SECTION 16910

INDUSTRIAL CONTROL PANEL

GENERAL

DESCRIPTION

Section Includes: Requirements for fabrication of Industrial Control Panel as shown on drawings and as specified herein.

Provides all material and labor requirements for Install and interconnect all control devices, wiring, terminations, labeling within the enclosures as specified on the drawings.

REFERENCES

The following is a list of standards that may be referenced in this section:

A. Joint Industrial Council (JIC).

B. National Electrical Manufacturers Association (NEMA).

C. National Fire Protection Association (NFPA): 70, National Electrical Code (NEC).

QUALITY ASSURANCE

A. Work: Follow approved trade practices, manufacturers’ recommendations, and applicable federal, local and state codes.

Instruments and control hardware associated with panels: Properly installed, wired, and tested at the shop and be suitable for operation.

This specification and panel drawings are intended to show and define panel design, fabrication.

B. Equipment.

1. Install following manufacturers’ recommendations using installation manuals for guidance and for details not shown on Drawings.

2. Provide for protection, insurance and proper storage.

3. Signals received from the field to/from control panel shall be made fully integrated and of the same type throughout circuit.

C. Connections to the top or back of cabinet: Not permitted without prior approval from the Commission.

D. Continuously protect and cover equipment from metal shards, dust, debris, and moisture.

E. Furnish changes resulting from deviations from panel drawings shall be submitted to the Commission Project Manager for approval.

F. Review WSSC Control panel drawings and submit any comments, question or clarification for approval prior to panel fabrication.

PRODUCTS

ENCLOSURES

A. NEMA Rating: Follow standards for NEMA type indicated on drawings or as specified herein.

1. NEMA Type 12 dust-tight:

a. Provided for indoor controlled environment locations as shown on drawings. Provide continuous gasket around door opening.

b. Phosphate coating for rust proofing and white enamel panel interior finish.

1) Exterior finish: Hoffman custom paint color #RAL7021 (T014) or ANSI-61 gray powdercoat.

2) Enclosures requiring legs: Paint color to match enclosure.

2. NEMA Type 4 watertight and dust-tight: Provided for indoor or outdoor locations as shown on Drawings.

3. NEMA Type 4X corrosion resistant: Provided for indoor and outdoor locations as shown on Drawings.

a. Door clamps and hinge pins: Stainless steel.

4. NEMA 12/13/4/4X nonmetallic Fiberglass

5. NEMA-rated panels: Hoffman Brand or equal.

B. General.

1. Designed for connection to 120VAC branch circuits.

2. Enclosures that contain interlocked control circuits or circuits supplied from external power source which cannot be de-energized by panel disconnect: Furnish with following warning label;

CAUTION: THIS EQUIPMENT MAY HAVE MORE THAN ONE POWER SOURCE OR IS INTERLOCKED WITH OTHER EQUIPMENT.

3. Mounted outdoors or in unheated areas: Provide internal condensation and freezing protection with thermostat control.

4. Fully enclosed units with front and/or rear access doors, as shown on drawings.

5. Provide vapor-phase protective corrosion inhibitors.

a. Inhibitor: Activated upon shipment to site.

b. Panels:

c. Approved Manufacturers:

1) Hoffman A-HC15E.

2) 10E.

3) Or Equal.

6. Front door-mounted nameplate that identifies panel inside, e.g., Pump Control

a. Nameplates.

7. Print pocket.

a. Mounted inside door.

b. Include one copy of relevant as-built drawings prior to shipment.

8. Factory back panels for mounting control panel components and equipment.

a. Side panels may be used to increase amount of available panel space.

b. 24 inch deep or greater that contain back panel: Supplied with studs for future installation of full-length side panels on both sides of enclosure.

9. Sufficient structural reinforcements to limit vibration and prevent distortion or damage to panel and components during shipment, installation, and operation.

C. Free-Standing Steel Enclosures

1. Single door: 12-gauge sheet steel.

2. Multiple door: 10-gauge steel.

3. Back panels and side panels: Minimum 12-gauge steel.

4. Full size back panels: Equipped with stiffeners and heavy duty supports as needed to ensure rigidity.

5. Exterior welds: Ground and sanded to smooth finish free of burrs.

6. Surface: Free of ridges, nuts, bolt heads, and similar protrusions.

7. Removable lifting lugs on top of enclosure designed to facilitate rigging and lifting of enclosure during installation.

8. Plugs: Provided to fill the lifting ring holes after installation is complete.

9. Full-length door with handle-operated three-point latch for front or rear access. Certain installations may require lockable door handles.

10. Floor stands or foot kits, when required, as shown on panel drawings.

11. Provide steel stiffeners as necessary to prevent deflection of back panels and doors due to heavy panel-mounted or door-mounted components.

a. Stiffener: Minimum 0.25 inches deep by 1-inch-wide tack welded to back of the panel or door.

D. Wall-Mounted Steel Enclosures

1. 14-gauge steel.

2. Back panels and side panels: Minimum 12-gauge steel.

3. Doors: Equipped with rubber gaskets and continuous hinges.

4. PLC enclosures: Equipped with 2-point latching door handles.

a. In wet or corrosive environments screw clamps may be required around perimeter of door to ensure tight seal.

b. Certain installations may require lockable door handles.

PANEL WIRING AND TERMINATIONS

A. Designed, manufactured and tested following latest standards listed herein.

B. Back panel and side panel wire bundles.

1. Run inside Panduit-style wire duct to facilitate tracing of circuits.

2. Exposed wire bundles connecting door-mounted devices and side panels to back panel are allowed.

3. Fastened down at suitable intervals, not to exceed 12 inches in length.

C. Segregate AC control power and signal wiring, and DC control power and signal wiring within panel as much as possible.

1. Group wires and cables according to function. Run in separate wire ducts and/or bundles.

2. Keep analog signals (4-20 mA and 0-10V) as far away from AC control power and signal wiring as possible.

E. Use flexible stranded copper wiring.

1. No solid conductor wire is permitted.

F. 120VAC and 24VDC wiring in panel: Type MTW, rated for operation at 600V at conductor temperatures not to exceed 90 deg. C.

G. Analog I/O and Instrumentation cable: No. 18 AWG, twisted, shielded single pair, instrumentation cable with minimum of six twists per foot and including continuous foil shield with drain wire. PVC-coated and rated for operation at 300V at conductor temperatures not to exceed 90 deg. C.

1. Individual Pair Shield: 1.35 mil, double-faced aluminum/synthetic polymer overlapped for 100% coverage.

2. Outer Jacket: 45‑mil nominal thickness.

3. Dimension: 0.31 inch nominal OD.

4. Conductors:

a. Bare soft annealed copper, Class B, 7-strand concentric, following ASTM B8.

b. 20 AWG, 7-strand tinned copper drain wire.

c. Insulation: 15‑mil nominal PVC.

d. Jacket: 4‑mil nominal nylon.

e. Pair conductors: Color-code Red (+), Black (-).

H. Minimum wire conductor sizing: Follow UL 508A standards for industrial control panels:

AC line side power : No smaller than 14 AWG.

AC line and control circuits: No smaller than 16 AWG.

DC line, load and control circuits: No smaller than 16 AWG.

Analog signal wiring: No smaller than 20 AWG.

I. Panel wiring: Color coded as follows:

BLACK

AC line, load and control circuits operating at line voltage.

RED

AC control circuits at line voltage which are controlled by a relay contact or other control element

YELLOW

Interlocked control circuits or any circuit supplied from external power source which cannot be de-energized by control panel disconnect.

J. Analog and instrumentation conductors: Color coded as follows:

1. RED: Positive (+)

2. BLACK: Negative (-)

K. Wire:

1. Run in continuous lengths from screw terminal to screw terminal.

2. Provide wire service loops to simplify removal of panel components.

3. Do not splice wiring.

4. Identified at both ends with white machine printed, sleeve-type labels.

a. Hand lettered wire labels are not allowed.

L. Wire numbering: Consistent with nomenclature used in control panel drawings.

M. 120 VAC Discrete Inputs: provide 120VAC to field equipment for signaling purposes only.

1. Wires: Red.

2. Field equipment: Equipped with 120VAC rated dry contacts and shall operate the dry contacts. All Emergency Stop and other alarm Inputs shall be wired Failed-Safe (normally closed), where the de-energized circuit represents an alarm.

3. For each dry contact, a pair of wires shall be installed and landed from the DPCS panel to the dry contact.

a. One wire shall be hot (+) the other shall be used to return power back to the DPCS when the dry contact is closed.

b. Both wires shall be continuous home-runs from field equipment panel to DPCS panel with NO intermediate terminations or splices.

c. A sample drawing will be provided and followed.

4. 120 VAC or 24VDC Relay Outputs: The DPCS panel will be Supplied with120VAC or 24 VDC control power from the field equipment for control purposes only.

5. Wires: Yellow to indicate foreign voltage.

6. DPCS Discrete Output card will provide a dry contact to switch power on and off. Each dry contact will only have one function and serve only one piece of field equipment (for example, a single dry contact cannot be used to turn on a pump and used to illuminate a panel light).

7. For each dry contact, a pair of wires shall be installed and landed from the DPCS panel to the field equipment.

a. One wire shall be hot (+) the other shall be used to return power back to the field equipment when the dry contact is closed.

b. De-energizing field equipment shall consequently de-energize the 120VAC or 24VDC control power.

c. Both wires: Continuous home-runs from field equipment panel to DPCS panel with NO intermediate terminations or splices.

d. A sample drawing will be provided and followed.

TERMINAL BLOCKS

A. Factory assembled on standard 35mm din rail mounted on standoffs to provide easy access to terminal screws.

1. Prefabricated terminal strips are not allowed.

B. Screw type with pressure plate (compressor type) requiring no lugs on connecting wires.

1. Rated for wire size 12 AWG or smaller.

2. Rated for 600 volt service.

3. Cage clamp style terminals are not allowed.

C. Furnished with engraved plastic markers displaying wire numbers or alphanumeric designation shown on drawings.

D. Reserve one side of each terminal block assembly for incoming field wiring.

1. Common connections and jumpers required for internal wiring on field side of terminal is not allowed.

2. No more than two wires terminated at any single screw terminal.

E. Through terminals and fuse terminals ganged together to create common voltage buses: Utilize internal screw jumpers.

1. Wire jumpers and comb jumpers are not allowed.

F. Fused terminal blocks.

1. Follow typical wiring diagrams for power distribution.

2. Required for overcurrent protection of analog input modules and discrete output modules not equipped with internal fuses or protected by interposing relays.

3. Provided with blown-fuse indicator and fast-acting, 5 x 20mm fuses, unless approved otherwise.

4. Cross section not greater than 8mm.

G. Terminal block assemblies for analog input and output channels.

8. Include ground terminals that connect directly to panel ground through din rail.

9. Ground terminals: Green and yellow in color.

H. Feed through terminal blocks: High density with cross section not greater than 2.5mm.

I. Approved Manufacturer.

10. Weidmuller brand

11. Or equal.

Terminal Type Wiedmuller Cat. No.

*Note: Discrete inputs terminal block assemblies require 2-tier terminals. The top tier is used for the individual inputs. The terminals on the bottom tier are ganged together using internal screw jumpers to form a voltage bus for wetting of field contacts.

PANEL MOUNTED DEVICES

A. Analog signals.

B. Panel and enclosure.

C. Instruments, pilot devices or operator panel mounted on outside of enclosure:

D. Panel mounted devices:

1. Mounted on din rail whenever possible

a. Din rail segments: Extended to include unused panel space.

a. Display device and/or descriptive names.

1) Engraved plastic nameplates or labels printed with indelible ink. Hand lettered markers are not allowed.

INTERPOSING RELAYS

A. Used when field equipment being monitored is not compatible with panel voltage.

1. Coils rated to match field equipment.

2. Contacts rated for no less than 5A.

3. Only one Form C contact per relay.

4. LEDs to indicate when coil is energized.

5. Manual override switches for testing.

6. Turck/Releco type C12-A21X or equal.

D. Provide surge suppressors on DC operated relay coils to reduce high transient voltage generated when circuit to operating coil is opened.

POWER DISTRIBUTION

A. Control panels: Furnished with two 120VAC, 20A-rated circuits.

1. Line filtered circuit for powering controllers, relay outputs, field contacts for digital inputs, 24VDC power supply, instrumentation, etc.

2. Auxiliary circuit for powering enclosure lights and utility receptacle.

1. Provide master disconnect switch and auxiliary branch circuit protectors (miniature circuit breakers).

1. Circuit breakers: Used on AC inputs to power supplies and auxiliary circuits.

2. Provide fused terminal blocks for 24VDC-powered devices and for connecting power to bottom tier of digital input terminal block assemblies.

1. Input terminals, branch circuit protectors, and fuse terminals: Mounted on din rail and grouped according to function.

1. Fuse terminals for digital input terminal block assemblies: Mounted next to digital input terminals.

1. Auxiliary Branch Circuit Protectors: Siemens Series SY with trip characteristic C, or equal.

1. Panel Power Supply, UPS and Battery

1. Provide DPCS panel with 24VDC power supply rated for either 5A or 10A.

2. Power supplied: Meet or exceed the following specifications.

1. Power Line Transient Protection.

1. Provide panels containing solid state electronic equipment with line voltage surge suppressor, provided with:

a. Surge arrester.

b. RFI filter.

c. Voltage clamp.

d. Terminals for incoming and load wires that shall trip power feed circuit breakers.

e. Automatic device reset.

f. Din rail mountable.

2. Approved Manufacturers.

1. ASCO brand 120VAC, 20A SURGE SUPRESSOR MODEL 277 .

1. Wiring.

Analog Wiring: No. 18 AWG, twisted, shielded single pair, instrumentation cable designed for noise rejection for process control, computer, or data log applications and following NEMA WC 55. Belden 88760 or equal.

a. Outer Jacket: 45‑mil nominal thickness.

b. Individual Pair Shield: 1.35‑mil, double-faced aluminum/synthetic polymer overlapped for 100 percent coverage.

c. Dimension: 0.31-inch nominal OD.

d. Conductors:

Additional guidelines Home runs from device’s terminal to panel’s terminal blocks with no intermediate connections or splices.

Intended and designed for use with 24 VDC or less: Considered Low Voltage.

Wire Identification Labels: White polyolefin heat shrink type.

Printed Labels: Produced using Brady Pro Plus marker printer or equal.

PILOT DEVICES

Selector Switches, Push buttons and Indicating Lights.

Selector switches, push buttons and indicating lights supplied: Heavy duty, NEMA 4/13, and UL listed.

Manufacturers:

Allen-Bradley Series 800T Or equal Selector Switches and Pushbuttons.

Supplied with operator mechanisms, appropriate number of contact blocks and any necessary legend plates bearing pertinent information.

Label contact block terminals for identification purposes and contain not less than one single-pole, double-throw contact.

Contact blocks: Heavy duty type, 10 amperes breaking current at 120 VAC.

Where contact blocks are handling low-level signal currents, contact material shall be gold or gold flashing over silver and rated 0.5 amperes at 120V AC.

Pushbuttons.

Provide stop and emergency pushbuttons in red, unless approved otherwise.

Provide other pushbuttons in black unless approved otherwise.

Use following color code for lenses of indicating lights:

FUNCTION COLOR FUNCTION COLOR

ON Red HIGH White

OFF Green AUTOMATIC White

CLOSED Green MANUAL Blue

OPEN Red LOCAL Blue

LOW White REMOTE White

FAULT White POWER ON White

TRIPPED White Low Level Bypass Red

Pushbutton operation: Momentary.

Provide pushbuttons with flush head bezels.

Selector Switch operation:

Maintain switch operation for local-remote, auto-manual, computer-manual, pump selection in all positions.

Spring return selector switches: Required following Drawings.

Indicating lights:

LED push-to-test type, voltage rating of 12-130VAC/VDC. It has a contact configuration of 1NO, 1NC.

CONTROL RELAY

Provide UL listed control relays supplied by same manufacturer to assure similar appearance and uniform operating characteristics.

All relays shall be sized for the load conditions.

Use DPDT or 4 PDT contacts as required by circuit and following Drawings.

Coil Voltages: 120VAC, 60Hz or 24VDC unless approved otherwise.

Light duty relays, less than 5 amps load.

General purpose machine tool relays with convertible contacts mounted on a standard mounting strip.

Shall have 10 amp rated Silver Cadmium Oxide contacts or contact material of comparable contact properties.

Shall have LED and mechanical visual indicators to show if relay is energized or not.

Multiple relay modules may be used, when approved by the Engineer.

Relay and base shall be approximately 22.5 mm in width. The base shall have a retaining clip. The base shall have a removable bracket so it can be panel or din rail mounted.

Shall have a pull-to-test button with manual latching.

Relay plugs and sockets: pin type.

Plug compatible with at least one other manufacturer’s relay with equal specification.

Manufacturer:

RELECO

OMRON Model MK.

Potter & Brumfield Series KRPA.

TIME DELAY RELAY

Provide UL listed time delay relays by same manufacturer to assure similar appearance and uniform operating characteristics.

Operate relay coils at 8 amperage 250 V AC and 30 VDC maximum contact voltage, 8A, general purpose type.

Use SPDT or DPDT contacts as required by circuit and following drawings.

Contacts: single contact, AgNi, 10 A rated operational current. Max AC loas 2500 VA and Max DC load 150W and 70W at 24V/220V respectively.

Operate relay coils at 120 V AC, plus or minus 15 percent, 60 Hz unless approved otherwise.

Install adjacent to one another on provided universal mounting strips using captive mounting screws.

Provide solid state timing units:

Relay action: Either on-delay or off-delay as shown on drawings.

Timing: Adjusted by self-contained potentiometer.

Repeat accuracy: Plus or minus 2 percent of the time setting or 20ms.

Timing ranges (dip switches): 0.6s, 6.0s, 60s, 6 min or 60 min.

Minimum reset time: <90 ms for one-delay.

Approved manufacturers:

RELECO CMD

DIGITAL DISPLAY

Provide a LED programmable process meter display with up to four setpoint outputs, implemented on plug-in cards with the following features:

Power 85-250VAC 60 Hz, 15VA or 11 to 36 VDC, 11 watts.

Annunciator:

MAX and MIN readout selected Totalizer Four setpoints alarms Unit label Response time: < 50 msec Memory: non-volatile E2PROM Nema 4X/IP65 Communication, relay card, analog output cards (options) Manufacturer:

Red Lion PAXP

DIGITAL TIMER

Provide din mount industrial multifunctional digital timer with the following features:

Type: Multifunction Digital Timer.

Display: 4-digit, 12mm high, negative transmissive LCD with tricolor (Red/Green/Orange) indication for process value.

Input: Universal DC voltage input (NPN/PNP switchable).

Output: Relay output (SPDT) or transistor output.

Power Supply: AC 120V and 24V or DC 12-24V models available.

Programming: Easy setting via front panel DIP switches or up/down keys.

Body: Ultra-compact, short body depth (59mm for specific models).

Protection: IP66/NEMA 4X rated for wet/dusty conditions.

Memory: Non-volatile EEPROM for settings.

Functions: Single-stage timing, Twin Timer mode for cyclic control, output counter.

Security: Front panel key protection.

Manufacturer:

OMRON H5CX-_-N Series.

PROGRAMMABLE LEVEL CONTROLLER

Provide a level programmable controller with the following features:

Input: Level programmable controller Signal input: Intrinsically safe any range within 0-50mA or 0-10V Output: four (4) SPDT relay outputs Power: Universal Power, 21.6-375Vdc or 90-260Vac Analog Output: Programmable Analog Output, any range between 0-20mA and 0-10V.

Housing/Enclosure: DIN-style housing mounts on 35mm DIN-rails.

Configuration/Setup: PC Configurable, USB Cable, Face-plate configurable.

Configurable alarms: High/low and rate-of-change alarms.

Hazardous Area Certifications: Non-Incendive/Div. 2, Zone 2.

Front panel analog signal display, controller status and alarm indication.

Manufacturer:

Moore Industries SPA2IS

EXECUTION

GENERAL

Wiring Identification:

Identify wiring at each termination with heat shrinkable.

Analog Cables:

Provide heat shrinkable sleeves over outer jacket of cable and conductors at cable termination points.

Ground shield of cable at monitoring control panel.

FACTORY ACCEPTANCE TEST (FAT)

Refer to Specification Section 16750 for Pump Control Panel operation

Conducting Factory test as follows:

For analog inputs, at field terminals using sourcing meter, induce a 4 to 20 mA DC signal.

Test signal at 0 percent, 50 percent, and 100 percent.

Observe and record the change of state at panel control display and at the output terminal block.

For digital inputs, jumper applicable terminals at the field connection terminal block.

Observe and record the change of the control panel pilot lights, control relays and output terminal blocks.

For analog outputs.

a. Test output at 0 percent, 50 percent, and 100 percent at terminals within the control panel controller to output field terminal.

b. Otherwise, disconnect one associated loop wire or fuse from terminal within control panel and generate signal.

Test output at 0 percent, 50 percent, and 100 percent.

c. Observe and record the change of state at I/O at field device.

For digital outputs.

Otherwise, jumper the signal at terminal within DPCS RIO panel.

Observe and record change of state at I/O at field device.

**WSSC**

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