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SPECIFICATION
NETWORK DESIGN AND CONVERSION GUIDE
PREPARED BY CERTAINTEED CORPORATION CENTRAL ENGINEERING INSULATION GROUP
CERTAINTEED CORPORATION
THIS SPECIFICATION IS THE PROPERTY OF CERTAINTEED CORPORATION AND ALL THE
INFORMATION CONTAINED HEREIN IS TO BE KEPT CONFIDENTIAL BY THE RECIPIENT AND
NOT TO BE USED OR DISCLOSED TO ANY OTHER PERSON, FIRM OR CORPORATION
WITHOUT OUR EXPRESS CONSENT; AND THE SPECIFICATION SHALL NOT BE HELD,
DIRECTLY OR INDIRECTLY, EXCEPT IN CONNECTION WITH OUR WORK.
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A. GENERAL SPECIFICATIONS
A1. This document outlines CertainTeed’s expectations for work to be completed. It does not detail all of
the work to be performed, and it does not indicate the exact order in which the work is to be
completed.
A2. COMPLIANCE WITH STANDARDS
A2.1. All materials and workmanship will be in accordance with the best current practices to the
satisfaction of CertainTeed. Adhere to the guidelines set forth in the National Electrical Code
(NEC), CertainTeed’s Engineering Standards and all applicable state and local building codes:
A2.1.1. National Electrical Code (NEC)
A2.1.2. Electrical Standard for Industrial Machinery (NFPA 79)
A2.1.3. Insulated Cable Engineers Association (ICEA)
A2.1.4. Standards of the Underwriter’s Laboratories (UL)
A2.1.5. National Electrical Manufacturer’s Association (NEMA)
A2.1.6. American Society for Testing Materials (ASTM)
A2.1.7. American National Standards Institute (ANSI)
A2.1.8. Institute of Electrical and Electronics Engineers (IEEE)
A2.1.9. Occupational Safety and Health Act (OSHA)
A2.1.10. International Organization for Standardization (ISO)
A2.1.11. International Electrotechnical Commission (IEC)
A2.1.12. Harmonized European Standards (EN)
A2.1.13. State and Local Regulations
A2.1.14. IBC and local state building codes
A2.1.15. FM and local state fire protection codes
A2.2. If, in the opinion of the contractor, there is anything in the drawings, or in the specifications that
will not strictly comply with the above laws, ordinances, and codes, or should local conditions
necessitate a rearrangement of items, the contractor shall consult with CertainTeed, before
proceeding with the work.
A3. All material used in this work shall be listed by Underwriter's Laboratories, Inc., and shall bear their
label where such approval is available for the type of material.
A4. All equipment shall conform to equipment currently used by CertainTeed for the purpose of
standardization.
A5. All materials provided by the contractor shall be new. No used materials are allowed.
A6. All documentation shall be in English.
A7. All equipment shall be provided with electrical schematics.
A8. GROUNDING
A8.1.Ground and bond equipment as required by NEC Article 250 and/or outlined herein and on the
engineering drawings.
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A8.2. Proper grounding of data center equipment is essential to protect equipment and
improve system reliability. Adhere to all guidelines as defined by TIA/EIA‐942
Telecommunications Infrastructure Standard for Data Centers and the National Electrical Code
(NEC).
A8.3.The two goals of the grounding system shall be to equalize electrical potentials and to create a
low resistance path to ground. Follow five basic principles when designing a grounding system
to accomplish these goals:
A8.3.1. The grounding system shall be intentional. Careful planning must be given to network
grounding. Use only high‐quality components. Only trained professionals should make any
connections.
A8.3.2. The grounding system shall be visually verifiable. When implemented properly, you
should be able to visually inspect every component of the grounding system, from the
equipment, to the rack, to the common bonding network (CBN), to the earth.
A8.3.3. The grounding system shall be adequately sized following TIA‐942 guidelines.
A8.3.4. The grounding system shall direct damaging currents away from equipment. Each rack
shall bond directly to the CBN, thereby directing current away from sensitive electronics.
A8.3.5. All metallic components in the data center shall be bonded to the grounding system.
Equipment, racks, cabinets, ladder racks, enclosures, and cable trays must be bonded to the
grounding system.
A8.4. Use permanent copper compression lugs that do not loosen over time.
A8.5.Use hardware, such as thread‐forming screws and paint‐piercing washers, and studs that cut
through the durable finishes that coat data center racks and cabinets, thereby creating a metal‐
to‐metal connection (bond).
A8.6. Use components, such as hardware and jumper cables, that are tested for their ability to
create electrical bonds and carry current.
A9. DATA/VOICE WIRING
A9.1.All data/voice wiring and components must meet or exceed the ANSI/EIA/TIA 568‐B.2 addendum
1 for implementation of CAT6 1GB Ethernet and ANSI/EIA/TIA 568‐B.3 addendum 1 for 50/125
fiber optic cable.
A9.2. All copper data/voice wiring shall be compliant with and meet the requirements as
specified by IEEE standard 802.3af‐2003 for Power Over Ethernet (POE).
A9.3.All data/voice cable splicing is prohibited.
A9.4. GENERAL ETHERNET DATA CABLE use Belden 7852A enhanced Category 6 (CAT6a):
#23 solid bare copper conductors, (4) bonded pairs, non‐shielded, PVC jacket, plenum rated.
A9.4.1. For Business networking use YELLOW jacket.
A9.4.2. For Camera networking use ORANGE jacket.
A9.4.3. For Production networking use BLUE jacket.
A9.4.4. For Production Workstation KVM extension use GRAY jacket.
A9.4.5. For Door Access networking use BLACK jacket.
A9.5. DATA/VOICE STATION MODULAR JACKS use Category 6, Belden, CommScope
Company SYSTIMAX, or approved equal, RJ45 (8P8C). Colors shall match the General Ethernet
Data Cable colors.
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A9.6.ETHERNET/IP DATA CABLE
A9.6.1. Use Belden 7929A enhanced Category 5 (CAT5e) when a 300V rating is required: #24
solid bare copper conductors, (4) bonded pairs, overall foil shielded (100% coverage) with
drain wire, industrial grade sunlight and oil resistant PVC jacket, non‐plenum rated.
A9.6.2. Use Belden 7958A enhanced Category 5 (CAT5e) when a 600V rating is required: #24
solid bare copper conductors, (4) bonded pairs, overall foil shielded (100% coverage) with
drain wire, industrial grade sunlight and oil resistant PVC jacket, non‐plenum rated
A9.6.3. For Machine networking use TEAL jacket.
A9.7. ANALOG TELEPHONE CABLE use Belden 1501A Category 5e: #24 solid bare copper conductors,
(4) nonbonded pairs, non‐shielded, PVC jacket, plenum rated. For Telephone networking use
WHITE jacket.
A9.8. VOICE (POTS/ANALOG) MODULAR STATION JACK use Category 5, Belden, Panduit,
CommScope Company SYSTIMAX, or approved equal, RJ11
A9.9. FIBER OPTIC DATA CABLE use Berk‐Tek OM2+ Adventum loose tube fiber optic cable:
50/125 µm, multimode, (12) fibers minimum, PVC jacket, indoor/outdoor rated. For a (12) fiber
cable, the Berk‐Tek part number would be LTR012LB3010/75. Fiber optic connectors shall be LC
type.
A9.10. STANDARD CORRUGATED HDPE (INNERDUCT) use Innerduct HDPE corrugated for fiber
optic installation under roof rafters for plant backbone system or in the office area in the
dropped‐down ceiling space.
A10. DATA NETWORK GUIDELINES
A10.1. The plant data network is a subnet of a larger network of Saint‐Gobain plants. Its
assigned range is 10.180.xxx.001 through 10.180.xxx.254. It shall include workstations, laptops,
printers, wireless access ports, managed switches and routers. It shall be a 10/100/1000 network
with POE capability.
A10.2. ETHERNET SWITCHES
A10.2.1. HP PROCURVE switches shall be used. They should be POE capable and shall support
external power supply whenever possible.
A10.2.2. 2920‐24G‐POE+ shall be used for topical application not exceeding 370 W for POE.
A10.3. WIRELESS ACCESS POINTS
A10.3.1. Modular Station Jacks (YELLOW) shall be used for Wireless Access Point drops.
A10.3.2. Locate drops every 150 linear feet of office space in the dropped ceiling area.
A10.3.3. Later wireless mapping survey will determine exact location of drops.
A10.3.4. HP PROCURVE MSMxxx wireless access points shall be used.
A10.4. HALLWAY NETWORK DROPS
A10.4.1. Modular Station Jacks (YELLOW) shall be used for System Furniture/workstations
network connections.
A10.4.2. Locate every 100 linear feet of office space.
A10.4.3. Systems furniture/work stations shall require (2) data/voice cables per work station
(except where CertainTeed designates differently on floor plans) on a 4‐outlet flush
mounted faceplate and shall be terminated onto two of the four RJ‐45 (8P8C) jacks.
A10.5. OFFICE NETWORK DROPS
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A10.5.1. Modular Station Jacks (YELLOW) shall be used for office network connections.
A10.5.2. Private, hard wall offices shall require (2) data/voice cables per office (except where
CertainTeed designates differently on floor plans) on a 4‐outlet flush mounted faceplate,
and shall be terminated onto two of the four RJ‐45 (8P8C) jacks.
A10.6. CONFERENCE ROOMS AND COPY EQUIPMENT AREA NETWORK DROPS
A10.6.1. Modular Station Jacks (YELLOW) shall be used for conference room and copy equipment
area network connections.
A10.6.2. Conference rooms, copy/equipment areas, etc. shall require (2) data/voice cables per
drop (except where CertainTeed designates differently on floor plans) on a 2‐outlet flush
mounted faceplate and shall be terminated onto the two RJ‐45 (8P8C) jacks.
A10.6.3. There shall be one face plate per opposing or adjoining walls.
A11.VIDEO PROJECTOR CONNECTIVITY Use a video projector AV extender wall plate system, such as
Parts Express part #183‐350, which allows for six video signals to be sent over two runs of conventional
Category 6 cables.
A12. VOICE OVER IP (VOIP)
A12.1. IPX Shall be provided by Alcatel‐Lucent.
A12.2. OMNIPCX (ATA) shall be provided by Alcatel‐Lucent
A12.3. ALCATEL‐LUCENT PHONES
A12.3.1. 4008 IP TOUCH – 2.7W
A12.3.2. 4018 IP TOUCH – 3.68W
A12.3.3. 4028 IP TOUCH – 4.04W
A12.3.4. 4038 IP TOUCH – 4.05W
A12.3.5. 4068 IP TOUCH – 4.82W (Bluetooth enabled 5.7W)
A12.4. HP PROCURVE SWITCHES
A12.4.1. MODULAR DESIGN HP PROCURVE 5406 BASE with 24‐port modules are preferred.
A13.PLANT PUBLIC ANNOUNCEMENT (PA) SYSTEM
A13.1. ZONES AREAS AND NAMING CONVENTION
A13.2. SPEAKERS HARDWARE (BOGEN)
A13.3. AMPLIFIERS AND CONTROLLERS HARDWARE (BOGEN)
A14. SECURITY ACCESS
A14.1. WIRING
A14.1.1. WIRING CONTROLLERS TO NETWORK (POE)
A14.1.1.1. Use enhanced Category 6 cable.
A14.1.1.2. Modular Station Jacks (BLACK) shall be used for the controllers.
A14.1.2. WIRING CARD READERS TO CONTROLLERS use 9‐conductor stranded, overall shield,
#22, Alpha 1299C or equivalent.
A14.1.3. WIRING DOOR DEVICES TO CONTROLLERS use 2‐conductor shielded, #18, Alpha
1897C or equivalent.
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A14.1.4. WIRING PUSH TO EXIT DEVICES TO CONTROLLERS use 2‐conductor shielded, #18,
Alpha 2421C or equivalent.
A14.2. CARDS use iClass SE cards (HID Global).
A14.3. CARD READERS use iClass SE Readers (HID Global) R10, R15, R30 or R40 as needed for
the application. These card readers are rated for outdoor use when installed with the proper
outdoor rated enclosure housing.
A14.4. CONTROLLERS use EDGE EVO EH400‐K (HID Global) networked controller, power over
Ethernet (POE). The cabling shall go back to the IT Server Room at plant Office Area.
A14.4.1. Controller shall be placed on the secured side in the header space above the door to
control.
A14.4.2. Card Readers shall be wired to controller from either side of the door depending on which
access to secure (Exit or Entrance or both).
A14.5. STRIKERS/ACTUATORS use any HID Global rated device.
A14.6. PRINTERS use DTC1000 Single‐sided ID card printer, full color printer and YMCKO
cartridge with cleaning roller.
A14.7. LOCK MANAGEMENT use Access Specialties’s FocalPoint Software
A14.8. TIME & ATTENDANCE
A14.8.1. Kronos 4500 Terminal with POE module and external HID iClass SE proximity reader shall
be used.
A14.8.2. In the later part of 2013, Kronos has plans to market a terminal with an internal iClass SE
reader. This will supersede the previous design.
A14.8.3. Modular Station Jacks (BLACK) shall be used for Kronos equipment drops where needed.
A15. ELECTRICAL ROOM ACCESS AND SURVEILLANCE
A15.1. ID Card access shall be provided.
A15.2. Door contact monitoring shall be provided to detect door opening and shall trigger video
capture. APC’s Netbotz devices shall be used for that functionality.
A15.3. Humidity/Temperature sensors shall be used to connect to the Netbotz units.
A15.4. The Netbotz shall not replace the NFPA requirement for fire detection and suppression
as required by applicable code.
A16. CAMERA NETWORK
A16.1. CAMERA HARDWARE, depending on the application, use
A16.1.1. Avigilon 2.0 Megapixel PTZ Day/Night Pendant Dome (2.0W‐H3PTZ‐DP20, bracket, and
POE injector (VOR‐OSP).
A16.1.2. Avigilon 5.0 Megapixel Bullet 9‐22mm f/1.6 Integrated IR (5.0‐H3‐BO2‐IR).
A16.2. DVR EQUIPMENT
A16.2.1. Clearpix Dell 2U Rack Mount Server, 15TB storage.
A16.2.2. Avigilon 1 Channel Entreprise License.
A16.2.3. Avigilon Enterprise Gateway.
A16.3. CAMERA DROPS
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A16.3.1. Modular RJ‐45 (8P8C) jacks (ORANGE) shall be used for cameras connections.
A16.3.2. Use 2‐outlet flush mounted faceplates.
A16.3.3. Use (2) enhanced Category 6 cables per drop, one live and one spare.
A16.3.4. Camera drops shall be located where indicated by CertainTeed.
A16.3.5. OFFICE AREA CAMERA DROPS shall be located above drop ceiling tiles.
A16.3.6. WAREHOUSE AREA CAMERA DROPS shall be located on building columns or exterior
walls.
A16.3.7. PRODUCTION AREA CAMERA DROPS shall be located on building columns, walls or
machinery as appropriate.
A16.3.8. OUTDOOR LOCATION CAMERA DROPS shall be located on exterior walls or stand‐
alone pole/stands.
A16.3.8.1. Outdoor rated enclosure and covers shall be required per NEC.
A16.3.8.2. Outdoor camera stations may require a heater to maintain proper operating
conditions.
A17. ENERGY MONITORING
A17.1. Every motor control center (MCC) shall be equipped with CT’s and PT’s sized
appropriately. CT’s and PT’s shall be connected to an Allen‐Bradley PowerMonitor1000.
A17.2. All PowerMonitor1000 shall be connected to the Process Control Network (PNET) for
data collection.
A18. IT SERVER ROOM/DATA CENTER
A18.1. Adhere to standards defined in NFPA 75‐2013 and NFPA 13‐2010.
A18.2. FIRE PROTECTION An FM‐200 fire suppressant system shall be sized, specified and
installed.
A18.3. ACCESS/SURVEILLANCE
A18.3.1. ID Card access shall be provided.
A18.3.2. Door contact monitoring shall be provided to detect door opening and shall trigger video
capture. APC’s Netbotz 570 device shall be used for that functionality, supplemented with
Netbotz Camera Pod 160.
A18.3.3. Humidity/Temperature sensors shall be used to connect to the Netbotz units.
A18.3.4. The Netbotz shall not replace the NFPA requirement for fire detection and suppression
as required by applicable code.
A18.4. ROOM SPECIFICATIONS
A18.4.1. Room walls, ceiling and doors should be sound isolated from other occupied areas.
A18.4.2. A single door between 42‐inches and 48‐inches wide and 8‐foot tall shall be used for
entry and exit to the server room.
A18.4.3. The server room shall have a minimum 9‐foot ceiling, 10‐foot preferred.
A18.4.4. The server room shall have no windows (for security, sound and environmental
management reasons).
A18.4.5. The server room shall have at least one phone.
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A18.4.6. The server room shall be fire rated since cabling and cooling systems are combined in the
same space.
A18.5. ELECTRICAL SYSTEMS
A18.5.1. The server room shall have separate, dedicated power panels for both computer
equipment and the A/C system. Mechanical and electrical systems should be designed for
long‐ term, maximum expected room utilization (though not to exceed 300 watts per
square foot).
A18.5.2. Building power quality should be considered when determining the need for isolation
transformers, UPS systems, and other power conditioning equipment. To the extent
possible, such heat generating support equipment should not be located in the server room.
A18.5.3. The electrical system should be designed to provide an isolated ground, dedicated
neutral, and a grounding grid.
A18.5.4. Emergency/backup power should not be tied into the building life safety system. The
department must supply and maintain separate backup power (e.g., UPS or generator) if
desired.
A18.5.5. The server room electrical distribution system should have easily accessible shunt trip
capabilities for emergency shutdown.
A18.6. SERVER RACK REQUIREMENTS
A18.6.1. APC extra deep and extra wide equipment rack shall be used, type NetShelter SX 42U
preferred.
A18.6.2. Horizontal Cable Organizer 1U with Brush Strip from Chatsworth or APC preferred.
A18.6.3. APC’s Data Cable Partition for Netshelter shall be used for vertical runs of cables in racks.
A18.7. RACK ACCESSORIES / CABLE LADDER TRAY
A18.7.1. Equipment racks shall be connected via a 12‐inch horizontal cable ladder rack/tray. The
horizontal rack/tray racks shall have (3) 12‐inch horizontal cable ladder rack/track “T”
connections to the server room wall designated as being the back of the racks. The
equipment and distribution racks are to be anchored to the floor. The overhead cable
ladder racks shall provide a route for the Category 6, fiber optics, and other communication
cables while providing stability to the equipment racks. (APC’s AR8166ABLK).
A18.7.2. 1U Airflow Management Blanking Panel Kit shall be used when appropriate.
A18.8. UNINTERRUPTABLE POWER SUPPLY (UPS)
A18.8.1. Per load calculations and a factor for expansion, the UPS shall be Symmetra PX 30kW
scalable to 40kW N+1, 208V
A18.8.2. Power Module, Symmetra PX 10kw, 208V
A18.8.3. Symmetra PX 40kW Extended Run Battery Frame and Battery Module
A18.9. POWER DISTRIBUTION UNITS (PDU)
A18.9.1. 120V TYPE PDU from APC shall be used.
A18.9.2. Rack PDU 2G. Metered, ZeroU, 8.6kW, 208V
A18.10. POD DESIGN AIR CONDITIONING SYSTEM
A18.10.1. APC’s InRow RP DX Air Cooled A/C and Condenser shall be used with bridge
partitions as appropriate.
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A18.10.2. APC’s Ceiling Panel Mounting Rail, Panel and Panel Lock System shall be
installed.
A18.10.3. Aisle Containment Lighting and Door shall be installed.
A18.10.4. FM Flooded Receiver shall be installed.
A18.11. ROOM AIR CONDITIONING SYSTEM
A18.11.1. Room heating, cooling and humidity control shall be via an independent HVAC
system (ie not connected to the main building system), with a return air design point
temperature and relative humidity of 72°F (±2°F) and 45% (±5%), respectively.
A18.11.2. There shall be sufficient clearance (minimum 4‐feet) between the HVAC unit
and computer racks in order to avoid potential damage from water leaks, as well as to allow
for maintenance access.
A18.11.3. Room design shall include appropriate planning for the removal of AC unit
condensate (either by gravity or pump).
A18.11.4. Sufficient cooling redundancy shall be considered and installed if possible. A
backup refrigerant‐based cooling system in parallel with the building chilled water system
and multiple AC units in an N+1 design should provide the best protection against failure.
A18.11.5. Sufficient future expandability and scalability shall be analyzed and designed in
conjunction with the mechanical and electrical system specifications.
A18.11.6. In both the design and operational phases, administrators should calculate the
“thermal buffer” of a room as a function of typical heat load and room air volume in order
to determine and plan for the time window between a cooling system failure (partial or
complete) and the point at which a room temperature limit has been reached.
A18.11.7. Administrators may wish to provide the means for automatic software and
hardware shutdown of systems based on various environmental conditions in the server
room, e.g., temperature, fire alarms, water sensors, etc.
A18.12. FIBER PATCH PANELS use 2U and 4U Sliding Modular Optic Shelves with Cassettes and
LC connectors, black, CommScope Company Systimax, or approved equal.
A18.13. CAT6 PATCH PANELS use 48‐port or 24‐port CAT6 black patch panel, Belden,
CommScope Company Systimax, or approved equal.
A19. DOCUMENTATION
A19.1. As a condition to certification of completion and prior to final acceptance of the work by
CertainTeed, the contractor shall deliver one complete set of construction drawings marked‐up,
"As Built", noting all additions, deletions and deviations of original issue construction drawings
to actual final completion.
A19.2. One complete set of blue line working drawings shall be maintained by the contractor
for use as record prints and retained on the jobsite throughout the progress of the work. All
variations from the contract drawings and any additional information required by these
specifications or by instruction from CertainTeed shall be entered on this record set of drawings
to be used to make as‐built drawings upon final completion of the work.
A19.3. The contractor shall provide copies of any and all cut sheets, manuals, maintenance and
calibration instructions applicable to material and equipment supplied.
A20. LABELING
A20.1. All Cables and wires shall be labeled at the time of installation. These labels shall conform
to the labeling plan agreed by CertainTeed and the Contractor.
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A20.2. At a minimum, the label on each cable/wire shall indicate end points (terminations) of
the individual cable and the station number.
A20.3. Each plate shall be labeled with CertainTeed’s approved labeling plan.
A20.4. Cross‐connect field appearances, when used, shall be labeled with the appropriate cable
numbers.
A20.5. All station‐type cabling must be labeled within 6 inches of its termination point at the
work location.
A20.6. All cables/wires shall be labeled at each end.
A20.7. A cable identification system shall be established in Excel in a format approved by
CertainTeed. At a minimum the Cable Record (schedule) shall include the information as follows:
cable number, cable runs from, cables runs to and length of cable run.
A21. TESTS AND INSPECTIONS
A21.1. Tests and inspections shall be made after the installation is completed in accordance
with all applicable specifications, codes and regulations.
A21.2. The contractor shall furnish competent personnel for all tests.
A21.3. All materials, equipment, and utilities required to perform the tests and inspection shall
be furnished by the contractor.
A21.4. All equipment shall be inspected, cleaned, checked for electrical and/or mechanical
operation, and all circuits shall be free of short circuits, ground faults or loose connections before
being energized.
A21.5. In making any test on equipment, the equipment manufacturer's instructions regarding
recommended test and check‐out procedures, special precautions and the like shall be strictly
observed. Where the test provisions of this specification conflict with the manufacturer's
recommended instructions, the latter shall take precedence.
A21.6. The contractor shall check all cable and wiring connections for conformity with latest
construction drawings and manufacturer's information.
A21.7. The contractor shall check all circuits for short circuit and/or ground faults.
A21.8. The contractor shall visually check all cables for damage along entire exposed sections.
A21.9. The contractor shall check continuity of all connections from one end of conductor to
another.
A21.10. Voice and Data Cabling Testing
A21.10.1. The contractor shall test the entire cable plant to ensure that all specifications
are met. In particular, tests shall be made on all data runs to ensure that ALL components
meet or exceed the performance characteristics as outlined in the ANSI/TIA 568B.1, 568B.2
and 568B.3 documents. Tests shall be documented and two (2) copies of the LAN Wiring
Plan document shall be provided. Other items in the LAN Wiring Plan document will include
wiring maps, connection segments and performance tests.
A21.10.2. Certifications shall include the following parameters for each pair of each cable
installed:
A21.10.2.1. Wire map (pin to pin connectivity)
A21.10.2.2. Length (ft)
A21.10.2.3. Attenuation
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A21.10.2.4. Near End Crosstalk (NEXT)
A21.10.2.5. Far End Crosstalk (FEXT)
A21.10.2.6. ELFEXT
A21.10.2.7. Attenuation/Crosstalk Ratio (ACR)
A21.10.2.8. Return Loss
A21.10.2.9. Propagation Delay
A21.10.2.10. Delay Skew
A21.11. Fiber Optic Cable Testing
A21.11.1. The Contractor shall test the entire cable plant to ensure that all specifications
are met. In particular, tests shall be made on all fiber runs to ensure that ALL components
meet or exceed the performance characteristics as outlined in standards ANSI/BICSI 002‐
2011, TIA 568‐C.0, TIA/EIA‐526‐14‐B, TIA/EIA‐526‐7, ISO/IEC 11801, 14763‐3, 61280‐4‐1
(MM), 61280‐4‐2 (SM), 61282‐11 and IEC 61300‐3‐35. Tests shall be documented and two
(2) copies shall be provided.
A21.11.2. Certifications shall include the following parameters for each cable installed:
A21.11.2.1. Tier 1: OLTS Table
A21.11.2.2. Tier 1: OLTS Results
A21.11.2.3. Tier 2: OTDR Traces
A21.11.2.4. Tier 2: OTDR Event Table
A21.11.2.5. Event Map
A21.11.2.6. Pass/Fail to TIA Cabling Standard.
A21.12. Should a test indicate the possibility of a fault within specific equipment, the contractor
shall locate the cause of such faults and replace such wires or equipment as may be necessary,
retest, and show elimination of fault.
A21.13. All parts, components, etc., found to be faulty as a result of the tests and check outs shall
be brought to the attention of CertainTeed.
A21.14. CertainTeed reserves the right to spot check the test results (either by CertainTeed or by
hiring an independent testing company). If the results vary more than 10% from the results
provided by the Contractor, the Contractor shall be required to prove his results are correct or
retest the entire system.
A21.15. Any circuits not meeting the established performance criteria as defined above will be
repaired and/or replaced and brought into full compliance with all standards mentioned prior to
the release of the circuit to the user.
A21.16. The contractor shall maintain a record for all electrical tests. Recorded data shall include,
but not be limited to, the following:
A21.16.1. Date of test
A21.16.2. Description and identification of the equipment tested
A21.16.3. Type of test and method of application
A21.16.4. Test equipment used
A21.16.5. Tabulated test data and results
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A21.16.6. Name of company and person making test
A21.16.7. Environmental conditions at the time and place of test and any other pertinent
information
A21.17. All test reports and records shall be submitted to CertainTeed for certification, final
approval and signature.
A21.18. Final acceptance will not only depend on equipment dependability, as determined by the
subject tests, but will depend on complete tests on all equipment to show that the equipment
will perform the functions for which it was designed.
A22. COMMISSIONING
A22.1. The contractor shall inspect all equipment and areas for a complete and vacuum‐clean
installation.
A22.2. The contractor shall verify that all equipment enclosures, doors, covers, nameplates, and
tags are securely installed.
A22.3. The contractor shall perform a final grounding and bonding of equipment inspection,
witnessed by CertainTeed.
A22.4. It is intended for each system to be operated as completely as possible during the
commissioning phase. The contractor shall make temporary connections for fluids, air, power,
control systems, etc., where necessary. All equipment and each system will be tested and
operated as a complete electrical installation.
A22.5. The contractor shall make available journeyman electricians to assist others (engineers
and technicians, etc.) during the start‐up and checkout of the installed equipment. He must be
knowledgeable of all wiring and circuitry installed.
A22.6. The startup of equipment and systems shall be executed in a planned orderly practical
manner. Safety systems shall be commissioned first.
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B. PRODUCTION NETWORKS
B1. Standard IT Network Configuration
B1.1. Business Network (BNET)
The BNET commonly hosts devices related to business activities such as Phone over/IP, email, SAP,
AutoCAD, Microsoft Office applications, printing. These activities are segregated from the Process
Network (PNET) so as not to hinder process controls, and data collection. Additionally, if a virus or malware
spreads on the BNET it will be made more difficult to spread onto the PNET because of that segregation
between the two networks.
B1.2. Process Network (PNET)
The PNET hosts all the automation controller and data collection systems related to production. It is
usually segregated from the BNET by a firewall stopping most (if not all) traffic from business stations and
from overall Internet. At this level, a device scan would only reveal workstations, servers, switches and
PLC’s. Drives and remote IO devices shall not be on this network. This helps segregate traffic, avoid
mistakenly taking over ownership of remote IO points and collect data with Historian servers.
Since most devices on the PNET may need to be accessed from the BNET from various requirements, its
IP address scheme shall be routable and be in the 10.180.xxx.1 through 10.180.xxx.254 range.
B1.3. Machine Network (MNET)
Any remote IO points, operator interface terminals (OIT), drives, and/or sensors shall be on the MNET and
associated to the PLC which owns them. Because none of those devices need to be accessed from the
BNET they shall have a private IP address in the 192.168.xxx.1 scheme. See recommended drawings for
naming convention and IP assignment requirements. Dwg 85‐00‐95‐0001‐4‐A0. Those devices will always
be available for configuration and programming through the RSLogix or Studio5000 programming
software through their logical master (PLC).
B2. Standard IT Items
B2.1. Firewall Appliance (ASA‐5506)
The current recommended Firewall appliance is the Cisco ASA‐5506 model. A 19” rack mount kit can be
purchased at firewalls.com. Its catalog number is RM‐CI‐T2. CertainTeed’s IT department is responsible
for its configuration. Everything downstream from that device is the responsibility of the plant.
B2.2. VMWare vSphere
When more than one server need to be installed on the PNET, it is recommended to install a vSphere
environment and create Virtual Machines (VM) of servers. The physical server class machine is thus
considered a host.
It enables greater scalability of the computing resources and flexibility for upgrades at future dates. Most
PNET would include an Historian and a Programming Server for remote access so a vSphere environment
is recommended in most cases.
vCenter Virtual Appliance from VMWare can be installed directly onto the Host to manage the ESXi
environment.
The use of Veeam for backup & replication shall be considered for the entire vSphere environment.
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B2.3. Wonderware Historian
To allow remote programming from System Integrators or others, a windows server shall be configured as
a Remote Terminal Server accessible from the BNET. It shall be made a Remote Desktop Services (RDS)
Server. Note that user CALs and RDS CALs (Client Access Licenses) will be needed to be installed on the
server. On the firewall Port 3389 by default will need to be open for that server IP address in order for
remote access.
Wonderware System Platform and/or Historian shall be configured on that server.
The common Wonderware account shall be wwUser, password “wonderware”.
B2.4. Remote Programming Server
To allow remote programming from System Integrators or others, a windows server shall be configured as
a Remote Terminal Server accessible from the BNET. It shall be made a Remote Desktop Services (RDS)
Server. Note that user CALs and RDS CALs (Client Access Licenses) will be needed to be installed on the
server. On the firewall Port 3389 by default will need to be open for that server IP address in order for
remote access.
It shall contain all necessary programming software to enable remote programming of any system on the
PNET. At a minimum, it shall have RSLogix5000 (Studio5000) Professional Edition, FactoryTalk Studio,
and/or Wonderware InTouch Studio.
User accounts shall be created for individuals needing access to this machine. They shall not be having
administrator rights for their account so as to prevent unauthorized changes to the server.
B2.5. Microsoft Licensing Server
The Firewall shall be configured in such a fashion that the Volume Licensing Server on the BNET is
accessible for all servers on the PNET. If that is not possible a machine shall be made the licensing server
on the PNET with access to the BNET licensing server through the Firewall.
B2.6. Time Sync
The BNET has a SNTP (Simple Network Time Protocol) server which shall be made accessible through the
firewall (UDP Port 123) so as to keep all PNET stations in sync. Usually NTP provides accuracies of 1‐50 ms.
If a greater precision is needed, one shall use a GPS device on the target network.
B2.7. Microsoft Patches Installation
Microsoft publishes a list of patches for its operating system (OS) once a month. Jointly with the
automation vendor (vendors may offer paid services for this feature), CertainTeed shall verify that those
patches have no negative effects on the control scheme. Once determined to be safe to install they shall
be installed on all Windows workstations at the opportune time so as not to disrupt operations and no later
than two (2) weeks after release from Microsoft.
B2.8. GFI Languard (optional)
To assist with the patches installation and general cybersecurity effort, GFI offers a product called GFI
Languard. It features patch management for operating systems (Windows, Mac OSX and Linux), patch
management for third‐party applications, vulnerability assessment and network and software auditing
among others.
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B2.9. McAfee Antivirus
CertainTeed’s standard antivirus (AV) is McAfee. A McAfee server is available on the business network with
the virus definition updates. The ASA firewall shall be configured so that machines on the process network
can reach the McAfee server. Individual machines on the PNET should be configured with the IP address
or DNS resolved name of the McAfee server.
B3. Obsolete Equipment Conversions
B3.1. DH+/RIO
It is possible to convert DH+/RIO to Ethernet/IP when using a third‐party interface from Prosoft. Its catalog
number is AN‐X2‐AB‐DHRIO. It would be primarily used if you need to connect older devices (Panelviews,
drives) on RIO or DH+ to newer devices on EthernetIP.
B3.2. Panelviews
DH+/RIO panelviews – such as the PV550 or 1400e – can be replaced by their equivalent PanelviewPlus.
Please refer to Allen‐Bradley’s 2711P‐AP002‐EN‐P brochure for further information. However once
converted to the new device DH+/RIO is not available. Therefore, it requires to either convert the PLC5 to
a ControlLogix processor or add temporarily the DHRIO interface from Prosoft to convert the panelview
Ethernet/IP interface back to DHRIO.
The legacy Panelview application can be directly converted to the PanelviewPlus format with the Allen‐
Bradley FactoryTalkView studio application. However, further tweaking may be needed to get the
application to communicate to the original PLC, especially if the DHRIO‐Ethernet/IP interface is used.
Allen‐Bradley’s 2711P‐AP001A‐EN‐P helps with the application conversion. Here are the steps required.
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B3.3. PLC5 Software
Refer to Allen‐Bradley’s brochure 1756‐RM85‐EN‐P for greater details. Here are the following steps:
The PLC5 or SLC500 program can be exported in a certain format and re‐imported on the ControlLogix
programming software (Chapter 1). Subsequently the program structure, data structure and instructions
need to be tweaked to match the new processor capabilities (Chapters 2,3 & 4). It is possible that some
functions can’t be translated and it will require manual intervention to port the legacy code (or section
thereof) to the Logix project.
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B3.4. PLC5 Hardware
B3.4.1. Discovery and Ranking
All obsolete equipment shall be inventoried and assessed for conversion criticality. A single PLC5 with no
HMI and 30 lines of code can likely be converted on a down‐day or extended maintenance outage. It is
likely that the Batch House PLC5 cannot be done until a rebuild.
A table shall be created with at a minimum the following columns:
Item PLC Name Program Size DH+ Node Rack IO cards Connectivity Critical Lvl
Where:
Item: sequential number
PLC Name: PLC5 program name
Program Size: amount of subroutines and lines of codes
DH+ node: address on the DH+ network
Rack: local and remote rack sizes and type (1771‐A2B, 1771‐A4B etc)
IO cards: line up of 1771 IO cards on each racks
Connectivity: which DH+ addresses are being messaged to and from this node.
Critical Lvl: subjective critical level of the PLC system. On a range from 1 (safe) to 5 (risky).
If the connectivity is null or minimal the PLC is easier to convert as a standalone project. The more
communications to other PLCs the more difficult it will be to convert as a standalone project.
Additionally, one shall also look at the translation cost as opposed to getting a newer application from an
equipment manufacturer instead. Converting the Batch House code as‐is will result in no improvements or
efficiency changes. It may be possible to develop a new code for the Batch House with new features
instead.
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B3.4.2. Phase 1 (1771‐ASB)
While the 1771‐ASB communication module is still available in the CertainTeed repository, the PLC5
processor on a system can be replaced by the 1771‐ASB module connected over Remote IO to a
ControlLogix rack with a 1756‐DHRIO or 1756‐RIO IO module.
The advantage is that no wiring has to be disturbed. The PLC5 code is translated to ControlLogix (see
software section above) and the ControlLogix hardware owns the PLC5 IO modules. See illustration below.
The 1756‐DHRIO has the advantage to have DH+ and RIO capabilities. Therefore, the ControlLogix
processor can be connected back to the DH+ network taking the spot of the PLC5 it replaced. Connectivity
to legacy Panelview may also be restored.
As the 1771‐ASB is now at its end‐of‐life, this solution may create risk as replacement 1771‐ASB modules
may not be available for purchase. Hence why it is critical for those modules to be stored in the CertainTeed
repository either for replacement parts purposes or to enter the phase 1 replacement of a legacy PLC5
system.
More details are available on page 100 and further of Allen‐Bradley’s brochure 1756‐UM514‐EN‐P.
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B3.4.3. Phase 2 (1771 IO replacement)
The PLC5 system can also be directly replaced by ControlLogix hardware by using a conversion hardware
kit. More information is available on Allen‐Bradley’s brochure 1492‐SG121‐EN‐P.
A base plate will replace the existing 1771‐AxB chassis and use the same mounting screw pattern.
Conversion modules will receive the existing 1771 wiring arms and be connected to 1756 IO module via
short 25‐pin and 37‐pin pre‐wired cables. A cover plate is installed on top of the wire assemblies to mount
the 1756‐style chassis with the 1756 IO modules.
The advantage is that no wiring is touched and the 1771 IO are removed from the system. The downside is
that the resulting system may be taller than the existing 1771 IO chassis and may not fit in the existing
enclosure. Careful measurements shall be required before selecting this option.
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However, Rockwell will offer custom made length of pre‐wired cables so as to install the ControlLogix
chassis in a derived panel. This may be the easiest solution when the existing panel is not deep enough for
the converted kit.
B3.4.4. Equipment Common Repository
Since the 1771 IO series and equipment is now an obsolete product, once a project is officially converted
to the ControlLogix platform, the PLC5 equipment shall be put in a common pool at the Kansas City
plant. All plants will have access to that pool to get critical pieces for their conversion project.
B3.5. 1336 Drives
Refer to Allen‐Bradley’s brochure PFLEX‐AP007‐EN‐P for more detailed information on selecting a 750‐
series drive as a 1336‐series drive .
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