sec c electric electronic august 2012

7/23/2019 Sec C Electric Electronic August 2012

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Motores John Deere Section CElectri c ElectronicRevised on August 2012 Page 1 of 45

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MOTORES JOHN DEERE, S.A DE C.V.

CONTROLS AND ELECTRICAL REQUIREMENTS


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ELECTRICAL SPECIFICATIONS

Table of Contents

6. Standard Controls Equipment6.1 Control System6.2 Human Machine interface (HMI)6.3 Local and distributed I/O6.4 Distributed I/O Networks6.5 Marquees or Display Units6.6 ID System6.7 Electrical Motors6.8 DC Power Supplies6.9 General Servo control

6.10 CNCs6.11 Variable Frequency Drives (VFDs)6.12Soft-Start Units6.13 Programming Software6.14 Acceptable Manufacturers6.15 Robots6.16 Vision Systems

7. Standard Controls Equipment Implementation

7.1 Panel Mounting7.2 PLC Spare Space7.3 Control System Wiring7.4 Control System Documentation7.5 Programmable Controller Design7.6 OEM Computer and Peripheral Equipment7.7 HMI Software Configuration7.8 Control and electrical enclosures

8. Motores John Deere modifications to NFPA-79 Standards


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1. Electrical systems and equipment shall conform to the specifications and theirmodifications, as outlined below. These specifications shall become a part of thevendor's proposal or quotation. Appropriate Motores John Deere (MJD)representatives must approve any change or deviation from these standards,

Deviation Request form must be filled out in order to communicate whether there isa specification, regulation or request, in the RFQ that the supplier is not able to fulfill,make commitment for, or comply with.

1.1. National Electrical Code - NFPA No. 70, latest edition.

1.2. SAE HS-1738, latest edition.

1.3. Occupational Safety and Health Act, 29CFR Part 1910, Subpart S, latestrevision.

1.4. Special emphasis to 29CFR 1910.147 Control of Hazardous Energy

1.5. All materials shall be UL-approved where applicable.

2. Exceptions

2.1. Wherever equipment, due to peculiarities in design, cannot conform tothese standards, it shall be so stated in the quotation.

2.2. Whenever equipment is a standard, or off-the-shelf unit, and not inconformance with this standard(s), a complete set of preliminary drawings,per Section N, shall accompany the quotation. No equipment will be givenapproval without such submittal.

2.3. Deviations: Deviations from this standard shall have the approval of theMJD representative in writing. Any waivers granted shall apply only to theorder in question and shall not be considered as permanent.

3. In areas where these standards overlap, the more stringent shall take precedence.

4. It is not the intent of these standards to cover all items or details of design andconstruction or to unduly limit the bidder's design or responsibility to furnishcomplete and satisfactory equipment adequately powered to safely perform thework. Throughout these specifications, suppliers for various components and/orpieces of equipment are indicated.

5. These should be construed as MJD suppliers, in their desire to reduce spare partinventory and maintenance know-how; it is also intended to establish a quality levelagainst which proposed alternatives may be compared. Alternate component and

equipment items must be listed in the quotation and will be given full considerationproviding that they be judged by MJD as equal and are in the interest of MJD.


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6. Standard Controls Equipment:This document serves as a guideline for the design of electrically controlledequipment. The following controls equipment is authorized for use in control systemsfor MJD. The builder will provide electrical prints, machine controller type, andsoftwares versions (HMI, PLCS, etc.) to be used, for approval before electrical

design approval and construction begins.A supplier that wishes to use another manufacturer or similar equipment from listedin this section may request the deviation from this specification from MJDrepresentatives. The request must be in writing and must contain the reason for thedeviation. MJD representative will authorize the use of these devices in writing only.

6.1. Contro l Systems.

The following control systems are authorized for their use in Motores JohnDeere:

6.1.1. Unrestricted use.

6.1.1.1. For small and medium size applications - Allen BradleyCompactLogix system, a 1769-L32E controller, usingfirmware revision 20.

6.1.1.2. For medium and big size applications - Allen BradleyControlLogix system, 1756-L61 to L65, or L7 controller,using firmware revision 20.

Supplier must have approval from MJD Maintenancedepartment on which firmware will be installed.

6.1.2. Restricted use.

These systems must be small isolated systems (no I/O networks)and that do not need to connect (Process Interlock) to any otherprocessors. MJD Maintenance department must provide writtenauthorization for the use of these processors.

6.1.2.1. Allen Bradley Micrologix 10006.1.2.2. Allen Bradley Micrologix 11006.1.2.3. Allen Bradley Micrologix 1500

6.1.3. Power feed to Controllers.

120VAC power feed to Controllers, HMI, PC, Panel Views, panellighting, and 120VAC power duplex outlet to personal computer willbe provided by a Daykin transformer, derived ahead of the maindisconnect, maintaining power when the main disconnect is open.


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6.2. Human Machine interfaces (HMI)

No PCs are allowed for CNC manufacturing equipment as HMIs. Otheralternatives would have to be pursued with the CNC & OEM suppliers.Deviation from this instruction would have to be authorized by the the

Maintenance and IT departments under formal and written submitted request(See Secc X IT Factory Spec).

The following HMI systems are authorized for local or remote use incontrol systems in MJD:

6.2.1. Unrestricted use

6.2.1.1. Allen Bradley Panelview 1000 Plus, Color screen,touchscreen or keypad/touchscreen, RS232 and Ethernetcommunications.

6.2.1.2. Allen Bradley Panelview 1500 Plus, color screen,touchscreen or Keypad/Touchscreen, RS232 andEthernet communications.

The following HMI software systems are authorized for local, remote ordistributed use in control systems in MJD.

6.2.2. Recommended use.

6.2.2.1. Rockwell Software - RSView 32 7.00 or above.6.2.2.2. Rockwell Software - FactoryTalk View ME 6.1.

6.3. Local and distr ibuted I/O

6.3.1. All local I/O points should be according to the control systemthat the supplier is using in the machine:

6.3.1.1. Allen Bradley 1769 CompactLogix.6.3.1.2. Allen Bradley 1756 ControlLogix.

6.3.2. For distributed I/O the following families of products can be use:

6.3.2.1. Allen Bradley 1794 Flex I/O.

6.3.2.2. Allen Bradley 1790 CompactBlock LDX I/O.6.3.2.3. Allen Bradley 1792 ArmorBlock Maxum.6.3.2.4. Allen Bradley 1732 ArmorBlock.6.3.2.5. Allen Bradley Devicenet devices such sensors, soft

starters, VFD.6.3.2.6. Festo DeviceNet Valvepacks.6.3.2.7. Turck DeviceNet Stations (I/O Blocks).6.3.2.8. Parker DeviceNet Valvepacks.


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6.4. Distr ibuted I/O NetworksThe following networks are authorized for distributed I/O use in controlsystems in MJD:


6.4.1.1. DeviceNet Network.6.4.1.2. ASI Network.6.4.1.3. Profibus DP Network.6.4.1.4. Ethernet I/P Network.

6.5. Marquees or Display Units

Marquees and informational display units shall be Adaptive Microsystems1 to 3 lines of characters of 3.5 to 4.5 height, with an Ethernet interface.

Allen Bradley DataLiner with Ethernet interface.

6.6. ID Systems


6.6.1.1. Barcode reader equipment, Please see section X forstandard equipment list or contact MJD IT department.

6.6.1.2. RFID Systems must be Balogh products.6.6.1.3. Barcode system for power & free carrier identification

must be Smarteye Auto-ID systems.6.6.1.4. Datamatrix ID readers must be Cognex products.

6.7. Electrical Motors

6.7.1. Operation VoltagesAll electrical motors must be 480 VAC, 3 phases, any deviationto this standard must be approved by MJD.

6.7.2. The following electrical motors can be use in applications in

MJD. All electrical motors must comply with NEMA PremiumEfficiency.

6.7.3.1. Baldor (Reliance)6.7.3.2. US Motors6.7.3.3. ABB6.7.3.4. SEW Eurodrive


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6.7.3. Motor Protection6.7.3.1. Overload protection.

All motors must be protected using overload devicesaccording with NEC standards. Could be of the followingtypes:

6.7.1.1. Thermal6.7.1.2. Bimetallic6.7.1.3. Solid State

6.7.3.2. Overcurrent protection.All electrical motors must be protected by usingthermomagnetic overcurrent protection according withNEC standards.

All protection devices must comply with NEMA or IEC standards.Motor protection using fuses are not permitted in MJD.

Motor protections must be monitored by PLC when applicable.Any deviation to this standard must be approved by MJD.

6.8. DC Power Supplies

The following switched power supplies will be used in control systemsdesigns, they must have multirange VAC input up to 500VAC.

All power supplies AC inputs and DC outputs must be protected bymagnetic breakers.

6.8.1. Sola Hevi/Duty6.8.2. Siemens

6.8.3. Acopian

6.9. General Servo Contro l

6.9.1. Servo controls using ControlLogix with Sercos or Fanuc 0i,Powermate iH. Control systems stated in section 6.1.1.2ControlLogix IS NOT PERMITID TO CONTROL GANTRYSYSTEM.

6.10. CNCs

6.10.1. Use Fanuc, and under written MJD permission in case of use

other equipment brand, Siemens is the second option.

6.10.1.1 Fanuc Series 30i/31i/32i Model A or B6.10.1.2 Siemens 840D SL, Di, DiS

6.11. Variable Frequency Drives (VFDs)

Variable Frequency Drives (VFDs) will be Allen Bradley products asfollows:


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6.11.1. Powerflex with 24 VDC control option and DeviceNet networkadapter (optional), Enclosure will be determined by MJD.

DC Drives will be Allen-Bradley products as follows:

6.11.2. Powerflex DC.

6.12. Soft-Start Units

6.12.1. Non-VFD motors will use Allen Bradley SMC Flex soft starterwith 24 VDC control option and Devicenet adapter (optional).

6.13. Programming Software

6.13.1 RSLogix 5000 for PLC Allen Bradley.6.13.2 Factory Talk View for PanelView Plus.

6.13.3 RSNetworx for DeviceNet and Controlnet networks.6.13.4 Fanuc Series CNCs6.13.5 Siemens Series CNCs

6.14 Acceptable Manufacturers.

It is not the intent of these standards to cover all items or details of designand construction, nor to unduly limit the bidders design or responsibility tofurnish complete and satisfactory equipment, adequately powered tosafely perform the work. Throughout these specifications, manufacturers

for various components and/or pieces of equipment are indicated. Theseshould be construed as the Owners preference, in the desire to reducespare parts inventory and maintenance know-how; it is also intended toestablish a quality level against which proposed alternatives may becompared. Alternate component and equipment items may be proposedand will be given full consideration providing that they be adjudged asequal and are in the interest of the Owner. Design specifications anddetails of the alternatives shall be submitted with alternate proposal. In allcases option a is the preferred manufacturer.

6.14.1. The following list indicates MJD Site preferences for suppliers of

electrical components. This list represents a desire to reducespare part inventory and to maintain a desired quality level. Thoseproceeded by an asterisk (*) are the most desirable. Alternatecomponents may be proposed and will be given full consideration.These alternate components must be detailed in the vendorsproposal and require the approval of the purchaser before use.Preferred Manufactures are as follows:


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6.14.1.1. Electric Controls (push buttons, selectors, pilot lights):

a. Allen Bradley. (*)b. Square Dc. Telemecanique.

6.14.1.2. Capacitors:

a. General Electric.b. Westinghouse.

6.14.1.3. Timing Devices

a. Allen Bradley. (*)b. Square D.c. Telemecanique

6.14.1.4 Limit Switches - Heavy Duty, Oil Tight, Plug-in:

a. Allen Bradley. (*)b. Square D.c. Telemecanique

6.14.1.5 Disconnect Switchesa. Square D (*)b. Allen Bradley

6.14.1.6 Proximity Switches (Capacitive, Inductive, Ultrasonic)a. Ifm Efector (*)

b. Allen Bradleyc. Turck

6.14.1.7 Photoelectric Sensorsa. Allen Bradley (*)b. Bannerc. Ifm Efector

6.14.1.8 Flow, level and pressure switches and transducers.a. Ifm Efector (*)b. Allen Bradley

c. Turckd. Banner

6.14.1.9 Sensor cables & Connectorsa. Turckb. Allen Bradleyc. Ifm Efectord. Lumberg


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6.14.1.10 Relays, Contactors, Circuit Breakersa. Allen Bradley (*)b. Telemecanique

6.14.1.11 Terminal Blocks and Power Terminal Blocks

(Screw Connection)a. Allen Bradley (*)b. Weidmuellerc. Phoenix Contact

6.14.1.12 Signaling (Beacons, Stack Lights, Horns)a. Allen Bradley (*)b. Federal Signal (Horns)

6.14.1.13 Safety Switches, Safety Relaysa. Allen Bradley (*)

b. Pilzc. Bannerd. STI Omron

6.14.1.14 Safety Interlocks for Operator/access Doora. Euchner (Actuator ZG type No. 016 849)

6.14.1.15 Safety Light Curtainsa. STI Omronb. SICKc. Banner

d. Allen Bradley

6.14.1.16 Multiconductor Cablesa. Olflexb. Alpha wirec. Carol Cabled. Dearborne. Belden

6.14.1.17 DeviceNet Mediaa. Allen Bradleyb. Turckc. Lumberg

6.14.1.18 I/O Distribution Boxesa. Turckb. Lumbergc. Allen Bradleyd. Ifm Efector


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6.14.1.19 Connectors multiplea. Hartingb. Phoenix Contactc. Weidmuellerd. Amphenol

e. Allen Bradley

6.14.1.20 Devicenet I/O Blocksa. Allen Bradley (*)b. Turckc. Lumbergd. Phoenix Contact

6.14.1.21 Pick-To-Lightsa. Banner

6.14.1.22 Wire Labelsa. Brady Self Laminatedb. Panduit Self Laminated

6.14.1.23 Wire Ductsa. Panduitb. Weidmueller

6.14.1.24 Control/Electrical/HMI Enclosuresa. Hoffman (*)b. Rittal

6.14.1.25 Product Impact Markersa. Telesis Pinstamp

6.14.1.26 PowerTracksa. Igus

6.14.1.27 Air condition for Enclosea. Pfannenberg (*)

6.15 Robots

6.15.1 ABB Robots must be integrated in MJD for materialhandling and manufacturing systems.

6.15.2 Any other Robot manufacturer must have writtenauthorization from MJDMaintenanceengineering.


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6.16 Vision Systems

6.16.1 Only Cognex systems must be implemented on machiningor assembly equipments.

a. Cognex In-Sight 5110 ID Reader (*)

7. Standard Implementation

MJD equipments must be designed to operate using 24 VDC for all controlsignals, the use of 120 VAC for this purpose is restricted and must beapproved by MJD Maintenace Engineering.

7.1. Panel Mount ing

7.1.1. The maximum height of any controls or electrical panels will be 5

feet (1.5 meters) above the finished floor. When the electricalpanel including a panel view or a HMI the height could be 7 feed(2.1 meters) and must have written authorization from MJDMaintenance engineering.

7.2. PLC Spare Space

The finished PLC control system after startup acceptance testing iscompleted will have:

7.2.1. Minimums of 20% free memory in the processor for programmingand data table.

7.2.2. A minimum of 20% unused I/O addressing for each panel with I/Olocated in it.

7.3. Control System Wiring

This section lays out the general requirements for all control systemwiring.

7.3.1. Process Interlocks

Process Interlocks: All communication between adjacent operationsthat interact in machines operating process. The function of these

signal are to act as an interlock to prevent improper operation orpossible damage to the equipment.

7.3.1.1. There will be no hardwired processor to processor (PLCto PLC) when required process interlocks.


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7.3.1.2. Process interlocks (PLC to PLC) must be via:

DeviceNet Network.ASI Network.Profibus DP Network.Ethernet I/P Network.

7.3.1.3. If the Process Interlock is between systems that have notNetwork link, then the interlock may be hardwired usingsafety relay connected to I/O and identified by yellowwiring. MJD should be aware for the approval of theactivity.

7.3.2. Data Process

Data Process is all information that is sent to an operation adjacent

to denote the Part type, Serial No., piece counter, date, etc.

7.3.1.2. Data Process (PLC to PLC) will be via Ethernet.

7.3.1.3. If the Data Process is between systems that have notEthernet, then may be hardwired using safety relayconnected to I/O and identified by yellow wiring. MJDshould be aware for the approval of the activity.

7.3.2. External Logic

7.3.2.1. No hardwired logic will be done external to the PLC. This

includes PID control (i.e. PID controllers are internal tothe PLC).

7.3.2.2. Exception: multiple limit switches are in series to a singleinput will only be allowed if the output of all of the limitswitches in the series chain have a separate input.

7.3.3. Safety Systems

7.3.3.1. All hardwired Safety Interlocks will be wired throughsafety relays and will be monitored in the PLC. Eachsafety interlock must be connected to an input in thePLC. The supplier for safety relays and safety PLCsshall be Allen Bradley with exceptions to be approved byJohn Deere.

7.3.3.2. E-STOP condition will disable all outputs through amaster control relay.


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7.3.3.3. E-STOP condition will on be reset by a MCR reset buttonlocated on the equipment panel.

7.3.3.4. All machines must have an audible alarm before the

MCR be actuated and sounds again 5 seconds beforethe auto cycle start.

7.3.3.5 Conductors inside control enclosures must comply withcolor code as follows:

BlackAll ungrounded control circuit conductors operating at thesupply voltage (480 VAC, 230 VAC)

RedUngrounded AC control circuits operating at a voltage

less than the supply voltage (120 VAC, 48 VAC, 24 VAC,12 VAC)

BlueUngrounded DC control circuits (5 VDC, 12 VDC, 24VDC, 48 VDC)

YellowUngrounded AC control circuits or other wiring, such asfor cabinet lighting, that remain energized when the maindisconnect is in the "off" position.

WhiteGrounded AC current-carrying control circuit conductor,regardless of voltage (VAC Neutral).

White with blue stripe or Blue with white stripeGrounded DC current-carrying control circuit conductor

Green or Green with yellow stripePhysical Ground

7.4. Control System Documentation

The following documentation must be supplied to MJD by the vendor.

7.4.1. Drawings must have a border that includes MJD Logo, vendorcompany logo, and project number that links the drawing to theequipment. AutoCAD template will be provided by MJD.

7.4.2. All machine drawings must be submitted to MJD in AutoCADdrawing format version 2011.


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7.4.3. Equipment that requires multiple sheets must have an index sheetfor all of the drawings in the print set. The index must give the filename of the drawing and what is documented on the sheet.

7.4.4. Panel Drawings

7.4.4.1. Panel Layout and Mounting.

This is a series of drawings that show the general physicalarrangement of equipment on the inside or outside of thepanel.

Also any mounting or foundation details will documented onthese drawings.

7.4.4.2. Panel Interconnections.

This is a series of drawings that show all panels, all terminal

blocks, and all conductors that are installed in a system.All wires will be numbered.All terminal blocks will be numbered in numerical ascendingorder, starting from top to bottom, or from left to right.Terminals block label will not be the wire number or I/Oaddress.Spare terminal blocks will be shown and labeled as spares.Shell be 10 percent of total in use on the terminal block.

7.5. Programmable Controller Design

7.5.1. All machines shall be controlled by a programmable controller. MJDwill monitor software development on a regular basis. All logicfunctions must be performed internal to the PLC. Inputs and/oroutputs shall not be wired in parallel or series.

7.5.2. The following drawings must be submitted with the design of anyequipment that is programmable.

7.5.2.1. Flowcharts for sequence of operations.

7.5.2.2. Flowcharts for PLC control sequence.

7.5.2.3. Block Diagrams of system functions.

7.5.2.4. Description of user operation of the equipment

7.5.2.5. Description of troubleshooting of the equipmentthis may include two levels of troubleshooting:


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a. Troubleshooting for the operator to provide simplesolutions to error conditions that do not requiremaintenance help.

b. Troubleshooting for the plant engineers to solveequipment malfunctions.

7.5.3. Wire Labeling

7.5.3.1. Each wire will be labeled at all termination points.

7.5.3.2. Wires connected to PLC or CNC I/O cards will be labeledwith the programming address.

7.5.3.3. Wires that are not connected to I/O points will be labeled

with numbers that is identified on the electricalschematic. The first numbers are the number of sheetand the last numbers will be the number of row.

7.5.3.4. If multiple conductor cable is used, the wire color will beadded to the electrical schematic in addition to the wirenumber.

7.5.4. Device Naming Conventions

7.5.4.1. Standard electrical symbols shall be used for all

diagrams. Refer to American National Standard Y32.2.

7.5.4.2. Symbols for logic devices shall be in accordance withNEMA standard IC-1 Industrial Control

7.5.4.3. Symbols for devices shall be identified by numbercombination and letter. The following table identifiesexamples of equipment naming conventions.


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Items Examples

Relays - General Use CR, CR1, CR2

- Master CRM

- Automatic CRA

- Electronically

Energized

CRE

- Manual (HAND) CRH

- Latch CRL1, CRL2

- Unlatch CRU1, CRU2

- Timers TR1, TR2

Overloads OL, OL1, OL3

Motor Starters M1, M2,

Reversing Motor Starters MF1 (Forward)MR1 (Reverse)

Plugswith Multiple Poles

PL1, PL2PL1/4, PL2/6

Solenoids SOL1, SOL2

Limit Switches LS1, LS2

Pressure Switches PS1, PS2

7.6. OEM Computers and Peripheral Equipment:

7.6.1 For specifications of personal computers supporting manufacturingor machining equipment, please see section X.

PCs that require additional features or hardware such as TapeDrives, additional RAM, a SCSI hard drive or any device not listedabove, must be bought as part of the original equipment and fullysupported by the vendor and the original supplier.

Power conditioning or UPS is not required since MJD will have acentral power supply to provide the factory shop floor regulated andbacked up energy.

It is required that if the vendor purchases the PC, they shouldinclude in the package as a single solution to avoid ownership of

manufacturing equipment performance concerns. Contact MJD ITdepartment for details on special pricing considerations from HP.Corporate Software & Technology (CS&T is providing standardconfigurations to Deere units in the U.S. they may assist in thepurchase of the computer).

7.6.2 Equipment enclosuresEnclosures with good ventilation is required for equipment installedon the shop floor since the temperature will be maintained at 80 85 (26-30C)degrees. Electrostatic or equivalent dust filters are


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also required.Do not Place Control equipment PLC or CNC at thetop of equipment that produce heat. Also the enclosure shouldhave a thermostat connected to the PLC in order to detect an over-temperature.

7.6.3 Air ConditioningManufacturing supporting systems equipment that requires airconditioners will be allowed to maintain the temperature orenvironment of machinery or supporting electronic equipment. Thepreferred brand will be PFANNENBERG. The air conditioner shouldhave a thermostat and a switch door in order to shut off the coolerin case of door open.

7.6.4 Equipment WarrantyPlease see section X for warranty information or contact MJD ITdepartment.

7.6.5 Asset TrackingAll invoices that include PCs should be stated as line items so thatasset management could be completed per any written policy forasset tracking.

7.6.6 Protocol and Network CardThe standard protocol is TCP/IP. Network connections through100baseT adapters.

7.6.7 Laser Printers

Please see section X for standard printer information or contactMJD IT department.

7.6.8 ExceptionsAny special need will be considered as exceptions. Eachexception will be considered on per proposal basis. In order toavoid outdated, unsupported and obsolete equipment beingpurchased, MJD IT department must be notified and wait for theirapproval.

7.6.9 ObsolescenceDue to continuous growth in computer equipment technology,obsolescence is an important factor to consider. Please contactMJD IT department if technical specifications in these guidelinesare lower than the top configuration in the computer market at thetime of purchase.

7.6.10 The following items shall also be supplied with the documentationpackage specified in Section F.2 where computer systems areinvolved:


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7.6.11 Computer listing of the implemented software shall be provided intriplicate. This must include executive and applications programs insource and object code listing form. A complete cross-referenceshall be provided to make such listing readable to experienced

programmers.

7.6.12 All applications software shall be flowcharted. All variables, tables,arrays, and similar such data handling information shall beadequately described. All mnemonics shall be defined anddescribed. All such information relating to the system software andall information necessary to provide programming support shall beprovided in a "Programmer's Manual." Such a manual shall beprovided in triplicate.

7.6.13 Diagnostics: A complete set of OEM (Original EquipmentManufacturer) Equipment Diagnostics shall be provided with the

machine or equipment being supplied. All necessary equipment,instructions, manuals, and corresponding media (magnetic tape,Compact disc, DVD, etc.) shall also be included as a part of thetotal computer system. This shall be done even in the case wherethe sole use of such equipment would be to run diagnosticprograms only. Triplicate documentation, schematics, manuals,etc., as specified else where in this section, shall apply to alldiagnostic equipment and software.

7.6.14 Where special interfaces have been implemented by the equipmentvendor not the OEM's product), diagnostic programs shall be

supplied to exercise such devices to the fullest extent of theapplication. That is, diagnostics for such equipment must besupplied; and they shall be capable of complete testing of thisdevice(s), as interfaced to the computer system. These diagnosticsmust be capable of pointing out any problem in such specialequipment. Documentation requirements shall equally apply tothese diagnostics.

7.6.15 Schematics, as specified in Section F.2 below, shall include theentire computer: processor, drivers, clocks, DMA circuitry, etc. Allcircuitry within the computer mainframe cabinet and complete

electronic and logic schematics shall be included for all such items.

7.6.16 All Original Equipment Manufacturer's (OEM) manuals,publications, data, and application information materials, for thespecific equipment supplied, shall be provided in triplicate in PDFformat. The basic computer, the interface equipment, theperipherals to the system, the mass-storage devices, and allequipment provided as part of a computer system shall be includedin this requirement.


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7.6.17 Training: Training credit, or tuition, for computer-OEM training shallbe included in the equipment quotation. The amount of credits, ortuition, to be included shall be for the normal duration of the OEM

computer hardware training course held at OEM's site only.Quotations will not be accepted without such inclusion.

7.6.18 A triplicate set of "Computer Operator's Manuals" shall be provided.This manual shall specify start-up procedures, bootloaderprograms, system operating instructions, program operationinstructions, and all similar procedures.

7.6.19 The vendor shall provide a method of system rebooting. This shallinclude the necessary media services, loading devices, andprogramming to allow the system user (MJD) to reload and restartthe entire computer system without assistance from any vendor,

either equipment or computer OEM--except in cases of hardwarefailure.

7.6.20 Where field implementation of computer systems requires on-siterevisions to hardware and/or software, all documentation andstorage media (stored copies of supplied software) shall beupdated. All final documentation shall, therefore, reflect the systemas delivered and as working at the user's site, Motores John Deere.Overall acceptance of the equipment will not be given withoutcompletion of this work by the equipment vendor.

7.6.21 The following information must be supplied with the EquipmentApproval Drawings (see F.2):

7.6.21.1 Itemized heat generation list of all equipment in thecomputer system in BTU/hour.

7.6.21.2 A list of minimum environmental criteria must besupplied. Statements concerning cleanliness, humidity,security, and space requirements shall be made at theapproval stage of the project.

7.6.21.3 Industry-standard component identification numbers shall

be used on the schematic drawings and on the circuitboards in the entire system. Specials and Mystery Chips(integrated circuit chips) are not acceptable.

7.6.21.4 Electronic-printed circuit boards, modules, andsubassemblies must be labeled with the manufacturer'sassembly part number and revision level.


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7.6.22 Effective Spare Memory Space and the percentage of unusedprocessor time shall be calculated and stated. A minimum of 20percent spare, direct-access memory shall be provided.

7.6.23 For detailed information on computer equipment, softwarestandards, restricted softwares, restricted use of Ethernet networksplease refer to section X IT Factory Spec

7.7 HMI Software Configuration

7.7.1 All control and data collection from HMI software will beaccomplished with the PLC Ethernet interface.

7.7.2. Control functions will take place during the scheduled portion of thebandwidth.

7.7.3 An ethernet connection in the HMI PC will be used for:7.7.3.1 Data upload

7.7.3.2 HMI screen database access

7.7.3.3 Possible alarm database access

7.7.3.4 Program file management.

7.8 Control and electrical enclosures

7.8.1 All enclosures will be without viewing windows.

7.8.2 All enclosures with programmable equipment will have a folding

shelf capable of holding a laptop computer.

7.8.3 Near the folding shelf will be an available fused 120VAC poweroutlet and ethernet port.

7.8.4 All enclosures including HMI panels must have a maximum of 6feet (1.50 meters) in height in order to comply with visual factorystandard in MJD.

7.8.5 Communication and power drops to the control panels must be inopposite sides of the enclosure in order to avoid any kind ofelectrical noise in networks.

7.8.6 All main control enclosures must be provided with fluorescent lightin all doors and must be connected to the Daykin transformer inorder to maintain the VAC supply if the main disconnect is off.

8 Motores John Deere Modif ications to NFPA-79 Standards.

The following shall apply to NFPA-79, unless noted otherwise (based on NFPA1994 edition).


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NOTE: The following changes, additions, deletions, revisions, etc. to NFPA-79 are for purposes of conformance to obsolete JIC and current John Deerestandards. The combination of this NFPA-79 standard and the followingmodifications shall be considered together as one binding standard.

8.1 Add to 1-1 (a): Modifications to this standard shall also support:

-- Uninterrupted production.-- Long life of the equipment.-- Ease and low cost of maintenance.

8.2 Add 2-1 (d): Approvals and Final Drawings:

8.2.1 Approvals: Approval shall be obtained before electrical componentsare installed on the industrial equipment. After preliminaryapproval, any deviations made by the equipment builder shall have

the approval (MJD) Electrical Engineering in writing before changesare made.

8.3 The following approval drawings and data are to be submitted for approval:

8.3.1 Wiring and elementary diagrams (schematics)

8.3.2 Sequence of operation.

8.3.3 Bill of Material (showing original manufactured part number).

8.3.4 Panel and control station layouts.

8.3.5 Interconnection diagrams.

8.3.6 Electrical layout drawings showing the relative location of electricalpanels and electrical devices on the equipment.

8.3.7 Recommended spare parts list(showing original manufactured partnumber). When the equipment supplier furnishes packagedsystems from other suppliers in conjunction with his equipment, theequipment supplier shall furnish all electrical diagrams and

maintenance instructions for the packaged systems.

8.4 The amount of timing required to submit this (and all other) documentationIs specified in Section O of this specification.

8.5 See also E.9.d and E.9.e (computers).

8.6 Final drawings: On completion of the industrial equipment and not laterthan the date of shipment, a complete set of non folded tracings orreproducible copies of final diagrams shall be forwarded to the purchaser.


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The quality of the tracings or reproducible copies shall permit makingchanges and clearly legible prints. If the industrial equipment buildermakes any field changes, they shall be recorded; and a reproducible copyof the changed drawing shall be forwarded to the purchaser or other

designated person. AutoCAD-produced drawings with CD or DVD are apreferred alternative to reproducible Mylar prints.

8.7 Add to 2-2 (b):

Where a relay contact appears on a sheet separate from the one on whichthe coil is shown, the purpose of the contact shall be describedimmediately above the contact without using abbreviations. Refer thatparticular contact to the sheet on which the coil is shown. And refer thecoil to the sheets on which every contact is used.

8.8 Add to 2-2 (c):

The purposes or function of controls such as switches, relays, starters,contactors, solenoids, timers, etc., shall be shown on diagrams adjacent totheir respective symbols. The number of positions of solenoid valves shallbe shown adjacent to the valve symbol. Descriptive terms for commandand status functions shall be in the present or past tense. Example: raisetransfer - transfer raised; advance transfer - transfer advanced. Termssuch as "transfer up" shall not be used.

8.9 Add to 2-2 (e):Each conductor shall have the same identification at all terminals and tiepoints.

8.10 Revise 2-2 (g):

An interconnection diagram shall be provided on systems having anumber of separate enclosures and/or control stations. It shall indicatethe interconnecting conductors between all terminals on each terminalblock for all panels and chassis comprising the complete electrical system.Each connection shall be identified, as shown on the elementary diagramblank spaces; and spare terminals shall be shown.

8.11 Add 2-2 (j):

Electrical diagrams, including panel layout, bill of material list, sequence ofoperation, etc., shall be on a 11" x 17" sheet size. Multiple sheets shall becross-referenced. All diagrams shall show the equipment serial number,the purchaser's drawing number, purchase order number, or similaridentification which will indicate the particular equipment to which thediagrams apply. Diagrams shall show all equipment in the electricalsystem including internal wiring at subassemblies.


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8.12 Add 2-2 (k):

An elementary diagram shall be furnished for each electrical system. Alogic diagram may be furnished in lieu of or in combination with, anelementary diagram. The elementary diagram shall be drawn between

vertical lines, which represent the source of control power. All controldevices shall be shown between these lines. Actuating coils of controldevices shall be shown on the right-hand side. All contacts shall beshown between the coils and the left vertical line.

8.12.1 Exception No. 1: Overload relay contracts may be connected to theright of the coil (common), if the conductors between such contactsand the coils of the magnetic devices do not extend beyond thecontrol enclosure.

8.13 Add 2-2 (l):

Control devices shall be grouped and drawn in the following order:

8.13.1 Sequencing and position indicating relays, etc.

8.13.2 Solenoids for valves.

8.14 Within each group, control devices shall be drawn in the order ofenergization--with the exception of solenoids common to a valve;example: clamp - unclamp. Contacts of multiple contact devices (e.g.,selector switches) shall be shown on the line of the elementary diagram

where they are connected in the circuit with a dotted line or arrow showingthe mechanical connection of the contacts.

8.15 Add 2-2 (m):

Electronic diagram shall include pertinent data for maintenance purposesas follows:

8.15.1 Voltage and current data for maintenance purposes.

8.15.2 Normal voltages on transformer windings.

8.15.3 Signal input and output voltages.

8.15.4 Oscilloscope traces, showing wave form and peak-to-peak voltageswhere meter readings are inadequate.

8.15.5 The instantaneous polarity of each transformer winding in phase-sensitive circuits.


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8.15.6 The electrical values of capacitors, resistors, inductances, andother electronic components.

8.16 Add 2-2 (n):

The panel layout shall show the general physical arrangement of allcomponents on the control panel. Devices may be represented by squareor rectangles and identified the same as on elementary diagram. Sparepanel space shall be dimensioned. A layout of operators console or pushbutton station shall be shown

Photographs of electronic chassis and similar complex devices may befurnished in lieu of panel layouts, provided each component is clearlyvisible.

8.17 Add 2-2 (o): bElectrical Layout: The electrical layout shall consist of an outline of theequipment, not necessarily to scale, showing the control panel enclosureand its dimensions, operator's console, and accessory units not attacheddirectly to the equipment, such as hydraulic power units, in their relativelocations. The drawing shall also show the location of control deviceswhose location cannot be readily determined from the elementary andother electrical diagrams, such as limit switches used on indexingmechanisms. All devices shall be identified as shown on the elementarydiagram.

Foundation Drawing: On equipment requiring conduit in the foundation,the minimum size, purpose, and location of the conduit to be used shall beshown on a foundation drawing.

8.18 Revise 2-3 (d):

The parts listed shall itemize electrical spare parts showing quantity used,manufacturer's name, type or model and catalog number of each deviceused, motor horsepower, frame size, type of enclosure and speed, andany other information necessary to order replacement electrical andelectronic items.

8.19 Revise 5-8 (b):

When disconnects are mounted in separate enclosures, each supplyingpower to part of a complete machine or equipment, the followingprovisions shall be made:

8.19.1 A main disconnecting means shall be furnished to de-energize theentire system.


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8.19.2 Special emphasis must be given to provide for control of hazardousenergy sources, OHSA Std. 1910.147.

8.19.3 The disconnecting means in any of the separate control enclosuresshall de-energize all current-carrying components in that enclosurewhen placed in the OFF position.

8.19.4 Exception: Control devices and terminals located in the enclosure,but energized from a remote source, need not be de-energized ifidentified by yellow wiring.

8.20 Add to 5-9 (a):

A suitable device, operated by a screwdriver or other common hand tool,shall be provided so that the interlocks may be bypassed and the paneldoors opened without disconnecting the power. Interlocking must be

reactivated automatically when panel doors are closed. Progressiveinterlocking, door to door, shall not be used.

8.21 Add 5-10 (e):

The operating handle shall be mounted on the front of the controlcompartment or enclosure, not on a door.

8.22 Add to 6-1:

Fuses for power and control shall be dual element types having aminimum interrupting capacity of 100,000 amperes at rated voltage.Fuses shall meet the performance standards outlined in NEMA Standard

FU-1, Low Voltage Fuses. Fuse dimensions shall conform to those listedfor NEMA Class H.

Exception: The interrupting capacity requirement does not apply to fusesin the control circuit below the main control circuit protective device(s).Examples are those used for protection of individual solenoids and smallsubassemblies.

8.23 Revise Table 6-5 (a):

Percent of full-load current for dual element fuses shall be 125. Non-timedelay fuses and circuit breakers not allowed for motor protection.

8.24 Revise 6-5 (b):

All motors above 1 hp shall have individual branch-circuit overcurrentprotection, as specified in 6-3. Individual branch circuit preparation formotors 1 hp, and less, may share common branch circuit overcurrentprotection providing:

8.24.1 Maximum size conductor is in accordance with Table 13-1(f).


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8.24.2 Fusing shall not exceed 20 amperes.

8.25 Add 6-6 (d):

External motor overload reset push buttons are not to be provided.

8.26 Add to 6-7:

In addition, motors shall be protected against stalled conditions by the useof a separate protective device, which is responsible to motor current.

8.27 Delete exceptions 1, 2, and 4 of 6-9 (b):

8.28 Add 6-12 (e):

Control circuit transformers shall conform to NEMA Standard ST-1,Specialty Transformers, Section 4, Machine Tool Transformers, and shallbe Type 1, without integral overcurrent protection. The transformer

primary winding shall be dual rated 240/480 volts at 60 cycles with asingle secondary winding rated 120 volts. Ratings for other frequenciesshall be as specified in the NEMA standards.

Exception: Transformers rated less than 75 volt-amperes (e.g., for use incombination motor starters) shall conform to NEMA Standard ST-1,Section 3, Control Transformers. Add to 7-2 (a), Exception 2.

8.29 Delete 6-13.

8.30 Add 7-4 (c):

Solenoids shall be relay controlled with separate normally open contactsof the same relay connected in each lead of the solenoid. Not more thantwo contacts shall control any solenoid. For PLC controls, each outputthat drives a solenoid requires an individual circuit fuse.

Exception: Where a grounded control circuit is specified, a single normallyopen contact shall be connected in the ungrounded lead of the solenoid.

8.31 Add to 7-11:

The circuit shall be protected from under voltage and return to the neutral

mode upon power failure, thus requiring the operator to re-select themanual or automatic mode. Pilot lights shall be used to indicate manualand automatic modes to the operator.

8.32 Add 7-18:

Plugging Circuits: Plugging switches or zero speed switches, used tocontrol the application or removal of power in order that moving parts maybe slowed down, stopped, or reversed, shall be provided with featuresincorporated in the control circuit to (1) prevent the re-application of powerafter the completion of the plugging operation, and (2) prevent the


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application of power through any manual movement of the plugging switchshaft of the motor or equipment. Timing relays are not permitted forplugging motors used for tapping at the end of the forward stroke.

8.33 Add 7-19:Movement Initiation by Limit Switches: Control circuits shall be designedso that when the equipment is in its home, or end of cycle, position,movement of any part of the equipment can be initiated by limit switchesonly if all of the following conditions are met:

8.33.1 The control is set for automatic operation.

8.33.2 The control is of the holding circuit type and is energized.

8.33.3 The condition of the automatic operation is indicated by pilot lights.

8.33.4 On slides using position in controls like CNC axis or Transfer lineaxis you should add an overtravel limit switch normally closed on bothsides of the slide. These switches will turn off the power to the drive onthat sensing.

8.33.5 The position on all slides using encoders in the motors must havelinear encoder to double check heads position.

8.34 Add 7-20:

Anti-repeat Operation: On equipment where continuous consecutivecycles of operation of the equipment are not a normal or a desired

operation, the circuit shall be arranged so that such operation cannot beobtained by the use of any button or control means available to theequipment operator. Specifically, continuous consecutive cycles shall notresult even though the cycle start button(s) is held continuously in the startposition. Timers shall not be used in anti-repeat circuits.

8.35 Add 7-21:

Changing from Rapid Traverse to Feed: Hydraulically actuated headsshall not require an energizing operation to change from rapid traverse tofeed rate.

8.36 Add 7-22:

One Station for Motor Starting: There shall be only one station effective atany time for starting all motors consecutively. However, multiple stopstations may be used.


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8.37 Add 7-23:

Overspeed Protection for DC Motors: Shunt and compound-wound DCmotors shall be equipped with overspeed, or field-loss protection, toprevent excessive motor speed.

8.38 Add 7-24:

Rotary Cam Limit Switches used as Sequence Control: Rotary camswitches shall not be used as sequence controls on equipment unless theposition of the equipment component or the location of the material inprocess is indicated by separate controls, such as limit switches, whichare interlocked with the rotary cam switch.

Exception: This requirement does not apply to presses.

8.39 Add 7-25:

Control of Valves: Electrically controlled (solenoid) hydraulic andpneumatic valves shall be applied in such a manner that, in the event ofpower failure, there will be no hazard or damage to the equipment.

8.39.1 Workpiece clamping applications. The clamping solenoid valveshall remain energized throughout the working cycle and until theunclamp solenoid is energized.

Example: Clamps actuated by hydraulic or pneumatic means andcontrolled by two-position, double-solenoid-operated four-way valves.

8.39.2 Indexing applications.

Example 1: Hydraulic-indexing mechanisms controlled by three-position, spring-center, double-solenoid-operated four-way valves.

Example 2: Pneumatic indexing mechanisms controlled by two single-solenoid, spring-offset, three-way valves; or a two- or three-positionfour-way valve.

8.40 Add 7-26:

Factory regulations prohibit machine operators from using disconnect

switch, except in case of emergency; therefore, all operations includingtiming motors, solenoids, etc., which run continuously during operation,must be started and stopped by use of a magnetic master control relay, orequivalent, rather than using the disconnect switch.

8.41 Revise 7-17:

Two-Hand Operations: Two push buttons shall be provided for eachoperator for protection against pinch points or other movement hazardsand shall include all of the following:


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8.41.1 The circuits shall require maintained depression of each buttonthroughout the cycle or until a point is reached in the cycle wherethe hazard ceases.

8.41.2 Each pair of buttons shall be located and arranged so thatoperation by means other than the two hands of the operator isprevented.

8.41.3 The circuit shall be designed and wired so that the equipmentcannot be operated unless both buttons at each station arereleased between successive operations.

8.42 Add 7-27:

Circuit Design and Interlocking: Where improper sequencing may create ahazard or cause damage to the equipment or work in process, protective

interlocks shall be provided. Their interlocks shall give protection againstboth:

8.42.1 Failure of one or more devices to function properly.

8.42.2 Improper sequencing in manual or automatic operation.

For set-up purposes, manual means, preferably by push buttons, shall beprovided to perform individual functions. Direct operation of solenoidvalve with rods or tools is not considered "manual means."

8.43 Add 7-28:

Multiple Start Stations: Where more than one cycle-start station isprovided, all start buttons shall be concurrently depressed to initiate thecycle and released between successive operations, unless interlocking isprovided to require either (1) the use of one station at a time, or (2) theinitiation of the cycle by depressing buttons in a specified sequence.

8.44 Add 8-3 (f):

Polyphase motor starters shall be of the magnetic type and shall not besmaller than the NEMA Size 1.

8.45 Add 8-5:

Control device external to the control enclosure, such as limit switches,push buttons, selector switches, valve solenoid enclosure and pressureswitches, shall be oil tight, heavy-duty type. Watertight (NEMA 4)enclosures shall be used where the machines are exposed to coolant,soluble oil, water, weather, or similar wet environment.


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8.46 Add 8-6:

Panel mounted control devices shall be front-mounted, connected, andwired.

Exception: This does not apply to such direct current and large alternatingcurrent equipment not commercially available for front connection.

8.47 Add 8-7:

Screw-type terminals with captive saddle straps or equivalent means ofretaining stranded conductors shall be provided on control devices.

Exception: This requirement does not apply to devices mounted externalto the control enclosure and normally equipped with leads, such as valvesolenoid and clutches.

8.48 Add 8-8:

Control devices and coils shall be marked in accordance with publishedpertinent standards or with the maker's name or trademark, orderingnumber, and applicable descriptive electrical specifications such asvoltage and frequency.

Exception: Where the device is too small to identify, the information shallbe shown on the diagram or stock list.

8.49 Add 8-9:

Electrically energized devices located external to the control enclosure,such as clutches, solenoids. Other coil-operated devices, precision andother small devices used for control shall be enclosed and include an oil-tight enclosure for conduit termination and connection purposes. Coilsshall have leads, which extend a minimum of 4 inches with pressureconnectors. Connections shall be bolted and taped.

8.50 Add 8-10:

Solenoids used for actuating valves, brakes, and other mechanisms shallhave a continuous duty rating.

8.51 Add 8-11:Additional transformer capacity of 25 percent above requirements, but notless than 100 volt-amperes nor more than 1000 volt-amperes, shall befurnished.

Exception: This requirement does not apply to control transformers usedin combination motor starters.


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8.52 Add 8-12:

Relays shall have a complete set of contacts (e.g., a four-pole block shallhave all contacts furnished).

8.53 Add 8-13:

The following devices shall not be used:

8.53.1 Stepping switches

8.53.2 Push selector switches for start-stop operations

8.53.3 Latch relays, except for memory indication

8.53.4 Relays with overlapping contacts

8.53.5 Neutral position switches

8.54 Add 8-14:

Group Starting of Motors: The starting of motors shall be in sequence sothat a group of motors started simultaneously will not exceed anaggregate of 60 hp.

8.55 Add to 9-1 (a):

Control enclosures and compartments shall be constructed inconformance with applicable sections of this standard and both of the

following:

8.55.1 NEMA Type 12 (See NEMA Standard IC-1, Industrial Control).

8.55.2 Underwriters' Laboratories Standard UL 508, Industrial ControlEquipment.

8.56 Add 9-1 (c):

Mounting feet or other suitable means external to the enclosure shall beprovided for equipment-mounted enclosures. Separately mountedenclosures shall be freestanding.

8.57 Add 9-1 (d):

There shall be no holes in the enclosure for mounting the enclosure ormounting controls within the enclosure without MJD Electrical Engineeringapproval.

8.58 Add 9-1 (e):

Conduit or wireway openings shall be cut only as required. One additionalhole may be cut in the side or bottom for temporary power line connection.


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Where wireway and conduit are disconnected for shipment, such openingsshall be sealed prior to shipment.

8.59 Add 9-1 (f):

Other equipment shall not be mounted on the exterior of the control

enclosure unless specified by MJD Electrical Engineering.

8.60 Add to 9-5:

Exception 1: In no case shall the depth of the enclosure be less than 8inches.

Exception 2: When the panel area of floor-mounted enclosure exceeds3,600 square inches, the minimum depth shall be 12 inches.

8.61 Add 9-6 (a):

Compartment doors, enclosures and enclosure doors shall be designed tohave sufficient rigidity to assure continuous proper alignment betweenmating parts, such as door fasteners and locking devices.

8.62 Add 9-6 (b):

Door aligning guides may be used to insure alignment. Reinforcementsshall be used, as necessary, to prevent door warpage.

8.63 Add 9-6 (c):

Door swing shall be a minimum of 165 degrees.

8.64 Add 9-6 (d):

Door swing shall be such that ready access to disconnect handle is notblocked.

8.65 Add 9-6 (e):

Continuous hinges (piano type), welded in place, are preferred for allenclosure doors.

8.66 Add 9-6 (f):

Door fasteners on small enclosures and compartments shall be designedto seal the door tightly around its perimeter. Vault-type hardware, whichlatches simultaneously at the top and bottom, shall be used on smallenclosure doors.

8.67 Add 9-6 (g):

Door fasteners on large enclosures and compartments shall be designedto seal the door tightly around its perimeter. Vault-type hardware, which


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latches simultaneously at the top, center and bottom, shall be used onlarge enclosure doors.

8.68 Revise 9-9:

The interior of enclosure and back panel shall be finished in white enamel

or lacquer; the interior of the doors shall be orange enamel or lacquer.

8.69 Add 10-2 (h):

Controls should be mounted on an exterior surface of the equipmentbetween 1-1/2 and 5 feet, but in no case less than 12 inches, above theoperating floor line.Terminal blocks shall be mounted a minimum of 12 inches above theoperating floor line.Terminal blocks located in compartments at sectional points shall not berecessed more than 4 inches from the equipment surface.

8.70 Add 10-2 (i):

Control devices, normally panel mounted, shall be mounted in oneenclosure or compartment.

8.71 Add 10-2 (j):

Control equipment shall not be mounted on the door or sides of theenclosure--except for such devices as push buttons, selector switches,and pilot lights. Such devices shall be wired from terminal strips on thecontrol panel.

8.72 Add 10-2 (k):Panel-mounted control components, such as relays, shall be mounted innumerical order from left to right and top to bottom corresponding to thepanel layout. Starters and contactors should be mounted in a similarmanner.

8.73 Add 10-2 (l):

Spare terminals shall be provided on each control panel. The numbershall be 10 percent of the total in use on the panel or a minimum of 8 forcontrol conductors and 3 for power conductors.

8.74 Add 10-2 (m):

A minimum of 15 percent of clear panel mounting space shall be providedon large panels and 30 percent on small panels to permit adding futurecontrol devices. On large panels, the total space should be divided intotwo or more spaces.

8.75 Add 10-2 (n):

The bottom of the lowest panel-mounted control device shall not be lessthan 18 inches above the operating floor line. In no case shall the top of


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the panel-mounted control devices be more than 5 feet above theoperating floor line.

8.76 Delete 10-6 (a) Exception 1.

8.77 Add 10-6 (d):

Plug-in devices and assemblies should be mechanically secure.Automatic locking upon full insertion is preferred.

8.78 Delete 11-1 (a) exception.

8.79 Add 11-1 (f):

Indicating lights shall be of the push-to-test type, powered by 24 VDC.

8.80 Delete 11-4 exception.

8.81 Add 11-5 (a):Push button and pilot light enclosures with six or more units shall beequipped with hinged covers.

8.82 Add 11-5 (b):

Where more than 16 units are required, terminal strips shall be furnishedin the enclosure.

8.83 Add 11-7 (d):

Push buttons shall be mounted on a surface, which is not less than 45

degrees from the horizontal plane.

8.84 Add 11-7 (e):

Pipe lines, tubing or devices for handling air, gases, or liquids shall not belocated in control stations.

8.85 Add 11-9:

Multiple Station Equipment:

8.85.1 Pilot lights shall be furnished to show the position of mechanicalcomponents, such as clamps, transfers, transfer fingers and

locators, and the functions shown in Table 11-1.

8.85.2 Pilot lights shall be located at the main control station and arrangedin accordance with the sequence of operations.

8.85.3 Push buttons shall be provided at the operator's main controlstation to provide complete manual operation in accordance withthe sequence of operation.


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8.85.4 An operator's control station, including a selector switch, shall beprovided at each station for manual operation of individual heads.The control circuit shall be interlocked to prevent operation from themain control station when the local selector switch is set in either

manual or off position. The nameplate on the selector switch shallread from left to right automatic-off-manual.

8.86 Revise 12-3 (b):

Control panel lights shall be supplied from source number (6).

8.87 Add to 12-3 (c):

Instrument lights and machine work lights shall be supplied from sourcenumber (1).

8.88 Delete 14-1 (a), Exception 5.

8.89 Delete 14-1 (f), Exception.

8.90 Add 14-1 (g):

Terminals on terminal blocks shall be numbered in numerical ascendingorder, starting from top to bottom, or from left to right.

Exception: Terminals for remote interlock wiring shall be groupedseparately.

8.91 Add 14-1 (h):

Power wiring external to the control enclosure shall be sized for the nextlarger hp motor, up to and including 25 hp.

8.92 Revise 14-2 (a):

Panel wiring shall be contained in panel wireways.

8.93 Add to 14-2 (c):

The male plug shall be connected to the load circuit. Power and controlcircuits shall not be carried in the same plug.

8.94 Add 14-2 (d):

The combined cross-sectional area of all conductors and cables shall notexceed 50 percent of the interior cross-sectional area of the panelwireways.


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8.95 Add 14-2 (e):

Control panels shall be equipped with terminal blocks for all externalwiring requiring No. 4 AWG and smaller conductors. Conductors largerthan No. 4 AWG may be terminated directly on the device.

Exception: This does not apply to supply line conductors.

8.96 Add to 14-3 (d):

The length shall not exceed 3 feet.

8.97 Add to 14-3 (e):

Fittings shall include basket weave or equivalent grips.

8.98 Add 14-3 (m):

Where equipment is constructed so that wiring must be disconnected forshipment, terminal blocks or plugs and receptacles in an accessibleenclosure shall be provided at the sectional points. Spare terminals shallbe provided in each terminal enclosure, external to the control panel. Thenumber shall be 10 percent of the total in use or a minimum of 6whichever is greater.

8.99 Add 14-3 (n):

Wiring external to the control panel shall have a termination at the terminalblocks on the control panel. One wire shall be returned, for test purposes,from a connection between limit switches, push buttons, or other devices

connected in series. The common side of the control circuit shall be wiredto a terminal in master terminal boxes.

8.100 Add 14-3 (o):

All raceways and conductors between equipment and separately mountedenclosures shall be furnished. Inside the cabling duct the power wiring(motor and servo power supply or high voltage VAC) must be separatedfrom communication and control wiring.

8.101 Add 14-3 (p):

Interlock control circuit wiring, which is energized from a remote controlpower source, shall be segregated in terminal boxes and readily identifiedwith yellow insulation so the conductors can be distinguished from otherwiring in the box. Boxes containing such wiring shall be indicated on aplate affixed to the outside of the cover which reads: Separately EnergizedInterlock Wiring.


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8.102 Add 15-1 (c):

Junction, Pull, and Terminal Boxes: Boxes shall be readily accessible inorder that maintenance personnel be able to probe voltages duringmachine operation without hazard from moving equipment. Guarding

and/or maintenance platforms shall be provided where necessary to meetthis requirement.

8.103 Add 15-1 (d):

Junction, pull, and terminal boxes shall be sealed with the followingconformance:

8.103.1 Materials: Gaskets shall be of an oil-resistant syntheticmaterial.

8.103.2 Doors: Door sealing gaskets shall be at least 1/8-inch thick

and shall be held firmly in place by a continuous metal retainer inaddition to the adhesive.

8.103.3 Covers: Cover sealing gaskets shall be at least 1/16-inchthick and shall be held firmly and permanently in place.

8.104 Add 15-3 (i):

Where conduit terminates in a threadless opening, a lock nut shall beprovided both inside and outside the enclosure, and the conduit end shallbe equipped with an insulating bushing. A suitable oil-tight means (suchas oil-resistant synthetic rubber O-ring and a metal cup) shall be provided

between the outside lock nut and opening. When the conduit enters theopening through a conduit connector, the shoulder of the connector mayservice as the outside lock nut. The O-ring assembly or an equivalentsealing device shall also be furnished when a lock nut is used as a jam nuton connectors fitted to threaded hubs.

8.105 Revise 15-4:

Intermediate Metal Conduit: Intermediate (steel) conduit shall be permittedand shall be installed in conformance with the provisions of Sections 15-3(b) through (i).

8.106 Revise 15-8 (d):

Where wireway is furnished in sections, the joints between shall fit tightlyand gasketed in conformance to 15-1 (d).


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8.107 Add 16-6 (a):

Motor Specifications: All electric AC motors shall be foot-mounted, cast-iron frames, high-efficiency type of manufacture specified by Section F.2.High-efficiency specification waived only where motor manufacturer

excludes special frame types from respective, high-efficiency motor line.All motors shall be totally enclosed, fan-cooled, except that motors smallerthan 2 hp may be totally enclosed, non-ventilated, and so sized that at theloads of normal operation of the equipment, the hp requirements of theequipment load will not exceed the nameplate hp of the respective motors.Motors shall have sufficient torque to accelerate the connected load within20 seconds with 80 percent of rated voltage maintained during the startingperiod. Motors shall be rated 460 volts, 3-phase, 60 cycle in sizes over100 hp. Motors 100 hp and smaller shall be rated either 230/460-volt, 3-phase, 60 cycle, or 460 volt, 3-phase, 60 cycle. Single-phase motors arenot acceptable without written approval of the user. The Plant

Engineering Department shall approve Method of starting motors of 100hp, or above.

8.108 Add 16-6 (b):

Totally enclosed motors shall be certified for continuous operation at fullnameplate power output in an ambient temperature of 40C and shall beClass B or Class F insulated.

8.109 Add 16-6 (c):

Explosion-proof motors shall be dust explosion proof or vapor explosionproof, as required, with sealed connectors and Class B insulation.

8.110 Add 16-6 (d):

Two-speed motors shall be the two-winding types for three-phase motors.

8.111 Add 16-6 (e):

Motor bearings shall be heavy-duty ball or roller type, with full provision forsuch thrust as is imposed by the specific load. Bearings for integralhorsepower motors shall have rating life (AFBMA B10 rating) or 30,000hours. Shop drawing shall be accompanied by evidence from the motormanufacturer that motor bearings meet this service requirement.

8.112 Add 16-6 (f):

It shall be understood (and the submitting of a bid is understood by themanufacturer as declaration to that effect) that the manufacturer will beresponsible for replacing any motor which, upon failure within five years ofinstallation, is found to have been equipped with bearings which do notmeet these rating life requirements. This guarantee requirement is inaddition to that specified herein before.


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C-40

8.113 Add 16-6 (g):

All motors shall be provided with effective mechanical seals at both endsof both bearing housings. These seals shall be such as to guaranteeeffective grease-tightness for the above-specified minimum average

bearing life. Bearings on motors 1/4 hp and larger shall be equipped withdouble seals.

8.114 Add 16-6 (h):

Unit bearing motors are not acceptable for any service, except uponspecial written acceptance by the purchaser.

8.115 Add 16-6 (i):

All frame sizes shall conform to NEMA Standard MG-1 latest edition andsubsequent addenda.

8.116 Add 16-6 (j):

Motors with belt drives shall be installed with approved belt tensionadjusting facilities; this will require bases, rails, and adjusting screws.

8.117 Add 16-6 (k):

Shop drawings for motor-driven equipment must be accompanied bycomplete information concerning the respective motors. This informationshall include the following:

-- Horsepower

-- Voltage-- Phase-- Frequency-- Speed-- Maximum temperature rise in continuous service-- Enclosure type-- Frame-- Bearings

-- Type of bearings-- Manufacturer's bearing numbers-- Type of lube fitting

-- AFBMA Rating Life (B-10 Basis)-- NEMA design code letter-- Thermal damage curve for motors 100 hp and larger-- Motor-load acceleration-time curve for motors 100 hp and larger-- Manufacturer-- Conductor material-- NEMA nominal and guaranteed efficiency ratings

Full load power factor rating


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C-41

8.118 Add 16-7:

Motors mounted within machine compartments or enclosures shall beprovided with sufficient space for ease of lubrication, servicing, andreplacement. Sufficient air circulation shall be provided so that the motor,

when under full-load conditions, will not exceed its rated temperature rise.

8.119 Add 16-8:

The motor compartment, or mounting space, shall be of sufficient size toaccommodate a NEMA frame size motor, complete with junction box, twoNEMA horsepower sizes larger, at the same speed, than thatrecommended by the industrial equipment builder for driving theequipment.

8.120 Add 16-9 (a):

Special motors with static and dynamic balance and noise control shall beused only to eliminate machine trouble from these sources. In no caseshall the degree of balance be less than that specified in NEMA StandardMG-1, Motors and Generators.

8.121 Add 16-9 (b).

Special characteristics of AC motors shall be shown on a separatenameplate mounted adjacent to the conventional motor nameplate. Themanufacturer's catalog numbers shall not be considered sufficient todesignate such characteristics. Typical examples are:

8.121.1 Special insulation

8.121.2 Special shaft length

8.121.3 Special torque

8.121.4 Special balance

8.121.5 Special lubrication

8.122 Add 16-10:

No motor shall be required to operate intermittently or continuously aboveits RMS hp rating.

8.123 Add 16-11:

Motors 300 hp and above shall have two sets of thermistors embedded inthe stator--one set to shut the motor down in event of over temperature,the second set to prevent over temperature on restart by requiringsufficient cooldown prior to restart.


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C-42

8.124 Revise 17-2 (b):

Equipment grounding conductors shall be insulated or bare and shall beprotected from damage by means equivalent to those provided for liveconductors. If an insulated equipment-grounding conductor is used, the

insulation shall be green (with or without a yellow stripe).

Exception: NEC250-79,f "The equipment bonding jumper shall bepermitted to be installed inside or outside of a raceway or enclosure.Where installed on the outside, the length of the equipment bonding

jumper shall not exceed 6 feet and shall be routed with the raceway orenclosure."

8.125 Add to 17-7:

Ungrounded control circuits shall be equipped with ground detector lights.Lens color to be clear.

8.126 Add 16-12:

Power factor correction capacitors: Capacitors shall be installed on allinduction motors rated at 10 hp or larger.

8.127 Add 16-13:

All capacitors shall be of the dust-proof design and equipped with externalfuse protection and shall conform to NEMA standards (latest revision).(No internal fusing allowed.) Only units by preferred suppliers will beacceptable. Polychlorinated Byphenels (PCBs) materials are illegal and

therefore, completely unacceptable as insulating material in any device.

8.128 Add 16-14:

All capacitor installations shall be in accordance with the NationalElectrical Code and as specified herein.

8.129 Add 16-15:

Capacitor units shall be connected on the line side of the motor starteroverload elements and switched with the motor.

8.130 Add 16-16:

It is intended that capacitor units be mounted on the exterior of the controlpanel enclosure where practical.

8.131 Add 16-17:

Wire, conduit, and capacitor sizes for 480-volt, 3-phase, 60-cyclecapacitor installations shall be in accordance with Table 16-19.


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8.132 Add 16-18:

Any induction motors larger than 10 hp not covered by the capacitorsindicated in Table 16-19 shall be sized according to the original motormanufacturer's data to correct to 90 percent lagging power factor.

8.133 Add Table 16-19:

TABLE 16-19 CAPACITORS (KVAR SIZES)480 VOLTS, 3 PHASE, 60 CYCLE

Design B Design C Design D

InductionMotor HPRating

MinWireSize

MinConduitSize

3600RPM

1800or1200RPM

900RPM

1800or1200RPM

900RPM

1200RPM

10 12 3/4 3 3 5 5 5 5

15 12 3/4 4 4 5 5 5 5

20 12 3/4 4 5 5 5 5 5

25 12 3/4 5 5 5 5 10 7-1/2

30 10 1 5 5 10 5 10 10

40 10 1 5 10 10 10 10 12-1/2

50 8 1-1/4 5 10 15 10 15 15

60 8 1-1/4 10 10 15 15 20 17-1/2

75 6 1-1/2 15 15 20 15 20 22-1/2

100 6 1-1/2 15 20 35 20 25 30

125 4 1-1/2 20 25 35 35 30 37-1/2150 2 1-1/2 25 30 45 35 50 45

200 1 2 35 40 50 45 50 60


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8.134 Add 20-1 Miscellaneous:

For motor installations where the motor is over 50 feet away from or out ofsight of the control panel, the following is to be provided.

-- A manually operable switch, which will disconnect the motor from itssource of supply, is placed within sight from the motor location. Thedisconnect, or circuit breaker, equipped with an auxiliary contact which willde-energize the motor starter. Units where the auxiliary contact opensprior to the main contacts opening are preferred.

Bridge runway conductors. Provide insulated conductors for full length ofrunway, U. S. Safety Trolley "Span Guard" or equal. Provide all requiredhardware for complete field installation to user's structural steel. Accessplatform for maintenance on runway conductors and shoes to bepermanently affixed to the Crane Bridge with proper safeguard to protect

personnel.Provide quick disconnect means for electric hoist. Half turn plug ispreferred

-- Trolley conductors. Festooned cable type. Cable to be supported bytrolleys running on a rail permanently affixed to crane girder.

-- Hoist limit switches. Heavy duty enclosed. Power circuit interruptingtype arranged for automatic reset. Geared upper and lower limit.

-- Crane motors. Totally enclosed, non-ventilated, ball bearing, wound

rotor type, 60-minute, 55-deg. C temperature rise rating for crane duty,Class F insulation.

8.135 Add 20-2:

Machine Run-off Inspection: MJD representatives will inspect machinery for complianceto this specification. A copy of the runoff checklist will be provided by MJDrepresentative to aid the vendor in preparation for such inspection. The list shall beinterrupted as a guide only and not as a substitute for the specification


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sec c electric electronic august 2012

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