A4_Revised_26_09_00_IEI-Controls_and_Instrumentation.pdf

Crescent District Office / Revised 05-05-2014 26 09 00 - 1 of 8 CONTROLS AND

INSTRUMENTATION

SECTION 26 09 00 - CONTROLS AND INSTRUMENTATION

PART 1 - GENERAL

1.01 DESCRIPTION

A. Work includes reinstalling the existing sewage pump station control panel and shipping to the jobsite as specified, and shown on the drawings for the control and protection of all motors and controlled equipment in conformance with manufacturer's recommendations and applicable codes.

B. Sample Operation and maintenance manuals for reference in preparing submittals are available at: <http://www.fs.fed.us/database/acad/elec/o&mmanuals/ommanuals.htm>

1. Note these sample submittals are from a collection of projects and not all materials for this project are shown. These are to aid in preparation of required contract submittals.

C. All items shown in the contract drawing shall be supplied by the Contractor except those items specifically labeled "NIC" or "GFP" in the drawings are not in this contract.

D. Contractor shall furnish all components shown on the contract drawings including the following, which shall be furnished by the Contractor, but installed by others:

E. This section of the specification applies to all motor controls specified herein.

1.02 RELATED SECTIONS

A. Contents of Division 26, Electrical and Division 01, General Requirements apply to this

Section.

1.03 REFERENCES AND STANDARDS

A. References and Standards as required by Section 26 00 00 and Division 01, General

Requirements.

B. In addition, meet the following:

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

1.04 SUBMITTALS

1.05 ABBREVIATIONS FOR ELECTRICAL/ELECTRONICS UNITS

A. Feet per second 3fps

B. Direct Current DC

C. Hertz (Cycles/Sec.) 60Hz

D. Volts Direct Current 24Vdc

E. Volts Alternating Current 120Vac

F. Peak to Peak 100Pk-Pk

G. Amperes Interrupting Current 22,000 AIC

H. Peak Inverse Voltage 600 PIV

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I. Milliseconds 2.5ms

J. Millivolts 3.0 mV

K. Microvolts 15uV

L. Amperes 20A

M. 120V

N. Megohms 10.6 Mohms

O. American Wire Gauge #14 AWG

P. Microseconds 2.8us

Q. Alternating Current AC

R. 300 W

S. Kilowatt 1.2KW

T. Root Mean Square RMS

U. Decibel 60db

V. Light Emitting Diode LED

W. Microwatts uW

X. Relative Humidity 10% RH

Y. Single Pole Double Throw SPDT

Z. Double Pole Double Throw DPDT

AA. 3 Pole Double Throw 3PDT

AB. 4 Pole Double Throw 4PDT

AC. Volt-Amperes 500 VA

AD. Kilohertz 10 KHz

AE. Milliampere 5.3 mA

AF. Ampere Hour 4.5 AH

AG. Pounds per square inch 100 psi

1.06 GOVERNMENT FURNISHED PROPERTY

A. Existing control panel to be reused.

B. The Government will supply available AutoCAD drawings of schematics, wiring diagrams if available, panel layouts, etc. legend sheets to the contractor to modify and add wire numbers notes and other required items. Return as-built CAD disks as required below.

C. Government CAD drawing borders and symbols shall be used in schematics and wiring diagrams.

D. System AutoCAD construction drawings to show equipment layout for use in preparing hydraulic and pneumatic and location drawings as required below.

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PART 2 - PRODUCTS

2.01 ALARM LIGHT 24VDC 3.5W

2.02 ALARM HORN 24VDC 3.5W

2.03 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 on

CONTROL AND POWER CONDUCTORS #20 to #10 AWG.

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.

2.04 NAMEPLATES

A. Provide nameplates for new equipment 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. Telephone Dialer

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

3. Cabinets

4. Alarm light, alarm horn

5. Remote annunciator in reception area

6. Indicating lights (Function)

7. Other devices used

8. Float switches

9. Disconnect plugs

B. Construction: Provide laminated plastic nameplates engraved to provide 1/4-inch or 3/16-inch 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. Engraved metal nameplates with white lettering on black background may be used in lieu of plastic nameplates on selector switches, push buttons, and lights.

2.05 INDICATOR LIGHTS, SELECTOR SWITCHES, PUSH BUTTONS (NEMA 4, 12)

(FURNAS)

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 Siemens / Furnas selector switches, push buttons, and oiltight indicator lights as described below:

1. Selector Switches

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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. and reed switches for both selector switches and push button operators. Contacts shall have two separate contact surfaces on the moveable contact. Contact rating 600 Vac.

d. Contact blocks shall be interchangeable from push button operators to selector switches and shall mount on the left or right side of all operators interchangeably, at any position in the stack.

e. Contact blocks must stack left and right side up to four deep for a total of 8 blocks per operator.

f. Contacts shall be silver, bifurcated.

g. Provide Siemens / Furnas 2 position 52SB2AAB, 3 position 52SB2BAB, 4 position

52SB2HAB selector switches.

2.06 SONALERT

A. Solid State piezoelectric audible signal warning device. Mounting through panel in 1.219-inch diameter hole. Operating voltage: 120 Vac or 24 Vac or DC. as shown. Sound level: 68-80 db.

Mallory SC628A for 24 Vdc or 24 Vac systems.

B. SC 110P for 120 Vac.

C. Locate in Reception area.

2.07 VOICE SYNTHESIZED TELEPHONE DIALER (SENSA-PHONE)

A. Provide a Sensa-Phone Model 1000 telephone dialer, or approved equal.

B. Unit shall be voice synthesized with ability to call up to four numbers in sequence (and repeat that sequence) until remotely aborted by dialing in.

1. Input 3 channels NO or NC logic, 4th channel temperature sensor, momentary contact closure.

2. Power 120 Vac Class II plug-in transformer 9 Vac output or battery backup for 15 hours.

Batteries 4D cells.

3. Additional Alarms Battery low, power off, high sound.

4. Call-in Status Any remote phone call in after a programmable ring count will have dialer go through all status alarms.

5. Dial-Out Status On-alarm unit will speak in English the following items.

a. Its own phone number.

b. Local time.

c. Temperature at dialer sensor.

d. High sound level alarm for over 10 seconds.

e. Power outage alarm greater than 30 seconds.

f. Alert condition 1, 2, or 3, if activated.

g. Battery condition.

h. Allow called party to listen to phone speaker for 15 seconds.

C. Abort Message Calling dialer after it has been aborted will tell phone number of person who has aborted alarm message.

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D. Reset Dialer shall be reset by removing alarm signal and depressing clear on keyboard.

E. Mounting Mount dialer on back panel with keyboard accessible. Provide easy removal, and excess cord length for convenient hand-held operation.

F. Abort Unit is aborted by calling Unit for 10 rings after message is received.

G. Use for pump station alarm in electrical room.

2.08 TELEPHONE TEST SET WITH SPEAKERPHONE AND OPTIONAL CORDS

A. Provide Harris Dracon model TS22A CO:

B. Central office style butt set, built-in cord with 346A plug.

C. Amplified speaker for line monitoring.

D. Redial in DTMF tone or pulse, nine memory recall.

E. Built-in ringer, reverse polarity LED.

F. Provide Harris Dracon CO Style LP471A Optional Cords:

1. Jack to angled bed of nails clips

2. Jack to RJ-11

2.09 TELEPHONE JACK

A. Provide standard modular 4 pin telephone jack wired to terminal block as shown. Mount on outside leg of control panel. RJ11X surface mount jack.

PART 3 - EXECUTION

3.01 GENERAL

A. Construct systems to provide sequence of operations as shown on the drawings.

3.02 CONTROL SYSTEM CONSTRUCTION AND INSTALLATION

A. Removed from current location.

B. Building and reinstalled in electrical room after temporary relocation during construction.

3.03 SEWAGE PUMP STATION CONTROL PANEL MODIFICATION

A. Provide a digital timer front panel mounted with digital readout for dosing time control for the existing sewage pump station control panel. Provide the following functions.

B. See Sheet AE 716 (Verify Sheet #)

1. The existing sewage pump station system is controlled by five float switches as follows:

a. LS-1 low level alarm redundant cut off. Line#34

b. LS-2 Both Pumps off Line #22

c. LS-3 Lead pump on energizes R1 to start lead pump Line #22

d. LS-4 Lag pump on energizes R2 to start lag pump Line #28

e. LS-5 High level alarm Line #44

2. This modification will add a digital repeat cycle timer TD-1 started by relay R1 contact

R1D from existing line # 66 to provide an on time of 1-60 minutes and an “off time” off cycle time of 1-300 minutes and at the end of the off time will allow the lead pump to operate for the “on time” 1-60 minutes, until the level falls below level switch LS-2. When level falls to LS-2 both pump off, relay R1 will be unlocked until level rises to LS-3 lead

Crescent District Office / Revised 05-05-2014 26 09 00 - 6 of 8 CONTROLS AND pump on. Pumping will not resume until level reaches LS-3 lead pump on. Pump cycle timer will reset after the off float LS-2 de-energizes relay R1 and start the variable 1-60 minute “on time”, and at the end of this time period the off time shall start for 1-300 minutes. At the end of the “off time” period the timer shall again allow the on time of 1-60 minutes to start lead pump.

3. Provide 24VAC power for new cycle timer electronics if possible. 120VAC will be allowed if a 24VAC timer is not available.

4. If the level continues to rise to LS-4 lag pump start the existing relay R2D line #62 will short across the alternator allowing both lead and lag pump to operate as currently shown, if the repeat cycle timer is in the on time mode. No change to this circuit is required.

5. Relay R1 will remain as the main start relay for 1 pump start. The new time delay relay

TD-1 will be in series with this relay R1.

6. To enable the new repeat cycle timer to start the repeat cycle time function, provide a new relay R13, 3PDT 24VAC, 11 pin 10A rated octal base relay identical to existing relay R6 with the coil connected to wire #60 pin 9 of R1D contact and wire #C. This new relay R13 will enable the new start circuit of the new TD-1 timer to start time cycle.

7. Insert a N.O output dry contact from the new TD-1A cycle timer in series with R1D wire

#60 before the alternator coil line #66. This TD-1A contact will control the operation of the two pumps with this new timed contact. Renumber wires # 60 to the right of R1D to

60A after the new TD-1 contact in installed.

8. Install a new two position, (Labeled: Floats / Timer), oil-tight selector switch on the door of the control panel. Selector switch shall match brand in panel. This two position switch will allow the operator to operate the system as is with only float switch control or with the new TD-1A contact to be shorted out if the cycle timer fails or normal mode with the cycle timer enabled.

9. Work required:

a. Provide a shop drawing for approval and PDF marked up cut sheets of new cycle timer and new interposing relay and any additional equipment required.

b. Modify the existing control panel schematic and wiring diagrams and dimensional drawings to reflect the above changes.

c. Modify panel will all the items listed above. Provide wire numbers on all conductors added, and modify schematic and wiring diagrams to match changes.

d. Add to the materials list all new components added.

e. Add all documentation to existing O&M manual for inclusion.

f. Provide written narrative in MS-Word format for operator of programming required for new cycle timer TD-1. Provide project specific instructions for programming timer in addition to manufactures programming information.

g. Test control system for pump cycle and float switch operation and all other alarm and control devices in panel as described in this section and in 260010.

h. Up date all drawings to as built conditions and all CAD drawings files.

i. Include all documentation drawings, cut sheets, narratives above in final O&M manual.

3.04 FIELD TESTS

A. Preliminary Electrical Field Tests

1. Preliminary electrical tests to consist of initial setup, adjustment of controls, pilot devices, and meters. Perform preliminary electrical tests to verify correct connections and operations of control system. Field tests will be performed on those panels in the schedule of items requiring field tests only.

B. Final Control System Field Tests

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1. The control system manufacturer shall test those control systems requiring field-testing in the field after installation at the final inspection in the presence of the Government COR.

2. The Government will notify the control manufacturer one week in advance of each test.

3. The control system manufacturer will provide a Field Engineer who has worked on the project design, and is familiar with the control circuitry to perform the tests and operating instructions.

C. Normal Operation Test

1. Test the control system to demonstrate normal operation of the system including all pilot devices (level flow, float and pressure switches), level probes, time relays, relays, motor starters, lights, indicator gages, etc., for correct operating sequence. All controlled devices

(motors, solenoids, etc.) will be connected and operating under normal load for tests.

Calibrate all setpoint controls, power supplies, and other electrical and electronic devices, which require calibration. Final adjustment of all operating setpoints and other adjustments shall be permanently marked by etching a mark on control adjustment device and marking with red paint. Test computer I/O boards with a test program.

D. Failure and Alarm Tests

1. Test all safety protection devices and circuits, indicator lights, alarm horn, etc., to demonstrate each separate type of failure and proper circuit operation for each condition.

2. Show actual operation of all protective and normal operation sensors. Shorting around or opening of circuits to simulate activation will not be allowed on either normal operation tests above or failure tests.

3. Test each motor thermal overload heater element by temporarily inserting one heater element in each overload relay, sequentially, sized to trip within 5 minutes or 67% of the actual measured running current of each motor or by adjusting trip knob on solid state overload relays, or by use of auxiliary loads. Supply heater elements for tests.

4. Demonstrate that the motor thermal overload trip, and breaker alarm trip will energize the alarm circuit, deenergize the motor, and perform other required control functions within the time limit specified above or by the overload trip time characteristic curve.

5. Replace the proper thermal overload element or adjust solid state overload trip in each starter after each test. Provide the COR the catalog numbers of the overload heaters and manufacturers tables with trip ratings to verify that the heater elements have been properly sized according to the nameplate current, service factor, and any temperature derating factors. Provide a tabular list of nameplate rated currents, motor service factors temperature derating multipliers, service factor derating multipliers and measured current for all motors to verify against overload trip ratings.

E. Test Switch Operation: Use each test switch to simulate opening, shorting around and automatic operation of all pilot devices. Demonstrate the normal operational sequence using the test switches, and all failure conditions which can be simulated with the test switches.

F. Operating Instructions: Provide a control manufacturer's Field Engineer at the site after testing to instruct Forest Service maintenance personnel in operation and normal maintenance of control system, pilot and controlled devices in addition to testing time required.

1. Provide 4 hours of onsite training, per panel.

2. The COR will inform the control manufacturer at the time of notice for the final testing the length of time required for operating instructions for each control panel.

3.05 FINAL CHANGES TO O&M MANUALS

A. After field-testing and any modifications to the control systems, update all O&M manuals to reflect all changes since factory construction. All sections described under FINAL

SUBMITTAL: OPERATION AND MAINTENANCE MANUALS above shall be updated to

Crescent District Office / Revised 05-05-2014 26 09 00 - 8 of 8 CONTROLS AND as-built condition. This includes all drawings, narratives, parts lists, cut sheets, adjustments, calibration instructions, operation and maintenance instructions, troubleshooting, sequence of operation and all other documentation.

END OF SECTION