Integrated Power Assemblies - Electro/Centers

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1 Supersedes TD E 12/02 Contents Integrated Power Assemblies Product Description Integrated Power Assemblies Section View Plan Views Typical Specifications

2 Quality Eaton Products in a Single Enclosure at a Lower Installed Cost Eaton Corporation invented the concept of grouping electrical distribution and control equipment in a modular enclosure called an Electro/Center...custom designed to meet each customer s specific requirements. This concept is now part of a family of solutions we call Integrated Power Assemblies (IPA). Each Integrated Power Assembly Arrives Complete and Ready to Connect Saving Time and Money When an IPA is delivered, all the customer typically needs to do is: (1) place it on the suitable foundation such as a concrete pad or base with similar strength and durability and (2) make the incoming and outgoing load connections. That s because an IPA is a complete unit and can be prewired and factory tested, if required. An IPA provides these significant cost savings: Lower Installation Cost Job site labor and material costs are sharply reduced because an IPA arrives complete, ready for connections. Minimal Start-up Time Each IPA is checked to ensure wiring accuracy, control scheme correctness, and equipment operation. Installation Delays Reduced Job site delays caused by trying to coordinate multiple vendors are eliminated. Reduced Procurement Time Scheduling and expediting are handled through a single-point contact and only one purchase order is required. Customized Design IPAs have very few restrictions. They can be of almost any size, shape or color and in addition to Eaton electrical distribution and control equipment, can include whatever other non-eaton equipment a customer may require. We Are Your Single Source for Integrated Power Assemblies Eaton s business offers the industry s most complete family of electrical distribution and control equipment and components, plus the widest selection of ratings. And we provide IPAs that meet or exceed distribution systems requirements. As a single-source supplier, we provide these significant advantages: Designing, Assembling and Testing The Eaton business certifies that all equipment and components are in compliance with applicable NEMA T, IEEE, ANSI, UL T and IEC standards. The building is certified to meet IBC requirements, while the installation of the equipment meets NEC T requirements. Consistent Terms and Conditions The Eaton business provides a single uniform set of terms and conditions for all equipment and components. Additionally, the terms and conditions are compatible with those of other Eaton products that may be on the same project providing the benefit of singlepackage negotiation. One Contact Point The Eaton worldwide network of engineers, sales representatives, and authorized distributors provides design and application assistance, pricing, delivery and warranty information. One Overall Warranty The Eaton business warrants all IPA equipment and components, plus the structure itself. Seismic Qualification Label (Unless required in specifications, not all buildings are certified to meet seismic ratings.) Eaton distribution equipment is seismically tested, seismically qualified, and exceeds requirements of both the IBC and the California Building Code (CBC). CBC building certification is included only when required by specifications. Typical Integrated Power Assembly 2

3 Technical Data TD E An Integrated Power Assembly Can Be Installed Where You Want Installation flexibility is essential since IPAs are often used in applications where a controlled, protective environment is required. However, the actual location of an IPA can often vary between customers. IPAs have been installed indoors at ground level or on mezzanines; outdoors on roofs; or as a separate detached structure. Typical Eaton Equipment That Can Be Installed in an Integrated Power Assembly All types of Eaton electrical equipment can be installed in an IPA, including: Medium voltage switch. Medium voltage VacClad-W metal-clad switchgear. Ampgard T medium voltage starters. Medium voltage non-segregated bus. Low voltage switchgear Type Magnum DS. Low voltage switchboards Pow-R-M-S fixed or drawout. Pow-R-Line C low voltage group mounted switchboards. Pow-R-Line C low voltage panelboards. Freedom 2100, IT. and Advantage motor control centers. Dry-type distribution transformers. Adjustable frequency drives. Automatic transfer switches. Pow-R-Way III low voltage bus. Microprocessor-based metering, protection, control and monitoring devices. IPA Assembly Area Front View Two-Story IPA Rear Equipment Access Doors 3

4 Additional Equipment and Modifications Since each IPA is custom designed, we not only provide the electrical gear you specify but can include any additional equipment and modifications requested. Some examples include: HVAC systems. Pressurization units. Battery systems. Annunciators. Communications equipment. Security systems. Marshaling cabinets. Installation and wiring of customer furnished PLCs and analyzers. Office or work areas. Plumbing and restrooms. Doors and windows. Indoor, outdoor and emergency lights. Wireway and cable trays. Custom paint color finishes. Switches and receptacles. Any other equipment specified by customer. Figure 1. Integrated Power Assembly Section Review A Variety of Industries and Service Organizations Communications. Food Processing. Heavy industry. Materials handling. Medical. Mining. Petrochemical. Pollution control. Air Conditioned Unit Power Generation. Public utilities. Pulp and paper. Rail and mass transit. Water and waste treatment. Many others. 4

5 Technical Data TD E A Broad Range of Applications Control center rooms. Equipment skids. Power generation. Generator systems. Motor control. NEMA-4X Non-walkin Equipment Enclosures. Offshore platforms. Pipelines. Power substations. Process control. Pumping Stations. Refineries. Switchgear enclosures. Many others. Figure 2. Layout Plan Views Example with Low Voltage Equipment Figure 3. Layout Plan Views Example with Low and Medium Voltage Equipment 5

6 Figure 4. Layout Plan View Example with Medium Voltage Equipment Typical Specifications General A. The specification covers requirements applicable to the provision of an Integrated Power Assembly (IPA). The IPA shall be environmentally controlled, and shall consist of a coordinated grouping of electrical power and control equipment as indicated on any accompanying data sheets and/or drawings. Any data sheets, drawings, or any other related documents accompanying this specification shall be considered a part of this specification. B. The supplier shall furnish, install, interconnect and test the equipment specified in any related documents. C. Site conditions shall be shown on the data sheet(s). These conditions shall be considered when sizing and designing equipment. D. Any exceptions to the specification shall be noted in the supplier s quotation, under a separate heading. For any portions of the specification which have not been excepted or clarified, the customer shall construe complete compliance by the supplier. Any exceptions to entire portions of the specification, and any notations of exception to anything which is not in the supplier s quotation shall be deemed non-responsive and shall be rejected. References A. All materials, equipment and labor supplied by the supplier shall be in strict compliance with the statutes, codes and standards listed herein. Where conflicts exist between statutes, codes and standards, the more stringent requirement shall prevail. Applicable statutes, codes and standards are as listed below: 1. American Institute of Steel Construction (AISC). 2. American National Standard Institute (ANSI). 3. American Society of Testing and Materials (ASTM). 4. American Welding Society (AWS). a. AWSD1.1, Structural Welding Code Steel. 5. National Fire Protection Association (NFPA). 6. National Electrical Code (NEC). 7. National Electrical Manufacturer s Association (NEMA). 8. Underwriters Laboratories (UL). 9. California Building Code (CBC) or IBC. CBC included only when required by specifications. Quality Requirements The IPA shall be manufactured under an established autonomous quality assurance program. The supplier shall have a designated quality assurance (QA) manager. The supplier must be ISO T 9002 certified, or have a quality system in place which corresponds with the requirements of ISO The successful bidder shall be pre-pared to submit for customer approval, any and/or all quality plans, forms and procedures applicable to the manufacture of the IPA. Construction A. The IPA shall be designed and constructed for outdoor use under wind and seismic load conditions per the IBC guidelines for the job site. B. The IPA and all components mounted thereon shall be designed for and anchored sufficiently for transportation to the job site. C. The skid shall be of all welded, seamless construction utilizing ASTM-A36 structural steel members, sized and arranged for proper strength, and able to withstand the stress and loads which will result when lifting the complete factory fabricated and equipped assemblies. Welding shall be in accordance with the requirements of AWSD1.1. All welding shall be performed by welders certified through the 4G position. Suppliers shall be prepared to show welders certificates. 1. Deflection shall be L/240. The IPA shall be suitable for installation on a concrete pad or on piers. 2. The skid shall be equipped with two (2) stainless steel ground pads located at opposite corners of the skid. 3. The skid shall be provided with a 8-10 mil coverage of bituminous mastic undercoating. 6

7 Technical Data TD E D. The floor shall be a minimum of 1/4-inch H.R. ASTM-A36 smooth steel plate welded to the perimeter and longitudinal and/or transverse structural members of the skid. The floor loading shall not bless than 250 PSF. 1. The floor shall be provided with floor cutouts where required for power and control cable entry/exit from the equipment. The cutouts shall be provided with 12 gauge galvanized coverplates. E. IPA construction: 1. IPA walls, roof and ceiling shall be fabricated from G90 galvanized steel. Exterior walls, exterior roof and interior ceiling shall be self-framing, interlocking design, with maximum panel width of 16 inches (406.4 mm). IPAs of framed construction are not acceptable. 2. Exterior walls shall be minimum of 18 gauge thickness, but rated to withstand the loading requirements of the job site. 3. Interior walls shall be minimum of 18 gauge thickness, but rated to withstand the loading requirements of the job site. 4. Exterior roof shall be minimum of 18 gauge thickness, but rated to withstand the loading requirements of the job site. The roof shall be sloped at 1/4-inch per linear foot, and shall be sloped away from the personnel doors 5. Interior ceiling shall be minimum of 18 gauge thickness, but rated to withstand the loading requirements of the job site. F. For IPAs which must be shipped in multiple shipping sections, NEMA 1 junction boxes will be provided at the shipping splits for easy breakdown of the IPA wiring for shipment and reconnecting at the job site. Prior to shipment, the open end/sides of each shipping section will be crated and weatherproofed for transit to the job site. The crating shall be performed by a company recognized and experienced in the trade. G. Where wall bulkhead penetrations are required, the cutouts shall be completely framed with 1/4-inch (6.1 mm) aluminum coverplates with neoprene gasket. All the penetrations shall be made in the walls prior to bending with the appropriate machinery. No manual cutting of wall penetrations via jigsaw, plasma torch, etc., shall be permitted. H. All fastening hardware shall be zinc plated. Welding of galvanized steel and rivets shall not be an acceptable method of exterior fastening. I. The IPA shall be provided with entrance doors as required by NEC and IBC. The doors shall be double-wall construction, with brushed aluminum panic with cylinder lock and thumblatch, brushed aluminum automatic closure with built-in hold-open device, prime coat hinges, thresh-old built into the door frame, neoprene gasket, drip shields/water flashing, DANGER, HIGH VOLTAGE, KEEP OUT sign, and a 12-inch (304.8 mm) removable transom above the equipment door only. The personnel door shall be 36-inch (914.4 mm) by 84-inch ( mm). The equipment door shall be 48-inch ( mm) by 84-inch ( mm). 1. When specified, the supplier shall provide landings and stairs for the IPA. The stairs shall be built in compliance with the IBC code, and shall be hot-dipped galvanized after fabrication. J. For equipment requiring rear access, the supplier shall provide 14 gauge galvanized steel, gasketed and hinged equipment rear access doors, with 3-point latching system with galvanized padlockable handles, DANGER HIGH VOLTAGE sign, and drip shields/water flashing. K. The walls, roof and floor shall be fully insulated, with a minimum of R-11 insulation. The walls and roof shall be provided with fiberglass batt type insulation. The floor shall be provided with polyurethane spray foam insulation. L. The IPA shall be provided with a paint system per the following: 1. As necessary, the skid shall be cleaned per SSPC-SP3 to remove rust and scale prior to painting. A 4-6 mil application of epoxy primer shall be provided. 2. The floor shall be provided with a 2-3 mil application of epoxy iron oxide primer, followed by 2-3 mil application of ANSI-61 gray with a non-skid finish. 3. The exterior and interior of the IPA shall be provided with a mil application of vinyl wash primer, followed by a 2 3 mil application of white polyurethane paint. M. The IPA shall be provided with an HVAC system, sized and provided by the supplier, considering the ambient site conditions, the dimensions of the IPA, the solar heat generated within the IPA, and the heat generated by the equipment within the IPA. The system shall be designed such that the sensible cooling capacity, NOT the total cooling capacity, will maintain an ambient temperature within the IPA of between 55 F winter and 80 F summer at design conditions. The system shall be provided with an electronic, automatic changeover thermostat. When the IPA is specified to be located in a classified environment, the supplier shall provide a HVAC/Pressurization system in strict compliance with NFPA 496 requirements. In the event of a classified installation, the supplier shall also provide all exterior electrical apparatuses and proper seals which are rated for use in the environment in which the IPA shall be installed. N. The supplier shall furnish all electrical distribution equipment necessary for the proper operation of IPA services within and without the IPA. The operating voltage of all distribution equipment shall be 120/208, three-phase. The primary side of any distribution transformers shall be 480V, three-phase. O. The IPA shall be provided with twin tube, rapid start, fluorescent lighting fixtures, controlled via three-way wall switches to be located at each entry door. P. The IPA shall be provided with 125V, 20A duplex receptacles at each entry door. Q. The IPA shall be provided with 70 watt high pressure sodium exterior lights at each entry door, controlled via photocell and H-O-A switch. R. All wiring shall be type THWN,#12 AWG minimum for powercircuits, minimum #14 AWG for control circuits. For all control interconnection wiring, both ends of the wire shall be provided with polyolefin sleeve type wire markers. S. EMT conduit shall be utilized for interior applications. RGS conduit shall be utilized for outdoor applications. T. Cable tray (if required) shall be aluminum, 6-inch (152.4 mm) high with 9-inch (228.6 mm) rung spacing. All fittings shall have a minimum of 12-inch (304.8 mm) radius. IPAs having cable tray systems shall be provided with structural steel channel supports embedded in the ceiling. The use of unistrut fastened directly to the ceiling for cable tray support shall not be permitted. The support from the channel supports shall be via allthread and unistrut hangers. U. 1/4-inch (6.1 mm) by 2-inch (50.8 mm) ground bar running the length of the IPA shall be provided, mounted approximately 6 inches (152.4 mm) above floor and connected to each end of the equipment ground bar. A #4/0 green insulated copper ground cable shall be provided from the ground bar to the exterior ground pads. A green insulated copper ground wire/cable will be provided from the ground bar to all auxiliary electrical equipment per NEC Table

8 Testing and Inspection The following testing and inspection shall be performed on the IPA: A. Continuity checks of all wiring installed by the supplier. B. Operational check of all IPA service apparatuses. C. Switchgear and motor control center shipping sections bus shall be respliced, torqued, and meggered. D. A certified test report shall be provided by the supplier s Quality Assurance manager. E. If necessary, secondary control power shall be provided for customer use. Available control power voltages shall be 480/3/60, /3/60 or /1/60. Submittals The supplier shall provide the following submittals: A. Quality plans, forms or procedures deemed necessary by the customer. B. Structural drawings including: 1. General Notes. 2. IPA plan view. 3. IPA base skid detail. 4. IPA elevations. 5. Stairs and landings detail (if applicable). 6. Certified structural calculations (if applicable). These technical data materials are published solely for information purposes and should not be considered all-inclusive. If further information is required, you should consult an authorized Eaton sales representative. The sale of the product shown in this literature is subject to the terms and conditions outlined in appropriate Eaton selling policies or other contractual agreement between the parties. This literature is not intended to and does not enlarge or add to any such contract. The sole source governing the rights and remedies of any purchaser of this equipment is the contract between the purchaser and Eaton. NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, AND DESCRIPTIONS CONTAINED HEREIN. In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations and description contained herein. C. Electrical drawings including: 1. Electrical notes. 2. IPA electrical plan, showing conduit, cable tray, wire tray,subfloor wireway and any other means of wiring transit. Drawings shall also include conduit fill. 3. IPA services wiring diagrams. 4. Grounding system plan. 5. Interconnection wiring diagrams. Definitions The National Electrical Code and NEC are registered trademarks of the National Fire Protection Association, Quincy, Mass. UL is a registered trademark of the Underwriters Laboratories Inc. International Building Code (IBC) is a trademark of the International Code Council. NEMA is the registered trademark and service mark of the National Electrical Manufacturers Association. ISO is the registered trademark and sole property of the International Organization for Standardization. Eaton Corporation Electrical Group 1000 Cherrington Parkway Moon Township, PA United States 877-ETN-CARE ( ) Eaton.com 2010 Eaton Corporation All Rights Reserved Printed in USA Publication No. TD E / TBG December 2010 PowerChain Management is a registered trademark of Eaton Corporation. All other trademarks are property of their respective owners.