41_22_15_-_Bridge_Crane_Electrical_Components_Amend_0004_0004.pdf

Folsom Warehouse – Bridge Crane Replacement Amendment No. 0004 American River Division Solicitation No. 140R2026R0017 Folsom Unit - Central Valley Project, California Specifications No. 20-C0942

Bridge Crane Electrical Components

Revised 41 22 15 - 1

SECTION 41 22 15

BRIDGE CRANE ELECTRICAL COMPONENTS

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Furnish, Install, and Test New Crane Electrical System for 30 Ton Bridge Crane:

1. Payment: Lump sum price offered in the Price Schedule.

1.02 REFERENCE STANDARDS

A. American Society of Mechanical Engineers (ASME)

1. ASME B30.2-2022 Overhead and Gantry Cranes (Top Running

Bridge, Single or Multiple Girder, Top Running Trolley Hoist)

B. Code of Federal Regulations (CFR)

1. 29 CFR 1910 - 2022 Occupational Safety and Health Standards

C. Facilities Instructions, Standards and Techniques (FIST)

1. FIST 3-9-2000 Methods for Coordinating System

Protective Equipment

D. Crane Manufacturers Association of America, Inc. (CMAA)

1. CMAA 70-2020 Top Running and Gantry Type Multiple

Girder Electric Overhead Traveling Cranes

E. Institute of Electrical and Electronics Engineers (IEEE)

1. IEEE 399-1997 IEEE Recommended Practice for Industrial and Commercial Power Systems Analysis

2. IEEE 519-2022 IEEE Recommended Practice and

Requirements for Harmonic Control In Electrical Power Systems

3. Deleted.

4. IEEE C57.13-2016 Instrument Transformers

F. International Electrotechnical Commission (IEC)

Revised 41 22 15 - 2

1. IEC 60825-1:2017 Safety of Laser Products – Part 1:

Equipment classification and Requirements

G. InterNational Electrical Testing Association (NETA)

2. NETA ATS-25 Acceptance Testing Specifications for

Electrical Power Equipment and Systems

H. International Society of Automation (ISA)

1. ISA 62381-2011 Automation Systems in the Process Industry

– Factory Acceptance Test (FAT), Site Acceptance Test (SAT), and Site Integration Test (SIT)

I. Material Handling Industry (MHI) Crane Manufacturers Association of America

(CMAA)

1. MHI CMAA 70-20 Top Running Bridge and Gantry Type

Multiple Girder Electric Overhead Traveling Cranes

J. National Electrical Contractors Association (NECA)

1. NECA 1-2023 Good Workmanship in Electrical

Construction

K. National Electrical Manufacturers Association (NEMA)

1. NEMA 250-2020 Enclosures for Electrical Equipment (1000

Volts Maximum)

2. NEMA ATS-2021 Standard for Acceptance Testing

Specifications for Electric Power Equipment and Systems

3. NEMA FU-1-2012 Low-Voltage Cartridge Fuses

4. NEMA ICS 1-2022 Industrial Control and Systems General

Requirements

5. NEMA ICS 2 – 2020 Industrial Control and Systems: Controllers, Contactors and Overload Relays, Rated Not More than 2000 Volts AC or 750 Volts DC

6. NEMA ICS 2.9-2002 AC Vacuum-Break Magnetic Controllers Rated 1500 Volts AC

Revised 41 22 15 - 3

7. NEMA ICS 3-2005 Medium Voltage Controllers Rated 2,001 to

7,200 VAC

8. NEMA ICS 5-2017 Control Circuit and Pilot Devices

9. NEMA ICS 7-2020 Adjustable-Speed Drives

10. NEMA ICS 6 – 2016 Industrial Control Systems: Enclosures

11. NEMA ICS 8-2019 Application Guide for Industrial Control

Systems Crane and Hoist Controllers

12. NEMA KS 1-2013 Enclosed and Dead-Front Switches (600 V

Maximum)

13. NEMA MG 1-2021 Motors and Generators

14. NEMA WC 70-2021 Nonshielded Power Cables Rated 2000

Volts or Less for the Distribution of Electrical Energy

L. National Fire Protection Association (NFPA)

1. NFPA 70-2023 National Electric Code (NEC)

M. Underwriters Laboratories (UL)

1. UL 50 – 2015 Enclosures for Electrical Equipment

2. UL 94 - 2023 Standard for Safety of Flammability of

Plastic Materials for Parts in Devices and Appliances Testing

3. UL 98 – 2016 Enclosed and Dead-Front Switches

4. UL 508-2018 Industrial Control Equipment

5. Deleted.

6. UL 1449-2021 Transient Voltage Surge Suppressors

1.03 DEFINITIONS

A. Deleted.

B. Deleted.

C. Deleted.

D. Class I Controllers: Controllers intended for use with CMAA crane service class C, D, E and F.

Revised 41 22 15 - 4

E. Class II Controller: controllers intended for use with CMAA crane services class A and B.

F. Deleted.

G. Deleted.

H. Dielectric test: tests made to determine ability of insulating materials and spacings to withstand specified overvoltages for a specified time without flashover or puncture.

I. Deleted.

J. Deleted.

K. Electric motor controller: device or group of devices that serves to govern in some predetermined manner the electric power delivered to the motor.

L. Electrical release indicator: A control circuit contact that changes state when the brake setting mechanism has moved to the release position.

M. Deleted.

N. Deleted.

O. Deleted.

P. Deleted.

Q. Deleted.

R. Deleted.

S. Main Line Contactor: A magnetic contactor used in the incoming power circuit from the main line collectors.

T. Main Line Disconnect Switch: A Manual switch that breaks the power lines leading from the main line collectors.

U. Master Switch: A manually operated device that serves to govern the operation of contactors and auxiliary devices of crane control.

V. Motor Control Enclosure: An assembly of electrical components which governs the flow of power to or from a motor in response to signals from a master switch, pushbutton station or automation control device.

W. Deleted.

Revised 41 22 15 - 5

X. MOV: Metal Oxide Varistor

Y. Deleted.

Z. Deleted.

AA. Deleted.

BB. Static Stepless Control: A type of control system with infinite speed control between minimum speed and full speed without the use of contacts.

CC. TDD: Total demand (harmonic current) distortion.

DD. THD(V): Total harmonic voltage demand.

EE. Deleted.

FF. Deleted.

1.04 SUBMITTALS

A. Submit the following in accordance with Sections 01 33 00 – Submittals and 01 33 26 – Electrical Drawings and Data:

B. RSN 41 22 15-1, Approval Drawings and Data:

1. Drawings:

a. Provide a title block that designates a unique drawing number and drawing title, including revision number and date.

b. Schematic Drawings:

1) Include schematic modifications on existing facility drawings.

2) Show all portions of the actual circuitry, regardless of whether the circuitry is located within the crane control enclosure, motor terminal box or at another location.

3) Description of operation.

c. Wiring Diagrams:

1) Show wiring modifications on existing facility drawings, where space allows.

d. Single-Line Drawings.

e. Three-Line Drawings.

f. Block Diagram Drawings.

Revised 41 22 15 - 6

2. Dimensioned plan, side and elevation views of crane control enclosures panelboard, motor controllers and VFD layout drawings including:

a. Show device layout, nameplate locations, nameplate legends, wireway, connection and support points and grounding locations.

b. Floor plans drawn to scale, showing required working clearances, and required area above and around VFDs. Show VFD layout and relationships between electrical components. Show support locations, type of support and weight on each support.

c. Supply layout and wiring diagrams showing the location of all Contractor supplied devices, protection relays, motor contactors and auxiliary devices.

d. Conduit service entrance locations and requirements.

3. Time-Current Characteristic Curves and Equipment Damage Curves:

a. Provide characteristic curves for motor circuit breaker or fuse, motor overload, and other protective devices.

b. Include motor inrush, full-load, and locked-rotor currents.

c. Curves to be plotted on same log-log graph.

4. Commercial product data.

a. Design Criteria.

b. Variable frequency drives: For each type and rating of VFD indicated.

1) Performance electrical ratings.

2) Operating characteristics.

3) Shipping and operating weights.

4) Furnished specialties and accessories.

5) Seismic qualification certificates for VFDs, accessories and components.

6) Product certificates.

7) Harmonic analysis study and report: In accordance with IEEE 399 and NETA ATS. Identify the effects of nonlinear loads and their associated harmonic contributions on the voltages and currents throughout the electrical system. Analyze designated operating scenarios.

8) Include recommendations for VFD input filtering to limit TDD and THD at each VFD to specified levels.

c. Electrification Systems.

Revised 41 22 15 - 7

d. Provide integral schedule of crane electrical components.

5. Electrical equipment ratings:

a. Voltage.

b. Ampacity.

c. Horsepower.

d. Short Circuit.

e. NEMA Sizes.

6. Low-Voltage Transformers:

a. Enclosures and accessories.

b. Unit Weight.

c. Voltage.

d. kVA.

e. Impedance ratings and characteristics.

f. Loss data.

g. Efficiency at 25, 50, 75 and 100 percent rated load.

h. Tap configurations.

i. Insulation system type.

j. Rated temperature rise.

7. Certified by a Professional Engineer.

C. RSN 41 22 15-2, Installation Plan and Procedures.

1. Storage, refer to Section 01 14 10 – Use of Site.

2. Installation Instructions:

a. Equipment erection.

b. Seismic anchorage of crane electrical components.

c. Grounding of control enclosures.

d. Conduit and cable interface.

3. Provide a narrative including details for installation plan and procedures.

a. Scope and preparation.

D. RSN 41 22 15-3, Final Product Data:

1. Operation and Maintenance Manuals including, but not limited to, the following data and drawings:

Revised 41 22 15 - 8

a. Title page/index.

b. Bill of materials.

c. Copies of informational data.

d. Half-size prints of As-Built drawings.

e. Time-current characteristic curves.

f. Equipment damage curves.

g. Motor circuit breaker ratings and settings.

h. Motor overload relay settings.

i. Undervoltage relay setting.

j. Power fuses for each size and type.

k. VFD emergency operation and maintenance.

l. Manufacturer’s written instructions for testing and adjusting thermal-magnetic circuit breaker and trip settings.

m. Manufacturer’s written instructions for setting field-adjustable overload relays.

n. Written instructions for testing, adjusting and reprogramming microprocessor control modules.

o. Manufacturer’s written instructions for setting field-adjustable timers, controls and status and alarm points.

E. Obtain Government acceptance prior to proceeding to the next design phase.

1. Design submittals, including re-submittals, shall contain drawings, criteria, and interview documentation and updates.

2. Include revised drawings and related documentation resulting from the review of the submittal and additional comments in the re-submittal.

1.05 DESCRIPTION OF WORK

A. The automation process encompasses everything from the reception of a control signal to the movement of the crane motors. The electrical subsystems are:

1. Digital Automation Control utilizing closed-loop vector position control, open-loop position control.

2. Electric crane motors and protection devices.

3. Gear train transmission to alter the torque or speed.

Revised 41 22 15 - 9

B. Provide new crane electrical components as specified herein. The design shall consist of a series of motor protection devices, programmable logic controllers, intelligent low-voltage devices, pendant control device, pushbuttons, control enclosures and motors specifically designed for crane operation, characterized by high starting torque and low starting current.

C. Provide new crane motor drives as specified herein. The design shall consist of separately enclosed, preassembled, combination VFDs, rated 600 Volts and less, for speed control of three-phase squirrel-cage induction motors.

D. Design, Furnish, Install, and Test: Crane Motor Controller Assembly and Crane Electrical Components.

E. Interface with PLC specified in Section 25 12 10 – Programmable Logic Controller.

1.06 RELATED WORK

A. Coordinate features of crane electrical components and accessory devices to be compatible with the following Sections:

1. Section 41 22 14 – Bridge Crane

2. Deleted.

3. Section 25 00 01 – Automation Control System

4. Section 25 12 10 – Programmable Logic Controller

1.07 DELETED.

1.08 PROJECT CONDITIONS

A. Plant Layout: See Section 52 00 00 – Drawings, for informational drawings showing general plant layout and work areas, if available.

B. Altitude: 500 feet.

C. Average maximum outdoor ambient temperature: 120 degrees F.

D. Relative Humidity Range: 25 to 89 percent.

1.09 DELIVERY, STORAGE, AND HANDLING

A. Accept equipment on site in shipping containers with labeling in place.

B. Protect equipment from damage, moisture, and dust, free from contact with soil and weather.

Revised 41 22 15 - 10

1.10 QUALIFICATIONS

A. Qualified Professional Engineers: Demonstrated experience on cranes of similar size and capacity as bridge crane under this specification on at least three separate crane contracts.

1. Licensed in the state of California.

B. Qualified Crane Electricians: Minimum of one licensed electrician during field wiring and critical aspects of the crane field work.

C. Crane Controls System shall be designed and manufactured by a company with a minimum of 10 years of specialized experience.

D. Installation Supervisor:

1. Responsible for installation of electrical components and materials.

2. Technically qualified to supervise installation and testing work, meeting with

COR approval.

3. Present or represented at work site during installation period.

4. Report, in writing to CO, work not in accordance with manufacturer's recommendations or other conditions possibly resulting in unsatisfactory job.

5. Maintain daily log of accomplished work.

E. VFDs and options shall be UL 508 listed as a complete assembly. The base VFD shall be UL listed for SCCR without the need for input fuses. Base VFDs with red label UL stickers requiring additional branch circuit protection are not acceptable.

F. VFDs shall be supplied with external filters. The entire assembly, including the bypass shall be seismically certified.

1. Provide seismic certification and installation requirements at time of submittal.

1.11 WARRANTY

A. Manufacturer’s standard form in which manufacturer agrees to repair or replace VFDs that fail in materials or workmanship within specified warranty period.

1. Warranty Period: Five years from date of turnover to the Government.

PART 2 PRODUCTS

2.01 DESIGN AND FUNCTIONAL REQUIREMENTS

A. Design electrical equipment layout of crane control on bridge girders, trolley and cab.

Revised 41 22 15 - 11

B. Components suitable for indoor operation in ambient operating temperature range from 20 to 120 degrees F at approximate elevation 500 feet above sea level.

C. The electrical design of the crane shall conform to CMAA 70, NFPA 70, NECA 1, ASME B30.2, NEMA ICS 8, and other requirements specified herein.

D. All hardware design and installation shall conform to OSHA Regulations per 29 CFR 1910.

E. All crane electrical components shall be industrial grade, commercially available and comply with UL.

F. All provided hardware shall be rated per UL 94, where applicable.

G. All crane components shall be rated for operation in the expected environment as described in section 1.08. Uprate motors, controls, and associated equipment as required for service in this environment.

H. All crane electrical components shall be located to be easily accessible for inspection and maintenance without removing other parts.

I. The Contractor shall coordinate equipment information with the motor manufacturer to ensure that the correct type of motor starters and protection equipment are provided, properly sized to operate and provide proper protection to the devices served.

J. The Contractor shall verify that all motor protection equipment will fit physically within the space allotted.

K. Provide independent relays, contactors, drive inputs or other logic components for directional control such that failure of a single device cannot result in motion in an unintended direction.

L. All electrical equipment shall be equipped with proper hazard signage per CMAA 70 and NFPA 70.

M. Power supply for the crane shall be 480 Volts, 3φ, 60 Hz. All power required for the operation shall be developed from this source.

1. Control Voltage: 120 Volts AC.

N. Runway electrification shall be furnished by the following:

1. Runway 4-bar conductor rail system to supply electrical power across the crane for bridge, trolley and hoist motions, fully compliant to CMAA 70 and NFPA 70.

a. Design the location, size and type of conductor rail bar system:

Revised 41 22 15 - 12

1) Sized for simultaneous motions of the hoist, bridge, trolley motions and ancillary loads.

2) The maximum continuous length of conductor rails shall not exceed 30 meters without an expansion joint.

3) Provide electrical continuity across the expansion joint on both sides with flexible copper conductors as per manufacturer’s standard.

4) The support assembly shall be capable of withstanding high impact and shocks resulting from crane movements.

5) Provide adequate tension and compression strength to withstand the weight of the collector system during crane motions.

6) Provision for connecting incoming feeder terminations to conductor rails.

b. Include all necessary cables and hardware to the crane from a wall or column mounted disconnect switch.

c. Provide emergency switches in a totally enclosed metal enclosure with an operating lever outside at each end of the bridge to cut-off power supply under emergency condition by tripping the mainline circuit breaker.

2. Fused disconnect switches.

O. Crane Control Systems:

1. Provide a separate motor controller for each motor.

a. Provide overload protection in accordance with NEMA ICS-2.

b. Electrically interlock contactors used for starting, stopping and reversing.

2. Provide simultaneous motions of the hoist and travel drive mechanisms.

3. Design to provide a Class II motor controller.

4. Hoist Motion Controls:

a. Provide multi-speed control with two specific speed points, minimum.

b. Provide AC Static Stepless Control with the following minimum requirements:

1) Master switches to provide variable-speed and torque control with 10:1 speed range, minimum.

2) Plugging and jogging control.

3) Non-wearing Solid state devices.

Revised 41 22 15 - 13

c. Provide Variable Frequency Control with the following minimum requirements:

1) PLC controlled allowing acceleration and deceleration rates to be adjusted digitally and independently for smooth stops and starts.

2) Jogging control capability.

3) Provide reduction of shock loading.

4) Load swing and positioning control.

5) Static reversing.

6) Closed-Loop Flux Vector Control.

7) Dynamic braking.

5. Travel Motion Controls:

a. Provide Variable Frequency Control with the following minimum requirements:

1) PLC controlled allowing acceleration and deceleration rates to be adjusted digitally and independently for smooth stops and starts.

2) Jogging control capability.

3) Provide reduction of shock loading.

4) Load positioning control.

5) Static reversing.

6) Open-Loop Control.

7) Anti-collision controller.

8) Dynamic braking.

b. Provide AC inverter duty, totally enclosed non-ventilated, squirrel cage induction type bridge and trolley drive motors.

6. Configure to allow simultaneous, independent operation of all motors.

7. Drive Control System

a. Provide static reversing, adjustable frequency controllers conforming to NEMA ICS 3, NEMA ICS 8 for the hoist and travel drives.

b. Design with infinitely variable electric drives. Provide two step infinitely variable speed control for the hoist and travel functions, controlled via pendant pushbuttons.

c. The hoist, and travel brakes shall set after associated controller decelerates motor to a controlled stop.

Revised 41 22 15 - 14

d. Size the hoist and travel controllers to provide sufficient starting torque to initiate motion of that crane drive mechanism from standstill with 0 to 225 percent of rated torque.

e. Drive motors shall run smoothly, without torque pulsations at the lowest speed, and be energized at a frequency not exceeding 60 HZ.

P. Control Enclosures

1. Individual control panels shall be provided for each motion of the bridge crane.

a. All power and auxiliary contactors, magnetic overload relays, time delay relays shall be housed in the enclosures.

2. Nameplates shall be provided for each enclosure and for equipment mounted to the enclosure per Section 2.20.

3. Enclosures shall be designed for operational environment.

4. Enclosures shall be designed according to CMAA 70, and NFPA 70.

5. Installation shall be properly secured to the crane structure provided with adequate lifting lugs. Anti-vibration pads shall be furnished.

6. Components shall be installed within enclosure in accordance with each component’s manufacturer recommended installation instructions.

7. Provide ventilation kits and heaters to prevent condensation.

8. Enclosure shall be installed on support similar to standard drawing 40-D-

60001.

9. Convenience Features:

a. 120VAC Convenience Outlet:

1) Rating: 120-Volt, 15 Ampere, 2-Pole, 3-Wire, polarized, GFCI

Included

2) Mounted in standalone enclosure with spring-loaded door.

Q. Coordinate features of motors, load characteristics, VFDs and accessory devices to be compatible with the following:

1. Torque, speed and horsepower requirements of the maximum anticipated load.

2. Ratings and characteristics of supply circuit and required control sequence.

3. Ambient and environmental conditions of installation location.

R. Emergency Crane Shutdown:

1. Provide fail-safe spring set electrically-controlled brakes when power is interrupted.

Revised 41 22 15 - 15

2. Release brakes with a mainline contactor pushbutton or a master switch for the associated drive.

3. Brakes shall automatically stop when there is a power failure.

4. Design electric system to be mechanically released.

5. Provide enclosures for electrical-controlled brake components conforming to

NEMA ICS 6.

S. Programmable Logic Controller Process Automation

1. Refer to Section 25 12 10 – Programmable Logic Controller.

T. If not specified on drawing, Contractor shall determine size and ratings of the following:

1. Circuit breakers.

2. Fuses.

3. Resistors.

4. Motor controllers, contactors and overload relays. Size overload relays in accordance with requirements of NFPA 70, NEMA ICS-2, and NEMA ICS-8.

5. Control circuit transformers.

6. Instrument transformers.

U. Conform to referenced IEEE, NEMA, NFPA, and UL standards.

V. Provide surge suppressors in accordance with UL 1449.

W. Transients and Harmonics Protection:

1. Provide transient protection for drive controllers that is internal to the drive.

2. Provide line reactors rated for continuous duty operation based upon the motor nameplate amperes.

3. Crane motors of 50 horsepower or greater shall have harmonics protection provided by an isolation transformer.

4. For drive motor branch circuits that exceed 150 feet in length, a reactor shall be connected in series with the controller load terminals to for standing wave protection.

2.02 RATINGS AND GENERAL REQUIREMENTS

A. General:

Revised 41 22 15 - 16

1. Design and test all electrical devices and circuits associated with crane controls system. All devices shall be furnished as described in the layout drawings and shall be mounted as indicated and wired by the contractor. The contractor shall provide updated wiring diagrams in Reclamation RESF format as part of the operations and maintenance manual.

2. UL Listed Equipment, Conform to NEMA ICS-1, ICS-6, and ICS-8.

2.03 DELETED.

2.04 VARIABLE FREQUENCY DRIVES

A. Enclosures per VFD shall be provided designed per Section 2.04, suitable for the corresponding VFD package.

B. Provided VFDs shall be in compliance with NEMA ICS 7, NEMA ICS 8 and NEMA ICS 61800-2.

C. VFDs shall be suitable for operation of NEMA MG 1, Design D hoist motors and Design B for travel, trolley and bridge motors.

D. Motions:

1. Hoist: Static reversing, adjustable frequency, speed regulated, open loop vector controller with dual-channel, incremental encoder feedback.

2. Bridge/Trolley: Static reversing, adjustable frequency, speed regulated, closed or open loop vector controller with dual-channel, incremental encoder feedback.

E. VFD model Allen-Bradley PowerFlex 755, 755-PP004, manufactured by Rockwell Automation, 1201 S. Second Street, Milwaukee, WI 53204; or equal, having the following essential characteristics:

1. Rating:

a. 480Volts, 3 φ, 60 Hz.

b. Contractor to determine the following ratings:

1) Rated Continuous Current.

2) Maximum Full-Load Current.

3) Rated Locked-rotor current.

4) Short-Circuit Withstand

2. Pulse Width Modulation (PWM), torque-rated for crane use.

3. Insulated gate bipolar transistors in inverter.

4. Dynamic Braking Diode Bridge.

Revised 41 22 15 - 17

5. Brake and load monitoring features for hoist motion:

a. Load monitoring to verify sufficient motor torque is developed before holding brake release.

b. Load monitoring to verify that holding brake is maintaining load before removing motor power.

c. Continuously monitor and alarm if holding brakes slip while crane is energized.

6. Fail-Safe Brakes and programming, such that electrical failure does not cause runaway motion.

7. Provide Dynamic Braking for all electric drives in accordance with CMAA 70.

a. Brakes to set only after associated controller decelerates the motor to a controlled stop.

8. Rated for operation in environment described in Section 1.08 and at ambient temperatures of 40 degrees centigrade at rated motor current.

9. Provide full rated output from a line of plus or minus 10 percent of nominal voltage and continuous operation without faulting from a line of minus 35 to 30 percent of nominal voltage.

10. The continuous rating of the controller shall not be less than 125 percent of the calculated motor full load current per CMAA 70 and NFPA 70.

11. Input alternating-current line reactor for voltage transient protection.

12. Conformal-Coated circuit boards.

13. Identical user interfaces, including digital display and keypad.

a. Keypads shall be removable, capable of remote mounting and allow for uploading and downloading of parameter settings.

b. Deleted.

14. Built-in time clock with battery backup with 10 years minimum life span.

a. The clock shall be used to date and time stamp faults and record operating parameters at the time of fault.

15. Programming held in non-volatile memory, not dependent on battery power.

16. Capability to utilize pre-programmed application macros to facilitate motor start-up.

17. Possess temperature- and program-controlled cooling fans which are removable without disturbing other components.

18. Capable of starting into coasting loads up to full speed and accelerate or decelerate to set point without tripping or component damage.

Revised 41 22 15 - 18

19. Design for High-Impact loads and standstill loads.

a. Speeds for all motors:

b. Infinitely-variable and -adjustable, with a slow or jog mode limited to 25 percent of rated speed.

c. Speed regulation: + [0.02] % of max. frequency.

d. Speed Response: Greater than 50 Hz.

e. Speed Control Range: 1:1,500.

f. Starting Torque: 225 percent of rated torque.

g. Speed detection to prevent load over-speed conditions.

h. Automatically reset inverse-time trip running overload protection contacts in each phase with thermal time constant set to be the same as motor.

20. Provide capability to automatically restart after an overcurrent, over-voltage, undervoltage or loss of input signal protective trip.

a. The number of restart attempts, trial time, and time between attempts shall be programmable.

21. The overload rating of the drive shall be 150 percent of its normal duty current rating for 1 minute.

22. Provide non-linear chokes to yield impedance equivalent to 5 percent to reduce harmonics to the power line.

23. Input and output current ratings shall be included on the nameplate.

24. The input rating of the VFD shall not be greater than the output current rating.

a. VFDs with higher input current ratings shall require the upstream conductors, protection devices and source transformers to be oversized per

NEC 430.122.

25. Provide AC transient surge protection:

a. MOVs, phase to phase and phase to ground.

b. Capacitor clamp.

26. Provide the following minimum Harmonics Protection:

a. Line reactor connected in series with each controller’s line terminals.

b. All reactors shall be rated for continuous duty operation based upon motor nameplate amperes and shall be designed for 60 Hz operation.

c. Isolation transformer for the motor branch circuit.

d. For motor branch circuits that exceeds 150 feet in length, a reactor shall also be connected in series with the controller load terminals to provide standing wave protection.

Revised 41 22 15 - 19

e. Compliance to IEEE 519 does not relieve the Contractor from the requirement to provide Active Front End drives.

27. Provide a programmable loss-of-load Form-C relay output.

a. Loss-of-load condition sensing algorithm shall include a programmable time delay that will allow for motor acceleration from zero speed without signaling a false loss-of-load condition.

28. If the input reference is lost, the VFD shall give the following operator options:

a. Stopping and displaying a fault.

b. Running at a programmable preset speed.

c. Hold the VFD speed based on the last good reference received.

d. Issue a warning.

29. Motors shall operate smoothly at all speeds without torque pulsations and shall only be energized within the frequency range of 50-60 Hz at rated speed.

30. Anti-Collision System:

a. Prevent collision between crane and runway stops, or other cranes, if applicable.

b. Prevent collision between trolley(s) and end stops, or other trolleys, if applicable.

c. Activate creep mode of crane and trolleys when within proximity to the other crane(s), other trolley(s), the end stops, or the runway stops.

31. Anti-Skewing System:

a. Correct misalignment of bridge end truck motion to prevent wheel and rail damage.

b. Software and laser-sensor based, closed-loop monitoring and adjustment.

32. “No Fly Zone” functionality as described in Section 25 00 01 “Automation

Control System” Article 2.02 A5 Collision Avoidance/” No-Fly Zone” function.

33. Labels:

a. Provide for pushbuttons, switches, indicating lights, load cell displays, and crane motion operation devices, as described in Article 2.19.

b. As applicable, indicate direction of motion and associated component.

34. Provide limit switches per Article 2.12.

35. Run permissive circuit: VFD shall provide a dry contact closure when motor does not operate. Two separate safety interlock inputs shall be provided.

36. The following operating values shall be capable of being displayed:

Revised 41 22 15 - 20

a. Output Voltage.

b. Output Frequency.

c. Motor Speed (RPM).

d. Motor Current.

e. Motor Torque.

f. Motor Power.

37. Provide the following minimum Inputs and Outputs:

a. Digital Inputs: Six programmable.

b. Digital Outputs: Six programmable.

c. Analog Inputs: Two programmable, accepts current or voltage signals.

d. Analog Outputs: Eight programmable, 0-20 mA or 4-20 mA. The outputs shall be programmed to output proportional to Frequency, Motor Speed, Output Voltage, Output Current, Motor Torque, Power, Active Reference and Active Feedback.

F. Provide any unlisted, required hardware for compatibility between VFDs and operator control device as described in Article 2.07.

G. Communications:

1. EIA-485 Port.

2. Modbus TCP, Profibus, EtherNet IP.

3. Serial communication shall include, but not limited to; run-stop controls and speed set adjustment.

4. Provide process variable feedback to the crane PLC.

H. Hoist Motor Variable Frequency Drive AC motor controller:

1. Closed-Loop Flux Vector Control

2. Deleted

3. If a Non-Design D motor is used, negative slip compensation shall be employed to emulate the speed-torque characteristic of a NEMA Design D motor in accordance with NEMA MG 1.

a. Provide to reduce the effect of motor slip.

b. Provide load torque signal to the speed controller to increase the output frequency in proportion to the load.

c. Utilize with direct torque control with an accuracy of 10 percent of the nominal motor slip, minimum.

Revised 41 22 15 - 21

4. Design to provide an Active Front End with the following minimum features:

a. Dynamic braking using a chopper IGBT and resistor combination; sized per manufacturer’s requirements.

b. Regenerative drive.

c. Active rectifier to mitigate harmonic distortion in accordance with IEEE

519.

d. IGBT Rectifier design providing four-quadrant operation.

1) Hoist motor produces either positive or negative torque. Motoring and regenerative power shall be maintained near unity power factor.

5. Provide hoist drives with a motor overtorque limit to lock out the hoist and prevent gross overload.

a. The overtorque limit shall be set at 225 percent of the motor torque required to hoist 100 percent load.

6. Hoisting functions shall not produce any rollback and shall produce no more than

1/8 inch of roll-up.

7. Hoist Brakes Operation:

a. Brakes shall release upon movement of the VFD drive controller from the OFF position and verification of motor torque.

1) Verify sufficient motor torque is developed before brake release.

2) Monitor load to verify holding brake adequately maintains load before removing power from the hoist motor.

3) Alarm under brake slip conditions.

b. The brakes shall set after the drive’s controller is returned to the OFF position and motors have regeneratively slowed to a controlled stop.

c. The hoist’s secondary brake shall be controlled separate from the primary brake and connected to a different output from the primary brake.

d. A three position maintained keyswitch shall be installed on the outside of the motor control enclosures for each hoist to allow for testing each brake independently.

1) Primary Brake Test.

2) Secondary Brake Test.

3) Normal: Allow both brakes and the drive to function in normal operation.

I. Travel and Bridge Motor Variable Frequency Drive AC motor controller:

Revised 41 22 15 - 22

1. Open or Closed-Loop Control.

Travel assemblies with one driven wheel on each side. Motors shall be self-contained gear reduction units.

2.05 ENCLOSURES

A. Unless otherwise specified, enclosures shall be designed and installed in accordance with NEMA 250, CMAA 70, and NFPA 70, where applicable and appropriate for contained hardware.

B. All enclosures and installed hardware shall be UL-Listed per UL 50 and UL 98, where applicable.

C. In addition, all enclosures to have the following features:

1. Conduit entry: Bottom and side entry.

2. Provide interior light with a door switch to turn lights off when the doors are closed.

3. Doors:

a. Hinged, latching, gasket-sealed.

b. Pad-lockable.

4. Support:

a. Wall mounted or Unistrut mounted in accordance with Standard USBR

Drawing 40-D-60001.

5. Heating and Ventilation Kits:

a. Where necessary for type of installed equipment and/or operating environment, provide thermostatically-controlled heaters and/or enclosure ventilation kits to regulate humidity and temperature to within safe operational parameters, or prevent buildup of hazardous gases.

b. Heaters and ventilation kits shall be selected based on equipment manufacturer recommendations, equipment compatibility, and environmental conditions.

D. Crane Control Enclosures

1. Locations: Bridge Crane Walkway

2. Fabricate control panels of solid sheet steel designed and constructed to conform to requirements of NEMA ICS 6.

3. Provide pilot light to indicate that power is available on load side of crane disconnect switch. Pilot light shall be white and labeled CRANE ENERGIZED.

Revised 41 22 15 - 23

4. Provide pilot light to indicate that the main contactor is energized. Pilot light shall be blue and labeled CONTACTOR ENERGIZED.

5. Provide a non-resettable hour meter for each VFD per Article 2.21, connected across the main line contactor, readable from the exterior of the main control panel, to indicate the elapsed number of hours the crane is energized.

2.06 HUMAN MACHINE INTERFACE

A. Location: On the outside of the PLC Enclosure.

B. Provide red pushbutton on enclosure to allow for reset functionality.

1. Reset function shall reset Emergency Stop/fault lockout/crane control permissives and allow crane operation.

C. Refer to Section 25 12 10 – Programmable Logic Controller.

2.07 PROGRAMMABLE LOGIC CONTROLLER

A. Location: Controls enclosure, nearby the crane, accessible from bridge crane walkway.

B. Refer to Section 25 12 10 – Programmable Logic Controller.

2.08 MANUAL CONTROL DEVICE

A. Where not described hardwired control (switch, pushbutton, joystick, etc.) characteristics shall conform to Article 2.13 “Hardwired Controls”.

B. Contractor shall provide all required hardware and components for wired crane control via a device possessing the following essential characteristics:

1. Pendant-style remote control device, attached to underside of crane.

2. Compatible with other provided hardware and capable of controlling all required and listed crane functionality.

3. Contractor shall provide pushbuttons, switches, visual indicators, and any other required components, compatible with selected control device and suitable for the operation of all listed crane functionalities.

a. Pushbuttons shall include tactile feedback for different stages of operation, where appropriate.

b. HORN function shall be controlled via pushbutton.

c. Hoist, Trolley, and Bridge motions shall be controlled pushbuttons with tactile feedback and multiple stages for different operating speeds.

Revised 41 22 15 - 24

d. Emergency stop functionality, to operate the main-line contactor and trigger Emergency Stop Permissive, shall be controlled via a red, latching, mushroom-head pushbutton.

1) Push to lock, turn and pull to release.

e. Crane control permissive shall be operated by shrouded, two-stage switch with maintained “ON” and “OFF” positions.

f. Provide Pilot light to indicate that control is active. Pilot light shall be green and labeled POWER ON.

g. Control switches/devices for required functionalities not listed shall be additionally provided by Contractor.

4. All pushbuttons, switches, indicating lights and joysticks shall be legibly and permanently marked per Article 2.19.

5. Provide double block contacts:

a. Mechanically interlocked.

b. Spring return operators.

2.09 DISCONNECTING MEANS

A. Disconnecting means in accordance with NFPA 70 Article 610.32.

B. Fused Disconnect Switch – Runway Contact Conductors:

1. Purpose: Disconnect isolation for crane power source with the following minimum requirements:

a. Type: Heavy-Duty, quick-make, quick-break, load interrupter, single-throw, and fusible.

1) Enclosed knife switch with externally operable handle interlocked to prevent opening front cover with switch in ON position.

2) Handle lockable in the OFF position.

b. Enclosure: NEMA Type 12:

1) 304 Stainless steel with brushed finish.

c. Provide auxiliary contacts to de-energize VFD motor controllers when operating local disconnect.

d. Provide monitoring micro switches for visual alarm indication at the crane control station.

e. Provide manufacturer’s equipment ground kit in all disconnect switches.

Revised 41 22 15 - 25

f. Readily accessible and operable from the ground or floor level.

g. Placed within view of the runway contact conductors.

h. Suitable for mounting in stand-alone enclosure.

i. Fuses: 600 Volts, current-limiting type, minimum.

j. Disconnect switch conform to NEMA KS 1 and UL listed.

C. Fuses for Disconnect Switch:

1. Fuses 600 Amperes and less: Dual element, time delay, and current-limiting type.

2. Rated Voltage: 600 Volt.

3. UL Class [ RK 1 ] [ RK 5 ] [ J ], Contractor to determine.

4. Interrupting Rating: Shall not be less than 50 percent of the combined short-time ampere rating of the motors or less than 75 percent of the sum of the short-time ampere rating of the motors required for any single motion.

a. In accordance with NFPA 70 Table 430.52(C)(1).

5. Fuses conform to NEMA FU 1, UL listed and in accordance with FIST 3-9..

D. Main-Line Circuit Breaker:

1. Purpose: disconnecting means from other power supplies on cranes with the following minimum requirements:

a. Rated Voltage: 600 Volts, 3 φ, 60 Hz, 3-pole.

b. Short Circuit Withstand: 50 kAIC RMS Symmetrical, minimum.

c. De-energized during:

1) Crane Shutdown

2) Undervoltage

3) Reverse-phase or open phase condition.

4) Motor overload.

d. Current Rating: shall have a continuous current-rating equal to or greater than the larger of:

1) Fifty percent of the combined intermittent-duty current ratings of all the motors on the crane, plus the rated current of auxiliary loads on the load side of the disconnecting means.

2) Seventy-five Percent of the sum of intermittent-duty current ratings of all motors required for the other crane motion having the largest horsepower plus the rated current of all auxiliary

Revised 41 22 15 - 26 loads (other than crane motions) on the load side of the disconnecting means.

2. NEMA Type 12 Enclosure.

3. In accordance with NEMA ICS 2, NEMA ICS 8 and NFPA 70, Article 610 part

IV.

2.10 INDICATOR LIGHTS AND WARNING DEVICES

A. Indicator lights and beacons shall be installed on the underside of the crane with LED type lights sized to be visible from the ground during any time of the day.

B. Provide the following minimum indicating lights in a stack under the crane and on the Crane PLC Enclosure for 120 VAC operation:

1. An “Amber” light to indicate movement of hoist, trolly, or bridge.

2. A “Red” light to indicate a major fault.

C. Provide a warning horn operable from the crane controller.

D. Provide a travel warning bell, automatically operated during hoist or travel motion, provided with silencing option at the HMI.

E. Provide a Warning Strobe or Rotating Beacon, automatically illuminated during hoist or travel motion.

F. Deleted

2.11 LOW-VOLTAGE GENERAL PURPOSE TRANSFORMERS

A. Capacity: Contractor to determine kVA rating.

B. Location: On the bridge walkway.

C. Type: Dry type, copper windings, and sized to have adequate capacity for control power requirements of the motor control circuit.

D. Primary Voltage: 480 volts, 60 Hz.

E. Secondary Voltage: 120 volts, 60 Hz.

F. Class: AA – Ventilated, Self-Cooled, 60kV BIL

G. Insulation: shall be rated at 220 degrees Celsius.

Revised 41 22 15 - 27

H. Winding Temperature: Rise shall be rated at 150 degrees Celsius above a 40 degree Celsius ambient.

I. Integral fuse block mounted on transformer.

1. Primary Fuses: 600 volt, current-limiting type.

2. Secondary Fuses: 250 volt, current-limiting type.

J. Transformer UL listed. Fuses conform to FU 1 and UL listed.

K. Transformers conform to IEEE C57.13.

L. Provide enclosure designed per Article 2.04, equipped with lifting eyes or brackets.

M. Ground core and coil assembly to enclosure by means of a visible flexible copper grounding strap sized to meet NEMA and UL standards.

N. Coil Conductors: Continuous windings with termination pads brazed or welded.

O. Isolate core and coil from enclosure using vibration absorbing mounts.

P. Nameplate: Include transformer connection data.

Q. Mounting: 75 kVA and less shall be suitable for wall, floor, or trapeze mounting.

R. Provide Electronic Temperature Monitor.

2.12 LIMIT SWITCHES

A. Provide heavy-duty quick-break double-pole double-throw type gear limit switches conforming to NEMA IA 10039.

B. The limit-switch interruption of a motion in one direction shall not prevent the opposite motion.

C. Provide NEMA 250 Type 12 limit switch housings.

D. Provide limit-switches to interrupt power to the control systems.

E. Upper and lower limit switches shall be provided for hoist drive. Rope guided actuated limit switches and proximity switches are not acceptable.

1. Provided a geared control circuit type limit switch.

2. Geared control circuit type limit switch.

F. Provide a secondary upper limit switch.

Revised 41 22 15 - 28

1. Upper limit switch: Block actuated.

2. Removes all power from the hoist drive motor and brake independent of the hoist drive controller.

3. Sets the brakes when the secondary limit is activated.

G. Provide limit switches for trolley and bridge travel.

1. Located on crane structure. Mounted rigidly to protect from misalignment or damage.

2. Slow limit: Activated when bridge or trolley is within 3 feet of end stops.

3. Stop limit: Activated when bridge or trolley contacts either travel stops. Sets the brakes when limit is activated.

4. Provide two one-way lever type limit switches.

2.13 CONTROL STATION

A. Provide a wired pendant pushbutton control station. Pendant cable shall be type SOO with strain relief hardware if suspended.

1. NEMA 250 Type 12 rated.

2. Heavy-duty, oil tight, momentary contact devices.

3. Pushbuttons shall be equipped with a guard to prevent accidental actuation.

4. Provide a pendant cable with a length capable of reaching to 4 feet above the

Warehouse floor.

5. Provide components required to provide control of the hoisting and crane travel.

6. Pushbuttons, switches, indicating lights and joysticks shall be legible and permanently marked.

7. Pushbuttons shall be designed to transmit a distinct notch or step feeling to the operator for each pressure or release action on the hand-controlled speed points.

8. Provide a maintained two-position selector switch for speed selection.

9. The three speeds shall be MICRO and NORMAL.

10. Hoist, Trolley, and Bridge motions shall be controlled with pushbuttons.

11. Provide a pushbutton for HORN.

12. Provide double block contacts:

a. Mechanically interlocked.

b. Spring return operators.

Revised 41 22 15 - 29

13. Provide a switch for powering on and off the crane.

a. Maintained position OFF.

b. Maintained position ON.

c. Spring return to ON from START.

14. Provide Pilot light to indicate that power is on. Pilot light shall be green and labeled POWER ON.

15. Emergency Stop Pushbutton:

a. Removes all power from motion circuits.

b. Push lock reset/push-pull type button.

1) Turn to release emergency stop function.

2) Trigger action latching.

2.14 DELETED.

2.15 POWER CIRCUIT RESISTOR RATINGS

A. Rated for continuous duty.

B. Corrosion resistant metal.

C. Size resistors in accordance with NEMA ICS-8 Table 2-3-1 or 2-3-2, part 11.

D. Rate resistors for applications requiring continuous duty, speed-regulating resistors, in accordance with NEMA ICS-8 Table 2-3-3, part 11.

E. Provide appropriate Class resistors, in accordance with NEMA ICS-8 Table 11-9-2.

1. Resistors for CMAA Class D, E, or F crane shall have a rating not less than Class

160 unless specified.

F. Provide dynamic braking resistor bank rated for contractor-determined back-current generated during braking under full-load conditions.

2.16 RELAYS AND TIMERS

A. General:

1. Relays shall be installed in accordance with manufacturer’s recommended installation.

2. When the output is turned off the relay coil will de-energize.

3. UL listed.

Revised 41 22 15 - 30

4. For applications requiring switching of very low current signals, such as 4-20 mA control loops, relays shall be hermetically sealed and use mercury wetted contacts.

5. All relays with similar functions shall be supplied by the same manufacturer.

B. Provide control, timing and interposing relays as required.

2.17 AUTOMATION CONTROL SYSTEMS

A. Refer to Section 25 00 01 – Automation Control Systems.

2.18 ELECTRIFICATION

A. In accordance of requirements with CMAA 70 Class C, Indoor Service.

B. Runway:

1. Contractor shall provide enclosed, rigid, four bar conductor system, suitable for use with furnished VFDs.

a. Contractor shall design location, size, length, and material of bridge travel conductors, per CMAA 70, Section 41 22 14 – Bridge Crane, operational environment described in Article 1.08, and all other project requirements.

b. Contractor shall provide all brackets, hangers, splice covers, power feeds, expansion gap assemblies and collectors as required by manufacturer.

2. Enclosures:

a. Rigid or flexible self-closing type, grounded, designed to cover all conductors, and shaped to prevent contact with conductors except through bottom collector opening.

3. Collectors:

a. Heavy duty, sliding-shoe, spring-loaded type, compatible with electrification system.

b. Collector arms: Designed to maintain positive collector contact with conductor during small amounts of misalignment caused by bridge movement past the runway beam.

c. Tandem collector heads for each conductor rail.

4. Rating:

a. Voltage: 600 Volts, maximum

b. Voltage drop along the conductors within three percent of the rated voltage.

c. Contractor shall determine the total expected load current.

Revised 41 22 15 - 31

d. Flame rating for all materials: UL 94 V-1.

5. Maximum conductor temperature: 85 degrees Celsius.

6. The maximum continuous length of conductor rails shall not exceed 30 meters without an expansion joint.

7. Rail Connectors: Clamping type connectors with insulated cap.

8. Anchor Clamps: Clamping element type.

9. Hanger Clamps: Freely rotating and height adjustable during thermal expansion.

10. Phase and ground end covers: conductor rail terminator protection against accidental contact.

C. Convenience Features:

1. 120VAC Convenience Outlet:

a. Location: Crane Bridge

b. Rating: 120-Volt, 15 Ampere, 2-Pole, 3-Wire, polarized, GFCI Included

c. Mounted in standalone enclosure with spring-loaded door.

2. 120 VAC Cord Reel:

a. Location: Mounted where accessible below crane

b. Rating: 120-Volt, 20 Ampere, 2-pole, 3-wire, polarized

c. Spring-Loaded, self-retracting cord reel with 50 feet of cord and plug.

2.19 SENSORS

A. Provide Laser sensors for anti-sway and anti-skew systems conforming to IEC 60825-1 with the following minimum characteristics:

1. Laser Angular Measurement Sensor:

a. Supply Voltage: 48 VDC.

b. Range: 40 meters.

c. Usable scanning angle: 180 degrees.

d. Angle resolution scanner: 0.25, 0.5 and 1 degrees.

e. Measuring resolution: 13.6 mm, minimum.

f. Wavelength of laser diode: 905 nm, infrared light.

g. Laser Class: Class I, in accordance with IEC 60825-1.

Revised 41 22 15 - 32

h. Beam divergence: 11.9 mrad.

i. Communication suitable for chosen PLC.

j. Vibration and shock resistant.

2. Laser Distance Sensor:

a. Supply Voltage: 48 VDC

b. Range: 0.05 up to 500m.

c. Measuring Accuracy: Plus or minus 1.0 mm.

d. High measurement speed: 250 Hz, 1000 Hz output rate.

e. Communication suitable for chosen PLC.

f. Analog Output: One programmable.

g. Digital Input: One programmable.

h. Digital Output: Two programmable.

i. Four LED’s for status signaling.

j. Laser Class: Class II, in accordance with IEC 60825-1.

B. Provide additional sensors as required for Obstacle Avoidance/No-Fly Zone capability as described in section 25 00 01 – Automation Control System, Article 2.02.A.5.

2.20 DELETED.

2.21 NAMEPLATES AND LABELS

A. Mark electrical equipment in accordance with corresponding requirements in Division 26 and Standard Drawing 40-D-6234.

2.22 DELETED.

2.23 SPARE PARTS

A. Provide a set of spare parts,…