006-Specifications2of2.pdf

SECTION 26 00 03

CONTROLS AND INSTRUMENTATION

1. PART 1 - GENERAL

1.1 DESCRIPTION

A. Work shall include design, fabrication, and testing of sewer treatment plant control panel.

At the existing pump building this control panel shall control the operation of a new packaged wastewater treatment plant system (Orenco Advantex AX100). The new control panel shall provide for the control and protection of motors and controlled equipment in conformance with the manufacturer's recommendations and applicable codes. Provide local alarms at the treatment plant in conformance with these specifications and applicable codes. Provide remote alarm connections from the treatment plant in conformance with these specifications and applicable codes. Control panel shall be provided by Orenco Systems or approved equal.

B. Work shall include design, fabrication, and testing of well control panel at new well pump building. This control panel shall provide for the control and protection of existing well pump motor and chlorine dosing system in conformance with manufacturer's recommendations and applicable codes. Provide local visual and audible alarms at each pump station in conformance with these specifications and applicable codes.

1.2 SEQUENCE OF OPERATION AND CONTROL PANEL REQUIREMENTS

A. Well Control Panel:

Well pump shall start on a remote start signal and shall stop on a remote stop signal from water tower.

There shall be a minimum pump run time (user-adjustable) to prevent the pump from short-cycling.

The fractional HP chlorine pump shall run anytime the well pump is running.

Control Panel Features

In the event of an alarm, the control panel shall activate a local light and an audible alarm. The audible alarm activation shall be on a user-adjustable time delay. Alarms shall be displayed locally on the panel and trigger an external audible and visual alarm on the building with a silence button on the panel. External alarm shall alarm on pump overload, high level, low level, motor power loss, and control power loss.

Provide door interlock shutting power off to the panel when the door is open, HOA switches for motor, overload trip alarm, and run time indicator.

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B. Wastewater Treatment Plant:

Recirculation Tank:

The recirculation tank contains two (2) pumps that shall run in a duplex alternating fashion, using On and Off timer settings as input by the system operator.

The pumping mode of the recirculation pumps shall depend on the input of three (3) float switches installed in the tank:

High Level Alarm Override Timer On/Off Low Water Alarm/Redundant Off

Normal system operation will keep the wastewater liquid level between the bottom and middle floats.

The pumps shall cycle on and off per the user-adjustable timer settings.

In periods of high flow, the wastewater liquid level in the tank may rise to the point where the middle float switch is raised. When this float is up, the system shall employ a second set of timer settings (also user-adjustable) that allow for a more aggressive set of on/off times to deal with the excess inflow. If these settings do not keep up with the flow and the top float is raised, an alarm will be sent to notify the operator of the high level condition.

In the event that the water level drops below the bottom float, all automatic pump activity is ceased and an alarm is set to notify the operator of the low liquid level.

During pump cycles, each pump amperage draw is monitored by a current sensor to ensure the pump is drawing an acceptable amount of current for its operation. In the event that the pump draws more current than the upper limit or less current than the lower limit (limits are user-adjustable), an alarm is set to notify the operator of the condition.

Wastewater Treatment Plant Control Panel Features:

All alarms, pump cycle, pump run time, and pump amp draw will be stored in the controller’s data logger memory for review and download by the system operator. The panel will be configured to store up to two years worth of daily run data and the last 200 alarm messages. Data may be downloaded either by phone line, direct connection via onboard serial port, or over a local network (provided a local network is available and the panel can access it through the onboard eithernet/RJ45 port).

In the event of an alarm, the panel shall activate a local light and an audible alarm; the audible alarm shall be on a user-adjustable delay. The panel will also contact an alpha-numeric pager or cell phone via the onboard auto dialer to notify operators or an alarm condition.

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The control panel shall have a touch screen display to allow the operator to view all the present system conditions, daily activities, alarm histories, and pump activity histories.

The touch screen shall allow the operator to make set-points adjustments without the use of a laptop.

Provide TVSS protection in control panel, TVSS shall be listed by UL 1449 and meet

IEEE C62.41-1991.

1.3 QUALITY ASSURANCE

A. All control systems shall be the product of one manufacturer who in the past one year was and still is successfully engaged in designing, assembling, and installing modular motor control systems, utilizing electromechanical and solid state components, electromechanical and subsystems.

B. The control systems manufacturer's factory shall have a minimum of one year of experience building control systems. Manufacturer shall be Orenco Systems, Incorporated, or approved equal. If a different manufacturer is to be provided, contractor shall provide submittal information for approval to the CO.

C. Submit, at time of bid, qualifications statement covering all aspects of this project, UL508A and UL 698A listing, and other qualifications to construct these systems to meet all requirements of these specifications and related sections.

1.4 UNDERWRITERS LABORATORIES LABELING

A. Provide an Underwriters Laboratories label, for each control panel, conforming to U.L.

standard 508A and UL 698A, (Industrial Control Panels for General Use).

B. All schematics in this contract shall be designed to U.L. 508A and UL 698A standard for listing.

C. Listings must be accepted by the States of Oregon.

D. Provide written certification at time of bid that manufacturer has been investigated and approved by U.L., to construct and label panels to this standard.

E. Provide all documentation necessary to verify that all components, construction methods and circuits conform to this standard.

F. Where specifications are more stringent than UL standard 508A and UL 698A the technical specifications shall take precedence. The contractor shall include any design change costs of a standard other than UL 508A and UL 698A being used to list the panels. Any alternate listing must be acceptable to the state where the control systems are installed.

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1.5 CODES AND STANDARDS

A. Conform to the most stringent requirements of U.L., NEMA standards, latest revision, NEC, OSHA, State, and local codes, or these specifications.

1.6 FACTORY ASSEMBLY

A. Factory design, assemble, operationally test and inspect new control systems at the factory prior to shipment, ready for field connection at internal terminal blocks. Field assembly will not be allowed. See Factory Testing, this section, for description of testing procedures.

1.7 SUBMITTALS

A. Comply with Section 01 33 00.

B. Type all Documentation on 8-1/2" x 11" white bond paper.

C. Provide Excel Version 2000 or newer spreadsheets for material lists, calculations, nameplate schedules, and other items listed below.

D. Provide PDF cut sheets as well as printed hard copies of all material submittals.

E. Write all typed documentation, functional descriptions, troubleshooting, operating instructions, material lists, nameplate schedules, all calculations, and other typed material on a word processor.

F. Word processor shall allow the Government to access the CD-ROM from the following Government-owned existing system:

1. "Microsoft Word For Windows 2000 " brand software processor in operating system for use on an existing Government-owned IBM PCAT. The floppy disk format must be compatible with the IBM PCAT disk drive. Provide two CD-ROM copies with above documentation, after as-built changes are made for each panels.

Provide a final typed copy of the as-built operation and maintenance manuals at the time of the final submittals. Initial and final submittals shall be printed on 8-1/2 x 11 inch paper on a laser printer. Print style shall be the same as these specifications Times New Roman.

2. Provide a separate CD-ROM with all information on it for each panel for O&M manuals.

3. The Contractor shall provide the word processing system. The Government will use the as-built data files for future changes and future control contracts. Standard manufacturer's operation and maintenance manual insertions need not be included on the CD-ROM.

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4. For each panel provide a separate file name on each disk for each major item such as:

a. Table of Contents

b. Schematic diagrams, each sheet a separate file

c. Physical Wiring diagrams, each sheet a separate file

d. Dimension diagrams, each sheet a separate file

e. Legends, symbols, and relay base diagrams, each sheet a separate file.

f. Materials list spreadsheet with vendors list,

g. Operating instructions

h. Functional descriptions

i. Troubleshooting instructions

j. Calibration instructions

k. Calculations spreadsheets and all other items separated by a tabbed section in the final O&M Manual.

G. Obtain written approval for the above submittals prior to construction, assembly, and delivery.

H. Submit a separate material list for each control panel.

I. Submit only one cut sheet for identical components used for separate control panels in this contract. A cut sheet may contain more than one item, provided that they are identified. Identify each cut sheet with a reference number to be identified on the materials list.

J. Shop drawings shall be accordion folded to 8-1/2" x 11" sheet size if in book.

K. Submittals shall have sufficient detail to determine if ratings, characteristics, and physical construction are equivalent to those specified. Submittals shall have schematics and ladder diagrams for all panels.

L. Where manufacturer's catalog sheets are used, indicate the specific items to be supplied in ink either by arrow, encircled on the sheet, or the inapplicable portion blocked out.

M. Submittals shall show any changes to be made resulting from substitution of equipment or materials for those that are specified. If these items have not been approved at time of bid, they may be rejected.

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1.8 INITIAL SUBMITTALS

A. Submit the following items to the CO bound copies for approval prior to installation of components for each control panel. Do not install equipment requiring submittals until submittals have been approved in writing by the CO. Integrate all submittals to show interrelationships between electrical, pneumatic, and hydraulic systems. Use unique numbering and name for each component shown. Provide a legend for each set of control panel drawings.

B. Submit both hard copies and electronic copy of all files used in making submittals on

CD-ROM.

1. Space components on ladder schematics, so that they line up vertically on the ladder diagram.

2. Provide legend symbols and standard details for all drawings on a separate disk.

Provide standard details and legend symbols made as individual blocks for assignment on an individual basis on future drawings. Provide attribute information for all symbols and blocks for text information prompt. The Government will review and approve all symbols.

3. Drawings must be sharp, clean, distinct, and legible. Workmanship must be in accordance with approved modern trade practices. Reproductions which do not conform to such standards will be rejected.

C. Drawing submittals: (Schematic, Wiring, Hydraulic, and Dimensional)

1. All sheets shall be read from bottom or right side for lettering.

a. The Government will retain possession of any drawings, designs, and master diagrams stick-on originals, CAD menus used in the contract drawings, with reuse rights on future projects.

b. Draw wiring diagrams on separate sheet from dimensional drawings.

c. Provide both hard copy and PDF copies of all drawings.

2. Ladder Schematic Diagrams:

a. Furnish 1/2 size (11" x 17") CAD drawn prints of complete system electrical and electronic elementary ladder schematic diagrams that show all circuits and all device elements in symbolic form using standard electrical symbols (switches, relays, lights, circuit breakers, motor starters, contacts, logic, overloads, modular circuit boards, etc.). Include schematics for all subassemblies: power supplies, stipend controllers, telephone dialers, all instrumentation, motorized timers, computer layouts, and other similar electronic and electrical system devices. Include pilot and controlled devices (pressure switches, motors, etc.). Draw circuits in the most direct possible line between and perpendicular to parallel lines representing opposite polarities or

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b. Provide unique identification names and numbers for all components not labeled on schematics such as indicator lights, selector switches, RTM, OC., etc. Indicate external connection points. Show motor starter sizes on schematic diagrams. Provide component names on back of door physical drawings.

c. Number each relay contact and coil and all other control components that have printed or labeled terminals with the pin or terminal numbers on each schematic diagram. This includes all subassemblies as described above.

d. Number each horizontal line of schematic diagram with a line number to reference to the functional description, and a line number reference to device elements that are controlled from another line (relays, contacts, etc.).

e. Show as-built overload heater numbers or settings if solid state relays are used, motor full load current or kW for other loads and service factor on the schematic diagram.

f. Show internal and maximum external wire sizes on schematics.

g. Manufacturer's package equipment schematics will be accepted for subassemblies (power supplies, instrumentation, etc.) in lieu of hand drawn schematics if lettering height is 1/8 inch minimum. Enlarge from original if necessary to obtain lettering height.

h. Show external control cable pair numbers on each external terminal and external wire destinations.

i. Show ratings of all pilot devices, current, voltage, etc.

j. Renumber any reference numbers for line, wire, or pin numbers on redrawn sheets.

k. Provide Pin and wire numbers on all locations.

3. Physical Wiring Diagrams

a. Draw to 1/2 scale (11" x 17") CAD drawn prints of the physical layout of all control system devices and accessory equipment (relays, switches, lights, circuit breakers, motor starters, terminal blocks, modular printed circuit boards, etc.) and the physical location of each wire on the connection terminals on these devices. Show all terminal numbers on all devices. Routing of wiring DOES NOT have to be shown on wiring diagrams in wireways.

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b. Use USFS standard blocks for wiring diagrams, these are located at:

http://www.fs.fed.us/database/acad/elec/sl500.dwg. Add additional symbols as require that are not on this drawing.

c. Provide a wiring diagram of components mounted on control panel back pan and a drawing showing components on back of all doors.

d. Include power panels with circuit names and numbers.

e. Show internal capacitors, contacts, transformers and taps, coil layouts, motors on all devices where applicable.

f. Identify drawing location with respect to entire panel, if it represents only a portion of a panel. Provide a location key map to correlate all drawings.

g. Identify external cable and wire destinations.

h. Provide wiring diagrams for all subassemblies: power supplies, instrumentation, etc.

i. Show the color code, number, and size, of each wire and all terminal point numbers. Show all internal control wiring including door mounted devices and external control wiring to controlled devices (motors, solenoids, light, etc.) and external wiring to all pilot devices (float switches, pressure switches, etc.), and controlled devices. Include any hydraulic or pneumatic lines and all shutoff and bleed valves. Number and name the control system components on the wiring diagram to correspond to those on the schematic diagrams. Reference wiring diagram numbering to functional description. Provide names and schematic number references on all external connection terminals (LS1-high level float switch, etc.). Include voltage, phase, horsepower, wattage, and current, as applicable. Include all terminal blocks and control cable pair numbers.

j. Provide a tabular list of wire color codes and wire size versus motor starter size and circuit breaker size.

4. Dimensional Drawings

a. Furnish a scaled drawing, 1/2 size (11" x 17") CAD drawn prints of the internal physical control panel layout and component placement with names.

b. Show external face of panel with all externally accessible or visible components (switches, lights, indicators, gages, nameplates, etc.) on separate drawing..

c. Show all internal components on separate drawing. Include nameplate schedules for review.

5. Hydraulic Diagrams (All Fluids)

a. Furnish ½ size (11” x 17”) CAD drawings of one line piping layout with flow control devices, pilot devices, flow direction, maximum pressures, gages, instrumentation, pumps, and motors with sizes.

b. Label all components and reference to the functional description.

c. The government will furnish construction drawings of the system to use for reference upon request.

D. Materials List

1. Submit a complete typed tabular list (Excel Spreadsheet) of all control component parts, all miscellaneous materials listed in PRODUCTS of this section and related sections.

a. Cross reference with item number

i. Item reference number all Materials List items to cut sheets and manufacturer's brochures with cuts showing physical construction of each item. Include the following in materials list:

ii. Model number

iii. Description,

iv. Size and rating

v. Source of supply, Vendor, with reference to vendors list.

vi. Quantity of each component

vii. U.L. status.

2. Sample materials list is at:

http://www.fs.fed.us/database/acad/elec/o&mmanuals/ommanuals.htm

E. SPARE PARTS LISTS

1. INCLUDE A SEPARATE SPARE PARTS LIST FOR EACH PANEL. Provide a separate tab worksheet in the materials spreadsheet for spare parts. Use same format as the enclosed sample Materials List. Include operation and maintenance instructions for all components. Edit Master List to show only those items to be included in each panel, on Material List and separate Spare Parts List.

a. Provide parts list for all subassemblies as described above under Ladder Schematic Diagrams. Include designation or reference number, part name, rating or value, part number, and source of supply.

F. Material and Equipment Cut Sheets

1. Submit complete materials manufacturers cut sheets of all control component parts, all miscellaneous materials listed in PRODUCTS of this section and related sections.

2. Provide first generation copies of manufacturer's brochures with cuts showing physical construction of each item.

a. Fax copies or illegible copies will not be accepted.

3. Mark each items to be supplied on each cut sheet.

4. Cross reference with item number

5. Include any information not on cut sheets or brochures to determine compliance with specifications. (Include reference number on cut sheets to materials list).

on each cut sheet to Materials List

G. Vendors list

1. Submit Material list and vendors list in an Excel 2000 format spreadsheet in hard copy and on disk.

a. Include a material suppliers list with names, addresses, and phone numbers of all purchase sources. Include vendors list as a separate tab in materials list spreadsheet on a separate work sheet.

b. Cross reference vendors list to materials list.

2. Sample vendors list is at:

http://www.fs.fed.us/database/acad/elec/o&mmanuals/ommanuals.htm

H. Calculations and Design

1. Provide all electrical engineering design and calculations required for construction for a complete control system. Properly size all equipment.

2. Submit detailed, typed calculations for transformer, power supply and circuit breaker and wire sizing. List all loads both running and inrush in tabular form.

Assume all devices energized unless otherwise shown. Submit any other calculations required.

3. Submit all calculations in a Excel format spreadsheet in hard copy and on disk.

4. Put calculations in a tab worksheet in materials list spreadsheet.

I. Nameplate Schedule

1. Submit a typed nameplate schedule in Excel spreadsheet format for review as described under Nameplates.

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2. Include this as a separate tab in materials list spreadsheet on a separate work sheet.

1.9 FINAL SUBMITTAL: OPERATION AND MAINTENANCE MANUALS

A. Imprint the front cover of the manuals with the following information: The name of the project, the control manufacturer, address, telephone number, the date of construction, and contract number.

B. Submit one preliminary complete copy for each project to the CO for approval at time of delivery for each project

C. Furnish manuals in 8-1/2" x 11" size in hard plastic cover, looseleaf, 3-ring binder.

Accordion fold drawings 11”x17” drawings to 8-1/2" x 11" size. Provide an index and tabs for listing contents. Arrange contents in order of their appearance in the specifications. Include Manufacturer's name, project name, contract number, date on each manual cover.

, but not later than the time shown in the schedule of items.

Half-size drawings may be used in this submittal. Ship the control panel with two sets of as-built schematic and wiring diagrams with each panel. The Government will return these O&M manuals after field testing on each panel has been performed for any changes to be updated to as-built.

D. Submit two copies of all disks (CD-ROM) of AutoCAD drawings, word processing documentation, spreadsheets and any other electronically generated data as described above in initial submittals above.

E. Provide the CO with one as-built set of drawings and all computer disks at time of shipping for each panel.

F. Panel costs shall include drawing and O&M Manual changes for minor field changes such as changes in heaters, motors, capacitors, breakers, etc.

G. Deliver four as-built approved bound copies of final Operation and Maintenance Manuals of each project to the CO prior to closing of the contract. Each manual shall contain all required information for each control panel on the project.

H. Deliver two copies each of Operation and Maintenance Manual's and drawings' CD-ROM disks with all as-built changes incorporated with the final copies of the manuals for each panel. Include CAD drawings and word processing disks, and spreadsheets and all cut sheets.

I. All typed information will be included on word processor disk for initial and final submittals.

J. Include the following as-built items in the final Operations and Maintenance Manuals:

1. Wiring, Schematic and Dimensional Diagrams

a. Return to the Government, the original half-size as-built electrical and electronic ladder schematic diagrams, wiring diagrams and dimensional

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b. Sample schematic and wiring diagrams are at:

http://www.fs.fed.us/database/acad/elec/o&mmanuals/ommanuals.htm

2. Component Manufacturer's Instructions

a. Include all component manufacturer's operations, installation, and maintenance instructions and parts lists for all electrical and mechanical components including those shipped with items.

b. Include complete operation instructions for the process control computer and the operator interface terminal, for normal operator use in changing all system parameters, loading and changing program, use of disk drive, monitor, keyboard, printer, modem. Write instructions for personnel with no computer background to operate.

3. Functional Description:

a. Submit a typed, written narrative functional description of all basic electrical/electronic control circuit operation. Reference each controlled and pilot device to its controlling elements and the sequential operationof these elements. Include all subassemblies.

b. Sample functional description is at:

http://www.fs.fed.us/database/acad/elec/o&mmanuals/ommanuals.htm

4. Calibration Procedures

a. Provide typed, step by step adjusting and calibration instructions for all equipment requiring calibration. Include all necessary equipment and tools required. Provide and reference tables and calculations required. Write instructions for an operator with limited electrical background which describe how to set up and use each piece of test and calibration equipment. Assume operator will have a Fluke 8060A digital volt meter.

5. Operation and Maintenance Instructions:

a. Include typed starting, installation, operation and maintenance instruction in layman’s language for system controls, including all electrical and electronic subassemblies as described above. Describe normal start up procedures, describe the function of the control system with reference to the pilot and controlled devices, instrumentation, time clocks, etc. to give an overall understanding of the system operation.

b. Sample Operation and Maintenance Instructions is at:

http://www.fs.fed.us/database/acad/elec/o&mmanuals/ommanuals.htm

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6. Materials List Spreadsheet

a. Submit as-built, typed materials list and equipment catalog sheets of all items as described above in Initial Submittals. Include separate spare parts list, and material supplier vendors list. Submit Excel spreadsheets.

b. Sample material list spreadsheets and suppliers lists are at:

http://www.fs.fed.us/database/acad/elec/o&mmanuals/ommanuals.htm

7. Vendors List

a. Submit final as-build vendors list as described above in initial submittals.

b. Include this as a separate tab in materials list spreadsheet on a separate work sheet.

8. Nameplate Schedule

a. Submit as-built typed nameplate schedule in Excel spreadsheet format for review as described under Nameplates.

b. Include this as a separate tab in materials list spreadsheet on a separate work sheet.

9. Materials Catalog Cut sheets.

a. Submit as-built equipment catalog sheets of all items as described above in Initial Submittals.

b. Note sample cut sheets listed below may not all represent material used in this project. Specifications take precedence.

c. Sample material cut sheets lists are at:

http://www.fs.fed.us/database/acad/elec/o&mmanuals/ommanuals.htm

10. Calculations

a. Provide as-built calculations as described above under initial submittals.

b. Include this as a separate tab in materials list spreadsheet on a separate work sheet.

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11. Master Details

a. Return to the Government any original Master Details used to make CAD menus or any new blocks for any project drawings and any contractor generated blocks on disk, and a hard copy plot.

1.10 FACTORY TESTING

A. The Government will observe and witness the factory test of each Control Panel. Notify the CO in writing, 10 days in advance of all tests and retesting. Provide 120 Vac 60 Hz, single phase power or other voltage and phases and compressed air or other media as required.

B. Provide an Engineer who has worked on the project and is familiar with the control functions to perform the tests. Test Control Panels as described below, calibrate and verify proper operation before notifying Government that panels are ready for testing.

Provide all tools, test equipment, materials and labor required, calibration equipment and standards.

C. Tests

1. Simulate all control functions by shorting across pilot device terminals with an external test switch box, by use of the test switches. Provide a test switch box with test switches to simulate all external pilot devices at one time.

2. Through the use of test switches, selector switches and external inputs from all instrumentation such as 4-20ma signals or other signals, sequence entire control system through all normal and alarm functions. Test each circuit and mark off on drawing each circuit tested to ensure complete testing.

3. Observe all normal process functions and all alarm functions. Test breaker trips, overload trips, indicator lights, etc., and other alarm circuits. Measure at output terminal blocks of all controlled devices to verify proper output voltage. Check motor starter contact continuity, voltage, and operation from line terminals to output terminal blocks. Provide a heat gun (or current load if solid state relays are used) to trip overload relays, and a regulated compressed air source if required.

Install overload heaters based on motor full load current.

4. Simulate the operation of all instrumentation (computer I/O, radio encoder, flow, pressure and level transmitter, indicators, DO. Controllers, Strip Chart Recorders, Telephone Dialers, Process Controllers), etc., after calibration by the use of appropriate voltages, currents, pressures, or other means to assure that external sensors will operate properly, and panel mounted equipment is working.

5. Provide a means of simulating operation through the use of test switches, current sources or other devices to demonstrate complete operational sequence.

6. Calibrate any equipment requiring calibration. Provide any test equipment, standards, material required.

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7. Any defects in material or workmanship found during testing shall be corrected and panel shall be retested until it works according to specifications.

2. PART 2 - PRODUCTS

2.1 U.L. LISTED OR RECOGNIZED CONTROL SYSTEM COMPONENTS

A. Furnish control system components of standard component manufacturer's catalog items, readily available from commercial sources. No specially designed circuit boards or components will be allowed.

B. All control system components shall be U.L. listed or component recognized and approved for required application. All components performing the same function shall be the product of one component manufacturer (relays, motor starters, transformers, power supplies, switches, circuit breakers, timers, lights, instrumentation, controllers, etc.).

C. Where non U.L. listed or non-component recognized equipment is specified or not available from any source, provide an isolation transformer, a GFI, (ground fault interrupter) and fuses as required to protect these components if not shown.

D. Provide design and other components or equipment as necessary to meet U.L. 508A and UL 698 listing standards. Provide submittals on these products if not listed in this products section.

2.2 PACKAGED AND/OR PRE-WIRED CONTROL SYSTEMS

A. Furnish packaged and/or pre-wired control systems complete in all respects including all required control functions. Conform in all respects to all portions of the specification.

Pre-wiring of control systems and packaged controls shall be complete including all required interconnections, integral wiring, and interunit conduit and wiring, ready for the indicated external connections.

2.3 WIRING

A. Plastic Wiring Duct and Wire Tying: Encase conductors on back panel in plastic wiring duct inside control enclosures. Bundle and tie any wires not in wiring duct with Nylon Ty-raps maximum 3-inch interval. Provide spiral nylon wrapping around flexible wiring harness to door mounted equipment. Bolt door harness to enclosure. There shall be no grounded devices, screws, or rivets inside wiring duct.

B. Provide wiring duct with snap on cover.

C. Numbering: Provide plastic machine numbered labels for each end of each control and power conductor corresponding to schematic diagram. Labels must have clear plastic adhesive covering which wraps around label number on wire to prevent falling off.

Labels may be computer generated.

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2.4 INSULATED TERMINAL ENDS:

A. Install insulated ring tongue or snap lock spade type compression or crimp-on tin plated copper terminals at each end of any conductors on any equipment requiring terminal ends.

B. Devices which are approved and will accept bare conductors will be permitted. Provide insulated terminal ends with inner metal crimping sleeve.

C. Install crimp-on terminals with a locking type terminal tool that will not release until proper compression is applied.

2.5 TERMINAL BLOCKS

A. Make internal control and power wiring connections on enclosed, numbered heavy duty, touch-proof, 600V 30A, molded in thermoplastic, compression clamp terminal blocks for wires #22 to #10 AWG. Must be UL Recognized.

B. Make internal control and power wiring connections on enclosed, numbered heavy duty, touch-proof, 600V 50A, molded in thermoplastic, compression clamp terminal blocks for wires #22 to #8 AWG. Must be UL Recognized.

2.6 GROUND TERMINAL BLOCKS

A. Make internal control ground wiring connections on enclosed, numbered heavy duty, touch-proof, 600V 30A, molded in thermoplastic, compression clamp ground terminal blocks, colored green and yellow, for wires #22 to #10 AWG where block makes contact with the rail at its base. Must be UL Recognized.

2.7 FUSE TERMINAL BLOCKS

A. Make internal control wiring connections where fusing is required with enclosed, numbered heavy duty, touch-proof, 600V 35A, molded in thermoset, where body of the block is grey and the plug shall be white, compression clamp terminal blocks for wires #18 - #8 AWG. Must be UL Recognized.

B. Fuses: Provide 250V, 1/2 A, 13/32" x 1-1/2" dual element or as indicated on drawings, Buss FNA pin indicating U.L. listed or approved equal.

C. Provide one spare fuse for each fused used.

2.8 TEST TERMINAL BLOCKS

A. Make internal control test wiring connections on enclosed, numbered heavy duty, touch-proof, 600V 20A, molded in thermoplastic, compression clamp terminal blocks for wires #22 to #8 AWG equipped with knife switch disconnect (short blade). Body of the terminal block shall be grey and the switch handle shall be orange. Must be UL Recognized.

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2.9 CIRCUIT BREAKERS DIN RAIL MOUNTED

A. Shall be thermal magnetic, rated 250VAC. Terminals shall be compression clamp with a captive screw. Shall accept wire size #20 to #8 AWG. Actuator shall be flush with the body of the circuit breaker to prevent accidental operation. Life: 4000 cycles, mechanical impact: 30g (gravity), ambient temperature 32 degrees F to 104 degrees F (0C – 40).

Circuit breaker shall be UL Recognized and touch-proof.

2.10 TERMINAL BLOCK NUMBERS

A. Terminal block numbers shall correspond to wire numbers and wiring on schematic diagram numbering sequence. Make all connections on terminals. NO INLINE SPLICES WILL BE PERMITTED. Provide a terminal block for all control cable conductors, including any spare conductors. Ground all unused conductors on terminal blocks.

Provide 600 Vac rated terminal blocks, 50 A minimum. Furnish with white marking strip on top of terminal block for terminal numbers. Size terminal blocks for wire lugs and ampacity. Field wire sizes are shown on drawings.

2.11 CONTROL DEVICE NUMBERING AND TERMINALS:

A. Control devices (relays, switches, etc.) shall have numbered screwdown, terminal connections which correspond with conductor, schematic and wiring diagrams numbering sequence.

2.12 CONTROL CABLE TERMINAL BLOCK SHIELDS:

A. Provide a removable metal shield over control cable terminal blocks for any field wire with less than 600V wire insulation such as telephone cable for remote connections.

Provide 2 inches space in front of terminal block to route cable. Separate terminals or lighting protectors from control cable from 600V rated wire.

2.13 INTRINSICALLY SAFE BARRIER TERMINALS:

A. Provide intrinsically safe barriers for panel external float switch and current sensors shown on drawings.

2.14 POWER WIRE TYPE & SIZE:

A. Provide internal copper MTW control panel power wiring loaded to maximum 80% of load current requirement based on U.L. 508A and UL 698A for 90 C wire. Provide minimum 19 strand. Provide minimum 1/32 inch of insulation on all wire where required by U.L. or otherwise. Provide 600V rated wire.

B. For motor and power circuits, provide wire sized to minimum 125% of maximum continuous enclosed current rating for all motor starters, contactors, and circuit breakers as per U.L. 508A and UL 698A.

C. Power wire for all motor starters shall be sized from main distribution block to output terminal load blocks for the full ampacity of each starter, regardless of actual motor load.

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2.15 CONTROL WIRE SIZE

A. Minimum #14 AWG 19 strand type AWM rated as MTW, or THHN 90 degrees C tinned Cu stranded

2.16 INSULATING PLASTIC SHIELDS

except where shown on drawings. Provide size and type as above for Power Wire. Other insulation types will be accepted with a minimum 90 degrees C temperature rating. Load wire to maximum at 80% of U.L. 508A and UL 698A allowable ampacities.

Provide 600V rated wire.

A. Provide an insulated clear plastic min ¼” thick cover over in-coming line lugs on main service disconnects, power distribution blocks, transformers with exposed terminals and other equipment with 120 Volt or higher exposed terminals that are not recessed into device such as circuit breakers .

2.17 NAMEPLATES

A. Provide nameplates indicating component name or schematic reference number for all components numbered and labeled corresponding to schematic diagram and wiring diagram: (submit nameplate schedule for review).

1. Internal and external switches (selector, test switches, power disconnect, etc.), indicate function (low level bypass, main disconnect, etc.), and schematic reference number TS1, SS3, etc.

2. Circuit Breakers (CB9, etc.)

Relays, motor starters, alternator relays, time delay relays.

(Schematic reference number is permissible, R4, M1, TD1.) On motor starters, contactors, and adjustable time delay relays and timers, also include motor name or function.

3. Overloads

4. Contacts

5. Timers (Function) and Schematic Reference, TD4 (well pump low flow)

6. Transformers

7. Power supplies (D.C. supply, battery charger, etc)

8. Terminal boards/blocks, TB1, TB2, etc.

9. Thermostat

10. Indicating lights (Function)

11. Adjusting points (Time delays, set points, D.C. limit alarm switches, etc.)

12. Strip heaters

13. Fans

14. Surge protectors

15. Other devices used

B. Construction: Provide laminated plastic nameplates engraved to provide 1/4" or 3/16" high white letters on black background. Embossed tape labels are not acceptable. Fasten with pressure adhesive or epoxy cement. Mount the nameplates on the back panel or on the wire duct cover where possible, and on front of panel above the respective devices.

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Engraved metal nameplates with white lettering on black background may be used in lieu of plastic nameplates on selector switches, push buttons, and lights.

2.18 TEMPERATURE LIMITATIONS

A. Design control panels to operate continuously in an ambient temperature of -30 to 120 degrees F.

2.19 CONTROL SYSTEM AC POWER SUPPLIES

A. Provide two-winding machine tool rated isolating transformers to supply 120 Vac and other voltages to operate all control circuiting with sufficient volt-amp capacity to operate all motor starter coils, relays, lights, and associated control devices as applicable.

B. Design control system to operate on nominal input voltage and maintain 95% of nominal output voltage under worse case load condition. Include transformer voltage regulation curves in submittals, detailed calculations for transformer sizing, Sealed and Inrush volt-ampere rating for each AC control device (relays, motor starters, solenoids, lights, etc.).

Assume all circuits energized simultaneously.

C. Do not exceed 90% of the transformer's continuous VA capacity. Provide minimum 250 VA transformer for 120/24 V and 500 VA transformer for isolation transformer 120, 240 V. Provide 3 taps on secondary of isolation transformer, 2 above, 1 below normal.

D. Verify all VA loads. Submit transformer calculations for each transformer.

E. Provide taps on primary side of isolation transformer to allow for voltage adjustment.

2.20 VENTILATION FAN & THERMOSTAT

A. Provide a ventilation fan with following characteristics:

1. All Metal Construction

2. Supply Voltage115 @ 50/60 Hz

3. Air Flow = 120 CFM

4. Noise = 34 SIL db

5. Dimension = 4-1/2" x 4-1/2" x 1-1/2"

6. Provide replaceable dust filters, (5 spare filters).

7. Provide U.L. listed louver for air outlet.

B. Louvers and Filters: Provide U.L. listed and approved ventilation louvers with removable filter for control panel enclosures where shown on drawings, sized for fans.

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C. Supply a 120VAC thermostat rated 20A, calibrated from 60deg – 100DegF with calibrated knob to operate ventilation fan.

2.21 MOTOR STARTERS AND CONTACTORS

A. Magnetic Motor Starters and Contactors

1. Furnish magnetic motor starters at all locations unless otherwise noted. Controllers shall be AC full voltage non-reversing type unless otherwise noted or shown, 2 pole NEMA Size 1, or larger unless shown on drawings.

2. All starters shall have overload relays.

3. All motors shall have one overload in each ungrounded phase. Provide auxiliary contacts as shown on the drawings.

4. Starters shall be constructed to NEMA & ICS Standards. Starters and contactors shall be identical except contactors shall be supplied without overload relays.

5. Provide 2 pole contactors, starters, and overload relays for all motors.

6. Provide magnet coils molded in epoxy, removable by two snap screws. Coils available in 120 Vac.

7. Sintered Silver - Cadmium Oxide contacts, double break wedge action closing, self cleaning, removable from front.

8. Gravity dropout contact breaking.

9. Arc box cover, removable by two screws.

10. All parts removable from starter without dismantling, disconnecting line or load wires.

11. Starters shall be modular construction type with replaceable coils, contact assemblies and overloads. Starters shall be available with melting alloy or bimetallic (ambient compensated or nonambient compensated) or solid state ambient insensitive overload relays with standard trip class 20 or quick trip (class

10) elements from one manufacturer.

12. Submit cut sheets showing starter construction, replaceable parts and parts list and maintenance instructions for each different size of starter.

13. Starters convertible to push button ON-OFF or HAND-OFF AUTO selector switch size 00-5.

14. Each starter shall be mounted in separate NEMA 1 metal enclosure.

B. Overload Relays

1. Provide information on settings of heaters for melting alloy or bi-mettalic overload relays and solid state overload relays where ratings must be multiplied, on starter cover.

2. Provide quick trip ambient compensated solid state overloads for submersible pump motors. Overload relays shall be adjustable over a 2:1 ratio. Provide Class 10 trip for overloads for submersible pumps

2.22 MAGNETIC CIRCUIT PROTECTOR BREAKERS (MCP)

A. Where the motor circuit breaker is installed in the same enclosure as the motor starter and associated overload protection devices, provide "magnetic only" trip circuit breakers. The magnetic trip unit shall be adjustable, and the breaker shall have a continuous rating suitable for the load served. "Magnetic only" circuit breakers shall not be separately mounted. MCP's shall have manual trip button.

B. Coordinate the indicated ratings and settings to conform to the requirements of the actual motors served under this contract and conform with equipment, motor, and control manufacturer's recommendations. The final installation shall provide the closest possible protection without unnecessary tripping. After final setting, mark the established setting position with red paint.

C. The "magnetic only" circuit breaker equipment and application shall conform to NEMA, U.L., and code requirements.

D. Provide auxiliary trip contacts to open on breaker trip or manual opening for three pole breakers. On 1 or 2 pole circuits, the third pole may be used for the auxiliary trip contact.

E. Provide motor circuit breakers with padlock stops for each motor circuit protector.

2.23 POWER AND CONTROL CIRCUIT OVERCURRENT PROTECTION

A. Provide power and control circuits with separate circuit breakers for short circuit and overload protection. Fuses will not be allowed. Provide trip curves for breakers in submittals.

2.24 CIRCUIT BREAKERS

A. General Purpose Circuit Breakers

1. Provide molded case circuit breakers with thermal-magnetic trip units and a common trip bar for two or three-pole breakers, connected internally to each pole so that the tripping on one pole will automatically trip all poles of each breaker.

Bails or clip will not be acceptable.

2. Provide breakers of the trip-free and trip-indicating bolt down type.

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3. Provide minimum breaker interrupting rating of 10,000 A for branch circuit breakers 5 A and larger, and 10,000 A symmetrical for main breakers. It is the responsibility of the contractor to determine available fault current and provide properly rated components.

4. All breakers directly connected to main incoming line terminals and feeder and subfeed breakers shall be rated with interrupting capacities greater than or equal to the available fault current.

5. Current limiting main breakers may be used in lieu of main breakers for interrupting capacity greater than 10,000 AIC. Subfeed breakers used in conjunction with current limiting breakers shall be minimum 10,000 AIC rated, and listed to be properly protected by the current limiting main breaker.

2.25 CONTROL RELAYS

A. General: Furnish plug-in electromechanical induction or solid state, relays, unless otherwise specified.

B. Relay Sockets

1. Provide plug-in relay sockets with screwdown numbered terminals. Furnish with snap-in plastic mounting track.

C. Normal Process Relays (General Purpose)

1. Provide 3PDT, 10 A 300 V minimum contact rating, 11 pin octal type keyed plug-

in. Continuous duty rated coil 120 Vac +15%. Provide plastic case relay where required for U.L. listing of relays.

2. Operating Temp: -45 degrees to +75 degrees C

3. Dielectric Strength: 500 VRMS 60 Hz between contacts

4. Insulation Resistance: 100 megohm minimum

5. Power Consumption: 2.2 VA maximum

6. Coil Temperature Rise Above 25 degrees C: 45 degrees C

7. Coil: Nylon Encapsulated

8. Mounting: 11 pin octal to fit RDI 11 BR-24 socket

9. Contact Rating: 10 A

10. Contact Material: 3/16" diameter, Silver-Cadmium Oxide, gold flashed

11. Contact life at rated load 300,000 operations minimum

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12. Mechanical Life: 10,000,000 minimum

13. Case: Polycarbonate case for U.L. listed relays.

D. On Delay Time Delay Relays

1. Solid state plug-in type delay on operate with 10 binary adjusting time switches on top of relay case.

2. Time Range:1-1023 seconds, 1-1023 minutes, .1-1023 seconds switch adjustable or as shown on drawings, time set in 1 second intervals by 10 ON-OFF switches on case by powers of 2nth. to 1023.

3. Voltage:120 Vac +20% as shown on drawings. Time Tolerance: +2%

4. Repeatability: +1%

5. Power consumption: 1 W max.

6. Contacts: 10 A, DPDT

7. Reset time 20 ms max.

8. Recycle time 2 ms max.

9. Mounting:8 pin octal type plug-in, contacts used on drawings to fit RDI 8 BR socket

10. Case: Plastic dust cover

11. Rated life: 500,000 min at rated load

12. Environment: -20 to 60 degrees C

13. Transient protection: 2500V for 10ms

E. Off Delay Time Delay Relays

1. Solid state plug-in type, delayed contact operation after power has been removed, with adjusting knob on top of relay case

2. Time Range: 20 seconds to 10 minutes. Knob adjustable

3. Time tolerance: +10%-0%

4. Voltage: 120 Vac +10%-15%

5. Repeat Accuracy: +1% of set point

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6. Contacts:5 A, DPDT resistive, 10,000,000 operations Mech, 200,000 operations Electrical

7. Reset time: 20ms max

8. Mounting: 8 pin octal plug-in type to fit RDI bases

9. Pins 2-7 are power.Timer to operate after power is removed from relay. Capacitor charge for relay up to 300 seconds. Separate trigger switch or power supply not required.

10. Operating Temperature: -22 to +149 degrees

11. Recycle time: 30 ms max.

12. Case: Plastic dust cover

2.26 INDICATOR LIGHTS, SELECTOR SWITCHES, PUSH BUTTONS (NEMA 4,

12)

A. Provide oil-tight industrial type indicator lights, selector switches and push-button with NEMA 4, 12 rating without boots. Mounting rings shall be octagonal chrome plated.

Lights and operators shall have die cast metal housings and panel locking tab to prevent rotation.

B. Oil-tight selector switches, lights and push buttons shall fit in 1-13/64" diameter hole.

C. Furnish selector switches, push buttons, and oiltight indicator lights as described below:

1. Selector Switches

a. Provide selector switches with long lever handles, gaskets between panel and operator base for push buttons and selector switches. Provide 2, 3, or 4 position selector switches as shown on drawings.

b. Selector switches shall be available in 2, 3, or 4 position models with a minimum of 5 cam codes in 3 positions switches. 1 cam code in 1 or 4 position switches. 2, 3, position key lock selectors shall be available.

c. Contact blocks shall be available in normally open, normally closed, normally open early make, normally closed late break and N.O. and N.C.