12e VAT - Inspection Data Sheet - Rev 04 - PCIS

Inspection Data Sheet #1 - Mechanical Inspection Checklist
Machine
Manufacture
r: Inspector: Date:
Passed
Item Inspection Item (Y/N) Comments
STATIC CHECKS
Are all components and materials as per specification? (SST, painted

1 steel, anodized aluminum, PVC, etc.) (Prod. areas SS316L)
2 Are the machine main frame and components rigidly constructed?
3 Are the components rigidly mounted and protected?
4 Are all machine stations properly aligned and secured?
5 Are all fasteners secured and properly sized? Proper materials?
6 Is the welding neat and non-porous? Nozzles per specification?
Is the machine configuration as per specification?

7 Verify layout drawings.
8 Is the machine clean designed as per specification?
9 Is the machine accessible for maintenance and lubrication?
10 Are the drive motors and gearboxes as per specification?
11 Are all belts and chains properly setup and tensioned?
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Machine
Manufacture
r: Inspector: Date:
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Is the central lubrication block present and properly piped to the

12 bearings?
Are all grease nipples on the machine easily accessible and color
13 coded?
14 Is safe lubrication possible during machine operation?
15 Are motors rigidly mounted to the conveyors with easy access?
16 Are all change parts labeled with size of product and color coded?
17 Are the speed control and jog speed control present?
Is the tube cleaning system as per specification?

18 - air blow cleaning and vacuum purging
19 Is the air filter and de-ionizing unit present?
Is the filling system built according to specification?

20 Verify with specification.
21 Are all seals, gaskets and hoses as per specification?
Are the hot air sealing, linear trimming and single side code
22 embossing system as per specified?
DYNAMIC CHECKS
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Manufacture
r: Inspector: Date:
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Can the magazine be loaded on the fly?

23 Check loading height.
24 Can the tubes be oriented properly?
25 Is the tube cleaning system functioning properly?
Is there any product trailing at the filling nozzle(s) after each fill?
26 The system should be a bottom up, positive shut-off filling system.
Are the hot air sealing and embossing mechanisms working

27 properly?
28 Is the trimming mechanism working properly?
29 Is the tube discharge mechanism working properly?
Is the indexing bucket conveyor tracking properly?

30 Verify belt type and specification.
Is the tube reject mechanism working properly?

31 (i.e. defective tubes, unfilled and unsealed tubes)
Is the machine a no tube - no fill system?

32 Verify.
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Skid/ Process
Manufacturer: Inspector:
Passed
Item Inspection Item (Y/N)
Date:
Comments
Inspection Data Sheet #2 - Electrical Inspection Checklist
Machine
Manufacture
r: Inspector: Date:
Passed
STATIC CHECKS
Go through every applicable paragraph on the PC&IS Strategy for

HABC Packing Systems and Packaged Equipment in Asia. On a
separate sheet, itemize all exceptions and proposal to meet
1 requirements.
Step through every applicable paragraph on key C&IS documents

(URD, Design Basis) including plant specific requests. On a separate
2 sheet, itemize all exceptions and proposal to meet requirements.
3 Confirm all components are as requested by P&G.
4 Are panels & boxes clearly and correctly labeled?
5 Is the panel layout as per drawing?
Are all DIP switches & VFD parameters as per Vendor documents?
6 Perform random check.
7 Are there adequate spare terminals and space in panel? (20% spare)
8 Are devices labeled as per DWG's & rigidly mounted?
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r: Inspector: Date:
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9 Are the sensors and proximity switches as per specification?
10 Is the location of electrical devices accessible for maintenance?
All wiring labeled @ each termination/connection using sleeve type

11 mark?
12 All wiring stranded?
13 Is the wiring properly labeled and easily identifiable?
14 Randomly pull some wires at terminals to check for tightness.
15 Are the fuse/breaker sizes correct?
16 220V duplex receptacle in control panel?
Ratings of electrical enclosures are IP65 (typical mounted on filler/),

else IP54? Confirm that panels enclosures meet the specified IP
17 rating.
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Manufacture
r: Inspector: Date:
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Has an effort been made to use clean design minimize locations

18 where dirt can gather?
19 Electrical conduit, wire ways clean design routing?
All components rigidly mounted and protected? Check for sharp

20 edges.
21 Liquid tite flex used for vibration, movement, adjustment, etc. areas?
22 Verify control voltage filter or UPS supplied?
Measure incoming current demand - should be less than nameplate

23 value.
Measure power supply 24VDC current supplied - should be less than

24 50 % of power supply max.
Separate ground conductor between instrument & equipment ground

buses. Measure resistance between them. If it is below several k-
25 ohm, Vendor must find incorrect instrument ground point & repair.
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Inspection Data Sheet #2 - Electrical Global Spec Check List
Machine
Manufacture
r: Inspector: Date:
Inspection Item Passed

Item (Y/N) Comments
STATIC CHECKS
1.2 CODES AND 1.2.1 Electrical equipment should meet or exceed the legal
STANDARDS requirements of all locations where P&G normally operates across
the world.
( Refer to the table in Global Spec Doc ) The VAT for a specific
project requires that the system as built must meet the code
1 requirements for the location where it will be installed.
1.2.4 Electrical materials, methods of construction must equal or
2 exceed the requirements of this specification.
1.2.5 The vendor shall provide all compliance documentation for the
3 standards to which the machine/ process skid must adhere.
1.2.6 Original Equipment Manufacture (OEM) shall have the
machine/ process skid inspected by a globally recognized electrical
certification organization (NRTL) to ensure all applicable standards
and or directives have been met for the specific location which it is
to be installed. This inspection process shall be completed by
adhering to the below:
1.2.6.1 First inspection shall be at the completed at the end of the
first design review.
1.2.6.2 Second inspection shall be completed after the machine has
achieved a 50% completion on the build for both mechanical and
electrical work.
1.2.6.3 Third inspection shall be completed at the end of build and
prior to the VAT.
4
1.2.8 All findings reports received by the Nationally Recognized
Testing Laboratories (NRTL) shall be provided to the P&G Controls
5 Contact upon OEM receipt from the NRTL.
1.2.9 OEM shall obtain a letter from the NRTL at the end of the third
inspection indicating that all applicable codes and regulations for the
site in which it is to be installed have been completed on this
machine/process skid build.
6
1.2.10 OEM shall use only listed or labeled equipment for ALL
components. (Underwriters Laboratories for US, CE for Europe)
7 (See Appendix 26.3 for list of components required to be listed or
labeled.)
1.2.11 All robot installations must follow all local codes as well as
ANSI/ RIA R15.06-1999 (Safety Requirements for Industrial Robots
8 and Robot Systems)
1.2.12 If OEM is requested to provide electrical services on site at
P&G, OEM must provide only qualified electrical persons and must
provide a completed Contractor Letter which can be found in
appendix 26.4 of this document.
9
1.3 LANGUAGE AND 1.3.1 All equipment nameplates and labels shall be in English and/
10 UNITS or the local language specified at the time of order.
1.3.2 Electronic displays shall be in English and the local language
specified at the time of order. Units of measure shall be displayed in
both English and Metric units?. It is acceptable to display one
language and unit set at a time with a switch to change language
11 and or units.
1.3.3 All training and operational documentation shall be provided in
12 English and/ or the local language specified at time of order.
1.3.4 All technical and maintenance documentation shall be
provided in English and/ or the local language specified at the time
13 of order. Units of measure shall be provided in both English and
Metric units.
1.4 PURCHASE OF 1.4.1 All purchases must be identified for P&G use to receive the
ELECTRICAL P&G discount from the component suppliers. Not a VAT item.
14 COMPONENTS This should be considered in Design phase
1.4.2 P&G Controls Contact will fill out the Attachment I document
15 and forward to Rockwell. This should be considered in Design phase
1.4.3 OEMs should use their local suppliers when purchasing
16 components to maintain good working relationships with the This should be considered in Design phase
vendors.
2.0 DOCUMENTATION 2.1.1 The vendor shall provide information necessary for the
REQUIREMENTS installation, operation, and maintenance of the electrical
2.1 GENERAL components and systems of a machine. Technical documentation
shall be supplied in hard copy and electronically. (AUTOCAD,
Microsoft WORD, Microsoft EXCEL are preferred formats)
17
2.1.2 Documented risk assessment including process and results of
18 the assessment.
2.1.3 All drawing documentation shall be reviewed with the P&G
Controls Contact. ANSI graphical symbols are preferred, but IEC
19 60617 - Graphical Symbols are acceptable.
2.1.4 The vendor shall provide copies of all documentation and
manuals for all components and devices installed on the equipment.
If possible, these should be in English and in the local language
specified at the time of order. If component documentation and
manuals are not available in the local language, then English
20 language versions shall be supplied
2.1.5 The vendor shall provide all licenses and documentation for
21 installed software on the machine/ process skid.
2.1.6 Source code shall be provided for all major control
programmable devices. Examples of such components are:
Programmable Logic Controller (PLC) / Servos/ Robots/ Personal
Computer (PC), vision systems, variable frequency drives (VFD)
and other “smart instruments”.
22
2.2 DOCUMENTATION 2.2.1 Technical documentation at a minimum shall comply with the
REQUIREMENTS FOR requirements listed in NFPA 79, Chapter 18- Technical
23 U.S. ONLY Documentation
EQUIPMENT
2.3 DOCUMENTATION 2.3.1 Technical documentation at a minimum shall comply with the
REQUIREMENTS FOR requirements listed in EN 60204-1, Clause 18- Technical
24 EU ONLY EQUIPMENT Documentation
2.4 ADDITIONAL 2.4.1.1 Architecture drawings shall include but not limited to:
DOCUMENTATION programmable controls, servos, vision systems, human machine
REQUIREMENTS FOR interface (HMI) and robots.
ALL REGIONS
25
2.4.1 NETWORK 2.4.1.2 Programmable controller layout drawings
ARCHITECTURAL 2.4.1.2.1 For PLCs - detail each occupied and spare slot.
26 DESIGN DRAWING
27 2.4.1.3 List of all control system hardware
2.4.1.4 Network architectural design shall describe the specifics of
how the chosen network platform shall be configured including all
28 dip switches, jumpers & software settings.
2.4.2 FLUID POWER 2.4.2.1 Shall show all devices and connections on the machine and
29 CONNECTION shall include tubing colors as well as any labels that are used.
DIAGRAM
2.4.3 2.4.3.1 An interconnection diagram shall be provided showing all
INTERCONNECTION interconnecting cables between Vendor's panel and machine or
DIAGRAM process skid. All wire tags, cable/conduit tags, terminal numbers
and panel names shall be shown. This drawing shall be separate
from the Network Architectural Design drawing.
30
2.4.3.2 Wiring Drawings - showing all field terminations and any
31 terminations to be performed by P&G.
2.4.4 BILL OF 2.4.4.1 Bill of materials shall be provided. All electrical components
MATERIALS & SPARE shall be listed. The following shall be identified: item number,
PARTS LIST equipment description (including electrical characteristics- voltage,
phases, current, and configuration), manufacturer, manufacturer
part number, OEM part number (if applicable), commercial model
number and vendor phone number.
32
2.4.4.2 The spare parts list may be a subset of the above list.
Include all items (and quantities) that should be kept on hand (as
33 recommended by the Vendor).
34 2.4.5 NAMEPLATE LIST 2.4.5.1.1 Control and I/O panels
35 2.4.5.1.2 All internal panel components, including terminal strips.
36 2.4.5.1.3 Motors
37 2.4.5.1.4 Disconnects
38 2.4.5.1.5 Pushbutton Stations
39 2.4.5.1.6 Sensors
40 2.4.5.1.7 Pneumatic Valve and or Manifolds
2.4.6 OWNERS 2.4.6.1 Required software and hardware configuration, installation,
MANUAL maintenance & safety information and all documentation listed
herein should be included in the Owner’s Manual. Include all
calculations and test results. A list of alarms and required response
41 shall be provided.
2.4.6.2 Troubleshooting information shall be specific to this
equipment and shall cover all problems anticipated during the
42 intended service. Charts shall be created for complicated
troubleshooting procedures.
43 2.4.7 OTHER 2.4.7.1 Drawing List (this should be drawing sheet 1)
DOCUMENTS 2.4.7.2 Equipment layout Drawing - show location of panels,
44 disconnects, motors, all field devices and safety devices
45 2.4.7.3 Panel layout Drawings
46 2.4.7.4 Elementary Drawings (i.e. Schematics)
47 2.4.7.5 Single Line Drawings (MCC’s)
2.4.7.6 Grounding requirements - a summary of external grounding
48 requirements
2.4.7.7 Servo and variable frequency drive (VFD) requirements
motor controller parameter list
49
50 2.4.7.8 Functional description of any special control devices
2.4.7.9 Timing diagrams, which are graphical representations of the
machine functions from 0 to 360 degrees (or 1 machine cycle). This
diagram should include cam switches, Programmable Limit
Switches, critical machine/ process skid functions, and servo
51 profiles.
52 2.4.7.10 Construction Specifications (if installation by others)
53 2.4.7.11 Sensor/ Instrument Specifications
3.0 SUPPLY VOLTAGE 3.1.1 This section provides installation requirements for the United
AND FREQUENCY States (U.S.), Europe (E.U.) and for Global usage.
54 3.1 GENERAL
3.1.2 Machines/ process skids intended for areas other than U.S. or
E.U. shall be designed for regional voltage requirements or as a
55 global design.
3.1.3 Following components are not permitted:
3.1.3.1 Auto- Transformers
3.1.3.2 Scott-T Transformers
56
3.1.4 480V to 415V or 480 to 380V voltage changes are not
57 permitted within the control panel.
3.1.5 All over current protection devices (OPCD) shall be full-voltage
58 and current rated. No slash rated protective devices are acceptable.
3.1.6 All low voltage control shall be 24VDC, due to improved
safety, and global trend toward 24VDC control systems and devices,
in addition to better performance of Direct Current (DC) vs.
Alternating Current (AC) in high speed sensing or switching
59 applications.
3.2 REQUIREMENTS 3.2.1 Equipment designed for solely within the U.S. shall be supplied
60 FOR U.S. DESIGN using standard U.S. voltage and current ratings.
61 3.2.2 Power Supply – 480 volts/3-phase/ 3-wire with ground/ 60 Hz
62 3.2.3 Lighting and Receptacles (on equipment 120 VAC)
3.3 REQUIREMENTS 3.3.1 Equipment designed for use solely within the E.U. shall be
FOR E.U. DESIGN supplied using standard European voltage and current ratings:
3.3.1.1 Power Supply – 400 volts/ 3-phase/ 4- wire with Protective
Earth (PE) ground /50 Hz
3.3.1.2 Lighting and Receptacles (on equipment) – 230 VAC
63
3.4 REQUIREMENTS 3.4.1 Equipment shall be suitable to be installed and powered by
FOR GLOBAL DESIGN systems with supply ranges from 400 volts AC/3-phase/4-wire with
PE ground / 50 and 60 Hz to 600 volts AC/3-phase/ 3-wire with
ground +/-10%/ 60 Hz.
64
3.4.1.1 Each power feed to a machine/ process skid will be
equipped with a Delta/Wye transformer with grounded wye point and
primary taps that will accommodate the voltage ranges and will
provide the desired equipment operating voltage range of 400 volts.
65
3.4.1.2 Transformer will be adequately sized to accommodate
marginal increase of horsepower caused by changes in the
66 equipment performance.
67 3.4.1.3 Power Supplies shall be auto ranging 110/ 220 VAC
3.4.1.4 Alternating Current (AC) motors must be connected to a
68 Variable Frequency Drive for maintaining the voltages per hertz
ratio.
3.4.1.5 Application performance must not be negatively affected by
69 the use of 50 Hz or 60 Hz.
3.4.1.6 All lighting on the equipment shall be 24 VDC or shall be
70 solid state ballast design with dual voltage and frequency settings.
4.0 CIRCUIT 4.1.1 Over-current protection devices shall be sized to provide
71 PROTECTION protection for devices as well as the conductors.
4.1 GENERAL
4.2 GLOBAL DESIGN 4.2.1 In general, circuit breakers are preferred. However, fuses may
72 (including U.S. and E.U.) be used.
4.2.2 Use only circuit breakers rated for branch circuit protection (i.e.
UL Listed under UL489 or multi-rated devices with UL and other EU
3rd party approval). Generally, branch rated circuit breakers are
molded case design, have high withstand rating (>20KA), are used
to protect wiring, and are necessary when the load-side wiring is
smaller than the line-side wiring of the breaker.
73
4.2.3 Circuit breakers rated for supplementary protection (i.e. UL
Recognized under UL 1077) shall not be used for branch circuit
protection. Generally, supplementary protection rated circuit
breakers are smaller in size, have low withstand rating (<10KA), and
are used to protect the final loads.
74
4.2.4 All protective devices shall be listed for the application and will
be rated for the desired application with regards to supply voltage,
operating current and short circuit current or Amps Interrupting
Capacity (AIC).
75
4.2.5 All components shall be rated for the short circuit current
available at the location where the machine/ process skid is to be
installed. If information is not available, assume an infinite bus
above upstream transformer. Provide calculations if requested by
76 P&G.
4.2.6 Each motor starter shall have its own circuit breaker. IEC
Type 1 protection is satisfactory. Group protection of motor circuits
77 will only be permitted if approved by P&G and must be compliant
with NEC 430.53.
4.2.7 Molded case circuit breakers shall be applied at no more than
78 75% of their rating.(Current and Interrupting)
4.2.8 Over current protection devices shall be rated for the applied
voltage as well as the maximum phase to phase as well as phase to
79 ground voltage.
4.2.9 Reverse fed circuit breakers will only be permitted if requested
80 by P&G.
5.0 GROUNDING 5.1 The 24 VDC systems shall be grounded at the negative terminal
of the power supply only. Exception is only when an internally
81 grounded power supply is used.
5.2 The common (neutral) on the control transformer secondary
82 shall be grounded.
5.3 No separate earth stakes for instrumentation/computer systems
will be used. Where a “clean” ground is required as part of the
vendor requirement a dedicated earth wire connected directly to the
power supply earth may be used.
83
5.4 Each electrical device, machine/ process skid base, metal
enclosure, door, support or steel structure shall be properly
84 grounded/ bonded to a common earth ground point.
5.5 A grounding lug suitable for a No. 25mm2 (or #4AWG) stranded
wire shall be provided inside the enclosure, attached to the
enclosure back not the sub-panel.
5.5.1 Connect external ground to the sub-panel and connect the
door to the enclosure back.
85
86 5.6 All ground wires shall be run inside conduit or integral to cable.
5.7 A separate grounding conductor minimum 1.25mm2 (or
#14AWG) shall be installed for each cable installed in a conduit,
87 flexible conduit or trunk system.
5.8 The resistance between the main power system ground point
88 and any point in the grounding system shall never exceed 5 ohms.
5.9 Bolted ground connections should be made with compression
89 type ring lugs complete with non-corrosive hardware and lock-
washer.
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90 5.10 Under no circumstances shall conduit be used in lieu of a
6.0 DEVICE/ ground.
6.1 Contactors and starters shall be protected for available short
COMPONENT circuit current. Only circuit breakers specified in the manufacture
RATINGS contactor or starter documentation as being approved for use at the
available short circuit current shall be used. The minimum rating for
any electrical device is 10kA.
91
6.2 All items which NEC requires to be listed shall be listed. This
includes but not limited to the main disconnect switch and main/
92 branch circuit protection. See appendix for NEC reference
document.
6.3 All components and wiring terminal blocks with voltages over 50
volts AC or DC shall be rated or classified as “touch safe” (per IEC
742 and IP20). All devices not capable of meeting this requirement
due to the nature of the equipment shall have exposed terminals
protected with a clear polycarbonate panel and labeled with a
93 “voltage” warning label.
7.0 WIRE AND CABLE 7.1.1 Wire push buttons and other components on doors with
7.1 GENERAL flexible wire to terminal blocks mounted on the enclosure’s sub-
94 panel. Provide flexible sleeves where each bundle of wires crosses
the door hinges.
7.1.2 Inside enclosure insulation must be rated for 60 degrees
95 Celsius (140 degrees Fahrenheit) minimum.
7.1.3 All other wiring Insulation must be rated for 90 degrees Celsius
(194 degrees Fahrenheit) minimum and suitable for wet/dry
locations. Leads in contact with heaters or heater surfaces where
the temperature could be from 60 degrees to 110 degrees Celsius
(140 degrees to 230 degrees Fahrenheit), 600-volt silicone insulated
type AVA copper wire or equal shall be used. For wire temperature
exceeding 100 degree Celsius (212 degrees Fahrenheit) non-
asbestos insulated nickel wire or equal shall be used.
96
Lacing of wires or use of tie-wraps in wireway is not permitted.
(Exception: Okay to use as needed to support the wires in a vertical
97 metallic
7.1.5 For multi-conductor cables, there may be additional
conductors within these cables that are not needed or used for the
application. All unused conductors within the multi-conductor cable
shall be bent back and taped. The conductors shall not be exposed.
98
7.1.6 Cables shall run continuously from termination to termination
with no splices. Junction boxes with terminals may be used to
connect or extend cables on the machine. If the machine/ process
skid is so constructed that cabling shall be disconnected for
shipment, plugs or terminal strips shall be provided at the sectional
points. For power cables, no plugs should be used – only terminal
strips or leave sufficient lengths of power cables on the machine/
process skid that can be terminated to the machine/ process skid
power source(s) in the field.
99
7.1.7 The OEM shall not route power and signal cables in close
proximity of one another except as absolutely necessary. OEM
should try to keep a minimum separation between power and signal
cables per the following table. If these separations cannot be
maintained, the P&G Controls contact shall be consulted.
100
7.1.8 Where power and signal cables are required to cross, the
101 lower voltage cable should cross the higher voltage cable at right
102 angles.
7.1.9 Terminal blocks shall be physically grouped by function.
7.1.10 Spare space for terminal strips shall be no less than 20% of
103 the total length of the installed din rail
7.1.11 Shielded cables should be grounded per the manufacturers
104 recommendations.
7.1.12 All terminal strips are to be located within the enclosure in
105 such a location as to make them readily accessible.
7.1.13 All terminal strips, terminals and wires shall have unique
identification, shall be clearly labeled and shall match the equipment
106 documentation. Wires shall be labeled identically at both ends.
107 7.1.14 Only one wire shall be connected to a terminal.
7.1.15 Conductors connected to all terminals shall first be crimped
with a solderless pin-type connector (i.e. ferrules). UL rating on
ferrules is obtained by using the terminal manufacturer’s
recommended ferrule and crimper.
108
7.1.16 Electrical conductors shall not be run through equipment
frame members as this is a violation of the NEC and presents a
109 safety concern if equipment frame is cut, drilled into.
7.1.17 Any low voltage cables that occupy the same equipment
enclosure, cable, or raceway with conductors rated 600V or less
shall have the same insulation rating as the maximum circuit voltage
applied to any conductor within the enclosure, cable or raceway. In
addition, supplemental or double insulation will also have to be used
per the requirements of IEC-60664-1.
110
7.1.18 Protective Earth (PE), connections shall follow the
111 requirements outlined below:
7.1.18.1 Use toothed star washers for safety bonding under a ring-
112 lug or other device to be grounded. Ring lugs must be double
crimped.
7.1.18.2 Use a locking type fastener to hold it in place. Fasteners
113 with integral washers may be used if they have external tooth stars
114 7.1.18.3 All star washers shall be steel (not copper, brass or bronze)
7.1.18.4 Non-conductive coatings such as paint and anodize shall
115 be removed in the area of the star washers.
7.1.18.5 The primary PE ground wire shall be the same size or
116 larger than the voltage carrying wires.
7.1.18.6 PE ground wires from the primary PE ground wire may be
wired in series (i.e. daisy chained) and branch circuits may have
reduced size wire, but must be able to carry the maximum fault
current for the devices being grounded
117
7.1.18.7 The primary PE ground connection shall be a single
dedicated conductor on a terminal and/or stud with a direct
118 connection to the main chassis or sub-panel and a dedicated locking
fastener
7.1.18.8 All primary PE grounds must be identified with the following
119 PE ground symbol:
7.2 WIRE SIZE 7.2.1.1 Wire size shall be determined by the following NEC
7.2.1 GENERAL guidelines regardless of the machine/ process skid destination:
NEC 310 with the following exceptions:
Flexible Cords and Cables: [NEC 400.12, Table 400.4]
Motors rated 1hp or less as permitted by [NEC430.22 (F)]
Control and Instrumentation circuits as permitted by:
NEC Article 725.27(A)
NEC Article 727.6
Motor control circuits as permitted by [NEC430.72]
Data communication circuits as permitted by [NEC Article 800]
120
7.2.2 All wire shall be dual rated or “harmonized” wire. Wire sizes
shall be AWG (American Wire Gauge). Use the conversion table 8
“Conductor Properties”, Chapter 9 of the NEC or Table D.1 in Annex
D of IEC 60204-1 to convert to metric units for Europe. Size wires
to use the next larger AWG for “in between” metric sizes. (See
appendix, at the back of this document for the conversion table from
121 NEC.)
7.2.3 Individual conductors shall be multi-stranded, copper wire with
a 600V minimum insulation rating. In general, all wiring shall be
122 type THHN/THWN – 90 degree, which is suitable for wet or dry
locations.
7.3 WIRE LABELING 7.3.1 All wires shall be tagged with a permanent, legible label and
123 marked identically at both ends.
124 7.3.2 Adhesive tape type labels are not acceptable.
7.3.3 Conductors shall be identified at each termination by number,
letter, color (either solid or with one or more stripes), or a
125 combination thereof and shall correspond with the technical
documentation.
7.3.4 Internal wiring on individual commercial devices purchased
completely wired (servo cables) shall not require additional
126 identification.
7.3.5 Where letters are used to identify conductors, they shall be
127 capital block letters. Numbers shall be Western style numerals in
128 block style.
7.4 WIRE COLORS As specified in the Global Specification Document
7.5 WIREWAY (INSIDE 7.5.1 All wiring inside the cabinet shall be installed in non-metallic
ENCLOSURE) wireway such as “Panel Channel,” “Panduit,” or equal. Wireways
must be one piece–not single sides clamped down. Vertical slot type
Panduit is preferred.
129
130 7.5.2 Covers shall be provided on all wireways.
7.6 WIREWAY 7.6.1 Where wireway is used in place of conduit, construction shall
131 (OUTSIDE be at least IP54 (NEMA 12).
ENCLOSURE)
7.6.2 It is preferred to run one machine/ process skid frame length
wireway along the side of the machine/ process skid and to make all
conduit runs from this wireway. (All devices and wiring should be
positioned higher than the lowest horizontal frame member.)
132
7.6.3 Wireway containing both control wiring and power wiring
133 should be divided centrally with the manufactures offered dividing
system.
7.6.4 Maximum fill within a wireway shall be 20% - (NEC Section
134 376.22 and see Table 310.15(B)
7.6.5 All conduit, wireways, and junction boxes must provide
135 continuous ground paths to the grounded enclosure.
7.6.6 Wireway should be installed in a manner where it is easily
136 accessible. (i.e. All covers should rotate 90o easily)
7.6.7 Wireway shall not be used as a mounting base for other
137 equipment, e.g. solenoid valves.
7.6.8 Wireway should be installed in a manner where it won’t
138 interfere with normal maintenance of the machine.
7.7 CONDUIT (RIGID 7.7.1.1 Rigid steel conduit shall be standard weight, mild rigid steel,
AND FLEXIBLE) hot dip galvanized, finished inside and out with a protective zinc
7.7.1 RIGID coating. Couplings, elbows and bends shall meet these same
requirements. The minimum trade size of conduit shall be ¾ inch or
metric equivalent. (1 ¼ inch conduit size shall not be used)
139
7.7.1.2 All conduit fittings and boxes shall be of the threaded hub
type with watertight gaskets. Conduit bodies shall be solid gasket
140 types with covers.
7.7.1.3 Meyer”Scru-Tite” hubs (or equivalent) (see picture to left)
shall be used whenever a conduit enters an enclosure or pull box if
the enclosure is not fitted with a threaded integral hub. The
substitute of lock nuts with integral or separate gaskets or o-rings is
141 not acceptable.
7.7.1.4 All threaded connections shall be coated with Thomas and
Betts”Kopr- Shield” CP8 compound or equivalent. Teflon tape or
142 compound shall not be used.
7.7.1.5 Conduit shall be cut smoothly and supported firmly. All
sharp edges, burrs, rough surfaces or threads, which may come in
contact with wire insulation, shall be removed. This applies to
conduit fittings, conduit, raceways and associated parts. All
connections shall make good electrical contact to ensure effective
143 bonding.
7.7.1.6 Route conduit to minimize the required number of fittings and
to provide maximum feasible protection from mechanical damage.
Route horizontal runs, if possible on the underside of frame
members. If horizontal runs must be routed on the side or top of
members, space them away from the surface whenever possible.
Conduit shall be securely held in place and arranged so as to not
interfere with operation, maintenance or cleaning of or around and
below the equipment and to avoid use as platform or step.
144
7.7.2 FLEXIBLE 7.7.2.1 Liquid tight flexible conduit (see picture to left), shall be used
145 to isolate equipment vibration or to connect to moveable terminal
boxes.
7.7.2.2 Maximum length of exposed flexible conduit outside of a
wireway shall be limited to 45cm (18”) for motor terminations.
Devices such as solenoids, proximity switches and photo eyes may
be extended to 90cm (36”).
146
7.7.2.3 Liquid-tight flexible metal conduit shall be constructed of
single strip, flexible, continuous, inter-locked and double wrapped
steel; galvanized inside and outside and with liquid tight jacket of
flexible polyvinyl chloride (PVC). Use conduit with continuous
copper grounding strip or run a ground wire to each separate flexible
147 conduit.
8.0 MOTORS 8.1.1 All Alternating Current (AC) or Direct Current (DC) motors
8.1 GENERAL shall be either IEC or NEMA design. (See appendix, at the back of
148 this document for the IEC and NEMA motor dimensions.)
8.1.2 Motors shall be marked, approved, or listed by a U.S. NRTL
(i.e. – UL, CSA, ETL) or an approved 3rd party notified body from
149 the EU (i.e. – TUV, VDE)
8.1.3 Motors shall comply with NEC Article 430 and the
150 requirements of Clause 15 of the EN 60204-1.
8.1.4 Where motor nameplates are not clearly visible after
151 installation, a duplicate nameplate shall be located in a clearly
visibleMotors
8.1.5 location.
shall be suitable for the environment in which they are
152 installed.
8.1.6 Motors controlled by Variable Frequency Drives shall be
inverter duty rated motors. Such motors shall be NEMA or IEC
153 inverter-duty rated.
8.1.7 Motors larger than 30 Hp (22.37 kW) must have winding
Resistance Temperature Detectors, (RTD) and temperature relay to
154 alarm or shut down at high temperature.
8.1.8 Thermal overload protection is required for all non-VFD
controlled motors with a power rating greater than ¾ Hp (2.24 kW).
155 Motors below ¾ Hp (2.24 kW) shall have overload protection.
8.1.9 Efficiency requirements for motors shall adhere to the
following:
8.1.9.1 NEMA Requirements covered under EPACT.
8.1.9.2 IEC EFF1 requirements
156
8.1.10 All motors shall exhibit the electrical performance
characteristics of IEC N type, (NEMA design B) motors with a
157 continuous duty rating of S1.
8.2 TERMINATIONS 8.2.1 Connections to motors shall be either; double crimped ring
terminals, bolted and taped or landed directly to the motor-supplied
158 terminal strips.
8.2.2 Motor junction boxes must be metal and rated for the
159 installation environment.
8.2.3 Motor leads will be continuous from termination to termination.
A ground wire will be run with the motor leads. For shipping breaks,
160 pull motor leads back to break point.
8.3 GROUNDING 8.3.1 A stranded copper insulated ground wire shall be terminated at
each motor (Inside the “J” box/ connection box) and originate from
the control panel. Vendor shall provide a ground buss in each
control panel this item applies.
161
8.3.2 If special duty motors or other special requirements warrant a
deviation from the above specification or if delivery problems occur
which will cause a change in the above specification, the P&G
Controls Contact should be notified.
162
9.0 MOTOR CONTROL 9.1.1 All AC motor starters are to be full voltage, 3 phase, 50/60 Hz,
with manual overload reset button in the cover, externally operated
163 with an auxiliary contact.
164 9.1.2 Starter coils must have 24VDC coils.
9.1.3 Circuit breakers in combination starters must be “horsepower
rated”, i.e., the breaker must be capable of interrupting the current
165 under locked rotor conditions.
9.2 DRIVES 9.2.1.1 If the Human Interface Module is mounted in the door of an
9.2.1 GENERAL enclosure it must retain the enclosures design integrity. If not,
166 H.I.M. shall be mounted on the Variable Frequency Drive (VFD).
9.2.1.2 All Variable Frequency Drives shall be equipped with thermal
motor overload, ground fault trip and remote alarm (dry contact).
The following items are configurable: variable torque, constant
torque, constant horsepower, acceleration/deceleration profiles, and
current limiting. The base installation for all VFDs shall be open loop
unless better than 3% accuracy is required on speed control, or if
the torque demand is extensive at low speeds, in which case either
closed loop or open loop vector control shall be considered.
167
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9.2.2 POWER 9.2.2.1 Variable Frequency Drives are required to be rated to
operate to manufacturer’s specification with machine/ process skid
design voltage applied. The designed frequency range shall not
extend outside the boundaries of 45 – 90Hz for all required functions
168 of the equipment.
9.2.2.2 Overload relay shall be mounted in the drive enclosure,
where possible. If this is not possible then the relay shall be
mounted in an external enclosure adjacent to the drive. The
overload relay shall be installed such that it can be reset without
exposing personnel to any live circuits.
169
9.2.2.3 Line reactors shall be based on manufacturer’s
recommendations. At a minimum, they are required on the load
170 side for all drive applications where the wire length is greater than
50’.
9.2.3 9.2.3.1 In an effort to minimize design and installation costs, using
COMMUNICATIONS communication networks to communicate to logic controllers is
recommended. All non-critical control signals to the drive or motion
controller should be sent over this network thus reducing the amount
of wiring to the controller.
171
9.2.3.2 OEM must obtain permission from the PC&IS Control
Contact on how variable frequency drives will communicate with the
172 control system.
9.2.3.3 Local implementations of DeviceNet / Ethernet/ Profibus are
173 acceptable.
9.2.4 INSTALLATION 9.2.4.1 Refer to the manufacturer’s installation manual for
AND WIRING recommended clearances around the drive controller to provide
174 adequate airflow for cooling.
175 9.2.4.2 Follow manufacturer’s recommendations for all cable
lengths.
9.2.4.3 Motor cables should be shielded and connected to both the
176 drive frame and the motor frame.
9.2.4.4 No more than 3 sets of motor leads from drive controllers
177 should be routed through the same single conduit.
9.2.4.5 Control cables shall not pass the variable frequency drive
within .3m (12in). Control cables shall not parallel motor power
178 cables. (Refer to chart in 7.1.7)
9.2.4.6 All feedback (encoder, resolver) wiring shall also be routed
179 away from power cables. Wireway with a divider may be used.
9.2.4.7 Disconnects for VFDs can be located on either the line or
load side of the VFD depending on local codes and or plant
preference. If the disconnect is mounted on the load side of the
VFD it must be capable of disabling the VFD prior to opening the
contacts. To achieve this requirement it is recommended that two
normally open auxiliary contacts be wired to the VFD enable circuit
where applicable to disable the output prior to opening the motor
180 lead contacts.
9.2.4.8 Suppression devices shall be installed on all relays;
solenoids and brake coils located in close proximity (same control
181 panel) of the VFD to reduce electrical noise.
9.2.4.9 Most VFDs do not provide short circuit protection on the
input power; therefore it is a recommendation that a circuit breaker
be installed on the line side of the VFD to protect against short
circuits. Circuit breakers should be sized for the maximum short
circuit rating of the incoming power. Circuit breakers must be
capable of interrupting the maximum short circuit current available
from the power source.(refer to the VFD manufacture for the
recommended circuit breaker sizes)
182
183 10.0 ROBOTICS ( N/A )
11.0 SENSING 11.1 Where applicable sensors shall utilize a standard M12, M18,
184 DEVICES M30 (barrel or cylindrical) housing.
11.2 The vendor shall provide all sensors and instrumentation
185 devices required to operate the machine.
11.3 An LED shall be mounted in sensors to indicate that the switch
186 is energized (contact is closed). (see picture below)
11.4 All sensors shall have an integral plug as part of the sensor
housing to facilitate quick change out of the sensor itself in the event
187 of a failure. (see picture below)
11.5 In the case where a sensor cable enters a raceway or
enclosure, the environmental rating (IP or NEMA) of the raceway or
188 enclosure must be maintained.
11.6 Electronic sensors shall be IP67 with three-wire PNP (sourcing)
type connection, if possible. Any 2-wire sensing devices need to be
189 approved by a Project Controls resource.
11.7 All relay and contactor coils, solenoids and reed switches shall
190 be protected with adequate surge suppressors (e.g. RC/ RL
circuits).
11.8 All sensing devices that are exposed and not contained within
the protected guarding of the machine/ process skid shall be
191 guarded to prevent damage.
11.9 Where sensor wiring is subjected to bending, ultra-high flexible
192 cable specifically designed for these applications shall be used.
12.0 VISION SYSTEMS 12.1.1 OEM shall provide an overview of the vision application and
193 12.1 GENERAL provide detail as to what attributes the vision system is looking for.
12.1.2 Images acquired by the camera shall provide adequate
contrast for the inspection. Sample images shall be provided to the
194 P&G Controls Contact.
12.2 PROGRAM 12.2.1 Statistical data indicating the number of passes and the
195 number of rejects shall be provided in the program.
12.2.2 Vision program shall be developed in a logical flow which
196 outlines the functional flow of the machine process.
197 12.2.3 Program shall be documented in English and the local
language.
12.2.4 Each vision tool used shall be documented with a tool tip or
198 color label.
12.3 LIGHTING 12.3.1 Light emitting diodes (LED) or high frequency ballast
199 fluorescents shall be used to illuminate the part of interest.
12.3.2 Color of the lighting shall be determined by the part of interest
200 and the attributes being inspected.
201 12.4 INTERFACE 12.4.1 Screen shall be provided for programming and or viewing.
202 12.4.2 Use of the machine HMI is permitted.
12.5 NETWORKING 12.5.1.1 Ethernet IP and Subnet mask shall be posted below the
12.5.1 Ethernet vision processor or camera.
203
204 12.5.1.2 Switches shall be used, No Hubs are permitted.
12.5.1.3 Vision to PLC Ethernet communications shall not be used
205 with an SLC processor.
12.5.2 DeviceNet 12.5.2.1 Node number shall be posted below the vision processor or
206 camera.
13.0 FLUID POWER 13.1 OEM shall provide a lockable air dump with silencer for the
207 equipment.
13.2 Air pressure switch shall be installed to inhibit start of machine/
process skid in the absence of at least 50 – 100 psig in the main
208 manifold. (actual pressure required shall be determined by the
vendor)
209 13.3 All tubing (within a bundle/group) shall be labeled.
210 13.4 All tubing and fittings shall be metric.
13.5 Suggested use of color coded pneumatic lines:
13.5.1 Silver – Supply lines to Filter Regulators, valves.
13.5.2 Blue – Extend for linear pneumatic actuators
13.5.3 Red – Retract for linear pneumatic actuators
13.5.4 Green – Rotate Right for rotary pneumatic actuators
13.5.5 Yellow – Rotate Left for rotary pneumatic actuators
13.5.6 Black – Vacuum lines
211
14.0 ENCLOSURES 14.0 ENCLOSURES
14.1 Enclosures of control equipment shall be suitable for the
environment they will be located in.
212
14.2 All control equipment shall be located and mounted so as to
facilitate the following:
14.2.1 Accessibility and maintenance of the equipment
14.2.2 Protection against the external influences or conditions under
which the equipment is intended to operate
14.2.3 Operation and maintenance of the machine/ process skid and
its associated equipment
213
14.3 All components shall be mounted on a #12 gauge steel sub
panel. The sub panel shall be mounted on metal studs, and the sub
214 panel shall be removable from the panel enclosure.
14.4 All components (PLC rack, relays, panel channel, etc.) must be
mounted using machine/ process skid screws and tapped holes. No
nuts and bolts or adhesives (except nameplates) may be used to
mount components.
215
216 14.5 All enclosures shall be labeled and correspond to the drawings.
14.6 Electrical enclosures containing components other than
terminals shall operate at an internal temperature less than 104oF
(40oC). If cooling is required, it shall be by means of an air-to-air
heat exchanger which is preferred or another means that maintains
the integrity of the enclosure and its NEMA/IP rating.
217
14.7 Use IP54 (NEMA 12), or equivalent construction with gaskets
of sponge rubber or neoprene. Cabinets shall be constructed of
218 formed sheet steel, #12 gauge minimum.
14.8 Enclosure cutouts for devices mounted through enclosures
shall be installed with a gasket to maintain the environmental rating
(IP or NEMA) of the enclosure. Gasket material shall be provided
for mounting bolts for devices mounted through enclosures.
219
14.9 The cabinet shall be equipped with full-length flush doors,
which close securely against the gaskets. The doors shall be
equipped with semi-concealed hinges. The door and hinge
arrangement shall be sufficiently rigid to maintain proper alignment.
The door shall open outward unobstructed for a minimum of 180
degrees and shall be equipped with a preferred three-point roller
latch and vault handle capable of being locked in the closed
position. The latch must latch at the top, bottom and center.
220
14.10 If a cabinet is to be larger than approx. 100cm X 120cm X
30cm deep (36” X 48” X 12” deep), the cabinet must include a door
221 switch light for illumination of the interior components.
14.11 All control panels shall have a minimum of 25% usable spare
222 space for future expansion.
14.12 All enclosures which house a Programmable Controller will
have a programming interface connection on the front of the
enclosure along with a service outlet. Vendor shall provide a
convenience outlet located inside of all other cabinets. (see
223 Programming Interface Section)
14.13 All convenience outlets shall be equipped with a GFCI with a
224 3 amp reset.
14.14 Enclosures shall not be used for mounting or support of
external devices, conduit or piping. No attachment shall be made to
the enclosure, except for the purpose of enclosure mounting or the
termination of electrical conduit. Machine vibration shall not be
transferred to any electrical panel
225
14.15 Panel doors shall be bonded and use bare braided cable for
bonding. If cable is used for PE ground purposes, cable must be
226 clearly identified as PE ground cable and appropriately labeled.
14.16 All enclosure doors shall be lockable via special tools or lock
227 handles on all non-interlocked doors.
14.17 Enclosures of control equipment shall be dual-rated
(NEMA/IP) enclosures suitable for the environment they will be
located in and shall provide a degree of protection of at least NEMA
Type 12 / IP 54. Refer to the manufacturer’s documentation for dual
228 rating information.
15.0 (EMC) 15.1 Use shielded cable for VFD and Servo motor applications.
ELECTROMAGENTIC Shield shall be grounded at both ends.
229 COMPATIBILITY
15.2 To increase the likelihood of passing the European EMC tests,
it is recommended to install Class A line filters on all drives. Contact
the drive manufacturer for assistance in selecting the appropriate
line filter for each drive.
230
15.3 OEM shall certify the equipment meets EU EMC testing
231 requirements as part of the CE marking.
16.0 SAFETY 16.1.1 Vendor shall conduct a risk assessment on the machine/
232 16.1 GENERAL process skid and provide the results to P&G.
16.1.2 Minimum safety category rating shall be Category 3 with
233 monitoring.
16.1.3 All of the safety electrical components which reside internal
to a control cabinet must be covered by lexan with stand-offs from
234 the sub-panel. (see below picture)
16.1.4 Label shall be provided located over the top left stand off bolt
235 indicating this is the machine safety circuit. Authorized personnel
only.
16.2 GUARD 16.2.1.1 Device shall incorporate a metal head design with integral
SWITCHES key funnel.
236 16.2.1 Locking Guard
Switches
237 16.2.1.2 Must be rated for the application in which it is used.
16.2.2 Non Locking 16.2.2.1 When using a two piece mechanical interlock switch, the
Guard Switches design may be either a metal head design with integral key funnel or
238 plastic body design with integral key funnel.
239 16.2.2.2 Must be rated for the application in which it is used.
16.3 SAFETY CIRCUIT 16.3.3.1 CAT 3 compliant machines for both pneumatic and
240 electrical systems.
16.3.3.2 Auxiliary contacts from the guard switches and local
disconnects provide annunciation thru PLC to the HMI showing
241 which disconnect is thrown or which guard door is open.
16.3.4 All devices in the safety and reset circuits (including
intermediate/interposing relays) must be EN/IEC approved safety
242 devices.
16.3.5 Besides the safety circuit, the only other acceptable
disconnecting alternative is to use a visible blade disconnect. These
disconnects shall be mounted at a standard height of approximately
60 inches above the floor to the center of the window.
243
16.4 ISOLATION OF 16.4.1 Solenoid locked safety guards/ doors and gates shall be used
HAZARDOUS ENERGY to protect operator as defined by the machine/ process skid risk
244 assessment.
16.4.2 A CAT 3 rated safety dump valve shall be located on the
machine/ process skid disconnect. A pressure switch shall be
located on the machine/ process skid side of this valve. On loss of
air, all motion shall be disabled until air pressure recovers and reset
button pressed. Components shall not be capable of dropping or
drifting after air loss.
245
16.4.3 All pneumatic and hydraulic solenoid valves MUST be de-
energized and exhausted when the air & power disconnects are in
the OFF position. If this action causes complications (i.e. jams,
dropping of product, incorrectly packaged product etc.), the issues
must be brought to the P&G Controls Contact’s attention during the
246 Bid stage.
16.4.4 Lockable disconnects and air dump valves should be readily
247 accessible and reviewed by the Project Controls contact.
16.4.5 All machine/ process skid functions to stop in “fail safe”
248 position due to power and/or air loss. Motion shall be re-initiated
only after
16.4.6 the safety
Safety relay is reset
relay contacts via hardwired
shall be a hard-wired resettopush-button
directly all motor
249 wired in series
controls, withbe
and shall a PLC output.to The
hardwired PLC
isolate outputpower
control shall from
be the
energizedoutput
controller only if cards
a logic(motion
check indicates that all software is ready for
16.4.7
motion.All removable equipmentonly).
guards/ doors (including gates)
250 shall be wired into a safety relay circuit with approved safety
16.5 EMERGENCY switches
16.5.1 unlessanbolted
Provide into position.
emergency stop circuit that shall be designed to
STOP CIRCUIT meet the requirements of the risk category determined by the risk
251 assessment for the machine.
16.5.2 The e-stop circuit shall function by removing power to
actuators that cause hazardous conditions as quickly as possible
252 without creating other hazards.
16.5.3 At least one e-stop button shall be installed to interrupt all
motion when pressed. Safety interlocks shall be wired to an
approved safety relay to be used as system or unit wide interlock as
defined by the safety analysis.
253
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16.5.4 Reset of the emergency stop circuit shall not automatically
restore power. Reset button shall be utilized to restore the power to
254 the equipment.
16.5.5 All emergency stop circuits shall comply with option 1 or 2
below (reference EN 60204-1 or NFPA 79, Chapter 9.2.5.4):
16.5.5.1 Option 1 – Be hard wired and may not rely on a PLC or
software for their operation (although software may be used to
monitor the E-Stop circuit). An input signal from each E-Stop device
shall be wired into the PLC to identify which device was activated.
16.5.5.2 Option 2 – Be part of a safety PLC system Certified by TÜV
Product Service for use in applications up to SIL 3 according to IEC
61508 and to EN 954-1, Category 4.
255
16.5.6 Rockwell, Siemens, and Pilz offer systems that are certified
and are acceptable suppliers of Safety PLC’s for use in machine/
256 process skid lock out and emergency stop systems.
17.0 DISCONNECTS 17.1.1.1 Disconnects shall be labeled to indicated function.
257 17.1 GENERAL
258 17.1.1.2 Readily available
259 17.1.1.3 Lockable in the off position.
17.1.1.4 Within line of sight of the part of the machine requiring
260 disconnection.
261 17.1.1.5 IEC disconnect handle shall be vertical ON, horizontal OFF.
17.1.1.6 Disconnect switch shall not be used as a junction box,
troughs or raceways for conductors feeding through or tapping off to
262 other switches.
17.1.1.7 The control enclosure main disconnect shall be front flange
mounted, operator type with current limiting circuit breakers listed or
263 labeled for application.
17.1.1.8 Each panel containing circuits of 300 volts or greater is to
be equipped with a main disconnect of a size rated for load
interruption and interlocked with the door to prevent access by
untrained personnel without first disconnecting this power supply.
264
17.2 TYPES 17.2.1 The following disconnects may be required depending on the
application: (P&G Controls Contact will work with the OEM to
265 determine the type, number and location for each.)
17.2.1.1 Main Incoming Power Disconnect – Disconnects power to
all equipment on machine. Includes logic power. (Maintenance).
Required on the Main Electrical Panel.
17.2.1.1.1 Yellow and Red
266
17.2.1.2 Panel Disconnects – Disconnects all power in panel
including motion bus. Not including PLC/controller Power, light, or
receptacle(s). Required for panels other than the main panel.
17.2.1.2.1 (Main Incoming Power Disconnect may perform this
function), if not, Black on Black
267
17.2.1.3 Motion Disconnect – Disconnects motion bus power
17.2.1.3.1 Black on Black
268
17.2.1.4 Local Disconnect – Disconnects individual AC motor or
machine/ process skid zone.
17.2.1.4.1 If the Category 3 safety circuit is installed, use Black on
Black
17.2.1.4.2 If an individual disconnect is required for a single motor
such as on a pump or on a conveyor, use the following:
17.2.1.4.2.1 Voltage rated disconnect between the variable
frequency drive and the motor with early make/ late break auxiliary
contacts wired to the enable of the drive.
17.2.1.4.2.2 Meltric plugs (shown on left), are also permitted for
disconnecting the motor for mechanical maintenance.
17.2.1.4.2.3 See the appendix for a schematics showing the above
methods.
269
18.0 CONTROL 18.1.1 The P&G preferred supplier for the control systems for
SYSTEMS controller and Motion control, Drives, and Human Machine Interface
18.1 GENERAL (HMI) is Rockwell. Honeywell and Wonderware are used for some
applications, but should first be reviewed with a Project Controls
270 resource.
18.1.2 OEM will provide a PLC or similar controller based on the
271 requirements of the machine.
18.1.3 The PLC/ controller isolation transformer, processor, DC
power supplies and I/O units are to be mounted to isolate them from
noise generated by other electrical components. They may be
mounted in a separate control panel enclosure or segregated in the
main panel compartment with a filter suppression device for the
PLC/ controller power.
272
18.1.4 The PLC/ controller I/O modules shall be individually wired to
terminal strips inside the PLC/ controller panel provided by the
OEM. All external electrical devices shall enter the PLC/ controller
panel and terminate at these terminal strips. There shall be a
minimum of 20% spare space available for the purchaser to install
273 additional terminals.
18.1.5 All control devices, such as photo eyes, starters, etc., will be
274 either inputs to or controlled by the PLC/ controller.
18.1.6 The I/O structure shall have a minimum of 20% spare
capacity for future expansion. Spare capacity means available rack
275 space not modules.
18.1.7 Refer to manufacturer’s installation manual for recommended
276 practices on installation and grounding.
18.1.8 Commanded motion shall be checked with a sensor unless
277 waived by P&G. Motion failure shall be alarmed.
18.2 NETWORKS 18.2.1.1 PC&IS Controls contact shall be made aware of and
278 18.2.1 GENERAL approve all network designs prior to implementation.
279 18.2.2 ETHERNET 18.2.2.1 Preferred communication practice for PLC to HMI is
18.2.3 CONTROLNET Ethernet
18.2.3.1 Preferred communication practice for PLC to PLC
280 communications for high speed synchronous communications.
18.2.4 DEVICENET 18.2.4.1 Vendor shall follow manufacture’s recommendations to
281 design an effective and reliable network.
18.2.5 SERCOS 18.2.5.1 Preferred communication practice for motion controllers to
282 servo drives.
283 18.2.6 PROFIBUS 18.2.6.1 Siemens network, for use with Siemens PLCs.
284 18.2.7 PROFINET 18.2.7.1 Siemens network, for use with Siemens PLCs.
19.0 SOFTWARE 19.1 Programming shall be organized and structured using modular
285 DESIGN code that aligns with the physical layout and/or function of the
equipment.
19.2 Making Skids/ Process programs shall follow ANSI/ISA-88
guidelines for the following:
19.2.1 ANSI/ISA-88.01-1995 Batch Control Part 1: Models and
terminology
19.2.2 ANSI/ISA-88.00.02-2001 Batch Control Part 2: Data
structures and guidelines for languages
19.2.3 ANSI/ISA-88.00.03-2003 Batch Control Part 3: General and
site recipe models and representation.
286
19.3 All machines other than making skids shall follow OMAC
287 guidelines (version 3), including the OMAC state model for
automatic operation
19.4 PLC/ controller shall be capable of storing different recipes.
288 Each shall be able of being called to run via the HMI.
19.5 The vendor will program and document the PLC/ controller
program using the manufacturer’s latest version. The PLC/ controller
program shall be commented in English or the local site language
with both rung and address comments. The vendor will provide the
purchaser with a source media containing a copy of the documented
program. All physical I/O shall be commented with symbols.
Symbols shall be used on all I/O devices and shall be consistent
with nomenclature used on elementary.
289
19.6 PLC/ controller programming shall include “First Out” alarm
logic to inform the operator the cause of the machine/ process skid
stop. Example: (stop button pressed, guard door opened, E-Stop
Pressed shall be included in the “First Out” logic.) The alarm
messages shall be displayed on the HMI.
290
19.7 Vendor shall ensure that the operation of the machine shall not
be affected if the scan time is increased by 20%. P&G requires this
291 additional scan time for downtime tracking and production
monitoring.
19.8 PLC/ controller shall include machine state information detailed
below:
19.8.1 1 – Stopped (stopping, stopped, Off, Aborting, Aborted
states)
19.8.2 2 – Running (Starting, Ready, Standby, Producing)
19.8.3 3 – Blocked (Lack of space to put product at discharge)
19.8.4 4 – Starved (Lack of product or materials at infeed)
292
19.9 PLC/ controller program should include a designated file for
293 alarm / stoppage messages.
19.10 A message shall display every time a button is pressed or
294 selection is made that does not have the intended outcome.
20.0 OPERATOR 20.1.1 Electronic displays shall be in English and the local language
INTERFACE specified at the time of order. It is acceptable to display one
20.1 ELECTRONIC language and unit set at a time with a switch to change language
DISPLAYS and or units.
295
20.1.2 Operator interface requirements shall comply with NFPA 79,
Chapter 10 – Operator Interface and Controls Devices and EN
296 60204-1, Clause 10.
20.1.3 The user interface to the machine/ process skid will utilize the
Allen Bradley range of products. The number and type of electronic
displays shall depend up on the complexity and requirements of the
application.
297
20.1.4 All HMIs shall be color unless specified otherwise by the P&G
298 Controls contact.
20.1.5 Supplier shall maintain consistent use of the following
throughout all operator interface screens:
20.1.5.1 Symbols
20.1.5.2 Colors
20.1.5.3 Text Descriptions
20.1.5.4 Fonts
20.1.5.5 Functions Keys
299
20.2 PUSHBUTTONS 20.2.1 The color code for push-buttons, pilot lights shall conform to
300 Global Spec
301 20.2.2 Pushbuttons shall be IEC format.
20.2.3 The vendor shall provide oil tight push buttons, selector
302 switches, pilot lights, etc. for local controls.
20.2.4 All start push buttons shall be momentary contact push-
303 button units.
20.2.5 Electronic display shall have a selection for lamp test if
304 applicable; otherwise, a separate button shall be installed for lamp
test.
20.3 EMERGENCY 20.3.1 Machines/ Process Skids must be equipped with a Category
STOPS BUTTONS 0 Stop.
20.3.2.1 Category 0 is an uncontrolled stop by immediately
removing power to the machine actuators.
305
20.3.3 Emergency stops must be a red mushroom head type with a
yellow circular background plate. Push button must be self-latching
306 and may only be reset manually.
20.3.4 Emergency stop push-pull buttons shall be positioned around
the machine/ process skid. Number of E-Stop buttons and location
307 of shall be determined based on the risk assessment and P&G
Controls Contact.
20.4 INDICATION 20.4.1 The vendor shall mount a tree light assembly on the machine.
BEACONS The tree light assembly shall be a four light model with Red, Amber,
308 Green and Blue as the primary colors
20.4.2 Light beacons shall also provide an audible alarm to
309 knowledge faults and or starts.
310 20.4.3 Audible horn shall sound on any flashing light.
20.4.4 Where necessary, the plant may adjust the colors on the light
311 beacon to promote plant safety and consistency.
20.5 PROGRAMMING 20.5.1 Control panels containing controllers such as PLCs, servo
INTERFACE controllers shall provide a programming interface port on the front of
312 the control panel enclosure.
20.5.2 Programming interface port shall retain the integrity of the
313 control panel.
20.5.3 Power outlets shall be for the local voltage and shall
314 incorporate a ground fault interrupter with a 3 amp reset.
21.0 NAMEPLATES 21.1.1 ALL electrical devices shall be labeled as follows:
21.1 GENERAL 21.1.1.1 Name – should also indicate function.
21.1.1.2 Searchable tag within PLC.
315
21.1.2 All equipment nameplates and labels shall be in English
316 and/or the local language specified at the time of order.
317 21.1.3 Nameplates will be white background with black letters.
21.1.4 Nameplates should be of engraved, laminated phenolic with
318 chamfered edges.
21.1.5 Attach nameplates permanently beside or above individual
components instead of on covers. Nameplates need to be mounted
such that the device can be replaced and the covers removed
without losing identification of the device.
319
21.1.6 Nameplates inside panels may be attached using an epoxy or
equivalent. Nameplates attached to the outside of an enclosure
must be attached using screws Identify all components as shown on
the drawings.
320
21.1.7 Identify starters, switches, push-button, pilot lights, relays,
321 and other components as called for on the layout drawings.
21.1.8 Per NEC 670.3, all control/ power panels mounted on the
equipment or on a separate base shall be labeled to indicate but not
limited to the following:
21.1.8.1 OEM name
21.1.8.2 Machine/ Process Skid Name
21.1.8.3 Machine/ Process Skid serial number
21.1.8.4 Rated Voltage, number of phases, Frequency, Full Load
Current for each Supply
21.1.8.5 Ampere rating of the largest motor or load
21.1.8.6 Maximum ampere rating of short-circuit and ground-fault
protective device.
21.1.8.7 Electrical diagram number(s) or the number of the index to
the electrical drawings for the machine.
322
22.0 MARKING AND 22.1 All markings should use international symbols as defined in
323 LABELING IEC 60417-2, ISO 7000, and EN 61310-1.
22.2 Marking and Labels are one area where machines cannot be
“global.” For marking and labeling that cannot be done with
international symbols (see 2.17.1 above) the labeling will need to be
modified for the local language of each country the equipment is to
324 be installed in.
23.0 HAZARDOUS
(CLASSIFIED)
ENVIROMENTS ( Not
Available )
325
24.0 STANDARD 24.1 The Vendor must submit for the purchaser’s review a list of the
COMPONENT LIST source equipment vendor, type, and quantity of material items and
equipment to be used. Failure to submit this list, or omission of
items, will require the Vendor to conform strictly to the specifications
as to source equipment vendor, type, and quality. “Approved
Equals” will not be accepted unless approval is obtained from P&G.
326
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Inspection Data Sheet #3 - Pneumatic Inspection Checklist
Machine
Manufacture
r: Inspector: Date:
Passed
Has an lockable manual air dump been provided and located

1 properly?
2 Has the safety startup valve been provided and located properly?
Is the air pressure switch properly set up to inhibit machine

3 operation in low are pressure condition?
4 Is the filter, regulator, lubricator provided with a pressure gauge?
5 Can the trapped air in the machine be evacuated properly?
6 Are all air cylinders and components as per specification?
Are all pneumatic components accessible for adjustment and

7 maintenance?
Are all components rigidly mounted and protected? Check for sharp
8 edges.
9 Are the air tubing in the flexible areas properly bundled together?
13 of 38
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Inspection Data Sheet #3 - Pneumatic Inspection Checklist
Machine
Manufacture
r: Inspector: Date:
Passed
10 Are the air tubing well mounted and protected against whipping?
11 Are the air tubing and fittings properly rated?
12 Are the silencers (mufflers) properly sized and mounted?
13 Note operating pressure. (The normal operating pressure is 6 Bar)
14 of 38
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Inspection Data Sheet #4 - Equipment Safety Inspection Checklist
Machine
Manufacture
r: Inspector: Date:
Passed
Are the disconnects (lockable) mounted in the correct locations?

1 Test.
2 Are the E-Stops mounted in the correct locations? Test.
3 Are the safety interlocks working properly? Test.
4 Is adequate guarding in place?
5 Are the motors, gearboxes, belts, chains properly guarded?
6 Are the gearboxes properly ventilated?
Is there safe access to all parts of the machine? All guarding to

7 access moving parts are to be interlocked.
8 Are the safety/warning signs present and located properly?
9 Are there any trip hazards associated with the base or other areas?
15 of 38
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Inspection Data Sheet #4 - Equipment Safety Inspection Checklist
Machine
Manufacture
r: Inspector: Date:
Passed
10 Are there any low level obstacles?
11 Check the machine for sharp edges or burrs.
12 Check the ergonomics of loading inputs.
13 Check the ergonomics of clearing jams.
14 Check the ergonomics of cleaning the machine.
Check the ergonomics of performing regular maintenance

15 procedures.
Check the conveyor for pinch points along the belt, chain, sprockets
16 and transfer areas?
16 of 38
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Inspection Data Sheet #5 - Operation Inspection Checklist
Machine
Manufacture
r: Inspector: Date:
Passed
Is the description of operation understandable? (i.e. fill adjust,

1 changeover procedure, etc.)
2 Are all operator interfaces clearly marked and understandable?
Is the function of each mechanical, electrical and pneumatic system

understandable and documented? All adjustable items must be
3 centerlined and documented.
17 of 38
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Inspection Data Sheet #6 - Documentation Inspection Checklist
Machine
Manufacture
r: Inspector: Date:
Passed
1 Does the documentation include a description of machine functions?
Does the documentation include a machine set up and operating

2 procedure including safety precautions and procedures?
3 Does the documentation include troubleshooting charts?
Does the documentation include a maintenance and lubrication

4 schedule?
5 Does the documentation include a mechanical spare parts list?
6 Does the documentation include a pneumatic spare parts list?
7 Does the documentation include an electrical spare parts list?
Does the documentation include the changeover procedures and

8 change parts list? Verify.
Does the documentation include the complete parts list with

9 commercial cross references?
18 of 38
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Machine
Manufacture
r: Inspector: Date:
Passed
Does the documentation include an installation procedure with

10 drawings, match marks, etc.?
11 Does the documentation include a layout and elevation drawing?
12 Does the documentation include a pneumatic layout and flow sheet?
13 Does the documentation include an electrical device layout?
14 Does the documentation include a panel layout?
15 Does the documentation include timing charts?
16 Does the documentation include the I/O and elementary drawings?
17 Does the documentation include a machine cleaning procedure?
18 Does the documentation include centerline adjustments?
19 of 38
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Machine
Manufacture
r: Inspector: Date:
Passed
Does the documentation include the detailed OEM literature? (i.e.

19 Allen Bradley, etc.)
20 Is the program listing printout included?
20 of 38
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Inspection Data Sheet #7 - Layout Inspection Checklist
Machine
Manufacture
r: Inspector: Date:
Passed
1 Is the discharge conveying height as per specified?
Does the machine and conveyor footprint conform to the

drawing?
2 Check key dimensions.
Does the machine and conveyor elevation conform to the

drawing?
3 Check key dimensions.
21 of 38
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Inspection Data Sheet #8 - GMP Inspection Checklist
Machine
Manufacture
r: Inspector: Date:
Passed
Is the clearance underneath the machine as per specification?

1 (200mm)
2 Is there access to all parts of the machine for cleaning?
Is the cleaning procedure complete and understandable? (i.e.

3 general, sealing jaws, etc.)
4 Are the motors mounted to conveyor using clean design?
5 Are the machine and conveyor supports clean design?
6 Are the electrical conduit, wireways clean design routing?
7 Are all guarding clean design with no product catch points?
8 Tri-clamp connections to all process piping?
9 Is the filling system (all product contact areas) 316L and passivated?
22 of 38
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Inspection Data Sheet #8 - GMP Inspection Checklist
Machine
Manufacture
r: Inspector: Date:
Passed
10 Is the surge tank and level probe sanitary design?
11 Are the filler piston/cylinder/nozzle all sanitary design?
12 Are the drain pans, and filler all sanitary design?
13 Is the whole process system completely drainable?
14 Is the whole process system completely sanitizable?
Is the filling system ready to operate without binding, jamming, etc.

15 immediately after washout and/or sanitation?
23 of 38
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Inspection Data Sheet #9 - Installation Inspection Checklist
Machine
Manufacture
r: Inspector: Date:
Passed
1 Are the lift points clearly labeled on the drawing?
Have centerline points for installation and startup been

2 documented?
3 Is there provision for height adjustment and anchoring?
Are the utility drop locations accurately shown on the

4 drawing?
Are the match marks on the equipment and drawings for

5 equipment installation and assembly provided?
24 of 38
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Inspection Data Sheet #10 - Input Material Inspection Checklist
Machine
Manufacture
r: Inspector: Date:
Passed
1 Is the tube material quality as per specification?
2 Is the tube material tolerances within specification?
Is the viscosity of the conditioner product as per specification?

3 Record viscosity.
Is the specific gravity of the conditioner product as per

4 specification? Record specific gravity.
25 of 38
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Inspection Data Sheet #11 - AM/ PM Checklist
Machine
Manufacture
r: Inspector: Date:
- Test Description: Following tests are aimed to ensure equipment is made to meet specification AM, PM design and AM step 3
capable! Mark “YES” if criteria is successfully achieved or “NO” in such case.
Criteria # Acceptance Criteria for AM/PM Yes/ No

1 Vendor's manual is in place
2 Nameplate data meets Engineering data sheet
3 Equipment does not reflect evidence of damage (forced deterioration, peeling, stricken, corroded).
4 Equipment is accessible for maintenance, operation and cleaning
5 Equipment tag is in place and visible.
6 Safeguards are in place according to health, safety and environmental program
7 Equipment has ground connection
8 Inlet / outlet flows are visually identified through arrows
9 Grout base meets sanitary design ( coved)
10 Bolts are inserted from bottom (in case they are installed in stain steel base)
11 All bolts / nuts are tightened according to autonomous maintenance
12 Nuts are visible from the outside
13 All bolts protrude from nuts by 2-3 thread lengths.
14 Inlet filter is in place
15 Emergency stop and jog buttons are in place (per design HMI) and have their own visual controls
16 Emergency stop and jog buttons are in place
17 Unbolt pipes from pump casing to check clearance (pipe should not impose strain on casing).
18 All grease nipples and others lubricants inlets are clean.
19 Lubrication inlet is labeled with the correct type and quantity of lubricant.
20 Lubrication inlets are dustproofed and indicate type of lubricant.
21 Pump couple meets plant standard (Star, Cage, ….).
For the following steps you must use safety gloves, safety glasses ,safety shoes
22 Verify that area around equipment is dry
23 CIL standard in place.
24 OPLs for each equipment in place
25 Standard maintenance procedures in places
26 On line adjustment procedure in place
27 Suggestion spare parts in place
28 Recommendation plan maintenance in place
29 Eliminate special tools, if need, ensure it in place
30 Centerlining in place and Visual control (cost justify)
Are all ACCEPTANCE CRITERIA successfully ACHIEVED?

Issued By: Date:
26 of 38
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Inspection Data Sheet #11 - AM/ PM Checklist
Machine
Manufacture
r: Inspector: Date:
- Test Description: Following tests are aimed to ensure equipment is made to meet specification AM, PM design and AM step 3
capable! Mark “YES” if criteria is successfully achieved or “NO” in such case.
Criteria # Acceptance Criteria for AM/PM Yes/ No

Comments:
27 of 38
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Inspection Data Sheet #12 - Eight (8) Hour Dry Run Test Before Official Shakedown
Machine
Manufacture
r: Inspector: Date:
Machine Setting:
Product: Air Pressure:
Design Speed: Chilled Water Temperature:
Data Readings:
Temperature (oC)
Noise
Total Current (A) # of Reading Main Gear Box Blower Brake
Reading Time L1/ L2/ L3 Stoppages (dB) Motor #1 Motor Clutch Comments
Stops:
Items Duration Cause of Stoppage
28 of 38
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Inspection Data Sheet #12 - Eight (8) Hour Dry Run Test Before Official Shakedown
Machine
Manufacture
r: Inspector: Date:
Target Criteria:
- Vibrations.
- Physical verification that all electric, pneumatic and hydraulic (where applicable) components are present, correct and functional as designed and specified.
- Overheating motors, gearboxes and drives must be less than 80 oC.
- Noise level not to exceed 80 dBA measured at 1 m distance from the tube filler operator panels.
- Power consumption - after 1 hour of machine operation, the power cannot increase more than 5% after the first hour of operation.
- No stoppages should occur. The cause will be analyzed, noted, repaired and the run resume from the beginning until no stoppages are encountered for the duration of this run.
29 of 38
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Inspection Data Sheet #13 - Induced Failure (IFT) Record Sheet
Machine
Manufacturer/
Project: Inspector: Date:
Machine Setting:
Product: Target Speed: Air Pressure:
Package Size: Actual Speed: Chilled Water Temperature:
Data Readings:
Pass 1
Run # Failure Mode Min Time Duration Comments
1 Guard door opened!
2 Normal Machine start and stop!
3 Emergency Stop!
4 No Air!
5 Chilled water/ hotair down!
8 Emergency Stop!
9 No Air!
13 Emergency Stop!
14 No Air!
30 of 38
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Machine
Manufacturer/
Machine Setting:
Data Readings:
Pass 1
18 Emergency Stop!
19 No Air!
23 Emergency Stop!
24 No Air!
28 Emergency Stop!
31 of 38
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Machine
Manufacturer/
Machine Setting:
Data Readings:
Pass 1
29 No Air!
33 Emergency Stop!
34 No Air!
38 Emergency Stop!
39 No Air!
32 of 38
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Machine
Manufacturer/
Machine Setting:
Data Readings:
Pass 1
No. of Runs Passed: Target: of passed
CONCLUSION:
IMPORTANT:
- DO NOT make more than one instance of hot air vacuum failure. Doing this repeatedly WILL SERIOUSLY put the life of the heating element at RISK.
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Inspection Data Sheet #14 - Product Run Record Sheet
Machine
Manufacturer/
Machine
Setting:
Data Readings:
Leg # Start Time Stop Time Duration Reason for Stoppage Action Comments
10
11
12
34 of 38
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Inspection Data Sheet #14 - Product Run Record Sheet
Machine
Manufacturer/
Machine
Setting:
Data Readings:
Leg # Start Time Stop Time Duration Reason for Stoppage Action Comments
13
14
15
16
35 of 38
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Inspection Data Sheet #15 - Package Quality Record Sheet
Machine
Manufacturer / Project: Inspector: Date:
Machine
Setting:
Data Readings:
Appearance Checks Appearance Checks
Contaminati Trimmin Burst Code Contaminati Trimmin Burst Code

Sample # on Orientation Wrinkle g Scufff Dent Test Emboss Sample # on Orientation Wrinkle g Scufff Dent Test Emboss
1 51
2 52
3 53
4 54
5 55
6 56
7 57
8 58
9 59
10 60
11 61
12 62
13 63
14 64
15 65
16 66
17 67
18 68
19 69
20 70
21 71
22 72
23 73
24 74
25 75
26 76
27 77
28 78
29 79
30 80
31 81
32 82
33 83
34 84
35 85
36 86
37 87
38 88
39 89
40 90
41 91
42 92
43 93
44 94
45 95
46 96
47 97
48 98
49 99
50 100
INTERNAL USE ONLY 36 of 38
Data Sheet #15
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Inspection Data Sheet #16 - Changeover Data Record Sheet
Machine
Manufacturer/
Project: Checked: Date:
Data Readings:
Pass (P)
or Fail
Leg # Date From (SKU 1) To (SKU 2) Time Used (min) Changover Participants (F)
37 of 38
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Inspection Data Sheet #16 - Changeover Data Record Sheet
Machine
Manufacturer/
Project: Checked: Date:
Data Readings:
Pass (P)
or Fail
Leg # Date From (SKU 1) To (SKU 2) Time Used (min) Changover Participants (F)
38 of 38
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Inspection Data Sheet #1 - Mechanical Inspection Checklist

Are all components and materials as per specification? (SST, painted

2 Are the machine main frame and components rigidly constructed?

3 Are the components rigidly mounted and protected?

4 Are all machine stations properly aligned and secured?

5 Are all fasteners secured and properly sized? Proper materials?

6 Is the welding neat and non-porous? Nozzles per specification?

Is the machine configuration as per specification?

8 Is the machine clean designed as per specification?

9 Is the machine accessible for maintenance and lubrication?

10 Are the drive motors and gearboxes as per specification?

11 Are all belts and chains properly setup and tensioned?

Is the central lubrication block present and properly piped to the

14 Is safe lubrication possible during machine operation?

15 Are motors rigidly mounted to the conveyors with easy access?

17 Are the speed control and jog speed control present?

Is the tube cleaning system as per specification?

19 Is the air filter and de-ionizing unit present?

Is the filling system built according to specification?

21 Are all seals, gaskets and hoses as per specification?

Can the magazine be loaded on the fly?

24 Can the tubes be oriented properly?

25 Is the tube cleaning system functioning properly?

Are the hot air sealing and embossing mechanisms working

28 Is the trimming mechanism working properly?

29 Is the tube discharge mechanism working properly?

Is the indexing bucket conveyor tracking properly?

Is the tube reject mechanism working properly?

Is the machine a no tube - no fill system?

Go through every applicable paragraph on the PC&IS Strategy for

Step through every applicable paragraph on key C&IS documents

3 Confirm all components are as requested by P&G.

4 Are panels & boxes clearly and correctly labeled?

5 Is the panel layout as per drawing?

8 Are devices labeled as per DWG's & rigidly mounted?

9 Are the sensors and proximity switches as per specification?

10 Is the location of electrical devices accessible for maintenance?

All wiring labeled @ each termination/connection using sleeve type

12 All wiring stranded?

13 Is the wiring properly labeled and easily identifiable?

14 Randomly pull some wires at terminals to check for tightness.

15 Are the fuse/breaker sizes correct?

16 220V duplex receptacle in control panel?

Ratings of electrical enclosures are IP65 (typical mounted on filler/),

Has an effort been made to use clean design minimize locations

19 Electrical conduit, wire ways clean design routing?

All components rigidly mounted and protected? Check for sharp

22 Verify control voltage filter or UPS supplied?

Measure incoming current demand - should be less than nameplate

Measure power supply 24VDC current supplied - should be less than

Separate ground conductor between instrument & equipment ground

Inspection Item Passed

Inspection Item Passed

Inspection Item Passed

Inspection Item Passed

Has an lockable manual air dump been provided and located

Is the air pressure switch properly set up to inhibit machine

4 Is the filter, regulator, lubricator provided with a pressure gauge?