SECTION 16443 MOTOR CONTROL CENTERS PART 1 - GENERAL

Read and conform to all electrical sections of these specifications,the general instructions for electrical division, section 16010, apply to and form part of all electrical sections. These shall be read in conjunction with design drawings. 1.01 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions apply to this Section. Requirements of all relevant sections of Division 16 apply to this section. B. Section 16441 MAIN SWITCH BOARD 1.02 A. B. 1. 2. 3. 4. SUMMARY This Section includes motor-control centers for use on ac circuits rated 600 V and less. Related Sections include the following: Division 16 Section 16269 Variable frequency controllers. Division 16 Section 16441 Main Switchboards. Division 16 Section 16045 Electrical works in connection with Mechanical services Star-Delta & Soft starters as shown in drawings for respective equipment

C.

Codes & Standards: The assemblies and the associated equipment shall conform to the requirements of the latest edition of the following standards and where applicable. .1 .2 .3 .4 .5 .6 .7 IEC 185 Current transformers IEC 186 Voltage transformers IEC 269 Low voltage fuses IEC 439 Low voltage switchgear and control gear assemblies DEWA Regulations & Any other applicable local laws and regulations IEC 292 Low voltage motor starters IEC 408 Low voltage air break switches, air break disconnecters, air break switch disconnecters and fuse combination switches.
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IEC 947 Low voltage switchgear and control gear

1.03 A.

SUBMITTALS Product Data: For each type of controller and each type of motor-control center. Include dimensions and manufacturer's technical data on features, performance, electrical characteristics, ratings, and finishes. Shop Drawings: For each motor-control center. 1. Include dimensioned plans, elevations, sections, and details, including required clearances and service space around equipment. Show tabulations of installed devices, equipment features, and ratings. Include the following: a. Nameplate legends. Each installed unit's type and details. b. Short-circuit current ratings of buses and installed units. c. Vertical and horizontal bus capacities. d. CE listing for series rating of overcurrent protective devices.. e. Features, characteristics, ratings, and factory settings of each motor-control center unit. 2. Wiring Diagrams: Power, signal, and control wiring for class and type of motor-control center. Provide schematic wiring diagram for each type of controller. Coordination Drawings: Floor plans, drawn to scale, showing dimensioned layout, required working clearances, and required area above and around motorcontrol centers where pipe and ducts are prohibited. Show motor-control center layout and relationships between electrical components and adjacent structural and mechanical elements. Show support locations, type of support, and weight on each support. Indicate field measurements. Field quality-control test reports. Operation and Maintenance Data: For motor-control centers, all installed devices, and components to include in emergency, operation, and maintenance manuals. In addition to items specified in Division 1 Section "Operation and Maintenance Data," include the following: 1. Routine maintenance requirements for motor-control centers and all installed components. 2. Manufacturer's written instructions for testing and adjusting overcurrent protective devices. Load-Current and List of Settings of Adjustable Overload Relays: Compile after motors have been installed and arrange to demonstrate that dip switch settings for motor running overload protection suit actual motor to be protected. QUALITY ASSURANCE
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B.

C.

D. E.

F.

1.04

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A. B. C.

Manufacturer Qualifications: A qualified manufacturer only. Refer clause 2.1 for approved sources. Source Limitations: Obtain motor-control centers and controllers of a single type through one source from a single manufacturer. Product Selection for Restricted Space: Drawings indicate maximum dimensions for motor-control centers, including clearances between motorcontrol centers, and for adjacent surfaces and other items. Comply with indicated maximum dimensions and clearances. Complete range of Motor Control Center shall be TTA (Totally Type Tested) assemblies as per IEC 60 439 standards. Comparison study of proposed switchboards with the type tested assemblies for all seven type tests specified in IEC 60 439 shall be submitted for approval. 1. The prototype assemblies shall confirm to the following 7 type test defined in IEC 439-1:a. Verification of temperature rise b. Verification of dielectric properties. c. Verification of short circuit withstand strength. d. Verification of the effectiveness of protective circuits. e. Verification of clearances and creepage distances. f. Verification of mechanical operation. g. Verification of degree of protection.

D.

1.05 A. B. C.

DELIVERY, STORAGE, AND HANDLING Deliver motor-control centers in shipping splits of lengths that can be moved past obstructions in delivery path as indicated. Accept switchboards on site. Inspect for damage. Store in a clean, dry space. Maintain factory wrapping or provide an additional heavy canvas or heavy plastic cover to protect units from dirt, water, construction debris, and traffic. Handle in accordance with and manufacturer's written instructions. Lift only with lugs provided for the purpose. Handle carefully to avoid damage to switchboard internal components, enclosure, and finish. COORDINATION Coordinate layout and installation of motor-control centers with other construction including conduit, piping, equipment, and adjacent surfaces. Maintain required workspace clearances and required clearances for equipment access doors and panels.
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D.

1.06 A.

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Coordinate size and location of concrete bases. Cast anchor-bolt inserts into bases. Concrete, reinforcement, and formwork requirements as specified else where in contract documents under section "Cast-in-Place" Concrete." Coordinate installation of roof curbs, equipment supports, and roof penetrations. These items as specified else where contract documents Section "Roof Accessories." Coordinate features, accessories, and functions of each motor-control center, each controller, and each installed unit with ratings and characteristics of supply circuit, motor, required control sequence, and duty cycle of motor and load. EXTRA MATERIALS Furnish extra materials described below that match products installed and that are packaged with protective covering for storage and identified with labels describing contents. 1. Spare Fuses: Furnish one spare for every five installed, but no fewer than one set of three of each type and rating. 2. Indicating Lights: Two of each type installed.

C.

D.

1.07 A.

PART 2 - PRODUCTS 2.01 A. APPROVED MANUFACTURERS Subject to compliance with requirements, provide products as per the list of specified manufacturers. MOTOR-CONTROL CENTERS 1. Cubicle Motor control centers shall be of indoor construction, dead front, metal enclosed multi-cubicle type, free standing, dust and vermin protected, front operated and of clean and modern appearance. The construction of motor control centers shall be minimum Form 4b in accordance with IEC 60439-1. MCCs will be fixed type. The panel shall be designed, manufactured and assembled by one manufacturer. The panel shall be made of folded steel construction, minimum 1.5mm thickness, fully rust proofed and stove enameled. All external bolts or screw heads shall be chrome or cadmium plated. All doors and removable covers or plates shall have suitable PVC or neoprene gaskets to prevent ingress of dust, vermin and insects. The panels shall be IP54 construction in accordance with IEC144.

2.02 A.

2. 3. 4. 5. 6.

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8.

9. 10. 11.

12. B. 1. 2. 3.

House each unit of the panel in its own cell fitted with a hinged door mechanically interlocked in such a manner that the cell door can only be opened when the switch is in the OFF position. Switching units shall be arranged in separate compartments or sections to protect against accidental contact with adjacent equipment when handling the elements in the section. Adequate cable ways shall be provided in the panels accessible by hinged lids or removable covers. Panels shall be fixed properly to the floor with foundation bolts grouted in the floor or bolted to channels laid across the cable trench. The panels shall include tin plated busbars, MCCBs, starters, instruments, earth bus etc., as specified herein before with ratings and arrangements as shown on the drawings, complete with necessary interlocks required to achieve the sequence and control stipulated, and all internal wiring and connections. The panels shall be tested at the manufacturers premises as well as after installation in accordance with tests stipulated in IEC439. Starters: Shall be read in conjunction with section 16045. Motor starters shall be of electromagnetic, air break type suitable for 3 phase, 50 Hz, 400V AC supply in accordance with IEC292. Starters shall be fixed type. Unless and otherwise indicated on the drawings, starters controlling motors less than 7.5 KW may be of the direct on line type and motors of 7.5 KW and higher ratings employ automatic star delta starters. Starters shall be provided with 3 phase overload relays having thermal characteristics suitable for the associated motor and its starting characteristics and suitably compensated for ambient air temperature variations. In addition, provide single phasing, under voltage and earth leakage protection for each motor starter. Contactors employed for motor starting duty shall be of continuous duty rating, utilization category AC3 with type 2 co-ordination. Each starter shall be provided with a set of ON and OFF push buttons, ON, OFF and TRIP indicating lamps and suitably scaled ammeter with selector switch for motor above 25HP.

4. 5.

C.

Internal Wiring PVC insulated, colour coded cables BS 6231. Factory installed, neatly bunched and supported and extended on to labeled terminal boards for the connection of external services. 3. Terminals: anti-turn solderless type suitable for cable sizes shown on the Drawings. 1. 2. Components 1. Components shall be the product of one manufacturer. Refer clause 2.1 for approved sources. 2. Switching and protective devices shall have clear on/off identification. 3. All components co-ordination of the motor control center to be in accordance with IEC 947-4.

D.

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4.

5.

6.

Each starter feeder shall be designed in accordance with the requirements of IEC 947-1. Rated insulation voltage shall be equal to or greater than 600 V confirming to IEC 947-4-1 for contactors. Contactor coils shall be replaceable type from front or side without having to disconnect power cables. Moulded Cases Circuit Breakers a. The moulded case circuit breakers shall comply with IEC 947-1 and IEC 947-2 standards and shall be of the quick make and quick break type having free toggle mechanism ensuring full contact pressure until time of opening, whether actuated automatically or manually. They shall be of utilisation category 'A' having rated service breaking capacity (Ics) as indicated in the drawings. The circuit breakers shall be suitable for isolation as per IEC 947-2 and shall have rated operation voltage of 500V 50 Hz and the insulation voltage of 750 V, 50 Hz. The breaker shall be available in 3 or 4 pole version as per the drawing. b. For MCCB with ratings upto 250A shall be equipped with magnetic units, which are fully interchangeable. Minimum frame size shall be 80A.The breakers with ratings over 250A shall be equipped with electronic trip units, which shall remain operational for ambient temperatures up to 60oC. Electronic trip unit shall comply with appendix F of IEC 947-2 standard. It shall be possible to fit lead seals to prevent unauthorised access to the settings of the electronic and thermal magnetic trip units. c. MCCB's upto 250A shall have fixed magnetic protection. d. MCCB's above 250A up to 630A frame size shall be equipped with electronic trip units shall sense the actual RMS values. Earth Fault Protection a. Earth Fault Relay to be solid state design, self-protected from high magnitude earthfaults and protected against dirt, vibration and moisture and shall comply to IEC 755, IEC 62020 & IEC 947-2 Appendix B. b. Relay to have a site-adjustable inverse time delay characteristic giving time delay characteristic giving time delay setting of instantaneous up to 5 seconds adjustable. c. Current sensitivity will be as indicated in single line drawings. Provide spaces for the future addition of control or switching units totalling at least 20% of the active spaces in the control centre. Future spaces shall be complete with bus, guide rails and all required parts, ready to receive a starter.

7.

8.

Each motor feeder shall be equipped with control panel but not limited to: Main MCCB with door interlocked rotary handle (lockable in the off position)
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Contactors for DOL / star-delta / soft starter / variable frequency drive. Thermal overload relay with built in single phasing prevention feature Hand-Off-Auto Control Switch Common Duty Selector Switch where applicable Thermal Relay where applicable RUN/TRIP lamps Auto changeover arrangement where applicable Hour run meter Ammeter above 3KW motors

All controls within each starter shall be 24V; fed via local 240/24V transformer located in each functional unit. Current transformers shall comply with IEC 185. .1 The conditional ratings of current transformers shall correspond with the F.B.A. rating, and shall be such as to maintain the overall metering accuracy as is necessary to operate the relays within the tolerances specified by the manufacturer. Current transformers shall have the following accuracies as a minimum. .1 .2 .3 Protection applications Indication Metering : Class 5P : Class 3 : Class 0.5

10.

.2

.3 The manufacturer shall ensure that the current transformers are such that the relays will operate correctly when set at any point within their ranges.

.4 Current transformers secondary wiring shall be earthed on one side through a removable link. Where current transformers are connected in star, the star point shall be earthed through a removable link. .5 .6 11. Shorting links shall be provided for each current transformer. Current transformer shall be cast resin insulated.

Voltage transformers shall comply with IEC 186. .1 Voltage transformers shall be suitable in rating and accuracy for their functions, loads and duties. As a minimum they shall have the following accuracies: .1 .2 Protection Applications Indication and Metering
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: Class 6P : Class 0.5

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The primary and secondary circuits of the voltage transformers shall be protected by fuses and the secondary winding shall be earthed at one point through a removable link. Voltage transformers shall be cast resin insulated.

.3

.4 The manufacturer shall provide m.c.b.s with auxiliary contacts or alternatively 4-pole m.c.b.' on the secondary side of the voltage transformers. 12. Three spare fuses of each rating of fuse used shall be provided and clipped inside each panel. Provide six spare indicator lamps and transformers clipped inside each panel. Indicators shall be of the integral transformer type. For details of power factor correction refer to Section 16686.

13.

14. 15.

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PART 3 - EXECUTION 3.01 A. EXAMINATION Examine areas and surfaces to receive motor-control centers for compliance with requirements, installation tolerances, and other conditions affecting performance. 1. Proceed with installation only after unsatisfactory conditions have been corrected. APPLICATIONS Select features of each controller to coordinate with ratings and characteristics of supply circuit and motor; required control sequence; duty cycle of motor, controller, and load; and configuration of pilot device and control circuit affecting controller functions. INSTALLATION See Division 16 Section "Basic Electrical Materials and Methods" for general installation instructions. Anchor each motor-control center assembly to steel-channel sills arranged and sized according to manufacturer's written instructions. Attach by bolting. Level and grout sills flush with motor-control center mounting surface. CONCRETE BASES Coordinate size and location of concrete bases. requirements with structural engineer. Verify structural

3.02 A.

3.03 A. B.

3.04 A. B.

Concrete base is specified in Division 16 Section "Basic Electrical Materials and Methods," and concrete materials and installation requirements are specified in Division 3. IDENTIFICATION Identify motor-control center, motor-control center components, and control wiring according to Division 16 Section "Electrical Identification." CONTROL WIRING INSTALLATION Install wiring between motor-control devices according to Division 16 Section "Conductors and Cables."

3.05 A.

3.06 A.

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B. C.

Bundle, train, and support wiring in enclosures. Connect hand-off-automatic switch and other automatic-control devices where applicable. 1. Connect selector switches to bypass only manual- and automatic-control devices that have no safety functions when switch is in hand position. 2. Connect selector switches with motor-control circuit in both hand and automatic positions for safety-type control devices such as low- and highpressure cutouts, high-temperature cutouts, and motor overload protectors. CONNECTIONS Conduit installation requirements are specified in other Division 16. Ground equipment according to Division 16 Section "Grounding and Bonding." FIELD QUALITY CONTROL Prepare for acceptance tests as follows: 1. Test insulation resistance for each motor-control center element, bus, component, connecting supply, feeder, and control circuit. 2. Test continuity of each circuit. Manufacturer's Field Service: Engage a factory-authorized service representative to perform the following: 1. To assist in field testing of equipment 2. Report results in writing. Perform the following field tests and inspections and prepare test reports: Perform each electrical test and visual and mechanical inspection, except for optional tests. Certify compliance with test parameters. 2. Correct malfunctioning units on-site, where possible, and retest to demonstrate compliance; otherwise, replace with new units and retest. 1. ADJUSTING Set field-adjustable switches and circuit-breaker trip ranges. DEMONSTRATION

3.07 A.

3.08 A.

B.

C.

3.09 A. 3.10

A. Engage a factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain components of motor-controls. END OF SECTION

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