UPDATELOGFORTECHNICALPROVISIONSDIVISION18

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10/1/12 TECHNICALPROVISIONS
DIVISION18OPERATINGCONTROLS

18.2 Products Product Specifications

18.2.1 Programmable Logic Controller (PLC) Control Panel

Design Standards

All verbiage for the entire section 18.2.1 has been replaced with
the following:

Reference Attachment A, herein, titled Panel
Design and Control Panel Component Selection
Guide.

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18.2.2 Outdoor and Indoor RTU Enclosures

Section 18.2.2 (Outdoor and Indoor RTU Enclosures) has been
deleted in its entirety.

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The following section has been renumbered:

18.2.3 2 Instrumentation Equipment Specifications

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The following section has been renamed:

18.3.2 Enclosure Signal and Control Circuit Wiring

187

187

189

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18-1
DIVISION 18

OPERATING CONTROLS


18.1 General

18.1.1 General Description

The telemetry system shall provide communications between field facility and the Central Control
Facility via data radio. All field equipment furnished under this Section shall be installed at the
locations as specified or shown on the Contract Documents. The equipment furnished for the
Central Facility will be installed as specified or shown on the Contract Documents.

18.1.2 Scope of Work

The Contractor shall furnish and install transducing, indicating, telemetering, recording, and alarm
equipment together with remote cabinets, all as shown on the drawings and specified herein. The
telemetering equipment shall perform the functions as shown on the functional diagrams and shall
meet the requirements of the specifications. All equipment shall be as specified, no exceptions
taken.

18.1.3 Related Work Specified Elsewhere

Electrical work specified hereunder shall conform to the requirements of this Section and the
applicable requirements of the Section entitled "Electrical General Provisions."

18.1.4 Reference Specifications, Codes, and Standards

Without limiting the generality of other requirements of these specifications, all work specified
herein shall conform to or exceed the applicable requirements of the referenced documents to the
extent that the requirements therein are not in conflict with the provisions of this Section; provided
that where such documents have been adopted as a code or ordinance by the public agency having
jurisdiction, such code or ordinance shall take precedence.

The equipment, materials, installation, and other work shall conform to all applicable regulations,
standards, specifications and codes which are current as of the date of the final inspection for this
Contract, including, but not limited to, those which are established by the following sources:

1. Instrument Society of America (ISA)
2. National Electrical Manufacturers Association (NEMA)
3. Occupational Safety and Health Administration (OSHA)
4. National Electrical Testing Association (NETA)
5. American National Standards Institute (ANSI)
6. National Fire Protection Association (NFPA)
7. Institute of Electrical and Electronic Engineers (IEEE)
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8. National Electrical Code (NEC)
9. Insulated Cable Engineers Association (ICEA)
10. Local power and telephone companies
11. Local authorities having jurisdiction over the work

Where the requirements set forth in these specifications or on the drawings are greater or more rigid
than the mandatory requirements referenced above, the applicable specifications or drawings shall
govern.

In the case of conflict between any mandatory requirements and specifications or drawings, the
mandatory requirements shall be followed in each case, but only after submitting such proposed
changes to the Owner for approval.

Nothing contained in these specifications or shown on the drawings will be so construed to conflict
with any national, state, municipal, or local laws or regulations governing the installation of work
specified herein, and all such acts, ordinances, and regulations, including the National Electrical
Code, are hereby incorporated and made a part of these specifications. All such requirements will
be satisfied by the Contractor at no additional expense to the Owner.

The drawings and specifications are complimentary to each other; what is called for by one shall be
as binding as if called for by both. If a conflict between drawings and specifications is discovered,
this shall be referred to the Owner as soon as possible for resolution. Should a conflict exist
between the drawings, specifications, and/or mandatory requirements (i.e., codes, ordinances, etc.),
it will be assumed that the more expensive method has been estimated, unless such alternate has
been agreed to prior to submission of bids.

18.1.5 Contractor Submittals

Shop Drawings: It is incumbent upon the Contractor to coordinate the work specified in these
Sections so that a complete instrumentation, computer, and control system for the facility will be
provided and will be supported by accurate shop and record drawings including an electronic
version in AutoCad, Landdesk Version 2005. Interface between existing instruments, existing
control panels, motor control centers, starters, control valves, flowmeters, chemical feeders, and
other equipment related to the instrumentation, control, and SCADA system shall be included in the
shop drawing submittal.

In these Contract Documents all systems, meters, instruments, and other elements are represented
schematically and are designated by numbers, as derived from criteria in Instrument Society of
America Standard ANSI/ISA S5.1. The nomenclature and numbers designated herein and on the
drawings shall be employed exclusively throughout shop drawings, data sheets, and similar
materials. Any other symbols, designations, and nomenclature unique to the manufacturer's
standard methods shall not replace those prescribed above, used herein, and on the drawings.

Should an error be found in a shop drawing during installation or start-up of equipment, the
correction, including any field changes found necessary, shall be noted on the drawing and
submitted finally "as-built" prior to acceptance of the project.
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Analog and SCADA System Hardware: This submittal shall be included in a singular, all-inclusive
submittal which shall include but not be limited to:

1. A complete index appearing in the front of each bound submittal volume. System
groups shall be separated by labeled tags.

2. A complete system block diagram.

3. Loop Diagrams: Drawings showing definitive diagrams for every instrumentation
loop system: These diagrams shall show and identify each component of each loop
or system using method, legend, and symbols from ANSI/ISA S5.4, extending the
format of ANSI/ISA S5.1 The loop diagram shall also show the spare loops and/or
spare I/O.

4. Loop description and/or facility operations descriptions.

5. Installation, mounting, and anchoring details for all components and assemblies,
including access requirements and conduit connection or entry details.

6. Panel wiring and/or diagrams shall be prepared and the field wiring integrated. They
shall include the following information:

a. Name of panel

b. Wiring and piping sizes and types

c. Functional name and manufacturer's designation for items to which wiring
and piping are connected

d. Terminal strip numbers

e. Electrical control schematics in accordance with ANSI standards

7. Field wiring and piping diagrams shall be prepared and be integrated with the panel
wiring diagram. They shall include the following information:

a. Wiring and piping sizes and types
b. Conduits in which wiring is to be located
c. Panel (e.g. RTUs, etc.) termination strip numbers
d. Location, function name, and manufacturer's designation of items to which
wiring and piping are connected

8. Drawings showing schematic diagrams for control circuits. Complete details on the
circuit interrelationship of all devices within and outside each Control Panel shall be
submitted using schematic control diagrams. The diagrams shall show numbered
terminals on components together with the unique number of the wire to be
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connected to each terminal. The diagram shall also show terminal assignments from
all primary measurement devices, such as flowmeters, and to all final control
devices, such as samplers, pumps, valves, and chemical feeders.

9. Interface with the existing control and monitoring system. This shall include any
and all modifications made to existing measurement and control circuits, equipment,
and wiring. It is the responsibility of the System Supplier to ascertain actual field
conditions of the existing circuits, equipment, and wiring. The Owner will provide
to the Contractor copies of all drawings and data that the Owner can find that show
such existing conditions. The Owner makes no representation as to the
completeness nor correctness of any such drawings and data and cannot guarantee
that complete or partial data exists for any of the facilities included in this contract.
Lack of such drawings shall not alleviate the contractual responsibility to ascertain
and implement interfaces and modifications to existing measurement and control
circuits, equipment, and wiring.

10. Complete and detailed bills of materials: A bill of material list, including quantity,
description, manufacturer, and part number, shall be submitted for each field-
mounted device or assembly, cabinet assemblies and subassemblies as well as for
the central computer system. Bills of material shall include all items within an
enclosure.

11. Data sheets for each component, together with a technical product brochure of
bulletin.

The data sheets shall show:

a Component functional description used herein and on the drawings;
b. Manufacturer's model number or other product designation;
c. Project tag number used herein and on the drawings;
d. Project system of loop of which the component is a part;
e. Project location or assembly at which the component is to be installed;
f. Input and output characteristics;
g. Scale range and units (if any) and multiplier (if any);
h. Requirements for electrical supply (if any);
i. Requirements for air supply (if any);
j. Materials of construction and of component parts to be in contract with, or
otherwise exposed to, process media;
k. Special requirements or features, such as specifications, for ambient
operating conditions;
l. Features and options which are furnished.

12. A separate technical brochure or bulletin shall be included with each instrument data
sheet. The data sheets shall be indexed in the submittal by systems or loops, as a
separate group for each system or loop. If, within a single system or loop, a single
instrument is employed more than once, one data sheet with one brochure or bulletin
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may cover all identical uses of that instrument in that system. Each brochure or
bulletin shall include a list of tag numbers for which it applies. Special options and
features which are furnished shall be identified.

13. Calibration, adjustment, and test details for all components and systems.

14. A list of recommended spare parts covering items which are furnished under this
Contract with the name, address, and phone number of the manufacturer and
manufacturer's local service representative or distributor of these parts.

Technical Manuals: Three (3) final sets of technical manuals shall be supplied for the Owner in
accordance with the Section entitled "Contractor Submittals," as a condition of acceptance of the
project. Each set shall consist of one or more volumes, each of which shall be bound in a standard
size, three-ring, looseleaf, vinyl plastic, hard-cover binder suitable for bookshelf storage. Binder
ring size shall not exceed three inches.

1. In addition to updated shop drawing information reflecting actual existing
conditions, each set of technical manuals shall include installation, connection,
operating, calibration, set points (e.g. pressure, pump control, time delays, etc.)
adjustment, test, troubleshooting, maintenance, and overhaul instructions in
complete detail. This shall provide the Owner with comprehensive information on
all systems and components to enable operation, service, maintenance, and repair.
Exploded or other detailed views of all instruments, assemblies, and accessory
components shall be included together with a complete list of parts and ordering
instructions.

2. Spare Parts List: The Technical Manual shall also include a list of recommended
spare parts for all the equipment furnished under this Section. After final system
acceptance, the list shall be annotated to indicate which items, if any, and quantity
are furnished as part of this Contract. The list shall also be furnished in accordance
with the section entitled "Contractor Submittals."

18.1.6 Quality Assurance

Unless otherwise specified, each individual instrument shall have a minimum accuracy of +0.5
percent of full scale and a minimum repeatability of +0.25 percent of full scale.

Installation Supervision: The System Supplier shall furnish services and technical information as
necessary to ensure that the instrumentation and SCADA system equipment is installed in a proper
and satisfactory manner. These services shall include, but not be limited to, providing the installing
contractor with information and direction prior to commencement of the installation work, periodic
inspections during the construction period, answering of all questions regarding the installation and
hook-up, and a complete check of the completed installation to insure that it is in conformance with
the requirements of the equipment manufacturer and the Contract Documents.

Calibration: The System Supplier shall furnish the services of trained technicians to perform a
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complete system calibration. Calibration shall be in accordance with subsection entitled
"Calibration, Testing, and Start-up" under the "EXECUTION" portion of this specification section.

Field Tests: The Contractors attention is directed to the article "EXECUTION" of this Section
which delineates all the tests that are required to be performed in the field in order to demonstrate
compliance with the Contract Documents.

18.1.7 Storage and Handling

All equipment and materials delivered to the job site shall be stored in a location which will not
interfere with the operations of other contractors or the Owner. Storage and handling will be
performed in a manner that will afford maximum protection to the equipment and the materials. It
is the Contractors responsibility to assure proper handling and on-site storage of instrumentation
and control equipment in accordance with the System Supplier's recommendations.

18.1.8 Environmental Conditions

The instrumentation, controls, and SCADA systems shall be designed and constructed for
satisfactory operation and long, low maintenance service under the following environmental
conditions:

1. Central Computer System:

a. Temperature range: 10 through 40 Celsius (50 through 104 Fahrenheit).
b. Thermal shock: 0.55 Celsius (1.0 Fahrenheit) per minute maximum
c. Relative humidity: 20% through 80% (non-condensing)

2. Remote Site Equipment:

a. Ambient temperature range: -18 through 60 Celsius (0 through 140
Fahrenheit)
b. Thermal shock: 1.0 Celsius. (1.8 Fahrenheit) per minute maximum
c. Relative humidity: 100% maximum

18.1.9 Service Requirements

The Contractor shall provide jobsite visits and services of a manufacturer's technical field
representative for calibration, testing, and startup of the following items.

1. Level Transmitters
2. Pressure Transmitters
3. Chemical Analyzers and Feeders
4. Flow Transmitters

At no separate additional cost to the Owner, the Contractor shall include the following services of
qualified technical representatives of the System Supplier (see Installation, Calibration, Testing, and
Start-up herein):

1. Supervise installation and connection of all instruments, elements, and components
of every system, including connection of instrument signals to primary measurement
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elements and to final control elements such as VFD, pumps, valves, and chemical
feeders.
2. Make all necessary adjustments, calibrations, and tests.
3. Instruct operating and maintenance personnel on the instrumentation. This time shall
be in addition to whatever time is required for other facets of work at the site and
shall be the Owners normal working days and hours.

18.1.10 Guarantee

The Contractor shall guarantee the performance and the hardware of all the instrumentation, control,
telemetry, and SCADA equipment, as specified herein, for a period of one year following the date
of completion and formal acceptance of the Work as specified under the General Conditions of
these specifications. To fulfill this obligation, the Contractor shall utilize technical service
personnel designated by the System Supplier to which the Contractor originally assigned project
responsibility for instrumentation. Services shall be performed within three calendar days after
notification by the Owner.

Equipment and materials which do not achieve design requirements after installation shall be
replaced or modified by the System Supplier to attain compliance, at no additional cost to the
Owner. Following replacement or modification, the Contractor shall retest the system and perform
any additional procedures needed to place the completed system in satisfactory operation and attain
design compliance approval from the Owner.

All parts, material (excluding consumables), labor, travel, subsistence, or other expenses incurred in
providing all the services and service visits during the one year warranty period shall be borne by
the System Supplier under the guarantee.

The warranty period shall start when the work has been completed and accepted by the Owner.

18.2 Product Specifications

18.2.1 Control Panel Design Standards

Reference Attachment A, herein, titled Panel Design and Control Panel Component Selection
Guide.

18.2.2 Instrumentation Equipment Specifications

Well Level Measurement System, Capacitance/Admittance: The level measurement system shall
consist of a sensing wire, an electronic transmitter, and interconnecting signal cable.

The transmitter shall be a solid state unit with 4-20 mA output with a maximum load resistance of
650 ohms at 24 VDC. The transmitter shall have span-adjustable switches, non-interacting zero,
and span fine tuning adjustments, transient (lightning/surge) protection and a selectable time delay
for response output.

The sensing wire shall be
5
/32-inch OD, flexible polypropylene covered cable, have spacers every
four feet, have stainless steel weight on the end, and have a flexible PVC boot at the top. The cable
length shall be 400 feet.
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The transmitter shall be mounted at the top in a weather-proof conduit housing with NPT
connections for the sensing wire/flexible boot and a NPT connection for the 4-20 mA signal
cable.

The well level measurement system shall be powered by an external 24 VDC power supply and
shall be a Drexelbrook or Sigma Controls, Inc. liquid level pressure probe, no substitutions.

Pressure Transmitters: Pressure transmitters shall be two-wire devices with the following features:
continuously adjustable span, zero, and dampening adjustments; integral indicator scaled in
engineering units, solid state circuitry, and 4-20 mA output. Accuracy shall be no greater than
+0.25 percent of span. Process wetted materials shall be 316 stainless steel. Body material shall be
316 stainless steel. Process connections shall be -inch NPT.

Pressure transmitters shall be Rosemount Model 3051, no substitutions.

Flowmeter Transmitters: Flowmeter transmitter shall be McCrometer Model Flow Com, V-Cone,
Magmeter, or EMCO Unimag.

18.3 Execution

18.3.1 Installation

General: Under the supervision of the System Supplier and in accordance with the manufacturer's
instructions, all systems specified in the Contract Documents shall be installed, connected,
calibrated, and tested; and, in coordination with the Owner, shall be started to place the system in
operation. This shall include final calibration in concert with equipment specified elsewhere in
these Contract Documents.

Nothing in this part of the specifications shall be construed as requiring the Contractor to utilize
personnel supplied by its designated System Supplier organization or any division thereof, to
accomplish the physical installation of any elements, instruments, accessories, or assemblies
specified herein. However, the Contractor shall employ installers who are skilled and experienced
in the installation and connection of all elements, instruments, accessories, and assemblies.
Electrical work shall be performed as specified in the applicable sections of Division 6.

The locations of equipment are approximate, unless dimensioned. The exact locations and routing
of wiring and cables shall be governed by structural conditions and physical interferences and by the
location of electrical terminations on equipment. Where job conditions require reasonable changes
in approximate locations and arrangements, the Contractor shall make such changes without extra
cost to the Owner.

All equipment shall be located and installed so that it will be readily accessible for operation and
maintenance. The Owner reserves the right to require minor changes in location of equipment prior
to roughing in without incurring any additional costs or charges.

The Contractor and System Supplier shall review the existing site conditions and examine all shop
drawings for the various items of equipment in order to determine exact routing and final
terminations for all wiring and cables.

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Installation and Connection: The Contractor shall install and connect all field-mounted components
and assemblies under the criteria imposed by these specifications and the System Supplier. The
installation personnel shall be provided with a final reviewed copy of the shop drawings and data.
In building interior locations, conduits shall be surface-mounted on walls or ceilings wherever
possible, and run parallel to building lines. Conduits shall not be routed on floors in areas subject to
foot traffic. In exterior locations conduit shall be routed below grade. Where concrete or asphalt
slabs exist, they shall be sawcut, conduits installed, and the cut repaired to original condition.
Exposed conduits and/or raceway shall be installed perpendicular or parallel to building lines.

Signal and low voltage wiring shall be run separately from power and 120-volt control wiring. All
analog signal loops shall be fused.

Bends shall be formed with proper tool and to uniform radii and shall be made without deforming or
thinning the walls of the tubing. Plastic clips shall be used to hold individual plastic tubes parallel.
Ends of tubing shall be square-cut and cleaned before being inserted in the fittings. Bulkhead
fittings shall be provided at all panels requiring pipe and/or tubing entries.

The Contractor shall have a technical field representative of the System Supplier instruct installation
personnel on any and all installation requirements; thereafter, the technical field representative shall
be readily available by telephone to answer questions and supply clarification when needed by the
installation personnel.

Final Checks: After all installation and connection work has been completed, the technical field
representative shall check it all for correctness, verifying polarity of electric power and signal
connections, and all other similar details. The technical field representative shall certify in writing
to the Contractor that for each loop or system checked out, all discrepancies have been corrected by
the installation personnel.

Removal of Abandoned Equipment: All existing instrument and control equipment that is no longer
required after the new system has been put into service shall be removed and delivered to the Owner
by the Contractor.

18.3.2 Control Circuit Wiring

Wiring Installation: All wires shall be run in plastic wireways except field wiring, wiring run
between mating blocks in adjacent sections, wiring run from components on a swing-out panel to
components on a part of the fixed structure, and wiring run to front panel-mounted components.
Wiring run from components on a swing-out of front panel to other components on a fixed panel
shall be made up in tied bundles. These bundles shall be tied with nylon wire ties and shall be
secured to panels at both sides of the "hinged loop" so that conductors are not strained at the
terminals. Signal and low voltage wiring shall be run separately from power and 120 volts control
wiring.

Wiring run to control devices on the front panels shall be tied together at short intervals with nylon
wire ties and secured to the inside face of the panel using adhesive mounts with screws.

Wiring to rear terminals on panel-mount instruments shall be run in plastic wireways secured to
horizontal brackets run above or below the instruments in about the same plane as the rear of the
instruments.

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Conformance to the above wiring installation requirements shall be reflected by details shown on
the shop drawings for the Owners review.

Wire marking: Each signal, control, alarm, and indicating conductor connected to a given electrical
point shall be designated by a single unique number which shall be shown on all shop drawings.
These numbers shall be marked on all conductors at every terminal using white numbered wire
markers which shall be plastic-coated cloth covered with clear heat shrink tubing or permanently
marked heat-shrink plastic and must be durable, smudge and fade resistant.

18.3.3 RTU I/O Configuration

Listed References: A list of the I/O requirements (including used, future signals, and implemented
spares) for each RTU is provided through the database list of the existing Central Computer System.

Additional Requirements: Any power supplies, signal isolators, converters, interposing relays, etc.
that are necessary to make existing signals and equipment compatible with the I/O cards shall be
furnished and installed as a part of this Contract.

The input/output signals to be connected to the new RTUs shall be only the existing input/output,
plus any new instruments furnished under this contract, unless otherwise noted.

18.3.4 Calibration, Testing, and Start-up

Calibration: All instruments and systems furnished by the Contractor shall be calibrated after
installation, in conformance with the component manufacturer's instructions. This shall provide that
those components having adjustable features are set carefully for the specific conditions and
applications of this installation and that the components and/or systems are within the specified
limits of accuracy. Defective elements which cannot achieve proper calibration or accuracy, either
individually or within a system, shall be replaced. This calibration work shall be accomplished by
the technical field representatives of the System Supplier whom the Contractor shall require to
certify in writing that for each loop of system, all calibrations have been made and that all
instruments are ready to operate.

Proof of Conformance: The burden of proof of conformance to specified accuracy and performance
is on the Contractor using its designated System Supplier. The Contractor shall supply necessary
test equipment and technical personnel if called upon to prove accuracy and/or performance, at no
separate additional cost to the Owner, wherever reasonable doubt or evidence of malfunction or
poor performance may appear.

Testing: All systems shall be exercised through functional and operational tests in the presence of
the Owner in order to demonstrate achievement of the specified performance. Operational tests
depend upon completion of work specified elsewhere in these Contract Documents. The scheduling
of tests shall be coordinated by the Contractor among all parties involved so that the tests may
proceed without delays or disruption by uncompleted work.

Start-up: When all equipment and systems have been assessed by the Contractor to have been
successfully carried through complete operational tests with not less than a minimum of simulation
and the Owner concurs in this assessment, system start-up by the Owners operating personnel can
follow.

ATTACHMENT A

Technical Provisions Division 18
Operating Controls

Panel Design and Control Panel Component
Selection Guide

Page 1 of 25

Panel Desi gn and Cont r ol Panel
Component Sel ec t i on Gui de

(ATTACHMENT A TO TECHNICAL PROVISIONS
DIVISION 18, OPERATING CONTROLS)













Document Control Panel Design and Component Selection Guide
Revision Number 2.00
Effective Date Oct 2nd 2012



Page 2 of 25

History
Revision Date Description of Change
1.00 08/31/2012 Initial Release
2.00 10/2/2012 Revisions

Contents
1 Introduction ............................................................................................................................ 4
2 Panel Design Requirements .................................................................................................. 4
2.1 Design Cycle .................................................................................................................. 4
2.2 Panel Certification .......................................................................................................... 5
2.3 Environmental ................................................................................................................. 5
2.4 Panel Wiring ................................................................................................................... 5
2.4.1 Spare channels ....................................................................................................... 5
2.4.2 IO Wiring ................................................................................................................. 5
2.5 Grounding ....................................................................................................................... 6
2.5.1 Ground bus .............................................................................................................. 6
2.5.2 Components ............................................................................................................ 6
2.5.3 I/O DIN rails ............................................................................................................. 6
2.6 Component Fastening .................................................................................................... 6
2.6.1 Backpanel direct mounted components .................................................................. 6
2.7 Wire Duct ........................................................................................................................ 7
2.8 Labels ............................................................................................................................. 7
2.8.1 Exterior enclosure label (on door) ........................................................................... 7
2.8.2 Interior enclosure labels (door) ................................................................................ 7
2.8.3 Backpanel component labels .................................................................................. 7
2.8.4 Terminal block labels ............................................................................................... 8
2.8.5 Wire labels ............................................................................................................... 8
2.9 Spare Components Kit ................................................................................................... 8
2.9.1 Spare Parts ............................................................................................................. 8
3 Enclosure ............................................................................................................................... 9
3.1 Enclosure ........................................................................................................................ 9
3.2 Laptop Shelf (Door) ........................................................................................................ 9
3.3 Fan ................................................................................................................................. 9
3.4 Cabinet Heater ............................................................................................................. 10
3.5 Heater Control .............................................................................................................. 10
3.6 Active Cooling ............................................................................................................... 10
3.7 Lighting ......................................................................................................................... 10
3.8 Door Stops .................................................................................................................... 11
3.9 Intrusion Switch ............................................................................................................ 11
4 Panel Power Distribution ..................................................................................................... 12
4.1 Power Supply (24VDC) ................................................................................................ 12
4.2 UPS Controller .............................................................................................................. 12
4.3 Battery .......................................................................................................................... 13
4.4 DC Distribution Fuse .................................................................................................... 13


Page 3 of 25

4.5 Analog I/O Fuses .......................................................................................................... 13
4.6 Circuit Breakers (branch protection) ............................................................................. 13
4.7 Circuit Breakers (supplementary) ................................................................................. 14
4.8 Surge Suppression ....................................................................................................... 14
5 Terminals ............................................................................................................................. 15
5.1 Feed-Through Terminal Blocks .................................................................................... 15
5.2 Fused Terminal Blocks ................................................................................................. 15
5.3 Grounding Terminal Blocks .......................................................................................... 15
6 Miscellaneous Backpanel Components ............................................................................... 16
6.1 DC Intermediate Relay ................................................................................................. 16
6.2 DC Intermediate Relay Socket ..................................................................................... 16
6.3 AC Intermediate Relay ................................................................................................. 16
6.4 AC Intermediate Relay Socket ..................................................................................... 17
6.5 Wire Duct ...................................................................................................................... 17
6.6 DIN Rail Standoffs ........................................................................................................ 17
6.7 120VAC Convenience Receptacles ............................................................................. 17
6.8 Signal Isolators / Converters ........................................................................................ 17
6.9 Panel High Temperature Switch ................................................................................... 17
6.10 Low Water Cutoff Relay ................................................................................................ 18
6.11 Grounding Bars ............................................................................................................ 18
7 PLC Components ................................................................................................................ 19
7.1 Processor ..................................................................................................................... 19
7.2 Rack ............................................................................................................................. 19
7.3 PLC Rack Power Supply .............................................................................................. 19
7.4 Discrete Input Module ................................................................................................... 19
7.5 Discrete Output Module .............................................................................................. 200
7.6 Analog Input Module ..................................................................................................... 20
7.7 Analog Output Module .................................................................................................. 20
7.8 I/O Module Terminal Block (DI, DO, AI, AO) ................................................................ 20
7.9 Expansion Rack Module ............................................................................................... 20
7.10 Expansion I/O Cable ..................................................................................................... 20
7.11 Expansion Terminator .................................................................................................. 21
8 Networking ........................................................................................................................... 22
8.1 Ethernet Switch ............................................................................................................ 22
8.2 Ethernet Cables ............................................................................................................ 22
9 Appendix A - Wiring Requirements .................................................................................... 233
10 Appendix B - Large Backpanel Layout ................................................................................ 24
11 Appendix C - Large Backpanel Layout.25




Page 4 of 25

1 I nt r oduc t i on
This document represents the minimum design and component requirements that
must be met for Ranch California Water District (the District) control panels in
unclassified areas. For control panels in classified areas the District will need to be
consulted for further design requirements.

For multi-bay enclosures which include an MCC, this document applies to the controls
section of the enclosure.

2 Panel Desi gn Requi r ement s
The following tables summarize the Districts panel design requirements. Where check
boxes are provided, the District has the option to request a given design requirement,
and should be consulted on a per panel basis.

2.1 Design Cycle
The following table is a summary of design cycle milestones and deliverables that are
required at RCWDs option.

Design Element Required
Pre-fabrication submittal:
Submit panel drawings electronically, with completed BOM to RCWD in 11 x
17 pdf format, with two weeks allowed for review
Yes
Include panel designers electrical load (power supply) calculation work
sheet(s), in pdf and spreadsheet format (so equations can be reviewed)

Include panel designers heat load calculation work sheet(s), in pdf and
spreadsheet format (so equations can be reviewed)

Include panel designers wire duct fill calculation work sheet(s), in pdf and
spreadsheet format (so equations can be reviewed)

Panel designer panel factory acceptance test:
Unwitnessed panel FAT required
Yes
Submit unwitnessed panel FAT procedure for District review
Witnessed panel factory acceptance test with District personnel at panel shop
Operations and maintenance manual:
Containing product data sheets for all components in BOM with reference to
BOM line item numbers, in pdf format
Yes
As-built submittal:
Submit as-built panel drawings electronically, in 11 x 17 pdf and CAD
formats, consult RCWD for AutoCAD version required for CAD files
Yes


Page 5 of 25

2.2 Panel Certification
Certification Required
UL508A listing

2.3 Environmental
Design Element Requirement
Expected ambient temperature range 10 118F
Panel fan (external air) Always required (unless otherwise specified)
Heating Always required (for humidity control)
Internal temperature range Internal panel temperature to be maintained between 45
115F

2.4 Panel Wiring
All internal panel wiring is to meet the standards as described in the Rancho
California Water District Project Wire Requirements table in Appendix A of this
document.

Specified wire gauge represents the minimum gauge for that conductor type; all
conductors shall be sized appropriately for the electrical load they serve.

In addition to this table, use of Telefast style, flying lead, or premade I/O module
cables is not permitted.

2.4.1 Spare channels
Design Element Requirement
I/O channels Provide a minimum of 4 spare points of each I/O type, include
additional I/O modules as needed to meet this requirement
Pre-wiring All spare points prewired to terminal blocks

2.4.2 IO Wiring
Design Element Requirement
Digital input channels All to be 24VDC wired to terminal strips (unless specified otherwise)
Digital output channels All to be 24VDC outputs individually wired to interposing relays (unless
specified otherwise)
Analog input channels All to be 24VDC 4-20mA individually fused and wired to terminal strips
Analog output channels All to be 24VDC 4-20mA individually fused and wired to terminal strips



Page 6 of 25

2.5 Grounding
2.5.1 Ground bus
Design Element Requirement
Ground bus Two ground bus strips will be mounted directly to backpanel, bond
ground bus strips together with single conductor, at one end of strips
only, with 12AWG (green wire)

2.5.2 Components
Design Element Requirement
Enclosure door(s) Ground door(s) to backpanel ground bus bar with a single conductor of
12AWG (green) wire
Back panel Provided through ground bus bars mounted to back panel
Components Each control component to have single conductor of appropriate size
run to ground bus, do not ground control components to back panel

2.5.3 I/O DIN rails
Design Element Requirement
AI/AO, DI, DO rail All I/O DIN rails to be isolated from backpanel with insulated DIN-rail
standoffs as required per section 6.6
Grounding Each I/O rail to have a single ground terminal block, directly connected
to the ground bus with a single conductor of 14AWG (green) wire

2.6 Component Fastening
Design Element Requirement
Mechanical fastening Components mounted directly to back panel (e.g. wire ductrail, ground
rails, etc.), to be fastened with machine screws by drilling and tapping
the panel
Sheet metal and self-tapping tech screws are not permitted

2.6.1 Backpanel direct mounted components
Design Element Requirement
PLC Direct mount to backpanel (no DIN rail)
Power supply Direct mount to backpanel (no DIN rail)
UPS Direct mount to backpanel (no DIN rail)
Convenience receptacle Direct mount to backpanel (no DIN rail)



Page 7 of 25

2.7 Wire Duct
Design Element Requirement
Size All duct to be sized to account for I/O quantity PLC rack is capable of
(including existing spare channels and PLC rack capacity)
Duct color Gray
Voltage separation AC and DC wiring to be segregated as much as possible, especially for
analog I/O and network cables (refer to sample drawing in Appendix B)

2.8 Labels
2.8.1 Exterior enclosure label (on door)
Design Element Requirement
Type Black plastic (background) engraved with white lettering
Format Text in all capitals
Contents RCWD will define required door labels on a per panel basis (e.g.
enclosure name, door lights, door push buttons, etc.)
Fastening Mechanically fastened, corrosion resistant machine screw fasteners
Sheet metal and self-tapping tech screws are not permitted

2.8.2 Interior enclosure labels (door)
Design Element Requirement
Type Thermal transfer label, Hellermann Tyton 795 material or equivalent
Contents Short circuit rating of panel
Panel designer contact information
Panel fabricator contact information

2.8.3 Backpanel component labels
Design Element Requirement
Type Thermal transfer label, Hellermann Tyton 795 material or equivalent
Format Text in all capitals
Contents All standalone electrical components or assemblies (PLC rack, terminal
busses, etc.) to have label on backpanel adjacent to component with
component number listed as seen on the electrical drawings (e.g.
FU215)
Alignment All labels applied cleanly:
No bubbles, no ink smears
Square relative to adjacent wire duct and components
Consistent alignment


Page 8 of 25

2.8.4 Terminal block labels
Design Element Requirement
Type White plastic, computer printed black text, mechanically affixed to the
terminal (i.e. no stickers)
Label on each side of the terminal
Format Text in all capitals
Contents Wire number for the circuit passing through the terminal block
Orientation Numerically sequential - small to large:
From left to right for horizontally mounted terminals
From top to bottom for vertically mounted terminals

2.8.5 Wire labels
Design Element Requirement
Label type Heat shrink, computer printed black text
Format Text in all capitals
Label application Each control wire or cable shall be assigned a unique identification
number
All conductors of the same circuit shall have the same identification
number
Numerical reservations Wire numbers:
0-99 reserved for power distribution
100-199 reserved for digital inputs
200-299 reserved for analog inputs
300-399 reserved for digital outputs
400-499 reserved for analog outputs
500-599 reserved for loop isolators and converters
Location All wire labels visible, clear of wire duct and termination
All wire labels aligned the same distance from termination, consistent
relative to all other wire labels
All wire labels aligned so text is facing outwards (readable)

2.9 Spare Components Kit
2.9.1 Spare Parts
Design Element Requirement
Fuses Vendor shall supply:
Six spare fuses of each size
1 spare relay for each type used in the panel



Page 9 of 25

3 Encl osur e
3.1 Enclosure
Required
Rating, indoor non-corrosive environment: NEMA-12
Rating, outdoor non-corrosive environment: NEMA-4
Rating, corrosive environment: NEMA-4X
Hazardous environment: Discuss classification with District
Material: NEMA-12 / NEMA-4: Steel, NEMA-4X Stainless Steel
Depth: 18 minimum
Paint: White powder coat (indoor and outdoor enclosures)
Latching: Screw clamps around door perimeter with padlock hasp
Door: Preference, opens from right to left relative to facing front of enclosure
Part/Model No: Hoffman (model line not specified)

3.2 Laptop Shelf (Door)
Required
Type:
Folding,18x18workingsurface,mountedtodoor
Part/Model No: HoffmanAASHLF1818orapprovedequivalent

3.3 Fan
Required
Type: Fan,roundACAxial,externalfanhoodwithremovablefiltercover
Filters: (forexternalvent)Antiinsect
Part/Model No: Dayton4WT44orapprovedequivalent




Page 10 of 25

3.4 Cabinet Heater
Required
Type: Radiant
Voltage: 120VACinput
Power: Sizeforrequiredheating
Part/Model No: PfannenbergFLHlineorapprovedequivalent

3.5 Heater Control
Required
Type: Integratedhumidityandtemperaturecontrol
Voltage: Ratedfor120VACswitching,upto8Aresistive
Part/Model No: HammondSKTH012009orapprovedequivalent

3.6 Active Cooling
When required per heat calculations
Type: AirConditioner
Part/Model No: DiscusswithDistrictifairconditionerrequired

3.7 Lighting
Required
Type: Fluorescentbulbwithintegrateddoorswitch
Type: Nooutlet,coolwhitebulbcolor
Voltage: 120VACinput
Size: 18or24long,usemaximumpermittedbyenclosuresize
Part/Model No: SaginawSCELF16D18NOorapprovedequivalent,sizedasneeded




Page 11 of 25

3.8 Door Stops
Required
Type: Holdsdooropenat90degrees
Part/Model No: HoffmanALGDSTOP2orapprovedequivalent

3.9 Intrusion Switch
Required
Type: Mechanicalrotarymicroswitch(notaplunger)
Type: 1NO/1NCcontacts,adjustablerollerlever
Wiring: Circuitclosedwhendoorclosed,24VDC
Part/Model No: Dayton4VZD3orapprovedequivalent



Page 12 of 25

4 Panel Power Di st r i but i on
4.1 Power Supply (24VDC)
Required
Type: Nonredundant,switching,DINrailmount
Voltage: 120VACinput,24VDCoutput
Capacity: Sizedsuchthatsupplyisnotmorethan75%loadedwithinitialdesign
Ripple: Lessthan50mVpp
Features: Alarmcontact,minimum90%typicalefficiency
Part/Model No: PulsQS5.241orapprovedequivalent,sizedforcapacityasrequired

4.2 UPS Controller
Required
Voltage: 24VDCpowerinput,12VDCbatterycharging,24VDCoutput
Battery size: Sizedappropriatetochargebatterysizeused
Battery: External
Mount: DINrail
Features: UPSenableinput,ready,onbattery,andbatteryqualitystatuscontacts
Enable: Enabledwhenpanelmainbreakerison
Part/Model No: PulsUB10.241orapprovedequivalent




Page 13 of 25

4.3 Battery
Required
Type: Sealedleadacid
Voltage: 12VDC
Battery size: 18Ah(perbatteryused)
Batteries: 2minimumregardlessofruntimecalculations
Runtime: Controlpaneloperationalfor24hoursminimum
Part/Model No: UPGUB12180orapprovedequivalent

4.4 DC Distribution Fuse
Required
Fuse: x1,timedelay,250VAC,10A(sizedforloadasrequired)
Part/Model No: BussmannMDL10Rorapprovedequivalent

4.5 Analog I/O Fuses
Required
Type: Glass,x1
Ratings: 1/8A(125mA)fastacting,250VAC@200AI.R/125VAC@10KAI.R.
Part/Model No: BussmannAGC1/16orequivalent

4.6 Circuit Breakers (branch protection)
Required
Type: DINrailmountedminiature,UL489compliant,singlepole
Ratings: 10kAIC,Dprotectivecurve,standardboxterminals(norings)
Size: Sizedappropriatelyforload
Part/Model No: EatonWMZTseriesorapprovedequivalent




Page 14 of 25

4.7 Circuit Breakers (supplementary)
Required
Type: DINrailmountedminiature,UL1077compliant
Ratings: Dprotectivecurve,standardboxterminals(norings)
Size: Sizedappropriatelyforload
Part/Model No: EatonWMZSseriesorapprovedequivalent

4.8 Surge Suppression
Required
Type: Solidstate,DINrailmounted
Protection: LinetoNeutral,LinetoGround,NeutraltoGround
Voltage: 120VACoperating
Current: 20Aoperating,30,000Atotalpeaksurgeperphase
Other ratings: 4763Hzoperatingfrequency,compressionscrewterminals
Features: FormCcontactforremotemonitoring(OKindication)
Part/Model No: SolarSTFE20010Norapprovedequivalent




Page 15 of 25

5 Ter mi nal s
5.1 Feed-Through Terminal Blocks
Required
Type: Singlelevel,screwconnection
Ratings: 8kVsurgevoltage,41Anominalcurrent,1000Vnominalvoltage
Part/Model No: PhoenixContactUT63044131orapprovedequivalent

5.2 Fused Terminal Blocks
Required
Type: Singlelevel,forglass6.3mmx32mmfuses(x1)
Ratings: 6kVsurgevoltage,32Anominalcurrent,600Vnominalvoltage
Part/Model No: PhoenixContactUT6HESI3046401orapprovedequivalent

5.3 Grounding Terminal Blocks
Required
Type: Singlelevel,screwconnection
Ratings: 8kVsurgevoltage,57AMaximumcurrent
Part/Model No: PhoenixContactUT6PE3044157orapprovedequivalent




Page 16 of 25

6 Mi sc el l aneous Back panel Component s
6.1 DC Intermediate Relay
Required
Type: Compactpowerrelay(icecube),
Type: withintegratedindicatinglightandsuppressiondiode
Ratings: Coil24VDC,ContactsDPDT,10A@30VDC/110VAC
Ratings: 50,000,000operationsmechanicallife,500,000operationselectricallife
Part/Model No: IDECRH2BULDDC24Vorapprovedequivalent

6.2 DC Intermediate Relay Socket
Required
Type: StandardDINrailmount
Ratings: M3.5screwswithcaptivewireclamp,300V,10Arating
Part/Model No: IDECSH2B05orapprovedequivalent

6.3 AC Intermediate Relay
Required
Type: Compactpowerrelay(icecube),
Type: withintegratedindicatinglight
Ratings: Coil120VAC,ContactsDPDT,10A@30VDC/110VAC
Ratings: 50,000,000operationsmechanicallife,500,000operationselectricallife
Part/Model No: IDECRH2PULAC120Vorapprovedequivalent




Page 17 of 25

6.4 AC Intermediate Relay Socket
Required
Type: StandardDINrailmount
Ratings: M3screwswithcaptivewireclamp,300V,10Arating
Part/Model No: IDECSR2P05orapprovedequivalent

6.5 Wire Duct
Required
Type: Narrowslot,graycolor,mechanicallyfastened
Part/Model No: Thomas&BettsTYseriesorapprovedequivalent

6.6 DIN Rail Standoffs
Required
Type: ElectricallyinsulatedDINrailsupport
Part/Model No: PhoenixContactAB/NS1201141orapprovedequivalent

6.7 120VAC Convenience Receptacles
Required
Type: 15AGFCIduplexwithmetalcovermountedinmetalgangbox
Part/Model No: LevitonN7599seriesorapprovedequivalent

6.8 Signal Isolators / Converters
Required when needed
Type: Looppoweredisolatingamplifier,selectableinput,420mAoutput
Part/Model No: PhoenixContactMCRCLPUII42814058

6.9 Panel High Temperature Switch
Required
Type: Operatingrange113to127DegF,30DegFdifferentialreset
Part/Model No: StancorSTC120orapprovedequivalent



Page 18 of 25


6.11 Grounding Bars
Required
Type: 12screwlugs,14AWGto4AWGwirecopperwire
Part/Model No: SchneiderElectricPK12GTAorapprovedequivalent

6.10 Low Water Cutoff Relay
Required when needed
Type: Series16solidstatepluginmodule
Part/Model No: Warrick16DMB1B0


Page 19 of 25

7 PLC Component s
7.1 Processor
Required
Type: Nonredundant
Features: Level2processor,4MBmemory,12MBPCMCIAcard
Ports: (3total):1xUSB,1xModbus/Serial,1xEthernetModBus/TCP
Part/Model No: SchneiderElectricM340,BMXP342020

7.2 Rack
Required
Type: 8or12slotrack(8minimum)
Part/Model No: SchneiderElectricM340,BMXXBP0800orBMXXBP1200

7.3 PLC Rack Power Supply
Required
Type: Nonredundant
Voltage: 24VDCinput
Output: 16.8Wmaximum(sumof3.3VDCand24VDCrackbuses)
Rack output: Upto8.3Wat3.3VDCtorack,upto16.8Wat24VDCtorack
Part/Model No: SchneiderElectricM340,BMXCPS2010

7.4 Discrete Input Module
Required
Type: 24VDC,16isolatedinputs,currentsinking,1common,3.5mAperchannel
Part/Model No: SchneiderElectricM340,BMXDDI1602



Page 20 of 25

7.5 Discrete Output Module
Required
Type: Solidstate,24VDC,16outputsprotected,1common,0.5Aperchannel
Part/Model No: SchneiderElectricM340,BMXDDO1602

7.6 Analog Input Module
Required
Type: 4inputs,highlevelisolated,420mAcapable,16bitresolution
Part/Model No: SchneiderElectricM340,BMXAMI0410

7.7 Analog Output Module
Required when AOs present
Type: 2outputs,highlevelisolated,420mAcapable,15bitresolution
Part/Model No: SchneiderElectricM340,BMXAMO0210

7.8 I/O Module Terminal Block (DI, DO, AI, AO)
Required
Type: 20wayremovableterminalblock,cageclampwithcaptivescrew
Part/Model No: SchneiderElectricM340,BMXFTB2000

7.9 Expansion Rack Module
Required when expansion racks used
Type: M340BusXrackexpansionmodule
Part/Model No: SchneiderElectricM340,BMXXBE1000

7.10 Expansion I/O Cable
Required when expansion racks used
Type: BusX,angledcable,2x9waySUBDconnector
Part/Model No: SchneiderElectricM340,BMXXBC008K



Page 21 of 25

7.11 Expansion Terminator
Required when expansion racks used
Type: BusX,lineterminator,2x9waySUBDconnector
Part/Model No: SchneiderElectricM340,TSXTLYEX




Page 22 of 25

8 Net wor k i ng
8.1 Ethernet Switch
Required
Type: Unmanaged,DINrailmount,metalhousing
Specs: 24VDCinput,
Specs: 5xRJ45port(minimum),10/100Mbps,autonegotiationandcrossing
Part/Model No: PhoenixContactFLSWITCHSFN5TX2891152

8.2 Ethernet Cables
Required
Type: Cat5e
Color: SCADALANGreen,PLCLANBlue,I/OLANRed




Page 23 of 25

9 Appendi x A Wi r i ng Requi r ement s
# DESCRIPTION
WIRETAG
PHASE/
CODE
LETTER
WIRE
COLOR
NONFIELD
INSULATION
TYPE
(CONTROL
PANEL
ENCLOSURE)
FIELD
INSULATION
TYPE
MINIMUM
AWGSIZE
(ALL
STRANDED
COPPER)
INSULATION
CLASS
1
480/277VAC,
3PH
A Brown
MTWonly
#4and
largerXHHW
#6and
smaller
THWN
THHN
PerN.E.C. 600V
B Orange
C Yellow
N Gray
G Green
2
208/110OR240
VAC,3PH
A Black
MTWonly
#4and
largerXHHW
#6and
smaller
THWN
THHN
PerN.E.C. 600V
B
Red,orange
ifHileg
C Blue
N White
G Green
3
110/220VAC,
1PH
L1 Black
MTWonly
THWN
THHN
PerN.E.C. 600V
L2 Red
N White
G Green
4
110VACswitched
control
n/a Red MTWonly

16 600V
5
Analog
input/output
n/a Violet MTWonly

18 600V
6
Discrete
input/output
n/a Blue MTWonly

18
600V
7
D/Ointerposing
relaycontact
outputs
n/a Yellow MTWonly

18
600V
8 +24VDCpositive +24v
Brown,blue
switched
MTWonly

18
600V
9 24VDCnegative 24v Orange MTWonly
18
600V
10 +12VDCpositive +12v Red MTWonly
18
600V
11 12VDCnegative 12v Black MTWonly
18
600V
12 Shieldedpair
+ Whiteorred 18
600V
Black 18


Page 24 of 25

10 Appendi x B - Lar ge Panel Layout




Page 25 of 25

11 Appendi x C - Smal l Panel Layout