Amendment_3_260900-ControlsAnd_instrumentation-20140806.doc

USDA Forest Service Project Specifications

SECTION 260900

Controls and Instrumentation

1. Part 1 - GENERAL

1.01 DESCRIPTION

A. Work includes fabrication, testing of one cistern tank level control system and well pump control panel and monitoring system integrated control panels, 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. This specification applies to the following control panels

1. Water Well system control panel

2. Cistern level monitoring and control panel.

3. At the contractors option a combined control panel with all water system controls and cistern level controls may be designed and built as one common system in one enclosure.

4. Contractor is required to design both well pump control panel and cistern level control system and supply all required documentation in this specification for both control panels.

5. Contractor is required to provide shop drawings as specified below for both control systems showing schematic diagrams, Physical wiring diagrams, and dimensional drawings showing all components to meet these specifications.

C. 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.

D. 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.

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

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

G. Manufacture and test the control systems in accordance with all applicable sections of Division 26.

H. See 3.03 SEQUENCE OF OPERATIONS AND HARDWARE REQUIRED below for required items and functions.

1.02 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 PLC’s and subsystems. The control systems manufacturer's factory shall have a minimum of 1 year's experience as a company building control systems. Manufacturer must have manufacturing facility within 500 miles of project site.

B. Control system manufacturer shall maintain a service organization with factory-trained personnel available on 24-hour notice within 500 miles of project site, for repair of control system.

C. Control panel manufacturer shall provide PLC specified in other divisions, and provide all system programming, testing and onsite startup.

D. Submit, at time of bid, qualifications statement covering all aspects of this project, UL508 listing, and other qualifications to construct these systems to meet all requirements of these specifications and related sections, on PLC systems and programming experience in water and sewage systems.

1.03 UNDERWRITERS LABORATORIES LABELING

A. Provide an Underwriters Laboratories label, for each control panel, conforming to U.L. standard 508, (Industrial Control Panels for General Use).

B. All schematics in this contract have been designed to U.L. 508 standard for listing.

C. Control panels with intrinsically safe circuits for hazardous areas

D. Listings must be accepted by the States of Oregon and Washington.

E. 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.

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

G. Where technical specifications (Division 16) are more stringent than U.L. standard 508, or approved equal, the technical specifications shall take precedence. The contractor shall include any design change costs of a standard other than U.L. 508 being used to list the panels. Any alternate listing must be acceptable to the state where the control systems are installed.

H. All panels shall be listed for service entrance.

1.04 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.

1.05 ABBREVIATIONS FOR ELECTRICAL/ELECTRONICS UNITS

1.06 GOVERNMENT FURNISHED PROPERTY

A. 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.

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

C. A sample well pump system control panel diagram will be supplied for reference in this design.

D. 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.

E. Sample Operation and Maintenance manuals and sample submittals are located 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. These are provided to show general format and detail required. These technical specifications govern submittal requirements.

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

1.07 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.

B. Field modifications will be allowed on existing systems to be modified as shown on drawings.

1.08 SUBMITTALS general

A. Submit three typed copies of initial submittals for each of the one panels as described below with catalog cuts, shop drawings and manufacturer's installation, operating and maintenance instructions of all material and equipment requiring submittals. Bind each copy with a three-ring type loose-leaf cover and index in the order they appear in the specifications.

B. Submit these document as per 16010 Submittals

C. Submit all documents in both Hard copy, and in electronic form as follows.

1. Manufacturers cut sheets PDF and hard copy mark to indicate material

2. Written documentation

PDF & MS Word DOC files

3. Drawings

PDF & Autocad DWG format

4. Materials lists Vendors list PDF & XLS spreadsheet

5. Calculations

PDF & XLS spreadsheet

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

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

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

G. 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 disk(s) 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.

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. Hydraulic diagrams, each sheet a separate file

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

g. Operations instructions

h. Functional description

i. Troubleshooting instruction

j. Calibration instructions

k. Materials list spreadsheet with vendors list,

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

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

I. Furnish complete material submittals. Partial submittals will be considered to expedite long delivery items. A complete initial submittal will still be required with all items shown if partial submittals are submitted.

J. For each project, submit a separate material list for each control panel.

K. 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.

1. Submit both hard copy print and manufacturers original PDF cut sheet marked up for all materials and equipment. Submit all

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

M. Submittals shall have sufficient detail to determine if ratings, characteristics, and physical construction are equivalent to those specified.

N. 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.

O. 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.

1.09 INITIAL SUBMITTALS

A. Submit the following items to the COR bound copies for approval prior to installation for each control panel. Do not install equipment requiring submittals until submittals have been approved in writing by the COR. 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. Sample Operation and Maintenance manuals and sample submittals are located 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. These are provided to show general format and detail required. These technical specifications govern submittal requirements.

2. Make complete submittals of all equipment within 30 calendar days of the notice to proceed for each project.

C. Submit both hard copies as listed below and electronic copy of all files used in making submittals on CD-ROM.

D. CAD Drafting

1. Provide Computer Assisted Drafting, (CAD) drawn sheets for all drawings required to be drawn.

2. Provide 1/2 size drawings plot to fit on 11" x 17" vellum or matte mylar as described above with inked drawings. Provide the government two sets of copies of as-built CD-ROM of all drawings,

3. All drawings shall be drawn full size (22.6" x 33.6" border) to have a minimum 1/2" between lines vertically. All drawings shall be drafted according to standards below. Use GFP supplied CAD border from schematic drawings.

E. C.A.D. Drafting Equipment

1. System shall be Auto CAD brand Version 2002 or 2004. Drawings shall be formatted on CD-ROM. Provide 2 copies of the final disks for each project with all drawings on these disks. Use the latest version available during life of contract. No other brand of software will be allowed.

2. All drawings shall be plotted half size on vellum (11" x 17") plot to fit. Laser printed drawings will be acceptable.

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

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

a. Draw all required schematic, wiring, and dimensional drawings on 3 or 4 mil, mat two-side Vellum sheets. Full size sheet border size to be exactly 22.6" x 33.6". Use inkjet printer for CAD drafted drawings. Use 0.35mm minimum line width for drawings. Laser printed drawings enlarged to 11 x 17" are also acceptable if legible.

b. Use only Roman S AutoCAD font, no substitutes.

c. Change date on drawing with any edits to match file date.

d. Put file name on each sheet ¼” high letters above lower right title block.

e. Minimum lettering height 1/16" on half-size plots.

f. 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.

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

2. Ladder Schematic Diagrams (Government Furnished in contract set Update as required)

a. Furnish 1/2 size (11" x 17") CAD drawn Xerox 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 voltage sources. Arrange circuits, which function inherently in a definite sequence to show that sequence. Use unique numbering and descriptive names for all components, referenced to the functional description. Number terminals and wires between components.

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. Include motor starting and running capacitor/relay circuits for single phase motors.

e. 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.). Draw all schematics with 1/2-inch vertical and horizontal spacing between all lines.

f. 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.

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

h. 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.

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

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

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

l. Provide Pin and wire numbers on all locations if not shown on Government Furnished schematics.

m. Provide all above information if not already shown on Government furnished schematic drawings.

3. Physical Wiring Diagrams

a. Draw to 1/2 scale (11" x 17") CAD drawn Xerox 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.

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, setpoint controllers, telephone dialers, turbidity monitor, motorized timers, instrumentation, etc., including all printed circuit boards. A circuit board component layout with component numbers will be accepted for a wiring diagram for printed circuit boards.

i. Manufacturer's wiring diagrams will be accepted for subassemblies in lieu of hand drawn diagrams if lettering height is 1/8" minimum. Enlarge from original if necessary to obtain lettering height.

j. 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. Use same format as enclosed sample drawing (SD-3) for general form of physical wiring diagrams. 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.

k. 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 Xerox prints of the internal physical control panel layout and component placement with names. On one drawing, show external face of panel with all externally accessible or visible components (switches, lights, indicators, gages, nameplates, etc.).

b. On second drawing, show all internal components including any hydraulic or pneumatic lines, including valving or adjusting points. Include nameplate schedules for review.

G. 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 such as PLC and other instrumentation.

a. Cross reference with item 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:

i. Item reference number

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

H. 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.

I. 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 on each cut sheet to Materials List

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

J. 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

K. Calculations and Design

1. Provide all electrical engineering design and calculations required for construction for a complete control system. Size any equipment whose size is not shown on drawings.

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.

L. Nameplate Schedule

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

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

1.010 FINAL SUBMITTAL: OPERATION AND MAINTENANCE MANUALS

A. Supply four printed typed Electrical Operation and Maintenance Manuals as specified. 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 COR for approval at time of delivery for each project, but not later than the time shown in the schedule of items. Half-size drawings may be used in this submittal. Ship the control panels 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.

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.

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 COR 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 COR 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 drawings of each control panel and external wiring as described above in initial submittals. Include one legend and one as-built half size blackline print of each wiring and each schematic diagram sheet in each manual.

b. Sample schematic and wiring diagrams are at: http://www.fs.fed.us/database/acad/elec/o&mmanuals/ommanuals.htm

2. One Line Diagrams (Pneumatic and Hydraulic)

a. Return to the Government, the original half size vellum as-built one line hydraulic and pneumatic diagrams of each control panel as described above in Initial Submittals.

b. Sample one line diagrams are at: http://www.fs.fed.us/database/acad/elec/o&mmanuals/ommanuals.htm

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 (motor, solenoid, light, pressure switch, etc.) to its controlling elements (relays, contacts, etc.) and the sequential operation of these elements. Include all subassemblies and modular printed circuit boards as described above under Ladder Schematic Diagrams. Make reference to the drawing number and line number of the schematic diagram on which control operation is occurring. Use same format as enclosed sample Functional Description (SD-4).

b. Sample functional description is at: http://www.fs.fed.us/database/acad/elec/o&mmanuals/ommanuals.htm

4. Operation and Maintenance Instructions:

a. Shall include typed starting, installation, operation and maintenance instructions in layman's language for system controls, including all electrical and electronic subassemblies as described above under Ladder Schematic Diagrams, controlled devices and pilot devices. Describe normal start-up procedures, i.e., turn on main breaker, turn selector switches to auto, etc. 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. Use same format as enclosed sample Operation Instructions (SD-5).

b. Sample Operation and Maintenance Instructions are at: http://www.fs.fed.us/database/acad/elec/o&mmanuals/ommanuals.htm

5. Calibration Procedures

a. Provide complete, typed, step-by-step adjusting and calibration instructions for all equipment requiring calibration. Include all necessary equipment and tools required. Provide any reference tables and calculations required. Write these instructions to include instructions to be specific for each project. Write them for an operator with limited electrical background, which describes how to set up and use each piece of test and calibration equipment. Just providing manufacturer instructions for these functions is not acceptable. Assume operator will have a Fluke 8060A digital volt meter. Reference any additional testing or calibrating instruments and how to use them.

b. Include calibration instructions for all electronic and electromechanical items:

i. Circuit Breakers - adjustable type

ii. Power supplies - how to adjust voltage

iii. Timers - how to set devices

iv. Instrumentation, setpoint controllers

v. Controllers

vi. Circuit Boards

vii. Transducers - Temperature/RH transmitters, pressure, flow and other electronic equipment.

c. Sample calibration instructions are at: http://www.fs.fed.us/database/acad/elec/o&mmanuals/ommanuals.htm

6. 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.

7. Step Troubleshooting Manuals

a. Shall be written specifically for each control system. Use same format as enclosed Troubleshooting Guide (SD-6). Include use of test switches for isolating defective relays, lights, controlled devices, (motors, pilot devices, motor starters, etc.).

b. Manual shall include a separate, typed, step procedure, troubleshooting manual for isolating mechanical, electrical, and computer problems, diagnosis and repair procedures for all control circuitry.

c. Troubleshooting manuals shall include common problems and corrective action for items such as motor overload, breaker trips, defective relays, starters, switches, power supplies, instrumentation, water in external wiring and a tabular list of typical symptoms and possible causes.

d. Include the use of component substitutions to identify problems.

e. Include troubleshooting procedures to isolate computer faults and circuit board replacements, both in the Government-furnished computer and in the I/O boards.

f. Sample troubleshooting manuals are at: http://www.fs.fed.us/database/acad/elec/o&mmanuals/ommanuals.htm

8. 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

9. 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.

10. 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.

11. 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

1.011 FACTORY TESTING

A. The Government will observe and witness the factory test of each Control Panel. Notify the COR 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 of PLC thru the uses 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.

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

D. Program Simulation

1. Provide a method of simulating all analog inputs, digital inputs and outputs from remote panels and sensors. Verify all PLC computer action and program menu selection, scheduling, alarming, data logging, and all other control functions performed according to specifications.

1.012 PRODUCTS PACKING AND SHIPPING

A. Crate Control Panels with 1/2 inch minimum solid plywood sheeting and sufficient blocking and protective material to prevent damage during shipment and storage. Cover panel with polyethylene film. Ship the panels to job site.

2. PART 2 - PRODUCTS

2.01 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 noncomponent 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. 508 listing standards. Provide submittals on these products if not listed in this products section.

2.02 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.

2.03 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 PANDUIT wiring duct with snap on cover.

C. Numbering: Provide RAYCHEM "ShrinkMark" white, or Scotch ("3M") adhesive vinyl or 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, or solid sleeves, on wires up to Size 10. Labels may be computer generated.

D. Color Coding: Color code internal control and power conductors with individual unique coloring for each separate numbered length of wire. Provide the same color for all wires of the same voltage. Provide color coding as follows:

Power wiring 115 Vac and above:

1. Control and Power wires 12 gage and larger may be color coded at 1-foot intervals with vinyl plastic tape in lieu of continuous insulation coloring.

2.04 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.

2.05 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. Minimum mounting width .238" (6mm). Wire stripping length: .37” (9.5mm). Recommended screw torque: 4.4-7.1 in lb. Entrelec 0115 116.07 (M4/6) mounted on standard 35mm DIN Rail. 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. Minimum mounting width .315" (8mm). Wire stripping length: .47” (12mm). Recommended screw torque: 7.1-8.9 in lb. Entrelec 0115 118.11 (M6/8) mounted on standard 35mm DIN Rail. Must be UL Recognized.

2.06 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. Minimum mounting width .238" (6mm). Wire stripping length: .37” (9.5mm). Recommended screw torque: 4.4-7.1 in lb. Entrelec 0165 113.16 (M4/6.P) mounted on standard 35mm DIN Rail. Must be UL Recognized.

2.07 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. Minimum mounting width .950" (24mm). Wire stripping length: .51” (13mm). Recommended screw torque: 10.6-12.3 in lb. Entrelec 0116 299.20 (M4/6) mounted on standard 35mm DIN Rail. For use with 13/32 x 1 ½ in fuse. 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.

2.08 Circuit Breakers (1-4A) Din Rail Mounted see general purpose circuit breakers for >5a.

A. Shall be thermal magnetic, rated 250VAC, 1 – 4A. 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). Entrelec “GMU” series. Must be UL Recognized. Circuit breaker shall be touch-proof.

2.09 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.

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

2.010 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. Minimum mounting width .238" (6mm). Wire stripping length: .37” (9.5mm). Recommended screw torque: 4.4-7.1 in lb. Entrelec 0165 113.16 (M4/6.P) mounted on standard 35mm DIN Rail. Must be UL Recognized.

2.011 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. 508 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. 508.

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.

2.012 Control Wire Size

A. Minimum #14 AWG 19 strand type AWM rated as MTW, or THHN 90 degrees C tinned Cu stranded 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. 508 allowable ampacities. Provide 600V rated wire.

2.013 Shielded Cable

A. Provide shielded cable on all low level instrumentation signal conductors, such as RTD's, 4-20 mA DC signals, electronic equipment inputs and outputs, digital signals, and all other areas where electromagnetic interference will affect instrument performance.

B. Provide shielded cable for loops for entire loop wiring inside panel.

C. Provide all computer board interwiring with shielded cable.

D. Provide gauge and number of conductors as required.

E. Provide shield drain wires in cable.

F. Provide 600V insulation on cable jacket.

G. Provide grounding terminals for all field connected shielded cable.

H. Ground shield to chassis ground at 1 point only to prevent internal ground loops.

I. Provide Belden 8719 #16 AWG 2 conductor cable with 600 VAC insulation.

2.014 Insulating plastic shields

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 120Volt or higher exposed terminals that are not recessed into device such as circuit breakers .

2.015 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. Instrumentation

8. Controllers

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

10. GFI Feedthrough

11. Motor circuit protectors

12. Well level transducers, and transmitters

13. Pressure transmitters

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

15. Cabinets

16. Thermostat

17. External indicators (gages) (Function)

18. Indicating lights (Function)

19. Pressure switches (schematic reference and function)

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

21. Lightning arresters

22. Lightning protectors

23. Service outlets, GFI outlets

24. Surge protectors

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

2.016 LIGHTNING ARRESTING EQUIPMENT (LINE VOLTAGE)

A. Provide lightning arrestor equipment for control panel service entrance equipment where shown.

B. Construction: Lightning arrestor rated for 0-650 V RMS, single or three phase as required, with impulse sparkover voltage of approximately 3.2 KV per 100 KV/us. Provide a 3/4" conduit for mounting in knockout holes in power panels or by a mounting bracket to enclosure surfaces. Provide gas tube or silicon carbide Square D SP3650 type arrestors or approved equal, SP117510 on 230 V single phase systems.

2.017 TEMPERATURE LIMITATIONS

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

2.018 Data and Signal Line Protector 4-20ma instrument (panel mount):

A. This protector is to be used in cistern panel for input from submersible level transducer.

B. Provide a DIN rail mounted multistage transient protector for 4-20 ma DC instrument loops. Provide a 3 pole common chambered gas tube and solid state silicon avalanche diodes capable of handling 20,000 ampere lightning currents. Automatic restoring no fuses, with the following characteristics:

C. Acceptable model: Bourns Model 1820-28-a1TRANSIENT SURGE PROTECTOR (120VAC) plug in type

2.019 Provide a Transient Surge Protector with the following characteristics:

15 Amperes (max.)

A. Operation Indicator Light.

B. Solid State Design MOV & chokes, and VFH capacitors C. U.L. 1449 Listed

D. High Impact Case/Stainless Steel Cover

E. Plugs into standard 15A duplex receptacle.

F. Provide Tripplite Model Ultrablock or approved equal.

2.020 CONTROL SYSTEM ac POWER SUPPLIES

A. Control system logic voltage to be 24VAC and 24VDC for all logic for the well pump control panel and the cistern level control panel.

B. Devices that are line voltage, such as power supplies, pump protector and starters for power terminals are acceptable.

C. Provide two-winding machine tool rated isolating transformers to supply 24 Vac and 120 Vac, and other voltages as shown to operate all control circuiting with sufficient volt-amp capacity to operate all motor starter coils, relays, lights, and associated control devices as applicable. Design control system to operate on nominal input voltage and maintain 95% of nominal output voltage under worse case load condition.