Amendment 7 Attach 7 Resp to Quest 69 70.pdf

FUZE ENGINEERING COMPLEX Sol. No.

PICATINNY ARSENAL, NJ AMENDMENT JULY 8, 2009

SECTION 41 22 23.26

POWERED HOISTS AND TROLLEY SYSTEM (NEW SECTION)

04/08

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASME INTERNATIONAL (ASME)

ASME B30.11 (2004) Monorails and Underhung Cranes - Safety Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings

ASME B30.16 (2007) Overhead Hoists (Underhung)Safety Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks and Slings

ASME HST-4 (1999; R 2004) Performance Standard for Overhead Electric Wire Rope Hoists

ASTM INTERNATIONAL (ASTM)

ASTM A 1023/A 1023M (2007) Standard Specification for Stranded Carbon Steel Wire Ropes for General Purposes

ASTM A 275/A 275M (2007) Standard Test Method for Magnetic Particle Examination of Steel Forgings

ASTM E 543 (2008a) Standard Practice for Agencies Performing Non-Destructive Testing

ASTM E 709 (2008) Standard Guide for Magnetic Particle Examination

MATERIAL HANDLING INDUSTRY OF AMERICA INC (MHIA)

MHI MH27.1 (2003) Specifications for Underhung Cranes and Monorail Systems

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 (2007) Standard for Motors and Generators

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2007; AMD 1 2008) National Electrical Code - 2008 Edition

SECTION 41 22 23.26 Page 1

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910.179 Overhead and Gantry Cranes

1.2 SYSTEM DESCRIPTION

Provide an electric powered hoist, electric powered trolley with power cable festoon, complete, tested and ready for operation. Hoist, trolley, festoon, equipment, materials, installation, examination, inspection, and workmanship shall conform to the applicable requirements of NFPA 70, ASME B30.11, ASME B30.16,, MHI MH27.1, as modified and supplemented by this specification. Reference in these publications to the "authority having jurisdiction" means the "Contracting Officer."

Hoist system shall be designed for 300 pound point load, minimum.

The composite beam shall be designed and installed by the pre-engineered wood building manufacturer. The electric powered hoist and festoon system shall be compatible with this beam; coordinate size and design load requirements with the pre-engineered wood building manufacturer.

Festoon system shall include an end camp which secures the power cable at the non-moving end, a tow trolley which is moved back and forth by the hoist trolley and a series of intermediate trolleys supporting the cable.

The quantity of intermediate trolleys is determined by two factors; the travel distance and the system and the depth of the cable loops. The trolleys shall roll smoothly in a specially formed "C" shaped track. Loop depth shall not exceed 4 feet.

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Hoist system, including attachments to existing building structure;

G Complete schematic wiring diagram with description of operation; G

SD-03 Product Data

Hoist System Powered Hoists and Trolley System; G Festoon System; G Trolley; G Pendant Pushbutton Station; G Hook Proof Test; G

Manufacturer's descriptive data and technical literature, performance charts and curves, catalog cuts, and installation instructions, and parts list.

SD-05 Design Data

SECTION 41 22 23.26 Page 2

Load Capacity calculations; G

Load and sizing calculations as specified.

SD-06 Test Reports

125% Rated Load test Operational Tests Wire Rope Breaking Strength Hook NDT Report

Tests and inspections reports. Magnetic particle inspection of hook and hook nut results.

SD-07 Certificates

Compliance with all listed Standards Semi-Annual Overload/Safe for Testing

SD-10 Operation and Maintenance Data

Powered Hoists, Trolley, and Festoon System; G

Submit Data Package 3 as specified in Section 01 78 23.00 18

OPERATION AND MAINTENANCE DATA.

1.4 QUALITY ASSURANCE

1.4.1 Certificates: Wire Rope

a. Certification of minimum wire rope breaking strength for each hoist, with traceable identification for each hoist installed. Where applicable, submit factory certification of the wire rope rated capacity.

b. Certification that the hoist, hook, and trolley system contains no hazardous material, asbestos, cadmium, lead, elemental mercury, or PCBs.

c. Semi-Annual Overload/Safe for Testing certification that the hoist, hook, and trolley system is safe to test on a semi-annual overload basis with a test load of 131.25% of rated capacity with no detrimental effects.

d. Certification that testing may be performed in which hoist, hook, and trolley system is subjected to a Loss of Power Test during operation with no detrimental effects.

e. Certification that the hoist, hook, and trolley system design and fabrication is in compliance with all listed standards.

f. Hook Proof Test certification that the hoist hook was subjected to a minimum static load of 200% of rated capacity for at least 10 minutes without deformation.

SECTION 41 22 23.26 Page 3

1.4.2 Pre-Erection Inspection

Before erection, the Contractor shall inspect the composite beam and hoist systems and components at the job site to determine compliance with specifications and manufacturer's data and shop drawings as approved.

Notify the Contracting Officer 5 days before the inspection.

1.5 DELIVERY, STORAGE, AND HANDLING

1.5.1 Delivery and Storage

Inspect materials delivered to site for damage; unload and store with minimum handling. Store materials on-site in enclosures or under protective coverings. Protect materials not suitable for outdoor storage to prevent damage or corrosion during periods of inclement weather, including subfreezing temperatures, precipitation, and high winds. Store materials susceptible to deterioration by direct sunlight under cover and avoid damage due to high temperatures. Do not store materials directly on ground. When special precautions are required, prominently and legibly stencil instructions for such precautions on outside of equipment or its crating.

1.5.2 Handling

Handle materials in such a manner as to ensure delivery to final location in undamaged condition. Make repairs to damaged materials at no cost to Government.

1.6 MAINTENANCE

Submit hoist, trolley and festoon cable system components, Data Package 3 for the entire system in accordance with Section 01 78 23.00 18 OPERATION

AND MAINTENANCE DATA.

PART 2 PRODUCTS

2.1 IDENTIFICATION PLATES

Provide manufacturer installed identification plates of non-corrosive metal showing, in clearly legible permanent lettering, the manufacturer's name, model number, capacity rating in pounds, and other essential information.

Also provide track beam identification plates showing the capacity of the system, in pounds, legible from the floor and from either side of the track beam.

2.2 POWERED HOISTS AND TROLLEY

Provide Powered Hoists and Trolley System, with an overhead electric festoon power cable mounted on a movable trolley. Provide motor operated trolley. The hoist and trolley shall meet the design requirements specified in ASME HST-4, Duty Class H3.

2.2.1 Capacity and Speed

Provide powered hoist and trolley system with a minimum rated capacity of 300 pounds. The hook lift capacity and speed shall be 1/4 ton capacity at 32 feet per minute. The hook lift maximum height limit is 65 feet above the finished floor, and at its lowest point 3 feet below the finished floor.

SECTION 41 22 23.26 Page 4

Trolley motor shall be 1/2 HP, 208 volts, 3-phase, 60 Hz.

Hoist motor shall be 1/2 HP, 208 volts, 3-phase, 60 Hz.

Hoist and trolley unit shall be configured for single point hard wired power connection to festoon system. Festoon system power cable shall be 208V, 3-phase 3-wire, equipment ground 20 ampere.

Application: Provide the following:

a. Travel: Refer to Drawings.

b. Loop Depth: 3 feet 9 inches.

c. Storage Distance: 5 feet 8 inches.

d. Cable Length/Loop: 7 feet 2.60 inches.

e. Active Travel/Loop: 6 feet, .29 inches.

f. Trolley Load: 1.19 lbs.

g. Ambient Temperature: 40 to 110 degrees F.

h. Speed: 150 feet/minute.

i. Acceleration: 1 feet/second.

j. I-Beam Length: Refer to Structural Drawings.

2.2.2 Material and Design Requirements

The powered hoist and trolley system shall include the following design requirements:

a. Powered hoists shall include a brake and a controlled braking means, and an overload limiting device.

b. Directional contactors shall include electrical and mechanical interlocks. Design the mainline contactor, along with the power-off/power-on circuitry to remove power from the drive motors, brakes and control circuit. The control circuit shall not operate unless a power-on button is depressed.

c. Overcurrent protection for the control circuit and control circuit transformer; fuse or circuit breaker protection for branch circuit short circuit and ground fault protection; and overload protection for each motor, motor controller, and branch circuit conductor shall all conform to the NFPA 70.

d. Provide safety (drop) lugs or a functional equivalent on the trolley frame to prevent derailment in the event of wheel failure.

e. The hoist and trolley shall be capable of all weather outdoor (-18 to 38 degrees C 0 to 100 degrees F) working conditions.

f. Provide festoon system operating on 208 volt, 3-phase, 60 Hz power supply.

2.2.3 Safety

Comply with the mandatory and advisory safety requirements of ASME B30.11, ASME B30.16, and 29 CFR 1910.179. The Contractor is responsible for checking the proper operation and condition of safety devices, electrical components, mechanical equipment, and structural assemblies prior to installation. Immediately report any observed defective components and replace. Submit structural and load capacity calculations verifying a

SECTION 41 22 23.26 Page 5 design safety factor of 5.

2.3 ELECTRIC WIRE ROPE HOIST

2.3.1 Hoisting Ropes

Provide the following:

a. Rope lengths sufficient to maintain a minimum of two full wraps of rope at the dead end(s) of the drum, with the block in its lowest indicated position.

b. Hoisting ropes shall conform to ASTM A 1023/A 1023M, improved or extra improved plow steel, regular lay, uncoated, 6 by 37 class construction, with an independent wire rope core. Provide proof of wire rope breaking strength test report.

c. Conform to ASME HST-4, Class H3, except as modified herein. All hoists shall be double reeved.

d. Wedge socket end connections or aluminum swages are not permitted.

2.3.2 Sheaves

Provide steel or ductile cast iron sheaves. Pitch diameter of running sheaves shall not be less than 16 times the rope diameter. Pitch diameter of non running sheaves shall not be less than 12 times the rope diameter.

Contact surfaces of sheaves shall be unpainted.

2.3.3 Drum

Provide steel or ductile cast iron drum. Pitch diameter of the drum shall not be less than 18 times the rope diameter. A minimum of two dead wraps of the hoisting rope shall remain on each anchorage when the hook is in its extreme low position. Contact surfaces of drums shall be unpainted.

2.4 TROLLEY

Provide a powered trolley drive designed to operate on American Standard I-beam or wide flange beams.

2.5 MOTORS

Motors shall conform to NEMA MG 1. All motors shall be minimum 60 minute duty rating. Motor insulation shall be Class H with a Class B temperature rise. Equip all motors with thermal trip type over-temperature protection.

Maximum motor speed shall not exceed 1800 RPM. Provide single speed magnetic control for the hoist and trolley.

2.5.1 Trolley Motors

Trolley drive motor shall be AC totally enclosed non-ventilated (TENV), squirrel cage induction type. Provide reduced voltage starting, acceleration and deceleration for the trolley drive.

2.5.2 Hoist Motors

Provide AC totally enclosed non-ventilated (TENV), squirrel cage induction type hoist motor.

SECTION 41 22 23.26 Page 6

2.5.3 Controls

2.5.3.1 Trolley Electric Drive

Provide static reversing, adjustable frequency controllers.

2.5.3.2 Hoist Electric Drive

Provide a static reversing, adjustable frequency, speed regulated, closed loop flux vector controller with encoder feedback. The hoist drive shall ensure that adequate motor torque is available to suspend the load before the brakes are released. For a hoist with one brake, two independent drive outputs energizing separate brake contactors, whose contacts are in series with the brake coil, are required to release the brake; or an additional separate brake contactor independent of the drive whose contact is in series with the drive controlled brake contactor. For hoists with two brakes, connect the secondary brake to a different output from the primary brake.

2.5.3.3 Electric Drive Speed Control

Each electric drive shall be infinitely variable. Provide speed control of the three step infinitely variable type for the hoist function, and two step infinitely variable type for the trolley function, controlled via pendant pushbuttons.

2.5.3.4 Dynamic Braking

Provide dynamic braking for both hoist and trolley electric drives. The hoist and trolley brakes shall set after the associated controller decelerates motor to a controlled stop. Size the hoist and trolley controllers to provide sufficient starting torque to initiate motion of that drive mechanism from standstill with 0 to 131.25 percent of rated load on the hook and not produce any rollback. The hoist controller shall enable the drive motor to develop full torque continuously at zero speed.

Drive motors shall run smoothly, without torque pulsations at the lowest speed and be energized at a frequency not exceeding 60 HZ for the trolley, and 120 HZ for the hoist drive, with less than full capacity on the hook.

2.6 CONTROLS

Provide control of electric hoist and trolley from a pendant pushbutton station. Arrange pushbuttons in accordance with ASME B30.11 recommendations. Control pendant shall extend 100 feet below the underside of the track beam.

2.7 LIMIT SWITCHES

Equip hoists with adjustable upper and lower limit switches for wire rope or limit stops for chain to prevent over-travel in both the raising and lowering directions. Equip electric wire rope hoist with a secondary upper limit switch, wired independently of the directional contactors and of the primary limit switch, so that activation results in the removal of power from the motor and brake. Use a three position spring return bypass key switch. In one direction the bypass keyswitch shall allow resetting of the secondary upper limit switch prior to resuming operation. During resetting of the secondary limit, the hoist shall operate in the lowering direction only. In the other direction, the keyed bypass switch shall allow

SECTION 41 22 23.26 Page 7 bypassing of the primary upper limit switch to allow the secondary limit switch to be tested on a periodic basis.

2.8 BRAKES

2.8.1 Hoist Load Brake

Provide hoist load brake that is capable of stopping and holding a 131.25% test load. If the hoist has more than one brake, each brake shall independently stop and hold 131.25% of rated capacity.

2.8.2 Trolley Brake

Provide trolley with either a non-coasting worm drive or with an electro mechanical brake that is spring applied, electrically released Trolley brake shall have a torque rating equal to or greater than 50% of the drive motor rated torque and be adjustable from 85% to 100% of its torque rating. Equip trolley brake with a manual release. Design to permit easy access for wear, inspection and setting.

2.9 LOAD BLOCK AND HOOK

Provide safety hook fitted with self-closing, spring loaded steel safety latch, and with hook nuts keyed to hook shanks by means of a setscrew installed in a plane parallel to the longitudinal axis of the hook shank, or by any other similar easily removable securing device. Provide unpainted hook and hook nut, permanently marked with an identification number. Clearly mark the hook and hook nut with a unique identification number corresponding to the number used in non-destructive test (NDT) reports.

2.9.1 Non-Destructive Testing

The following requirements apply:

a. The Hook NDT Report supplier shall provide a letter certifying that the requirements of ASTM E 543 are met.

b. The NDT supplier shall develop, and submit for review, procedures, including technique sheets specific to the types, shapes, and sizes of the parts being examined (e.g., shank hook, eye hook, duplex hook, eye bar nut). For the magnetic particle method, the procedures shall adequately describe the orientation of the hook or nut, or pin with the magnetizing equipment.

c. These procedures shall be reviewed by a Level III examiner who is independent of the NDT supplier and is certified in the applicable NDT method.

2.9.2 Hook and Hook Nut Magnetic Particle Inspections

The hook and hook nut shall be magnetic-particle inspected in compliance with ASTM E 709 over the entire area in accordance with ASTM A 275/A 275M, with the following restrictions: Do not use DC yokes (including switchable AC/DC yokes used in the DC mode) and permanent magnet yokes. Do not use automatic powder blowers or any other form of forced air other than from a hand-held bulb for the application or removal of dry magnetic particles.

Remove arc strikes. Equipment ammeters shall have an accuracy of +/- 5 percent of full scale (equipment ammeter accuracy other than that stated is

SECTION 41 22 23.26 Page 8 acceptable provided the MT procedure states that a magnetic field indicator is used to establish and verify adequate field strength for the aspects of the inspection). The acceptance standard is no linear indications greater than 1/16 inch.

2.10 BEARINGS

All bearings except those subject to a small rocker motion shall be anti-friction type. Provide a means for lubrication for bearings not considered to be lifetime lubricated by the manufacturer.

2.11 ELECTRIFICATION

Provide electrical work for the powered hoist and trolley, and festoon system in accordance with NFPA 70 and Section 26 20 00 INTERIOR

DISTRIBUTION SYSTEM.

2.12 PAINTING SYSTEM

Provide manufacturer's standard painting brilliant yellow of components.

Provide a primer and a finish coat. Blast clean all components prior to painting. Primer shall be inorganic zinc type. Provide epoxy finish coat formulated for marine environments. Paint coats shall be smooth and even, free of runs, sags, orange peel, or other defects.

PART 3 EXECUTION

3.1 INSTALLATION

Install the powered hoist and trolley system, and festoon system, complete in accordance with the approved submittals and in condition to perform the operational and acceptance tests.

3.2 FIELD QUALITY CONTROL

3.2.1 Post-Erection Inspection

After erection, the Contractor, the Contracting Officer, and a representative of the activity maintaining organization, shall jointly inspect the hoist systems and components to determine compliance with specifications and approved submittals. Notify the Contracting Officer days before the inspection. A list of deficient items, including a determination of criticality will be provided to the Contractor for corrective action. Outstanding items shall be noted for correction during the inspection. Items considered critical (load bearing, load controlling, or operational safety devices) shall be corrected prior to further testing.

Upon correction, provide a report of the inspection indicating the system is considered ready for operational tests.

3.2.2 Operational Tests

a. After erection and inspection, test the festoon, hoist and trolley as specified herein. Test the systems in service to determine that each component of the system operates as specified, is properly installed and adjusted, and is free from defects in material, manufacturing, installation, and workmanship. Rectify all deficiencies disclosed by testing and retest the system or component to prove the system is operational.

SECTION 41 22 23.26 Page 9

b. Furnish loads for testing, operating personnel, instruments, and all other necessary apparatus.

c. Furnish test loads, operating personnel, instruments, and other apparatus as necessary to conduct field tests on hoist and trolley, and festoon. Perform test and final adjustments of the equipment under the supervision of the Contracting Officer, and a representative of the activity crane maintaining organization.

3.2.3 Test Data

Record test data on appropriate test record forms suitable for retention for the life of the system. Record operating and startup current measurements for electrical equipment (motors and coils) using appropriate instrumentation (i.e., clamp-on ammeters). Compare recorded values with design specifications or manufacturer's recommended values. Abnormal differences (i.e., greater than 10 percent from manufacturer's or design values) shall be justified or appropriate adjustments performed. In addition, note any high temperatures or abnormal operation of any equipment or machinery , investigate and correct. Record hoist and trolley speeds during each test cycle.

3.2.4 Hook Tram Measurement

Measure hook for hook throat spread before and after load test. Establish a throat dimension base measurement by installing two tram points and measuring the distance between these tram points (plus or minus 1/64 inch ). Record this base dimension. Measure the distance between tram points before and after load test. An increase in the throat opening from the base measurement is cause for rejection.

3.2.5 No-Load Test

a. Hoist: Raise the load hook the full operating lift distance and verify satisfactory operation of hoist, upper limit switches, lower limit switch, and the hoisting and lowering speeds. Operate the hoist at low and high speed in both directions.

b. Trolley: Operate trolley assembly the full length of the beam section in both directions. Operate trolley at low and high speed in each direction. Verify satisfactory operation and verify trolley speed.

3.2.6 125% Rated Load Test

125 Percent (plus 5 percent minus 0) of rated capacity

a. Hoist Static Test: Raise test load approximately one foot above the floor and hold for 10 minutes. Observe load lowering that may occur which indicates malfunction of hoisting component or brake.

Lower the test load to the floor until the hoist line is slack.

b. Hoist Dynamic Test: Raise the test load to approximately 5 feet above the floor. Lower the load back to the floor. Stop the test load at least once while lowering and observe proper brake operation. Wait 5 minutes, then repeat the above cycle.

c. Load Brake Test (if equipped): Raise test load approximately 5 feet.

SECTION 41 22 23.26 Page 10

With the hoist controller in the neutral position, release the holding brake. The load brake must hold the test load. Again with the holding brake in the released position, start the test load down at low speed and return the controller to off position as the test load lowers. The load brake must stop and hold the test load. If the load brake does not stop the test load, but prevents the test load from accelerating, activities will contact the OEM or activity engineering organization to ensure that the load brake is operating as designed.

d. Loss of Power Test: Raise the test load approximately 3 feet and while lowering test load at low speed, cut main power to hoist. The load must stop.

e. Trolley Test: With test load hoisted to a height of one foot above the floor, operate trolley the full distance of the composite beam in both directions. Observe for any malfunctioning of the trolley assembly.

3.2.7 Rated Load Speed Test

With the hoist loaded to rated capacity, raise and lower the load verifying that the hoisting and lowering speeds are provided as specified. With the hoist loaded to rated capacity, operate trolley along the beam verifying that the trolley speed is provided as specified. Further, verify that the trolley stops in each direction within a distance (in feet) equal to 10 percent of rated capacity high speed (in feet per minute) when initially traveling at high speed and carrying the rated capacity load. Record voltage, amperage, hoisting and lowering speeds, and motor speed for each motor.

SECTION 41 22 23.26 Page 11

3.3 FIELD TEST PROCEDURES

3.3.1 Hooks

Record hook serial number. Measure the hook for hook throat spread before load testing. Install two tram points on hook throat. Measure the distance between these tram points (+/- 1/64 inch). Record this base dimension.

Check operation of safety latches.

Load Hook Unique Identification Number _________________

Load Hook Nut Unique Identification Number _________________

Load Hook Throat Measurement - Before Load Testing _________________

Load Hook Safety Latches SAT_____ UNSAT_____ NA_____

3.3.2 Preparing For Load Testing

a.) Select a safe test area and clear all traffic, unauthorized personnel, and equipment from test area. This test area shall be roped off or otherwise secured to prevent entry of unauthorized personnel and equipment.

b.) All rigging used in crane load testing shall conform to applicable OSHA regulations and ASME standards for inspection and testing. Note that test loads INCLUDE the weight of rigging used to connect them to the load block.

3.3.3 Precautions During Load Testing

a.) Observe extreme caution at all times.

b.) Personnel shall remain clear of suspended loads and areas where they could be struck in the event of component failure.

c.) Raise test load only to a height sufficient to perform the test.

3.3.4 Testing

Inspection Codes: SAT = Satisfactory, UNSAT = Unsatisfactory, NA=Not applicable

3.3.4.1 No Load Test

Pendant Control

From the pendant station energize the main line contactor by activating the START button.

a.) Power On SAT_____ UNSAT_____ NA_____

De-energize the crane by activating the E-STOP button.

b.) E-Stop SAT_____ UNSAT_____ NA_____

SECTION 41 22 23.26 Page 12 c.) Power Off SAT_____ UNSAT_____ NA_____

SECTION 41 22 23.26 Page 13

From the pendant controller check all the function of the crane. Verify that the motions match the button labels and the directions of operation are correct.

d.) Main Hoist Up SAT_____ UNSAT_____ NA_____ e.) Main Hoist Down SAT_____ UNSAT_____ NA_____ f.) Trolley North/West SAT_____ UNSAT_____ NA_____ g.) Trolley South/East SAT_____ UNSAT_____ NA_____ h.) Indicator Lights SAT_____ UNSAT_____ NA_____ (Power On, Power Available, etc.)

Motor Controls

Hoist controls shall be tested to verify that sequencing and timing are in accordance with the requirements of the specification.

Record the following: Nameplate: Actual:

a.) Disconnect Switch Voltage __________Volts __________Volts b.) Current (High Speed) Up __________Amps __________Amps c.) Voltage (High Speed) Up __________Volts __________Volts

Note: The current and voltage will be measured at the disconnect switch.

d.) Current (High Speed) Down __________Amps __________Amps e.) Voltage (High Speed) Down __________Volts __________Volts

Note: The current and voltage will be measured at the floor disconnect switch.

Hoist Speeds: Measure hoist speed in FPM at fast speed in each direction.

Actual Required a.) Up (High Speed, No Load) _______ FPM _______ FPM b.) Down (High Speed, No Load)_______ FPM _______ FPM

Measure hoist speed in FPM at slow speed in each direction.

c.) Up (Slow Speed) _______ FPM _______ FPM d.) Down (Slow Speed) _______ FPM _______ FPM

Note: Full speed tolerance is 10%. Rated high speed is 7 fpm with fast speed switch in the OFF position.

Test Trolley Controls to verify that sequencing and timing are in accordance with the requirements of the specification.

SECTION 41 22 23.26 Page 14

Record the following: Nameplate: Actual:

a.) Disconnect Switch Voltage _________Volts _________Volts b.) Current (High Speed) North/East _________Amps _________Amps c.) Voltage (High Speed) North/East _________Volts _________Volts d.) Current (High Speed) South/West _________Amps _________Amps e.) Voltage (High Speed) South/West _________Volts _________Volts

Note: The current and voltage will be measured at the floor disconnect switch.

Measure trolley speed in FPM high speed in each direction.

Actual Required a.) North/East (High Speed) ________ FPM ________ FPM b.) South/West (High Speed) ________ FPM ________ FPM

Measure trolley speed in FPM slow speed in each direction.

c.) North/East (Slow Speed) ________ FPM ________ FPM d.) South/West (Slow Speed) ________ FPM ________ FPM

Note: Full Speed tolerance is 10%.

Bumper Stops: At slow speed, contact the trolley bumpers with the bumper stops. Verify satisfactory performance of the bumpers, and the alignment of the bumpers with stops.

SAT_____ UNSAT_____ NA_____

Limit Switches

Test all limit switches to determine that they function and that all associated functions occur in accordance with specifications.

Hoist Upper Geared Limit Switch (Primary)

Raise the hoist. Slowly raise the hoist into the upper-geared limit switch and verify that the hoist stops after the limit switch is tripped and the hook is only capable of lowering. Ensure that the runout distance at full speed is greater than the distance to the weighted upper limit by gradually increasing hoist control lever travel to achieve full hoist speed and verify that the weighted limit is not tripped when the geared limit is engaged at this "full speed." If the hoist is equipped with a slow down function, verify that the hoist speed decreases to 25% (+/- 10%) of the full rated speed before entering the primary limit switch.

a.) Hoist in slow speed approaching Upper-Geared Limit Switch SAT_____ UNSAT_____ NA_____

SECTION 41 22 23.26 Page 15 b.) Hoist Upper Geared Limit Switch SAT_____ UNSAT_____ NA_____ c.) Hoist can lower only SAT_____ UNSAT_____ NA_____ d.) Hoist slows before primary limit SAT_____ UNSAT_____ NA_____ (if slow down enabled)

Hoist Upper Limit Switch (Secondary)

Using the geared limit switch by-pass key switch, by-pass the hoist upper-geared limit switch and continue slowly raising the hoist. Once the switch is tripped, verify that the hoist motion stops and hoist drive is inoperable.

a.) Hoist in slow speed approaching Upper Limit Switch SAT_____ UNSAT_____ NA_____ b.) Hoist Upper Limit Switch SAT_____ UNSAT_____ NA_____ c.) Hoist drive inoperable SAT_____ UNSAT_____ NA_____

Using the hoist reset key switch, reset the hoist drive and verify that the hoist is only operable in down direction until the upper limit switch is deactivated.

d.) Hoist Up inoperable SAT_____ UNSAT_____ NA_____ e.) Hoist can lower only SAT_____ UNSAT_____ NA_____

Hoist Lower Geared Limit Switch

Lower the hoist. Slowly lower the hook into geared lower limit switch.

When the limit switch is tripped, verify that the hoist motion stops.

Verify hoisting up capability for lower limit switch.

a.) Hoist in slow speed approaching Lower Geared Limit Switch SAT_____ UNSAT_____ NA_____ b.) Hoist Lower Geared Limit Switch SAT_____ UNSAT_____ NA_____ c.) Hoist up capability SAT_____ UNSAT_____ NA_____

3.3.4.2 Hoist Load Testing

50 Percent of Rated Capacity (+5%, -0%) Load Test

Dynamic Load Test.

Record the actual certified weight, including rigging, that will be used:___________Lbs.

1. Place 50% (+5%, -0%) of rated load on the hook.

2. Start at ground level and hoist up to one foot below upper limit using the full range of speeds.

3. Hoist down to one foot above ground level using full range of

SECTION 41 22 23.26 Page 16 speeds.

4. Measure and record the motor current, voltage, and hook speed in FPM at maximum speed in both directions.

Record the following: Nameplate: Actual:

a.) Current (High Speed) Up _________Amps _________Amps b.) Voltage (High Speed) Up _________Volts _________Volts c.) Current (High Speed) Down _________Amps _________Amps d.) Voltage (High Speed) Down _________Volts _________Volts

Note: The current and voltage will be measured at the floor disconnect switch.

Measure hoist speed in FPM at fast speed in each direction.

Hoist Actual Required a.) Up (High Speed) ________ FPM ________ FPM b.) Down (High Speed) ________ FPM ________ FPM

Measure hoist speed in FPM at slow speed in each direction.

a.) Up (Slow Speed) ________ FPM ________ FPM b.) Down (Slow Speed) ________ FPM ________ FPM

Note: Speed tolerance is 10%

SECTION 41 22 23.26 Page 17

3.3.4.3 100 Percent of Rated Capacity (+0%, -5%) Load Test

A. Dynamic Load Test.

Record the actual weight of the certified weight, including rigging gear that will be used:_______ Lbs.

1. Trolley loss of power test

Raise the test load approximately midway between the trolley and any permanent obstructions on the operating floor. Starting at a safe distance from walls or other obstructions, attain a slow speed of trolley travel.

While maintaining a safe distance from obstructions, disconnect the main power source to simulate a power failure. Restart trolley travel and allow the drive to reach an intermediate speed. Repeat the simulated power failure. Restart trolley travel and allow the drive to reach maximum operating speed. Repeat the simulated power failure. Verify that the trolley stops and that the brake sets properly at all speeds.

SAT_____ UNSAT_____ NA_____

2. Hoist loss of power test at rated load

Raise the test load a minimal distance. Lower the test load at slow speed. Disconnect the main power source and return the controller to the neutral position to simulate a power failure. Restart hoist in a downward direction and allow the drive to reach an intermediate speed. Repeat the simulated power failure. Restart hoist in a downward direction and allow the drive to reach maximum operating speed. Repeat the simulated power failure. Verify that the hoist stops and that the brake sets properly to bring the test load to a stop at all speeds.

SAT_____ UNSAT_____ NA_____

3. Hoist Maximum Speed Test at rated load

Measure and record the motor current, voltage, and hook speed in FPM at maximum speed in both directions. Stop the load during hoisting and lowering to verify that brake stops and holds the load.

Record the following: Nameplate: Actual:

a.) Current (High Speed) Up _________Amps _________Amps b.) Voltage (High Speed) Up _________Volts _________Volts c.) Current (High Speed) Down _________Amps _________Amps d.) Voltage (High Speed) Down _________Volts _________Volts

Note: The current and voltage will be measured at the floor disconnect switch.

SECTION 41 22 23.26 Page 18

Measure hoist speed in FPM at fast speed in each direction.

Hoist Actual Required a.) Up (High Speed) ________ FPM ________ FPM b.) Down (High Speed) ________ FPM ________ FPM

Measure hoist speed in FPM at slow speed in each direction.

a.) Up (Slow Speed) ________ FPM ________ FPM b.) Down (Slow Speed) ________ FPM ________ FPM

Note: Speed tolerance is 10%

5. Rollback Check

Check rollback. With the load approximately 2 feet above the ground, engage the hoist up controller to the slowest hoist position. Verify that the motor turns in raise direction only.

SAT_____ UNSAT_____ NA_____

B. Trolley Functionality Test.

1a.) Operate the trolley the full distance of the runway in both directions. Verify that the brake operates properly. Measure and record the distance required to come to a full stop from rated speed.

_________________Stopping distance

SECTION 41 22 23.26 Page 19

1b.) Measure and record the motor current, voltage, and hook speed in FPM at maximum speed in both directions.

Record the following: Nameplate: Actual:

a.) Current (High Speed) North/East _________Amps _________Amps b.) Voltage (High Speed) North/East _________Volts _________Volts c.) Current (High Speed) South/West _________Amps _________Amps d.) Voltage (High Speed) South/West _________Volts _________Volts

Note: The current and voltage will be measured at the floor disconnect switch.

Measure Trolley speed in FPM high speed in each direction.

a.) North/East (High Speed) ________ FPM ________ FPM b.) South/West (High Speed) ________ FPM ________ FPM

Measure trolley speed in FPM at slow speed in each direction.

c.) North/East (Slow Speed) ________ FPM ________ FPM d.) South/West (Slow Speed) ________ FPM ________ FPM

Note: Speed tolerance is 10%

3.3.4.4 125 Percent of Rated Capacity (+5%, -0%) Load Test

A. Dynamic Load Test

Record the actual weight of the certified weight, including rigging, that will be used: _________ Lbs.

1. Control and Brake Stop Test

Place 125% (+5%, -0%) of rated load on the hook. Raise and lower test load on each controller point and visually observe smooth control between points. Stop the load during hoisting and lowering to verify that the brake stops and holds the load.

SAT_____ UNSAT_____ NA_____

SECTION 41 22 23.26 Page 20

2. Hoist loss of power test

Raise the test load a minimal distance. Lower the test load at slow speed. Disconnect the main power source and return the controller to the neutral position to simulate a power failure. Verify that the hoist stops and that the brake sets properly to bring the test load to a stop.

NOTE: This test is designed to also verify proper operation of dynamic load brakes including eddy current brakes and regenerative braking.

SAT_____ UNSAT_____ NA_____

B. Hoist Brake(s) Test

Raise the test load approximately 1 foot and hold for 10 minutes. If more than one brake on the hoist, manually open the secondary brake during the primary brake test. Rotate load and hook to check for smooth bearing operation. Observe for noticeable lowering of test load that may occur which will indicate the malfunction of hoisting components or brakes. If more than one brake on the hoist, close the secondary brake and manually open the primary brake. Repeat the 10 minute test.

SAT_____ UNSAT_____ NA_____

C. Trolley Test

Operate the trolley the full distance of the bridge in both directions (if clear trolley space is available). Verify smooth control and proper brake operation.

SAT_____ UNSAT_____ NA_____

Comments:

-- End of Section --

SECTION 41 22 23.26 Page 21