

EP bonding directly to lightning electrodes is recommended.

Earth solar panels and batteries at one point only on battery bus.DO NOT ADDITIONALLYEARTH BATTERIESas isolation will be bypassed.DO NOT ADDITIONALLYEARTH SOLAR PANEL WIRESas charge regulator will be BYPASSED.

BATTERY NEGATIVE

BUS

HOUSEROOF ARRAY

GROUND MOUNT

AIR TERMINATION

AIR TERMINATION

Installation in accordancewith AS1768 (Int.) - 2003Electrically isolated from

structure.

Lightning Protectionin risk areas equal to or > 40 thunder-days.(see BoM map)

EARTHING PLAN

16mm sq.

Use AS3000 todetermine required size.

35mm sq.Insulated cablesecurely fastenedto structure.

Use AS3000 todetermine required size.

16mm sq.

Typically 500 mm above highest part of array.

Typically 500 mmabove highest part of array.

LIGHTNING PLAN

Only required if lightning

protection is implemented.

Earth stakes added (if required) until Electrode resistance to Earth of 10 Ω or less is

achieved. Or drive 4 stakes to be assuredof complying.

Earth stakes added (if required ) until Electrode resistance to Earth of 10 Ω or less is

achieved. Or drive 4 stakes to be assured of complying

NOTE:Refer to Sheet 2 graphs to determine need and elevation of Air terminal(s).

35mm sq.Insulated cablesecurely fastenedto structure.

6mm sq.

min 6mm sq.

6mm sq.

RCD NEUTRAL

LINK

BL Enclosure

Residual Current Device (RCD)protected circuit Neutrals

Non (RCD)protected circuitNeutrals

Genset Neutral

Note:If generator has existing MEN (multiple earth neutral) point.DO NOT connect the generators Earth to the BL Main Earth.

16mm²

16mm sq preferred

16mm sq preferred

clamp

Example12mm dia bare copper roddriven in 1.2m

RCD

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Protection provided by distant air termination

0.05.0

10.015.020.025.0

30.035.040.045.050.0

0 10 20 30 40 50

RADIUS (metres)

Air

Ter

min

atio

n he

ight

GRAPH 1.

This graph shows the radius of protection provided by a single point Air termination with respect to its height above the highest point of the object being protected.

This is to be used to decide the area required to protect and how best to achieve it.

GRAPH 2.

This graph shows the radius of protection provided by an existing single point Air termination (eg. communications tower) with respect to its height above the highest point of the object being protected.

This is to be used to decide if the area being evaluated is already offered protection by an existing facility.

NOTE:These can both also be applied to determining the area of protection an Air terminal on the house would provide to a ground mount array. It would often be more cost effective to install the Air terminal at the house to protect the enclosure equipment, with the added advantage that the height offers protection to the adjacent ground mount array.

7 7

Radius of protection

0.0

1.0

2.0

3.0

4.0

5.0

0.0 5.0 10.0 15.0 20.0 25.0

RADIUS (metres)

Air

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9 < < 1 < $

9 < < 1 < $ < $ /

/// /// /// /// 8 6 2 ) ' * &0 0 &' * &0 ( =: ' & 2

# > > 0 + ' =0 ' ' * ' #

$ $ ' &' &&0 * &&0 0 &' * $

Radius of protection (r)9.4m for 1m high air terminalwith respect to its height above the roof.

1m high air terminal (h)

Bare copper down conductor(25 x 3mm) to be seperated from roof to reduce galvanic corrosion or use 35mm² insulated cable.

4 lightning stakes 12mm in diameter, 1200mm long not more than 1m from each other connected by 16mm² cable.

Main Earth stake

Common earth bonding min. 6mm²(bare copper can be used if buried).

Installation notes1. Main earth stake and lightning stakes to be as close as possible.2. Graph 1 in drawing BL-04-07-E002 to be used where the installation differs from example.3. Graph 2 in drawing BL-04-07-E002 to be used where a communications tower or similar structure already exists within 45m of array.4. Use of ground resistivity improvement powder to reduce soil resistivity is recommended.5. Contractor to determine soil resistivity (less than 10 Ù) or alternately as a minimum, use 4 earth stakes of 12mm diameter and 1200mm length driven into the ground spaced not more than 1m apart and connected by 16mm² or greater cable.

TYPICAL INSTALLATION

Design notes1. Standard protection, Protection Level 3 (PLIII) adopted using rolling sphere method as described in AS1768(Int.) - 2003.2. Limited protection required for side of building as risk is low.

3. r = Sq root of (2ah - h2) Where a = radius of the sphere, h = height of rod and r = horizontal protected distance. Using the values h = 1m, a = 45m (from PLIII) produces r = 9.4m.4. Air terminal (lightning rod) is used to divert the lightning discharge that might otherwise strike a vulnerable part of the system or house.5. The down conductors and earthing electrodes (lightning stakes) are used to deliver the lightning current into the earth.6. Bushlight area of protection includes the PV array and enclosures. Other means of protection include surge diverters and MOV's (metal oxide varistors).7. Lightning protection is to be provided when the thunder days are equal to or exceed 40 days (see BoM map in AS1768(Int.) - 2003). 8. If special circumstances exist at a site in an area of less than 40 thunders days a risk assessment as per AS1768(Int.) - 2003 shall be carried out to determine if it is appropriate to implement the lightning protection plan. e.g. overhead power reticulation.

Height less than 10m

PV Array

PV ARRAY STRUCTURE

Fax: (08) 9360 2204 [email protected]

Ph: (08) 9360 7351

MURDOCH WA 6150South Street

MURDOCH UNIVERSITY

TECHNICAL SERVICESBUSHLIGHT

BL1B TECHNICAL

Note: Dimensions to suit PV modules used, tilt angle and footings to suit site and specifications.

1V1B-04-02-M001-03

20 MODULE TILT ANGLE 20°

TYPICAL GROUND MOUNT

1V1B-04-02-M001-03.dwg

SPECIFICATION



Bushlight

Site Information

23/09/2005 Site Information Page 1 Contract: NQ07-0905 Household Renewable Energy Systems

Index of Site Information Site Name Description

8-1 Fish Hole BL1V3

Photos

Number Description

1 Fish Hole Layout

2 Fish Hole Layout showing Solar Array and Bushlight Enclosure Locations

3, 4 & 5 Generator Details

6 House 1 – Interior Roof

5 House 1 / Shelter

Maps Number Description

1 Kowanyama Location

2 Fish Hole Location

3 Fish Hole Site Layout


Photo: 1 Description: Fish Hole Layout

Outdoor Shelter House 1

Outdoor Kitchen Location

Shower / Laundry Toilet


Photo: 3, 4 & 5 Description: Generator Details

Generator

Generator Location (Future)

Connection Method


Photo: 6 Description: House 1 (Enclosed Shed) Interior Roof

Photo 7 Descrition: House 1 / Open Shelter

23/09/2005 Site Information Contract: NQ07-0905 Household Renewable Energy Systems

Map: 1 Description: Kowanyama Location


Map: 2 Description: Fish Hole Location Map


Map: 3 Description: Fish Hole Site Layout

Installation Instructions: Bushlight Household Energy System

The Installation Instructions and Commissioning Forms provided here are for general information only. A complete Operating Manual which includes these Installation Instructions and Commissioning Forms will be provided with each Bushlight equipment enclosure. The system installation will be based upon the technical specification, system drawings and the installation instructions as provided by the Operating Manual. On completion of the installation the Operating Manual with the completed Commissioning Documents is to be left on site by the Contractor. .

Bushlight

Installation Instructions and Commissioning Forms


Installation Instructions: Bushlight Household Energy System - 1 -

Installation and Commissioning Instructions

Installation Instructions

Shipping List The equipment listed in the following table should be included on delivery of this product.

Equipment Quantity

Remote User Interface (RUI) 1

(Up to 2 RUIs may be delivered with each system)

Equipment Enclosure 1 Spares Kit 1

Bush (50mm) 1 Glands (25mm) 6

Enclosure Keys (Square) 2 RUI Key 1 (‘T’ Type) 1

Battery Enclosure 1 or 2 (depending on the system)

Fastening Plates 10

Battery Enclosure Installation • Depending on individual installation requirements there may be more than one Battery

enclosure to be installed. The first enclosure requires the Equipment enclosure to be mounted on top of it, which will have all the solar array and household power cabling, so this needs to be positioned in the most practical location for these connections. Refer to Bushlight drawing BL1V2-04-03-G003 Enclosure Layout, for details of physical layout requirements.

• The two Battery enclosures need to be positioned as close to their final destination as possible ensuring that there is a 75mm rear clearance. Once in position both enclosures need to be levelled and adequate support needs to be provided for the plinths. The first enclosure then needs to be fastened to the floor using Dyna-bolts or an approved fastener for the surface that it is being secured too, and the fastener plates. The fasteners should be secured through the holes in the fastener plates, with the plates clamping down on the plinth edge. If there is only one Battery enclosure being installed then the remaining securing fasteners should be installed and tightened.

• Once this enclosure has been secured with two fasteners the second enclosure can be butted up against the side of the first enclosure after both the hole covers have been removed from the feed though holes on the adjoining sides of the two panels (Refer to Figure 0-1).

• Once joined these two holes will be linked by a common bush which will provide a path for the second battery connection cables. Once the second enclosure has been positioned hard up against the first it too should be fastened using appropriate fasteners through the holes in the fastener plates with the plates clamping down on the plinth bottom edge. If the feed through holes on the two enclosures line up the enclosure can be finally fastened using one more fastener per enclosure and ensuring the other fasteners have been tightened firmly.


• Once the two enclosures have been secured, the feed through hole can be bushed. This is done using a 50mm plastic bush which should be sealed using silicon compound to prevent moisture ingress and gas leakage from this joint.

Do not install batteries as there is work to be completed which will be easier to achieve prior to battery installation.

Figure 0-1: Equipment and Battery Enclosure – Side View

Equipment Enclosure Installation • The Equipment enclosure is to be installed on top of one of the installed Battery enclosures.

Before the Equipment enclosure can be installed some preparation is required. As the Equipment enclosure and the Battery enclosure are the same size a gasket between the two needs to be made using the foam sealing tape supplied. This gasket can be made by running a line of the tape along the top of the Battery enclosure 25mm inside the outer edge of the roof of the enclosure, removing the backing tape to expose the adhesive surface of the tape as it is being positioned. A complete loop should be formed the whole way around the Battery enclosure roof.

• The removable plate on the top back left-hand corner of the Battery enclosure should be removed along with all nuts and bolts.

• Remove all the hole filling grommets from the lid of the Battery enclosure to be fitted with the Equipment enclosure, there should be 9 of them.

• Remove the blanking plugs installed in the bottom of the Equipment enclosure.


• The Equipment enclosure should be lifted into place. This will take four able bodied adults to minimise the risk of personal injury and damage to the two enclosures. When positioning the Equipment enclosure it is important that the installed gasket material on top of the Battery enclosure is not damaged.

• Once in place and lined up bolt the two enclosures together. This should be done by passing the bolts down through the bottom of the Equipment enclosure with a nylon washer under the bolt head. On the other end of the bolts should be a nylon washer which should be against the Battery enclosure lid surface, then a normal washer followed by a spring washer and nut. The nylon washers are there to protect the painted surfaces of the enclosures. It is important that when fastening the two enclosures together that all attempts are made to minimise scratches to the Battery and Equipment enclosures.

• Once the two enclosures are bolted together the glands and blanking plug can be installed in the bottom of the Equipment enclosure (back left-hand corner). These glands will allow for the cables for connection of the batteries and battery temperature probes.

Inverter Installation • The inverter should be supplied with all connections ready to plug into the Equipment

enclosure. • Lift the inverter on to the rails in the left hand cubicle of the Equipment enclosure,

backwards so the display is facing the back of the enclosure, this may take two people as the inverter is very heavy. This will allow for easy connection of all required plugs and sockets. The plug for the connection of the 24VDC is a large grey item (Refer to Figure 0-2).

• Connect the control and monitoring plugs. These plugs are small green plugs that simply push into the sockets located on the back of the inverter. As they are significantly different sizes it should be easy to match the correct plug and socket. Once the plugs are correctly installed, place and screw the white cover into position over the two plugs, ensuring the cables are not damaged in the process.

• The 240VAC connection is located on the wall between the left and right-hand enclosures. It is a surface mounted plug and should match up with the plug that is connected to the back of the inverter on a short lead.

• Once all the connections are made, checked and the white cover placed over the control/monitoring connections the inverter can be rotated so that the front is facing the front of the enclosure and its feet correctly locate on the rails. This may require two people to complete as the inverters are very heavy.

Figure 0-2: Inverter Plug Connections


Charge Controller Installation • If more than the single charge controller supplied with the Equipment enclosure is required

they should be installed on site. • The charge controllers require two connections. The first is the battery and array

connections which are made through the large power connector which mates with the one that is pre-wired in the left cubicle of the Equipment enclosure. This should be the same as that used on the supplied charge controller. (Refer to Figure 0-3).

• The second connection is the one between the charge controller and the PLA regulator module. This should be made with the supplied cable that comes with the regulator (Refer to Figure 0-3 and Figure 0-4).

• Once electrically connected and the cover secured the charge controllers can be bolted into place on the pre-drilled mounting plate located immediately below the inverter mounting rails. The charge controllers are held in place using the four Phillips head bolts, nuts and washers supplied.

Figure 0-3: Charge Controller Connections


Figure 0-4: Charge Controller / Regulator Connector Cable

Connection of Solar Arrays Depending on the installation up to three solar arrays can be individually connected to the Equipment enclosure. Prior to making the connections to the solar array care should be taken to ensure that the chance of an electrical fault has been minimised. It is recommended that the cabling be connected to the Equipment enclosure end first, checked then connected to the marshalling boxes. This would minimise the chance of shorting live cables together, or shorting them to the Equipment enclosure or other metal work. There are several holes located on the left-hand and right-hand sides of the enclosure to bring the solar array cabling into the Equipment enclosure. Remove the required hole covers and install glands as required to bring the cabling into the enclosure. There is a slotted duct that runs the length of the back of the Equipment enclosure that can be used to run the cables into the right hand cubicle. If more than one round cable or if figure 8 cable is passed through a gland then the gland should be sealed with a silicon compound to ensure a water tight seal. The terminals for connecting the solar array can be located on the right hand side of the wall between the left and right cubicles. These are large bolt type terminals, which will require the cable being terminated to be lugged with appropriated sized lugs with 10mm holes, to suit. The first solar array should be connected to terminal 1 and 3 of terminal strip TS01. The positive cable should be connected to terminal 3 and the Negative Cable to terminal 1. The Second Solar array should be connected to terminals 5 and 7, with the positive being connected to terminal 7 and negative to terminal 5. The third solar array is connected to terminals 9 and 11, with the positive being connected to terminal 11 and the negative connected to terminal 9.

Connection of Batteries The cables for connecting each battery bank are supplied pre-lugged with each Battery enclosure and they are long enough to be run in this manner. The supplied cables should not be shortened or


modified in any way unless approved by a Bushlight representative. For the details for exact connection of the batteries please refer to the Bushlight battery installation drawing. The connection to the first battery bank string, which is located beneath the Equipment enclosure is made through the holes located in the back left-hand corner of the enclosure. The two cables for connection of the battery banks should be taken through individual holes while the temperature thermocouple should be taken through its own gland. The thermocouple should be sealed with silicon in the gland once installed in it final position, this is done to prevent the ingress of gas discharged from the Battery enclosure. The two battery leads should also be sealed with a small bead of silicon once final installation has been completed. All glands that access the Battery enclosure should be sealed tightly and the surface of the enclosure the gland passes though thoroughly cleaned to prevent a poor seal caused by dust and dirt. Prior to connecting the cabling to the batteries or the bottom of the battery circuit breaker the battery circuit breaker should be switched OFF. The cabling for the battery connection should be made from the battery isolation circuit breaker to the batteries to minimise the chance of electrical fault. The circuit breaker is the type which will require the cables to be lugged with the corrected sized lugs with a 8mm hole for connection to the circuit breaker using the bolts fitted to the circuit breaker. The connections for the second Battery enclosure if installed are also taken through the holes located in the back left-hand corner of the enclosure. These cables should be connected the same way as the first battery connections, as they are also connected to the bottom of the battery isolation circuit breaker. The cables for the second battery bank will pass through the bush which connects the two Battery enclosures.

Connection of Household power & Lighting Circuits. The connection of the 240VAC supplies to the household are all made on terminal strip TS02, which is located on the lower right-hand side of the back plate of the right-hand cubicle of the Equipment enclosure. Prior to installation all 240VAC circuit breakers should be switched OFF, and the supply from the inverter should be unplugged to minimise the chance of electrocution and electrical faults. Refer to Bushlight drawing BL1V2-04-01-E002 for the terminal allocation for the 240VAC distribution. Also refer to terminal layout drawing BLIV2-04-01-E006. Terminal Table – House Circuits Wire No.’s

TS02 – Main Cabinet System Load

6 (Active), 7 (Neutral), 8 (Earth) Essential Circuit 1 H19, K10, H90

8 (Earth), 9 (Neutral), 10 (Active) Essential Circuit 2 H90, H19, K12

11 (Active), 12 (Neutral), 13 (Earth) Essential Circuit 3 K14, H19, H90

13 (Earth), 14 (Neutral), 15 (Active) Essential Circuit 4 H90, H19, K16

16 (Active), 17 (Neutral), 18 (Earth) Discretionary Circuit 1 K18, H19, H90

18 (Earth), 19 (Neutral), 20 (Active) Discretionary Circuit 2 H90, H19, K20

21 (Active), 22 (Neutral), 23 (Earth) Discretionary Circuit 3 K22, H19, H90

23 (Earth), 24 (Neutral), 25 (Active) Discretionary Circuit 4 H90, H19, K24

26 (Active), 27 (Neutral), 28 (Earth) Generator Circuit 1 K27, H20, H90

29 (Active), 30 (Neutral), 31 (Earth) Generator Circuit 2 K28, H20, H90


Terminal Table – House Circuits Wire No.’s

31 (Earth), 32 (Neutral), 33 (Active) Generator Circuit 3 H90, H20, K29

TS04 – Main Cabinet System Control 1 Battery voltmeter –Ve K7

2 Battery voltmeter +Ve - (0V)

3 24VDC Supply K37

4 RUI PBE4 L1

5 RUI PBD1 L2

6 RUI PBD2 L3

7 RUI Essential Circuit Lamp S7

8 RUI Discretionary Circuit Lamp S8

9 RUI Fault Lamp L6

10 RUI E4 Circuit Lamp L7

11 RUI D1 Circuit Lamp L8


13 Power Use Meter – Ve F3

14 Power Use Meter +Ve F4

Connection of the Remote User Interface RUI The Remote User Interface, RUI, is simple to connect to the Equipment enclosure. There is a dedicated set of terminals on terminal strip TS04 (Refer to Figure 0-5). Once a suitable location for the RUI has been chosen and the enclosure securely mounted, it is connected back to the Equipment enclosure using a single multi core cable. The connections for the RUI can be found on Bushlight drawings BL1V2-04-01-E003, BL1V2-04-01-E005 and terminal layout drawing BLIV2-04-01-E006. The RUI is a copy of the bottom right hand corner of the Equipment enclosure operator interface. The buttons and lamps function the same way, and once installed and operational the meters should read the same value as that on the Equipment enclosure. The connections should be checked prior to energising the Equipment enclosure, and the core numbers of the multi-core cable should be documented on one or both of the drawings, this will aid in fault finding at a later stage. Terminal Table – RUI Connections Wire No.’s

TS06 – RUI Enclosure System Control 1 24VDC Supply K37

2 RUI PBE4 L1

3 RUI PBD1 L2

4 RUI PBD2 L3

5 RUI Essential Circuit Lamp S7

6 RUI Discretionary Circuit Lamp S8


Terminal Table – RUI Connections Wire No.’s

7 RUI Fault Lamp L6

8 RUI E4 Circuit Lamp L7



11 Battery voltmeter –Ve K7

12 Battery voltmeter +Ve -(0V)

13 Power Use Meter –Ve F3

14 Power Use Meter +Ve F4

Figure 0-5: Inside Equipment Enclosure – Front View

Commissioning Checklist: Bushlight Household Energy System - 0 -

Commissioning Checklist

Bushlight Household Energy System The following document is to be filled in by the installation contractor on site. This checklist is very similar to that used by Bushlight in its own commissioning process to ensure the system installation meets the technical specification of the tender. The specific information gathered regarding the system components is used as a record of the system. It is intended that this document be used in conjunction with the contract documents, notably the technical specification, drawings and the tender schedule A.

Site Details

Community name Contract No Location

Name of person(s) commissioning Date Time

PV Array Mark as correct if specification item is fulfilled. Comment on problems or irregularities.

Specification Item Check Comments All PV module fixings to be corrosion resistant and tamperproof, TORX with security pin or approved equivalent. Appropriate tool provided in spares kit by contractor.

All cables protected by rigid or corrugated conduit

The module junction boxes shall have all entry points sealed to maintain the IP rating.

Separation of metals must be achieved between array frame, panels, and any other “dissimilar” metal objects (i.e. the use of Flash Tack between array frame and tin roof).

PV module to marshalling box & marshalling box to Bushlight Enclosure cables correctly sized

Serial numbers of all PV modules recorded in table provided

Roof Mount Array A minimum PV module clearance of 50mm to be provided above the roof surface

Penetration of roof sheets to mount the array should be minimised (where possible use of existing penetrations) and to be suitably sealed to prevent water ingress

Any conduit penetrating the roof shall be protected by properly mounted Dektite boot or approved equivalent

Ground Mount Array Minimum 500 mm clearance between ground and lowest edge of PV array

Weed matting and aggregate laid under array to a radius of 2 metres from the array extremities

Marshalling Boxes Mark as correct if specification item is fulfilled. Comment on problems or irregularities.

Specification Item Check Comments


Marshalling box enclosure shall be IP56 compliant

A single marshalling box per charge controller

Each marshalling box to accommodate a maximum of 10 array strings.

Each individual array string wired to a single appropriately rated circuit breaker in the marshalling box

One MOV per circuit breaker fitted from +VE lead to Earth

Earth link for the MOV's to be connected to the enclosure Main Earth link by a green/yellow earth wire of 6mm sq

All marshalling box cable entry points to have conduit glands fitted

Label identifying the array to be affixed to the front hinged cover with permanent adhesive

Roof mounted array: Marshalling boxes located in shaded position above and near to Bushlight enclosure. Ground mount array: Mounted in a shaded location under the array.

Cable sizes adhere to requirements as noted in the table below

Earthing and Lightning Protection Mark as correct if specification item is fulfilled. Comment on problems or irregularities.

Specification Item Check Comments

Air termination a minimum of 500mm above highest part of array

Down conductor from air termination a minimum of 35mm sq insulated cable securely fastened to structure

Air termination and down conductor electrically isolated from structure

Lightning earth stakes added (if required) until electrode resistance to Earth of 10 Ohms or less is achieved

For household roof arrays, 6-16mm sq EP bonding directly to lightning earth electrodes from protective earth stakes for

Equipment Enclosure Mark as correct if specification item is fulfilled. Comment on problems or irregularities.

Specification Item Check Comments Equipment Enclosure installed in a sheltered location and protected from direct sun and strong weather

Perforated metal tray affixed to wall covered by a metal cover (top hat or similar) to protect cables from marshalling box to enclosure

Conduits securely fixed to the support structures

All cable penetrations to equipment enclosure fitted with appropriately sized glands

Enclosure positioned so minimum clearance from rear of enclosure to wall is 75mm

Complete spare part kit provided in appropriate container

Operation and maintenance manual provided with enclosure

All regulator programme settings correctly match those specified in installation manual

Inverter programme settings correctly match those specified in installation manual


Shunt testing completed and shows correct shunt operation

Remote User Interface (RUI) installed and fully functional

Bushlight maintenance log book provided and first meter readings taken

Battery Enclosure Mark as correct if specification item is fulfilled. Comment on problems or irregularities

Specification Item Check Comments Batteries installed so at least 25mm clearance is maintained from enclosure

Batteries spaced so at least 10mm clearance is maintained between cells

Inter-cell connections shall be made via flexible links with double crimped lugs with heat shrink or equivalent protection.

Inter-cell connections to be of a type approved by the battery manufacturer and be such that terminals are not under expected site conditions subjected to mechanical strain

Cell interconnections are equal in length and size, with the exception being the end of the row on each tier. (These shall be of equal size and kept as short as possible)

Cabling from strings to enclosure to be of equal length and cross sectional area. They will exit the battery enclosure via the glands provided by the battery enclosure manufacturer

The temperature sensor from each charge controller to be positioned centrally on a battery string and on the side of a battery near the Positive terminal

Corrosion inhibiting grease to be applied to all terminals

All battery terminals have insulated covers or shrouds

Battery safety signage to be provided and attached to the battery enclosure. As per AS4509.1 section 3.5

Battery maintenance kit provided including: - Two appropriately sized insulated spanners - Anti corrosion spray - Cleaning and safety equipment - Two spare inter-cell links and terminal connectors

- Sealed storage container for kit

Individual cell voltages collected and documented

Individual cell serial numbers documented (if available)

The cells in each string to be numbered with 1 being the lead Positive battery

Where 2 strings of batteries are required:

The cells to be arranged so that one string is contained in each enclosure

The layout and connection points of the cables shall comply with drawings 1V1B-04-02-G001-04

Identical connections shall be used on each string


Equipment Specifications Verify all system components match the Schedule A. Comment on problems or irregularities.

PV Array Equipment Component Quantity Manufacturer Model Rating (Wp) Comments PV Modules

Marshalling Boxes Array Frames Orientation(o) Tilt (o)

Enclosure Equipment Component Quantity Manufacturer Model Serial No Location Comments

Inverter Equipment Enclosure Batteries See other table Battery Enclosure(s) Regulator 1 Equipment Enclosure Regulator 2 Equipment Enclosure Regulator 3 Equipment Enclosure Regulator Synchronizer Equipment Enclosure Equipment Enclosure Battery Enclosure(s) ------ Remote User Interface ------ Spare Parts Kit ------ Equipment Enclosure Battery Maintenance Kit ------ Battery Enclosure


Circuit configuration Verify all circuit configurations are correct and functioning as described in the Schedule A.

Circuit Type No Name CB (A)

Timer (Hrs)

PE Cell (Y/N) Circuit Loads Checked & Comments

Essential 1 Untimed Essential 2 Untimed Essential 3 Untimed Essential 4 Discretionary 1 Discretionary 2 Discretionary 3 Untimed Discretionary 4 Untimed Genset Only 1 Untimed Genset Only 2 Untimed

Genset Only 3 Untimed

Meter Readings Document meter readings from meters on Bushlight Enclosure user interface RE System Hours Gen Hours Gen AC kWh RE AC kWh Solar DC kWh


Battery Serial Numbers and Cell Voltages Document cell voltages (and serial numbers where available)

Cell No Serial Number Cell Voltage Cell No Serial Number Cell Voltage 1 13 2 14 3 15 4 16 5 17 6 18 7 19 8 20 9 21

10 22 11 23 12 24

Solar Array Data Document cloud cover and time of test. Test and document these parameters for each array string.

Time of testing Cloud Cover at time of testing (%) Array String No Voc Isc Vop Iop

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.


PV Module Serial Numbers Document all PV module serial numbers

Module Serial Number Module Serial Number Module Serial Number 1 21 41 2 22 42 3 23 43 4 24 44 5 25 45 6 26 46 7 27 47 8 28 48 9 29 49

10 30 50 11 31 51 12 32 52 13 33 53 14 34 54 15 35 55 16 36 56 17 37 57 18 38 58 19 39 59 20 40 60


Shunt Testing Use the following tests to verify all shunts are functioning correctly. Ensures Shunts Zeroed prior to commencing checks.

Regulator Reading (A) Shunt Number Voltage across

shunt (mV) Ratio

75mV:200A

Inverter Reading

(A) 1 2 3 Expected Results Pass

Shunt 1 (Load) DC load reading on inverter matches

measured value

Shunt 2 (Solar In) Charge current on inverter matches

combined regulator value

Shunt 3 Test Parameter Multiplier Inverter Reading

Multiplied Value

Expected Results Pass

Discretionary off -------- A -------- > 6 Amp on inverter Discretionary Enable Discretionary on -------- A -------- 0 Amp on inverter

Ambient Temp Input 1 Temperature 25mV/oC V

Adjusted value matches

ambient temperature

Regulator voltage Input 2 Battery voltage 1V/13V V

Adjusted value matches regulator voltage reading


Site Photographs The following photographs are required each commissioning site

Commissioning Photographs Required Completed

General view of PV array and frame in relation to nearby structures Close up view of PV array – generally indicating tilt and orientation Close up view of array frame – fixation to PV Modules Close up view of array frame – fixation to roof Under view of PV modules – showing cabling and conduit connections

PV Array, Frames & Cabling

Conduit roof penetration (for roof mounted arrays) – i.e. via Dektite boot Marshalling boxes in relationship to enclosure (if roof mounted array ) or array (ground mount array) Close up of each marshalling box - external Marshalling

Boxes Close up of each marshalling box - internal View of air termination in relation to PV array (for ground mounted arrays) View of air termination in relation to house (for roof mount arrays) View of down conductor for lightning protection

Lightning Protection And Earthing

All earths on site – main earth, lightning protection and generator Showing enclosure location in relation to house and array Equipment and battery enclosure(s) as a unit Close up of equipment enclosure front panel showing user interface Close up of equipment enclosure internal workings (left and right) Side view of cable entry to equipment enclosure Equipment enclosure serial number name plate

Equipment & Battery Enclosures

Close up of each string showing cells, connections, cables & temp probes New or replacement appliances All existing switchboards Views of Remote user Interface – Close up and relative position Descriptive views of all defects Various site views for use in Bushlight documents

Other

Images of Bushlight system users where signed permissions previously granted


Site Layout Map Scaled drawing of the installation site and surrounds including all the features specified below

Include: True North All relevant buildings, trees and structures including heights if shading array PV array Bushlight

Enclosures Generator Lightning protection Earthing sites New overhead or underground cables Known existing

overhead or underground cables