FY14_Mac_Lock_Modernization_Amendment_0003_Specs_8-21-14.pdf

FY14 Mac Lock Modernization - Amendment 0003 FY14MCLMPC1

SECTION TABLE OF CONTENTS

DIVISION 26 - ELECTRICAL

SECTION 26 24 19.00 40

MOTOR CONTROL CENTERS

PART 1 GENERAL

1.1 REFERENCES

1.2 SYSTEM DESCRIPTION

1.2.1 Rules

1.2.2 Coordination

1.2.3 Standard Products

1.2.4 Nameplates

1.3 SUBMITTALS

1.3.1 Meeting at the Manufacturers Factory

1.4 DELIVERY, STORAGE, AND HANDLING

1.5 MAINTENANCE

1.5.1 Accessories and Tools

1.5.2 Spare Parts

PART 2 PRODUCTS

2.1 CONNECTIONS

2.2 MOLDED CASE CIRCUIT BREAKERS

2.2.1 Trip Units

2.2.2 480-Volt AC Circuits

2.2.3 120/240-Volt AC Circuits

2.2.4 125-Volt DC Circuits

2.3 WIRING

2.4 TERMINAL BLOCKS

2.4.1 Types of Terminal Blocks

2.4.1.1 Short-Circuiting Type

2.4.1.2 Load Type

2.4.2 Marking Strips

2.5 SPACE HEATERS

2.6 MOTOR CONTROL CENTERS

2.6.1 Specified Products

2.6.2 General Design

2.6.3 Enclosures

2.6.3.1 Unit Compartments

2.6.3.2 Motor Control Center Doors and Covers

2.6.3.3 Horizontal Wireways

2.6.3.4 Vertical Wireways

2.6.3.5 NEMA 12 Enclosures

2.6.3.6 Thermostatically Controlled Strip Heaters

2.6.4 Buses

2.6.4.1 Horizontal Bus

2.6.4.2 Vertical Bus

2.6.4.3 Ground Bus

2.6.5 Combination Starters

2.6.5.1 Magnetic Contactors

SECTION 26 24 19.00 40 Page 1

2.6.5.2 Auxiliary Contacts

2.6.5.3 Overload Relays

2.6.5.4 Control Circuit Disconnects

2.6.6 Molded Case Circuit Breakers in Unit Compartments

2.6.7 Panelboards for Motor Control Centers

2.6.8 Distribution Transformers

2.6.9 Wiring for Motor Control Centers

2.6.9.1 Contractor's Wiring

2.6.9.2 External Connections

2.6.9.3 Terminal Blocks

2.6.10 Control Transformers

2.6.11 Accessories and Control Devices

2.6.11.1 Control Stations

2.6.11.2 LED Indicating Lights

2.6.11.3 Control Relays

2.6.12 Metering Section

2.6.13 Space for Mounting PLC's

2.7 DEVICENET

2.7.1 General

2.7.2 DeviceNet Cable

2.7.3 DeviceNet Cable Layout

2.7.4 Power Supply

2.7.5 Scanner Modules

2.7.6 DeviceNet System Performance

2.7.7 DeviceNet Units

2.7.7.1 Motor Starter Units

2.7.7.2 Variable Frequency Drives and Soft Starters

2.7.7.3 Feeder Disconnects

2.8 PROGRAMMING OF PARAMETERS

2.9 INTELLICENTER SOFTWARE

2.10 TESTING

2.11 PAINTING

2.12 FACTORY TESTS

2.12.1 Motor Control Centers Tests

2.12.1.1 Operational Tests

2.12.1.2 Short Circuit Tests

PART 3 EXECUTION

3.1 INSTALLATION

3.2 FIELD TESTING

-- End of Section Table of Contents --

SECTION 26 24 19.00 40 Page 2

SECTION 26 24 19.00 40

MOTOR CONTROL CENTERS

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASME INTERNATIONAL (ASME)

ASME B1.1 (2003; R 2008) Unified Inch Screw Threads (UN and UNR Thread Form)

ASME B1.20.1 (1983; R 2006) Pipe Threads, General Purpose (Inch)

ASTM INTERNATIONAL (ASTM)

ASTM B187/B187M (2011) Standard Specification for Copper, Bus Bar, Rod and Shapes and General Purpose Rod, Bar and Shapes

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 1 (2000; R 2008; E 2010) Standard for Industrial Control and Systems: General Requirements

NEMA ICS 2 (2000; R 2005; Errata 2008) Standard for Controllers, Contactors, and Overload Relays Rated 600 V

NEMA ICS 6 (1993; R 2011) Enclosures

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2014; AMD 1 2013; Errata 2013; AMD 2 2013) National Electrical Code

UNDERWRITERS LABORATORIES (UL)

UL 489 (2013) Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit-Breaker Enclosures

UL 845 (2005; Reprint Jul 2011) Motor Control Centers

1.2 SYSTEM DESCRIPTION

These specifications include the design, fabrication, assembly, wiring, testing, delivery, installation and testing of the items of equipment and

SECTION 26 24 19.00 40 Page 3 accessories and spare parts listed in the Schedule and shown on the drawings.

Within 30 calendar days after date of award, submit for the approval of the Contracting Officer six (6) copies of electrical equipment drawings, including all motor control units and protective devices. Provide a single-line diagram, equipment list and nameplate schedule.

Within 30calendar days after date of award, submit for the approval of the Contracting Officer six (6) copies of electrical equipment drawings.

Submit an individual wiring diagram for each motor control center. Wiring diagrams shall be in a form showing physical arrangement of the control center with interconnecting wiring shown by lines or by terminal designations (wireless). Provide a single-line diagram, equipment list and nameplate schedule for each motor control center.

1.2.1 Rules

The equipment shall conform to the requirements of NFPA 70 unless more stringent requirements are indicated herein or shown. NEMA rated and UL listed equipment has been specified when available. Equipment must meet NEMA and UL construction and rating requirements as specified. No equivalent will be acceptable. Immediately notify the Contracting Officer of any requirements of the specifications or Contractor proposed materials or assemblies that do not comply with UL or NEMA. International Electrotechnical Commission (IEC) rated equipment will not be considered an acceptable alternative to specified NEMA ratings.

1.2.2 Coordination

The general arrangement of the motor control centers is shown on the contract drawings. Any modifications of the equipment arrangement or device requirements as shown on the drawings is subject to the approval of the Contracting Officer. If any conflicts occur necessitating departures from the drawings, details of and reasons for departures shall be submitted and approved prior to implementing any change. Completely assemble all equipment at the factory. The motor control centers may be disassembled into sections, if necessary, for convenience of handling, shipping, and installation.

1.2.3 Standard Products

Material and equipment shall be standard products of a manufacturer regularly engaged in their manufacture and shall essentially duplicate items that have been in satisfactory use for at least 2 years prior to bid opening. All materials shall conform to the requirements of these specifications. Materials are to be of high quality, free from defects and imperfections, of recent manufacture, and of the classification and grades designated. All materials, supplies, and articles not manufactured by the Contractor shall be the products of other recognized reputable manufacturers. If the Contractor desires for any reason to deviate from the standards designated in these specifications, he shall, after award, submit a statement of the exact nature of the deviation, and shall submit, for the approval of the Contracting Officer, complete specifications for the materials which he proposes to use.

1.2.4 Nameplates

Make nameplates of laminated sheet plastic or of anodized aluminum

SECTION 26 24 19.00 40 Page 4 approximately 1/8 inch thick, engraved to provide white letters on a black background. Fasten the nameplates to the equipment in proper positions with anodized round-head screws. Lettering shall be minimum 1/2 inch high. Nameplate designations shall be in accordance with lists on the drawings, and as a minimum provide for the following equipment:

a. Motor Control Centers

b. Individual items of equipment mounted in the Motor Control Centers

Provide equipment of the withdrawal type with nameplates mounted on the removable equipment in locations visible when the equipment is in place.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Drawings; G, AOF

Shop Drawings; G, AOF

Within 30 calendar days after date of award, submit for the approval of the Contracting Officer six (6) copies of outline drawings of all equipment to be furnished under this contract, together with weights and overall dimensions. Drawings shall show the general arrangement and overall dimensions of the motor control centers. These drawings shall show space requirements, details of any floor supports to be embedded in concrete and provisions for conduits for external cables.

Motor Control Centers; G, AOF

SD-03 Product Data

Equipment; G, AOF

Within 30 calendar days after date of award submit for approval six (6) copies of such descriptive cuts and information as are required to demonstrate fully that all parts of the equipment will conform to the requirements and intent of the specifications.

Data shall include descriptive data showing typical construction of the types of equipment proposed, including the manufacturer's name, type of molded case circuit breakers or motor circuit protectors, performance capacities and other information pertaining to the equipment.

Factory Tests

Submit, within a minimum of 14 days prior to the proposed date of tests, six (6) copies of manufacturer's routine factory test procedures and production line tests for all motor control centers.

SD-06 Test Reports

SECTION 26 24 19.00 40 Page 5

Factory Tests

Submit six (6) complete reproducible copies of the factory inspection results and six (6) complete reproducible copies of the factory test results in booklet form, including all plotted data curves, all test conditions, a listing of test equipment complete with calibration certifications, and all measurements taken.

Contractor's and Contracting Officer's Representatives must sign and date report.

SD-08 Manufacturer's Instructions

Submit manufacturer's instructions for the following including special provisions required to install equipment components and system packages. Detail within special notices hazards and safety precautions.

Motor Control Units

Protective Devices

1.3.1 Meeting at the Manufacturers Factory

The contractor shall schedule a meeting at the manufacturers factory 7 days after submittal of SD-02 Shop Drawings, Shop Drawings and SD-03 Product Data, Equipment. Notify the Contracting Officer a minimum of 14 days prior to the proposed date so that arrangements can be made for the Contracting Officer to be present. The following individuals shall be in attendance at the meeting. The foreman overseeing the MCC installation for the contractor. The Product Engineer for the manufacturer. The meeting shall be conducted in the Continental United States. The purpose of the meeting is to review the submittal with the manufacturers product engineer and the contractor in a face to face setting.

1.4 DELIVERY, STORAGE, AND HANDLING

Ship the equipment as completely assembled and wired as feasible so as to require a minimum of installation work. Each shipping section shall be properly match marked to facilitate reassembly, and shall be provided with removable lifting channels with eye bolts for attachment of crane slings to facilitate lifting and handling. Any relay or other device which cannot withstand the hazards of shipment when mounted in place on the equipment shall be carefully packed and shipped separately. Mark these devices with the number of the panel which they are to be mounted on and fully identified. All finished painted surfaces and metal work shall be wrapped suitably or otherwise protected from damage during shipment. Prepare all parts for shipment so that slings for handling may be attached readily while the parts are in a railway car or transport truck. Sections of equipment crated for shipment shall be of such size, including crates, that they will pass through a 60 by 48-inch hatch opening. Carefully package and clearly mark all spare parts and accessories.

SECTION 26 24 19.00 40 Page 6

1.5 MAINTENANCE

1.5.1 Accessories and Tools

A complete set of accessories and special tools unique to equipment provided and required for erecting, handling, dismantling, testing and maintaining the apparatus to be furnished by the Contractor.

1.5.2 Spare Parts

Furnish spare parts as specified below. All spare parts shall be of the same material and workmanship, shall meet the same requirements, and shall be interchangeable with the corresponding original parts furnished.

a. 2 - Fuses of each type and size.

b. 1 - Circuit breaker auxiliary switch.

c. 2 - Operating coils for each size ac contactor.

d. 1 - Operating coil for each size dc contactor.

e. 2 - Complete sets of 3-pole stationary and moving contact assemblies for each size ac contactor.

f. 1 - Complete set of 2-pole stationary and moving contact assemblies for each size dc contactor.

g. 3 - Contactor overload relays of each type and rating, each relay with a complete set of contact blocks.

h. 1 - Spare set of heater elements for each heater rating provided.

i. 2 - Indicating lamp assemblies of each type.

j. 1 - Control transformer of each type and rating.

k. 1 - Control relay of each type and rating.

l. 1 - Contactor auxiliary contact of each type.

m. 4 - One quart containers of finish paint for indoor equipment.

n. 2 - One quart containers of the paint used for the exterior surfaces of outdoor equipment.

o. 4 - Keys for motor control center door lock.

PART 2 PRODUCTS

MCC manufacturer shall design, install at factory, and document those features marketed herein. MCC to consist of off-the-shelf components installed at the MCC manufacturing facility.

2.1 CONNECTIONS

All bolts, studs, machine screws, nuts, and tapped holes shall be in accordance with ASME B1.1. The sizes and threads of all conduit and fittings, tubing and fittings, and connecting equipment shall be in

SECTION 26 24 19.00 40 Page 7 accordance with ASME B1.20.1. All ferrous fasteners shall have rust-resistant finish and all bolts and screws shall be equipped with approved locking devices. Manufacturer's standard threads and construction may be used on small items which, in the opinion of the Contracting Officer, are integrally replaceable, except that threads for external connections to these items and meet the above requirements.

2.2 MOLDED CASE CIRCUIT BREAKERS

Molded case circuit breakers shall conform to the applicable requirements of UL 489. The circuit breakers shall be manually-operated, shall be quick-make, quick-break, common trip type, and shall be of automatic-trip type unless otherwise specified or indicated on the drawings. Operate all poles of each breaker simultaneously by means of a common handle. The operating handles shall clearly indicate whether the breakers are in "On," "Off," or "Tripped" position and shall have provisions for padlocking in the "Off" position. Provide personnel safety line terminal shields for each breaker. The circuit breakers shall be products of only one manufacturer, and shall be interchangeable when of the same frame size.

2.2.1 Trip Units

Except as otherwise noted, the circuit breakers, of frame sizes and the trip unit ratings as shown on the drawings, shall be provided with combination thermal and instantaneous magnetic or solid state trip units.

The Government reserves the right to change the indicated trip ratings, within frame limits, of the trip devices at the time the shop drawings are submitted for approval. The breaker trip units shall be interchangeable and the instantaneous magnetic trip units shall be adjustable on frame sizes larger than 150 amperes. Nonadjustable instantaneous magnetic trip units shall be set at approximately 10 times the continuous current ratings of the circuit breakers.

2.2.2 480-Volt AC Circuits

Circuit breakers for 480-volt or 277/480-volt ac circuits shall be rated 600 volts ac, and shall have an UL listed minimum interrupting capacity of 14,000 symmetrical amperes at 600 volts ac.

2.2.3 120/240-Volt AC Circuits

Circuit breakers for 120-volt ac circuits shall be rated not less than 120/240 or 240 volts ac, and shall have a UL listed minimum interrupting capacity of 10,000 symmetrical amperes.

2.2.4 125-Volt DC Circuits

Circuit breakers for 125-volt dc circuits are to be two-pole rated 125/250 or 250 volts dc, and have an UL listed minimum interrupting capacity of 10,000 amperes dc.

2.3 WIRING

All control wire is to be provided per manufacturer requirement and industry standards.

2.4 TERMINAL BLOCKS

Control circuit terminal blocks for control wiring shall be molded or

SECTION 26 24 19.00 40 Page 8 fabricated type with barriers, rated not less than 600 volts. The terminals shall be removable binding, fillister or washer head screw type, or of the stud type with contact and locking nuts. The terminals are to be no less than No. 10 in size and having sufficient length and space for connecting at least two indented terminals for 10 AWG conductors to each terminal. The terminal arrangement is subject to the approval of the Contracting Officer and not less than four (4) spare terminals or 10 percent, whichever is greater, shall be provided on each block or group of blocks. Modular, pull apart, terminal blocks will be acceptable provided they are of the channel or rail-mounted type. Submit data showing that the proposed alternate will accommodate the specified number of wires, are of adequate current-carrying capacity, and are constructed to assure positive contact between current-carrying parts.

2.4.1 Types of Terminal Blocks

2.4.1.1 Short-Circuiting Type

Furnish short-circuiting type terminal blocks for all current transformer secondary leads and shall have provision for shorting together all leads from each current transformer without first opening any circuit. Terminal blocks shall meet the requirements of paragraph CONTROL CIRCUIT TERMINAL BLOCKS above.

2.4.1.2 Load Type

Provide load terminal blocks rated no less than 600 volts and of adequate capacity for the conductors for NEMA Size 3 and smaller motor controllers and for other power circuits except those for feeder tap units. The terminals shall be of either the stud type with contact nuts and locking nuts or of the removable screw type, having length and space for at least two indented terminals of the size required on the conductors to be terminated. For conductors rated more than 50 amperes, screws shall have hexagonal heads. Conducting parts between connected terminals shall have adequate contact surface and cross-section to operate without overheating.

Each connected terminal shall have the circuit designation or wire number placed on or near the terminal in permanent contrasting color.

2.4.2 Marking Strips

Provide white or other light-colored plastic marking strips, fastened by screws to each terminal block, for wire designations. Make the wire numbers with permanent ink. The marking strips shall be reversible to permit marking both sides, or two marking strips shall be furnished with each block. Marking strips shall accommodate the two sets of wire numbers. Each device to which a connection is made shall be assigned a device designation in accordance with NEMA ICS 1 and each device terminal to which a connection is made shall be marked with a distinct terminal marking corresponding to the wire designation used on the Contractor's schematic and connection diagrams. The wire (terminal point) designations used on the Contractor's wiring diagrams and printed on terminal block marking strips may be according to the Contractor's standard practice;

however, provide additional wire and cable designations for identification of remote (external) circuits for the Government's wire designations.

Prints of drawings submitted for approval will be so marked and returned to the Contractor for addition of the designations to the terminal strips and tracings, along with any rearrangement of points required.

SECTION 26 24 19.00 40 Page 9

2.5 SPACE HEATERS

Provide space heaters where indicated on the drawings.

2.6 MOTOR CONTROL CENTERS

2.6.1 Specified Products

Allen-Bradley Company Motor Control Centers specified for this project are listed in the following reports attached to this specification:

A-B Reference: 5057954 / 17 A-B Reference: 5057954 / 18 A-B Reference: 5057954 / 19 A-B Reference: 5057954 / 20

2.6.2 General Design

Design each motor control center for operation on 480-volts ac, 3-phase, 60-Hz system, and ensure that equipment conforms to all the applicable requirements of NEMA ICS 8, UL 845 and NFPA 70. List and label vertical sections and individual units under UL 845 where ever possible. In lieu of the UL listing, certification from any nationally recognized, adequately equipped, testing agency that the individual units and vertical sections have been tested and conform to the UL requirements of that agency will be acceptable when approved by the Contracting Officer. Provide NEMA Class I, Type B or C as indicated in the bid item list, motor control centers in accordance with NEMA ICS 2.

2.6.3 Enclosures

Each motor control center shall consist of the required number of vertical sections of 90 inches nominal height, bolted together, with steel channel sills and suitable for mounting against a wall. Vertical section shall be 15 or 30 inches deep and buses, control wiring, control transformers, small power transformers, terminal blocks, line terminals, cable supports, and clamps shall be accessible from the front. Enclosure shall be NEMA Type

12. Fabricate the control centers from smooth select steel sheets shaped and reinforced to form rigid free-standing structures. Metal thickness for enclosures shall be not less than specified in NEMA ICS 6 without exception. Fabricate and bolt vertical edges of sections exposed to view so that the joints will not pass a 1/16 inch gage. Design each structure for addition of future sections required. Isolate individual compartments from adjacent compartments. Make provisions for leveling the entire assembled motor-control center sections and bolting them together so that they form a contiguous structural enclosure.

Lifting angles shall be 7 gage, and shall be provided on the top of each section, and shall extend the entire width of the section, and shall be capable of supporting the entire weight of the motor-control center section without distortion. Provide base channels with holes to facilitate floor mounting and leveling.

2.6.3.1 Unit Compartments

Each operating unit shall contain equipment as shown on the drawings, mounted in an individual cell. The unit assembly, except main circuit breakers, panelboards and auxiliary control devices, shall be drawout type removed from the front, without rear access or disturbing other units in

SECTION 26 24 19.00 40 Page 10 the control center assembly. All drawout type unit assemblies shall have positive guide rail system to ensure alignment of connection to vertical bus. Units shall be mechanically interlocked with the door to prevent removal while in the energized position. Each removable unit shall have provision for padlocking in a position in which it is disconnected from the vertical bus although not removed from the stationary structure. Provide all ventilating openings with corrosion-resistant insect-proof screens on the inside. Provide bus closing plugs for all unused openings in vertical bus barriers.

Compartments for future combination motor-control units shall be complete with hardware, buses, and hinged doors ready to receive future draw-out units. Compartments for spare combination motor-control units shall be complete with buses, hinged doors, and draw-out units but without load terminal connections. Spare spaces shall be complete with buses and screwed-on front cover plates.

2.6.3.2 Motor Control Center Doors and Covers

Provide each unit compartment, including blank compartments for future use, with either a flange-formed or a rolled-edge door. Mount each door on fully-concealed or continuous full-length piano-type hinges and provide with positive fasteners. Prevent door sag by proper alignment of hinges made of sufficiently strong material. Interlock the door fastenings to prevent opening when the equipment is energized. The external operating handle shall clearly indicate whether the equipment is in an "ON", "OFF" or "TRIPPED" position.

2.6.3.3 Horizontal Wireways

Structure shall have a minimum 6 inches high wireway at the top and a 6 inches minimum wireway at the bottom. Both horizontal wireways shall run the length of the structure. Provide a master terminal block compartment with full length wireway space at the top in all Type C assemblies.

Provide cover plates on the side of the assembly to permit extension of the horizontal bus and wireway when vertical sections are added. Horizontal wireways of back to back sections shall allow complete access front to rear.

2.6.3.4 Vertical Wireways

Provide 78-inch full height vertical wireways in all vertical sections accepting multiple plug-in components. Vertical wireways shall connect with horizontal wireways at the top and bottom and be a 4 i3/6 inches wide x 7" deep. Provide barriers in sections containing both ac and dc vertical buses. Provide doors on each vertical wireway. The exposed surface of any door shall not deviate more than 1/16 inch from a true plane.

2.6.3.5 NEMA 12 Enclosures

The motor control center shall be non-walk in NEMA Type 12 enclosure as shown on the drawings. The outside enclosure shall consist of smooth select steel sheets on a structural steel frame. Provide full-length single or double doors with top and bottom bolts and a center latch operated by means of a keyed handle. Steel sheets and doors shall be not less than No. 10 gage thick and doors shall have bent angle or channel edges with all corner seams welded and ground smooth. Assemble the motor control center within the enclosure with adequate gaskets and structure to assure a measure of vandal resistance. Ventilating openings and an effective insulating air space of approximately 2 inches shall be provided

SECTION 26 24 19.00 40 Page 11 below the roof of the structure which shall slope from front to back for adequate drainage. The outside edges of the control center base shall permit easy sealing at the concrete surface with mastic compound.

2.6.3.6 Thermostatically Controlled Strip Heaters

Thermostatically controlled strip heaters as specified in paragraph entitled, SPACE HEATERS, of this section, shall be provided where indicated.

2.6.4 Buses

All buses shall be of copper and all bolted splices and connections between buses and for extensions or taps for equipment shall be tin or silver-plated. Copper bars and shapes for bus conductors shall conform to the applicable requirements of ASTM B187/B187M. All splices for field assembly shall be bolted with at least two bolts and shall employ the use of "Belleville" washers in the connection. The bus ratings shall be based on a 65 degree Celsius maximum temperature rise in accordance with UL 845 requirements. Bus shall have a short-circuit current rating of not less than 65,000 RMS symmetrical amperes. Support all bus work on wet process porcelain insulators, glass polyester, or suitable molded material.

2.6.4.1 Horizontal Bus

Provide each control center assembly with a three-phase main horizontal bus, with a continuous current rating not less than 800 amperes, located across the centerline of each vertical section. Drill the ends of horizontal buses for future extensions.

2.6.4.2 Vertical Bus

Provide each vertical section with a three-phase vertical bus with a continuous current rating of 600 amperes connected to the horizontal bus by brazing, welding, or bolting. Where the incoming feeder breakers are located at the bottom of a control center, rate the vertical bus in that section the same as the main horizontal bus. Extend vertical buses from the horizontal bus to the bottom of the lowest available unit mounting space. Isolate the vertical bus from wireways and equipment in compartments.

2.6.4.3 Ground Bus

Provide a copper ground bus full width at the bottom of the motor control center line-up. Provide a full clamp-type solderless copper or copper alloy lug for No. 2/0 AWG stranded copper cable at each end of the bus for connection to the station grounding system. Ground bus shall be capable of carrying the rated short-circuit current available in the motor-control center.

2.6.5 Combination Starters

Combination motor controller units shall contain molded-case circuit breakers, auxiliary and pilot devices and a magnetic contactor with thermal overload relays and full voltage starter where indicated on the drawings.

The ratings of motor circuit protectors, air circuit breakers, contactors, motor controllers and other devices shall be as shown on the drawings. All combination motor controller units shall have short circuit ratings equal to 65K or greater. Where control push-buttons, indicating lamps, "Hand-Off-Automatic" switches, and similar control devices are associated

SECTION 26 24 19.00 40 Page 12 with a unit, mount them on the unit compartment door. Door-mounted components shall not interfere with access within the compartments. Motor circuit protectors shall be only part of the combination starters as required by NFPA 70 and shall conform to all requirements of paragraph MOLDED CASE CIRCUIT BREAKERS, except that trip units shall have provision for locking the selected trip setting.

2.6.5.1 Magnetic Contactors

Magnetic contactors shall be of the NEMA sizes indicated on the drawings.

The rating, performance and service characteristics shall conform to the requirements of NEMA ICS 2 for contactors with continuous current ratings for the duty indicated. Contactors for motor control shall be rated for full-voltage starting (Class A controllers). Contactors shall be suitable for at least 200,000 complete operations under rated load without more than routine maintenance. Minimize the interruption arc and flame by suitable arc chutes or other means so that no damage will be done to other portions of the device. The arc chutes, if provided, shall be easily removable without removing or dismantling other parts. The contacts shall be easily removable. All current-carrying contact surfaces shall be silver-surfaced or of other approved material to prevent the formation of high resistance oxides. The contactor shall operate without chatter or perceptible hum while energized. Coils shall be suitable for continuous operation 120-volt ac circuits. Alternating-current contactors shall be three-pole, except where otherwise noted, and shall be insulated for 600 volts ac and of the electrically- operated, magnetically-held type. Direct-current contactors shall be two-pole, suitable for controlling circuits operating at 125 volts dc, insulated for 250 volts dc, electrically-operated, magnetically-held type and adequate for full-voltage motor starting service.

2.6.5.2 Auxiliary Contacts

Each controller shall be provided with a minimum of two (2) auxiliary contacts which can be easily changed from normally open to normally closed. Where indicated on the drawings, provide a fourth auxiliary contact and red and green indicating lights.

2.6.5.3 Overload Relays

Except as otherwise indicated, each controller shall be provided three NEMA Class 20 thermal overload relays with external manual reset. Prior to shipment of the control centers, the Contracting Officer will furnish the ratings of the heater elements to be installed in the relays by the Contractor.

2.6.5.4 Control Circuit Disconnects

Disconnect control circuit power when the unit compartment is opened.

2.6.6 Molded Case Circuit Breakers in Unit Compartments

Molded case circuit breakers for installation in unit compartments shall meet the requirements of paragraph MOLDED CASE CIRCUIT BREAKERS.

2.6.7 Panelboards for Motor Control Centers

Panelboards shall meet the requirements of Section 26 24 16.00 40

PANELBOARDS.

SECTION 26 24 19.00 40 Page 13

2.6.8 Distribution Transformers

Dry type transformers for power and lighting loads shall be furnished with voltage and kVA ratings as indicated on the drawings. The transformers shall conform to the requirements for general-purpose transformers in IEEE C57.12.01. Protect each transformer on the primary side with a molded case circuit breaker as indicated on the drawings. Transformers shall be fixed frame type.

2.6.9 Wiring for Motor Control Centers

All wiring shall meet the requirements of paragraph WIRING. Provide heavy-duty clamp type terminals for terminating all power cables entering the control centers.

2.6.9.1 Contractor's Wiring

Form wiring into groups, suitably bound together, properly supported and run straight horizontally or vertically. There shall be no splices in the wiring. The manufacturer's standard pressure-type wire terminations for connections to internal devices will be acceptable. Add terminal blocks for wiring to devices having leads instead of terminals. Use ring tongue indented terminals on all wires terminated on control terminal blocks for external or interpanel connections and at shipping splits. All stud terminals shall have contact nuts and either locking nuts or lockwashers.

2.6.9.2 External Connections

Power and control cables will enter the control centers at the top. Where power and control entry points are not shown, and terminal blocks are not given on the drawings, the Government will furnish this information to the Contractor after award of contract.

2.6.9.3 Terminal Blocks

Terminal blocks shall meet the requirements of paragraph TERMINAL BLOCKS above. In no case shall the terminals provided for circuit breakers or contactors accommodate less than the number or size of conductors shown on the drawings. Give special attention to wiring and terminal arrangement on the terminal blocks to permit the individual conductors of each external cable to be terminated on adjacent terminal points.

2.6.10 Control Transformers

The control transformers shall be rated 480-120 volts and shall conform to the requirements for control transformers in NEMA ST 1. Control transformers shall have adequate volt-ampere capacity for the control functions indicated and an additional 10 percent capacity. Install transformers without primary fuses. Except as otherwise indicated on the drawings, each unit compartment shall provide a fuse for control power in one secondary lead and shall have the other secondary lead grounded. The unit disconnect shall be equipped with a normally open contact to isolate the control circuit from the source when the controller disconnect is open.

2.6.11 Accessories and Control Devices

Control accessories shall be provided, and shall be suitable for mounting on the front of, or inside, the control centers. Control accessories shall meet the applicable requirements of NEMA ICS 2. Mount relays and other

SECTION 26 24 19.00 40 Page 14 equipment that mechanical vibration will not cause false operation.

2.6.11.1 Control Stations

Push-button stations and selector switches shall conform to NEMA ICS 2, shall be of the heavy-duty, oil-tight type, rated 600 volts ac, and have a contact rating designation of A600. Provide switches with escutcheon plates clearly marked to show operating positions. Provide sufficient contact blocks to make up the electrically separate contacts required for lead-lag selector switches.

2.6.11.2 LED Indicating Lights

Furnish red and green LED's where shown on the drawings, indicating contact "open" and "closed" position. The LED's shall be accessible and replaceable from the front of the control center through a finished opening in the compartment door. The LED assemblies shall be of the heavy duty oiltight, watertight, and dusttight type.

2.6.11.3 Control Relays

Control relays shall be of the electrically operated, magnetically held, self-reset, open type, suitable for mounting inside the starter compartments, and shall be 120-volt ac. Contacts shall be as indicated on the drawings and shall have a contact rating designation of A600 or N600, as required, in accordance with NEMA ICS 2.

2.6.12 Metering Section

Provide metering section with instruments as indicated on the drawings.

2.6.13 Space for Mounting PLC's

Provide space for mounting of Programmable Logic Controllers (PLC's) as indicated on the drawings.

2.7 DEVICENET

2.7.1 General

The MCC shall have DeviceNet cabling integrated throughout the vertical sections.

Each motor starter, AC drive and soft starter in the MCC shall be supplied with a means to communicate via DeviceNet.

2.7.2 DeviceNet Cable

Per the National Electrical Code article 300-3(c} (1} and the Canadian Electrical Code (Rule 12-904} the DeviceNet cable shall have an insulating rating equal to at least the maximum circuit voltage applied to any conductor within the enclosure or raceway, i.e., no special separation, barriers or internal conduit is required for the DeviceNet conductors. The DeviceNet cable used for the trunk line shall be flat cable rated 8.0 A, 600 V, Class 1.

The DeviceNet cable used for the droplines to connect DeviceNet units shall be round cable rated at 8.0 A, 600 V, Class 1.

SECTION 26 24 19.00 40 Page 15

2.7.3 DeviceNet Cable Layout

A DeviceNet trunkline shall be routed through the MCC line-up, behind barriers that isolate the trunkline from the unit space and wireways to prevent accidental mechanical damage during MCC installation

Six DeviceNet ports shall be provided in the rear of each full height vertical wireway to simplify installation, relocation, and addition of plugin MCC units.

The DeviceNet component within each plug-in unit shall be connected to one of the six DeviceNet ports in the vertical wireway with cable outlined above in the DeviceNet Cable section.

The addition or removal of a unit from the DeviceNet system shall not interrupt the operation of other units within the system.

2.7.4 Power Supply

The DeviceNet system in the MCC shall include a power supply that conforms to DeviceNet requirements and has the ODVA checkmark. The power supply shall provide 24 Vdc and shall be rated no less than 8.0 A.

2.7.5 Scanner Modules

The DeviceNet system in the MCC shall include a DeviceNet scanner module that conforms to the DeviceNet requirements.

As an alternative to a traditional DeviceNet scanner module, linking devices can be used to link different communication networks to the MCC DeviceNet system (such as linking ControlNet to DeviceNet or Ethernet to DeviceNet).

2.7.6 DeviceNet System Performance

The DeviceNet system shall be designed to operated at 500 kbaud to maximize the system performance, unless precluded by the cumulative length of the trunk and drop lines. To achieve best performance, 250 kbaud shall be the minimum communication rate.

The DeviceNet system shall be qualified to communicate and perform under normal and adverse MCC electrical environments (e.g. contactor electrical operation, contactor jogging duty and unit short circuit fault).

The DeviceNet system shall be capable of Automatic Device Replacement (ADR).

The DeviceNet system shall be capable of On-Line Scanlist changes at Run allowing network modifications to be performed on a DeviceNet system that is running.

The DeviceNet system shall be capable of the following scan modes: Polled, Change of State (COS), Strobe and Cyclic.

The DeviceNet system shall be capable of transmitting and receiving data via I/O and explicit messaging.

SECTION 26 24 19.00 40 Page 16

2.7.7 DeviceNet Units

2.7.7.1 Motor Starter Units

Each motor starter shall have an electronic overload really with the following features:

Ori-board DeviceNet communication

LEOs for status indication

Test/Reset buttons

Adjustable trip class (5 to 30)

General purpose I/O (minimum 2I/10, optional 4I/20), rated for 110-120 Vac or 24 Vdc as specified on the drawing

Unconnected Message Manager to allow the proxying of more than one master device

Protective functions with programmable trip level, warning level, time delay and inhibit window:

Thermal overload Underload Jam Current imbalance Stall Phase loss Zero sequence ground fault sensitive to 1.0 A (optional feature) PTC thermistor input (optional feature)

Current Monitoring Functions:

Phase current Average current Full load current Current imbalance percent Percent thermal capacity utilized Ground fault current (optional feature)

Diagnostic Information:

Device status Warning status Time to reset Trip status Time to overload trip History of last five trips

2.7.7.2 Variable Frequency Drives and Soft Starters

Each variable frequency drive unit and soft starter unit shall have a DeviceNet communication module to communicated the status over DeviceNet.

2.7.7.3 Feeder Disconnects

Where required, fusible disconnect and circuit breaker feeder circuits

SECTION 26 24 19.00 40 Page 17 shall have a DeviceNet I/O Module containing at least three inputs (open, close, and trip) and zero output. The inputs of the DeviceNet I/O module shall be rated for 110-120 Vac or 24 Vdc as specified on drawings.

2.8 PROGRAMMING OF PARAMETERS

The Device~et node address shall be set for each unit per the drawings.

All other parameters may be left at the factory default setting.

The DeviceNet System components shall be pre-configured to operated at the appropriate baud rate.

2.9 INTELLICENTER SOFTWARE

The MCC shall be provided with pre-configured IntelliCENTER software. The software shall be capable of viewing multiple MCC line-ups. The IntelliCENTER software communication driver shall allow the software to be installed and operated on Ethernet, ControlNet, or DeviceNet. The IntelliCENTER software shall be capable of functioning as a stand alone software package or as an ActiveX control in a Human Machine Interface (HMI). The IntelliCENTER software shall be capable of displaying the following:

Elevation View

Dynamically displays status information based on reading data from devices in MCC line-up Sizeable view to allow ease of viewing multiple MCC line-ups Unit nameplate information Unit status indicators (ready, running, warning, fault, no communication)

Unit Motor View

Pre-configured for a specific unit Real time monitoring via analog dials and trending Data configurable for customized viewing Modifying device parameters

Spreadsheet View

User configurable for customized monitoring Sorting and cascading functions Custom user fields

Event Log

Track history of MCC unit Automatic logging of trips, warnings and changes Manual entry of events

Documentation

Front elevation drawings Unit wiring diagrams User manuals Spare parts list

SECTION 26 24 19.00 40 Page 18

2.10 TESTING

The MCC with IntelliCENTER technology shall be powered up, configured, and tested in an IS09001 facility to ensure each unit communicates properly prior to shipment.

2.11 PAINTING

Interior and exterior steel surfaces of equipment enclosures shall be thoroughly cleaned and then receive a rust-inhibitive phosphatizing or equivalent treatment prior to painting. Exterior surfaces shall be free from holes, seams, dents, weld marks, loose scale or other imperfections.

Interior surfaces shall receive not less than one coat of corrosion-resisting paint in accordance with the manufacturer's standard practice. Prime exterior surfaces, fill where necessary, and give no less than two coats baked enamel with semigloss finish. Equipment located indoors shall be ANSI Light Gray (excpet in the case of sole source equipment), and equipment located outdoors shall be ANSI Light Grey (except in the case of sole source equipment). All touch-up work shall be done with manufacturer's coatings as supplied under paragraph Spare Parts.

2.12 FACTORY TESTS

Each item of equipment supplied under this contract shall be given the manufacturer's routine factory tests and tests as specified below, to insure successful operation of all parts of the assemblies. All tests required herein shall be witnessed by the Contracting Officer unless waived in writing, and no equipment shall be shipped until it has been approved for shipment by the Contracting Officer. Notify the Contracting Officer a minimum of 14 days prior to the proposed date of the tests so that arrangements can be made for the Contracting Officer to be present at the tests. The factory test equipment and the test methods used shall be subject to the approval of the Contracting Officer. Reports of all witnessed tests shall be signed by witnessing representatives of the Contractor and Contracting Officer. Bear the cost of performing all tests and include in the prices bid in the schedule for equipment. All factory tests for the Motor Control Centers shall be conducted in the Continental United States or Canada.

2.12.1 Motor Control Centers Tests

2.12.1.1 Operational Tests

The correctness of operation of each air circuit breaker or motor circuit protector and magnetic contactor and of all control devices, accessories and indicating lamps, shall be checked. These checks shall be made at rated voltage with power supplies to the main buses. All magnetic contactors shall also be checked for proper operation with power at 90 percent of rated voltage.

2.12.1.2 Short Circuit Tests

If the unit is not UL labeled for the specified short circuit, the Contractor may submit design tests demonstrating that satisfactory short-circuit tests, as specified in NEMA ICS 2, have been made on a motor control center of similar type of construction and having the same available short circuit current at the motor terminals, including any motor contributions, as the motor control centers specified to be furnished under these specifications.

SECTION 26 24 19.00 40 Page 19

PART 3 EXECUTION

3.1 INSTALLATION

Complete assembly shall be electrically and mechanically connected and assembled from coordinated subassemblies shipped in complete sections from the manufacturer. Installation shall be aligned, leveled, and secured to the supporting construction in accordance with the manufacturer's recommendations.

3.2 FIELD TESTING

Motor-control centers shall be subjected to continuity and insulation tests after the installation has been completed and before the motor-control center is energized.

Contractor shall provide test equipment, labor, and personnel to perform the tests required in the field. Conduct continuity tests using a dc device with bell or buzzer.

Motor-control centers shall be completely isolated from extraneous electrical connections. Substation feeder breakers, circuit breakers in switchboards, and other disconnecting devices shall be used to isolate the motor-control center under test.

Conduct insulation tests on 600-volt motor-control centers using a 1,000-volt insulation-resistance test set. Record readings every 15 seconds for the first minute and every minute thereafter for 10 minutes.

Resistance between phase conductors and between phase conductors and ground shall be not less than 50 megohms.

Conduct insulation tests on motor-control centers 480 volts or less using a 500-volt insulation-resistance test set. Record readings every 15 seconds for the first minute and every minute thereafter for 10 minutes.

Resistance between phase conductors and between phase conductors and ground shall be not less than 25 megohms.

Prior to final acceptance the motor control center shall be energized and loaded (to the maximum load possible, but not less than 10 percent of expected full load)for a minimum of 10 minutes and the temperature measured, with a non-contact device, to verify connection integrity. The temperature detector shall be accurate within 0.5 degrees C. Each phase temperature of 3 phase circuits and individual connections compared to other similarly loaded connections shall be within 3 degrees C of each other. Temperatures outside these values warrant investigation.

Conduct phase-rotation tests on all three-phase circuits using a phase-rotation indicating instrument. Phase rotation of electrical connections to motors and other connected equipment shall be clockwise.

Record test data and include location and identification of motor-control centers and megohm readings versus time.

Final acceptance shall depend upon the satisfactory performance of the motor-control centers under test. No motor-control center shall be energized until recorded test data have been approved by the Contracting Officer. Provide final test reports to the Contracting Officer. Reports shall have a cover letter/sheet clearly marked with the System name, Date, SECTION 26 24 19.00 40 Page 20 and the words "Final Test Reports - Forward to the Systems Engineer/Condition Monitoring Office/Predictive Testing Group for inclusion in the Maintenance Database."

-- End of Section --

SECTION 26 24 19.00 40 Page 21

DIVISION 26 - ELECTRICAL

SECTION 26 29 23

VARIABLE FREQUENCY DRIVE SYSTEMS UNDER 600 VOLTS

PART 1 GENERAL

1.1 REFERENCES

1.2 RELATED REQUIREMENTS

1.3 SYSTEM DESCRIPTION

1.3.1 Performance Requirements

1.3.1.1 Electromagnetic Interference Suppression

1.3.1.2 Electromechanical and Electrical Components

1.3.2 Electrical Requirements

1.3.2.1 Power Line Surge Protection

1.3.2.2 Sensor and Control Wiring Surge Protection

1.4 SUBMITTALS

1.5 QUALITY ASSURANCE

1.5.1 Schematic Diagrams

1.5.2 Interconnecting Diagrams

1.5.3 Installation Drawings

1.5.4 Equipment Schedule

1.5.5 Installation instructions

1.5.6 Factory Test Results

1.6 DELIVERY AND STORAGE

1.7 WARRANTY

1.8 MAINTENANCE

1.8.1 Spare Parts

1.8.2 Maintenance Support

PART 2 PRODUCTS

2.1 VARIABLE FREQUENCY DRIVES (VFD)

2.2 ENCLOSURES

2.3 WIRES AND CABLES

2.4 NAMEPLATES

2.5 SOURCE QUALITY CONTROL

2.5.1 VFD Factory Test Plan

PART 3 EXECUTION

3.1 INSTALLATION

3.2 FIELD QUALITY CONTROL

3.2.1 VFD Test

3.2.2 Performance Verification Tests

3.2.3 Endurance Test

3.3 DEMONSTRATION

3.3.1 Training

3.3.1.1 Instructions to Government Personnel

3.3.1.2 Operating Personnel Training Program

3.3.1.3 Engineering/Maintenance Personnel Training

SECTION 26 29 23 Page 1

SECTION 26 29 23 Page 2

SECTION 26 29 23

VARIABLE FREQUENCY DRIVE SYSTEMS UNDER 600 VOLTS

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE 519 (1992; R 1993; Errata 2004) Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems

IEEE C62.41.1 (2002; R 2008) Guide on the Surges Environment in Low-Voltage (1000 V and Less) AC Power Circuits

IEEE C62.41.2 (2002) Recommended Practice on Characterization of Surges in Low-Voltage (1000 V and Less) AC Power Circuits

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 (2008) Enclosures for Electrical…