Industrial electrical installations operate at a different scale and risk profile to commercial work. Fault currents can reach tens of kiloamperes, motor inrush currents challenge protection coordination, and a single incorrectly specified cable or protection device can mean weeks of unplanned downtime. PrismTech's industrial electricians hold the experience and licences required for high-voltage-adjacent work, and we apply engineering-grade documentation to every project regardless of size.
Machine Wiring and Motor Control
New plant installations, machine relocations, and production line modifications all require machine wiring that conforms to AS/NZS 60204.1 — the Australian standard for safety of machinery: electrical equipment. This standard specifies cable types, enclosure ingress protection ratings (IP54 minimum for most factory environments), emergency stop circuit categories, and control panel earthing. PrismTech reads and works from OEM electrical schematics, fabricates and wires control panels to these drawings, and commissions equipment with the machine builder's representatives present.
Motor control is a core industrial electrical discipline. We install and commission direct-on-line (DOL) starters, star-delta starters, and variable speed drives (VSDs) from major manufacturers including Schneider Electric, ABB, Siemens, and Rockwell. VSD installations require careful attention to motor cable length (to manage reflected wave voltage), earthing of the VSD output cable screen, and EMC cable management to prevent interference with PLC communications and proximity sensors on adjacent machinery.
PLC Integration and Control System Wiring
Programmable logic controllers (PLCs) form the nervous system of modern automated plant. PrismTech's industrial team wires PLC I/O enclosures from engineering drawings, terminates field instruments (4-20mA transmitters, thermocouples, RTDs, digital I/O devices), and installs communications infrastructure including EtherNet/IP, PROFIBUS, and Modbus TCP/IP networks. We work within the automation contractor's commissioning schedule and maintain clear separation between power wiring and signal wiring to prevent noise-induced faults on analogue inputs.
Where customers are expanding existing plant, we carry out modification work to running production lines during scheduled shutdowns. Shutdown electrical work is planned in advance: cable routes are surveyed, materials are pre-cut and labelled, and test procedures are written before the plant stops. This preparation compresses the actual shutdown window to the minimum required.
High-Load Distribution and Switchgear
Industrial facilities with large motor loads, resistance heating, or arc-furnace equipment require careful power distribution design. PrismTech designs and installs main switchboards, motor control centres (MCCs), and power factor correction panels that comply with AS/NZS 61439 — the switchgear and controlgear assemblies standard. Each board is fault-level rated to match the available prospective short-circuit current at its installation point, verified against the upstream protection device's let-through energy.
- Machine wiring and commissioning to AS/NZS 60204.1
- Motor control centres with DOL, star-delta, and VSD starters
- PLC I/O panel fabrication, field instrument termination, and comms network installation
- 415V three-phase distribution boards and MCC assemblies to AS/NZS 61439
- Shutdown electrical planning and execution for running production facilities
- Thermographic inspection and condition monitoring of high-current connections
Safety Systems and Compliance
Industrial safety electrical systems — emergency stops, safety relays, light curtain monitoring, and interlocked guard circuits — must be designed and verified to the appropriate safety integrity level under AS/NZS 62061 or AS/NZS 4024.1503. PrismTech installs these systems to the design engineer's specification and provides verified loop test records to demonstrate that each safety function achieves its required performance level before plant is handed back for production.
Industrial facilities carry significant risk when electrical compliance is treated as an afterthought. Engage PrismTech during the plant design phase and we will resolve cable sizing, protection coordination, and earthing system design before the concrete is poured and the steel is erected — because retrofitting solutions in a live factory is far more expensive and disruptive than getting it right from the start.
Frequently asked questions
What standards govern industrial electrical installations in Australia?
The primary standards are AS/NZS 3000 (wiring rules), AS/NZS 60204.1 (machinery electrical equipment), AS/NZS 61439 (switchgear assemblies), and AS/NZS 62061 (safety integrity of machinery). We work to all applicable standards and provide compliance documentation at project handover.
Can you work on our plant during scheduled shutdowns to minimise production impact?
Yes, and this is our preferred approach for significant modification work. We survey the work scope in advance, pre-cut and label all cable, and write step-by-step test procedures so the actual shutdown window is as short as possible. We've turned complex motor control modifications in 12-hour windows.
Do you install and commission variable speed drives?
Yes. We specify, install, and commission VSDs from ABB, Schneider Electric, Siemens, and Rockwell. VSD commissioning includes motor cable screening, drive parameter setup, functional testing across the full speed range, and handover documentation including drive parameter backup files.
How do you handle fault response for critical plant breakdowns?
PrismTech maintains a 24/7 industrial breakdown response. Our industrial team carries common motor protection components, control fuses, and contactor spares on the service vehicle. Where the fault requires engineering investigation, we mobilise within two hours and provide a root-cause assessment alongside the immediate repair.