item 599.210500na – bayville bridge electrical drive … · ieee 81 - ieee guide for measuring...

ITEM 599.210500NA – BAYVILLE BRIDGE ELECTRICAL DRIVE AND CONTROL SYSTEM

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DESCRIPTION 1.01 WORK DESCRIPTION

A. This section covers the electrical requirements for supply, service, delivery, storage, installation, testing and commissioning of bridge motorized machinery equipment and control system.

B. Provide supervision, labor, and assistance to manufacturer’s field representative and/or technical directors for equipment to be installed as a part of this Contract.

C. The Contractor shall provide service of qualified system integration company to develop and produce substantially completed electrical installation shop drawings as integrated system for Engineer’s review and approval. The substantially completed installation shop drawings shall be developed based on the final shop drawings of the actual equipment procured. The substantially completed installation shop drawings shall include layout/assembly/installation drawings of equipment, components terminal boxes and terminations drawings, schematic diagrams, point-to-point interconnection wirings with cable tags and termination identification for field installation. The Contractor shall coordinate all activities required to produce the substantially completed installation shop drawings.

1.02 REFERENCES A. Electrical systems shall be engineered, manufactured and installed in accordance with the

National Electrical Codes. The design and engineering of the electrical installation shall satisfy all statutory requirements of the national and/or local authorities of the country in which the electrical installation will be located. The electrical installation shall be suitable for the site conditions as specified. Where necessary, special attention shall be paid to the selection and installation of electrical equipment suitable for seismic conditions. Where relevant, the specific publications are referenced herein.

B. The following documents form part of the Special Specification to the extent stated. Where differences exist between codes and standards, the one affording the greatest protection shall apply. Unless otherwise noted, the referenced standard edition is the current one at the time of commencement of the work:

1. Occupational Safety and Health Administration – OSHA

2. The American Association of State Highway and Transportation Officials - AASHTO

3. National Fire Protection Association – NFPA

ANSI/NFPA 70 - National Electrical Code

ANSI/NFPA 70B - Recommended Practice for Electrical Equipment Maintenance


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ANSI/NFPA 70E - Standard for Electrical Safety in the Workplace

ANSI/NFPA 99 - Standard for Healthcare Facilities

ANSI/NFPA 101 - Life Safety Code

ANSI/NFPA 110 - Emergency and Standby Power Systems

ANSI/NFPA 780 - Installation of Lightning Protection Systems

4. Institute of Electrical and Electronic Engineers – IEEE

ANSI/IEEE C2 - National Electrical Safety Code

ANSI/IEEE 43 - IEEE Recommended Practice for Testing Insulation Resistance of Rotating Machinery

ANSI/IEEE 48 - IEEE Standard Test Procedures and Requirements for Alternating-Current Cable Terminations 2.5 kV through 765 kV

IEEE 81 - IEEE Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Ground System Part I: Normal Measurements

IEEE 100 - The Authoritative Dictionary of IEEE Standards Terms

IEEE 400 - IEEE Guide for Field Testing and Evaluation of the Insulation of Shielded Power Cable Systems

IEEE 519 - IEEE Recommended Practice and Requirements for Harmonic Control in Electric Power Systems

IEEE 1584 - IEEE Guide for Performing Arc-Flash Hazard Calculations

IEEE 1584a - IEEE Guide for Performing Arc-Flash Hazard Calculations – Amendment 1

5. International Electrical Testing Association – NETA

ANSI/NETA ETT - Standard for Certification of Electrical Testing Technicians

ANSI/NETA ATS - Acceptance Testing Specifications for Electrical Power Equipment and Systems

6. National Electrical Manufacturers Association – NEMA

NEMA AB4 - Guidelines for Inspection and Preventive Maintenance of Molded-Case


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Circuit Breakers Used in Commercial and Industrial Applications

ANSI/NEMA C84.1 - Electrical Power Systems and Equipment Voltage Ratings (60 Hz) NEMA MG1 - Motors and Generators

1.03 RELATED REQUIREMENTS

Section 599.0614 COMMON WORK RESULTS FOR ELECTRICAL, apply to this section with additions and modifications specified herein.

1.04 SUBMITTALS

A. Shop Drawings:

1. The Contractor shall submit copies of vendor, producer or manufacturer data for materials, devices and subsystems or standard or proprietary products. These shall include design and installation shop drawings, catalog cuts, specifications, testing requirements, and installation instructions for the following items, but not excluding other items or materials not specifically mentioned herein. Product Data:

a. Bridge Operator’s Control Console

b. Bridge Machinery Control Panel c. Variable Frequency Drives d. Motor Starter/Controller e. Span Drive Motors f. Motorized Brakes g. Limit Switches h. Over-speed Switches i. Uninterruptible Power Supply (UPS) j. Recommend Spare Parts

2. A number of electrical equipment items specified as part of the electrical work are to be provided to others for mechanical installation, followed by electrical installation under the herein specified electrical work. The dimensions of these items are critical for their installation and integration into the bridge mechanical machinery system. Their dimensions are indicated on the mechanical Contract Drawings and have been obtained from information provided by various equipment manufacturers. The dimensions have not been obtained from manufacturer’s certified drawings (certified drawings are drawings certified by the manufacturer to be dimensionally accurate and which contain sufficient detail to determine if the requirements of the Contract Documents have been satisfied). The Contractor shall, as part of its procurement process, obtain certified drawings for these items from the manufacturers and provide them to others responsible for the mechanical work in the preparation of the Shop and


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Erection Drawings for the bridge machinery. The certified drawings shall be submitted in support of the developed Shop Drawings. The Contractor shall notify the Engineer of any dimension of any specified item that deviates from the Contract Drawings. These items shall consist of the following:

a. Drive motors

b. Brakes

c. Limit switches

d. Span position rotary cam limit switches

e. Over Speed Switches

3. Complete bills of materials, assembly and installation drawings shall be furnished. These drawings shall clearly indicate weights of equipment, how the work is to be performed in the field including foundation requirements, equipment clearances required for operation and maintenance access and as required by applicable codes.

4. Assembly and installation drawings shall be given identifying marks and essential dimensions for locating each piece of equipment or assembled unit with respect to the bridge and its required equipment foundation. Each unit shall be cross-referenced to the Shop Drawing on which it is detailed or indicated in physical and functional terms.

5. Certificates: Provide UL certified for applicable equipment and material.

6. Customer connection and power wiring diagrams.

7. Interconnection diagrams between equipment assemblies, and external interfaces, including power and signal conductors. Include for enclosures and external devices.

8. The ASD certification of compliance to IEEE 519 B harmonic analysis for particular jobsite including total harmonic voltage distortion and total harmonic current distortion (TDD). The ASD manufacturer shall provide calculations; specific to this installation, showing total harmonic voltage distortion is less than 5%. Input line filters shall be sized and provided as required by the ASD manufacturer to ensure compliance with IEEE standard 519.

9. Schedule of equipment supplied. Schedule shall provide a cross reference between manufacturer data and identifiers indicated in shop drawings. For complete assemblies, such as ASD's, provide the serial numbers of each assembly, and a sub-schedule of components within the assembly. Show circuits and device elements for each replaceable module.

10. Installation drawings with adjustable speed drives and motors indicated. Indicate ventilation requirements, adequate clearances, and cable routes.

11. Provide recommended spare parts listing for each assembly or component.


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12. Installation instructions issued by the manufacturer of the equipment, including notes and recommendations, prior to shipment to the site. Provide operation instructions prior to acceptance testing.

13. Factory Test Plan and Test Reports. Submit within 7 working days after completion of test.

14. Startup and Commissioning Plan and Report:

a. Provide Startup and Commissioning Plan

b. Provide Factory Acceptance Test

c. Provide Electrical Construction Field Testing and Commissioning Report

d. Manufacturer's Field Reports: Submit to Departmental Representative manufacturer's written report, within 3 days of review, verifying compliance of Work and electrical system and electrical power and control testing.

1.05 QUALITY ASSURANCE

A. Regulatory requirements: Perform electrical construction in accordance with industry acceptable practice and complies with applicable country, region and local codes.

B. Equipment and components shall be listed and labeled by Underwriter’s Laboratories (UL) or other nationally recognized testing laboratory. Equipment shall comply with all applicable (IEEE) standards. Components for use in hazardous locations shall be UL-listed or Factory Mutual (FM)-approved for the hazardous classification, division, and group.

C. Manufacturer of equipment specified shall be recognized in industry for normally supplying this type of equipment. Manufacturer shall be ISO certified.

D. The adjustable speed drive (ASD) shall be manufactured by a company with at least twenty (20) years of experience in the production of this type of equipment. The ASD manufacturing facility shall be ISO 9001 and ISO 14001 certified.

E. Contractor shall develop detailed, step by step, testing and commissioning plan for placement of electrical equipment, apparatus, and completed electrical system in service. Contractor shall execute the plan, and document the performance and test results. Contractor shall take corrective actions necessary to bring the failed and/or noncompliance test results into conformance at no additional cost to the COUNTY.

F. The motors, drives, and motor starter/controller shall include a 2-year warranty for all material and workmanship defects. The warranty period will begin from the date of the COUNTY’s acceptance of the bridge being fully operational.

1.06 DELIVERY, STORAGE, AND HANDLING


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A. Pack, ship, handle, and store in accordance with manufacturer’s requirements.

B. Ship equipment completely factory assembled unless physical size, arrangement, configuration, or shipping and handling limitations make this impracticable. Shipping splits and required field assembly shall be identified with equipment submittals. Shipping splits shall be provided with clear instructions for field assembly and designated interconnection terminations for interconnection between the shipping splits.

C. Separately packaged parts and accessories shall be consolidated and shipped together with equipment. Mark each container clearly to identify contents and as belonging with main equipment.

D. Equipment shall be protected against damage during shipment, handling, and storage. Damage incurred during shipment shall be repaired at no cost to COUNTY.

MATERIALS 2.01 OPERATOR CONTROL CONSOLE

A. One (1) bridge tender control console shall be furnished, located in the bridge tender house.

B. Bridge tender control consoles shall be provided for monitoring and control of bridge operation. All devices for controlling and monitoring the operation of the bridge span, standby generator and navigation equipment shall be mounted in and on the control consoles as indicated on the Contract Drawings and as herein specified.

C. The control console shall be of neat, substantial construction. It shall be fabricated from No. 10 gauge 302 stainless steel sheet properly formed and reinforced to provide adequate strength. The welded console top shall be fabricated of No. 10-gauge Type 302 stainless steel sheet with a non-glare, satin finish. The front HMI and control device panel shall be provided with pivoted on 90-degree hinges and secured with flush-type latches all as indicated on the Contract Drawings. The control console shall be neatly fitted up with close joints; all rough edges or corners shall be ground off smoothly, and all projecting edges rounded off. All metal hardware shall be of substantial construction, and shall have a satin-chrome plate finish. All equipment mounting screws and bolts shall be stainless steel.

D. The sheet portions of the console and all metal reinforcing shall be painted inside with two coats and outside with three coats of paint consisting of one coat of primer followed by two coats of enamel on the outside surfaces, and one coat of primer and one coat of enamel on the inside surfaces. The finish coat shall be of a color to match the house interior. Color samples shall be submitted to the Engineer for approval. The stainless steel console top shall not be painted.

E. Special care shall be taken throughout the construction to ensure that the stainless steel console top and the equipment mounted thereon are completely protected from damage


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or defacement at all times. All control switches, pushbuttons, the HMI and other control devices shall be mounted within the body of the consoles. The indicating lights for each operation shall be mounted adjacent to the control device governing that operation and provided with a means of lamp test as indicated on the Contract Drawings. The means of lamp test proposed shall be submitted to the Engineer for approval. All devices shall be compatible with the requirements of the control system and shall be of Allen Bradley manufacture their 800T series or Engineer approved equal, suitable for oil tight/watertight operation and provided complete with transparent boot to exclude harmful contaminants.

F. The escutcheon plates of all control switches, pushbuttons and indicating lights shall be made of aluminum with a satin finish and shall be engraved with an identifying legend as indicated on the Contract Drawings.

G. The wiring within the control console shall be flame-retardant, ethylene-propylene insulated, switchboard wire, Type SIS. The wiring shall be arranged systematically so that all circuits can be readily traced. All conductors shall be terminated on easily accessible terminal blocks mounted inside at the rear or as appropriately determined by the systems vendor for Engineer approval. Spare terminals that total at least 20 percent of those actually used shall be provided. Wiring shall be identified at equipment terminals by marking the adjacent area with bright yellow painted numbers or by other Engineer approved means to correspond to conductor designations appearing on the Contractor's wiring diagrams.

H. The bridge tender control console shall operate from a 120 Volt, 60 Hz source and be powered from the dedicated bridge tender house UPS indicated on the Contract Drawings and as specified herein.

I. The Contractor shall submit outline drawings including dimensioned layout, schematic and wiring diagrams of the control console together with catalog cuts, dimensional details and descriptive details of all proposed consoles mounted devices to the Engineer for approval prior to fabrication.

2.02 COMBINATION CONTROLLER PANEL

A. Material and Construction:

1. Panel, control cabinet, switchboard, motor control center, and switchgear wiring shall use flame retardant cross-linked polyethylene (XLP) or flame retardant ethylene-propylene rubber (EPR) insulation

2. Steel material shall comply with UL 845 and CSA requirements.

3. Structures shall be totally enclosed, dead-front, free-standing or wall-mounted assemblies as indicated on the drawing. Structures shall be of heavy gauge steel bolted together to form a rigid assembly, minimum of 12-gauge steel. The entire assembly shall be constructed and packaged to withstand normal stresses included in transit and during installation. The system shall be rated for an available short circuit capacity of 65,000 rms amperes up to 600 volts, unless indicated otherwise on one-line diagrams.


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B. Barriers:

1. All power bussing and splice connections shall be isolated from the unit compartments and the wireways.

2. Barriers shall be provided to compartmentalize the power block section from control block section, and to prevent the contact of any energized bus or terminal by a fish-tape inserted through the conduit or wireway areas.

C. Structures ingress protection ratings shall be shall be minimum as follow:

1. NEMA Type 1A (gasketed) for indoor enclosed in conditioned space general purpose

2. NEMA Type 12 (industrial duty) for indoor ventilated only or un-conditioned space

3. NEMA Type 3R non-walk-in (rainproof) for outdoor installation.

D. Main Disconnect

1. The motor controller panel shall be provided with main circuit breaker disconnect. A lever handle operator must be provided on each disconnect. The circuit breaker operators shall include a separate TRIPPED position to clearly indicate a circuit breaker trip condition. It shall be possible to reset a tripped circuit breaker without opening the control unit door. Clear indication of disconnect status shall be provided.

2. A mechanical interlock shall prevent the operator from opening the unit door when the disconnect is in the ON position. Another mechanical interlock shall prevent the operator from placing the disconnect in the ON position while the unit door is open. It shall be possible for authorized personnel to defeat these interlocks.

3. Provisions shall be provided for locking all disconnects in the OFF position with up to three padlocks.

4. Unit construction shall combine with the vertical wireway isolation barrier to provide a fully compartmentalized design.

E. Combination Starters

1. All combination starters shall use a unit disconnect. Magnetic starters shall be furnished in all combination starter units. All starters shall utilize NEMA/EEMAC rated contactors.

2. Starters shall be provided with electronic thermal overload units. The electronic thermal overload unit shall have the following features:

a. Selectable trip class (10E, 20E, 30E)

b. Adjustable current setting ranges c. Overload protection with phase loss sensitivity

d. Temperature compensation up to +70°C and self-supply

e. Automatic or manual reset, sealable


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f. Stop and test function.

3. When provided, control circuit transformers shall include two primary protection fuses and one secondary fuse (in the non-ground secondary conductor). The transformer shall be sized to accommodate the contactor(s) and all connected control circuit loads. The transformer rating shall be fully visible from the front when the unit door is opened.

4. When a unit control circuit transformer is not provided, the disconnect shall include an electrical interlock for disconnection of externally powered control circuits.

5. Auxiliary control circuit interlocks shall be provided where indicated. Auxiliary interlocks shall be field convertible to normally open or normally closed operation.

6. NEMA/EEMAC Size 1-4 starters shall be mounted directly adjacent to the wireway so that power wiring (motor leads) shall connect directly to the starter terminals without the use of interposing terminals. Larger starters shall be arranged so that power wiring may exit through the bottom of the starter cubical without entering the vertical wireway. Units provided in MCCs rated for arc resistance shall be fitted with 12-gauge steel doors and control station panels.

F. Feeder Circuit Protective Devices - Breakers

1. Feeder and non-motor load breakers shall be 3-pole and shall be rated for symmetrical short circuit current as required. Neither series rating nor power fuses acceptable.

2. Molded Case Circuit Breakers: NEMA AB 1, FS W-C-375

3. Provide bolt-on type circuit breakers with integral thermal and instantaneous magnetic trip in each pole (common trip type).

4. Provide circuit breakers, UL listed as Type HACR, for air conditioning equipment branch circuits.

5. Provide circuit breakers, UL listed as Type SWD, for lighting circuits.

6. Provide UL Class A ground fault interrupter circuit breakers where specified on panelboard schedules and/or the Drawings.

7. Breakers shall be operated by a position indicating toggle-type handle and shall have quick-make, quick-break over center switching mechanism that is trip free.

8. Automatic tripping of device shall be indicated by handle position.

9. The minimum symmetrical interrupting rating for circuit breakers shall be as specified on the panelboard schedule and/or Drawings. Series rated breakers are not acceptable.

G. Trip Unit: 1. Provide adjustable instantaneous magnetic trips for breaker with frame size 100

amperes.

2. Provide interchangeable trip units with adjustable trip pick up and delay settings for breaker with frame size 225 amperes.


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3. Provide solid state trip units with long-time, short-time, instantaneous, and ground fault (LSIG) tripping characteristics for breakers with frame size 400 amperes and higher

H. Control and Indications

1. Selector switches:

a. Type: Non-illuminated.

b. Contact rating: 10 amperes at 120-volts ac, 60 Hz.

2. Pilot lights:

a. Type: Standard.

b. Input: Full voltage, 120-volt ac, 60 Hz.

c. Lamp type: LED.

d. Lens color:

• Red: Danger, run, or open. • Amber: Shutdown, caution, pre-alarm, or abnormal. • Green: Stop, closed, or satisfactory. • White: Power available, ready. • Blue: Status.

3. Pushbuttons:

a. Type: Non-illuminated.

b. Configuration: Single-operator, number of poles as required for application.

c. Contact rating: 10 amperes at 120-volts ac, 60 Hz. 4. Operator:

a. Flush head: Start applications.

b. Extended head: Stop applications.

c. Mushroom head: Emergency stop applications.

5. Button color:

a. Red: Danger, run, or open. b. Green: Stop, closed, or satisfactory. c. White: Power on.

6. Digital Display:

a. Display: 4 digits (-1999 to 9999) red LED, 0.56” high. b. Decimal point: Up to 3 decimal places. c. Update rate: 3.7 to 5 times per second. d. Input signal: 4-20mA, externally powered. e. Output signal: Not required.


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f. Relay outputs: None required. g. Enclosure: 1/8 DIN, high impact plastic. h. Electrical classification: NEMA 4X, IP65 front. i. Supply voltage: 24-volt dc. j. Electrical connection: Screw terminal blocks. k. Mounting: Control panel.

7. Legend plates: As required for application.

I. Control Relay

1. Function: General logic hardware interlocks.

a. Type: Plug-in. b. Construction: Continuous duty. c. Coil voltage: As applicable. d. Switch configuration: 3-SPDT. e. Indication: Mechanical or LED to indicate energized relay. f. Switch rating: 10 amperes at coil voltage. g. Mounting: Socket for DIN-rail mounting.

2. Function: Interposing relay for PLC output.

a. Type: Plug-in. b. Construction: Continuous duty. c. Coil voltage: As applicable. d. Switch configuration: 2-SPDT. e. Indication: Mechanical or LED to indicate energized relay. f. Switch rating: 5 amperes minimum at coil voltage. g. Mounting: Socket for DIN-rail mounting

J. Signal splitter:

1. Input signal: 4-20 mA, externally powered.

2. Output signals: Dual, independent, 4-20 mA, internally powered.

3. Power requirements: 24-volt dc.

4. Mounting: DIN rail.

K. Surge suppressor:

5. Type: Pluggable surge suppression modules fitting into fixed base with hot swapping capability.

6. Capacity:

a. Current: Up to 10kA surge current handling. b. Peak clamping voltage: <= 41.6-volt dc c. Resistance: 2.2 ohm in-line.

7. Analog signals:


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a. Circuits: 1 or 2 - 24-volt dc. b. Signals: Suitable for 4-20 mA current, thermocouple or mV.

8. Discrete 24-volt dc signals:

a. Circuits: 2 or 4. b. Signals: Suitable for 24-volt dc discrete circuits.

9. Discrete 120-volt ac signals:

a. Circuits: 2. b. Signals: Suitable for 120-volt ac discrete circuits.

L. DC power supply

1. Provide 1 or more 24-volt dc power supplies, as necessary, within each panel to power field transmitters, I/O, and related equipment.

2. Type: Redundant.

3. Input voltage:

a. One 120-volt ac from plant uninterruptable power supply. b. One 120-volt ac from plant essential service power supply.

4. Rating: Amperage shall be 200% of required capacity.

M. Terminations

1. Cable entrance shall, at a minimum, be in accordance with NEC cable bending requirements.

2. Main incoming cables shall terminate within control center on main lug or main breaker termination point as indicated. Terminations shall have adequate dedicated space for type, number, and size of cable used. Lugs shall be compression-type with anti-turn feature. Feeder cable terminations shall facilitate installation with special attention given to larger size starters and feeder breakers.

N. Space Heater

1. Provide thermostat controlled space heaters in each vertical section when required per manufacturer recommendations. A single thermostat shall control space heaters within each vertical assembly.

2. Provide space heater with circuit protection and disconnecting mean.

O. Terminal Blocks

1. When Type B wiring is specified, all starter units shall be provided with unit control terminal blocks.

2. Terminal blocks shall be the pull-apart type with a minimum rating of 250 volt and 10 amps. All current carrying parts shall be tin plated. Terminals shall be accessible from inside the unit when the unit door is opened. Terminal blocks shall be DIN rail mounted


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with the stationary portion of the block secured to the unit bottom plate. The stationary portion shall be used for factory connections, and shall remain attached to the unit when removed. The terminals used for field connections shall face forward so they can be wired without removing the unit or any of its components.

3. When Type C wiring is specified, all starter units shall be provided with unit control terminal blocks as described for Type B wiring along with power terminal blocks for size 1-3 units. An additional set of terminal blocks shall be provided in a terminal compartment located in each section. These terminal blocks shall be pre-wired to the unit terminals so that all field control connections can be made at the terminal compartments.

4. Nameplates shall be engraved phenolic nameplates for each MCC and unit compartment. Shall be gray background with white letters, measuring a minimum of 1.5 in (38 mm) H x 6.25 in (159 mm) W total outside dimensions.

2.03 ADJUSTABLE SPEED AC DRIVE A. Performance Requirements

1. The ASD shall be rated to operate at the following environmental operating conditions:

a. Ambient temperature: 0 to 40C (continuous operation). b. Altitude 0 to 1000 meters above sea level without derating.

2. Electrical and electromechanical components of the Adjustable Speed AC Drive (ASD) shall not cause electromagnetic interference to adjacent electrical or electromechanical equipment while in operation.

3. Control panel shall have surge protection, included within the panel to protect the unit from damaging transient voltage surges. Surge arrestor shall be mounted near the incoming power source and properly wired to all three phases and ground. Fuses shall not be used for surge protection.

4. I/O functions as specified shall be protected against surges induced on control and sensor wiring installed outdoors and as shown.

5. Output voltage and current ratings shall produce the torque-speed performance requirements of driven motors throughout the speed range including minimum starting torque, constant and variable speed operation, acceleration and deceleration torque. The adjustable speed drive shall not be the limiting factor of the driven motors. Motor and drive system’s thermal load ability must also be considered.

B. Product Description

1. The ASD shall be solid state AC to AC inverter controlled device utilizing the latest isolated gate bipolar transistor (IGBT) technology. The ASD shall be Direct Torque Control (DTC) technology.

2. The ASD shall be provided with environment EMC / RFI filter.


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3. The ASD shall be provided with dynamic braking chopper with 100% continuous duty internally mounted in ASD enclosure.

4. The ASD shall accept speed reference signal from encoder.

5. The ASD shall have the following operational control functions, features, and parameters:

a. Steady state speed accuracy within 1/10th the slip without an encoder, for process repeatability.

b. 100% motor torque from zero speed available for acceleration with the ASD continuous current rating equal to or greater than the motor full load amp rating.

c. At and below 90% speed, 100% torque is achievable even with 10% low line voltage.

d. Ability to limit torque to protect the mechanical system with a common single torque setting above and below field weakening.

e. Ability to provide torque in % of motor shaft torque (within +/- 4% linearity) on the ASD control panel, analog output or via field bus of actual.

f. Have available the ability to operate in open loop torque control, with an ability to switch between speed and torque control on the fly with the change of state to a digital input.

g. Have an ability to share load or speed between two or more induction AC motors connected to the same system, when those motors are controlled by separate ASDs.

h. The ASD shall be equipped with a front mounted operator control panel with configurable displays showing, bar graph and meter. Keypad with keys for Run/Stop, Local/Remote, Increase/Decrease, Reset, Menu navigation and Parameter select/edit. The display of the control panel shall have the following features: • All parameter names, fault messages, warnings and other information shall be

displayed in English words or standard English abbreviations to allow the user to understand what is being displayed without the use of a manual or cross-reference table.

• During normal operation, the display shall be programmable to display the values of the following operating parameters:

• speed reference, and run/stop forward/reverse and local/remote status. • Speed/torque in percent (%), RPM or user-scaled units • Output frequency, voltage, current and torque • Power and kilowatt hours • Heatsink temperature and DC bus voltage • Status of discrete inputs and outputs • Values of analog input and output signals • Values of PID controller reference, feedback and error signals

i. The control panel shall be used for local control, for setting all parameters, and for stepping through the displays and menus.

j. A copy function to upload and store parameter settings from an ASD and download


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stored parameter settings to the same ASD or to another ASD shall exist. k. An intelligent start-up assistant shall be provided as standard. The Start-up routine

will guide the user through all necessary adjustments to optimize operation. l. The control panel shall be removable, capable of remote mounting and allow for

uploading and downloading of parameter settings as an aid for start-up of multiple ASDs.

m. Wall mountable or panel mountable in the switchgear enclosures n. Include a control panel mounted on the front of the ASD o. Include coated circuit boards as standard p. Include integrated DC choke q. Include internally mounted braking chopper for use in dynamic braking with 100%

continuous duty operation. r. Provide optional features required to achieve system operation and function

requirements shall be provided and mounted by the ASD manufacturer and shall also be available as field installable kits as an alternative.

C. Ratings

1. The ASD shall be rated to operate from 3-phase power at nominal supply voltage as indicated on the drawings. The overvoltage trip level shall be a minimum of 30% over nominal, and the under-voltage trip level shall be a minimum 35% under the nominal voltage.

2. The ASD shall be rated to operate from input power source frequency of 48Hz to 63Hz.

3. The ASD current rating shall be minimum of 150% of the full load ampere rating of the drive motor. The ASD shall have the capacity, output voltage and current ratings required to produce the torque-speed performance requirements of driven motors throughout the speed range including minimum starting torque, constant and variable speed operation, acceleration and deceleration torque. The adjustable speed drive shall not be the limiting factor of the driven motors. Motor and drive system’s thermal loadability must also be considered. The correctly sized drive, meeting all the requirements, shall be provided at no additional cost to the State.

4. The ASD shall have a heavy duty overload current capacity of 150% minimum of ASD rated current for a minimum of one (1) minute.

5. The ASD efficiency shall be 98% or better of the full rated capability of the ASD at full speed and load.

D. Protective Features

1. For each programmed warning and fault protection function, the ASD shall display a message in complete English words or Standard English abbreviations. The five (5) active and most recent fault messages and times shall be stored in the ASD’s fault history.

2. The ASD shall include internal MOV’s for phase to phase and phase to ground line voltage transient protection.


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3. Output short circuit and ground fault protection rated for 100,000 amps without relying on line fuses shall be provided per UL508C.

4. Motor phase loss protection shall be provided.

5. The ASD shall provide electronic motor overload protection qualified per UL508C.

6. Protection shall be provided for AC line or DC bus overvoltage at 130% of maximum rated voltage or under-voltage at 65% of min. rated voltage.

7. The ASD shall protect itself against input phase loss.

8. A power loss ride through feature shall allow the ASD to remain fully operational after losing power as long as kinetic energy can be recovered from the rotating mass of the motor and load.

9. Stall protection shall be programmable to provide a warning or stop the ASD after the motor has operated above a programmed torque level for a programmed time limit.

10. Underload protection shall be programmable to provide a warning or stop the ASD after the motor has operated below a selected underload curve for a programmed time limit.

11. Over-temperature protection shall provide a warning if the power module temperature is less than 5C below the over-temperature trip level.

12. Input terminals shall be provided for connecting a motor thermistor (PTC type) to the ASD’s protective monitoring circuitry. An input shall also be programmable to monitor an external relay or switch contact.

E. Safety Functions Module

1. Provide Safe stop 1 (SS1) function to brings the machine to a stop (STO) using a monitored deceleration ramp. It is typically used in applications where the machinery motion needs to be brought to a stop (stop category 1) in a controlled way before switching over to the no-torque state.

2. Provide safe stop emergency (SSE) which can be configured to, upon request, either activate STO instantly (category 0 stop), or first initiate motor deceleration and then, once the motor has stopped, activate the STO (category 1 stop).

3. Provide safe brake control (SBC) provides a safe output for controlling the motor’s external (mechanical) brakes, together with STO.

4. Provide safely-limited speed (SLS) ensures that the specified speed limit of the motor is not exceeded. This allows machine interaction to be performed at slow speed without stopping the drive. The ASD shall have a minimum of four individual SLS settings for speed monitoring.

5. Provide safe maximum speed (SMS) which monitors that the speed of the motor does not exceed the configured speed limit.


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6. Provide prevention of unexpected startup (POUS) ensures that the machine remains stopped when people are in a danger area.

7. Provide safe speed monitor (SSM) function which provides information that speed is within the configured limits.

F. Control Inputs and Outputs

1. Discrete Inputs

a. Minimum of seven (7) discrete inputs shall be provided. b. A minimum of seven (7) of the inputs shall be independently programmable with

function selections (run/stop, hand-off-auto, etc.). c. Inputs shall be designed for use with either the ASD’s internal 24 VDC supply or

a customer supplied external 24 VDC supply

2. Discrete outputs

a. Minimum or three (3) form C relay contact outputs shall be provided b. All outputs shall be independently programmable to activate function selections

including; c. Operating conditions such as drive ready, drive running, reversed and at set speed d. General warning and fault conditions e. Adjustable supervision limit indications based on programmed values of operating

speed, speed reference, current, torque and PID feedback. f. Relay contacts shall be rated to switch 2 Amps at 24 VDC or 115/230 VAC.

3. Analog Inputs

a. Minimum of two (2) analog inputs shall be provided: b. Two (2) must be selectable for either a current or a voltage input. c. Resolution of analog inputs must be at least 11 bits total resolution d. Inputs shall be independently programmable to provide signals including speed /

frequency reference, torque reference or set point, PID set point and PID feedback / actual.

e. A differential input isolation amplifier shall be provided for each input. f. Analog input signal processing functions shall include scaling adjustments,

adjustable filtering and signal inversion. g. If the input reference is lost, the ASD shall give the user the option of the following.

The ASD shall be programmable to signal this condition via a keypad warning, relay output and/or over the serial communications bus. • Stopping and displaying a fault • Running at a programmable preset speed • Hold the ASD speed based on the last good reference received

h. Cause a warning to be issued, as selected by the user. When inputs are used as speed references, reference signal processing shall include increase/decrease floating point control and control of speed and direction using a “joystick” reference signal. Two (2) analog inputs shall be programmable to form a reference by addition,


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subtraction, multiplication, minimum selection or maximum selection.

4. Analog Outputs

a. Minimum of two (2) 4-20 mA analog outputs shall be provided. b. Outputs shall be independently programmable to provide signals proportional

to output function selections including output speed, frequency, voltage, current and power.

5. Digital Inputs/Outputs

a. Minimum of two (2) digital inputs/outputs shall be provided. b. At least one (1) can be programmed as a frequency input. At least one (1) can

be programmed as a frequency output.

6. Safety Inputs

a. Have a Safe Torque Off (STO) terminal integrated in the drive as a standard. The STO function will meet a Safety Integrity Level (SIL) 3 and a Performance Level (PL) e.

G. Communication

1. The ASD shall be capable of communicating with other ASDs or controllers via a serial communications link. A variety of communications interface modules for the typical overriding control systems shall be available.

2. Interface modules shall be available for a wide selection of protocols including but not limited to:

a. Modbus b. Ethernet IP c. ModBus TCP d. ControlNet e. DeviceNet f. Profibus g. ProfiNet h. CANOpen

3. Interface modules shall mount directly to the ASD control board or be connected via fiber optic cables to minimize interference and provide maximum throughput.

4. I/O shall be accessible through the serial communications adapter. Serial communication capabilities shall include, but not be limited to: a. Run-Stop control b. Hand-Off-Auto Control c. Speed Adjustment d. PID (proportional/integral/derivative) control adjustments e. Current Limit f. Accel/Decel time adjustments


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5. The ASD shall have the capability of allowing the overriding controller to monitor feedback such as process variable feedback, output speed/frequency, current (in amps), % torque, power (kW), kilowatt hours (resettable), operating hours (resettable), relay outputs, and diagnostic warning and fault information.

6. A connection shall also be provided for personal computer interface. Software shall be available for ASD setup, diagnostic analysis, monitoring and control. The software shall provide real time graphical displays of ASD performance.

H. Control Functions and Adjustments

1. Output frequency shall be adjustable between 0Hz and 500Hz. Operation above motor nameplate shall require programming changes to prevent inadvertent high-speed operation.

2. Stop mode selections shall include coast to stop and ramp to stop.

3. The ASD shall be capable of controlling deceleration of a load without generating an overvoltage fault caused by excessive regenerated energy. Overvoltage control on deceleration shall extend the ramp time beyond the programmed value to keep the amount of regenerated energy below the point that causes overvoltage trip.

4. The ASD shall be capable of starting into a rotating motor with or without existing magnetic flux on the motor regardless of the motor direction. From the time the start signal is given to the ASD to the time the ASD has control of the motor shall not exceed two (2) seconds. Once the ASD has control of the motor it will than accelerate or decelerate the motor to the active reference speed without tripping or faulting or causing component damage to the ASD. The ASD shall also be capable of flux braking at start to stop a reverse spinning motor prior to ramp.

5. The ASD shall have the ability to automatically restart after an overcurrent, overvoltage, under-voltage, or loss of input signal protective trip. The number of restart attempts, trial time, and time between reset attempts shall be programmable.

6. Control functions shall include two (2) sets of acceleration and deceleration ramp time adjustments with linear and an s-curve ramp time selection.

7. Speed control functions shall include:

a. Adjustable min/max speed limits. b. Selection of up to 7 preset speed settings for external speed control. c. Three sets of critical speed lockout adjustments. d. A built-in PID controller to control a process variable such as pressure, flow or

fluid level.

8. Functions shall include energy optimization for optimizing efficiency and limit the audible noise produced by the motor by providing the optimum magnetic flux for any given speed / load operating point.

9. The ASD shall be capable of sensing a loss of load (broken belt / broken coupling) and


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signal the loss of load condition. The ASD shall be programmable to signal this condition via a keypad warning, relay output and/or over the serial communications bus. Relay output shall include programmable time delays that will allow for ASD acceleration from zero speed without signaling a false underload condition.

10. Three (3) programmable critical frequency lockout ranges shall be provided to prevent the ASD from operating the load continuously at an unstable speed.

11. The ASD shall offer software to select the ASDs action in the event of a loss of the primary speed reference.

I. Performance and Verification Test

1. A proposed test plan shall be submitted to the COUNTY at least 28 calendar days prior to proposed testing for approval. The COUNTY and/or COUNTY’s Engineer reserves the right to witness all tests and review any documentation. The contractor shall inform the COUNTY and/or COUNTY’s Engineer at least 14 working days prior to the dates of testing.

2. Contractor shall provide video tapes, if available, of all training provided to the COUNTY for subsequent use in training new personnel. All training aids, texts, and expendable support material for a self-sufficient presentation shall be provided.

3. "Performance Verification Test" plan shall provide the step-by-step procedure required to establish formal verification of the performance of the ASD. Compliance with the Special Specification requirements shall be verified by inspections, review of critical data, demonstrations, and tests.

4. The COUNTY and/or COUNTY’s Engineer reserves the right to witness all tests, review data, and request other such additional inspections and repeat tests as necessary to ensure that the system and provided services conform to the stated requirements. The contractor shall inform the COUNTY and/or COUNTY’s Engineer at least 14 calendar days prior to the date the test is to be conducted.

J. Training

1. Coordinate training requirements with the COUNTY.

2. Provide the services of competent instructors who will give full instruction to designated personnel in operation, maintenance, calibration, configuration, and programming of the complete control system. Orient the training specifically to the system installed.

3. Instructors shall be thoroughly familiar with the subject matter they are to teach.

4. The number of training days of instruction furnished shall be as specified. A training day is defined as eight hours of instruction, including two 15-minute breaks and excluding lunch time; Monday through Friday.

5. Provide a training manual for each student at each training phase which describes in detail the material included in each training program. Provide one additional copy for


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archiving.

6. Provide equipment and materials required for training. Unused copies of training manuals shall be turned over to the COUNTY at the end of last training session.

7. Provide one 2-hour training session at the site at a time and place mutually agreeable between the Contractor and the COUNTY.

8. Provide session to train 4 operation personnel in the functional operations of the system and the procedures that personnel will follow in system operation. This training shall include:

a. System overview b. General theory of operation c. System operation d. Alarm formats e. Failure recovery procedures f. Troubleshooting


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2.04 MOTORS

A. General Requirements

1. Motors shall be in accordance with applicable requirements of NEMA MG-1, NFPA 70, IEEE 112, and UL 1004.

2. Motor installed on or within bridge structure shall be severe duty motors, and shall meet or exceed the IEEE 841 standards for severe duty TEFC induction motors.

3. The motor’s torque characteristics in relation to the speed and starting current, shall conform to the motor design classification. The torque characteristics of all induction motors shall be as required to accelerate the inertia loads of the motor and driven equipment to full speed without damage to the motor or the equipment at any voltage from 90% to 110% of motor nameplate voltage.

4. The motors shall be designed to adequately braced for direct-on-line starting, with full rated voltage applied at their terminals. The starting performance of the motors shall comply with NEMA MG-1 requirements.

5. Electric motor of sizes 1 – 500 horsepower shall meet “NEMA Premium efficiency class IE3 standards.

6. Motors driven by adjustable speed drive shall have duty ratings be suitable for operation on an adjustable speed drive over the operational speed range duty cycle without exceeding the maximum temperature rise.

7. Maximum voltage dip at motor terminal during initial starting condition, for motor started directly across line shall not exceed 20% of the system nominal voltage.

8. Motor locked rotor current shall be limited to 650% when started at full voltage.

9. The motors shall withstand the dynamic torque stressing due to the switching phenomena (direct-on-line starting, short-circuit followed by transfer to another source and re-acceleration).

B. Motor Frame and Enclosure System:

1. Motor’s frame construction shall be heavy-duty, using cast iron or welded steel construction. Motor frame, fan covers, end brackets, drip shields, and bearing housing shall be cast iron with corrosion-resistant treatment. Motor supporting feet shall be an integral part of frame for very rigid mounting and to minimize vibration.

2. The motor housings shall be rated IP65, and provided with stainless steel hardware and nameplate. The motor shall be rated for high humidity environments and the winding insulation shall be extra heavy duty. The motor frames shall be provided with condensation drains. Locate drain holes at low point of motor in final mounted position.

3. Provide ground lug connection; locate bolt holes on motor frame, external to, and on same side as terminal box.


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C. Stator and Stator Assembly

1. The motors of 250hp and larger shall have form wound coils and a sealed Vacuum Pressure Impregnation (VPI) insulation system with epoxy resins.

2. The motors smaller than 250hp may have form wound or random wound coil. The motors with form wound coil shall have a sealed VPI insulation system with epoxy resins that withstand an immersion type test as required by applicable reference standards. The motors with random wound coil shall have a moisture resistant VPI insulating system or another type of insulation designed to prevent growth of fungus and ingress of moisture.

3. Windings shall be copper and the winding insulation shall be of Class F at least, but the temperature rise shall correspond to Class B conditions.

4. The six (6) terminals of the three (3) phases of the stator windings shall be brought out in the main motor terminal box for testing purposes.

D. Rotor and Shaft Assembly

1. The rotor squirrel-cage shall be made copper, copper-alloy bars or shall be fabricated aluminum, or integrally die-cast aluminum. Rotor shall be epoxy-coated.

2. Motor shaft shall be machined, carbon steel capable of transmitting torque produced by motor.

E. Bearings

1. Construct and provide bearing and bearing housing seals to prevent dirt or moisture from entering motor. The bearings shall be protected by a dust-proof and water-proof enclosure according to IP55 degree of protection or higher.

2. The bearings with oil lubrication shall be fitted with a sight gauge marked with the proper oil level and shall have fill and drain openings. When oil rings are used, means shall be provided for observing oil ring rotation while the motor is operating. The bearings with grease lubrication shall have grease valves for lubrication while the motor is running.

3. Where insulated bearings are required as a protection against the occurrence of shaft currents, one or both bearings shall be insulated, in consideration of the motor driven equipment assembly. At motors with one shaft extension, at least the bearing opposed to the driven equipment has to be insulated. At motors with two shaft extensions, both bearings have to be insulated, as well as one of the shaft couplings. Generally, piping and conduit to insulated bearings shall also be insulated.

4. Anti-friction type bearings shall be grease lubricated and have minimum rated life L10 with a median life no less than 50% of L10 life, as defined by AFBMA. Reliability of each bearing shall be greater than 90%.

5. Provide interior bearing caps or other suitable means to prevent lubricant from entering motor.


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6. Design bearings so damage does not occur by axial rotor movement during motor startup and shutdown.

7. Motors provided with roller bearings or angular contact ball bearings shall be fitted with a transport lock to prevent damage to the bearings, due to vibration, during transport.

8. Shaft and bearings for belt-connected motor shall withstand normal belt pull of equipment furnished and momentary and continuous overloads due to acceleration caused by incorrect belt tension.

9. Bearings for motors shall be designed to carry 200% of maximum thrust develops during starting and stopping, and while operating at any capacity on rated performance curve.

10. Motors shall have metallic bearing isolators on each bearing.

11. Furnish vertical motors coupled to vertical pumps with non-reversing ratchets and bolted couplings with case drip shields.

F. Lubrication System

1. System shall be capable of operating at least 8,000 hours without requiring addition of grease or complete change of grease.

2. Provide system with readily accessible grease inlet and outlet plugs in bearing housings to enable regreasing while motor is in service.

G. Anti-Condensation Space Heaters

1. Provide low surface-temperature, anti-condensation space heaters for motors installed indoors and outdoors for motor size indicated. The heater shall be mounted on inside of motor frame or winding end turns. Anti-condensation space heaters shall be provided in all the motors of the following types:

a. Indoor motors rated 250HP and larger. b. Outdoor motors rated 25HP and larger

2. The space heaters shall have sufficient capacity to keep the motor windings and internal parts dry when the motor is not running.

3. Space heaters shall be rated and designed to operate at the supply source voltage indicated on the design drawings. Space heaters shall be suitable for installation environment.

4. The space heaters and their connections shall be protected against accidental contact with the personnel, but shall be accessible for service and replaceable in the field.

5. Flame retardant insulated wires shall be used for the space heater connections.

6. Sheath temperature at 110% of rated voltage, when operating at ambient temperature, shall not exceed 200°C or cause motor insulation temperature to exceed 130 °C,


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whichever is more restrictive.

H. Motor Terminal Boxes

1. Equip each motor with corrosion resistance, cast iron terminal boxes, unless indicated otherwise.

2. Provide motor with oversized terminal box to accommodate oversize motor power supply cables and to allow ample room for bending radius and stiffness of motor supply cables, and for terminating grounding conductor. For the motors larger than 100 kW, two (2) cable entrances shall be provided.

3. Main terminal boxes shall be capable of rotation in 90° increments to permit connection on any one of four sides. The direction of the cable entrance in the terminal boxes, especially for the main terminal box, shall be adjustable in the field and changeable at a later date.

4. Provide motor lead seal and separator gasket between motor frame and terminal box.

5. Provide main terminal boxes with threaded conduit entrances or hubs for cable glands.

6. Terminate main lead electrical connections with tinned lugs suitable for cooper and aluminum conductor cables.

7. The terminal leads of the motor windings, of the heaters and of the monitoring devices shall be connected to terminals in separate terminal boxes (one for each of the lead groups indicated above). Each terminal box shall have a corresponding mark or an indication of the purpose.

8. Motor main or accessory leads that pass outside the motor enclosure shall be protected against mechanical damage.

I. Identification and Tagging

1. Securely attach embossed or stamped, stainless steel nameplates with stainless steel screws or pins.

2. Nameplate shall contain standard information in accordance with applicable reference standards.

3. If identification number cannot be included on motor nameplate, provide separate stainless steel equipment identification nameplate in accordance with equipment identification as indicated.

4. Motor power and space heater circuits may be derived from different sources. Covers of motor terminal boxes containing space heater leads shall be provided with nameplate reading: “ISOLATE MOTOR AND HEATER CIRCUITS BEFORE REMOVING COVER”.

J. Specific Technical requirements for special purpose motor

1. Span Drive Motor


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a. HP Ratings: as indicated on drawing b. NEMA Motor Characteristic: Design D c. RPM: 900 d. Duty Cycle: 30-Minute Duty Cycle e. Rated Voltage: 480V, Three-phase, 60 Hz. f. Motor construction: Meet or exceed the IEEE 841 standards for severe duty TEFC

induction motors. g. Insulation Class: F h. Refer to Special Specification for Mechanical Work for brake requirements. i. Motor Brake Features and Functions: The brake will engage whenever the motor

is disconnected from the line, the current of the brake coil is also interrupted, which makes the coil stop actuating. The braking system shall allow for normal braking or fast braking. The bridge rectifier connection shall be configured for normal braking. The alternating current (AC), 120V power supply for the bridge rectifier shall be obtained from an independent source. Provide brake with manual release lever to allow the motor shaft to be released in emergency cases or power outages.

j. Accessories: position indication via rotary cam limit switch with dry contact outputs for the following positions: Nearly Open, Fully Open, Nearly Close, Fully Closed, Open Over Travel, and three spare output positions. Limit switches shall be in NEMA 4X stainless steel enclosure.

k. Provide over/under speed switches for control system monitoring of machinery speed for alarm and system shutdown. Provide a complete speed switches system with sensor and pulser wrap suitable for the application. Provide speed switch with two individually adjustable relay set points and dual relay outputs, overspeed and/or underspeed protection selectable, while monitoring a single rotating shaft. Also provide the following features: Increased or Decreased Start Delay Interval; No Start Delay; Reduced or Enlarged Set Point Hysteresis; Set Point Over 990 rpm, Calibration in Percent of Speed, and Signal Loss Protection; Inactivation in Overspeed Mode.

2. Machinery Brake Motor a. Motor size and performance characteristics shall be per manufacturer standards

and mechanical performance requirements. b. NEMA Motor Characteristic: Design D c. RPM: 1800 d. Duty Cycle: Intermittent e. Rated Voltage: 480V, Three-phase, 60 Hz. f. Type of Motor Enclosure: Severe Duty, TEFC g. Insulation Class: F h. Accessories: position indication dry contact outputs for brake set, brake release,

and manual release. Limit switches shall be in NEMA 4X stainless steel enclosure.


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K. When electrically driven equipment differs from that indicated as a basis of design, make adjustments to the motor size, wiring and conduit systems, disconnect devices, and circuit protection to accommodate the equipment actually installed, at no additional cost to the COUNTY.


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2.05 TEMPERATURE SENSOR

A. Function: Monitor temperature on a wide range of industrial machinery including motors,

gearboxes, liquid tanks, piping, etc.

B. Sensor mounting applications:

1. Flat surface mount- mounts onto any flat surface with a #10 machine screw

2. 1/4-28 threaded stud- screws into any 1/4-28 tap

3. 1/4 in stainless steel probe with compression fitting mount (tanks, piping, bearing zerk grease fittings)

C. Operating Temperature (Measurement Probe): -40° C → +120° C

D. Certifications / Approvals: UL Listed, Intrinsically Safe (IS)

E. Features and auxiliaries:

1. Attachment probe, sensor, 2-wire 4-20 mA signal conditioner, and cable in one

2. 2-wire, loop-powered 4-20 mA analog output

3. Compatible with PLCs, meters, and data acquisition systems

4. Manufacturer pre-wired connection and hardware as required

F. The Contractor shall submit outline drawings, dimensioned layout, switch contact configuration diagram and specification data sheet of the temperature sensors to the Engineer for approval prior to procurement.

2.06 MECHANICAL LIMIT SWITCHES

A. Function: Monitor position of machinery parts; protecting equipment and personnel from

dangerous contacts and/or conditions.

B. Construction:

1. Metallic, industrial heavy duty design

2. Suitable for application in harsh industrial or corrosive environments

3. Electrically isolated bodies for industrial/corrosive environments

4. Zinc casings sealed w/ epoxy resin

5. Shock and vibration resistant

6. Stainless steel operating rod or lever arm

7. Stainless steel cable gland

8. Limit switch operating heads are as indicated in the Limit Switch Application Table


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C. Operating Temperature: -40 °C to 85 °C

D. Enclosure Rating / Degree of Protection: NEMA 4X / IP67.

E. Minimum Actuation Speed:

1. Slow action contacts: 0.060 m/s

2. Snap action contacts: 0.001 m/s

F. Ratings:

1. Rated operational voltage: 130 V

2. Rated Thermal Current: 10A min

3. Rated Insulation Voltage: 300V minimum

G. Certifications / Approvals: UL & CSA

H. Features and auxiliaries:

1. The switches shall be provided with 2 NO and 2 NC contacts

2. The Contractor shall furnish formed galvanized steel supporting brackets and associated stainless steel hardware.

3. Manufacturer pre-wired connection

4. The joint of the mechanism between the spring buffer and the plunger rod shall be covered with a watertight, neoprene bellows-type boot.

I. The Contractor shall submit outline drawings, dimensioned layout, switch contact configuration diagram and specification data sheet of the limit switches to the Engineer for approval prior to procurement.

2.07 GEARED LIMIT CAM SWITCH


dangerous contacts and/or conditions.

B. Construction:

1. Industrial heavy-duty design with combines gear reducer, coupling and cam switches




5. Stainless steel housing


7. Limit switch operating heads are as indicated in the Limit Switch Application Table


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D. Enclosure Rating / Degree of Protection: NEMA 4X / IP66.

E. Number of cam switch channels:

F. Step-up or step-down gear options (1:1 to 2500:1): as required

G. Cam Programming: 4° to 356° (1 …99%)

H. Switch Ratings:

1. Permanent Current: 6A

2. Switching Current: 10A 250V AC / 6A 24V DC

3. Mechanical Life: 10 x 106

4. Cycles.

I. Speed: 3000 rpm max., rotate in either direction

J. Certifications / Approvals: UL & CSA

K. Features and auxiliaries:

1. The switches shall be provided with 2 NO and 2 NC contacts


3. Manufacturer pre-wired connection

4. The joint of the mechanism between the spring buffer and the plunger rod shall be covered with a watertight, neoprene bellows-type boot.

L. The Contractor shall submit outline drawings, dimensioned layout, switch contact configuration diagram and specification data sheet of the limit switches to the Engineer for approval prior to procurement.

2.08 INDUCTIVE PROXIMITY SENSORS


dangerous contacts and/or conditions. An inductive sensor detects metallic objects without requiring physical contact with the targets to be sensed

B. Construction:

1. Industrial heavy duty design

2. Stainless steel body




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D. Enclosure Rating / Degree of Protection: NEMA 4X, IP69K

E. Rated operational voltage: AC/DC (90-132VAC; 18-50 VDC)

F. Output current (continuous): 300 mA

G. Sensor output circuit: 3-wire PNP (use with ‘sinking’ PLC input card)

H. Response time: Up to 2000 Hz

I. Noise immunity: high

J. Short circuit protection

K. Certifications / Approvals: UL & CSA

L. Features and/or auxiliaries:

1. LED indicator

2. Manufacturer pre-wired connection; shielded cable


M. The Contractor shall submit outline drawings, dimensioned layout, switch contact configuration diagram and specification data sheet of the limit switches to the Engineer for approval prior to procurement.

2.10 INCLINOMETER

A. Function: Monitor angular position(s), single or dual axis, of machinery, equipment

and/or structure for indication B. Construction:

1. Industrial heavy duty design suitable for application in harsh industrial or corrosive

environments

2. Stainless Steel or Die-cast aluminum alloy housing



C. Operating Temperature: -40 °C to 80 °C D. Enclosure Rating / Degree of Protection: IP68. E. Dual axis measurement range: ±80° min. F. Absolute Accuracy: ±0.1° or better


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G. Resolution: 0.01° or higher resolution

H. Measurement axis: 2 axis

I. Output type:

1. Digital output: RS232

2. Voltage output: 0.5~4.5VDC; or

3. Current output: 4~20mA J. Power supply voltage range: 11~36VDC


L. Features and auxiliaries:

1. Manufacturer pre-wired connection – connector and cable


M. Single-axis digital display inclinometer:

1. LED Display

2. Operating Temperature: -10 °C to 50 °C

3. Enclosure Rating / Degree of Protection: IP65.

4. Axis measurement range: ±1°～±80°

5. Accuracy: ±0.1° or better

6. Resolution: 0.01° or higher resolution

7. Response time: 0.2 s

8. Measurement axis: single-axis

9. Direct connect Input: a. Digital; or b. Current range: 4-20mA DC; or c. Voltage range: -10~300 V DC

N. The Contractor shall submit outline drawings, dimensioned layout and specification

data sheet of the inclinometer to the Engineer for approval prior to procurement.

2.11 RESOLVER


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B. Function: Detect rotational position and velocity feedback of motor shaft; protecting

equipment and personnel from dangerous under-speed/over-speed conditions. Resolver generates analog output to represent rotational position of motor shaft. If power is lost, its output will be correct whenever power is restored.

C. Construction:

a. Shaft type, Heavy duty, brushless construction design suitable for application

in harsh industrial or corrosive environments b. Electrically isolated bodies for industrial/corrosive environments c. Shock and vibration resistant d. Stainless steel cable gland

D. Number of Speed: 8

E. Frequency range: 400 – 5,000 Hz

F. Operating Temperature: -30 °C to 80 °C

G. Enclosure Rating / Degree of Protection: NEMA4X/IP67.

H. Interface Type: resolver-to-digital (R/D) converter

I. Certifications / Approvals: UL & CSA

J. Features and auxiliaries:

1. Manufacturer pre-wired connection – connector and cable 2. The Contractor shall furnish formed galvanized steel supporting brackets and

associated stainless steel hardware.

K. The Contractor shall submit outline drawings, dimensioned layout and specification data sheet of the resolver to the Engineer for approval prior to procurement.

2.12 SHAFT SPEED SENSOR WITH RELAY

A. Function: Provide shaft speed sensor that provides a 4-20 mA output signal directly proportional to the rotational speed of a monitored shaft. Monitor speed for alarm and shutdown; protecting equipment and personnel from dangerous under-speed/over-speed conditions.

B. Construction:

1. Industrial heavy duty design suitable for application in harsh industrial or corrosive environments

2. Cast aluminum housing




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C. Operating Temperature: -40 °C to 60 °C D. Input Signal: Magnetic alternating, 0.1 Hz to 9,999 Hz

E. Analog Output Signal: 4-20 mA with programmable end-points: (4 mA @ user min.

rpm); (20 mA @ user max. rpm)

F. Number of Set-points: 2

G. Set-point Range (RPM): 10-999

H. Gap distance between the speed switch and disc or wrap: 1/4" ± 1/8"

I. Contact Arrangement: 2 SPDT Form C J. Relay Contact Rating: Isolated, 5 Amp, 250 VAC, 30 VDC Resistive K. Enclosure Rating / Degree of Protection: NEMA 4X / IP67. L. Certifications / Approvals: UL & CSA

M. Features and auxiliaries:

1. Selectable over-speed or under-speed or zero speed configuration

2. 2 SPDT relay outputs

3. Visual set-point adjustment

4. Built-in start delay

5. Test Unit (simulates unwanted conditions for testing purposes)

6. Manufacturer’s bracket assembly and mounting hardware as required


N. The Contractor shall submit outline drawings, dimensioned layout and specification

data sheet of the encoders to the Engineer for approval prior to procurement. 2.13 TACHOMETER, COUNTER & DISPLAY

A. Function: Monitor and displays speed rate or time-in-process. Work in conjunction

with a shaft-mounted pulser disc or pulser wrap which generates an alternating magnetic field that is picked up by the sensing head. The sensor transmits the speed as a digital pulse frequency to the tachometer for display.

B. Construction:

1. Industrial heavy-duty design suitable for application in harsh industrial or corrosive


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environments




C. Operating Temperature: -0 °C to 50 °C D. Input Power Options: 115 VAC (60 Hz) E. Number of Set-points: 2 or 6 programmable as “over” or “under” and/or Forward and

Reverse

F. Set-point Range (RPM): 10-999

G. Gap distance between the speed switch and disc or wrap: 1/4" ± 1/8" H. Input Frequency Range: 0.01 Hz to 4,000 Hz

I. Response Time: Minimum 0.02 seconds

J. Output Contact Arrangement: Two programmable Form C relay contact outputs.

K. Relay Contact Rating: Isolated, 5 Amp, 250 VAC, 30 VDC Resistive

L. Analog output: Programmable 4-20 mA

M. Enclosure Rating / Degree of Protection: NEMA 4X / IP67.

N. Certifications / Approvals: UL & CSA

O. Features and auxiliaries:

1. Programmable over-speed and/or under-speed; forward and reverse configuration

2. Selectable sensor input

3. LED status indicators



P. The Contractor shall submit outline drawings, dimensioned layout and specification

data sheet of the encoders to the Engineer for approval prior to procurement.


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2.14 SHAFT SPEED SWITCH

A. Function: Monitor speed for alarm and shutdown; protecting equipment and personnel

from dangerous under-speed/over-speed conditions.

B. Construction:

1. Industrial heavy-duty design suitable for application in harsh industrial or corrosive environments





D. Input Power Options: 115 VAC (60 Hz)

E. Number of Set-points: 2

F. Set-point Range (RPM): 10-999

G. Gap distance between the speed switch and disc or wrap: 1/4" ± 1/8"

H. Contact Arrangement: 2 SPDT Form C

I. Relay Contact Rating: Isolated, 5 Amp, 250 VAC, 30 VDC Resistive

J. Enclosure Rating / Degree of Protection: NEMA 4X / IP67.


L. Features and auxiliaries:

1. Selectable over-speed or under-speed or zero speed configuration

2. 2 SPDT relay outputs

3. Visual set-point adjustment

4. Built-in start delay

5. Test Unit (simulates unwanted conditions for testing purposes)



M. The Contractor shall submit outline drawings, dimensioned layout and specification data sheet of the encoders to the Engineer for approval prior to procurement.


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CONSTRUCTION 3.01 PROTECTION AGAINST CORROSION

A. Provide equipment enclosures with the standard finish by the manufacturer when used for most indoor installations. For indoor installation, hot-dip galvanized ferrous metals hardware is acceptable.

B. For outdoor installation of electrical equipment, provide stainless steel hardware such as, but not limited to, anchors, bolts, braces, boxes, bodies, clamps, fittings, guards, nuts, pins, rods, shims, thimbles, washers, and miscellaneous hardware.

C. Where connected to dissimilar metal, provide suitable fittings and treatment.

3.02 HAZARDOUS AREA APPLICATIONS:

A. Electrical equipment, wiring devices, enclosures, junction boxes, raceways, fittings, and seals in areas classified as hazardous shall be constructed and installed in accordance with the requirements of the National Electrical Code.

3.03 INSTALLATION

A. Operator Control Console and Controller Panel

1. Install equipment in accordance with the approved manufacturer's printed installation drawings, instructions, wiring diagrams, and as indicated on project drawings and the approved shop drawings. A field representative of the drive manufacturer shall supervise the installation of all equipment, and wiring.

B. Motor

1. Connect motor with flexible metallic conduit.

2. Install, align, and connect motors in accordance with the equipment manufacturer's instructions.

3. Mount motors with bolts. Ensure motor feet are coplanar within 0.0254 millimeters, and base mounting points are accessible and adjustable to enable machine alignment. Install alignment jack bolts for motors 15 hp or larger to enable alignment.

4. Provide commercially die-cut shims, without seams or folds, made of corrosion resistant stainless steel.

5. Perform motor and load alignment under the direction of the manufacturer's representative. Recheck alignment of motors and adjust as required after the motor has been in operation for not less than 48 hours. Provide written final alignment settings as part of the final test data.


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3.04 FIELD QUALITY CONTROL

A. Manufacturer's Field Services:

1. Provide manufacturer's field services to support inspection of product installation, startup, testing and commissioning in accordance with manufacturer's instructions and recommendations. Arrange and pay for services of manufacturer's factory service engineer to supervise start-up of installation, check, adjust, balance and calibrate components and instruct operating personnel. Provide these services for such period, and for as many visits as necessary to put equipment in operation, and ensure that operating personnel are conversant with aspects of its care and operation.

2. Obtain written report from manufacturer verifying compliance of product installation, startup, testing and commissioning in accordance with manufacturer's instructions and recommendations.

B. Progress Cleaning:

1. Conduct work progress cleaning and leave Work area clean at end of each shift.

2. Upon completion of work remove surplus materials, rubbish, tools and equipment in accordance with requirements of construction/demolition waste management and disposal of the contract.

3.05 INSPECTION, TESTING, AND COMMISSIONING

A. Inspection checklists, functional tests, start-up and commissioning documents are the normal procedure of ensuring that the bridge machinery equipment, power and control systems are properly installed and function as intended design. Contractor shall be responsible for the start-up and commissioning activities. The Contractor in cooperation with subcontractors and the A/E shall develop inspection checklists, and testing and commissioning plan during the Construction Phase.

B. The Contractor shall complete inspection and functional checklists for all pieces of equipment and documentation shall be submitted to the COUNTY for verification and approval prior to Acceptance Performance Testing. Acceptance Performance Test shall include:

1. Visual and mechanical Inspection. 2. Electrical tests.

3. System performance and functional tests.

C. Specified products shall be tested as a system for conformance to Special Specification

requirements prior to scheduling the acceptance tests.


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D. Contractor shall notify the COUNTY and the Engineer provide written certification that the electrical equipment and/or sub-systems installation is properly completed and function in accordance with the Contract Documents, applicable codes and standards, and manufacturer’s requirements; and that the system is ready for System Acceptance Performance Tests. Any outstanding items or non-conformance shall be clearly indicated on the submittal document and an action item shall have been initiated.

3.06 PERFORMANCE VERIFICATION

A. "Performance Verification Test" plan shall provide the step-by-step procedure required to establish formal verification of the performance of the bridge operation. Compliance with the specification requirements shall be verified by inspections, review of critical data, demonstrations, and tests.

B. The COUNTY and/or COUNTY’s Engineer reserves the right to witness all tests, review data, and request other such additional inspections and repeat tests as necessary to ensure that the system and provided services conform to the stated requirements. The contractor shall inform the COUNTY and/or COUNTY’s Engineer at least 14 calendar days prior to the date the test is to be conducted.

3.07 PERFORMANCE VERIFICATION

A. Provide one 2-hour training session at the site at a time and place mutually agreeable between the Contractor and the COUNTY.

B. Provide session to train up to 10 operation personnel in the functional operations of the system and the procedures that personnel will follow in system operation. This training shall include:

1. System overview

2. General theory of operation

3. System operation and Operating Sequence

4. Trouble and Fault Alarms

5. Failure recovery procedures

6. Troubleshooting


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METHOD OF MEASUREMENT

The work for this item will be measured on a lump sum basis.

BASIS OF PAYMENT

The lump sum price bid per bridge shall include the cost of all labor, materials, and equipment required to complete the work of this item.

Progress Payments will be authorized as a percentage of the lump sum price based upon the following schedule:

Ten percent (10%) of the lump sum price will be paid upon completion and approval of shop drawings.

Thirty percent (30%) of the lump sum price will be paid upon procurement of equipment and completion of Factory Acceptance Test (FAT).

Thirty percent (30%) of the lump sum price will be paid upon completion of field installation.

Twenty percent (20%) of the lump sum price will be paid upon completion of all field testing and commissioning.

The remainder ten percent (10%) of the lump sum price will be paid once the punchlist item, documentation and final approval has been completed.

Payments will be paid under: Item 599.210500NC – BAYVILLE BRIDGE ELECTRICAL DRIVE AND CONTROL SYSTEM

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