SPECIFICATIONS.pdf

Specifications Circuit Breaker Test Set

JML DOC 1214-6437

1. SCOPE

1.1. Scope. The purchase description set forth below describes the minimum requirements of the Government for a Circuit Breaker Test Set. It is the Government’s intent that a single primary contractor be awarded this contract and be responsible for the provision of equipment, and the accomplishment of all work detailed by this specification.

2. REQUIREMENTS

2.1. Design. The item offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

2.2. Construction. The Circuit Breaker Test Set shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the Circuit Breaker Test Set to its maximum rating and capacity without distortion.

2.2.1. Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

2.2.2. Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

2.2.3. Corrosion Control. All system components shall be protected against corrosion and deterioration by appropriate material selection, application of coatings and sealants. The system and its parts shall be painted on all sides, prior to assembly, except mating surfaces such as mounting flanges and motor shafts. Painting shall result in a highly wear-resistant finish, which guarantees continued protection to the surfaces covered against the specified environment under all service conditions. Exposed ferrous parts such as screws, bolts, nuts, washers shall be treated to resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as cadmium or chrome plating, galvanizing or other electrical/chemical process, or stainless steel is acceptable. Stainless steel parts shall be passivated. Aluminum parts shall be anodized or chemically treated followed by two coats of weather-resistant exterior paint. Dissimilar metals shall not be used in direct contact with each other without suitable means for preventing electrolytic corrosion. All paint shall be lead and chromate free.

2.2.4. Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, or filling with solder or paste shall be used for reclaiming any defective part.

2.2.5. Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

2.2.6. Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's work station(s). An emergency stop button shall be installed and accessible to the operator. When depressed, the emergency stop button shall eliminate energy to the system.

2.2.7. OSHA Compliance. The equipment component parts shall be in compliance with 29 CFR 1910, NFPA 70 and NFPA 79. Approval shall be as specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart “O”, Machinery and Machine Guarding paragraph 1910.212 and Subpart “S” Electrical, paragraph 1910.303 and paragraph 1910.399.

2.2.8. Safety Signs and Labels. Safety signs and labels in accordance with NEMA Z535.4 shall be securely attached to the equipment in visible locations, at the point of hazard(s), with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the signs.

2.2.9. Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11.

The safety devices shall not interfere with the operation of the Circuit Breaker Test Set. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

2.2.10. Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment.

Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

2.2.11. Interchangeability. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts. Foreign-sourced replacement parts shall be interchangeable with domestically supplied components or be readily available from a domestic source.

2.2.12. Measuring and Indicating Device Graduations. All measuring and indicating devices on the Circuit Breaker Test Set shall be graduated in the inch/pound or both inch/pound and metric.

2.2.13. Calibration. The Circuit Breaker Test Set shall be registered in the Navy’s METRL (Metrology Requirements List) database in accordance with PSNS&IMF P4734.1F (Metrology and Calibration Program Manual, Chapter 14), to ensure calibration test procedures have been identified and authorized by the Department of the Navy. The Circuit Breaker Test Set shall be calibrated per OEM requirements. The calibration certificate shall be provided to the Government.

2.3. Components. The Circuit Breaker Test Set shall consist of not less than the following components.

2.3.1. Electrical System. The machine shall conform to NFPA 79. The existing electrical power source available at the installation site is 480 VAC, 1 Phase, 60 Hz. The machine’s electrical system shall be tolerant of voltage fluctuation of ± 10 percent. The electrical system shall be complete, including transformers required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device, controlling all electrical power to the equipment, shall be utilized on the machine with means of lockout in the off position only.

2.3.1.1. Motors. Motors shall be rated for continuous duty and shall have ball or roller bearings of the sealed and permanently lubricated type. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors 1 HP and above shall meet the requirements of NEMA MG 1.

Each motor shall have an identification plate to identify manufacturer, model identification, serial number, voltage, amperage, horsepower, phase, frequency and frame number written in the English language. Servo motors are exempt from these requirements. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s), unless otherwise specified herein.

2.3.1.2. Solid-State Components. Solid-state design shall be employed throughout for electronic components. Use of selenium and other similar aging devices shall be permitted only in the application of voltage surge protection to other solid-state components. Solid-state components shall not be adversely affected when subjected to power line transients and surges typically experienced in industrial environments. Series and parallel connections of solid-state devices without forced sharing circuitry for voltage and current, respectively, is not permitted. Solid-state devices shall be capable of handling the electrical load imposed by operation of the machine to its maximum capability.

2.3.1.3. Electrical Enclosures. Electrical components of the equipment shall be contained in enclosures of drip-proof construction and of minimum size consistent with good design practices and ventilation of components, meeting the requirements of NEMA Type 12.

2.3.1.4. Cable and Hose Carriers. All flexible power lines, cables, conduits, and hoses necessary to connect the linear sliding, powered, assemblies to stationary utilities and controls shall be contained within a flexible cable and hose carrier arrangement. Conductors located on the cable and hose carrier shall be adequately cradled or secured at regular intervals and in an orderly manner. Cable and hose carrier design shall ensure that flexible conductors are not stretched, crimped, pinched, or scraped over the full travel of the track. A guide arrangement shall be provided to insure straight motion of the track, parallel to slide motion, without twist or binding. Each cable and hose carrier shall be located in a position that will allow access and egress to the operator and control panel without interference as well as afford the best possible protection of the conductors. All conductors shall be of sufficient length to allow full travel of connected components and shall be connected at both ends to junction boxes and manifolds in proximity to the track ends to facilitate replacement of conductors. All conductors shall be labeled at both ends. Installation of the cable and hose carrier s in the overhead position is not allowed.

2.3.2. Energy Isolating Devices. The equipment shall be provided with energy isolation devices (e.g. power switches, safety devices, circuit breakers, valves) that protect personnel from the release of hazardous energy and are integral to the component being isolated and locked out. The devices shall be designed and manufactured such that they can be padlocked in the OFF position. This includes both mechanical and electrical devices. An energy isolation device shall be installed as the first energy control device on all major components of the system such that the component can be isolated at the component level.

2.4. Facility Electrical Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

2.5. Size, Capacity, Accuracy. The size, capacity, and accuracy of the Circuit Breaker Test Set shall be not less than specified in Table I., Table II., and Table III.

Table I. Size / Capacity Max Allowable Installation Space (H,W,D) Height: 45 in. / Width: 48 in. / Depth: 28 in.

Max Weight 1,300 LBS Input Supply 480 VAC, 1 PH, 60 Hz Output Current See Table II (below)

Table II. Output Current 9V

(parallel) 18V

(series) Over-load Duty Max ON time

Min OFF time

6,000 A 3,000 A 1x 100% continuous N/A 8,400 A 4,200 A 1.4x 50% 15 min. 15 min.

12,000 A 6,000 A 2x 25% 5 min. 15 min.

18,000 A 9,000 A 3x 10% 1.5 min. 15 min.

24,000 A 12,000 A 4x 6% 45 sec. 15 min.

30,000 A 15,000 A 5x 4% 4 sec. 2 min.

42,000 A 21,000 A 7x 2% 2 sec. 2 min.

60,000 A 30,000 A 10x 1% 1 sec. 2 min.

Table III. Range / Accuracy Current Ranges 0-1,000 A / 5,000 A / 25,000 A / 100,000 A

Current Accuracy +/- 0.5% of reading + 0.5% (continuous) +/- 1% of reading + 1% full scale (pulse)

Timer Ranges 0-9999.999 sec.

0-9999.9 cycles

Timer Accuracy +/- 0.5% of reading +/- 1 count Digital Voltmeter Input Range 0-600 VAC

Digital Voltmeter Input Accuracy 1% of full scale

2.6. Standard Equipment. All standard equipment required for proper operation of the Circuit Breaker Test Set (such as special tools) shall be furnished.

2.7. Marking on Instruments, Control Panels, and Plates. All words on instruments, control panels, and plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

2.7.1. PCB Label Plate. A label plate containing the PCB Certification information shall be permanently and securely attached in the vicinity of the manufacturer’s identification plate.

2.7.2. Nameplate. A nameplate shall be permanently and securely attached to each machine.

The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

Nomenclature Manufacturer's name Manufacturer's model designation Manufacturer's serial number Power input (volts, total amps, phase, and frequency) Contract Number or Order Number Date of manufacture

2.8. Operating and Maintenance (O&M) Manuals. Three (3) hard copies and one (1) electronic copy(s) of the O&M Manuals shall be provided with the machine. O&M manuals shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language. Technical Data shall contain at a minimum:

a. Data shall enable an average journeyman mechanic to operate, program, maintain, and repair the equipment.

b. Complete instructions and information for all equipment, components, assemblies, subassemblies, attachments, and accessories.

c. Operating instructions including programming requirements, pre-operational checks, start up, shut down and emergency shutdown procedures.

d. Maintenance and service instructions, including all preventive maintenance schedules, and lubrication charts.

e. Trouble-shooting guides.

f. Parts list containing: illustrations, part numbers, part nomenclature, original manufacturer, cross reference numbers, and recommended spare parts, including quantities.

g. Energy control procedure, in accordance with 29 CFR 1910.147, to bring equipment to a zero energy state for maintenance.

h. All mechanical and electrical schematics with a table of contents showing discrete components, block diagrams, wiring diagrams with inputs and outputs identified, system electrical interface documents, and drawings for the specific model of all machine equipment/drives/controls supplied.

i. All final “as-built” contract drawings shall be provided on CD or DVD disc(s). The format of the drawing files shall be in AutoCAD version 2010 or older. Files shall have DWG or DXF extensions.

j. Safety Data Sheets (GHS-SDS format) for all hazmat required to operate the machine per OEM specifications.

2.9. PCB Certification. Written certification from the manufacturer that the equipment contains no detectable PCBs (less than two (2) parts-per-million) shall be provided. The certification shall be on manufacturer’s letterhead, and signed by a company official who is empowered to provide same. A PCB label plate stating the PCB compliance certification shall be supplied and attached to the equipment.

2.10. Warranty. Supplies and services furnished shall be covered by warranty from defects in design, materials and workmanship. The warranty shall be the manufacturer’s standard commercial warranty which shall conform to all the requirements of the contract. Acceptance of the manufacturer’s standard commercial warranty shall not minimize the rights of the Government under clauses in the contract, and in any conflict that arises between the terms and conditions of the contract and manufacturer’s warranty, the terms and conditions of the contract shall take precedence. The warranty period shall commence when final acceptance has been achieved as determined when all contract line item numbers have been processed.

2.11. Workmanship. Workmanship of the Circuit Breaker Test Set shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

2.3.2. Energy Isolating Devices. The equipment shall be provided with energy isolation devices (e.g. power switches, safety devices, circuit breakers, valves) that protect personnel from the release of hazardous energy and are integral to the compone...