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1/2 Cup

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As I posted #51 one of my many projects is to replace the Main Switchboard to the property.

View media item 27582
I was not able to find a suitable domestic switchboard that would cater for my needs and any thing industrial was to large to fit in the existing space i have without making some huge changes and being without power for a day or so whilst the change over was undertaken so the solution is to build my own.
Specs are;
100 amp 415 volt three phase supply.
Manual change over switch for a gen set alternative supply
Surge and over voltage protection.
Safety switches (Residual Current Devices) to all circuits up to 20 amps (light and power only)
Off peak 2 rate metering.
The enclosure is made from CNC routed 3mm brushed aluminium which is still a work in progress.

I have the choice of 2 DIN mounted manual change over switches to isolate the generator supply from the mains so there is no chance of a back feed either way as they are mechanically interlocked with OFF position.
I have also considered using an Auto Transfer Switch but for the times that we may use it, the expense is not justified. Our power supplies here are reasonably reliable.
No load shedding will be required.

Option 1 - link below.

http://www.hagerelectro.com.au/prod...ntrol-indication/changeover-switches/3483.htm

Option 2 - link below.

http://www.socomec.com.au/range-man...ml?product=/changeover-switch-sirco-m_en.html

I will be using a permanently installed 50 amp 415 volt three phase appliance inlet to supply the switch board from the portable generator.

http://powertranz.com.au/clipsal-56...-ip66-industrial-socket-appliance-inlet-.html

The installation will comply to the relevant Australian Standards in terms of installation, earthing and over current protection.

I will follow up with a block diagram to show how it is all pieced together.
 
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1/2 Cup

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WOW. That is very well done. Much better than the plastic finished types you see. Is that a power point in the bottom right hand corner ? If so what is the idea of that ?

I have some size and application limitations, so building my own was the only option. I am relying on a favour from a friend of a friend to get the alumium CNC work done for the actual chassis so that has been a bit of a hold up with the project, that said i am not in any hurry as the old switchboard is more than adequate and safe, I just needed to bring it into the 21 st. century using the latest gear and conforming to the current Australian Standards because I can. (Its an electrician thing)
You have often heard about a mechanics car?? Well I have debunked the myth on electricians own home wiring - inspections welcome..:thumbup:

Good eye for detail and you are correct, that is a power point on the bottom RH corner. They are DIN mounted as per the circuit breakers, didn't realy need one there but did it any way, it may come in handy at some point. Most of our switchboards at work have them installed as standard.
 
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1/2 Cup

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So what is the idea of a power point in that situation ? I have seen them before but never known why that is done.

At work we use them to plug in a lap top for programming stuff, fitting say a power analyser that requires 240, using power tools etc.

Don't tell Mrs 1/2 Cup but it is so that she can plug in the vacuum to do the front porch:lol_hitti Sure beats me sweeping..
 
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1/2 Cup

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I always understood them to be used if the circuits failed the single power point was on its own circuit.:headscrat

As for the secret. Mums the word. ;)

They certainly can be on their own circuit, correct.:thumbup:
As you can see i have gone over the top, bear in mind a "normal" domestic switchboard would have about 1/10th of the circuits i have.
All of the circuits are that lightly loaded as it makes for very easy additions should i choose to do so in the future and all within the rules as set out in AS3000:2007. Future proofing so to speak.
There is nothing stopping you doing that, as it clearly exceeds the minimum standards.

The other reason i have installed a socket outlet there is sheer convienience for Mrs 1/2 Cup.:lol_hitti
 

HOTFR8

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normally they are put into temporary switchboards during construction.

Well that sounds like common sense and a practical idea.

They certainly can be on their own circuit, correct.:thumbup:
As you can see i have gone over the top, bear in mind a "normal" domestic switchboard would have about 1/10th of the circuits i have.
All of the circuits are that lightly loaded as it makes for very easy additions should i choose to do so in the future and all within the rules as set out in AS3000:2007. Future proofing so to speak.
There is nothing stopping you doing that, as it clearly exceeds the minimum standards.

The other reason i have installed a socket outlet there is sheer convienience for Mrs 1/2 Cup.:lol_hitti

Did you wire a clean line for the computers ? Many used to do that to stop electrical interference.

You are on the money there, temporary supplies to construction sites have them all the time, you would rarely see one with out a heap of socket outlets installed.:thumbup:

Do you mean like in the power pole temporary supplies you see at building sites ?
 
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1/2 Cup

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Did you wire a clean line for the computers ? Many used to do that to stop electrical interference.

HOTFR8,

The power supply originates from, in my case from the Supply Authority and into the future will have generator back up. The government has mandated that the supply to our premises meet defined performance criteria but as you know invariably we get spikes, surges, brownouts, harmonic distortion and voltage fluctuations from time to time.
I am grappling with that very issue on one of our pump sites at the moment, where the pump, when it runs you could fry an egg on it, its that hot! We have checked all the basics in terms of fault finding but could not find the cause until we installed a power analyser and found one phase having the sine wave being clipped every fifth cycle.
We have data logged the supply and have just presented that to the Supply Authority as evidence and not just second guessing something as it is clearly an issue with the supply that they will have to correct under the supply agreement.
In respect to having a "clean supply" there are a number things that you can do, putting in a dedicated circuit will not necessarily give you that, given that we are in the lap of the gods so to speak when it comes to power.
Basically you have got to filter out the incoming or site generated nasties, electronics are very sensitive to these and this can be achieved by using one or more of the following;
1. Power conditioning the incoming supply. can be expensive.
2. Power factor correction, not really applicable in yours or my situations.
3. Installing a UPS to those dedicated circuits or equipment you may want to protect and now a days is probably the most cost effective method of protection.
4. Install surge diverters to protect you from the over voltage spikes, my new switchboard will have these installed.

I hope this helps and answers your question.

Cheers
 
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Bob Heine

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I think most of the developed world has made major improvements in the stability of their power grids. I also think our modern computers have more tolerant power management.

Near the dawn of the computer age (1965) IBM assigned me to Unit Record (keypunch and sorter) maintenance and repair at a major account in Manhattan. In my free time I helped with routine maintenance on the data center equipment. The 7010 system was experiencing failures around 7:30pm several times a week, right in the middle of some very large and critical tape-sorting routines. The building was new and had the latest and greatest power distribution system. Consolidated Edison (Con-Ed) met with the IBM team and showed (with graphs and charts) that its power was "extremely stable," with less than 1% fluctuation. The IBM mainframe guys started monitoring the Con-Ed lines coming into the building, just to verify the Con-Ed data. Turned out the power was being switched off for as much as one second every night and their fluctuation data was based on 6-minute increments. Con-Ed finally confessed that they manually switched their Manhattan grid in the evening -- from receiving power from the suburbs -- to supplying power to the suburbs. The process involved a bank of very large knife switches operated by a big burly employee. The solution involved a large bank of lead-acid batteries.

While not perfect, power grids have improved over the past 50 years.
 
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1/2 Cup

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That's a fascinating story Bob, the company I work for has some smaller Hydro setups at its major water storage dams which have seen major upgrades in recent years, they are owned and operated by various Power Distribution companies. In terms of stability of the network, the challenges we face here in Australia are firstly distance and ageing infrastructure.

Other supply problems we face here as well are;

. The up take of grid connected solar is also presenting issues with the network to the point that the supply voltage has increased from around 230 / 240 vac to 250 vac plus when I measured it here recently. You are now required by the power company to have an assessment done of the network in your area and a permit issued with their approval prior to any new solar installation.

. The additional loads imposed on the grids that were not designed to accommodate the huge increases in split system air conditioner installations we have seen over the last few years.

. Variable speed drives and harmonics.

. Power factor.

. Compact fluorescent, energy saving lighting has also become popular but is also causing headaches for the supply authorities again with harmonics.

I have to agree with your comment in regards the power management tolerance of modern electronics, it is a key selection criteria for us across the board when we are looking at our infrastructure.

Cheers:thumbup:
 
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HOTFR8

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The last few posts sure make for very interesting reading.

I set up my computer and office here (as I have posted many times before) with two small 80 watt solar panels and battery back up (A flash UPS supply I admit) also on a battery tender to charge from the mains as I have experienced and had tested here may times for voltage fluctuations. The Solar system has protected the computer but the treatment plant pump that runs on the mains was affected by these voltage drops.

Fast forward a few years and add the property is now all solar with battery back up feeding back to the grid. The inverter now filters this problem that Power Cor could not fix. They did admit we had an issue (brown out I think it is called) but to them it was all with in tolerances yet the pump in the treatment plant did not like the drop in power.
 
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1/2 Cup

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We are in holiday mode here at the Shed Downunder and not too much is happening in the shed, we have our Son, Daughter in law and first grandson (18 month old) down from Sydney and staying with us for the next week. Its been a special time for us and are taking the time to make the most of it whist they are here.

I was musing through some pictures last night, after the little bloke had gone to bed and I had some quiet time to myself and found some that I thought would be of interest. Some may be aware that I have my Private Pilots licence.

This was my dads Cessna 150M that I logged some 200 hours in command before he sold it a couple of years ago.

View media item 36499

I have always had a passion for Warbirds and in particular any thing that sports a Rolls Royce Merlin power plant. I was over the moon when Mrs 1/2 Cup presented me with an opportunity to fly in one for my 50th. as this has been on my bucket list since I was knee high to a grass hopper.

View media item 36500
VH - JUC a Commonwealth Aircraft Corporation CA-18 Mk21 or P51D Mustang built under licence in Australia in 1947.
Pre flight checks complete.


View media item 36501
Me in the jockey seat, the aircraft has dual controls and was fortunate to have some time in command under instruction.:thumbup:
 
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drs23

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Very detailed and interesting thread Mr. 1/2 Cup. You sir do turn out some fine work. Very impressive.

As a side note, I'm not a pilot but enjoyed studying WWII aircraft as a kid and the P-51 Mustang was always my favorite. I'm quite envious of your BD gift from Mrs. 1/2 Cup. Kudos to you sir. :beer:
 
OP
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1/2 Cup

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Very detailed and interesting thread Mr. 1/2 Cup. You sir do turn out some fine work. Very impressive.

As a side note, I'm not a pilot but enjoyed studying WWII aircraft as a kid and the P-51 Mustang was always my favorite. I'm quite envious of your BD gift from Mrs. 1/2 Cup. Kudos to you sir. :beer:

Many thanks for your kind comments Sir.:thumbup:
In reading through the thread myself, it gets a little wayward at times and will do into the future but thats all part of it I am guessing. This is my first and only forum that I have been actively engaged in.
The forum has provided me with heaps of inspiration, ideas and the motivation since joining and made me get of my **** and have a go.

Cheers:thumbup:
 
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Bob Heine

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In terms of stability of the network, the challenges we face here in Australia are firstly distance and ageing infrastructure.
1/2Cup and HOTFR8,

I would add population to your list. The population when we lived there (1989-91) was about 17 million and I see it has grown to more than 23 million today. That's still less than the population of Texas yet you deal with an area roughly the same size as the lower 48 states in the US. Your population supports a really large infrastructure -- amazingly well, I might add. Only power outages I recall were bush fire and storm related. We lucked out with the really expensive March '90 hailstorm (http://www.bom.gov.au/nsw/sevwx/18mar90.shtml) because our car was parked in the garage when the storm passed though the area. The following months were a bad time to buy a used car anywhere in or near Sydney, with the likelihood of hidden hail damage being quite common.

The worst power outage came on Monday 21 January 1991 http://www.bom.gov.au/nsw/sevwx/21jan91.shtml. My office was located in Cumberland Forrest, near Castle Hill and the storm came through there just before quitting time. The power went out so I left the office about 5:00 pm, figuring the hour drive home would take a bit longer. Ended up taking me 3.5 hours to drive the 38 miles because of all the downed trees. Early on the Low Fuel warning light came on. No worries -- except that the few petrol stations I passed had neither power nor emergency generators. When I finally passed out of the disaster area around Frenchs Forrest and fueled up my '89 Toyota Camry Ultima, I was able to put 60 litres into the 60-litre tank. I figure there was less than a cup of fuel left in the tank.

As bad as that storm was (50,000 homes lost power), power was restored to the last 2,000 home by the following Tuesday.

The home we rented in Manly was brand new -- we were the first to live in it. It was the upper floor of a 3-family double-brick building. It had almost all the modern amenities, including all Bosch kitchen appliances and a stacked washer and dryer in the laundry room. Only thing missing was central heat and air conditioning. We ended up using space heaters in the bedrooms and the fireplace in the lounge. Because the "For Sale" sign listed the place for $595,000A, I didn't think to ask if it had central heat before we signed the rental agreement.

The oddest electrical item was the lighting. The central hallway, dining and lounge spaces had recessed down-lights with American-style Edison E26 sockets. Only reason I noticed was two hallway bulbs burned out about 3 months after we moved in, At $7.99A each it caught my attention. If used daily, the E26 bulbs lasted about 3 months so we put table and floor lamps with bayonet style bulbs in the dining and lounge rooms and those were still working fine when we left.

Since this is a Garage Journal thread, I'll show the other oddity in the home. It came with two garages (front of the bottom level was 4 garages but my camera didn't have an 'ultra' wide angle lens).
CliffStreetHome_zpsa0ca1f0a.jpg


The garages on either side of the entry gates were connected to our unit on the second floor. Each one is big enough for one car. My wife was deathly afraid of driving in Sydney so we only had one car. The other garage became a wine cellar and very marginal workshop My company allowed us to air freight one 1,500 lb. container for two years worth of necessities so none of my tools made the trip. That's part of the reason I bought a new Camry.
CliffStreetGarage_zpse7f4ec84.jpg
 

Carves

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I have always has a passion for Warbirds and in particular any thing that sports a Rolls Royce Merlin power plant. I was over the moon when Mrs 1/2 Cup presented me with an opportunity to fly in one for my 50th. as this has been on my bucket list since I was knee high to a grass hopper.


Mrs 1/2 Cup deserves 2 outlets on that power board ... and a new vacuum cleaner .. ;);)


Nice power board too .. :thumbup: ... Do you travel and work, for small quantities of beer ?? .. :lol:
 

jonahbones

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Best surge and filter power boards are from Thor technologies in WA been using them for years. Clean sine wave make electronics very happy. However you do need to be willing to invest in a product engineered to do the job.

Sent from my GT-P1000 using Tapatalk
 
OP
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1/2 Cup

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1/2Cup and HOTFR8,

I would add population to your list. The population when we lived there (1989-91) was about 17 million and I see it has grown to more than 23 million today. That's still less than the population of Texas yet you deal with an area roughly the same size as the lower 48 states in the US. Your population supports a really large infrastructure -- amazingly well, I might add. Only power outages I recall were bush fire and storm related. We lucked out with the really expensive March '90 hailstorm (http://www.bom.gov.au/nsw/sevwx/18mar90.shtml) because our car was parked in the garage when the storm passed though the area. The following months were a bad time to buy a used car anywhere in or near Sydney, with the likelihood of hidden hail damage being quite common.

The worst power outage came on Monday 21 January 1991 http://www.bom.gov.au/nsw/sevwx/21jan91.shtml. My office was located in Cumberland Forrest, near Castle Hill and the storm came through there just before quitting time. The power went out so I left the office about 5:00 pm, figuring the hour drive home would take a bit longer. Ended up taking me 3.5 hours to drive the 38 miles because of all the downed trees. Early on the Low Fuel warning light came on. No worries -- except that the few petrol stations I passed had neither power nor emergency generators. When I finally passed out of the disaster area around Frenchs Forrest and fueled up my '89 Toyota Camry Ultima, I was able to put 60 litres into the 60-litre tank. I figure there was less than a cup of fuel left in the tank.

As bad as that storm was (50,000 homes lost power), power was restored to the last 2,000 home by the following Tuesday.

The home we rented in Manly was brand new -- we were the first to live in it. It was the upper floor of a 3-family double-brick building. It had almost all the modern amenities, including all Bosch kitchen appliances and a stacked washer and dryer in the laundry room. Only thing missing was central heat and air conditioning. We ended up using space heaters in the bedrooms and the fireplace in the lounge. Because the "For Sale" sign listed the place for $595,000A, I didn't think to ask if it had central heat before we signed the rental agreement.

The oddest electrical item was the lighting. The central hallway, dining and lounge spaces had recessed down-lights with American-style Edison E26 sockets. Only reason I noticed was two hallway bulbs burned out about 3 months after we moved in, At $7.99A each it caught my attention. If used daily, the E26 bulbs lasted about 3 months so we put table and floor lamps with bayonet style bulbs in the dining and lounge rooms and those were still working fine when we left.

Since this is a Garage Journal thread, I'll show the other oddity in the home. It came with two garages (front of the bottom level was 4 garages but my camera didn't have an 'ultra' wide angle lens).
CliffStreetHome_zpsa0ca1f0a.jpg


The garages on either side of the entry gates were connected to our unit on the second floor. Each one is big enough for one car. My wife was deathly afraid of driving in Sydney so we only had one car. The other garage became a wine cellar and very marginal workshop My company allowed us to air freight one 1,500 lb. container for two years worth of necessities so none of my tools made the trip. That's part of the reason I bought a new Camry.
CliffStreetGarage_zpse7f4ec84.jpg

I have to agree with you, i clean forgot about population growth.

I do recall those storms in Sydney and there has been many fairly nasty ones since, we went there in October the day after one such storm which reeked havok around the Hornsby area, the humidity levels for days after reminded me of Darwin during the Wet season.

There have been times when we have seen hail damaged cars from NSW come on the market down here in Victoria and its not hard to pick some of them in car parks around Sydney, some haven't even bothered to repair them.

Thats a different house you had in Manly, i would hate to think what it would be worth now?

Sydney driving, IMHO, is like Melbourne driving on steroids, heaps of traffic and narrow roads by comparison.

Interesting your issues in regards to your E26 lamps, i have found that some just don't last the distance wether that be from poor quality manufacture, the ES type lamp holder, voltage fluctuation.:dunno: I tend to buy recognised brands and don't have much issue here with lamps.

Cheers:thumbup:
 
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1/2 Cup

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Mrs 1/2 Cup deserves 2 outlets on that power board ... and a new vacuum cleaner .. ;);)


Nice power board too .. :thumbup: ... Do you travel and work, for small quantities of beer ?? .. :lol:

I have the room for 2 outlets:lol_hitti
and she has a new vac:thumbup:

Thanks for the compliments on the board.:thumbup:

I do travel for work, and do do large quantities of beer:beer: My sister once asked me how much to install a ceiling fan (one only) in her home and my response was it will start at $1000.00 plus materials and "other expenses" needless to say i missed out on the job - she thought i was joking - NOT!! mind you it is a flat roofed home.
 
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OP
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1/2 Cup

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Best surge and filter power boards are from Thor technologies in WA been using them for years. Clean sine wave make electronics very happy. However you do need to be willing to invest in a product engineered to do the job.

Sent from my GT-P1000 using Tapatalk

We do have some Thor stuff at work in the IT world, they love it.:thumbup:
and also use Eaton Powerware and Eltek Power supplies then Critec, Enrico Surge stuff.
 
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Bob Heine

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Thats a different house you had in Manly, i would hate to think what it would be worth now?

Sydney driving, IMHO, is like Melbourne driving on steroids, heaps of traffic and narrow roads by comparison.
If the current ads are an indication, the place would be selling for $1.5 to $2.5 million Australian. The two one-car garages would probably sell for $595,000.

You're right about Sydney driving. I vividly remember having to do a NASCAR start whenever the traffic light turned green. If you could see the number plate on the car in front of you, you were too far back and the traffic signal would go yellow. And don't get me started on the driving test in Manly...

I would be remiss if I didn't at least point out the puzzling sign a visitor to downtown Melbourne sees. I had to slowly pass three of them before I figured out how to make the turn properly. Having a streetcar thrown into the mix made it especially fun.
TurnSigninMelbourne.jpg
 
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1/2 Cup

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If the current ads are an indication, the place would be selling for $1.5 to $2.5 million Australian. The two one-car garages would probably sell for $595,000.

You're right about Sydney driving. I vividly remember having to do a NASCAR start whenever the traffic light turned green. If you could see the number plate on the car in front of you, you were too far back and the traffic signal would go yellow. And don't get me started on the driving test in Manly...

I would be remiss if I didn't at least point out the puzzling sign a visitor to downtown Melbourne sees. I had to slowly pass three of them before I figured out how to make the turn properly. Having a streetcar thrown into the mix made it especially fun.
TurnSigninMelbourne.jpg

:lol_hitti I try to avoid them at all costs, it just doesn't seem right or left.

:shocking:
 

HTGTS350

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I didn't realise there had been a debate, those of us who don't live in either know what shitholes they are, however I had the misfortune of being in Perth last year and it isn't that far behind.
 

Pumba

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THOSE ****** HOOK TURNS:shocking:

Was in Melbourne a couple of years ago for a mates wedding with the (now) wife and another mate. Didn't really have any idea of direction or final location and blindly followed the GPS in the rental car from the airport to the city centre. With no knowledge of hook turns or tram line etiquette it was an interesting drive to say the least.

Think the only reason I didn't get kicked out of the drivers seat was that no one else in the car was willing to give it ago!

Really didn't help (and was not aware prior to getting in to the CBD) that it happened to be the same week as the GP.
 
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HOTFR8

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IMHO Sydney is like Melbourne on steroids only using billy goat tracks.
( disclaimer; not trying to revive the great Melbourne / Sydney debate here)

Did you get the jumper leads out today :dunno:

I didn't realise there had been a debate, those of us who don't live in either know what shitholes they are, however I had the misfortune of being in Perth last year and it isn't that far behind.

I would prefer Melbourne to Sydney. Perth is OK. Adelaide I do not mind and once some one explained you never cross a King William (street names change either side of King William Street) I also got to know Adelaide as well. Canberra is weird as the road are all over the place. I was also told if you can not say anything nice then you are best to shut up. So I will not any anything about Brisbane, Darwin or Hobart.

THOSE ****** HOOK TURNS:shocking:

Was in Melbourne a couple of years ago for a mates wedding with the (now) wife and another mate. Didn't really have any idea of direction or final location and blindly followed the GPS in the rental car from the airport to the city centre. With no knowledge of hook turns or tram line etiquette it was an interesting drive to say the least.

Think the only reason I didn't get kicked out of the drivers seat was that no one else in the car was willing to give it ago!

Really didn't help (and was not aware prior to getting in to the CBD) that it happened to be the same week as the GP.

Same week as the GP. Be glad you got home safely. I hate being near the city when that is on.

Getting off topic again so I am going to ask about that switch ?
 
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1/2 Cup

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HOTFR8,

I have done a rough sketch of how the manual change over switch fits into the scheme of things, I have kept it fairly basic.
The generator will not be permanently connected, only to be brought out as required and weekly test running.
Just prior to Christmas I put in an expression of interest for the 10 kva Kabota unit at work, it will be some time before they move on selling it, anyway I am not in a hurry.

View media item 36529
I have not purchased the switch or the socket inlet as yet but the links below will give you the picture.

http://www.hagerelectro.com.au/prod...ntrol-indication/changeover-switches/3483.htm

http://powertranz.com.au/clipsal-56...-ip66-industrial-socket-appliance-inlet-.html

The socket inlet is basically an industrial version of your generator inlet except mine will be three phase.
The system complies fully with the requirements of AS/NZS3000:2007 Electrical Installation Standards that allows for the safe operation of an alternative power source.
 
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