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SECTION 16440:

GUIDELINE SPECIFICATION FOR

SWITCHBOARDS, PANELBOARDS AND
CONTROL CENTERS

0 31/01/06 I Issued for Use

REV DATE DESCRIPTION PREPARED BY RC APPROVED

KINGDOM
OFSAUDIARABIA ~~~I ~}iJ1~I
forJubail&Yanbu
RoyalCommission ~ 1~ 4#J.oJ I 44fJ 1
 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

TABLE OF CONTENTS

Item No Title Page No

PART 1 GENERAL............................................................................................................... 1

1.01 DESCRIPTION OF WORK .................................................................................. 1

1.02 SECTION INCLUDES .......................................................................................... 1

1.03 RELATED SECTION............................................................................................ 1

1.04 REFERENCE ....................................................................................................... 1

1.05 DEFINITIONS....................................................................................................... 3

1.06 SUBMITTALS....................................................................................................... 4

1.07 QUALITY CONTROL ........................................................................................... 5

1.08 HEALTH AND SAFETY CONSIDERATIONS...................................................... 5

1.09 FACTORY TESTING ........................................................................................... 5

1.10 SERVICE CONDITIONS...................................................................................... 5

1.11 ENCLOSURES .................................................................................................... 6

1.12 DELIVERY, HANDLING AND STORAGE ........................................................... 6

PART 2 PRODUCTS ............................................................................................................ 8

2.01 GENERAL ............................................................................................................ 8

2.02 SWITCHBOARDS................................................................................................ 8

2.03 PANELBOARDS ................................................................................................ 15

2.04 CONTROL CENTER.......................................................................................... 18

PART 3 EXECUTION ......................................................................................................... 28

3.01 GENERAL .......................................................................................................... 28

3.02 INSTALLATION OF EQUIPMENT ..................................................................... 28

3.03 TESTING AND COMMISSIONING .................................................................... 29

Rev 0 i Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

PART 1 GENERAL

1.01 DESCRIPTION OF WORK

A. This Section specifies minimum technical requirements for designing, manufacturing,

supplying, installing, storing, handling, testing and commissioning of Switchboards,
Panelboards and Control Centers as specified and shown on and the Contract
Documents.

1.02 SECTION INCLUDES

A. Switchboards

B. Panelboards

C. Control Center

1.03 RELATED SECTION

A. Section 01320 Construction Progress Documentation

B. Section 01330 Submittal Procedures

C. Section 01410 Regulatory Requirements

D. Section 01450 Quality Control

E. Section 01650 Product Delivery Requirements

F. Section 01660 Product Storage and Handling Requirements

G. Section 16055 General Provisions for Electrical Works

H. Section 16060 Grounding and Bonding

I. Section 16120 Cables and Conductors

J. Section 16130 Raceway and Boxes

K. Section 16410 Enclosed Switches and Circuit Breakers

1.04 REFERENCE

A. The referred codes and standards are intended to provide an acceptable level of
quality for materials and products. In case of conflict between these standards and
the text of this Specification, the Specification text shall govern.

B. The latest revision of the referred codes and standards shall be used wherever
applicable. In case of conflict, the Contractor shall propose equipment conforming to
one group of codes and standards.

Rev 0 1 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

C. ANSI American National Standards Institute

1. ANSI C37.20.1 Metal-Enclosed Low-Voltage Power Circuit Breaker

Switchgear

2. ANSI Z55.1 Gray Finishes for Industrial Apparatus and

Equipment

3. ANSI C57.12 General Requirements For Liquid Immersed

Distribution, Power, and Regulating Transformers

4. ANSI C57.13 Requirements for Instrument Transformers

D. ASTM American Society for Testing and Materials

1. ASTM A47M Standard Specification for Ferritic Malleable Iron

Castings

2. ASTM A123M Standard Specification for Zinc (Hot-Dip Galvanized)

Coatings on Iron and Steel Products

3. ASTM B187M Standard Specification For Copper, Bus Bar, Rod,

and Shapes and General Purpose Rod, Bar, and
Shapes

E. IEC International Electro-Technical Commission

1. IEC 60439 Low Voltage Switchgear and Controlgear Assemblies

2. IEC 60529 Degrees of Protection Provided by Enclosures

3. IEC 60617 Graphical Symbols and Diagrams

4. IEC 60947 Low Voltage Switchgear and Controlgear

F. IEEE Institution of Electrical and Electronics Engineers

1. IEEE 142 Recommended Practice for Grounding of Industrial

and Commercial Power System

2. IEEE 315 Graphic Symbols for Electrical and Electronic

Diagram

3. IEEE C57.12 General Requirements For Liquid Immersed

Distribution Power and Regulating Transformer

G. NEMA National Electrical Manufacturers' Association

1. NEMA PB1 Panelboards

2. NEMA PB2 Deadfront Distribution Switchboards

3. NEMA 250 Enclosures for Electrical Equipment

Rev 0 2 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

4. NEMA ICS 2 Industrial Control and Systems: Controllers,

Contactors and Overload Relays, Rated 600 V

5. NEMA ICS 6 Industrial Control and Systems : Enclosures

6. NEMA SG 5 Power Switchgear Assemblies

H. NFPA National Fire Protection Association

1. NFPA 70 National Electrical Code

I. UL Underwriters Laboratories Inc.

1. UL 50 Enclosure For Electrical Equipment

2. UL 845 Motor Control Center

3. UL 891 Dead Front Switchboards

4. UL 1008 Transfer Switch Equipment

5. UL 1332 Organic Coatings for Steel Enclosures for Outdoor

Use Electrical Equipment

1.05 DEFINITIONS

A. controller: A device or group of devices that serves to govern, in some

predetermined manner, the electric power delivered to an apparatus to which it is
connected.

B. control centers: An assembly of devices mounted in enclosed sections and

intended for controlling various equipment such as motors.

C. dead front: Equipment without live parts exposed to a person on the operating side
of the equipment.

D. listed: Equipment, materials or services included in a list published by an

organization that is acceptable to the authority having jurisdiction and concerned with
evaluation of products or services that maintains periodic inspection of production of
the listed equipment or periodic evaluation of services and whose listing states that
the equipment, materials or services either meet appropriate designated standards or
have been tested and found suitable for a specified purpose.

E. live parts: Energized conductive components.

F. low voltage: A voltage level of less than 1000 V. In this section, the intended
application “low voltage” shall be up to 600 V.

G. motor control center: An assembly of one or more enclosed sections having a

common power bus and principally containing motor control units.

H. moulded case circuit breaker: A device assembled as an integral unit in a

Rev 0 3 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

supporting and enclosing housing of insulating material designed to open and close a
circuit by non-automatic means and to open the circuit automatically on a
predetermined over-current without injury to self when properly applied within its
rating.

I. panelboard: A single panel or group of panel units designed for assembly in the form
of a single panel, including buses and automatic over-current devices, and equipped
with or without switches for the control of light, heat or power circuits designed to be
placed in a cabinet or cut-out boxes placed in or against a wall, partition or other
support and accessible only from the front.

J. switchboards: A large single panel, frame or assembly of panels on which switches,

over-current and other protective devices, buses and usually instruments are
mounted on its face, back or both. Switchboards are generally accessible from the
front and are not intended to be installed in cabinets.

1.06 SUBMITTALS

A. The Contractor shall submit to the Royal Commission under the provision of
SECTION 01330, the following items for their review and/or approval before
commencing work:

1. Shop Drawings and Manufacturer's Literature

a) Shop Drawings
1) Layouts, showing concrete pad dimensions, conduit entrance and
available space, bus duct connections, electrical ratings,
nameplate nomenclature, schematic and wiring diagram and,
single line diagrams in accordance with relevant standards as
specified in par. 1.04, indicating connections and controls.
b) List of Manufacturers
1) Switchboards.
2) Panelboards.
3) Control Centers.

2. Maintenance Data and Operating Instructions

a) Manufacturer’s catalogs giving description of the equipment and its
components.
b) Manufacturer’s operating and maintenance instructions.
c) Part list.
d) Illustrations and diagram of components.
e) Recommended list of spare parts along with pricelist.
f) Factory test report.

3. Quality Program as specified in SECTION 01450.

B. The Contractor shall submit Field Test Report after completion of testing and
commissioning.

Rev 0 4 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

1.07 QUALITY CONTROL

A. The Contractor shall be responsible for the quality of work and shall develop and
propose programs and methods of construction and testing such as to achieve the
specified quality to the approval of the Royal Commission in accordance with
SECTION 01450.

1.08 HEALTH AND SAFETY CONSIDERATIONS

A. All works undertaken in relation to this Specification are to be completed in full

accordance with the respective health and safety requirements established by the
following:

1. Kingdom of Saudi Arabia

a) Legislation. Regulation, Standards and Codes.

2. Royal Commission Regulations

a) Standards, Contractual Conditions, and Health and Safety Systems.

3. Contractor
a) Health and Safety Standards and System as accepted by the Royal
Commission.

B. In the absence of any of the above, best accepted industry practice shall be
employed throughout.

1.09 FACTORY TESTING

A. All equipment and materials shall be tested at the factory in accordance with latest
applicable codes and standard. All type of tests as per applicable codes and
standards shall be performed on first unit of every new design. The Contractor shall
notify the Royal Commission in writing not less than 30 days prior to the scheduled
starting date of the factory tests.

B. The Royal Commission reserves the right of deputing their representative for
witnessing the factory tests.

C. Upon completion of factory test and before shipment of the equipment or material,
the Contractor shall submit 5 certified copies of the test reports not latter than
10 days after completion of all factory test for review and approval of the Royal
Commission.

1.10 SERVICE CONDITIONS

A. Switchboards, Panelboards and Control Centers installed indoors shall be suitable for
continuous operation under the following service conditions:

1. Ambient Air Temperature

Rev 0 5 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

a) A maximum of 40°C.
b) A minimum of 0°C.
c) Average temperature measured over a period of 1 month is 35°C.

2. Relative Humidity (Average Value)

a) For a period of 24 hours, does not exceed 95%.
b) For a period of 1 month, does not exceed 90%.

B. Switchboards, Panelboards and Control Centers installed outdoors shall be suitable

for continuous operation under the following service conditions.

1. Ambient Air Temperature

a) A maximum of 50°C.
b) A minimum of 0°C.
c) Average temperature measured over a period of 1 month is 45°C.

2. Altitude is less than 1000 m, unless a higher altitude is specified on the

Contract Drawings.

3. Average Value of Relative Humidity

a) For a period of 24 hours, does not exceed 95%.
b) For a period of 1 month, does not exceed 90%.

4. Relative humidity may be temporarily 100%.

C. Switchboards, Panelboards and Control Centers shall be installed in classified areas

as indicated on the Contract Drawings, and shall meet the relevant standards, listed
in par. 1.04, for classification requirements.

1.11 ENCLOSURES

A. The Switchboards, Panelboards and Control Centers shall meet relevant standards,
listed in par. 1.04, for enclosure requirements.

1.12 DELIVERY, HANDLING AND STORAGE

A. The Contractor shall deliver, handle and store equipment and material units in
accordance with SECTIONS 01650 and 01660, as well as the following
requirements:

1. Provide marking on each item in accordance with the referenced standards.

2. Ship each unit securely wrapped, crated and wrapped or packaged and
labeled for safe handling in shipment and to avoid damage or distortion.

3. On arrival at site, the equipment/material shall be checked for completeness

and physical damage.

Rev 0 6 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

4. Lift the equipment using eyes, yokes, and skids provided for the purpose by
manufacturer.

5. Store all indoor units protected from weather and protect all units from physical
damage from work of other trades.

6. Provide supports for vertical units to prevent them from overturning.

7. Be responsible for damages occurring during transportation and storage of the

equipment.

Rev 0 7 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

PART 2 PRODUCTS

2.01 GENERAL

A. All goods and products covered by these Specifications shall be procured, when
available, from an in-Kingdom manufacturer. Procurement of all goods manufactured
out-of-Kingdom shall be approved by the Royal Commission.

2.02 SWITCHBOARDS

A. Construction of Switchboards

1. The Switchboards shall be used in commercial buildings at 600 V and below

for service entrance, power, or lighting distribution, and as the secondary
section of unit substations. The switchboard and devices shall have ratings as
indicated on the Contract Drawings.

2. The switchboards shall be a completely, self-supporting, steel-enclosed dead-

front type construction of the required number of vertical sections to form one
metal-enclosed switchboard 2280 mm high.

3. The construction shall consist of a structural or formed steel frame carefully

braced and welded into a rigid structure that shall maintain its alignment and
not be damaged in shipment or erection, or by stresses resulting from short-
circuits.

4. The switchboard shall have frame structure of 2.5 mm minimum thick formed
steel channels with welded sub-frames bolted to longitudinal members and
reinforced at corners. Side, top and rear covers (panels) shall have minimum
thickness of 1.5 mm or code-gage steel, bolted to the switchboard structure.

5. The removable rear access panels shall be of the concealed hinged type, or
screw-on type. The front shall be completely enclosed with hinged panels
covering each breaker, metering or blank compartment.

6. The hinged covers shall be provided with concealed hinges, latches, and cut-
outs where necessary for ventilation, operating mechanism, mechanical trip
and position indication.

7. Adequate ventilating louvers shall be provided only in the hinged panels where
required to limit the temperature rise of current-carrying-parts, including
contacts, to values specified in IEEE standard rules for enclosed equipment.

8. All openings shall be protected against entrance of falling dirt, water or other
foreign matter. Filters are not required for indoor assemblies. Each
switchboard shall be mounted on a 100 mm concrete pad and anchored to two
100 mm channel iron sills by tack welding or bolting.

9. Sills shall be furnished by the Contractor to suit the switchboard and shall be
leveled and grouted flush into the concrete pad by the Contractor.

10. Where space for future is indicated, all necessary buses and straps shall be

Rev 0 8 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

provided.

11. Each compartment, such as circuit breakers, metering current transformer,

bus, cable compartment, etc., of the total assembly shall be completely
isolated on the top, bottom (except for cable compartments) and sides from all
other compartments by suitable metal barriers without openings.

12. Approved barriers shall be placed between adjacent sections of the

switchboard and all openings in the barriers for bus bars shall be closed with
approved snug-fitting, non-hygroscopic, arc-resistant material. All openings in
barrier for cables shall be closed with approved snug-fitting, arc-resistant
material.

13. Each switchboard shall have an engraved nameplate fixed by stainless steel
screws. The nameplate shall indicate a facsimile of the switchboard bussing
and switch device arrangement, both in English and Arabic.

14. Each switch shall be equipped with a nameplate which indicates the name of
the equipment to which the feeder conductors are connected. Feeder numbers
used on the drawings shall be applied on the switch nameplates.

15. All devices located within a switchboard shall be provided with suitable
nameplates to identify item and function. The nameplates of protective devices
shall indicate ANSI device number.

16. Each vertical section of switchboard shall be provided with thermostatically

controlled space heater located at the bottom of the section. Heating elements
shall have a voltage rating of approximately twice the heater supply voltage for
extended service life. Heating element shall be designed to eliminate internal
condensation with a relative humidity of 95% and temperature fluctuation from
0 to 50°C.

17. All enclosure parts shall be thoroughly cleaned, degreased and given a
phosphatizing treatment to inhibit rust and to prime the metal for the finish
coating. A 5 micron (0.2 mil) thick electrostatic powder paint coat shall be
applied to all surfaces. The paint type and process shall meet UL 1332 for
electrical equipment steel enclosures. All exterior enclosure covers and doors
shall be painted ANSI Z55.1 No. 61 gray (Munsel 8.3/G.10/0.54).

18. Front Accessible - Front Connected Switchboards

a) Designed to be installed against the wall.

b) All mechanical and electrical connection shall be made from the front.

c) Multiple-section switchboards have backs lined up.

d) Switchboards are enclosed on all sides except the bottom.

e) Maximum rating of 2000 A.

f) Draw-out low-voltage AC power circuit breakers are not available as

branch devices.

Rev 0 9 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

g) Load-side risers are not available.

19. Rear Accessible - Front Connected Switchboards

a) Designed to be free-standing.

b) Designed for rear accessibility.

c) All main connections shall be made from the front.

d) All normal maintenance in the main bus shall be performed from the
rear.

e) All line and load connections for branch devices are made from the
front.

f) Cross bus is located behind the branch devices and is available only
from the rear.

g) Multiple-section switchboards have fronts lined up.

h) Capable of accepting all components.

20. Rear Accessible - Rear Connected Switchboards

a) Designed to be free-standing.

b) Designed for rear accessibility.

c) All main connections shall be made from the rear.

d) All normal maintenance in the main bus shall be performed from the
rear.

e) All line and load connections for branch devices are made from the rear.

f) All cross bus and line and load connections branch devices accessible
only from the rear.

g) Multiple-section switchboards have fronts lined up.

h) Capable of accepting all components.

21. Sub-main, tie and feeder devices shall be individually mounted and arranged
for stationary (dead-bolt plug in) mounting, unless otherwise indicated. Also,
they shall be arranged to be individually removable from the front of the
switchboard.

22. Main devices shall be individually mounted and arranged for stationary (draw-
out) mounting, unless otherwise indicated.

23. Main device shall be completely isolated from the feeder sections of the
switchboard both in the device section and the cable section of the cubicle.

Rev 0 10 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

The cable section shall also be isolated from the main horizontal bus bar.

24. The following components are allowed in switchboards:

a) Service protectors or main devices.

b) Molded-case circuit breakers, group or individually mounted.

c) Fusible switches.

d) Motor starters.

e) Low voltage AC power circuit breakers (generally limited to main or tie

position).

f) Bolted pressure and high-pressure switches.

g) Transfer devices or switches.

h) Instrumentation, Metering, and Relaying

1) Instrumentation and metering included the metering equipment,
voltmeters, ammeters, wattmeter, voltage and current
transformers, etc.

25. All feeder device line and load connection straps shall be rated to carry the full
continuous current rating of the device frame (not trip rating). The load
connection straps shall be insulated and extended beyond the main bus.

26. Switchboard standardized to IEC rated 400 A and below shall be acceptable
as low voltage switchboards.

B. Bus Bars for Low Voltage Switchboard

1. All bus bars shall conform to ASTM B187M, 98% conductivity copper with
silver plated contact surfaces. In no case shall dimensions be such that at
rated load the current density in any copper bus bar exceeds 1,000 A per
645 mm2 of cross-section.

2. The bus bars shall be braced to withstand or exceed the short circuit rating of
the switchboard as indicated on the Contract Drawings for the service
conditions as specified in par. 1.11.

3. All buses shall be rigidly held by bus supports which have high and indefinitely
long lasting dielectric qualities, are moisture resistant, non-carbonizing, non-
tracking and have vertical creepage surface to prevent faults due to build up of
conductive dirt. Bus bar spacing shall not be less than and spacing of bus
fastening point shall not be more than those specified in UL 891.

4. The bus bars shall run continuously through all sections of switchboards, with
provision made for extension at either end for future expansion.

5. Bus bars shall be uniformly arranged to provide A-B-C sequence left to right
(from front), front to rear and top to bottom. The bus bar shall be accessible

Rev 0 11 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

from the rear for the connections.

6. Bus bars shall be so mounted on the switchboard that no current carrying part
(bus bar, nuts, bolts, connectors, switch parts, etc.), is less than 25 mm from
grounded parts of the switchboard.

7. The vertical bus in main and feeder sections shall be insulated and isolated
from main horizontal bus.

8. Each phase of the main horizontal bus shall be insulated/isolated from each
other and device load lugs (taping is not acceptable). Bus joints shall be
insulated with removable caps to allow maintenance without removal of the
barriers or tape.

9. If neutral bus is required, the bus rating shall be equal to phase bus.

10. A ground bus of minimum half the size of the phase bus bar, shall be provided
running the full length of the switchboard, bolted to each vertical section. The
internal ground bus of the service bus duct servicing the switchboard shall be
bonded to the above grounding bus in a manner meeting all code
requirements.

C. Wiring

1. Wiring shall meet relevant standards as specified in par. 1.04. All conductors
shall be copper materials, except conductors that are internal to pre-
manufactured devices, integral parts or components of manufactured
equipment, and plating of the copper, silver or copper/silver alloy base
conductor materials.

2. Control and secondary wiring shall be 2.5 mm2 stranded copper conductors
only.

3. Each wire shall be identified with thermo-plastic, slip-on wire markers with
permanently printed characters. Snap-on or adhesive type markers are
prohibited.

D. Terminal

1. Insulated, ring tongue or locking type fork, compressed (crimped) terminals

shall be provided for all wiring terminations. Soldered terminals are not
acceptable.

2. All connection points between assembly devices and field wiring shall be made
with terminal blocks. 20% spare terminal block points shall be provided.

3. Terminal blocks shall be one piece, phenolic, barrier type, rated 20 A, 600 V
minimum with numbered marking strips and suitable for two terminations per
point. A maximum of 2 wires per point is permitted.

4. Current transformer circuits shall use ring tongue terminals. Shorting terminal
blocks shall be provided for current transformer circuits.

Rev 0 12 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

E. Switching, Monitoring and Controlling Devices

1. Main Circuit Breaker

a) MCCB rated up to 1200 A with electronic trip shall be used as incomer

while for rating above 1200 A CB shall be used up to 4000 A rating.
However, it is recommended to use ACB up to 3000 A. The code
permits two or more services when the capacity requirements are in
excess of 3000 A at 600 V or less. For specification of MCCB and ACB,
refer to SECTION 16410.

b) Equipment ground-fault is recommended when the switchboard is

applied on grounded-wye system.

c) Ground-fault shall be provided on electrical services of more than 150 V

to ground for any service disconnecting means rated 1000 A or more.
See relevant standards for minimum requirements.

d) The breaker shall be equipped with adjustable long time, short time and
instantaneous trip elements. The breaker shall employ a spring-
operated, stored-energy mechanism that assures high-speed closing of
the breaker contacts, independent of the operating force.

e) The switchboard main circuit breaker shall be equipped with a ground

fault protection system. The system shall be a "Ground Break" system
consisting of a sensor, relay and monitor panel.
1) The sensor shall be responsive to the ground current transformer
and shall include a test winding. The sensor shall have sufficient
window size to enclose all conductors.
2) The relay shall be solid state, 120 V, and shall provide direct
operation of the shunt trip device of the switchboard main circuit
breaker. The relay shall be continuously adjustable from 5 to 60 A
and shall have a time delay range of 0.30 to 1 second. Once the
settings have been selected, adjusting knobs shall be capable of
being clamped into position by means of a clamping bar on face
of the relay.

f) A control transformer shall be provided with a 120 V secondary and a

380 V (or voltage level as indicated on the Contract Drawings), 60 Hz
primary at the main breaker for ground fault control power.

2. Branch Circuit Breakers

a) The branch circuit breakers shall be the same type as the main circuit
breaker except for frame and over-current trip ratings. Those shall be as
shown on the Contract Drawings.

3. Monitoring Panel

a) The monitor panel shall be a flush mounted unit rated at 120 V. The
panel shall allow testing of the system with or without tripping the main
circuit breaker. A pilot light shall be provided to indicate presence of
control power.

Rev 0 13 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

b) The panel shall be provided with an alarm and annunciator circuit. The
multiple alarm units shall have common test, acknowledge and reset
push buttons. The red push button shall be marked "TEST" and the
yellow push button shall be marked "RESET." The acknowledge push
button shall be green in color. Annunciators shall be in energized mode
for normal conditions. Under fault conditions, annunciators shall flash
and an audible horn shall be energized. When the alarm is
acknowledged, the horn shall be silenced and annunciators shall
continue flashing until circuit is reset.

c) A red colored ground fault lamp shall light to show that the “Ground
Break” relay has operated to trip the main breaker. The reset button
must be pushed to reset the relay after the fault has been located and
before the breaker can be closed.

d) Instructions for performing tests shall be printed on the face of the

monitor panel.

e) Voltmeters shall be panel mounted, heavy-duty type, suitable to operate

on a potential transformer with phase selector switch to measure phase-
to-phase and phase-to-neutral voltage. The size of voltmeter shall be
approximately 114 mm2 graduated from zero to 600 V with black figures
on white background. The accuracy class of voltmeter shall be Class 1.
The volt meter shall be protected with a 2 A fuse.

f) Three ammeters, suitable to operate on a current transformer for the

measurement of line current shall be provided. The ammeter shall be
provided with maximum demand indicator and shall have accuracy
Class 1. The size of the ammeter shall be approximately 114 mm2 and
shall have graduations as indicated on Contract Drawings with black
figures on white background. The ammeters shall be provided with
shorting links.

g) The potential transformers shall conform to ANSI C57.13 and shall be

wound type with polarity markers suitable for operating meters and
relays. The isolation transformer shall have a voltage ratio of 600 V :
600 V and shall withstand basic impulse insulation level of 10 kV full
wave.

h) All selector and synchronizing switches shall be maintained contact type

with oval handle. The synchronizing switches shall be provided with
removable key.

i) All pushbuttons on control switchboards shall be oil-tight, heavy-duty

type constructed in such a manner as to prevent accidental actuation.

j) Indicating lights shall be of the incandescent type. Incandescent lamps

shall have an integral transformer or series voltage-dropping resistor
sized so that the applied voltage is 80% of the rated lamp voltage. All
lamps shall be replaced from the front. Individual indicating lamps shall
be of the push-to-test type.

Rev 0 14 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

2.03 PANELBOARDS

A. Construction of Panelboards

1. General

a) Electric systems in commercial and industrial buildings shall include

panelboards, which utilizes circuit breaker devices (fuse devices shall
only be used for control circuits of instrument or monitoring devices).

b) Panelboards is generally classified into two categories:

1) Lighting and appliance panels and power distribution panels.
2) Panelboard mountings of motor starter units - lighting contactors
may also be involved.
3) Refer to the relevant standards for other requirements pertaining
to the two categories of panelboards.

c) The panelboards shall be fabricated from galvanized steel sheet. The

panel shall be cleaned, de-greased and pre-treated with a phosphating
process to inhibit rust. The panelboards shall then be primed with zinc
and then finished with 2 coats ANZI Z55.1 No. 61 gray paint or IEC RAL
7035 light gray epoxy polyester powder paint.

d) The panelboards with hinged doors shall be dead-front construction and

tamper proof. Back-plates shall be provided inside the panels to give
devices rigid support and proper alignment. A tumbler type cylindrical
door lock with 2 flat keys per panelboard shall be provided. All panel
locks shall be keyed alike. Bigger panel doors shall have minimum of
2 latches with 1 key or as per recommendation of manufacturer. All
materials for door lock devices shall be rust proof.

e) Panelboards shall have bolt-on MCCBs, either with electronic trip units
or just normal thermal-magnetic trip units, or as indicated on the
Contract Drawings. Refer to SECTION 16410 for the specification of
enclosed switches and circuit breakers.

f) Panelboards shall be equipped with a minimum of 20% spare breakers

and a minimum of 20% spare pole spaces. The size of circuit breakers
shall be representative of the connected breakers within the
panelboards.

g) The panelboard shall be durably marked by the manufacturer with the

voltage, current rating, number of phases for which they are designated
and with manufacturer’s name and trademark in such a manner so as to
be visible after installation.

h) All panelboard circuits shall be legibly identified as to purpose or use on

a circuit directory located inside of panelboard door. The directory shall
be covered by clear plastic or glass plate and metal frame.

i) Each panel shall have a 25 mm wide laminated plastic nameplate that is

attached on panel by aluminum rivets or stainless steel screws. The

Rev 0 15 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

nameplate shall show the panelboard number or ID in Arabic and

English with 13 mm high white cut-in text.

2. The breakers shall have quick-make and quick-break toggle mechanisms,

inverse-time trip characteristics and shall be trip free on overload or short-
circuit. Automatic release is to be secured by a bi-metallic thermal element
releasing the mechanism latch.

3. The breaker shall have trip ratings as indicated on the Contract Drawings or in
the panelboard schedules. Breakers shall have a minimum interrupting
capacity of 10,000 A symmetrical at 240 V. A magnetic armature shall also be
provided to trip the breaker instantaneously for short circuit current above the
overload range. The magnetic trip devices shall be adjusted at the factory to
"low" trip setting ampere values.

4. Lighting and Appliance Panelboard

a) These panels shall have more than 10% of the over-current devices
rated 30 A or less, for which neutral connections are provided.

b) Not more than 42 over-current devices (other than those provided for
the mains) of lighting and appliance branch-circuit panelboards shall be
installed in any one cabinet. For this purpose, a 2-pole circuit breaker
shall be considered as 2 over-current devices and 3-pole circuit breaker
shall be considered as 3 over-current devices.

c) When the 42 poles are to be exceeded, 2 or more separate boxes are

allowed. A common front for multiple boxes is allowed.

5. Power Distribution Panelboards

a) This type includes all other panelboards not defined as lighting and
appliance panelboards. The 42-over-current protective device limitation
does not apply.

b) The size shall not exceed practical and physical limitations, such as the
standard box height and widths available.

c) A common front for multiple boxes is not allowed.

d) Rating shall be for all single-phases or multi-phases, or both, through

600 V and less, 50 to 1600 A, 1200 A maximum branch.

e) Over-current protective device shall be bolt-on type, unless otherwise

indicated.

6. Panelboards Mounted with Motor Starter Units

a) This type includes small number of motor starters grouped together into
a panelboard. This panel is not applicable for the grouping of a large
number of motors to be controlled from one location, rather use MCC.

b) This consists of combination units utilizing either MCCB or motor circuit

protector fusible disconnects with motor starters.

Rev 0 16 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

c) The combination starters shall be factory-wired and assembled.

d) Terminal blocks shall be furnished near each unit when external control
wiring required in not combined units.

7. Multi-Section Panelboards

a) This type includes lighting and appliance panelboards or power

distribution panelboards requiring more than one box. Unless a main
over-current device is provided in each section, each section shall be
furnished with a main bus and terminals of the same rating for
connection to one feeder.

b) There are 3 methods commonly used for interconnecting multi-section

panelboards.
1) Gutter Tapping
(a) A wireway to run the feeder. Fabricated rectangular shape
galvanized steel duct that is dimensioned as per relevant
standards as specified in 1.04. This shall meet
requirement of relevant standards.
2) Sub-Feeding
(a) A second set of main lugs of each panelboard section,
except the last in the lineup.
3) Through-Feeding
(a) A second set of main lugs (through-feed) are provided on
the main bus at the opposite end from the main lugs of
each section, except the last in the lineup.

c) Lighting and appliance panels shall have bolt-on main over-current

protective devices. Circuit branches can be bolt-on or plug-in type circuit
breakers (MCCB or MCB). The plug-in type bus bars and circuit
breakers shall be silver-plated joints or overlapping joints.

B. Bus Bars For Panelboards

1. The bus bars shall be tin-plated, except where joints are overlapping or mating
surfaces that shall be silver plated or copper with 98% conductivity as per
relevant standards listed in par. 1.04.

2. The phase arrangement on 3-phase buses shall be A, B, C from front to back,

top to bottom, or left to right, as viewed from the front of the panelboard.

3. The bus bars shall be so located as to be free from physical damage and shall
be held firmly in place.

4. The arrangement of bus bars shall be such as to avoid overheating due to

inductive effect.

5. A neutral bus bar of the same rating as that of phase bus shall be provided
and shall have numbered terminals for connection of neutral wires.

Rev 0 17 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

6. A ground bus shall be secured inside the panelboard. Panelboard cabinets

and panelboard frames shall be in physical contact with each other and shall
be bonded to ground bus.

C. Wiring

1. An insulated conductor used within the panelboard shall be listed, flame

retardant, and shall be rated not less than the voltage applied to it and not less
than the voltage applied to other conductors or bus bars with which it may
come in contact.

2. The enclosure for a panelboard shall have the top and bottom wire bending
space sized in accordance with NEC Table 312.6(B) for the largest conductor
entering or leaving the enclosure. The side wire bending space shall be in
accordance with NEC Table 312.6(A) for the largest conductor to be
terminated in that space.

D. Terminal Blocks

1. In panelboards, load terminals for field wiring (including grounded circuit

conductor load terminals and connections to the ground bus for load
equipment grounding conductor) shall be located so that it will not be
necessary to reach across or beyond an un-insulated ungrounded line bus in
order to make connections.

2. All wire and cable connections to the main circuit bus system shall be
terminated using 2-hole compression connectors.

3. All wires and cables 95 mm2 (4/0 AWG) and larger shall be terminated using
compression connectors.

2.04 CONTROL CENTER

A. Motor starters and motor control centers are covered under control centers.

1. Control centers are commonly used in commercial buildings for starting,

stopping, and protecting the motor/s to which it is connected.

2. It is also applicable for grouping of large motors to be controlled from one

location.

3. The control center shall be equipped, unless otherwise indicated, with a main
over-current device, motor starters, motor contactors, overload protection
device and necessary interconnections, instrumentation and control wiring.

B. Motor Starters

1. Motor starters (or combinations thereof) shall be provided for mechanical

equipment and systems if not specified under the Mechanical Sections, as
indicated in the appropriate specification or Electrical Drawings.

2. Motor starters are composed of magnetic contactors and mechanically held

relays. Both devices shall be of the single coil, electrically operated and

Rev 0 18 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

mechanically-held type. Positive locking shall be obtained without the use of

hooks, latches or semi-permanent magnets.

a) Main contacts shall be double break silver-to-silver type protected by the

arching contacts. Contacts shall be self-aligning and renewable from the
front of the panel or MCC.

b) Control connection shall be clearly marked “L” for line, “C” for closing,
and “O” for opening. Remote control switches with protection shall be as
per standards.

c) Magnetic contactors and mechanically held relays shall be rated 600 V

and below or as indicated on the Contract Drawings, 60 Hz service and
127 V 60 Hz control, of amperage as indicated.

3. Motor starters shall be rated for continuous current suitable for the associated
motor in accordance with related standards specified in par. 1.04 and as
shown on the Contract Drawings. Minimum size of a starter shall be NEMA 1
size.

4. All starters must be equipped with thermal overload relays in each ungrounded
conductor as per NEC Article 430.32 and shall be sized in accordance with
nameplate rating of motor supplied.

5. If starters are provided with disconnect switches or motor circuit protector type
circuit breaker as the main disconnecting device, the motor circuit protector
shall be an adjustable instantaneous only type. The handle mechanism used
to operate the circuit breaker shall be labeled with ‘ON,’ ‘OFF’ and ‘TRIP’
positions; and that of the disconnect switch with ‘ON’ and ‘OFF’ positions.

6. The handle mechanism shall be arranged to operate in vertical up for ‘ON’

position and down for ‘OFF’ position. The handle shall be mechanically
interlocked with a door to prevent it opening when the circuit breaker or
disconnect switch is in the closed position. A defeater shall be provided to
bypass the interlock to allow a qualified person to do maintenance. There shall
be provisions for padlocking the handle in the ‘OFF’ position.

7. The Contractor shall supply:

a) Across the line manual starters for all motors of rating ½ HP and below
shall be operable on 127 V, single phase, 60 Hz supply.

b) Across the line magnetic starters for all motors above ½ HP and up to
200 HP shall be operable on 380 V (or voltage level as indicated on the
Contract Drawings), 3-phase, 60 Hz supply.

c) Combination starters for all motors where overload relays and other
devices for motor overload protection that are not capable of opening
short-circuits or ground faults, shall be protected by fuses or circuit
breakers with ratings or settings in accordance with Section 430-52 of
NEC.

d) Reduced voltage starters shall be provided for large motors where:

Rev 0 19 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

1) The calculation of voltage drop due to motor starting indicates that

the applied voltage at the motor terminals will be less than 80% of
the motor nameplate voltage and operation of the motors on the
same bus, or any other buses of the system is affected by voltage
depression.
2) The load or the connection between the load and the motor may
be damaged by sudden application of full voltage starting torque.
3) The motors are started several times in an hour or draws an
excessive starting current.

8. Manual Starters

a) The manual starter shall have a quick-make, quick-break toggle

mechanism with position indicator showing "ON" and "OFF" positions
and shall conform to the relevant standards specified in par. 1.04. It
shall be provided with trip-free manual reset thermal overload relays
with a position indicator showing "TRIPPED" position. The starter shall
be provided with a red indicating light showing the running condition of
motor and green indicating light showing the stopped condition. The
overload relay shall have a field adjustment allowing up to ± 10%
variance in ratings of the nominal heater value.

9. Magnetic Starters

a) The magnetic starter shall be provided with:

1) Oil-tight pushbuttons, control switches, contactors with extra
interlocking contacts and various indicating lamps as required and
as shown on the Contract Drawings. The indicating lamp shall be
of the filament type. The filament lamps shall have an integral
transformer or series voltage-dropping resistor sized so that the
applied voltage is 80% of rated lamp voltage. The lamps shall be
replaced from the front. Individual indicating lamps shall be of the
push-to-test type.
2) 380 V primary to 127 V secondary control transformer (or voltage
ration as indicated on the Contract Drawings) with a fuse in one
line of the secondary circuit and the other line grounded.
3) Trip free manual reset thermal overload relay, one per phase.
Overload shall have ± 15% adjustment from nominal heater rating
to compensate for ambient conditions or to provide closer
overload protection upon installation.
4) Two auxiliary single pole, double throw contacts in addition to the
normally open holding circuit interlock contact. Space also shall
be provided for 2 additional single pole, double throw contacts.

10. Combination Starters

a) The combination starter shall be provided with:

1) Across the line magnetic starter as specified in par. 2.04 B.7.
2) Fusible switch or circuit breaker as shown on the drawing. The
minimum frame size of the breaker shall be 100 A and interrupting

Rev 0 20 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

capacity of 22,000 A symmetrical at 380 V or as indicated on the

Contract Drawings.

11. Reduced Voltage Starter

a) The reduced voltage starter shall be considered for what it is used for to
ensure efficient operation, especially in larger motor sizes. Starters that
reduce in rush current each have unique characteristic, and are as
follows:
1) Autotransformer Reduced Voltage Starters
(a) They shall be used for the applications where highest
starting torque is required for reduced starting current of the
motor. During starting of motor, autotransformer reduced
voltage starters shall provide reduced current with a
minimum sacrifice of starting torque. Autotransformers shall
have adjustable taps to reduce starting voltage to 50, 65, or
80% of full-line voltage.
2) Part Winding Reduced Voltage Starters
(a) Part-winding reduced voltage starters shall be provided on
motors with 2 separate parallel windings on the starter. The
windings used during start shall draw about 65 to 80% of
the rated locked rotor current. During running, each winding
shall carry approximately 50% of the load current.
3) Star-Delta Reduced Voltage Starter
(a) Star-delta reduced-voltage starters shall be provided on the
motors having stator windings not connected internally and
all 6 motor leads available for connection. During starting,
the motor shall be connected in star configuration to draw
reduced starting line current. The motor shall be
reconfigured to a delta connection for running condition.
4) Primary Resistance Reduced Voltage Starter
(a) Primary resistance reduced voltage starters are provided
on motors used for belt-driven or gear-driven equipment.
During starting, the motor shall be energized through a
resistor in each of the 3 incoming lines. Part of the voltage
shall be dropped through the resistors. The motor shall
receive 70 to 80% of the full-line voltage. As the motor
picks up speed, a time-delay relay shall close a separate
set of contacts, shorting out the resistors and applying full
voltage to the motor.
5) Solid State Reduced Voltage Controllers
(a) These are more advanced starters and shall be used where
greater control of starting, running and stopping of motor is
required. Solid-state reduced voltage controllers shall apply
voltage gradually from some low initial value to 100%
voltage resulting in reduced in rush current and smooth
acceleration of the motor.

Rev 0 21 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

12. Reversing Starters

a) The Contractor shall supply reversing starters for motors used for
various applications such as the opening or closing of valves. The
direction of rotation of the motor shall be changed by changing the
direction of current flow through the winding. This shall be achieved by
interchanging supply between phase A and C of 3-phase motors.

C. Motor Control Center

1. The LV motor control centers shall be preferred for applications involving

central control of LV multiple motors. Applicable standards as specified in
par. 1.04.

2. Construction of Motor Control Centers

a) The motor control center shall consist of a number of basic vertical

structures. Each basic structure shall have a vertical bus system
connected to a horizontal bus system. The horizontal bus system in a
segregated location is behind, on top, or on the bottom of the vertical
system. The total height of the motor control system shall not be more
than 2280 mm. See par. 2.02, for construction specification.

b) Each vertical section shall consists of a number of basic units, which

contain combination or unitized combination starters with or without
control transformers, combination reversing, or multiple-speed, reduced
voltage starters, etc.

c) The basic units in vertical sections shall be prefabricated and plugged

(draw-out type) into the vertical bus structure. Class 4 to NEMA
standards and below shall be draw-out type.

d) Larger combination starters, see relevant standards for meeting

requirement, shall be bolted to the vertical bus structure, or unless
otherwise indicated on the drawings.

e) All compartments (maximum of 6 compartments per vertical assembly)

are multiple of a basic dimension (usually 76 and 152 mm). The total
width of each vertical section shall be 500 mm (minimum) or as per
manufacturer basic width.

f) The construction of motor control center shall have the same

specification as specified in par. 2.02, except as specified herewith.

g) In specifying, designing or selecting motor control centers, incoming and

outgoing wireway shall be considered.

h) Metering shall be given consideration, or as required by the Contract

Drawings, such as to voltmeters and respective voltmeter switches;
ammeters for each motor starters or one ammeter, in the bus, or both;
kilowatt meters; power factor meters; and running time meters. These
functions could be also on programmable, solid-state, multi-function
devices with digital read-outs and outputs.

Rev 0 22 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

i) Provide identification labels for each motor starter indicating the motor
or device controlled. Device, such as meters, circuit breakers, and
fuses; and each compartment, the enclosing devices, or the operational
parts. The nameplate shall be bolted or riveted by stainless steel bolts or
non-corrosive materials; shall be of laminated plastic materials with
white background and with 5 mm high black cut-in letters.

j) Provide openings, bus stubs with jointing materials and accessories for
future motor control expansion.

k) Provide spare parts such as entire starters, circuit breakers and fuses (if
specified protective device or parts thereof) that are subject to periodic
replacement.

l) Relevant standards classify that motor control centers have different

classes of assemblies. The design may specify the physical
arrangement of units within the motor control center; however,
arrangement shall be subject to the design parameters of the
manufacturers.

m) All circuit components within each unit shall be factory wired. The type
of wiring requirement shall meet relevant standards.

n) Each compartment shall be provided with an individual door, mounted

on removable pin hinges. The door shall be mechanically interlocking
with the unit protective device to prevent the door opening or closing
when the device is in the “ON” position. A defeater shall be provided to
bypass the interlock.

o) A horizontal wireway with removable doors shall be provided at the top

and bottom for wiring between sections, incoming conduit and cables,
motor and control wiring.

p) A vertical wireway shall be provided in each vertical assembly on the

right side, full length, with 2 doors top and bottom mounted on
removable pin hinges, and secured by quarter turn indicating fastener.

q) Motor control centers may be grouped in a central location. It shall be

self-supporting and may have units mounted on the front and back, or
only on the front. Control centers shall have minimum of 500 mm in
depth for free standing. Control centers may be mounted on walls.

r) The short-circuit capability of a motor center shall be determined by its

structure, individual controllers, and other current-carrying components.
Current limiting reactors are available as part of the motor control center
lineup to reduce available short-circuit currents so that economical
combination starters can be specified.

s) The short-circuit rating shall be equal or greater than the available

current on the line terminals. If current-limiting means are used, only
components ahead of these current-limiting means should be capable of
withstanding the available short-circuit current.

Rev 0 23 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

3. Bus Bars for Motor Control Centers

a) General
1) Each vertical section shall be provided with a main 3-phase
insulated horizontal bus at the top, and with a 3-phase insulated
vertical bus to distribute power to the combination starters and
feeder units in the vertical section. A full neutral copper bus bar
shall be provided as specified on the Contract Drawings. A
continuous bare copper ground bus shall be provided throughout
the length of the control center.
2) All bus bars shall conform to ASTM B187M, 98% conductivity
copper with silver plated contact surfaces. Horizontal and vertical
buses shall be tin or silver plated and shall be braced to withstand
the minimum RMS symmetrical fault current of 32 kA at a
utilization voltage of 380 V, or as specified on the drawings. Bus
ratings shall be based on 50°C rise over a 40°C ambient.
3) All buses shall be rigidly held by bus supports which have high
and indefinitely long lasting dielectric qualities, are moisture
resistant, non-carbonizing, non-tracking and have a vertical
creepage surface to prevent faults due to build up of conductive
dirt. Bus bar spacing shall not be less than and spacing of bus
fastening point and shall not be more than those specified in
UL 845.
4) The phase arrangement on 3-phase horizontal common power
and vertical buses shall be A, B, C from front to back, top to
bottom, or left to right, as viewed from the front of the Motor
Control Center.

b) Horizontal Bus Bar

1) Each MCC section shall contain 3 main horizontal bus bars,
housed in an isolated compartment, which shall run continuously
through all sections of the MCC, with provision made for
extension at either end for future expansion.
2) Bus bar and other types of bolted connections in the bus
compartment shall be accessible from the front of the MCC lineup
through sliding or removable covers in each vertical section.
3) The main horizontal bus shall be continuous and unspliced within
each shipping section. Where the buses are spliced for shipping
purposes, the contact surfaces at the splice joint shall be tin or
silver plated. The bolts, springs, washers, splice plates and
instructions required to complete the splice shall be provided.
4) The main horizontal bus rating shall be as specified on the
drawings. The minimum rating shall be 800 A.

c) Vertical Bus Bar

1) Each vertical section shall contain 3 full length copper vertical bus
bars connected to the horizontal main bus bars at the top of each
vertical section.
2) The vertical buses shall be isolated from the starter unit area of

Rev 0 24 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

the vertical sections by a barrier made of a rigid insulating

material.
3) If MCC will not be equipped with a shutter mechanism to close the
plug-in stab openings to the vertical bus, plugs shall be provided
in the unused plug-in stab openings.
4) The vertical bus bar shall be rated as specified on the drawing.
The minimum rating shall be 600 A.

d) Ground Bus Bar

1) A continuous, horizontal tin-plated copper ground bus of cross-
sectional area 6 x 50 mm, shall be located across the complete
length of the MCC lineup, with provisions made for extensions at
either end for future expansion.
2) Provisions shall also be made to terminate a 120 mm2 copper
ground system cable at each end. The ground bus shall be routed
at the lower rear of the line up. Minimum current rating of the
horizontal ground bus shall be 300 A.

4. Wiring

a) All equipment shall be completely wired within the control center for
control and operation. Wiring shall be in accordance with NEMA Class II
Type B.

b) Control wiring, rated at 90°C or greater, shall consist of stranded copper

conductor having cross-sectional area not less than 2.5 mm2. Wire
insulation shall be Type SIS switchboard wire, 600 V class,
thermosetting and moisture, heat, oil and flame resistant.

c) All internal wiring shall be identified with slip-on wire markers. Wiring
requiring external connections shall be brought to terminal blocks for
attachment of external leads. All external wiring shall be identified with
duplicate cable tags. One tag, with black lettering on white, shall be
applied by use of a heat-shrinkable sleeve, fire retardant, resistant to
industrial solvents, contaminants and sunlight. The second tag shall be
metallic, corrosion resistant and shall be installed by use of cable ties
resistant to industrial solvents, contaminants and sunlight. The cable
shall be identified as per wiring drawings with the service number (i.e.
motor no., panel etc.). The cable identification shall also show the
source equipment (MCC, switchgear no. etc.). Wires shall be terminated
with full-ring, insulated, compression connectors.

d) The following starter wiring points shall be brought out to separate

terminal block points for external connections:
1) Both sides of the control transformer secondary.
2) Both sides of the seal-in contact.
3) Starter operating coil terminal normally connected to one side of
the seal-in contact.
4) Both terminals of auxiliary contacts.

Rev 0 25 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

e) Power cables shall be terminated using compression-type terminal

connectors furnished for all power cables. Power cables will be XLPE
insulated with PVC jacket.

f) Control and feeder power cables will enter the motor control center
assembly either from the top and/or bottom. Suitable supports shall be
provided within the motor control center housing for power and control
cables.

g) The motor space heater circuit shall be factory wired from the heater
circuit breaker in the distribution panel board to the terminal block in
each starter compartment for remote connection. The motor space
heater circuit shall be wired through a normally closed auxiliary contact
of starter for automatic energizing of space heater when motor is
stopped. One branch circuit breaker shall be provided in the motor
control center space heaters for manual switching of heaters.

5. Terminal Blocks

a) Terminal blocks shall be provided for all secondary and control wiring
requiring external connections. The terminal block shall be front
mounted with minimum rating of 10 A, and shall be provided with marker
strips. The contractor shall supply 20% spare terminals.

6. Protection, Control and Metering

a) Provide incoming feeders, motor feeders and monitoring and controlling

devices as shown on the Contract Drawings.

b) All control devices such as oil tight ‘ON’ - ‘OFF’ or ‘OPEN’ – ‘CLOSE‘
push buttons, ‘H-O-A’ selector switches, ‘ON,’ ‘OFF,’ ‘TRIP’ and
annunciation indicating lamps and all control circuit elements as well as
protection and metering devices such as ammeters, voltmeters, watt
meters and power factor meters shall be provided as shown on the
Contract Drawings when conventional controls are used.

c) Preferred system of protective relaying, metering and monitoring shall

be the microprocessor based configurable controller.
1) Provide control modules to perform the indicated input and output
control functions.
(a) Modules shall incorporate faceplates having membrane-
type push buttons and LEDs. All push button and LED
functions shall be furnished with clearly written
identification.
(b) Provide a metering module capable of displaying phase
and line currents, current at the time of trip, phase and line
voltages, power, power factor, etc.
(c) Control modules shall be provided with 1.8 m connection
cord and single plug-in wiring to accommodate a jack
provided in the motor starter enclosure.

Rev 0 26 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

(d) Provide modules to cover applications ranging from full-

voltage non-reversing, reversing, multi-speed and reduced
voltage starters as required.
(e) Microprocessor shall be capable of monitoring electrical
current, receiving commands either by contact closures or
digital data, giving commands by means of contact closure
to the motor starters and other devices under its control,
and transferring information by alphanumeric display to the
operator and by digital signals to other equipment.
(f) Microprocessor unit shall be mounted on the door of the
starter. Specific data entry to suit the actual application
shall be programmed into the device in accordance with
manufacturer’s instructions.
(g) Unit shall draw its 120 V power supply from a control power
transformer located in the starter unit.
(h) When specified on single line diagram, the following motor
protection functions shall be required. Numbers in
parenthesis are ANSI device numbers.
(i) Overload (51).
(ii) Locked rotor (48).
(iii) Phase unbalance (46).
(iv) Ground fault (50G/51G).
(v) Undercurrent/under power (37).
(vi) Over temperature (49).
(vii) Under voltage (27).
(i) Microprocessor shall measure control circuit voltage and
prevent energizing of the coil on voltages below 78 V AC
and/or voltages above 135 V AC.
(i) Microprocessor shall continuously monitor the coil
circuit voltage and current so as to maintain constant
coil power at a level to maintain main contact closure
and minimize coil power consumption.
(ii) Provide electronic circuitry that protects the coil from
switching surges.
(iii) Microprocessor shall wait for 3½ cycles of control
start signals prior to activating a close to prevent
starts resulting from momentary voltage spikes,
switching transients, fluttering contacts, and shorted
programmable logic control outputs.
(j) Provide an addressable communication card capable of
transmitting all data over a compatible 2-wire, local area
network to a central computer for storage and printout.
Reprogramming of the central monitoring unit (CMU) shall
not be required when adding a communication module. The
network shall also be capable of transmitting data in
RS232C format via a translator module.

Rev 0 27 of 30 Contract No:

 SECTION 16440
SWITCHBOARDS, PANELBOARDS & CONTROL CENTERS

PART 3 EXECUTION

3.01 GENERAL

A. The Contractor shall provide all materials, equipment and labor as deemed
necessary for complete and proper execution of the work.

B. After the installation is complete and properly adjusted, the Contractor shall conduct
operating tests. The various equipment and systems shall be demonstrated to
operate in accordance with the requirements of the specifications. Tests shall be
performed in the presence of the Royal Commission's representative. The Contractor
shall provide electric power, instruments and personnel necessary for performing the
various tests.

3.02 INSTALLATION OF EQUIPMENT

A. General

1. All installation details, write-up on handling of the equipment, instruction

manuals and latest revised drawings furnished by manufacturer shall be
available at site prior to installation of the equipment. These details shall be
reviewed by Royal Commission’s representative. The details and instructions
furnished in these documents shall be followed carefully during installation of
the equipment.

2. All buildings and rooms for the installation of the equipment shall be ready,
complete and clean. All embedded channels and anchor bolts shall be in place
as per the layout drawings. The clearances around the equipment shall be as
per Article 110.26 of NEC.

3. All the facilities required for transportation of electrical equipment from store to
site such as competent manpower, crane and trucks of adequate capacities
shall be supplied by Contractor.

4. All equipment moved to the site shall be inspected for damage or deterioration
during storage. Tag numbers and nameplates shall be verified with the details
given on the Contract Drawings.

B. Installation of Switchboard and Motor Control Center

1. Each switchboard and motor control center section shall be mounted on a

100 mm concrete pad and anchored to two 100 mm minimum channel iron
sills, by tack welding or bolting. Sills shall be furnished by the Contractor to suit
the motor control center and shall be leveled and grouted flush into the
concrete pad by the Contractor.

2. All shipping sections shall be installed on foundations and connected together

as per the layout drawings and manufacturer’s recommended practice.

3. All bus bars of the shipping sections shall be connected together by stainless
steel nut and bolts as per manufacturer’s instructions. The torque applied on
nuts and bolts shall be as recommended by manufacturer.

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4. All power and control wiring shall be completed as per the Contract Drawings.

5. Ground complete switchboard and motor control center and motor starters as
specified in SECTION 16060.

C. Installation of Panelboard

1. The Panelboard shall be installed in dedicated spaces and protected from

damage.

2. The Contractor shall mount panel on wall or flush in walls. Wall mounted
panels shall be securely fastened to the wall utilizing expansion bolts or
mounting channels. The panels shall be mounted square to the building lines;
the mounting height of the center line of the top protective device shall not be
greater than 1800 mm above finished floor.

3.03 TESTING AND COMMISSIONING

A. General

1. The Contractor shall carry out all site tests in accordance with approved test
procedure to ensure that the equipment and materials comply with the
specifications and operational requirements. All tests are subject to witnessing
by the Royal Commission’s representatives.

2. At least 4 weeks prior to scheduled tests, the Contractor shall submit to the
Royal Commission an outline of the plan and procedures to be used in
performing the site inspection and site tests. This outline shall include a brief
description of the test equipment, connection diagrams, proposed tests and
procedures, test sheets, calculations, reference drawings and minimum/
maximum test and performance values in conformance with applicable
standards which will be used to determine conformance with the specification
and acceptability of the equipment and installation.

3. Upon completion of installation and prior to final acceptance, each component

of each system shall be tested to the complete satisfaction of the Royal
Commission. The various equipment and systems shall be demonstrated to
operate in accordance with the requirements of the specifications.

4. The Contractor shall provide all test instrumentation, equipment and

accessories necessary for demonstration and putting the equipment into
operation. Before commissioning, the Contractor shall submit all calculations of
relay settings and coordination curves to the Royal Commission for approval.

5. All testing equipment shall be calibrated by approved authorities and

calibration certificate shall be provided to Royal Commission for their review
and approval.

6. Upon completion of all testing the Contractor shall submit 5 copies of a

certified report attesting that each test has been performed in accordance with
the approved test procedures. The report for each test shall include the name
of the person in-charge of test and the date of performance. All factory and
field test reports shall be included in Operation and Maintenance Manuals.

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B. Test and Check-Out on Switchboards and Motor Control Center

1. Check ground bus bar continuity and connection to plant ground grid. The
grounding resistance shall comply with recommendations of IEEE 142.

2. Check that all connections and identifications are made in accordance with the
relevant schemes. Check all connections for tightness.

3. Perform insulation resistance test on power and control wiring and verify that
the insulation resistance of ungrounded conductor to ground is a minimum of
10 Mgohms.

4. Perform ratio and polarity test on instrument transformer.

5. Perform operational tests on various components, including electrical and

mechanical interlocking, local and remote control, local and remote position
indication, local and remote alarm indication, local and remote measuring and
metering, etc. Perform current injection, as required, to verify proper operation
of devices.

6. Perform functional tests on all control circuits using elementary diagram.

7. Set and test all overload relays and protective devices as per relay
coordination study data sheets.

8. While testing operation of circuits and controls, operate each control a

minimum of 10 times and each circuit continuously for a minimum of ½ hour.

9. Perform functional tests on communication network between local area and

central computer, including transmitting data in RS232C format via a translator
module.

C. Test and Check-Out on Motor Starters and Panelboard

1. Test equipment enclosures for continuity to the grounding system.

2. Test that insulation resistance to ground of ungrounded conductor is a

minimum of 10 Mgohms.

3. Test circuits for connections in accordance with the wiring diagram. Check all
connections for tightness.

4. Test operation of circuits and controls. When testing, operate each control a
minimum of 10 times and each circuit continuously for a minimum of ½ hour.

END OF SECTION

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