November 21, 1997

Contract \# **TW-0928**

SPECIAL SPECIFICATION

SECTION 16920-S

[MOTOR CONTROL CENTERS]{.underline}

Page

PART 1 - GENERAL

1.01 Scope

1.02 Requirements

1.03 Applicable Specification and Standards

PART 2 - PRODUCTS

2.01 General

2.02 Construction-Assembly

2.03 Basic Components

2.04 Bus Bars and Short Circuit Rating

2.05 Power Stabs

2.06 Control Wiring

2.07 Control Components

2.08 Indicating Lights

2.09 Nameplate

PART 3 - EXECUTION

3.01 General

3.02 Adjustments

3.03 Inspection

3.04 Operational Test

3.05 Shop Drawings

SPECIAL SPECIFICATION

SECTION 16920-S

[MOTOR CONTROL CENTERS]{.underline}

# PART 1 - GENERAL

## 1.01 [SCOPE]{.underline}

> The work covered by this section of the specifications includes the
> furnishing and installation of a complete motor control center (MCC)
> as described herein and as indicated on the drawings.

## 1.02 [REQUIREMENTS]{.underline}

> Comply with applicable provisions of Special Specification Section
> 16001-S, Electrical Work.

## 1.03 [APPLICABLE SPECIFICATION AND STANDARDS]{.underline}

A. The motor control centers covered by this specification shall be
designed and assembled in accordance with the applicable standards of
ANSI, IEEE, and NEMA including, but not limited to, the latest additions
of the following standards:

UL 508

ANSI/NEMA ICS1

ANSI/NEMA ICS2

UL 845

ANSI/NFPA 70

B. The motor control center and all components shall meet all
requirements of the latest National Electrical Code and the Occupational
Safety and Health Act.

# PART 2 - PRODUCTS

## 2.01 [GENERAL]{.underline}

A. All equipment and material shall be new and shall bear the
manufacturer\'s name and trade name. The equipment and material shall be
essentially the standard product of a manufacturer regularly engaged in
the production of the required type of equipment and shall be the
manufacturer\'s latest approved design.

B. All applicable equipment shall have Underwriters Laboratory or
another test laboratory approved by SNL Engineer label or listing.

C. MCCs shall be wired for NEMA Class I, Type B, as defined by NEMA
Standards Publications \"Industrial Control No. ICS-322, Part 22.

D. The MCC is to be three phase, four wire with full capacity neutral
termination plate, 60 Hz, with voltage and bus ratings as specified on
the drawings and integrally suitable for connection to an available
fault current of 42,000 amperes RMS symmetrical at the incoming line
terminals unless otherwise shown on contract drawings.

E. The MCC shall consist of one or more vertical sections bolted
together to form a rigid, free standing assembly and shall be so
designed as to permit future additions of vertical sections, and
interchanging of units. MCCs shall be constructed to meet or exceed the
requirements of the latest published standards of NEMA Publication ICS
2-322, and UL 845 for Motor Control Centers.

F. MCC shall be of \"Dead Front\" construction.

G. MCCs shall be as manufactured by Allen Bradley, General Electric,
Square \"D\", Westinghouse or approved equal.

## 2.02 [CONSTRUCTION-ASSEMBLY]{.underline}

A. Enclosure shall be NEMA 1 with gasketing (1G), unless otherwise
specified. All gasketing shall be closed cell neoprene or equivalent.

B. Incoming line lugs compartment shall be accessible from the top entry
rated to match the main horizontal bus rating, unless otherwise shown on
contract drawings. Incoming line lugs compartment shall be supplied with
conical washers lug mounting hardware and be designed to accept lugs for
copper-only conductors having NEMA 2-hole spacing dimensions (1-3/4\"
between hole centers).

C. Removable lifting angles shall be mounted full width at the top of
the motor control center line-up.

D. Vertical sections shall contain a 12-inch high horizontal wire way
for incoming line and wiring between sections located at the top of all
sections or 6-inch high minimum for structures utilizing center mounted
power bus. A 6 inch high horizontal wire way shall be located at the
bottom of all sections.

E. A separate removable vertical wire trough door shall be furnished for
each vertical section. The wire trough permits field wiring to units to
be secured in place in the wire trough area rather than drawn through
cutouts into the unit. Cable tie supports are to be furnished in the
vertical wire trough to hold cable and wiring in place. Each individual
unit compartment shall be provided with a side barrier to permit pulling
wire in the wire trough area without disturbing adjacent unit
compartments.

F. MCC vertical sections shall be totally enclosed freestanding,
self-supporting, well ventilated, front accessible only, and rated for
40°C ambient temperature.

G. All structural metal parts shall undergo a multi-step cleaning,
rinsing, and painting process resulting in complete coverage of uniform
thickness. This process shall be maintained and controlled by rigid
quality control standards.

H. Surfaces shall be painted in accordance with the following:
Standard - All interior and exterior surfaces (except back plates of
unit inserts) shall be painted ANSI 61 or 49 light gray. The back plates
of the unit inserts shall be painted ANSI 70 off white.

I. All unpainted parts, except bus work, shall be plated for corrosion
resistance.

## 2.03 [BASIC COMPONENTS]{.underline}

A. Each unit compartment shall be provided with an individual front
door. Starter and feeder tap unit doors shall be interlocked
mechanically with the unit disconnect device to prevent unintentional
opening of the door while energized and unintentional application of
power while the door is open. Means shall be provided for releasing the
interlock for intentional access and/or application of power.

B. Equip each motor control unit with a combination starter with a
molded case motor circuit protector type circuit breaker and a magnetic
starter. The motor circuit protector shall be an adjustable
instantaneous-only type. The magnetic starter shall include Class 20 (as
defined per ICS-2-222) overload relay protection unless specified on
contract drawings. The motor circuit protector, the magnetic starter,
and the overload heaters shall be sized to suit motor or load being
served.

C. The overload relays shall be phase \"trip-free.\" After an overload,
it shall be necessary to press and release the reset button to reset the
overload. After reset, depressing the reset button shall not affect
operation of the overload contact. Continuous depression of the reset
button shall not cause automatic reset of the contact. The overload
relay shall be of the contact reset type. Relays which are convertible
from manual to automatic reset function are not acceptable.

> A readily visible indicator shall be provided to indicate the tripped
> position of the overload. It shall be possible to add, remove, or
> replace overload assemblies without removing other starter components.
> Relay shall be available with a N.O. isolated auxiliary alarm contact.
>
> Overload relays which provide adjustable tripping current are
> unacceptable. The only means of adjusting tripping current shall be by
> changing heater elements.

D. Padlocking arrangements shall permit locking the disconnect device
OFF with the door closed or open.

E. Each magnetic starter shall be rated for full voltage non reversing,
across the line starting, unless otherwise noted on contract drawings.
Only one starter per cubicle will be permitted unless the starter is
reversing, two speed or a reduced voltage type. If a reduced voltage
starter is required, it shall be an auto-transformer closed transition
-type unless otherwise noted on contract drawings.

F. Each magnetic starter shall come with the NEMA type contactors. No
I.E.C. (European style) or NEMA rated I.E.C. type contactors will be
permitted.

G. All full voltage starter units through NEMA size 5 shall be of the
draw out type. Draw-out provisions shall include a positive guide rail
system and stab shrouds to absolutely ensure alignment of stabs with the
vertical bus. Power wiring to stabs shall be contained within the draw
out unit. Overload relays shall be reset from outside the enclosure by
means of an insulated button.

H. Combination starter unit specified with type B wiring shall contain
drawout split-type terminal blocks. In the LOCKOUT position, all
terminal blocks are split so that no foreign source of power can enter
the unit. Combination starter units Sizes 1-3 up to 48 inches high shall
be removable from the section without the need of disconnecting power or
control leads to the terminal blocks.

I. Control terminals shall be saddle or pressure plate type captive to
the screw head. All terminals shall be accessible for wiring, testing,
and maintenance without removing or disturbing other components on the
starter.

J. Combination motor controller units shall be equipped with individual
control power transformers with minimum size 100 VA or sized for load,
plus 50 VA, whichever is greater. Protect control transformers with two
fuses on the primary side and one fuse on the secondary side.
Transformers shall have secondaries rated at 120V and will be dry type.

K. Coils shall be thermoset, hot pressure encapsulated, identified with
manufacturer\'s name or trademark, catalog or replacement number,
voltage, and frequency.

L. Exact sizes and accessories of components shall be as indicated on
contract drawings.

M. Each starter for motors 5 hp and above is to be furnished with power
factor correction capacitors, unless otherwise noted on contract
drawings. Capacitors shall be sized per specific load, complying with
manufacturer\'s standard materials, design, recommended switching, and
construction in accordance with published product information, and as
required for a complete installation.

> Provide factory-assembled capacitors of types, sizes, ratings, and
> electrical characteristics indicated; for use with induction motors,
> and capable of correcting power factor to 95% or greater. Construct of
> internally fused, individually replaceable, unit cells enclosed in a
> cubicle in the MCC. Provide capacitors with discharge resistors which
> reduce voltage to 50 volts or less within 1 minute after capacitors
> are disconnected. The capacitors shall be connected on the line side
> of the overload heaters.

## 2.04 [BUS BARS AND SHORT CIRCUIT RATING]{.underline}

A. Main Horizontal Bus

> Power shall be distributed by means of a horizontal bus running the
> entire length of the MCC with a current rating as noted on the
> contract drawings. Provide for future extensions from either end by
> means of bolt holes or other approved methods. The main bus shall be
> copper enclosed in an isolated compartment at the top or center of
> each vertical section and shall be isolated by sliding barriers from
> wire troughs, starters and other areas. All bus and splice bar
> connections shall be accessible by sliding the barrier panels to the
> open position. Main bus splicing between shipping splits shall be
> accomplished from the front without any structural disassembly
> required.

B. Vertical Bus

> Each vertical bus shall be copper as standard and shall be 600A rated
> unless main horizontal bus is mounted in center of vertical section,
> then 300A rated. Full height of vertical bus bars are to be protected
> against accidental contact by a labyrinth barrier to provide
> insulation and isolation with shutters which automatically cover stab
> openings when units are withdrawn.

C. Bus Short-Circuit Bracing

> All power busses shall be braced to withstand a fault current of
> 42,000 amperes RMS symmetrical, unless otherwise noted on contract
> drawings.

D. Ground Bus

> A 1/4 inch by 2 inch copper ground bus shall be provided the entire
> length at the bottom of the motor control center line-up. Ground bus
> will be drilled and lugs furnished for the incoming line and each
> motor or circuit breaker feeder. The lugs will be sized for the ground
> conductors shown on the contract drawings.

## 2.05 [POWER STABS]{.underline}

A. The unit plug-in power stab assemblies shall be electrolytically tin
or silver plated copper for a low resistance connection and designed to
tighten during heavy current surges.

B. The stabs shall be backed by spring steel clips to provide and
maintain a high pressure, two point connection to the vertical bus. They
shall be free floating and self aligning during plug-in. Wiring from the
unit disconnecting means to the plug-in stabs shall not be exposed at
the rear of the unit. The power cable termination at the plug-in stab
shall be a maintenance free crimp type and shall be mounted in a two
piece support assembly. This support shall provide a separate isolated
pathway for each phase, thus minimizing the probability of a unit fault
condition reaching the power bus system.

C. Automatic shutters shall be provided for isolation of unused stab
openings. These shutters shall close concurrently with the removal of
unit plug-in stabs.

## 2.06 [CONTROL WIRING]{.underline}

Provide 600 volt, type TBS, or SIS control wiring with minimum rated
temperature of 90 degrees C. All control wiring shall be labeled on both
ends to match terminal wiring. Control circuits and indicating lights
shall be 120 volts located within each starter cubicle. Control circuit
conductors shall be grounded in accordance with the NEC and shall be
arranged so that an accidental ground will not start the motor.

## 2.07 [CONTROL COMPONENTS]{.underline}

A. Starters controlled by automatic devices shall be provided with a
Hand-Off Automatic selector switch mounted on the starter case and
connected so the motor can be manually operated regardless of the
position of the automatic control device. The selector switch shall not
be connected to supersede any safety device or interlock.

B. Provide starters with a sufficient number of auxiliary contacts (N.O.
and/or N.C.) to accomplish the control and interlocking schemes
required. Provide additional relays if required to obtain the correct
control.

C. Each starter shall have provision for a minimum of four auxiliary
contacts in any combination of open or closed arrangement without
changing the mounting dimensions of the starter. It shall be possible to
add, remove, or replace auxiliary contacts without removing or
disturbing other components on the starter. The auxiliary contacts shall
be interchangeable on Size 1 through 6 starters. The auxiliary contact
mounting provision should also accept accessories, such as a surge
suppressor or time delay contact. One extra set of N.O. and N.C.
auxiliary contacts shall be provided on each starter.

## 2.08 [INDICATING LIGHTS]{.underline}

Provide associated red (running) and green (off) indicating lights,
semiflush-mounted in front of compartment panel or on draw-out unit,
visible through the unit door, to show the \"running\" and \"off\"
positions of starter. Where two-speed starters are provided, the
indicating lights shall show the speed condition. The indicating lights
shall be industrial grade, NEMA 13 LED type.

## 2.09 [NAMEPLATE]{.underline}

A. Master nameplate shall be 6\" x 2\" black phenolic with white
engraved characters. Engraved characters shall be 1\" high.

B. Unit starter identification shall be provided. They shall have
dimensions of 3-5/8\" x 1-1/8\". Engraved characters shall be 1/4\"
high.

C. All phenolic nameplates shall be attached using two steel
self-tapping screws.

D. All unit starters shall have an identification label, indicating
whether a catalog number or serial number description, located inside
the unit compartment.

E. Each vertical section shall have a stamped, metallic identification
nameplate indicating: serial number, bus rating, and vertical section
reference number. The nameplate shall be externally mounted near the
center of the vertical wire way door of each section.

# PART 3 - EXECUTION

## 3.01 [GENERAL]{.underline}

A. The Contractor shall receive and properly store the equipment and
material pertaining to the electrical work. The equipment shall be
tightly covered and protected against dirt, water, chemical or
mechanical injury, and theft. The manufacturer\'s directions shall be
followed completely in the delivery, storage, protection, and
installation of all equipment and materials.

B. The Contractor shall provide and install all items necessary for the
complete installation of the equipment as recommended or as required by
the manufacturer of the equipment or a required by local code without
additional cost to Sandia.

C. It shall be the responsibility of the Contractor to clean the
electrical equipment, make necessary adjustments, and place the
equipment into operation before turning equipment over to Sandia. Any
paint that was scratched during construction shall be \"touched up with
factory-color paint to the satisfaction of Sandia. Any items that were
damaged during construction shall be replaced.

## 3.02 [ADJUSTMENTS]{.underline}

A. After installation, but before the equipment is energized, all bolted
connections of current-carrying parts shall be tightened with a torque
wrench to the value recommended by the equipment manufacturer.

B. The contractor shall adjust all motor circuit protectors and size the
overload relay heaters to assure proper protection of motors. The
settings shall be documented and turned into the Sandia delegated
representative. As a minimum, the documentation shall include the
following:

[MCC:]{.underline} NAME

<table style="width:100%;">
<colgroup>
<col style="width: 10%" />
<col style="width: 8%" />
<col style="width: 9%" />
<col style="width: 12%" />
<col style="width: 9%" />
<col style="width: 9%" />
<col style="width: 9%" />
<col style="width: 9%" />
<col style="width: 9%" />
<col style="width: 12%" />
</colgroup>
<tbody>
<tr class="odd">
<td>Cubicle</td>
<td>Motor</td>
<td></td>
<td></td>
<td></td>
<td></td>
<td colspan="2"><p>Motor Circuit</p>
<p>Protector</p></td>
<td colspan="2">Overload Relay</td>
</tr>
<tr class="even">
<td><u>No</u>.</td>
<td><u>H.P.</u></td>
<td><u>Volts</u></td>
<td><p><u>Full Load</u></p>
<p><u>Amps</u></p></td>
<td><p><u>Locked</u></p>
<p><u>Rotor</u></p>
<p>Amps</p></td>
<td><p><u>Service</u></p>
<p><u>Factor</u></p></td>
<td><u>Type</u></td>
<td><u>Setting</u></td>
<td><u>Type</u></td>
<td><p><u>Current</u></p>
<p><u>Range &amp; Setting</u></p></td>
</tr>
<tr class="odd">
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
</tr>
<tr class="even">
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
<td></td>
</tr>
</tbody>
</table>

## 3.03 [INSPECTION]{.underline}

After the installation is complete, a field representative of the
equipment manufacturer shall conduct a field inspection of the
installation to assure correct installation in conformance with the
manufacturer\'s recommendations. The Sandia delegated representative
shall be present during this inspection.

## 3.04 [OPERATIONAL TEST]{.underline}

A. The contractor shall perform an operational test on the motor control
center concurrently with the mechanical systems operational test. The
operational test will include:

\(1\) Infrared thermography of all bus and plug-in units while under
load.

\(2\) Operational check-out of all control components (i.e., pilot
lights, selector switches, auxiliary relays, etc.) within the MCC units.

\(3\) Load readings for each motor or feeder unit to show phase
voltages, currents, and power factor.

> Any defective components will be corrected and re-tested.

B. The operational test will be witnessed by the Sandia delegated
representative and copies of the infrared thermography, load readings,
and corrected deficiencies report will be turned in to Sandia.

## 3.05 [SHOP DRAWINGS]{.underline}

The contractor shall supply a final, complete set of as-built
reproducible shop drawings detailing the electrical construction of
these units. These drawings shall be done on the same size sheet as the
original construction drawings and shall show complete wiring diagrams
from the incoming terminal strip. These diagrams shall show all
terminals and components in their \"to-scale\" or relative location, and
any wire groupings or cablings that will occur, along with any color
coding used on all wiring. The [elementary (ladder) diagram]{.underline}
on the construction drawings is to be reproduced by the vendor.

END OF SECTION