262416_Panel_Boards_TechSpecs_JULY_2012.pdf

26 24 16: TECHNICAL SPECIFICATIONS: LOW VOLTAGE PANEL BOARDS

This document contains proprietary information and is protected by Copyright laws and should hence not be copied or published, in part or in whole, in any form or manner without the written approval of the Integrated Bureau for Engineering & Consultations (IBEC). The document shall be used for viewing and reference for the purposes of the project mentioned in footer below only.

US Embassy in Cairo Page 1 of 7 Electrical Retrofit of Housing Compounds (Maadi 11/11, Maadi 55/17, Zamalek)

JULY 2012 (100% FINAL)

Low Voltage Panel Boards

Technical Specs

This document contains proprietary information and is protected by Copyright laws and should hence not be copied or published, in part or in whole, in any form or manner without the written approval of the Integrated Bureau for Engineering & Consultations (IBEC). The document shall be used for viewing and

US Embassy in Cairo Page 2 of 7

JULY 2012 (100% FINAL)

1. GENERAL

1.1. DESCRIPTION:

1.1.1. This section specifies the furnishing, installation and connection of panelboards.

1.2. SUBMITTALS

1.2.1. Sufficient information, clearly presented, shall be included to determine compliance with drawings and specifications.

1.2.2. Include electrical ratings, dimensions, mounting details, materials, wiring diagrams accessories and weights of equipment. Complete nameplate data including manufacturer’s name and catalog number.

1.2.3. Two complete sets of documentation will be supplied with the panels. Each set will include but will not be limited to, set of drawings (single line diagram, layout, internal layout, wiring and control diagrams), catalogs, test certificates, product data sheets, operation, maintenance, and installation instructions.

1.2.4. Supplier shall submit a detailed settings table showing the setting ranges of all protections provided (whether built into the switching devices or provided separately) and the factory default settings of such protections

1.2.5. Supplier shall submit current-time characteristics for all supplied circuit breakers

1.2.6. Bidder must submit a detailed quotation supported by necessary drawings and a clear list of deviations and/or alternatives

1.2.7. Successful bidder must have a complete and detailed set of drawings approved by the client’s consultant before commencing to manufacture

1.2.8. The panels will be warranted against defects of manufacture for a period not less than 18 months from delivery or 12 months from commissioning and start up.

2. PRODUCTS

2.1. General Provisions:

2.1.1. The panel board will be of the factory assembled type, with a design by one of the renowned switchgear manufacturers of European or American origin (ABB, Schneider Electric, Siemens, General Electric, Moeller), or manufactured by an approved equal which is one of the firms regularly engaged in the manufacture of low voltage switchgear of the types and capacities required and specified here and whose products have been in satisfactory use in similar service and location for not less than 5 years.

2.1.2. All main components and switching devices should be of European or American origin made by one of the renowned manufactures (ABB, Schneider Electric, Siemens, General Electric, Moeller, or approved equal).

2.1.3. Panel boards shall be of the metal enclosed, factory assembled, with busbar construction for power distribution and structure made of steel.

2.1.4. Panel board, circuit breakers, and all other power or control devices will comply with the latest relevant IEC standards including but not limited to:

2.1.4.1. IEC 60439: Low-voltage switchgear and controlgear assemblies

2.1.4.2. IEC 60529: Degree of protection provided by enclosures

This document contains proprietary information and is protected by Copyright laws and should hence not be copied or published, in part or in whole, in any form or manner without the written approval of the Integrated Bureau for Engineering & Consultations (IBEC). The document shall be used for viewing and

US Embassy in Cairo Page 3 of 7

JULY 2012 (100% FINAL)

2.1.4.3. IEC 60947: Low-voltage switchgear and controlgear

2.1.5. The Distribution system adopted will be TN-S.

2.1.6. All equipment must be able to function correctly and safely when connected to the power supply of the plant. i.e. 380V, 3-phase, 50Hz, with earthed neutral.

2.1.7. All electrical components will be sized for continuous 24 hrs/day duty at rated capacity at 40 degrees centigrade ambient temperature (or ambient temperature indicated on design single line diagrams).

2.2. Enclosure:

2.2.1. The panels shall be made of sheet steel of thickness not less than 1.5mm with doors and structure being reinforced to insure rugged and safe construction.

2.2.2. A removable cable gland plate made of sheet steel of not less than 3 mm in thickness will be provided.

2.2.3. The panels will be electrostatically powder painted with the manufacturer’s standard color.

2.2.4. All internal parts of the panel will be either painted or galvanized without compromising the earthing of the panels.

2.2.5. All cable entry in equipment must be through a gland of suitable size. All remaining openings must be sealed

2.2.6. The panels will be of the wall mounted design (unless indicated otherwise on the design single line diagram).

2.2.7. Front plates will be provided to prevent any contact with any live parts when the panel door is open. Front plates (mirror) provided to prevent any contact with live parts when the panel door is open shall in no way prohibit the adjustment of protections and circuit breaker trip units with the front plate in place. In other words all adjustments and settings should be possible without need for removing the front plate.

2.2.8. The panels will be designed and manufactured to withstand symmetrical short circuit currents for 1 second.

2.2.9. The degree of protection of the panels will be minimum IP42 for indoor applications and IP54 for outdoor applications (unless otherwise indicated on the design single line diagram).

2.2.10. All internal switchgear components must be finger touch proof (IP2X) or above. Panels shall have removable transparent covers protecting all components inside the panel operating above 50V to earth and which are not "Touch Safe (IP2X)”

2.2.11. Panel boards shall be of such dimension that adequate space is available for maneuvering and connecting the incoming and outgoing cables.

2.2.12. Panel boards shall have a form of separation Form 1 or Form 2 as indicated on the design single line diagram.

2.2.13. For MCC Panel, the Form of Separation is Form 3.

2.2.14. Cable entry for all incoming and outgoing units shall be from the top or as per the indications on the design single line diagrams. Verification of cable entry and exit according to site conditions is necessary.

2.2.15. Generally, provision will be made for terminals for connection of cables with sizes and numbers per phase as indicated on the single line diagram.

This document contains proprietary information and is protected by Copyright laws and should hence not be copied or published, in part or in whole, in any form or manner without the written approval of the Integrated Bureau for Engineering & Consultations (IBEC). The document shall be used for viewing and

US Embassy in Cairo Page 4 of 7

2.2.16. All enclosures and metal parts that do not carry any current must be connected to the ground.

2.3. Circuit Breakers and Switching Devices:

2.3.1. All circuit breakers will be rated for at least the symmetrical 3-phase short circuit current indicated on the design single line diagram. The short circuit breaking capacity will be on basis of Service short circuit capacity not Ultimate short circuit rating (except for miniature circuit breakers which will follow whatever indications are shown on the single line diagrams).

2.3.2. No circuit breakers above 63A shall be of the miniature type. Circuit breakers above 63 A shall be molded case or air (power) circuit breakers.

2.3.3. All circuit breakers above 250A shall have an electronic type trip unit. The circuit breakers will be provided with electronic trip units with long time, short time, and instantaneous settings available.

2.3.4. Ground fault protection will be provided whenever indicated on the single line diagram.

2.3.5. All circuit breakers and switching devices are assumed to be of the Three (3) Pole construction unless otherwise indicated on the design single line diagram.

2.3.6. The short time withstand of any Load Switch (Disconnecting Switch) will be coordinated with the trip time of the upstream protective device to ensure the Load Switch will withstand the prospective short circuit current expected to pass through for the duration of the trip time of the upstream protective device.

2.3.7. Coordination between any circuit breaker and series contactor will be Coordination Type 2.

2.3.8. Unless otherwise indicated, all Contactors will be rated for AC3 duty class for motor applications and AC1 duty class for lighting applications.

2.4. Labeling:

2.4.1. All circuit breakers must be labeled with the load name using engraved type labels which will be provided to identify the switching circuits.

2.4.2. All internal components and devices must be labeled using engraved labels.

2.4.3. All external labels will be of the engraved type with suitable dimension and attached by screws or rivets. The use of adhesive is unacceptable for external labels.

2.4.4. Each Panel board shall be provided with an engraved type external label with the following data included on the label:

2.4.4.1. Name of panel board

2.4.4.2. Fed from

2.4.4.3. Rated Voltage/Frequency/Current

2.4.4.4. Number of phases + Neutral + Earth

2.4.4.5. Short Circuit Level.

2.5. Busbars:

2.5.1. The panel board will be provided with high quality copper busbars with current ratings as indicated on the design single line diagram.

2.5.2. The busbar will be properly de-rated for an ambient temperature of 35ºC (or higher if indicated otherwise on the design single diagram).

2.5.3. All busbars provided inside the panel board will be made of high grade copper that is treated to

This document contains proprietary information and is protected by Copyright laws and should hence not be copied or published, in part or in whole, in any form or manner without the written approval of the Integrated Bureau for Engineering & Consultations (IBEC). The document shall be used for viewing and

US Embassy in Cairo Page 5 of 7

JULY 2012 (100% FINAL)

ensure protection against oxidation and smearing under the thermal conditions of normal operation.

2.5.4. All busbars installed inside the panel board shall be of quality and craftsmanship that provides a busbar with no sharp edges.

2.5.5. Manufacturer will make provision for adequate bracing (support) and spacing of busbar systems to guarantee the busbar construction will withstand the symmetrical short circuit indicated on the design single line diagram.

2.5.6. Panel boards shall be provided with a suitable earth bar and neutral bar with adequate provision for the connection of a circuit protective conductor for each outgoing line.

2.5.7. The neutral bus will be at least half the phase bus in cross-section except for the UPS Output Panels where it shall be at least 1.7 times the phase bus.

2.5.8. UPS Output Panels will have a Secured Bus Design.

2.5.9. The copper ground bus will extend the length of each panel board with provision at each end for the customer to attach a suitable earthing conductor.

2.5.10. It is preferred that all power distribution (main) inside the panels will be done using copper busbars.

2.5.11. Any busbar links from a switching device to the main busbar that may rotate around a single point of fixation if enough force is applied shall be provided with additional means (points) of fixation to prevent this rotation under the influence of the mechanical forces of a short circuit. The additional fixation shall ensure the distances between the phases of the link are maintained under all circumstances.

2.5.12. Busbar links from a switching device to the main busbar that are longer than 200mm shall be covered by heat shrinkable insulation on all 3 phases. The heat shrinkable insulation may be applied to only the middle phase after approval from the owner/consultant.

2.5.13. Extension copper terminals (links) will be provided on the cable side terminal of a circuit breaker (or any switching device) to facilitate the connection of the number and size of cables indicated on the design single line diagram if such a connection is not directly possible on the circuit breaker terminal. Such links shall be fully separated by solid insulation between the phases adequate to guarantee the prevention of any accidental and/or vermin bridging of the phases.

2.5.14. All busbars will be clearly marked R-S-T or L1-L2-L3

2.5.15. All cable ends inside switchgear will be clearly marked R-S-T or L1-L2-L3

2.6. De-rating:

2.6.1. All circuit breakers, power circuit devices, and busbars will be properly de-rated for the design ambient temperature.

2.6.2. All circuit breakers, power circuit devices, and busbars will be properly de-rated for installation in respective switchgear.

2.6.3. All circuit breakers, power circuit devices, and busbars will be properly de-rated for the Degree

(Index) of Protection (IP) respective of the panel.

2.6.4. All circuit breakers, power circuit devices, and busbars will be properly de-rated for the Form of

Separation (Segregation) respective of the panel.

This document contains proprietary information and is protected by Copyright laws and should hence not be copied or published, in part or in whole, in any form or manner without the written approval of the Integrated Bureau for Engineering & Consultations (IBEC). The document shall be used for viewing and

US Embassy in Cairo Page 6 of 7

2.7. Auxiliary Circuits and Wiring:

2.7.1. All wiring will be terminated and clearly marked and numbered.

2.7.2. Terminal blocks will be used to complete all auxiliary interconnections.

2.7.3. Terminal blocks will be numbered and will be grouped according to function.

2.7.4. Means shall be provided to indicate whether or not the incoming supply line is energized. It is preferred to use three indicating lamps (R-S-T) for this purpose.

2.7.5. For each of the incoming and outgoing switching devices that are electrically operated (On-Off) indicating lamps and (On-Off) push buttons will be provided on the external door of the panel board.

2.7.6. Each Lighting and/or sockets panel board shall be provided with a durable circuit chart fixed to the inside of the door of the panel bearing the details of the circuits fed by each of the outgoing lines.

2.7.7. Control & data cables must be in separate conduit (ducts) than power cables.

2.7.8. The minimum size for power wiring will be 2.5mm2. The minimum size for control wiring will be

1.5 mm2.

2.7.9. Minimum earthing conductor size will be 10mm2.

2.7.10. All cables will be continuous and will not be spliced or joined.

2.7.11. Cables with solid conductors are not allowed. All cables must be stranded.

2.7.12. All wires shall be of the stranded type. No single strand (solid) wires are allowed.

2.7.13. All 220V single phase circuits (loads) must be distributed on the three phases so that they provide balanced three phases loading with discrepancy between phases of no more than 15%

2.7.14. Panels shall have drawing pockets on the inside of the doors

2.7.15. Control wiring shall be ferruled with plastic wire markers (numbers) at both ends.

2.7.16. All control wires shall carry same marking as used in schematic wiring diagrams.

2.7.17. No more than one conductor is to be terminated on one terminal.

2.7.18. Color coding of wires will be as per the following

Phase Power Black (L1, L2, L3) DC Power Black (+, -) Power Neutral Dark Blue Earth Green/Yellow DC Control Light Blue AC Control Red

2.7.19. Inside the panels no device will be blocking or obscuring another device.

2.7.20. All connections must allow ample room for their removal.

2.7.21. Wire terminations will be crimped not bare wire or soldered. Spade crimps must be used. Eyelet type crimps are not to be used.

2.1. Instrumentation:

2.1.1. Three ammeters, one voltmeter with seven position selector switch, and one digital kW/kWH meter will be provided on the incoming feeder whenever indicated. All measuring instruments will be suitably rated and will be of at least class 1.5. One digital multi-meter in place of the above instruments will also be acceptable.

This document contains proprietary information and is protected by Copyright laws and should hence not be copied or published, in part or in whole, in any form or manner without the written approval of the Integrated Bureau for Engineering & Consultations (IBEC). The document shall be used for viewing and

US Embassy in Cairo Page 7 of 7

JULY 2012 (100% FINAL)

3. EXECUTION

3.1. INSTALLATION

3.1.1. Installation shall be in accordance with the Manufacturer’s instructions, the NEC, as shown on the drawings, and as specified.

3.1.2. Locate panelboards so that the present and future conduits can be conveniently connected.

Coordinate the sizes of cabinets with designated closet space.

3.1.3. Install a typewritten schedule of circuits in each panelboard after being submitted to and approved by the Resident Engineer. Schedules, after approval, shall be typed on the panel directory cards and installed in the appropriate panelboards, incorporating all applicable contract changes pertaining to that schedule. Include the room numbers and items served on the cards.

3.1.4. Mount the panelboard fully aligned and such that the maximum height of the top circuit breaker above finished floor shall not exceed 1980 mm (78 inches). For panelboards that are too high, mount panelboard so that the bottom of the cabinets will not be less than 150 mm (6 inches) above the finished floor.

3.1.5. For panelboards located in areas accessible to the public, paint the exposed surfaces of the trims, doors, and boxes with finishes to match surrounding surfaces after the panelboards have been installed.

3.1.6. Directory-card information shall be typewritten to indicate outlets, lights, devices, and equipment controlled and final room numbers served by each circuit and shall be mounted in holders behind protective covering.

3.1.7. Where new panels are to be installed in existing backboxes, backboxes shall have rust and scale removed from inside. Paint inside of backboxes with rust preventive paint before the new panel interior is installed. Provide new trim and doors for these panels. Covers shall fit tight to the box with no gaps between the cover and the box.

3.2. Testing:

3.2.1. All routine tests according to IEC will be attended by client representatives and it’s consultant in factory before delivery of the panels. The panel boards will be subjected to full routine tests as per IEC requirements. Such tests will include and will not be limited to: Insulation resistance test, dielectric test, high voltage power frequency test (on main and auxiliary circuits), full electrical and mechanical function tests, and testing of protective relays by current injection (circuit continuity and validation of CT ratio by primary injection and trip settings by secondary injection).

3.3. Training:

3.3.1. Training shall be provided for client personnel on the procedures for start up, testing and operation. Three operator's manuals shall be provided showing full installation and operating instructions.

End of Specification