PEUMANSEND CREEK REGIONAL JAIL

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1 SECTION PROGRAMMABLE LOGIC CONTROLLER PART 1 GENERAL 1.1 RELATED DOCUMENTS A. Contract Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this section. B. Related work specified elsewhere: 1 Locking Control System 2 Closed Circuit Television System 3 Intercom System 4 Paging System 5 Inmate Call-in System 6 Passive Duress Systems 7 Access Control Systems 8 Electrical 1.2 SUMMARY A. The work included under this section of the specification consists of modifying the existing (Modicon by Schneider Electric) programmable logic controller (PLC) based door control system to support the new PLC-controlled intercom system being provided and installed under this contract. Currently all controlled and monitored points are homerun to the designated PLC I/O units. The upgraded (PLC) control system shall continue to directly control door hardware operated and monitored by the existing locking control system/graphic locking control panels, and the two existing TCS system/touchscreen PC workstations. Upon valid activation from the graphic locking control panel system or TCS system signals will transmit to the upgraded PLC system to effect unlocking the appropriate door hardware. The current locking control systems has (Modicon ) PLC processor modules, and have (Modicon ) Ethernet compatible PLC network interface modules refer to the Contract Drawings for other details. Ethernet compatible PLC network interface modules are installed into the PLC rack slot at all existing PLC processor rack locations. The contractor shall reuse the existing (Modbus Plus ) PLC communication network and retain the (Modbus Plus ) PLC communication networking between the existing PLC processor rack locations and the existing respective Remote PLC I/O locations. The current PLC communication networks currently connect via (Modbus Plus ) PLC communication networks with the (Owner furnished) fiber optic cables. Retain and reuse all existing PLC racks and PLC power supplies, etc. Reuse existing PLC I/O input/output modules installed within the existing PLC racks and retain the existing field devices, and graphic locking control panels cabling and wiring currently connected to the existing PLC I/O modules. Reuse the existing interface relays and equipment to receive door position status signals into the PLC system for proper system operation (i.e., door unlock, door status annunciation, forced door alarm, door held-open alarm, etc.). The PLC system modified and reconfigured under this project shall interconnect with the new intercom, and paging systems is provided and installed under this project by the Contractor to effect the specified audio voice intercommunication operations. The new intercom system shall perform audio switching operations upon intercom station and/or paging zone selection, via interface with the modified PLC system and updated touchscreen system. The CCTV system shall interface with the modified PLC system and updated touchscreen system for automatic camera call-up to dedicated monitors. The existing Card Access System shall be retained and reused and interface with the modified PLC system and updated TCS system for door unlocking functions initiated via the access control system. Modules are defined herein as devices, which plug into a chassis/rack and are keyed to allow installation in only one direction. The design must prohibit upside down insertion of the modules as well as safeguard against the insertion of a module into the wrong PLC rack slot. PROGRAMMABLE LOGIC CONTROLER Page 1 of 6

2 B. Provide all labor, materials, equipment, software, and programming, and supervision to install, calibrate, adjust and check out the completely functional and operational PLC system. As needed as a requirement of this project the DIV 17 contractor shall add PLC I/O modules into the existing PLC rack locations to accommodate the new PLC-controlled intercom system being provided and installed under this project. C. Each programmable logic controller (PLC) shall be a stand-alone system, engineered to support all local function requirements. Remote building PLC processor rack locations are provided with Ethernet network connections to the main PLC processor location in the Administration Building and other building security equipment room locations. PLC equipment basically consist of, but are not be limited to: central processing modules, data network communication modules, input/output modules, system module PLC rack, power supplies, batteries, cables, software, programmer/loader, printer, and all associated wiring and hardware. D. The following codes or standards shall be utilized for the implementation of work within this section: 1 National Electrical Code 2 National Fire Protection Association (NFPA) 101 Life Safety Code 3 American National Standards Institute (ANSI)/N.F.P.A. 78 Lightning Protection Code 4 National Electrical Manufacturers Association (NEMA)/ Industrial Controls Standards (ICS) 1 5 General Standards for Industrial Control and Systems. N.E.M.A. ICS 2 6 Standards for Industrial Control Devices, Controllers, and Assemblies. N.E.M.A. ICS 3 7 Industrial Systems. N.E.M.A. ICS 6 8 Enclosures for Industrial Controls and Systems. 9 All equipment shall be UL listed. 1.3 SYSTEM CONFIGURATION A. The existing PLC-programmable logic controller rack locations having processor modules communicate with each other via (Modbus plus) protocol. Existing PLC processor rack locations also having existing remote I/O rack locations also communicate between each other via (Modbus Plus) protocol. The existing PLC system currently communicates with the two existing touchscreen workstations, existing Intercom systems, and existing CCTV system via Gigabit network switch and (Modus Plus)/TCP Ethernet bridge. The Contractor shall be responsible for downloading the existing (Modicon Concept V2.6) PLC programs from the existing PLC system processors, and modifying, decompiling and compiling the PLC programs as needed to provide and support all devices and special functions as described in the specifications and shown on the Contract Drawings. Where possible the existing PLC programming and subsequent programming techniques shall not vary in technique from the main controller to each remote PLC. At the discretion of the Contractor they may reprogram the new Upgraded PLC systems from scratch and not use the existing (Modicon Concept V2.6) PLC programs contained in the existing PLC system processors memory as long as the revised programming provides and supports all existing devices and existing functions operations currently being performed by the PLC systems and TCS systems and as described in the specifications and shown on the Contract Drawings. B. Each programmable logic controller (PLC) shall be a stand-alone system, engineered to support all current local function requirements and additional functions required by this project. Remote building PLC processor rack locations are currently outfitted with Ethernet network connections to the main PLC processor location in the Administration Building. PLC equipment basically consist of, but is not limited to: central processing modules, data network communication modules, input/output modules, PLC system module rack, power supplies, batteries, cables, software, programmer/loader, printer, and all associated wiring and hardware. 1.4 QUALITY ASSURANCE A. The existing programmable controller processor are able to withstand conducted susceptibility tests as outlined in NEMA ICS 2 current version, NEMA ICS 3 current version, section 2 of IEEE 472 current version and ANSI C37.90A current version. PROGRAMMABLE LOGIC CONTROLER Page 2 of 6

3 B. All modified PLC equipment units under this project shall be subjected to a burn in test of 60 degrees C for at least 24 hours. C. The Contractor shall not install any new PLC equipment prior to confirming the existing security equipment room areas have environmentally controlled climate, and the area can be closed and secured. D. Equipment that is not protected will be rejected and replaced with new equipment at no additional cost to the Owner, but at the expense of the Contractor. 1.5 ACCEPTABLE MANUFACTURERS A. The following manufacturer is capable of meeting the requirements of these Specifications for programmable logic controller: 1. (Modicon by Schneider Electric) 1.6 DOCUMENTATION A. Submit shop drawings indicating layout of completed rack assemblies, interconnecting cabling, cabinet dimensions, one-line diagrams, Ethernet gigabit switch equipment, and other major component connection requirements. Provide product data cut sheet information for all major pieces of equipment relative to the PLC system including processor size and speed, memory capacity and type, input and output modules, PLC rack, power supply, communication modules, cabling, etc. B. Shop drawings shall have detailed information regarding placement of PLC in security equipment cabinet, as well as interconnection with other related equipment (such as batteries, expansion I/O racks, interface connections with existing CCTV, existing Card access, new Intercom and Paging Systems being provided and installed under this project, etc.). C. System software shall be fully documented and presented to the user as as-built data upon project completion. Documentation prints out and data file shall contain, but not limited to, the following items: 1 General system information. 2 I/O configuration (graphic representation of the I/O configuration and wiring details of the I/O field wiring connections). 3 Table of Mnemonics (up to 32 characters per variable) 4 Application (software configuration of the application including configuration of type of processor, memory size, function blocks, etc.) 5 Program Listing with Comments (annotated) 6 Cross References (Lists of variables used in the program classified in order by their physical addressed and Mnemonics) 7 Summary (Table of contents of the complete set of documents) 8 Point to point wiring diagrams. 9 Ladder-logic programming diagrams PART 2 - PRODUCTS 2.1 TECHNICAL REQUIREMENTS A. A major requirement of this project regarding the existing (Modicon by Schneider Electric) programmable logic controller systems shall be to successfully modify and reconfigure the existing systems to have the capability of allowing for future expansion of the system by the addition of hardware and user software. B. The existing PLC processor module, power supply module, plus inputs and outputs module, and existing (Modicon by Schneider Electric) 140-NOM communication module, (Modicon by Schneider Electric) 140CRA communication module, and (Modicon by Schneider Electric) 140-NOE communication module are of a modular design and shall be retained and reused. Modules are defined herein as devices, which plug into a chassis/rack and are keyed to allow installation in only one direction. The design must prohibit upside down insertion of the modules as well as safeguard against the insertion of a module into the wrong PLC rack slot. C. Upgrading the PLC system shall produce no delay in the overall system performance from activation of a control point or device to the actual operation or indication of device as specified in these Specifications. D. All existing hardware of the programmable controller currently are capable of operating at an ambient PROGRAMMABLE LOGIC CONTROLER Page 3 of 6

4 temperature of 0 to 60 C (32 to 140 F), with an ambient temperature rating for storage of up to +85 C (+185 F). The programmable controller hardware shall function continuously in the relative humidity range of 5% to 95% with no condensation. The programmable controller system shall be designed and tested to operate in the high electrical noise environment of an industrial plant. The PLC system shall not be affected by induced or stray voltages that will cause false activations or alarm conditions. 2.2 PROGRAMMABLE LOGIC CONTROLLER RACK A. The configuration of the existing equipment PLC racks is by either software or dip switch settings. B. The existing (Modicon by Schneider Electric) PLC racks currently are installed within standard NEMA Type 12 enclosures and shall be retained and reused for this project. The existing PLC racks have dedicated rack slot for the existing power supply module, CPU, and dedicated rack slots for the existing input/output modules, and spare slot for communication module. As needed as a requirement of this project the DIV 17 contractor shall add PLC I/O modules into the existing PLC rack locations to accommodate the new PLC-controlled intercom system being provided and installed under this project. C. The existing PLC racks shall be maintained in a manner to prevent electromagnetic interference. 2.3 POWER SUPPLY MODULE A. The existing (Modicon by Schneider Electric) 140-CPS (PS VAC) PLC Power Supply module shall remain mounted into the first slot of the racks having processor modules. It has LED status indications for external power. An alarm contact is built in and shall be used under this project as needed. The AC Power Supply is capable of operating on 110VAC or 220VAC, 50/60 Hz selectable from the same module. B. The power supply shall automatically shut down the PLC system whenever its output current is detected at exceeding 125% of its rated current. C. The power supply shall monitor the incoming AC line voltage for proper levels. When the power supply is wired to utilize 120 VAC power, the system shall function properly within the range of 97 to 132 VAC. If the voltage level is detected as being out of range for more than one half line cycle, the power supply shall automatically shut down the system and remain disabled until the proper voltage level returns. In addition, the power supply shall provide surge protection, isolation, and outage carry over up to 2 cycles of the AC line. D. Retaining and reusing the existing PLC processor and the PLC Ethernet communication module in the existing PLC racks, and after adding PLC I/O modules to support the new PLC controlled intercom system being provided and installed under this project at no additional cost to the Owner the Contractor shall upgrade the PLC power supply if the existing power supplies are not capable of supplying the required new load. 2.4 PLC PROCESSING MODULE A. The existing CPU modules (Modicon ) 140-CPU (140-CPU Admin. Building) respectively shall be retained and reused as part of this project. The existing CPU modules are self-contained units, providing ladder rung program execution and support remote or local programming, support I/O scanning and inter-processor and other functions, perform internal diagnostic checking and give visual indication to the user by illuminating status indicators when fault is detected. B. The existing CPU s are multi-processor based unit to allow the system to operate on a real-time, multi-tasking basis. The existing CPU s have on board memory. All internal memory shall be battery backed for a period of not less than six weeks. C. The front panel of the existing CPU module has a connector that provides inter processor communication to peripheral support devices. D. All data objects in the PLC program shall be identified mnemonically. I/O points shall utilize a geographic or bit-map addressing scheme. All data, program, and constant memory shall be configurable by the DIV 17 Contractor as required by the functions defined in the specifications. E. The main CPU front panel shall include indications showing status of the following functions: 1 Power 2 Program or run mode 3 Run/fault status PROGRAMMABLE LOGIC CONTROLER Page 4 of 6

5 4 Status of outputs 5 Force status F. Non-volatile memory shall store the operating system information to protect against loss in the case of power loss or system shut down. Only at the time of a hardware change shall this configuration status be altered or re-entered. G. Provide a complete CPU for back-up of system. System shall be turned over to the user and if the main CPU fails the units can be changed out by reconnecting wiring. On start up the backup CPU shall update the status of the system and work normally. 2.5 INPUT AND OUTPUT MODULES A. The existing (Modicon by Schneider Electric) 140DDI VDC input module and the (Modicon by Schneider Electric) 140DDO VDC output module both are modules that shall be retained and reused in this project. It shall be possible to replace any input or output module without disturbing field wiring. All existing wiring to the existing graphic locking control panels and to the existing field devices from the existing I/O modules is via hard wired connections and shall be retained and reused in this project. B. Discrete output modules should have self-contained fuses for overload and short circuit protection for the module. All devices connected to I/O shall be individually fused and a fuse shall be provided for each interface relay. Fuses shall be coordinated with the manufacturer of the devices. Fuses shall be set for overload and short circuit current. All input modules shall have a specified filter time constant to limit the effects of voltage transients. A shorted or grounded circuit shall not affect the operation of the PLC to perform locking control functions. A malfunction in any I/O channel shall affect the operation of only that particular channel. C. All communications on the input/output channels between the remote I/O and the CPU are digital in nature (discrete voltages). Each I/O module shall contain a visual indicator to display ON/OFF status of individual input or output points. As needed as a requirement of this project the DIV 17 contractor shall add PLC I/O modules into the existing PLC rack locations to accommodate the new PLC-controlled intercom system being provided and installed under this project. 2.6 INTERFACE AND PERIPHERAL EQUIPMENT A. Programming terminal and equipment already exists and shall be retained and reused as needed for this project. Programming terminal shall be loaded (hard disk) with all current programming upon presentation to Owner at completion of work. B. Programming PC shall be capable of accessing and downloading all programming directly at PLC CPU. All software shall be backed up on flash/usb drive or CD. Flash/USB drive and CD drive to be integral to programmer. Flash/USB drive or CD shall be turned over to the Owner. C. A standard format ink jet printer 30-ppm black color, and 24-ppm color printing exists and shall be retained and reused for this project. D. For doors controlled both by the existing access control system and by the modified PLC system, activation of a valid card reader should cause a signal to be sent through the (ACS) controller equipment, and then through interconnection with the PLC system a signal is sent directly from the PLC system to the designated door lock hardware to unlock the door. Touching a door unlock icon on the touchscreen workstation for a door that is also card reader controlled would cause a signal to transmit through the PLC system directly to the designated door lock hardware to unlock the door, and also a signal from the PLC system is sent to the (ACS) controller equipment preventing an unauthorized access alarm in the (ACS) system. PART 3 -EXECUTION 3.1 PLC INSTALLATION A. As needed as a requirement of this project the DIV 17 contractor shall add PLC I/O modules into the existing PLC rack locations to accommodate the new PLC-controlled intercom system being provided and installed under this project. PROGRAMMABLE LOGIC CONTROLER Page 5 of 6

6 B. Modify PLC programming using existing processors and communications modules, and new I/O modules. 3.2 PLC NETWORK A. The Contractor shall retain and reuse the existing (Owner furnished) fiber optic cables that under the scope of this project are connected to the existing (Modicon ) Ethernet compatible PLC network interface modules. 3.3 SYSTEM WIRING A. All wiring shall be installed in concealed conduit except wiring installed in equipment rooms. Conduit installed in equipment rooms can be exposed and surface mounted. B. All wiring shall conform to other sections of this Specification. C. The use of butt splice equipment or wire nuts in equipment cabinets is acceptable. 3.4 SPARES A. Provide the following spare parts to the owner: 1 1-spare input module 2 1-spare output module 3 1-spare PLC power supply 4 1-spare communication module END OF SECTION PROGRAMMABLE LOGIC CONTROLER Page 6 of 6

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