ITEM 599.061801ER MOVABLE BRIDGE CONTROL ......ANSI/NETA ATS - Acceptance Testing Specifications for...

ITEM 599.061801ER – MOVABLE BRIDGE CONTROL SYSTEM

Erie County of 82 01/31/2020

DESCRIPTION

1.01 GENERAL REQUIREMENT

A. This section includes general requirements for supply, delivery, storage, installation,

testing and commissioning of the Control System required under the scope of the contract.

B. Provide supervision, labor, and assistance to manufacturer’s field representative and/or

technical directors for equipment to be installed as a part of this Contract.

C. The Contractor shall provide service of qualified system integration company to develop

and produce substantially completed electrical installation shop drawings as integrated

system for Engineer’s review and approval. The substantially completed installation shop

drawings shall be developed based on the final shop drawings of the actual equipment

procured. The substantially completed installation shop drawings shall include

layout/assembly/installation drawings of equipment, components terminal boxes and

terminations drawings, schematic diagrams, point-to-point interconnection wirings with

cable tags and termination identification for field installation. The Contractor shall

coordinate all activities required to produce the substantially completed installation shop

drawings.

D. The design drawings of the control system are intended to convey functional and

performance requirements of the movable bridge control system. The design drawings of

the control system does not show all of the required components and circuit wiring

interconnections required to provide a complete and fully function bridge control system.

The contractor shall provide a fully integrated, complete automation control system, fully

programmed (in terms of automation, control logic, operator interface, alarm and events

logging) and ready for proper operation of the movable bridge. The supply shall be

complete and shall include all equipment and components, system interconnections,

configuration and software programming necessary to guarantee the proper control of the

movable bridge from operator control panel and/or HMI.

E. The control system equipment and components selection, system configuration, control

panel(s) design, electrical shop drawings and schematic diagrams, control system

programming (in terms of automation, control logic, operator interface, alarm and events

logging) and integration shall be performed by the Control System VENDOR’s

application engineer(s) to meet all of the system performance requirements.

F. The requirements of other related Special Specification sections shall also apply for

installation and coordination of work.

1.02 PERFORMANCE REQUIREMENTS

A. The control system shall be designed, configured, and programmed to perform the

functions as described and illustrated in the design drawings and in the Special

Specifications.



B. The control system shall provide be provided with the following redundancy:

1. The control system shall have a redundant controllers and associated programs.

Failure of one controller shall not render the bridge inoperative. Redundant I/O are

not required.

2. The controller shall have redundant power supply.

3. The bridge span leaves can be control from the HMI screens located on the operator

control console in each of the tower. The HMI control screens shall be programmed

and configured the same way.

4. The control system I/O’s shall be segregated for each set of drive-motor such that the

loss of any I/O module shall not render more than one set of drive-motor to be

inoperative. The control system shall allow selection of an alternate set of drive-motor

and be able to operate the bridge.

C. The requirements contained in other sections of the Special Specifications shall also apply

for installation and coordination of work.

1.03 REFERENCES

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

National Electrical Codes. The design and engineering of the electrical installation shall

satisfy all statutory requirements of the national and/or local authorities of the country in

which the electrical installation will be located. The electrical installation shall be suitable

for the site conditions as specified. Where necessary, special attention shall be paid to the

selection and installation of electrical equipment suitable for seismic conditions. Where

relevant, the specific publications are referenced herein.

B. The following documents form part of the Special Specification to the extent stated.

Where differences exist between codes and standards, the one affording the greatest

protection shall apply. Unless otherwise noted, the referenced standard edition is the

current one at the time of commencement of the work:

1. Occupational Safety and Health Administration – OSHA

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

3. National Fire Protection Association – NFPA

ANSI/NFPA 70 - National Electrical Code

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

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

ANSI/NFPA 99 - Standard for Healthcare Facilities



ANSI/NFPA 101 - Life Safety Code

ANSI/NFPA 110 - Emergency and Standby Power Systems

ANSI/NFPA 780 - Installation of Lightning Protection Systems

4. Institute of Electrical and Electronic Engineers – IEEE

ANSI/IEEE C2 - National Electrical Safety Code

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

Rotating Machinery

ANSI/IEEE 48 - IEEE Standard Test Procedures and Requirements for Alternating-

Current Cable Terminations 2.5 kV through 765 kV

IEEE 81 - IEEE Guide for Measuring Earth Resistivity, Ground Impedance, and Earth

Surface Potentials of a Ground System Part I: Normal Measurements

IEEE 100 - The Authoritative Dictionary of IEEE Standards Terms

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

Power Cable Systems

IEEE 519 - IEEE Recommended Practice and Requirements for Harmonic Control in

Electric Power Systems

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

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

Amendment 1

ANSI/IEEE C37.90.1: Standard Surge Withstand Capability (SWC) Tests for

Protection Relay Systems.

ANSI/IEEE C37.90.2: Trial Use Standard Withstand Capability of Relay Systems to

Radiated Electromagnetic Interference from Trans-receivers.

5. International Electrical Testing Association – NETA

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

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

and Systems

6. National Electrical Manufacturers Association – NEMA



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

Circuit Breakers Used in Commercial and Industrial Applications

ANSI/NEMA C84.1 - Electrical Power Systems and Equipment Voltage Ratings (60

Hz) NEMA MG1 - Motors and Generators

AB-1: Molded Case Circuit Breakers

ICS-1: General Standards for Industrial Control and Systems

ICS-2: Standards for Industrial Control Devices, Controllers and Assemblies

ICS-4: Terminal Blocks for Industrial Use

ICS-6: Enclosures for Industrial Controls and Systems

7. International Society of Automation (ISA):

1. ANSI/ISA-50.00.01: Compatibility of Analog Signals for Electronic Industrial

Process Instruments

2. ANSI/ISA-51.1: Process Instrumentation Terminology

3. ANSI/ISA -18.2 – Management of Alarm Systems for the process Industries

(Article 11 – HMI Design for Alarm Systems)

8. International Electrotechnical Commission (IEC)

1. IEC 61131 Program languages for PLC based systems

2. IEC 61508 Functional Safety of Electrical/Electronic/Programmable Electronic

Safety-related Systems

3. IEC 61000 series Electro Magnetic Compatibility (EMC)

1.04 SUBMITTALS

A. Shop Drawings:

1. The Contractor shall submit copies of vendor, producer or manufacturer data for

materials, devices and subsystems or standard or proprietary products. These shall

include design and installation shop drawings, catalog cuts, specifications, testing

requirements, and installation instructions for the following items, but not excluding

other items or materials not specifically mentioned herein. Product Data:

a. Bridge Operator’s Control Console



b. Bridge Machinery Control Panel

c. Adjustable Speed Drives

d. Motor Starter/Controller

e. Span Drive Motor

f. Motorized Brakes

g. Limit Switches

h. Inclinometers

i. Resolvers

j. Absolute Encoders

k. Over-speed Switches

l. Uninterruptible Power Supply (UPS)

m. Schematic wiring diagrams

n. Package control system architecture

o. Bill of material

p. General arrangement drawings

q. Wiring Diagram: cross wiring diagrams from field terminal strip to intrinsically

safe barrier (if applicable), terminals etc. (drawings and database format - Excel)

r. System cable schedule(s) including cable number, number of wire, wire size, etc.

s. Input/Output (I/O) list (with indication of range, unit, alarm and safety thresholds)

t. Functional description all the equipment included in the package

u. Product specifications of all control equipment included in the package

v. Control logic diagrams (open and closed control loops, automatic sequences,

functional groups, interlocks) covering all the equipment included in the package

w. Control graphic displays for the HMI

x. Recommend Spare Parts

2. A number of electrical equipment items specified as part of the electrical work are to

be provided to others for mechanical installation, followed by electrical installation

under the herein specified electrical work. The dimensions of these items are critical

for their installation and integration into the bridge mechanical machinery system.

Their dimensions are indicated on the mechanical Contract Drawings and have been

obtained from information provided by various equipment manufacturers. The

dimensions have not been obtained from manufacturer’s certified drawings (certified

drawings are drawings certified by the manufacturer to be dimensionally accurate and

which contain sufficient detail to determine if the requirements of the Contract

Documents have been satisfied). The Contractor shall, as part of its procurement

process, obtain certified drawings for these items from the manufacturers and provide

them to others responsible for the mechanical work in the preparation of the Shop and



Erection Drawings for the bridge machinery. The certified drawings shall be submitted

in support of the developed Shop Drawings. The Contractor shall notify the Engineer

of any dimension of any specified item that deviates from the Contract Drawings. These

items shall consist of the following:

a. Adjustable Speed Drives

b. Resolvers and Encoders

c. Inclinometers

d. Over Speed Switches

e. Limit switches

3. Complete bills of materials, assembly and installation drawings shall be furnished.

These drawings shall clearly indicate weights of equipment, how the work is to be

performed in the field including foundation requirements, equipment clearances

required for operation and maintenance access and as required by applicable codes.

4. Assembly and installation drawings shall be given identifying marks and essential

dimensions for locating each piece of equipment or assembled unit with respect to the

bridge and its required equipment foundation. Each unit shall be cross-referenced to

the Shop Drawing on which it is detailed or indicated in physical and functional terms.

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

6. Customer connection and power wiring diagrams.

7. Interconnection diagrams between equipment assemblies, and external interfaces,

including power and signal conductors. Include for enclosures and external devices.

8. The ASD certification of compliance to IEEE 519 B harmonic analysis for particular

jobsite including total harmonic voltage distortion and total harmonic current distortion

(TDD). The ASD manufacturer shall provide calculations; specific to this installation,

showing total harmonic voltage distortion is less than 5%. Input line filters shall be

sized and provided as required by the ASD manufacturer to ensure compliance with

IEEE standard 519.

9. Schedule of equipment supplied. Schedule shall provide a cross reference between

manufacturer data and identifiers indicated in shop drawings. For complete assemblies,

such as ASD's, provide the serial numbers of each assembly, and a sub-schedule of

components within the assembly. Show circuits and device elements for each

replaceable module.

10. Installation drawings with adjustable speed drives and motors indicated. Indicate

ventilation requirements, adequate clearances, and cable routes.

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

12. Installation instructions issued by the manufacturer of the equipment, including notes

and recommendations, prior to shipment to the site. Provide operation instructions prior

to acceptance testing.



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

test.

14. Startup and Commissioning Plan and Report:

a. Provide Startup and Commissioning Plan

b. Provide Factory Acceptance Test

c. Provide Electrical Construction Field Testing and Commissioning Report

d. Manufacturer's Field Reports: Submit to Departmental Representative

manufacturer's written report, within 3 days of review, verifying compliance of

Work and electrical system and electrical power and control testing.

15. Factory Acceptance Test (FAT) Procedures

16. Site Acceptance Test (SAT) procedures

17. Test Report

18. Certificates

19. Project Software with backup copy

20. Closeout Submittals Warranty

21. Sustainable Design Submittals:

a. Construction Waste Management: Submit project Waste Management Plan

highlighting recycling and salvage requirements.

b. Recycled Content: Submit listing of recycled content products used, including

details of required percentages or recycled content materials and products, showing

their costs and percentages of post-industrial content, and total cost of materials for

project.

1.05 CLOSEOUT SUBMITTALS

A. Operation and Maintenance Data: submit operation and maintenance data for electrical

equipment and installations for incorporation into manual.

1. Submit Operation and Maintenance (O&M) Data for the provided equipment, product,

or system, defining the importance of system interactions, troubleshooting, and long-

term preventive operation and maintenance. Compile, prepare, and aggregate O&M

data to include clarifying and updating the original sequences of operation to as-built

conditions. Organize and present information in sufficient detail to clearly explain

O&M requirements at the system, equipment, component, and subassembly level.

Documents must be fully legible. Operation and Maintenance data must be consistent

with the manufacturer's standard brochures, schematics, printed instructions, general

operating procedures, and safety precautions. Include an index preceding each O&M

section.



2. The Contractor shall provide Operation and Maintenance Manuals to be contained in

one or more volumes. The Engineer will review preliminary copies of the O&M

Manuals and the Contractor will incorporate the changes made into the final manual.

Provide for each system and principal item of equipment as specified in technical

sections for use by operation and maintenance personnel.

3. Type of Information Required

a. Operating Instructions - Provide specific instructions, procedures, and illustrations

for the following phases of operation for the installed model and features of each

system.

b. Full as-built sequence of operations for the bridge operation.

c. Safety Precautions and Hazards - List personnel hazards and equipment or product

safety precautions for operating conditions. Provide recommended safeguards for

each identified hazard.

d. Operator Prestart - Provide procedures required to install, set up, and prepare each

system for use.

e. Startup, Shutdown, and Post-Shutdown Procedures - Provide narrative description

for Startup, Shutdown and Post-shutdown operating procedures including the

control sequence for each procedure.

f. Normal Operations - Provide Control Diagrams with data to explain operation and

control of systems and specific equipment. Provide narrative description of

Normal Operating Procedures.

g. Emergency Operations - Provide Emergency Procedures for equipment

malfunctions to permit a short period of continued operation or to shut down the

equipment to prevent further damage to systems and equipment. Provide

Emergency Shutdown Instructions for fire, explosion, spills, or other foreseeable

contingencies.

h. Operator Service Requirements - Provide instructions for services to be performed

by the operator and/or maintenance personnel such as lubrication, adjustment,

inspection, and recording gauge readings.

i. Environmental Conditions - Provide a list of Environmental Conditions

(temperature, humidity, and other relevant data) that are best suited for the

operation of each product, component or system. Describe conditions under which

the item equipment should not be allowed to run.

j. Operating Log - Provide forms, sample logs, and instructions for maintaining

necessary operating records.

k. Full as-built print out of software program.

l. Preventive Maintenance Plan, Schedule, and Procedures Provide manufacturer's

schedule for routine preventive maintenance, inspections, condition monitoring

(predictive tests) and adjustments required to ensure proper and economical

operation and to minimize repairs. Provide instructions stating when the systems

should be retested. Provide manufacturer's projection of preventive maintenance

work-hours on a daily, weekly, monthly, and annual basis including craft

requirements by type of craft. For periodic calibrations, provide manufacturer's

specified frequency and procedures for each separate operation.



m. Troubleshooting Guides and Diagnostic Techniques -Provide step-by-step

procedures to promptly isolate the cause of typical malfunctions. Describe clearly

why the checkout is performed and what conditions are to be sought. Identify tests

or inspections and test equipment required to determine whether parts and

equipment may be reused or require replacement.

n. Wiring diagrams and control diagrams - Provide point-to-point drawings of wiring

and control circuits including factory-field interfaces. Provide a complete and

accurate depiction of the actual job specific wiring and control work. On the

diagrams, the cables and the terminals identifications shall be identically to actual

installation configuration and numbering.

o. Spare Parts and Supply Lists -Provide lists of spare parts and supplies required for

repair to ensure continued service or operation without unreasonable delays.

Special consideration is required for facilities at remote locations. List spare parts

and supplies that have a long lead-time to obtain.

p. Warranty information.

B. Final “As-Built” Drawings shall be submitted for review and approval at the completion

of the project. Any field modification during construction and/or deviations from the

approved Shop Drawings shall be clearly indicated. Reproducible drawings shall be made

on sheets using the Project standard title block. These drawings shall be stamped "As

Built", immediately above the title block.

C. Print or engrave operating instructions and frame under glass or in approved laminated

plastic. Post instructions where directed. For operating instructions exposed to weather,

provide weather-resistant materials or weatherproof enclosures. Ensure operating

instructions will not fade when exposed to sunlight and are secured to prevent easy

removal or peeling.

1.06 EXTRA STOCK MATERIALS

A. Provide the following spare parts:

1. One (1) indicating light unit for each type and color used.

2. Two (2) indicating light colored caps for each type and color used.

3. Twelve (12) indicating light unit lamps for each type used.

4. One (1) circuit breaker for each size and type used. One (1) complete overload relay

for each size and type used.

5. Two (2) pushbutton contact blocks for each size and type used.

6. Two (2)-selector switch contact blocks for each size and type used.

7. Two (2)-control relays of each size and type used.

8. One (1) PLC processor module.

9. One (1) PLC I/O module of each type used.



10. One (1) PLC Power supply modules.

11. One (1) ethernet radio.

1.07 QUALITY ASSURANCE

A. Regulatory requirements: Perform electrical construction in accordance with industry

acceptable practice and complies with applicable country, region and local codes.

B. Equipment and components shall be listed and labeled by Underwriter’s Laboratories

(UL) or other nationally recognized testing laboratory. Equipment shall comply with all

applicable (IEEE) standards. Components for use in hazardous locations shall be UL-

listed or Factory Mutual (FM)-approved for the hazardous classification, division, and

group.

C. Manufacturer of equipment specified shall be recognized in industry for normally

supplying this type of equipment. Manufacturer shall be ISO certified.

D. The adjustable speed drive (ASD) shall be manufactured by a company with at least

twenty (20) years of experience in the production of this type of equipment. The ASD

manufacturing facility shall be ISO 9001 and ISO 14001 certified.

E. Contractor shall develop detailed, step by step, testing and commissioning plan for

placement of electrical equipment, apparatus, and completed electrical system in service.

Contractor shall execute the plan, and document the performance and test results.

Contractor shall take corrective actions necessary to bring the failed and/or

noncompliance test results into conformance at no additional cost to the CITY.

F. The motors, drives, and motor starter/controller shall include a 2-year warranty for all

material and workmanship defects. The warranty period will begin from the date of the

CITY’s acceptance of the bridge being fully operational.

G. The programmable controller system manufacturer shall be a Company specializing in

manufacturing these products with minimum 5 years documented experience. VENDOR

shall use manufacturers whose equipment will continue to be manufactured for a period

of at least 5 years or who will maintain a stock of compatible spare parts for a period of

15 years after start-up of the control system.

H. The company specializing in programming systems specified shall have minimum 5 years

of documented experience. VENDOR shall demonstrate minimum of 5 years of

experience for projects of similar size and complexity involving control systems with

continuous process operation, PID loop control, data communications, graphic screens

and reports in similar applications.

1.08 DELIVERY, STORAGE, AND HANDLING



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

B. Ship equipment completely factory assembled unless physical size, arrangement,

configuration, or shipping and handling limitations make this impracticable. Shipping

splits and required field assembly shall be identified with equipment submittals. Shipping

splits shall be provided with clear instructions for field assembly and designated

interconnection terminations for interconnection between the shipping splits.

C. Separately packaged parts and accessories shall be consolidated and shipped together with

equipment. Mark each container clearly to identify contents and as belonging with main

equipment.

D. Equipment shall be protected against damage during shipment, handling, and storage.

Damage incurred during shipment shall be repaired at no cost to CITY.

MATERIALS

The following product specification form a basis for the design of the automation control system for

the bridge. The Contractor’s control system vendor shall determine the specific hardware, software,

programming, and configuration required to provide functions, features, and performance as specified

and as indicated on the design drawings.

2.01 OPERATOR CONTROL CONSOLE

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

house.

B. Bridge tender control consoles shall be provided for monitoring and control of bridge

operation. All devices for controlling and monitoring the operation of the bridge span,

standby generator and navigation equipment shall be mounted in and on the control

consoles as indicated on the Contract Drawings and as herein specified.

C. The control console shall be of neat, substantial construction. It shall be fabricated from

No. 10 gauge 302 stainless steel sheet properly formed and reinforced to provide adequate

strength. The welded console top shall be fabricated of No. 10-gauge Type 302 stainless

steel sheet with a non-glare, satin finish. The front HMI and control device panel shall be

provided with pivoted on 90-degree hinges and secured with flush-type latches all as

indicated on the Contract Drawings. The control console shall be neatly fitted up with

close joints; all rough edges or corners shall be ground off smoothly, and all projecting

edges rounded off. All metal hardware shall be of substantial construction, and shall have

a satin-chrome plate finish. All equipment mounting screws and bolts shall be stainless

steel.

D. The sheet portions of the console and all metal reinforcing shall be painted inside with

two coats and outside with three coats of paint consisting of one coat of primer followed

by two coats of enamel on the outside surfaces, and one coat of primer and one coat of



enamel on the inside surfaces. The finish coat shall be of a color to match the house

interior. Color samples shall be submitted to the Engineer for approval. The stainless steel

console top shall not be painted.

E. Special care shall be taken throughout the construction to ensure that the stainless steel

console top and the equipment mounted thereon are completely protected from damage

or defacement at all times. All control switches, pushbuttons, the HMI and other control

devices shall be mounted within the body of the consoles. The indicating lights for each

operation shall be mounted adjacent to the control device governing that operation and

provided with a means of lamp test as indicated on the Contract Drawings. The means of

lamp test proposed shall be submitted to the Engineer for approval. All devices shall be

compatible with the requirements of the control system and shall be of Allen Bradley

manufacture their 800T series or Engineer approved equal, suitable for oil tight/watertight

operation and provided complete with transparent boot to exclude harmful contaminants.

F. The escutcheon plates of all control switches, pushbuttons and indicating lights shall be

made of aluminum with a satin finish and shall be engraved with an identifying legend as

indicated on the Contract Drawings.

G. The wiring within the control console shall be flame-retardant, ethylene-propylene

insulated, switchboard wire, Type SIS. The wiring shall be arranged systematically so that

all circuits can be readily traced. All conductors shall be terminated on easily accessible

terminal blocks mounted inside at the rear or as appropriately determined by the systems

vendor for Engineer approval. Spare terminals that total at least 20 percent of those

actually used shall be provided. Wiring shall be identified at equipment terminals by

marking the adjacent area with bright yellow painted numbers or by other Engineer

approved means to correspond to conductor designations appearing on the Contractor's

wiring diagrams.

H. The bridge tender control console shall operate from a 120 Volt, 60 Hz source and be

powered from the dedicated bridge tender house UPS indicated on the Contract Drawings

and as specified herein.

I. The Contractor shall submit outline drawings including dimensioned layout, schematic

and wiring diagrams of the control console together with catalog cuts, dimensional details

and descriptive details of all proposed consoles mounted devices to the Engineer for

approval prior to fabrication.

2.02 COMBINATION CONTROLLER PANEL

A. Material and Construction:

1. Panel, control cabinet, switchboard, motor control center, and switchgear wiring shall

use flame retardant cross-linked polyethylene (XLP) or flame-retardant ethylene-

propylene rubber (EPR) insulation

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



3. Structures shall be totally enclosed, dead-front, free-standing or wall-mounted

assemblies as indicated on the drawing. Structures shall be of heavy gauge steel bolted

together to form a rigid assembly, minimum of 12-gauge steel. The entire assembly

shall be constructed and packaged to withstand normal stresses included in transit and

during installation. The system shall be rated for an available short circuit capacity of

65,000 rms amperes up to 600 volts, unless indicated otherwise on one-line diagrams.

B. Barriers:

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

and the wireways.

2. Barriers shall be provided to compartmentalize the power block section from control

block section, and to prevent the contact of any energized bus or terminal by a fish-tape

inserted through the conduit or wireway areas.

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

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

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

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

D. Main Disconnect

1. The motor controller panel shall be provided with main circuit breaker disconnect. A

lever handle operator must be provided on each disconnect. The circuit breaker

operators shall include a separate TRIPPED position to clearly indicate a circuit breaker

trip condition. It shall be possible to reset a tripped circuit breaker without opening the

control unit door. Clear indication of disconnect status shall be provided.

2. A mechanical interlock shall prevent the operator from opening the unit door when the

disconnect is in the ON position. Another mechanical interlock shall prevent the

operator from placing the disconnect in the ON position while the unit door is open. It

shall be possible for authorized personnel to defeat these interlocks.

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

three padlocks.

4. Unit construction shall combine with the vertical wireway isolation barrier to provide

a fully compartmentalized design.

E. Combination Starters

1. All combination starters shall use a unit disconnect. Magnetic starters shall be

furnished in all combination starter units. All starters shall utilize NEMA/EEMAC

rated contactors.

2. Starters shall be provided with electronic thermal overload units. The electronic

thermal overload unit shall have the following features:



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

b. Adjustable current setting ranges

c. Overload protection with phase loss sensitivity

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

e. Automatic or manual reset, sealable

f. Stop and test function.

3. When provided, control circuit transformers shall include two primary protection fuses

and one secondary fuse (in the non-ground secondary conductor). The transformer

shall be sized to accommodate the contactor(s) and all connected control circuit loads.

The transformer rating shall be fully visible from the front when the unit door is opened.

4. When a unit control circuit transformer is not provided, the disconnect shall include an

electrical interlock for disconnection of externally powered control circuits.

5. Auxiliary control circuit interlocks shall be provided where indicated. Auxiliary

interlocks shall be field convertible to normally open or normally closed operation.

6. NEMA/EEMAC Size 1-4 starters shall be mounted directly adjacent to the wireway so

that power wiring (motor leads) shall connect directly to the starter terminals without

the use of interposing terminals. Larger starters shall be arranged so that power wiring

may exit through the bottom of the starter cubical without entering the vertical

wireway. Units provided in MCCs rated for arc resistance shall be fitted with 12-gauge

steel doors and control station panels.

F. Feeder Circuit Protective Devices - Breakers

1. Feeder and non-motor load breakers shall be 3-pole and shall be rated for symmetrical

short circuit current as required. Neither series rating nor power fuses acceptable.

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

3. Provide bolt-on type circuit breakers with integral thermal and instantaneous magnetic

trip in each pole (common trip type).

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

branch circuits.

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

6. Provide UL Class A ground fault interrupter circuit breakers where specified on

panelboard schedules and/or the Drawings.

7. Breakers shall be operated by a position indicating toggle-type handle and shall have

quick-make, quick-break over center switching mechanism that is trip free.

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

9. The minimum symmetrical interrupting rating for circuit breakers shall be as specified

on the panelboard schedule and/or Drawings. Series rated breakers are not acceptable.



G. Trip Unit:

1. Provide adjustable instantaneous magnetic trips for breaker with frame size 100

amperes.

2. Provide interchangeable trip units with adjustable trip pick up and delay settings for

breaker with frame size 225 amperes.

3. Provide solid state trip units with long-time, short-time, instantaneous, and ground fault

(LSIG) tripping characteristics for breakers with frame size 400 amperes and higher

H. Panel Control and Instrumentations

1. Selector switches:

a. Type: Snap-action, rotary switches

b. Switch sections: as required

c. Switch poles: as required

d. Switch positions: as indicated on drawings

e. Switch detent angle: 45°

f. Continuous rating 30A-600V

g. Max. making ability: 95A

h. Momentary current: 3 seconds, 200A 30 seconds, 75A 60 seconds, 60A

i. Interrupting current: 120VAC, 20A; 240VAC, 15A; 600VAC, 6A; 125VDC, 3A

250VDC, 1A

j. Dielectric strength: 2200Vrms

k. Insulation resistance: 100 megaohms

l. Contact resistance: 10 miliohms

m. Switch mountings 3-Hole Waterproof Mount

n. Handle: Pistol-grip handle

2. Pilot lights:

a. Type: Standard.

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

c. Lamp type: LED.

d. Lens color:

• Red: Danger, run, or open.

• Amber: Shutdown, caution, pre-alarm, or abnormal.

• Green: Stop, closed, or satisfactory.

• White: Power available, ready.



• Blue: Status.

3. Pushbuttons:

a. Type: Non-illuminated.

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

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

d. Operator Heads:

• Flush head: Start applications.

• Extended head: Stop applications.

• Mushroom head: Emergency stop applications.

e. Button color:

• Red: Danger, run, or open.

• Green: Stop, closed, or satisfactory.

• White: Power on.

I. Control Relay

1. Function: General logic hardware interlocks.

a. Type: Plug-in.

b. Construction: Continuous duty.

c. Coil voltage: As applicable.

d. Switch configuration: 3-SPDT.

e. Indication: Mechanical or LED to indicate energized relay.

f. Switch rating: 10 amperes at coil voltage.

g. Mounting: Socket for DIN-rail mounting.

2. Function: Interposing relay for PLC output.

a. Type: Plug-in.

b. Construction: Continuous duty.

c. Coil voltage: As applicable.

d. Switch configuration: 2-SPDT.

e. Indication: Mechanical or LED to indicate energized relay.

f. Switch rating: 5 amperes minimum at coil voltage.

g. Mounting: Socket for DIN-rail mounting

J. Signal splitter:

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

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

3. Power requirements: 24-volt dc.

4. Mounting: DIN rail.



K. Signal convertor:

1. Type: Universal

2. Inputs:

• Thermocouple

• RTD

• Resistor. 2-wire, < 8KOhm

• Potentiometer: 3-wire, < 8KOhm

• Voltage: -20mV to 2400mV

3. Outputs:

• Current: 4-20mA into 500Ohm load

• Power required: 18-30Vdc

• Mounting: DIN rail

• Accessories: Configuration software and cable kit for interconnection

L. Surge suppressor:

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

capability.

5. Capacity:

a. Current: Up to 10kA surge current handling.

b. Peak clamping voltage: <= 41.6-volt dc

c. Resistance: 2.2 ohm in-line.

M. Intrinsically safe barriers:

1. Function: Isolate instruments installed in hazardous areas

2. Type: Isolated switching

3. Hazardous area classifications: Class I, II, III; Division 1, Groups A through G

4. Power required: 24Vdc

5. Mounting: Nonhazardous area on DIN rail

6. Channels: 1

N. Analog signals:

a. Circuits: 1 or 2 - 24-volt dc.

b. Signals: Suitable for 4-20 mA current, thermocouple or mV.

O. Discrete 24-volt dc signals:



a. Circuits: 2 or 4.

b. Signals: Suitable for 24-volt dc discrete circuits.

P. Discrete 120-volt ac signals:

a. Circuits: 2.

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

Q. DC power supply

1. Provide 1 or more 24-volt dc power supplies, as necessary, within each panel to power

field transmitters, I/O, and related equipment.

2. Type: Redundant.

3. Input voltage:

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

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

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

R. Programmable Panel Display (Basis of design: Dwyer Series SPPM2)

1. Inputs: Mini-USB, 6-line screw terminal analog, 4 x ±40 V, or 4 to 20 mA, 8 x digital

I/O.

2. Outputs: 4 x PWM, 2 x alarms (open collector).

3. Accuracy: ±0.05% ±0.1 mV (typ).

4. Resolution: 0.04 mV (max ) or 4 decimal places.

5. Power Supply: USB port or 5 to 30 VDC.

6. Current Consumption: 400 mA at 5 VDC.

7. Display: 4.3˝ (10.9 cm) TFT LCD with 262k colors.

8. Display Resolution: 480 x 272 pixels.

9. Sampling Rate: 10 samples/sec.

10. Temperature Limits: 32 to 104°F (0 to 40°C).

11. Warm Up: 15 sec.

12. Mounting: Panel mount.

13. Electrical Connection: Multi-pin DIL’s, 1 mini-USB, and 1 RS232.

14. Computer Requirements: Compatible with Windows® 7, Windows® 8, and

Windows® 10.

S. Digital Display:

1. Display: 4 digit (-1999 to 9999) red LED, 0.56” high



2. Decimal point: Up to 3 decimal places

3. Update rate: 3.7 to 5 times per second

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

5. Enclosure: 1/8 DIN, high impact plastic

6. Electrical classification: NEMA 4X, IP65 front

7. Supply voltage: 24Vdc or 120Vac as applicable.

8. Electrical connection: Screw terminal blocks

9. Mounting: Control panel

T. Terminations

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

requirements.

2. Main incoming cables shall terminate within control center on main lug or main breaker

termination point as indicated. Terminations shall have adequate dedicated space for

type, number, and size of cable used. Lugs shall be compression-type with anti-turn

feature. Feeder cable terminations shall facilitate installation with special attention

given to larger size starters and feeder breakers.

U. Space Heater

1. Provide thermostat control space heaters in each vertical section when required per

manufacturer recommendations. A single thermostat shall control space heaters within

each vertical assembly.

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

V. Terminal Blocks

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

terminal blocks.

2. Terminal blocks shall be the pull-apart type with a minimum rating of 250 volt and 10

amps. All current carrying parts shall be tin plated. Terminals shall be accessible from

inside the unit when the unit door is opened. Terminal blocks shall be DIN rail mounted

with the stationary portion of the block secured to the unit bottom plate. The stationary

portion shall be used for factory connections, and shall remain attached to the unit when

removed. The terminals used for field connections shall face forward so they can be

wired without removing the unit or any of its components.

3. When Type C wiring is specified, all starter units shall be provided with unit control

terminal blocks as described for Type B wiring along with power terminal blocks for

size 1-3 units. An additional set of terminal blocks shall be provided in a terminal

compartment located in each section. These terminal blocks shall be pre-wired to the



unit terminals so that all field control connections can be made at the terminal

compartments.

4. Nameplates shall be engraved phenolic nameplates for each MCC and unit

compartment. Shall be gray background with white letters, measuring a minimum of

1.5 in (38 mm) H x 6.25 in (159 mm) W total outside dimensions.

2.03 ADJUSTABLE SPEED AC DRIVE

A. Performance Requirements

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

a. Ambient temperature: 0 to 40C (continuous operation).

b. Altitude 0 to 1000 meters above sea level without derating.

2. Electrical and electromechanical components of the Adjustable Speed AC Drive (ASD)

shall not cause electromagnetic interference to adjacent electrical or electromechanical

equipment while in operation.

3. Control panel shall have surge protection, included within the panel to protect the unit

from damaging transient voltage surges. Surge arrestor shall be mounted near the

incoming power source and properly wired to all three phases and ground. Fuses shall

not be used for surge protection.

4. I/O functions as specified shall be protected against surges induced on control and

sensor wiring installed outdoors and as shown.

5. Output voltage and current ratings shall produce the torque-speed performance

requirements of driven motors throughout the speed range including minimum starting

torque, constant and variable speed operation, acceleration and deceleration torque. The

adjustable speed drive shall not be the limiting factor of the driven motors. Motor and

drive system’s thermal load ability must also be considered.

B. Product Description

1. The ASD shall be solid state AC to AC inverter controlled device utilizing the latest

isolated gate bipolar transistor (IGBT) technology. The ASD shall be Direct Torque

Control (DTC) technology.

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

3. The ASD shall be provided with dynamic braking chopper with 100% continuous duty

internally mounted in ASD enclosure.

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

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

parameters:

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



repeatability.

b. 100% motor torque from zero speed available for acceleration with the ASD

continuous current rating equal to or greater than the motor full load amp rating.

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

voltage.

d. Ability to limit torque to protect the mechanical system with a common single

torque setting above and below field weakening.

e. Ability to provide torque in % of motor shaft torque (within +/- 4% linearity) on

the ASD control panel, analog output or via field bus of actual.

f. Have available the ability to operate in open loop torque control, with an ability to

switch between speed and torque control on the fly with the change of state to a

digital input.

g. Have an ability to share load or speed between two or more induction AC motors

connected to the same system, when those motors are controlled by separate ASDs.

h. The ASD shall be equipped with a front mounted operator control panel with

configurable displays showing, bar graph and meter. Keypad with keys for

Run/Stop, Local/Remote, Increase/Decrease, Reset, Menu navigation and

Parameter select/edit. The display of the control panel shall have the following

features:

• All parameter names, fault messages, warnings and other information shall be

displayed in English words or standard English abbreviations to allow the user

to understand what is being displayed without the use of a manual or cross-

reference table.

• During normal operation, the display shall be programmable to display the

values of the following operating parameters:

• speed reference, and run/stop forward/reverse and local/remote status.

• Speed/torque in percent (%), RPM or user-scaled units

• Output frequency, voltage, current and torque

• Power and kilowatt hours

• Heatsink temperature and DC bus voltage

• Status of discrete inputs and outputs

• Values of analog input and output signals

• Values of PID controller reference, feedback and error signals

i. The control panel shall be used for local control, for setting all parameters, and for

stepping through the displays and menus.

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

stored parameter settings to the same ASD or to another ASD shall exist.

k. An intelligent start-up assistant shall be provided as standard. The Start-up routine

will guide the user through all necessary adjustments to optimize operation.

l. The control panel shall be removable, capable of remote mounting and allow for

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

ASDs.

m. Wall mountable or panel mountable in the switchgear enclosures

n. Include a control panel mounted on the front of the ASD



o. Include coated circuit boards as standard

p. Include integrated DC choke

q. Include internally mounted braking chopper for use in dynamic braking with 100%

continuous duty operation.

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

requirements shall be provided and mounted by the ASD manufacturer and shall

also be available as field installable kits as an alternative.

C. Ratings

1. The ASD shall be rated to operate from 3-phase power at nominal supply voltage as

indicated on the drawings. The overvoltage trip level shall be a minimum of 30% over

nominal, and the under-voltage trip level shall be a minimum 35% under the nominal

voltage.

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

3. The ASD current rating shall be minimum of 150% of the full load ampere rating of

the drive motor. The ASD shall have the capacity, output voltage and current ratings

required to produce the torque-speed performance requirements of driven motors

throughout the speed range including minimum starting torque, constant and variable

speed operation, acceleration and deceleration torque. The adjustable speed drive shall

not be the limiting factor of the driven motors. Motor and drive system’s thermal load

ability must also be considered. The correctly sized drive, meeting all the requirements,

shall be provided at no additional cost to the State.

4. The ASD shall have a heavy-duty overload current capacity of 150% minimum of ASD

rated current for a minimum of one (1) minute.

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

full speed and load.

D. Protective Features

1. For each programmed warning and fault protection function, the ASD shall display a

message in complete English words or Standard English abbreviations. The five (5)

active and most recent fault messages and times shall be stored in the ASD’s fault

history.

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

voltage transient protection.

3. Output short circuit and ground fault protection rated for 100,000 amps without relying

on line fuses shall be provided per UL508C.

4. Motor phase loss protection shall be provided.

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

6. Protection shall be provided for AC line or DC bus overvoltage at 130% of maximum

rated voltage or under-voltage at 65% of min. rated voltage.



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

8. A power loss ride through feature shall allow the ASD to remain fully operational after

losing power as long as kinetic energy can be recovered from the rotating mass of the

motor and load.

9. Stall protection shall be programmable to provide a warning or stop the ASD after the

motor has operated above a programmed torque level for a programmed time limit.

10. Underload protection shall be programmable to provide a warning or stop the ASD

after the motor has operated below a selected underload curve for a programmed time

limit.

11. Over-temperature protection shall provide a warning if the power module temperature

is less than 5 degree below the over-temperature trip level.

12. Input terminals shall be provided for connecting a motor thermistor (PTC type) to the

ASD’s protective monitoring circuitry. An input shall also be programmable to monitor

an external relay or switch contact.

E. Safety Functions Module

1. Provide Safe stop 1 (SS1) function to brings the machine to a stop (STO) using a

monitored deceleration ramp. It is typically used in applications where the machinery

motion needs to be brought to a stop (stop category 1) in a controlled way before

switching over to the no-torque state.

2. Provide safe stop emergency (SSE) which can be configured to, upon request, either

activate STO instantly (category 0 stop), or first initiate motor deceleration and then,

once the motor has stopped, activate the STO (category 1 stop).

3. Provide safe brake control (SBC) provides a safe output for controlling the motor’s

external (mechanical) brakes, together with STO.

4. Provide safely-limited speed (SLS) ensures that the specified speed limit of the motor

is not exceeded. This allows machine interaction to be performed at slow speed without

stopping the drive. The ASD shall have a minimum of four individual SLS settings for

speed monitoring.

5. Provide safe maximum speed (SMS) which monitors that the speed of the motor does

not exceed the configured speed limit.

6. Provide prevention of unexpected startup (POUS) ensures that the machine remains

stopped when people are in a danger area.

7. Provide safe speed monitor (SSM) function which provides information that speed is

within the configured limits.

F. Control Inputs and Outputs

1. Discrete Inputs

a. Provide number of the discrete inputs and I/O extension modules as required to



perform the control/alarm/indication functions as indicated on the design drawing

and as specified. The inputs shall be independently programmable with function

selections (run/stop, hand-off-auto, etc.).

b. Inputs shall be designed for use with either the ASD’s internal 24 VDC supply or

a customer supplied external 24 VDC supply

2. Discrete outputs

a. Provide number of the discrete outputs and I/O extension modules as required to

perform the control/alarm/indication functions as indicated on the design drawing

and as specified. All outputs shall be independently programmable to activate

function selections including; Operating conditions such as drive ready, drive

running, reversed and at set speed.

b. General warning and fault conditions

c. Adjustable supervision limit indications based on programmed values of operating

speed, speed reference, current, torque and PID feedback.

d. Relay contacts shall be rated to switch 2 Amps at 24 VDC or 115/230 VAC.

3. Analog Inputs

a. Minimum of two (2) analog inputs shall be provided:

b. Two (2) must be selectable for either a current or a voltage input.

c. Resolution of analog inputs must be at least 11 bits total resolution

d. Inputs shall be independently programmable to provide signals including speed /

frequency reference, torque reference or set point, PID set point and PID feedback

/ actual.

e. A differential input isolation amplifier shall be provided for each input.

f. Analog input signal processing functions shall include scaling adjustments,

adjustable filtering and signal inversion.

g. If the input reference is lost, the ASD shall give the user the option of the following.

The ASD shall be programmable to signal this condition via a keypad warning,

relay output and/or over the serial communications bus.

• Stopping and displaying a fault

• Running at a programmable preset speed

• Hold the ASD speed based on the last good reference received

h. Cause a warning to be issued, as selected by the user. When inputs are used as speed

references, reference signal processing shall include increase/decrease floating

point control and control of speed and direction using a “joystick” reference signal.

Two (2) analog inputs shall be programmable to form a reference by addition,

subtraction, multiplication, minimum selection or maximum selection.

4. Analog Outputs

a. Minimum of two (2) 4-20 mA analog outputs shall be provided.

b. Outputs shall be independently programmable to provide signals proportional

to output function selections including output speed, frequency, voltage, current

and power.



5. Encoder Module (FEN-01)

a. General

i. Max. power consumption: 350 mA at 24 V (Max. combined power

consumption of encoders, latches and cabling 5W)

ii. Degree of protection: IP20

iii. Ambient conditions: The applicable ambient conditions specified for the

drive in its Hardware Manual are in effect.

b. TTL encoder input

i. Output voltages: +5.5 V DC -5%, -8% 180 mA

ii. CH A, CH B, CH Z: RS-422/485, differential, 500 kHz (max)

iii. Maximum cable length: 30 m with a 5 V encoder (0.5 mm2 cable for

power supply)

iv. Performance:

1. Speed range: -32768 … 32767 rpm

2. Speed resolution: 0.04 RMP (24 bits)

3. Position resolution: 16 M / rev (24 bits)

4. Position accuracy: 4x pulse count / rev

v. Isolated together with digital inputs

6. Digital Inputs/Outputs

a. Minimum of two (2) digital inputs/outputs shall be provided.

b. At least one (1) can be programmed as a frequency input. At least one (1) can

be programmed as a frequency output.

7. Safety Inputs

a. Have a Safe Torque Off (STO) terminal integrated in the drive as a standard. The

STO function will meet a Safety Integrity Level (SIL) 3 and a Performance Level

(PL) e.

G. Communication

1. The ASD shall be capable of communicating with other ASDs or controllers via a serial

communications link. A variety of communications interface modules for the typical

overriding control systems shall be available.

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

limited to:

a. Modbus

b. Ethernet IP

c. ModBus TCP



d. ControlNet

e. DeviceNet

f. Profibus

g. ProfiNet

h. CANOpen

3. Interface modules shall mount directly to the ASD control board or be connected via

fiber optic cables to minimize interference and provide maximum throughput.

4. I/O shall be accessible through the serial communications adapter. Serial

communication capabilities shall include, but not be limited to:

a. Run-Stop control

b. Hand-Off-Auto Control

c. Speed Adjustment

d. PID (proportional/integral/derivative) control adjustments

e. Current Limit

f. Accel/Decel time adjustments

5. The ASD shall have the capability of allowing the overriding controller to monitor

feedback such as process variable feedback, output speed/frequency, current (in amps),

% torque, power (kW), kilowatt hours (resettable), operating hours (resettable), relay

outputs, and diagnostic warning and fault information.

6. A connection shall also be provided for personal computer interface. Software shall be

available for ASD setup, diagnostic analysis, monitoring and control. The software

shall provide real time graphical displays of ASD performance.

H. Control Functions and Adjustments

1. Output frequency shall be adjustable between 0Hz and 500Hz. Operation above motor

nameplate shall require programming changes to prevent inadvertent high-speed

operation.

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

3. The ASD shall be capable of controlling deceleration of a load without generating an

overvoltage fault caused by excessive regenerated energy. Overvoltage control on

deceleration shall extend the ramp time beyond the programmed value to keep the

amount of regenerated energy below the point that causes overvoltage trip.

4. The ASD shall be capable of starting into a rotating motor with or without existing

magnetic flux on the motor regardless of the motor direction. From the time the start

signal is given to the ASD to the time the ASD has control of the motor shall not exceed

two (2) seconds. Once the ASD has control of the motor it will than accelerate or

decelerate the motor to the active reference speed without tripping or faulting or

causing component damage to the ASD. The ASD shall also be capable of flux braking

at start to stop a reverse spinning motor prior to ramp.

5. The ASD shall have the ability to automatically restart after an overcurrent,



overvoltage, under-voltage, or loss of input signal protective trip. The number of restart

attempts, trial time, and time between reset attempts shall be programmable.

6. Control functions shall include two (2) sets of acceleration and deceleration ramp time

adjustments with linear and an s-curve ramp time selection.

7. Speed control functions shall include:

a. Adjustable min/max speed limits.

b. Selection of up to 7 preset speed settings for external speed control.

c. Three sets of critical speed lockout adjustments.

d. External speed reference control and speed adjustment control.

e. A built-in PID controller to control a process variable such as pressure, flow or

fluid level.

8. Functions shall include energy optimization for optimizing efficiency and limit the

audible noise produced by the motor by providing the optimum magnetic flux for any

given speed / load operating point.

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

signal the loss of load condition. The ASD shall be programmable to signal this

condition via a keypad warning, relay output and/or over the serial communications

bus. Relay output shall include programmable time delays that will allow for ASD

acceleration from zero speed without signaling a false underload condition.

10. Three (3) programmable critical frequency lockout ranges shall be provided to prevent

the ASD from operating the load continuously at an unstable speed.

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

primary speed reference.

12. The ASD shall have Brake Open Torque Source and Brake Open Delay functions. The

Brake Open Torque Source defines a source that is used as a brake opening torque

reference if its absolute value is greater than the setting of parameter for Brake open

torque, and its sign is the same as the setting of Brake open torque. Brake Open Delay

defines the brake open delay, ie. the delay between the internal open brake command

and the release of motor speed control. The delay timer starts when the drive has

magnetized the motor and increased the motor torque to the level required for brake

release. Simultaneously with the timer start, the brake control logic energizes the brake

control output and the brake starts to open. Set this parameter to the value of mechanical

opening delay specified by the brake manufacturer.

13. ASD shall be provided with an internal brake chopper, which is used to handle the

energy generated by a decelerating motor. When the DC voltage rises high enough, the

chopper connects the DC circuit to an external brake resistor.

I. Performance and Verification Test

1. A proposed test plan shall be submitted to the CITY at least 28 calendar days prior to

proposed testing for approval. The CITY and/or CITY’s Engineer reserves the right to



witness all tests and review any documentation. The contractor shall inform the CITY

and/or CITY’s Engineer at least 14 working days prior to the dates of testing.

2. Contractor shall provide video tapes, if available, of all training provided to the CITY

for subsequent use in training new personnel. All training aids, texts, and expendable

support material for a self-sufficient presentation shall be provided.

3. "Performance Verification Test" plan shall provide the step-by-step procedure required

to establish formal verification of the performance of the ASD. Compliance with the

Special Specification requirements shall be verified by inspections, review of critical

data, demonstrations, and tests.

4. The CITY and/or CITY’s Engineer reserves the right to witness all tests, review data,

and request other such additional inspections and repeat tests as necessary to ensure

that the system and provided services conform to the stated requirements. The

contractor shall inform the CITY and/or CITY’s Engineer at least 14 calendar days

prior to the date the test is to be conducted.

J. Training

1. Coordinate training requirements with the CITY.

2. Provide the services of competent instructors who will give full instruction to

designated personnel in operation, maintenance, calibration, configuration, and

programming of the complete control system. Orient the training specifically to the

system installed.

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

4. The number of training days of instruction furnished shall be as specified. A training

day is defined as eight hours of instruction, including two 15-minute breaks and

excluding lunch time; Monday through Friday.

5. Provide a training manual for each student at each training phase which describes in

detail the material included in each training program. Provide one additional copy for

archiving.

6. Provide equipment and materials required for training. Unused copies of training

manuals shall be turned over to the CITY at the end of last training session.

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

between the Contractor and the CITY.

8. Provide session to train 4 operation personnel in the functional operations of the system

and the procedures that personnel will follow in system operation. This training shall

include:

a. System overview

b. General theory of operation

c. System operation



d. Alarm formats

e. Failure recovery procedures

f. Troubleshooting 2.04 MOTORS

A. General Requirements

1. Motors shall be in accordance with applicable requirements of NEMA MG-1, NFPA

70, IEEE 112, and UL 1004.

2. Motor installed on or within bridge structure shall be severe duty motors, and shall

meet or exceed the IEEE 841 standards for severe duty TEFC induction motors.

3. The motor’s torque characteristics in relation to the speed and starting current, shall

conform to the motor design classification. The torque characteristics of all induction

motors shall be as required to accelerate the inertia loads of the motor and driven

equipment to full speed without damage to the motor or the equipment at any voltage

from 90% to 110% of motor nameplate voltage.

4. The motors shall be designed to adequately braced for direct-on-line starting, with full

rated voltage applied at their terminals. The starting performance of the motors shall

comply with NEMA MG-1 requirements.

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

class IE3 standards.

6. Motors driven by adjustable speed drive shall have duty ratings be suitable for

operation on an adjustable speed drive over the operational speed range duty cycle

without exceeding the maximum temperature rise.

7. Maximum voltage dip at motor terminal during initial starting condition, for motor

started directly across line shall not exceed 20% of the system nominal voltage.

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

9. The motors shall withstand the dynamic torque stressing due to the switching

phenomena (direct-on-line starting, short-circuit followed by transfer to another source

and re-acceleration).

B. Motor Frame and Enclosure System:

1. Motor’s frame construction shall be heavy-duty, using cast iron or welded steel

construction. Motor frame, fan covers, end brackets, drip shields, and bearing housing

shall be cast iron with corrosion-resistant treatment. Motor supporting feet shall be an

integral part of frame for very rigid mounting and to minimize vibration.

2. The motor housings shall be rated IP65, and provided with stainless steel hardware and

nameplate. The motor shall be rated for high humidity environments and the winding

insulation shall be extra heavy duty. The motor frames shall be provided with

condensation drains. Locate drain holes at low point of motor in final mounted position.



3. Provide ground lug connection; locate bolt holes on motor frame, external to, and on

same side as terminal box.

C. Stator and Stator Assembly

1. The motors of 250hp and larger shall have form wound coils and a sealed Vacuum

Pressure Impregnation (VPI) insulation system with epoxy resins.

2. The motors smaller than 250hp may have form wound or random wound coil. The

motors with form wound coil shall have a sealed VPI insulation system with epoxy

resins that withstand an immersion type test as required by applicable reference

standards. The motors with random wound coil shall have a moisture resistant VPI

insulating system or another type of insulation designed to prevent growth of fungus

and ingress of moisture.

3. Windings shall be copper and the winding insulation shall be of Class F at least, but

the temperature rise shall correspond to Class B conditions.

4. The six (6) terminals of the three (3) phases of the stator windings shall be brought out

in the main motor terminal box for testing purposes.

D. Rotor and Shaft Assembly

1. The rotor squirrel-cage shall be made copper, copper-alloy bars or shall be fabricated

aluminum, or integrally die-cast aluminum. Rotor shall be epoxy-coated.

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

by motor.

E. Bearings

1. Construct and provide bearing and bearing housing seals to prevent dirt or moisture

from entering motor. The bearings shall be protected by a dust-proof and water-proof

enclosure according to IP55 degree of protection or higher.

2. The bearings with oil lubrication shall be fitted with a sight gauge marked with the

proper oil level and shall have fill and drain openings. When oil rings are used, means

shall be provided for observing oil ring rotation while the motor is operating. The

bearings with grease lubrication shall have grease valves for lubrication while the

motor is running.

3. Where insulated bearings are required as a protection against the occurrence of shaft

currents, one or both bearings shall be insulated, in consideration of the motor driven

equipment assembly. At motors with one shaft extension, at least the bearing opposed

to the driven equipment has to be insulated. At motors with two shaft extensions, both

bearings have to be insulated, as well as one of the shaft couplings. Generally, piping

and conduit to insulated bearings shall also be insulated.

4. Anti-friction type bearings shall be grease lubricated and have minimum rated life L10

with a median life no less than 50% of L10 life, as defined by AFBMA. Reliability of

each bearing shall be greater than 90%.



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

motor.

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

startup and shutdown.

7. Motors provided with roller bearings or angular contact ball bearings shall be fitted

with a transport lock to prevent damage to the bearings, due to vibration, during

transport.

8. Shaft and bearings for belt-connected motor shall withstand normal belt pull of

equipment furnished and momentary and continuous overloads due to acceleration

caused by incorrect belt tension.

9. Bearings for motors shall be designed to carry 200% of maximum thrust develops

during starting and stopping, and while operating at any capacity on rated performance

curve.

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

11. Furnish vertical motors coupled to vertical pumps with non-reversing ratchets and

bolted couplings with case drip shields.

F. Lubrication System

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

grease or complete change of grease.

2. Provide system with readily accessible grease inlet and outlet plugs in bearing housings

to enable regreasing while motor is in service.

G. Anti-Condensation Space Heaters

1. Provide low surface-temperature, anti-condensation space heaters for motors installed

indoors and outdoors for motor size indicated. The heater shall be mounted on inside

of motor frame or winding end turns. Anti-condensation space heaters shall be

provided in all the motors of the following types:

a. Indoor motors rated 250HP and larger.

b. Outdoor motors rated 25HP and larger

2. The space heaters shall have sufficient capacity to keep the motor windings and internal

parts dry when the motor is not running.

3. Space heaters shall be rated and designed to operate at the supply source voltage

indicated on the design drawings. Space heaters shall be suitable for installation

environment.

4. The space heaters and their connections shall be protected against accidental contact

with the personnel, but shall be accessible for service and replaceable in the field.

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



6. Sheath temperature at 110% of rated voltage, when operating at ambient temperature,

shall not exceed 200°C or cause motor insulation temperature to exceed 130 °C,

whichever is more restrictive.

H. Motor Terminal Boxes

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

otherwise.

2. Provide motor with oversized terminal box to accommodate oversize motor power

supply cables and to allow ample room for bending radius and stiffness of motor supply

cables, and for terminating grounding conductor. For the motors larger than 100 kW,

two (2) cable entrances shall be provided.

3. Main terminal boxes shall be capable of rotation in 90° increments to permit connection

on any one of four sides. The direction of the cable entrance in the terminal boxes,

especially for the main terminal box, shall be adjustable in the field and changeable at

a later date.

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

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

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

aluminum conductor cables.

7. The terminal leads of the motor windings, of the heaters and of the monitoring devices

shall be connected to terminals in separate terminal boxes (one for each of the lead

groups indicated above). Each terminal box shall have a corresponding mark or an

indication of the purpose.

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

against mechanical damage.

I. Identification and Tagging

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

screws or pins.

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

standards.

3. If identification number cannot be included on motor nameplate, provide separate

stainless steel equipment identification nameplate in accordance with equipment

identification as indicated.

4. Motor power and space heater circuits may be derived from different sources. Covers

of motor terminal boxes containing space heater leads shall be provided with nameplate

reading: “ISOLATE MOTOR AND HEATER CIRCUITS BEFORE REMOVING

COVER”.

J. Specific Technical requirements for special purpose motor



1. Span Drive Motor

a. Manufacturer/Model: Magnetek/Spartan High Efficiency

b. HP Ratings: 100-hp

c. NEMA Motor Characteristic: Design D

d. RPM: 580

e. Duty Cycle: 30-Minute Duty Cycle

f. Rated Voltage: 460V, Three-phase, 60 Hz.

g. Full Load Amps: 155A

h. Service Factor: 1.15

i. Insulation Class: H

j. The Contractor shall performance routine maintenance on the existing drive

motors per manufacturer recommendation and perform motor insulation

resistance to test integrity of the motor windings. The existing drive motor shall

be retrofitted with new shaft mounted, absolute encoder and overspeed switch.

The Contractor through the Control System Integrator shall determine the

requirement and make final selection for the absolute encoder and overspeed

switch and coordinate the installation requirements. Refer to Special Specification

for Mechanical Work for related scope of work requirements.

k. Spare Drive Motor: The Contractor shall provide one spare drive motor with the

same physical and electrical parameters as the existing motor such that the spare

motor can be used as direct replacement. The spare motor shall be equipped with

encoder and overspeed switch same as on the existing motor.

2. Machinery Brake Motor

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

and mechanical performance requirements.

b. NEMA Motor Characteristic: By Manufacturer

c. RPM: By Manufacturer

d. Duty Cycle: Intermittent

e. Rated Voltage: 460V, Three-phase, 60 Hz.

f. Type of Motor Enclosure: Severe Duty, TEFC

g. Insulation Class: F

h. Accessories: position indication dry contact outputs for brake set, brake release,

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

enclosure.

K. When electrically driven equipment differs from that indicated as a basis of design, make

adjustments to the motor size, wiring and conduit systems, disconnect devices, and circuit

protection to accommodate the equipment actually installed, at no additional cost to the

CITY.

2.05 POWER METER

A. Function: Monitor the energy consumption of the ASD drives used for the lift motors.



B. Meter is a powerful energy meter that provides accurate electrical energy measurements

and offers advanced capabilities for power quality analysis and determining electrical

power reliability. The meter is transducer base with a separate display.

C. Power Supply

1. Input Voltage Range: High Voltage Option (96 to 276) V AC or V DC @50/60 Hz.

2. Input Voltage Range: Low Voltage DC Option (18 to 60) V DC.

3. Protection Short-circuit protection and auto-restart when failure is removed.

4. Frequency Range (42.5 to 69.5) Hz.

5. Power Consumption (Burden) Max.: 20 VA/12.5 W approximately without optional

I/O modules or display. 40 VA Max with I/O and display. Typical: 12 VA/7.8 W at

120 V AC.

D. Voltage Inputs

1. UL Measurement Category Category III.

2. Range: Absolute Maximum rating, between any voltage inputs: (20 to 720) V AC.

3. Measurement Modes and Services to Monitor: 2, 2.5, 3 element measurements.

Services: single or polyphase, Wye, 3 or 4 wire Delta. Current hookup with CT, only.

4. Input Impedance: 10 M per voltage input.

5. Pickup Voltage: 5 V AC.

6. Voltage Input Maximum Continuous Rating: 720 V AC between any two voltage

inputs.

7. Voltage Input Withstand Capability: Meets ANSI C37.90.1 surge withstand capability.

8. Reading: Programmable Full Scale to any PT ratio.

E. Current Inputs

1. Supports Class 2 and Class 20: 1 or 5 A nominal, 20 A maximum.

2. Pickup Current: Shall begin reading at 0.001 A (1 mA), 0.5% accuracy on watt readings

at pickup current.

3. Current Input Maximum Continuous Rating: 30 A AC maximum continuous rating.

4. Current Input Withstand Capability: 100 A for 10 s, 300 A for 3 s, 500 A for 1 s.

5. Maximum voltage from current inputs to Earth Ground: 40 V AC.

6. Reading: The current inputs are transformer rated and onlyto be connected to external

CTs.

7. Burden: 0.028 VA @ 20 A input/phase.

8. Isolation: Between human accessible I/O connections and power, voltage current



inputs: 2500 V AC. Between power and voltage and current inputs: 2500 V AC.

Between human accessible I/O connections: 500 V AC. Isolation is Hi-Pot test verified

in factory.

9. Sensing Method: RMS.

10. Line Frequency Range: (42.5 -69.5) Hz.

11. Operating Temperature: (-25 to +70) oC/(-32 to +158) oF.

12. Storage Temperature: (-40 to +70) oC/(-40 to +158) oF.

13. Protection Class: IP30.

F. Specifications:

1. Multilevel Cyber Secure Encrypted Configuration

2. Advanced Web Server with Waveform Analysis Tools

3. Up to 1024 Samples per Cycle-based Measurements 0.06% Energy Accuracy Over

Wide Dynamic Measurement Range; ANSI C12.20 0.1S Class Accuracy

4. Highly Accurate and Stable Measurements

5. 6 Available Communication Ports, Including Modbus and DNP3 Protocols

6. Two Independent Ethernet Ports, with Unique IP Addressing and Port Control for

Security

7. Meter is equipped with an internal clock crystal accurate to 3.5 PPM over the full

operating temperature range and 5 PPM at over ten years of use. This highly accurate

trimmed clock design allows users to maintain accurate time when running on crystal

synchronization. The meter's clock crystal will drift less than 6 seconds per month from

(0-40) °C. Additional time sync methods:

a. Modbus time sync.

b. IRIG-B time sync.

c. DNP3 time sync.

d. SNTP time sync.

8. Measures power quality, including waveform recording and IEC 61000-4-7, IEC

61000-4-15, and IEC 61000-4-30 Class A compliance.

G. Communications

1. The RS-485 port will be used to communicate with an LED display unit offering 75

data screens which display Voltage, Current, Power, Energy, Phase Angle and Phase

Sequence, as well as Instantaneous, Max/Min and THD data.

2. One of the independent Ethernet ports will be used to communicate with the host

processor which will have the ability to communicate to multiple computer-based

systems, providing data to entities throughout an enterprise.



2.06 TEMPERATURE SENSOR

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

gearboxes, liquid tanks, piping, etc.

B. Sensor mounting applications:

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

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

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

grease fittings)

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

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

E. Features and auxiliaries:

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

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

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

4. Manufacturer pre-wired connection and hardware as required

F. The Contractor shall submit outline drawings, dimensioned layout, switch contact

configuration diagram and specification data sheet of the temperature sensors to the

Engineer for approval prior to procurement.

2.07 MECHANICAL LIMIT SWITCHES

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

dangerous contacts and/or conditions.

B. Construction:

1. Metallic, industrial heavy-duty design

2. Suitable for application in harsh industrial or corrosive environments

3. Electrically isolated bodies for industrial/corrosive environments

4. Zinc casings sealed w/ epoxy resin

5. Shock and vibration resistant

6. Stainless steel operating rod or lever arm

7. Stainless steel cable gland

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



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

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

E. Minimum Actuation Speed:

1. Slow action contacts: 0.060 m/s

2. Snap action contacts: 0.001 m/s

F. Ratings:

1. Rated operational voltage: 130 V

2. Rated Thermal Current: 10A min

3. Rated Insulation Voltage: 300V minimum

G. Certifications / Approvals: UL & CSA

H. Features and auxiliaries:

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

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

associated stainless steel hardware.

3. Manufacturer pre-wired connection

4. The joint of the mechanism between the spring buffer and the plunger rod shall be

covered with a watertight, neoprene bellows-type boot.

I. The Contractor shall submit outline drawings, dimensioned layout, switch contact

configuration diagram and specification data sheet of the limit switches to the Engineer

for approval prior to procurement.

2.08 SPAN LIMIT CAM SWITCH


dangerous contacts and/or conditions.

B. Construction:

1. Industrial heavy-duty design with coupling and cam switches




5. Stainless steel housing




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


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

E. Number of cam switch channels: 6

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

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

H. Switch Ratings:

1. Permanent Current: 6A

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

3. Mechanical Life: 10 x 106

4. Cycles.

I. Speed: 300 rpm max., rotate in either direction

J. Certifications / Approvals: UL & CSA

K. Features and auxiliaries:

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



3. Manufacturer pre-wired connection

4. The joint of the mechanism between the spring buffer and the plunger rod shall be

covered with a watertight, neoprene bellows-type boot.

L. The Contractor shall submit outline drawings, dimensioned layout, switch contact


for approval prior to procurement.

2.09 ABSOLUTE ENCODER

A. Function: Monitor the position of the span to be indicated on the HMI screen. The encoder

will mechanically connect to one of the shafts coming off of the worm gear reducer. (.977

revolutions from ground position to the top of spam travel.)

B. Construction:

1. Industrial heavy-duty design



2. Stainless steel body

3. Superior shaft seals and bearings that stay sealed to keep contaminants out, despite

temperature cycles or liquid sprays. Encoder seals are protected by mechanical barriers

to prevent flexing or failure. Superior bearings permit much larger side and axial loads.

4. Unbreakable encoder disks

5. Stainless steel shaft

6. All stainless construction.

7. Ultra-long-life internal gearbox.

8. Suitable for application in harsh industrial.

C. Specifications

1. Operating Power: 10 - 30 VDC

2. Current: 400mA at 10V, 160mA at 24V maximum (Ethernet version)

3. Output Format: Ethernet/IP

4. Accuracy: +/-0.02° (+/-1 arc-min)

5. Shaft Loading: axial 9lbs [40n], radial 25lbs [110N]

6. Temperature: -40° to 85°C

7. Environment: IP66

8. Vibration: 10G, 10 – 1000Hz

9. Shock: 30G, 11mS duration

2.010 INDUCTIVE PROXIMITY SENSORS


dangerous contacts and/or conditions. An inductive sensor detects metallic objects

without requiring physical contact with the targets to be sensed

B. Construction:

1. Industrial heavy-duty design

2. Stainless steel body




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



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

F. Output current (continuous): 300 mA

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

H. Response time: Up to 2000 Hz

I. Noise immunity: high

J. Short circuit protection

K. Certifications / Approvals: UL & CSA

L. Features and/or auxiliaries:

1. LED indicator

2. Manufacturer pre-wired connection; shielded cable


M. The Contractor shall submit outline drawings, dimensioned layout, switch contact


for approval prior to procurement. 2.011 INCLINOMETER

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

and/or structure for indication

B. Construction:

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

environments

2. Stainless Steel or Die-cast aluminum alloy housing




D. Enclosure Rating / Degree of Protection: IP68.

E. Dual axis measurement range: ±80° min.

F. Absolute Accuracy: ±0.1° or better

G. Resolution: 0.01° or higher resolution



H. Measurement axis: 2 axis

I. Output type:

1. Digital output: RS232

2. Voltage output: 0.5~4.5VDC; or

3. Current output: 4~20mA

J. Power supply voltage range: 11~36VDC


L. Features and auxiliaries:

1. Manufacturer pre-wired connection – connector and cable



M. Single-axis digital display inclinometer:

1. LED Display

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

3. Enclosure Rating / Degree of Protection: IP65.

4. Axis measurement range: ±1°～±80°

5. Accuracy: ±0.1° or better

6. Resolution: 0.01° or higher resolution

7. Response time: 0.2 s

8. Measurement axis: single-axis

9. Direct connect Input:

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

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

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

2.012 SHAFT INCREMENTAL ENCODER

A. Function: Monitor the position of the motor shaft and send it to the variable speed drive

to very accurately control the speed of the motor.

B. Construction:




environments

2. Cast aluminum housing



C. Performance

1. Pulses per revolution: 4,096

2. Measurement step: 90° electrical/pulses per revolution

3. Reference signal:

a. Number: 1 b. Location: 90° electrical, logically gated with A and B or 180° electrical,

logically gated with B.

D. Specifications:

1. Lines/pulses per revolution: 4,096

2. Through hollow shaft

3. Electrical interface: 5.5 V, TTL/RS422

4. Enclosure rating up to: IP66

5. Maximum output frequency: <= 600 kHz

6. Ambient temperature: -20 °C … +70 °C

7. Load current 4.5 V … 5.5 V, TTL/RS422: 40 mA

2.013 SHAFT SPEED SWITCH

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

from dangerous under-speed/over-speed conditions.

B. Construction:


environments

2. Cast aluminum housing






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

E. Number of Set-points: 2

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

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

H. Contact Arrangement: 2 SPDT Form C

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

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


L. Features and auxiliaries:

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

2. 2 SPDT relay outputs

3. Visual set-point adjustment

4. Built-in start delay

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

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



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

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

2.014 MAIN AUTOMATION CONTROLLER (SEL-2240 AXION)

A. The automation control system shall be designed to operate properly in a harsh

environment condition with vehicle traffic vibration, high moisture and salinity ratio. The

operating environment includes possible electromagnetic and radio frequency fields. All

signal and power wiring shall be designed to avoid interference from electromagnetic

equipment.

B. The automation control system shall be a microprocessor-based system. The design of the

automation control system is based on Schweitzer, SEL-2240 AXION I/O

processors/controllers. Specific functions, features and performance requirements shall

include the following:

1. Real-Time Automation Controller (RTAC) provides high-speed, deterministic control

and performance.



2. Modular design supports custom configuration mix of analog and digital I/O modules

3. Hardware and components meet or exceed IEEE 1613 specifications for harsh

conditions.

4. Exe-GUARD® whitelist antivirus technology allows only authorized applications to

run.

5. Web-based human-machine interface (HMI) for system-wide visualization and control.

C. The microprocessor-based system shall operate simultaneously on multiple serial and

Ethernet communications networks. It shall provide a combination of functions that

include digital input and digital output support, deterministic logic processing, automatic

transmission of outgoing messages and processing of responses, data scaling, data

aggregation, simultaneous collection of data from multiple server devices, and

simultaneous data access for multiple client (master) devices. The system shall be immune

to and not emit RFI and EMI.

D. Provide automation controller with operational and functional requirements are as

follows:

1. Operating Temperature. The programmable automation controller shall have an

operating temperature range of –40° to +85°C (–40° to +185°F) and a power supply

input operating voltage range of 85–264 Vac/85–275 Vdc.

2. Protocols. The information processor shall provide the following protocols:

a. Server: SES-92, FTP, SFTP b. Client: CP2179, SEL ASCII and Binary, SNMP c. Client/Server: DNP3 serial, DNP3 LAN/WAN, IEC 61850 MMS, Modbus®

RTU, Modbus TCP, LG 8979, IEEE C37.118, IEC 60870-5-101/104 d. Peer-to-Peer: IEC 61850 GOOSE transmit and receive messages, Parallel

Redundancy Protocol

3. Redundant Power Supply Operation. The system shall allow the use of two power

supply modules that continuously share load. If the incoming power for one module

becomes unavailable, the remaining power supply shall have sufficient capacity to

accommodate an entire node.

4. Digital Inputs Sequential Events. The system shall maintain a user-configurable record

of digital input operations on the EtherCAT network that is accurate to 1 ms.

5. DC Analog Inputs. The system can include as many as 16 DC analog input modules.

Input ranges are ±20 mA, ±2 mA, and ±10 V.

6. DC Analog Outputs. The system can include as many as 16 DC analog output modules.

Output ranges are ±20 mA and ±10 V.

7. AC Metering Inputs. The system can include as many as 16 CT/PT analog input

modules. Input ranges are 0–22 A for CT inputs and 5–400 V for PT inputs.

8. AC Protection Inputs. The system can include as many as 16 CT/PT protection

modules. Input ranges are 0–20 A for CT inputs and 6–300 V for PT inputs.



9. Intelligent and Secure Components. All electronic equipment shall continuously self-

test and report internal errors. The system shall have a hardwire contact indicating

system health.

10. IEC 61131-3 Programming. The system shall include an integrated IEC 61131-3

programming environment, with the ability to monitor and control every connected

Ether CAT I/O module, protective relay, and other serial or Ethernet-based intelligent

electronic devices (IED) continuously. The IEC 61131-3 programming environment

shall be integrated in one software package with the communications protocol mapping

environment.

11. Role-Based Security. The system shall incorporate independent user-based security

with strong passwords, role-based accounts, and settable account expirations dates. The

system shall provide a mechanism to map security related system tags into SCADA

reports.

12. Central Authentication. The system shall use Lightweight Directory Access Protocol

(LDAP) to provide central user account authentication.

13. Selectable Processing Interval and Solve Order. The system shall include a method to

configure the deterministic processing interval for protocol communications and

custom logic. The system shall also include a method to configure the processing

sequence of software tasks.

14. High-Speed Peer-to-Peer Communication. The system shall use MIRRORED BITS®

communications and IEC 61850 GOOSE protocol to transmit and receive high-speed

digital data to/from IEDs to create custom protection and control schemes. IEC 61850

GOOSE shall be an available option for the system.

15. IEC 61850. The information processor shall have an option to support IEC 61850

GOOSE transmit and receive messaging. There shall also be an option to support IEC

61850 MMS client/server for polling and sending data sets and reports from IEDs.

16. Deterministic Ethernet Fieldbus. The system shall use EtherCAT protocol to operate a

deterministic, Ethernet-based fieldbus network for connected I/O modules.

17. Web-Based HMI. The system shall have web-based HMI that has complete access to

all system tags available.

18. Serial Communications Ports. The system shall have four serial ports that shall be

software configurable for EIA-232 or EIA-485 communications modes. Each serial

port connector shall have an available demodulated IRIG-B time-synchronization

signal.

19. Ethernet Communications Ports. The CPU module for the system shall have two

Ethernet ports that can operate simultaneously on different networks through

independent MAC addresses.

20. Alarm Output. There shall be an alarm contact output to signal internal errors and

malfunctions. The alarm contact shall be programmable so that the alarm conditions

that activate the output can include additional conditions.



21. Environmental Testing. All system modules shall be tested to IEEE 1613-2003 for

communications and networking equipment in electric power substations. The system

modules shall also be tested to the same standards as those used for protective relays.

22. Retained Memory. The system CPU shall have nonvolatile memory available for user-

programmable retained variables.

23. Engineering Access. The system CPU shall have methods to create transparent

connections between any two serial or Ethernet communications ports for engineering

access.

24. Reliability. The vendor shall supply the actual measured mean time between failures

(MTBF) for the device upon request.

25. Service. The device shall include no-cost technical support for the life of the product.

26. Manufacturer. The device shall be manufactured in the U.S.A.

27. Conformal Coating. The device shall have conformal coating for each module to

protect the circuit boards from harsh environments.

28. Warranty Return. The manufacturer will endeavor to support a 72-hour turnaround on

all warranty repairs.

29. The device shall include a ten-year warranty for all material and workmanship defects.

The warranty period will begin from the date of the CITY’s acceptance of the bridge

being fully operational.

2.015 RTAC INFORMATION PROCESSOR (SE-3530-4)

A. Provide high-performance, rugged information processor designed for harsh environment

and suitable for use in industrial control and automation systems. The RTAC Information

Processor shall provides complete and flexible system control with integrated security,

seamless configuration, unified logic, and reliability. It converts data between multiple

protocols, communicates with any configured and connected device, and comes with an

embedded IEC 61131 logic engine.

B. The basis of design specification is based on Schweitzer, SEL-3530-4 RTAC Information

Processor. Provide system configuration as required to perform all of the required control,

monitoring, communication functions for the designed application. Specific functions,

features and performance requirements shall include the following:

1. Powerful 32-bit microcontroller for relay-speed I/O, logic, and communications.

2. Operating temperature range of –40° to +85°C (–40° to +185°F); for use indoors and

in outdoor cabinets.

3. No moving parts combined with an industrial design that meets and/or exceeds the

IEEE 1613 specification for harsh environments. The RTAC Information Processor

shall have high availability built to withstand vibration, electrostatic discharge (ESD),

and extreme temperatures.



4. Secure access point with central authentication and role-based user authentication,

access logs, and secure engineering access via Secure Shell (SSH).

5. Error-correcting code (ECC) RAM for data integrity.

6. No fans: quiet, clean, and reliable.

7. Provide conformal coating.

8. Simple Setup with preconfigured device templates. The Tag Processor provides

methods to map data relationships between communications protocols visually.

9. Multiple Device Functions in One Reliable Device. Use a single RTAC as a protocol

gateway, RTU, logic processor, PAC, engineering port server, event processor, and

system-wide SER logger/viewer.

10. Proven Reliability. The RTAC is designed and tested to withstand vibration, electrical

surges, fast transients, and extreme temperatures that meet or exceed protective relay

standards and IEEE 1613 “Standard Environmental and Testing Requirements for

Communications Networking Devices in Electric Power Substations.”

11. IEC 61850. Integrate high-speed control schemes between the RTAC and relays with

IEC 61850 GOOSE peer-topeer messaging. Poll and send data sets and reports from

other IEDs with IEC 61850 MMS client/server.

12. Integrated HMI. Build custom human-machine interface (HMI) displays quickly and

easily without the need for mapping data tags. Because it is web-based, no special

software is needed for viewing HMI displays.

13. Protection Against Malware and Other Cybersecurity Threats. Protect your RTAC

system with exe-GUARD®, which uses advanced cryptographic algorithms to

authorize the execution of any program or service on the system. Any tasks not

approved by the whitelist are blocked from operation.

14. User Security. Assign individual user and role-based account authentication and strong

passwords. Use Lightweight Directory Access Protocol (LDAP) for central user

authentication.

15. Integrated Security Management. Comply with NERC/CIP user authentication,

logging, and port control requirements.

16. Standard IEC 61131-3 Logic Design. Create innovative logic solutions directly in

ACSELERATOR RTAC by using any of the editor tools: Tag Processor, Structured

Text, Ladder Logic, or Continuous Function Chart.

17. Flexible Protocol Conversion. Apply any available client or server protocol on any

serial or Ethernet port. Each serial port can be used in software-selectable EIA-232 or

EIA-485 mode. The two rear Ethernet ports can optionally be copper or fiber-optic

connectors.

18. Standard Data Management. Map and scale data points easily between protocols in

small and large systems. You can also normalize IED data into common data types,

time-stamp formats, and time zones.



19. Single-Point Engineering Access. Gain engineering access to station IEDs through a

single serial port, external modem, or high-speed network connection.

2.016 RTAC COMPUTER (SEL-3355)

A. The automation controller computer shall be designed to operate properly in a harsh

environment condition with vehicle traffic vibration, high moisture and salinity ratio. The

operating environment includes possible electromagnetic and radio frequency fields. All

signal and power wiring shall be designed to avoid interference from electromagnetic

equipment.

B. The following features and enhancements shall be are included in the system:

1. x86-64 Architecture, 2.8 GHz quad-core CPU.

2. Microsoft Windows operating systems with all of the software required for bridge

control, monitoring, reporting, and security functions.

3. The system shall include rear-panel I/O connectors for linking to networks, peripherals,

storage, video, audio, alarm, and serial

4. I/O—all with protection against electrical shock and surge.

5. Two load-sharing, hot-swappable power supply modules, enabling you to power the

SEL-3355-2 from two independent power sources for maximum availability and

without needing to use inverters.

6. Two 2.5-inch SATA drives.

7. One 1 TB high-performance, industrial-rated, solid-state drives (SSD).

8. The integrated SATA controller supports Redundant Array of Independent Disks

(RAID) configurations to maximize data availability and improve storage volume

performance.

9. DVI, DisplayPort, and HDMI video connections.

10. Analog HD audio inputs and outputs enable connection to amplified speakers,

microphone, and audio sources for clear audible user feedback, audio capture and

analysis, and voice recognition.

11. Four rear-panel and two front-panel USB ports for connection to a local keyboard,

mouse, and any USB peripherals. Each port is individually current-limited, protecting

the system from external short circuits, and enabling high-power devices such as USB

hard drives to be powered from any USB port.

12. Supports as many as four standard PCIe form-factor expansion cards and one 32-bit

PCI card, enabling you to customize the system I/O to meet your application needs.

Choose from a selection of SEL PCIe expansion cards or install your own custom,

third-party expansion card.

13. Two 10/100/1000 Mbps Ethernet port connections on the rear panel support high-speed



network connectivity and enable connections to independent networks or redundant

paired network connections. Network interface cards such as the SEL-3390E4 Quad-

Gigabit Ethernet Card can be added to the SEL-3355-2 for additional network

connectivity.

14. Two standard EIA-232 serial ports enable connection to adjacent electronic devices

such as automation controllers, communications radios, and modems. As many as four

SEL-3390S8 Serial Expansion Cards can be added to the SEL-3355-2 for applications

that require many serial I/O connections and IRIG time synchronization and

distribution.

15. System Monitoring and Watchdog. An embedded controller works in unison with the

SEL SysMon software to provide an extra level of computer system reliability and to

detect failures in the application software or operating system. The system logs any

abnormal conditions, enables the system alarm to alert operators of a problem, and, if

necessary, can perform a self- reboot to return to a normal operating state.

16. Alarm Contact Output. SEL SysMon software controls the alarm contact output to

signal in case of system health problems or malfunctions. The Form C contact supports

both normally open and normally closed alarm operation.

17. Remote Management. Supports remote access over Ethernet by using Windows

Remote Desktop or Intel vPro Active Management Technology (AMT), enabling full

access to system video, keyboard, mouse, and storage.

18. Warranty Return. The vendor shall support a 72-hour turnaround on all warranty

repairs.

19. Warranty. The device shall include a ten-year for all material and workmanship defects.

In addition, the warranty shall cover accidental customer-induced damage.

2.017 DISCRETE PROGRAMMABLE AUTOMATION CONTROLLER (SEL-2440)

A. The Discrete Programmable Automation Controller (DPAC). Apply the DPAC to satisfy

stand-alone or distributed input, output, and communications needs. The automation

controller shall be designed to operate properly in a harsh environment condition with

vehicle traffic vibration, high moisture and salinity ratio. The operating environment

includes possible electromagnetic and radio frequency fields. All signal and power wiring

shall be designed to avoid interference from electromagnetic equipment.

B. The basis of design specification is based on Schweitzer, SEL-2440 Discrete

programmable Automation Controller. Provide system configuration as required to

perform all of the discreet input and output monitoring, communication functions for the

designed application. Specific functions, features and performance requirements shall

include the following:

1. Powerful 32-bit microcontroller delivers relay-speed I/O, logic, and communications.

2. Communicate with DNP3, Modbus®, and IEC 61850 protocols over Ethernet and



serial connections. Direct and select-before-operate (SBO) outputs are supported.

3. Isolated dry inputs (16 or 32)

a. Optoisolated b. MOV protection c. Level sensitive inputs. d. 300 V input maximum

4. Electromechanical outputs (32 or 16)

a. Pickup time <5 mS b. 6 A continuous carry c. 30 A make per IEEE C37.90 d. MOV protection

5. One front USB port

6. The DPAC does not require special communications software. Use any system that

emulates a standard terminal system for engineering access to the device.

7. –40° to +85°C (–40° to +185°F) (not applicable to UL installations. UL rated 40°C)

8. Power Supply 120VAC, Range: 19.2-264VAC

9. Standard Protocols: SEL protocols, SEL Mirrored Bits communications, SEL ASCII

and Fast Message, SEL Messenger Points, Modbus serial and Modbus TCP/IP, and

DNP3 and DNP LAN/WAN

10. Standards: IEEE C37.90-1989, IEC 60255 and 6100, and IEEE 1613-2003

11. Electrical Equipment for Measurement, Control, and Laboratory Use: IEC 61010-

1:2013 UL 508:2018 C22.2 No. 61010-1:12 IEC 61010-2-201:2013 UL 61010-2-

201:2017 C22.2 No. 61010-2-201:14 Measuring Relays and Protection Equipment:

IEC 60255-26:2013 IEC 60255-27:2013

12. 2000 Vac/2500 Vdc HiPot

13. 2U panel-mount 124.5 mm H x 502.9 mm W x 158.1 mm D (4.90 x 19.80 x 6.23 in)

14. Warranty Return. The vendor shall support a 72-hour turnaround on all warranty

repairs.

15. Warranty. The device shall include a ten-year for all material and workmanship defects.

In addition, the warranty shall cover accidental customer-induced damage.

16. Programmable Automation and Logic

a. 32 logic variables b. 32 math variables c. 32 timers d. 32 counters e. 32 remote control points f. 128 remote analog points g. 32 latching points

17. Optional Features



a. IEC 61850 communications b. Conformal coating

2.018 ETHERNET RADIO (SEL-3060B)

The serial radio transceiver shall be a microprocessor-based and shall provide wireless

ethernet radio communication. Self-checking functions shall be included. The basis of design

specification is based on Schweitzer, SEL-3060B ethernet radio which uses the 2.4 GHz ISM

band. Specific functions, features and performance requirements shall include the following:

A. Operates in Harsh Environments. Operates reliably between –40° and +85°C (–40° to

+185°F), and complies with IEEE 1613, IEEE C37.90, and IEC 60255 standards.

B. Two Operating Modes. Supports point-to-point radio operation for higher performance

and point-to-multipoint for efficient and economical data gathering from remote

locations. In point-to-multipoint mode, as many as 63 nodes are supported and a repeater

can be configured using two collocated radios.

C. Two RJ45 10/100BASE-T Ethernet Ports Provide Connectivity. Offers a wireless LAN

extension for an Ethernet LAN in a substation and compatibility with Ethernet field

devices.

D. Operates in License-Free Frequency Bands for Simplicity and Lower Cost. Provide SEL-

3060B which uses the 2.4 GHz ISM band.

E. Long-Range Operation Connects More Devices. Supports communications links of 7

miles (SEL-3060B point-to-multipoint).

F. High Data Rate for Higher Bandwidth Applications. Transfers data at a rate of 1 Mbps,

suitable for surveillance video.

G. Offers Low Latency for Ethernet Control Applications. Offers 6–12 ms latency for IEC

61850 GOOSE messages using point-to-point operation.

H. Uses Encrypted Wireless Communication for Security. Includes 128-bit AES encryption

for wireless transmission.

I. Easy-to-Use Interface Streamlines Radio Commissioning.

J. Power input: 9–30 Vdc at less than 4 watts

K. Output power: +20 dBm for SEL-3060A, +17 dBm for SEL-3060B

L. Receive sensitivity: –93 dBm at 1% packet error rate (PER) for SEL-3060A, –91 dBm at

5% PER for SEL-3060B

M. Warranty. The radio shall have a minimum ten-year warranty.



2.019 MANAGED 24-PORT ETHERNET SWITCH (SLE-2730M)

The serial radio transceiver shall be a microprocessor-based and shall provide wireless

ethernet radio communication. Self-checking functions shall be included. The basis of design

specification is based on Schweitzer, SEL-3060B ethernet radio which uses the 2.4 GHz ISM

band. Specific functions, features and performance requirements shall include the following:

A. Operating Temperature Range: –40° to +85°C (–40° to +185°F)

B. Dual Power supply: 120 Vac @ 45–65 Hz, Hot-swappable, redundant.

C. Supports tagged and untagged 802.1Q VLANs to separate SCADA and IEC

61850GOOSE messages from other traffic.

D. Features IEEE 802.1p traffic prioritization through configurable CoS and DiffServ

mappings to four service levels to support critical substation messaging.

E. Easily connect to a laptop computer during initial setup using the front-panel

10/100BASE-T Ethernet port, which by default functions as a Dynamic Host

Configuration Protocol (DHCP) server.

F. Sixteen 10/100 Mbps copper or 100mbps fiber ports in four-port modules.

G. Restrict access to select end stations via IEEE 802.1X MAC-based port security. Ports

can be disabled through settings. Manage the switch via an HTTPS secure web server.

SNMPv3 provides secure network management. The switch can forward syslog security

logs to up to three central servers.

H. Enable fast network recovery after a topology change due to a link failure, via IEEE

802.1D-2004 RSTP.

I. Monitor ingress and egress traffic for each port and view network statistics via an

encrypted connection. Port mirroring supports mirroring ingress and egress frames to a

target port.

J. Enhances network performance by supporting the filtering of multicast MAC addresses.

K. Supports SNMPv1/v2c/v3 network management protocols.

L. Allows devices across the local-area network to identify themselves and their capabilities

via IEEE 802.1AB.

M. Uses a secure GUI-based management interface for all switch settings.

N. Supports authentication of firmware through digital signatures.

O. Synchronizes with system time using NTP or can use its own internal clock.



P. Authenticates and authorizes users via user-based accounts.

Q. Monitors health and function, and reports state changes.

R. Maintains logs locally and forwards event messages via the Ethernet network.

S. Filters Ethernet traffic volume on individual ports and ensures reasonable data throughput

on ingress/egress traffic. 2.020 OPERATOR HMI TOUCH PANEL

Provide AIS Rugged Touch Panel PCs with the following features: IP65/NEMA 4 rated

compact aluminum housing, no rotating parts (fan/ HDD), energy-efficient with 100%

dimmable display brightness, fan-less operation up to ambient temperatures of 50 °C; and

resistance to high temperature, vibration, shock and EMC for 24-hour continuous operation

without maintenance.

Display (Basis of design: AIS HMI-TPND0U-24AR-X00H)

Size in inches / resolution in

pixels

24" / FWXGA, 1920 x 1080

Brightness / luminance 250 nits / 250 cd/m²

MTBF of backlight LED-backlight up to 100,000 hours in Eco mode

Touchscreen Single-touch (resistive analog)

System hardware

Processor Intel® Core™ i7-4650U Processor; 4M Cache up to

3.30 GHz, 15 W maximum TDP

Cores / speed 2 / 1.7 GHz

Memory / # of slots 16 GB / 2 slots

Graphics / video Intel HD graphics; DirectX 11.1, OpenCL /GL, and 4K videos

Quick Sync encoder

RAID RAID 1 system with onboard RAID controller

Drives

Mass storage 1 x 180 GB SSD, configurable up to 2 x 180 GB SSD RAID1

preconfigured

Secondary storage 32GB m-SATA SSD

Optical drives Connection via USB port



Interface ports

Ethernet 2 x Ethernet TCP/IP - RJ45

USB 4 x USB 3.0

Serial COM1: RS232/422/485 ; COM2: RS232, isolated

Graphic 1 x VGA; 1 x HDMI

Audio 1 x Line-in, 1 x Line-out

General features

Operating system Windows Embedded 7 32/64 bit ; Windows Embedded 8

Free expansion slot 1 x PCIe (x4)

Current supply 24 V DC; 9.6 to 28.8 V, isolated

Bezel / housing Aluminum / aluminum

Mounting options Panel PC: Panel / wall mount Box PC: Wall / DIN

rail mount

Packages / bundles Packages with Wonderware InTouch, ready-to-use HMI

software

Environment / ambient conditions

Degree of protection /

thermal

Front: IP66; Rear: IP20 / Fanless

Electromagnetic

compatibility CE, FCC A, EN 61000-6-4, EN 61000-6-3, CISPR22, RoHS

Vibration during operation Tested according to DIN IEC 60068-2-64: 5 - 500 Hz: 1 Grms

Shock during operation Tested according to DIN IEC 60068-2-27: 15 gn for 11 ms

Ambient temperature 0-50°C (32-122°F)

Relative humidity 30% to 95% at 40°C (no condensation)

Certifications / regulations UL/cUL/IEC 61010-1, UL/cUL/IEC 62368-1, CB reports

available for all models

2.021 POWER METER DISPLAY (P40N+)

Provide Nexus® Series substation meters with a long-life LED display, alpha-numeric serial

indications that allow field personnel to easily identify reading values. Features include 75

data screens which display Voltage, Current, Power, Energy, Phase Angle and Phase



Sequence, as well as Instantaneous, Max/Min and THD data.

A. SPECIFICATION

1. Maximum Input Voltage: 30V DC

2. Minimum Input Voltage: 12V DC

3. Maximum Power Consumption: 5 Watts

4. Nominal Power Consumption: Approximately 3 Watts

5. RS-485 Modbus Communication

6. Operating Temperature Range: -20°C to + 70°C / -4°F to +158°F

7. Overall Dimensions (H x W x L): 5.25 x 5.25 x 1.79 in / 13.34 x 13.34 x 4.54 cm

2.022 APPLICATION SOFTWARE, OPERATING SYSTEM, AND LICENSES

A. All software packages, even if not mentioned in this Special Specification, necessary to

implement control logics and to perform the package supervision shall be included with

the relevant licenses.

B. The licenses shall not have restriction concerning the number of signals that can be

managed. Neither partial licenses (like database licenses with limitation on record number

configuration) nor fixed deadline licenses are acceptable.

C. All system configuration and application developed for project application shall be

provided both in compiled and in source version, in order to allow any modification and

reload by the CITY/CONTRACTOR.

D. The source files shall be properly commented during the implementation to allow a

complete understanding by the maintenance staff.

E. Detailed operating instruction for programming and configuration shall be supplied by

the VENDOR.

F. Standard software license shall be assigned to the CITY for software provided upon initial

installation of each software component. Software licenses shall be issued in CITY’s

name and transferred without restrictions to the CITY upon completion of Project.

G. Extend to the CITY all rights of software purchased including telephone support during

warranty period shall be extended to the CITY.

H. Complete software and programming backup package shall be provided by VENDOR at

the end of the project. 2.023 PANEL FACTORY WIRING



A. Control Power wire:

1. Rating: 600V, 90ºC, PVC insulation/jacket, Type MTW.

2. Conductors: Stranded copper, 12 AWG.

B. Analog signal cable:

1. Configuration: Twisted pair, shielded, and jacketed.

2. Insulation: 300V, 60ºC, PVC, color-coded to permit identification of each conductor.


4. Shield: Metalized foil or tinned copper braid providing 100% coverage against noise

together with 20 AWG stranded tinned drain wire.

C. Discrete signal wire:

1. Rating: 600V, 90ºC, PVC insulation/jacket, Type MTW.


D. Power and discrete signal wire insulation color:

1. BLK: Line voltage.

2. BRN: Line voltage/fused.

3. RED: 120Vac.

4. ORG: 24Vac.

5. YEL: Caution/may be live from remote power source.

6. GRN: Ground.

7. BLU: Dc negative.

8. VIO: Dc positive.

9. WHT: Neutral at GND potential.

E. Wires and cables shall be grouped and routed from terminal blocks to panel-mounted

instruments in separate raceway as follows:

1. Low voltage/low current dc analog signals (30V/50mA or lower).

2. High-voltage dc alarm signals (48V or greater).

3. Low-voltage ac control signals (120V or lower).

4. High-voltage ac power signals (greater than 120V).

F. Provide surge suppressor terminal blocks for analog and discrete signals for field devices

not located within the same building structure as the source I/O Modules:

1. Analog signal blocks: Voltage rating 24Vac/dc.



2. Discrete signal blocks: Voltage rating 24/120Vac/dc.

G. Terminal block requirements:

1. Type: High-density.

2. Voltage: 600V.

3. Wire range: 30 AWG to 12 AWG.

4. Termination: Screw clamp compression with pressure plate equipped with fuse (for

digital output signals) and knife-edge. Fuse Blown LED indication shall be available

for fused terminals.

5. Mounting: Rail-mounted with end anchors and barriers. All terminal strips shall be

tagged with Multi-cable Tag Number, and each terminal shall be individually identified

with a progressive number.

6. Spare: Provide greater amount of 20% or 6 terminals per terminal strip

7. Install power distribution blocks to parallel feed to power control devices. Parallel

wiring from instrument to instrument is not acceptable.

8. Provide plug-in strip for ac supply power to devices requiring ac power via power cord.

9. Circuit protection

a. Install individual circuit breakers for protection of control panel power supply circuits as identified above.

b. Group circuit breakers on separate terminal strip away from low-voltage instrumentation circuitry.

c. Provide fuses for protection of individual instrumentation circuits. Instrumentation circuits for field-mounted instruments may be combined in logical groupings of no more than 10 devices/signals.

d. Provide 8 AWG internal copper grounding bus for ground connections. e. Wire tags:

• Type: Embossed, heat-shrink tubing. Fiber tape tagging not acceptable.

• Color: White.

• Identify both ends of wires and/or cables with permanent wire marker. 2.024 PANEL AUXILIARY SERVICE EQUIPMENT

A. Fluorescent lighting fixtures of sufficient size and quantity to provide 30 to 50 foot-

candles of illumination within panel. Wire to UL-approved switch mounted inside panel.

B. Duplex, 120-volt ac, 3-wire grounded type convenience outlets. Provide 1 duplex

receptacle per 12 sq ft of subpanel area. Service outlets shall be powered from separate

voltage source (non-UPS feeding line) than instrumentation and controller equipment.

2.025 PANEL AUXILIARY SERVICE EQUIPMENT



A. Fluorescent lighting fixtures of sufficient size and quantity to provide 30 to 50 foot-

candles of illumination within panel. Wire to UL-approved switch mounted inside panel.

B. Duplex, 120-volt ac, 3-wire grounded type convenience outlets. Provide 1 duplex

receptacle per 12 sq ft of subpanel area. Service outlets shall be powered from separate

voltage source (non-UPS feeding line) than instrumentation and controller equipment. 2.026 CONTROL SYSTEM POWER DISTRIBUTION

A. Electrical power to all systems shall be 120Vac, 60 Hz, single phase with neutral solidly

grounded, from redundant Uninterruptable Power Supply (UPS).

B. Non-UPS 120Vac 60 Hz, single phase, with neutral solidly grounded, from electric board

shall be provided for auxiliary power requirement like lighting, service socket, etc. of

controller cabinets.

C. Control cabinets fan when required will be powered by redundant 120Vac from normal

power supply.

D. The Vendor shall provide the necessary power supply conditioning for transients and

surges resulting from a noisy process environment and shall state limitations of his

equipment.

E. The Vendor shall regulate power individually for all I/O points and within each controller

group. 2.027 CONTROL SYSTEM PROGRAMMING REQUIREMENTS

A. The control system shall be fully configured and programmed to perform bridge operation

function functions as described in the Special Note - Sequence of Operation and as

functionally illustrated on the design drawings.

B. The control system shall be fully configured and programmed to maintains alarms and

events logs locally and forwards event messages via the ethernet network to telephone

numbers and email addresses. The CITY will provide the telephone numbers and email

addresses for the event messages to be sent to 14 days prior to factory witness testing

(FAT).

C. Provide the following alarm notifications and alarm event logs as a minimum:

1. PRIORITY 1 ALARM/EVENT LOGS

a. BRIDGE POWER OUTAGE b. EMERGENCY STOP ACTIVATED c. BRIDGE ON EMERGENCY GENERATOR d. CONTROL SYSTEM FAILURE ALARM e. PROGRAMMABLE LOGIC CONTROLLER FAILURE(S) f. CONTROL SYSTEM COMMUNICATION FAILURE(S) g. DRIVE(S) FAULTS



h. SYSTEM OVERSPEED TRIP

PRIORITY 2 ALARM/EVENT LOGS

a. CONTROL SYSTEM TROUBLE COMMON ALARM b. SPAN DRIVE MOTOR(S) OVERLOAD c. BRAKE MOTOR(S) OVERLOAD d. SPAN LOCK MOTOR(S) OVERLOAD e. MOTOR BRAKE(S) MANUALLY RELEASED f. MACHINERY BRAKE(S) MANUALLY RELEASED g. TRAFFIC GATE(S) IN MANUAL HAND CRANK h. BYPASS SWITCHES IN BYPASSED POSITION

2. INDICATIONS:

a. TRAFFIC SIGNAL LIGHT INDICATION (GREEN/YELLOW/RED/FLASHING YELLOW)

b. SPAN POSITION NAVIGATION LIGHT (GREEN/RED) INDICATION c. DIGITAL POSITION OF SPAN LEAVES (FC/NC/NO/FO/OT) d. SPAN POSITION HEIGHT (FEET) e. OUT OF SKEW ANGLE (DEGREE) f. POSITION OF ALL BRAKE(S) (SET/RELEASED) g. POSITION OF ALL SPAN LOCK(S) (PULLED/DRIVEN) h. POSITION OF TRAFFIC GATE(S) (RAISED/LOWERED) i. POSITION OF ALL LIMIT SWITCH(ES) j. CONTROL SYSTEM IN MANUAL MODE k. ON-COMING TRAFFIC GATE(S) BYPASSED l. OFF-GOING TRAFFIC GATE(S) BYPASSED m. TAIL LOCK(S) BYPASSED n. TRAFFIC SIGNAL(S) GO TO GREEN BYPASSED o. SPAN LEAF FULLY CLOSED LIMIT SWITCH(ES) BYPASSED

CONSTRUCTION DETAILS

3.01 EXAMINATION

A. Verification of Conditions: verify that conditions of substrate previously installed under

other Sections or Contracts are acceptable for installation in accordance with

manufacturer's written instructions.

1. Visually inspect substrate in presence of Departmental Representative and Consultant.

2. Inform Departmental Representative and Consultant of unacceptable conditions

immediately upon discovery.

3. Proceed with installation only after unacceptable conditions have been remedied and

after receipt of written approval to proceed from Departmental Representative.

3.02 PROTECTION AGAINST CORROSION

A. Provide equipment enclosures with the standard finish by the manufacturer when used for

most indoor installations. For indoor installation, hot dip galvanized ferrous metals

hardware is acceptable.



B. For outdoor installation of electrical equipment, provide stainless steel hardware such as,

but not limited to, anchors, bolts, braces, boxes, bodies, clamps, fittings, guards, nuts,

pins, rods, shims, thimbles, washers, and miscellaneous hardware.

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

3.01 INSTALLATION

A. The electrical installation work shall be installed as indicated on the Contract Drawings

and in accordance with approved shop drawings and manufacturer’s recommendations.

B. All associated construction and installation work shall be installed using good installation

judgement and in accordance with all prevailing national and local codes and ordinances.

C. Install equipment in accordance with the approved manufacturer's printed installation

drawings, instructions, wiring diagrams, and as indicated on project drawings and the

approved shop drawings. A field representative of the drive manufacturer shall supervise

the installation of all equipment, and wiring.

D. Motor

1. Connect motor with flexible metallic conduit.

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

instructions.

3. Mount motors with bolts. Ensure motor feet are coplanar within 0.0254 millimeters,

and base mounting points are accessible and adjustable to enable machine alignment.

Install alignment jack bolts for motors 15 hp or larger to enable alignment.

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

resistant stainless steel.

5. Perform motor and load alignment under the direction of the manufacturer's

representative. Recheck alignment of motors and adjust as required after the motor has

been in operation for not less than 48 hours. Provide written final alignment settings as

part of the final test data.

E. Field Instruments

1. Provide field instrument NEMA 4X, stainless steel termination box required for

connection of field instrument cables to field wiring cables. The field instrument

termination box Connect motor with flexible metallic conduit.

2. Provide all the necessary mounting using stainless steel brackets and hardware required

to securely mount the field instrument devices. Where practical, use adjustable bracket

to allow field adjustment of instrument position during testing and commissioning. The

Contractor is to field located field instruments, set their position and make field



adjustment as necessary to provide proper function and performance required by the

bridge control system.

3. Install, align, connect, calibrate, and make necessary adjustment in accordance with the

equipment manufacturer's instructions.

3.02 FIELD QUALITY CONTROL

A. Manufacturer's Field Services:

1. Provide manufacturer's field services to support inspection of product installation,

startup, testing and commissioning in accordance with manufacturer's instructions and

recommendations. Arrange and pay for services of manufacturer's factory service

engineer to supervise start-up of installation, check, adjust, balance and calibrate

components and instruct operating personnel. Provide these services for such period,

and for as many visits as necessary to put equipment in operation and ensure that

operating personnel are conversant with aspects of its care and operation.

2. Obtain written report from manufacturer verifying compliance of product installation,

startup, testing and commissioning in accordance with manufacturer's instructions and

recommendations.

3. The control equipment and instrumentation devices are to be reviewed for

conformance, system compatibility, and be coordinated by the control system

integrator.

B. Progress Cleaning:

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

2. Upon completion of work remove surplus materials, rubbish, tools and equipment in

accordance with requirements of construction/demolition waste management and

disposal of the contract.

3.03 INSPECTION, TESTING, AND COMMISSIONING

A. Inspection checklists, functional tests, start-up and commissioning documents are the

normal procedure of ensuring that the bridge machinery equipment, power and control

systems are properly installed and function as intended design. Contractor shall be

responsible for the start-up and commissioning activities. The Contractor in cooperation

with subcontractors and the A/E shall develop inspection checklists and testing and

commissioning plan during the Construction Phase.

B. The Contractor shall complete inspection and functional checklists for all pieces of

equipment and documentation shall be submitted to the CITY for verification and

approval prior to Acceptance Performance Testing. Acceptance Performance Test shall

include:



1. Visual and mechanical Inspection.

2. Electrical tests.

3. System performance and functional tests.

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

requirements prior to scheduling the acceptance tests.

D. Contractor shall notify the CITY and the Engineer provide written certification that the

electrical equipment and/or sub-systems installation is properly completed and function

in accordance with the Contract Documents, applicable codes and standards, and

manufacturer’s requirements; and that the system is ready for System Acceptance

Performance Tests. Any outstanding items or non-conformance shall be clearly indicated

on the submittal document and an action item shall have been initiated.

E. The VENDOR shall be responsible for all the necessary tests of the control system, both

Factory Acceptance Test (FAT) and the Site Acceptance Test (SAT). Testing shall

include both hardware and software items included in its scope of supply.

F. Testing shall include all system hardware, communications, back-up and redundancy

operations, 100% of I/O points (including spares) with simulated inputs and outputs

(hardware I/O simulator with real tag numbers shall be arranged before testing), local

panel (if any), and any other external device communications interface. Testing shall also

include complete integrated testing of the interfaces including field devices, relay

panel(s), machinery control equipment, and operator control console.

G. Testing shall include functional tests of all logic block diagrams, including all associated

interfaces with the operator console and graphic displays. All testing is to be carried out

to show that the system operates correctly and in compliance with the provided logic

drawings, cause and effect matrix, ladder logic, block diagrams.

H. In the event testing is interrupted for repairs or modification of the Automation Control

System, the CONTRACTOR / CITY may require testing be restarted completely.

I. VENDOR shall provide all necessary test equipment and software including any special

software or hardware required for a complete functional test of the system.

J. VENDOR shall clear and CONTRACTOR shall re-test and approve all punch list items

before the Automation Control System may be released for shipping. In presence of any

pending punch list, the advanced shipping may be authorized by the CONTRACTOR.

K. The VENDOR shall provide the necessary assistance to co-ordinate the field tests, to

supervise the commissioning and start-up activities, to perform the training activities

applicable for the package.

L. The CITY’s representative(s) may attend all of the tests. Any limitation on time required



for the tests is not accepted: any test is considered ended if and only if completed in every

part.

3.04 FACTORY ACCEPTANCE TEST (FAT)

A. The electrical testing shall consist of factory testing of the major items of variable

frequency drives, span drive motors, control panels, and simulated field devices I/O as an

integrated system. These tests shall be conducted by the equipment manufacturer and

witnessed by the Engineer as specified herein. The manufacturer shall submit test

certificates and supporting data corroborating that the testing was performed and

successfully completed in accordance with this Special Specification. The Engineer

testing shall be conducted at the manufacturer’s plant or as elsewhere approved by the

Engineer. The manufacturer shall submit his test procedures to the Engineer for approval

prior to conducting the tests that would constitute acceptance of the manufactured

equipment.

B. The following items of equipment shall be factory tested in the presence of the Engineer:

1. The integrated testing of the variable frequency drive, motors, brakes, starter control

panels, control panels, HMI’s, communications, redundancy, and field devices I/O

interfaces. Spare drive motor shall be used at the factory test.

2. Span motor and variable frequency drive controller tested under load at either the motor

manufacturer or the drive manufacturer’s facility or some of the third-party

independent testing companies’ facility to be approved by the Engineer. The load

testing shall conform to that described herein and include dynamometer testing.

C. The factory testing of each system described above shall consist of completely wiring and

cabling the systems as defined on the approved shop drawings in preparation for the tests.

D. Performing complete functional tests shall be in accordance with the Engineer approved

test procedure.

E. The control system functional tests shall verify the bridge operating sequences for all

modes of operation and prove the relay logic in accordance with the specified sequence

and correct functionality of all control system permissive interlocks.

F. The motor/drive combination shall be factory tested to verify and document that the

combination meets all operating loads and duty cycle specified.

G. The tests shall also include the determination of the variation in speed and motor currents

with motor torques from zero to the maximum designed torque for the drive system. The

speed-current-torque curve shall also be determined for overhauling torque and include

the effects of the motor control equipment on imposed overhauling loads. None of these

curves developed by the manufacturer’s computer program will be accepted in lieu of

actual load tests. Note all tests shall be performed using the integrated motor and variable



frequency drive controller combination and drive system shall be tested and coupled to

dynamometer to simulate the load of the bridge and also to simulate out of balance

conditions to prove the integrity of the proposed load sharing control. These tests shall,

in every respect prove the ability of the combination to achieve the herein drive motor

performance.

H. These tests shall be witnessed by the Engineer and the Engineer shall be given at least

three (3) weeks advanced notice of the scheduled tests.

I. The FAT will concern all the equipment and developed software within VENDOR scope

of supply, as well as the integration with other subsystem supplied by different

VENDORS.

J. Schedule and testing procedures shall be submitted to the CONTRACTOR/CITY as early

in the design as possible, but not less than 60 days prior to test. After schedule approval,

at least 4 weeks prior to the start of testing, the VENDOR shall provide the following

documentation:

1. Detailed FAT procedure

2. Full documentation concerning hardware

3. Full documentation concerning software configuration complete with relevant

comments

4. Records of all test’s priory performed by the VENDOR

5. Records of power-up of all Automation Control system components

K. This documentation, even if not issued as final review, shall be completed and detailed.

L. CITY/CONTRACTOR may ask to postpone the starting date of FAT if any material

omissions or relevant errors in the documentation are met.

M. Prior to the FAT all the necessary equipment shall be fully assembled, wired and

connected in order to test all the functionality of the supply. The VENDOR shall provide

test documentation for all electronic devices and for the cards before system assembling.

N. The VENDOR shall organize the testing activities and make available all the assistance

and equipment necessary so that the testing activity proceeds as quickly as possible.

Location, staff and equipment to perform the test are completely at VENDOR charge.

O. Hardware FAT shall be performed before and independently from Software FAT.

P. During the test, all the mentioned documents shall be available.

Q. The control system shall be installed in its final configuration and mainly the following

items shall be tested:



1. Hardware components and power supply

2. Visual check in order to verify the equipment quantities and conformity to drawings

and contractual characteristics, identification tags, safety coverings, cable run,

interconnection between panels, etc.

3. Project documentation check

4. Insulation resistance and dielectric test of components

5. Redundancy systems test

6. Test of all I/O cards

7. Test of loss of power and subsequent power up

8. Automation Control System diagnostic

9. Application software

10. HMI Graphics

11. Communication

R. As general statement, 100% of hardware (spares included) and application software shall

be tested. In order to facilitate the tests, the VENDOR shall provide all the needed

equipment to simulate digital/analog inputs, to check the status of digital/analogue outputs

and to simulate serial link communication.

S. All the application software will be tested by simulation of all I/O (software simulating

the field is accepted).

T. After the completion of the hardwired FAT, testing procedure shall foresee a complete

integrated testing of the bridge control interfaces (System Integration Test). All the

necessary hardware components and software application necessary to perform the test

will be provided by the VENDOR.

U. Since the Software FAT may be performed after the delivery of the hardware at site, the

VENDOR shall foresee all the necessary equipment in order to proceed with software test

without any additional cost charged to the CITY or CONTRACTOR.

V. All the anomalies, defections or changes will be reported and corrected by the VENDOR

before the end of testing or, at least with the CONTRACTOR approval, before shipment.

CONTRACTOR shall re-test and approve all punch list items before the Automation

Control system may be released for shipping. If during the test activity problems occur so

that it will be difficult to continue, in the opinion of the CONTRACTOR personnel, the

testing will be interrupted until the VENDOR remedies to these problems. In the event

testing is interrupted for repairs or modification of the Automation Control System, the

CITY or CONTRACTOR may require testing to be restarted from the beginning.

W. A check list shall be issued during the FAT at VENDOR’s workshop. Detailed check list



shall be prepared by the VENDOR and included in the FAT procedure. Other tests can be

required according to the project needs and will be defined during detailed engineering.

X. Positive result in the test does not release the VENDOR from his responsibilities to

provide a system completely working and to perform all the modification, which could be

necessary to assure system correct working in the field.

Y. After successful completion of the FAT, the FAT completion report shall be signed by

the VENDOR and CONTRACTOR/CITY.

Z. A final report shall be issued at the end of FAT, highlighting possible reservation as far

the CONTRACTOR/CITY are concerned; shipment authorization will be generally

issued by the CONTRACTOR only after the complete solution for the pending

reservation.

3.05 SITE ACCEPTANCE TEST (SAT) AND COMMISSIONING ASSISTANCE

A. The Site Acceptance Test is intended to verify that the system, as accepted at FAT

completion, will still perform on site as per Special Specification after the shipment. This

test will be performed after erection and wiring completion but jointly with the loop tests

on each individual loop.

B. It shall fully cover all the functionalities of the system that could have been degraded by

dismounting, packing, shipping and installing the system on site (i.e. I/O cables

connections, power supply connections, HW integrity, etc).

C. The other checks shall be repeated as “Sample”, with an extent suitable to demonstrate

that the system has been properly restarted and the configuration correctly reloaded.

D. VENDOR's technicians shall be on site during field test to perform the test and solve any

problem that could arise.

E. Before performing the test, VENDOR is asked to issue and submit for

CONTRACTOR/CITY approval, a Site Acceptance Test Procedure complete with

checklists identifying each test to be performed.

F. The tests, start up and commissioning activities at construction site in charge to the

VENDOR shall at minimum include:

1. Test without auxiliary voltage and insertion of auxiliary voltage

2. check of installed equipment (quantity, quality)

3. check of insulation of cables and equipment electric materials

4. check of cables for continuity and conformity to drawings

5. switch on operating voltage to equipment after checking protection settings



6. Calibration of all adjustable monitoring equipment (limit switches, position

transducers, level transducers, thermostats, level switches, pressure switches, etc.)

7. Calibration and proper operation checkout of all field equipment: controls, local

commands indicators, actuators both electric and electro-pneumatic

8. Check of the interface equipment to PLC by checking the corresponding readings

(alarms, indicators, measurement readings, etc.)

9. No load tests (with the machines energized)

10. Check of direction of rotation of the machines

11. Check of machine power consumption and protection settings

12. Calibration and check the proper operation of the electrical and hydraulic machine

controls, which are possible only when the machine is running

13. Test of the entire software with all I/O connected in their final configuration; all the

controls, sequences, interlocks and specific functions of the program shall be tested

locally from the panel interface (if any) and remotely from the main control room.

G. VENDOR representative shall have at their disposal all the necessary equipment for

testing and put the system into service.

H. The commissioning and system tests include the download of the final hardware/software

configuration.

I. Any software programming change required by Contractor on site and implemented by

Vendor personnel shall be considered part of the Site Acceptance Test scope of work.

3.06 PERFORMANCE VERIFICATION

A. "Performance Verification Test" plan shall provide the step-by-step procedure required to

establish formal verification of the performance of the bridge operation. Compliance with

the specification requirements shall be verified by inspections, review of critical data,

demonstrations, and tests.

B. The CITY and/or CITY’s Engineer reserves the right to witness all tests, review data, and

request other such additional inspections and repeat tests as necessary to ensure that the

system and provided services conform to the stated requirements. The contractor shall

inform the CITY and/or CITY’s Engineer at least 14 calendar days prior to the date the

test is to be conducted.

3.07 TRAINING

A. VENDOR shall provide training course to instruct the operator and maintenance

personnel on the main operation and maintenance acknowledgments for control system.

1. Operator course to instruct the operators for package management maintenance



2. The course content shall contain as a minimum:

a. Introduction to the system hardware and software b. System configuration c. Programmed Control Logic and Sequence of Operation d. Development of graphic displays (where foreseen) e. Installation f. Routing and Preventive maintenance

B. The VENDOR shall submit the courses contents to the CONTRACTOR and the CITY

for approval priory to be held the training courses.

C. The control system vendor’s training course and training materials shall be incorporated

in the overall training sessions.

D. Provide one two 8-hour days training session at the site at a time and place mutually

agreeable between the Contractor and the CITY.

E. Provide session to train up to 6 operation personnel in the functional operations of the

system and the procedures that personnel will follow in system operation. This training

shall include:

1. System overview

2. General theory of operation

3. System operation and Operating Sequence

4. Trouble and Fault Alarms

5. Failure recovery procedures

6. Troubleshooting

3.08 WARRANTY

A. Warranty period: refer to Commercial documentation.

B. Performance warranty:

1. If a failure of performance achievement occurs, the VENDOR shall provide all the

necessary action to satisfy with this Special Specification requirements including

addition or replacement of system components, system re-configuration, etc.

2. Provide extended warranty for controller equipment, software and firmware supplied.

Warranty shall provide replacement parts and software and firmware maintenance for

installed system to the CITY for period extending through start-up and acceptance

period of the project and for period of 10 years.

3. Warranty provisions of license agreement shall cover system software and firmware

including any third-party software supplied with system.



4. Provide telephone support service for period beginning with delivery of equipment and

extending throughout warranty period. Service shall provide telephone consultation

services as required on operation, configuration development, trouble shooting, and

maintenance of system hardware or software by persons in Contractor’s organization

who are thoroughly familiar with equipment and software supplied.

3.09 SEQUENCE OF OPERATION

3.09.01 GENERAL DESCRIPTION OF CONTROL FUNCTIONS

A. The bridge Operator Control Console is provided with a master control power “ON” /

“OFF” Control Switch (maintained contacts, keyed switch). The control system is

energized for operation in an “ON” position; and de-energized in the “OFF” position. The

master control power ON / OFF Select Switch should remain in ON position, unless the

bridge is not going to require operation for a long period of time.

B. The lift span has four span drive/motor sets: Span Drive/Motor 1 and Drive/Motor 2 on

the South Tower (Near Side); and Span Drive/Motor 3 and Drive/Motor 4 on the North

Tower (Far Side). Only one set of drive/motor in each tower is required for normal

operation. The other drive/motor provides backup redundancy. Each set of drive/motor

is selectable via a selector switch located on the Operator Control Console. The following

are the selectable combinations:

1. Drive/Motor 1 and Drive/Motor 3




C. The bridge Operator Control Console is provided with a Speed Select Switch (maintained

contacts switch), which allow the bridge to operate at 100% speed, 75% speed, 50%

speed, or 25% speed. Note that the bridge span will automatically operate at creep speed

(~10%) at the final approach to fully open position and to fully closed position.

D. Traffic Signal “Red” / “Green” Selector Control Switch (maintained contacts switch) is

use to signal vehicle and pedestrian traffic to come to a stop (Red Light) prior to and

during bridge operation, and to release (Green Lights) vehicle and pedestrian traffic after

the completion of bridge operation cycle and bridge is fully seated.

E. The bridge Operator Control Console is provided with traffic gates “Raise” / “Lower”

Control Switch (momentary contacts, spring return switch) for each of the traffic warning

gates and barrier gates. The operator must hold the switch at the “Raise” or at the “Lower”

position for the gate to operate. The operator simply releases the switch handle, spring

return to center to stop the gate(s) motion. The traffic warning gates, and barrier gates

are provided with flashing warning lights on gate arms and warning bells. The flashing

warning lights on gate arms and warning bells activated prior to and during the gate arm



is in motion. The warning bells deactivated when the gate arm is no longer in motion.

The flashing warning lights on gate arms continue to flash until the gate arm is back in

fully raised position.

F. The bridge Operator Control Console is provided with the Lift Span “Open” / “Close”

Control Switch (momentary contacts, spring return switch). The operator must hold the

switch at the “Raise” or at the “Lower” position for the lift span to operate. The operator

simply releases the switch handle, spring return to center to stop the lift span motion.

G. The bridge Operator Control Console is provided with “Normal”/ “Bypass” Control

Switch (maintained contacts, keyed switch). In “Normal” position, the normal control

permissive interlocks of the control system are active. In “Bypassed” position, the normal

control permissive interlocks of the control system are intentionally bypassed by the

qualified bridge operator or maintenance personnel, which allows the continuation of

bridge operation sequence. When in bypass mode, the bridge operator and/or

maintenance personnel must confirm that the bridge is in safe condition and/or situation

before the bridge operation sequence is continue. The following permissive bypass

switches have been provided:

1. On-coming Gate Lowered Permissive Bypass

2. Off-going Gate Lowered Permissive Bypass

3. Barrier Gates Lowered Permissive Bypass

4. Span Fully Seated Permissive Bypass

5. Barrier Gates Raised Permissive Bypass

6. Off-going Gate Raised Permissive Bypass

7. On-coming Gate Raised Permissive Bypass

8. Traffic Signal Go To “Green” Permissive Bypass

H. Traffic Safety Interlocks. The following traffic safety interlocks shall be implemented in

the PLC logic program:

1. Traffic warning gates are prohibited from being lowered when the traffic signal light is

green.

2. On-coming gates must be lowered first before the off-going gates can be lowered, and

off-going gates must be raised first before the on-oncoming gates can be raised.

3. Span leaves are prohibited from being raised with any gate raised or traffic signal green.

4. Traffic signals cannot turn green with any gate(s) not in fully raised position.

I. Span Operation Permissive: The following conditions will prohibit lift span operations:

1. Traffic safety interlocks have not been satisfied

2. Loss of power



3. Drive fault(s)

4. Drive motor(s) overload

5. Overspeed protection trip

6. Out of skew condition

7. Loss of control system communication

J. EMERGENCY STOP button: Available at all times. Will disrupt control power and open

main power contactors to all the machinery motors including span lift motors, warning

gate motors, barrier gate motors, machinery brake motor, motor brakes. The brakes will

automatically set when E-stop is activated or when there is a power outage. The E-Stop

is activated by the bridge operator or maintenance personnel anytime when there is an

unsafety conditions that may endanger lives or damage equipment are observed during

the bridge operation. The control system must be reset after the E-Stop has been activated

(E-Stop button pressed).

K. Waring Marine horn available at all times. The warning horn is use to warn personnel in

the vicinity of the bridge that the bridge is about to operate and to stay away or move

away into safe areas.

3.09.02 LIFT SPAN RAISE SEQUENCE

Initiate State:

A. Turn CONTROL POWER switch to “ON”. System ready to start operation.

1. ALPHA - NUMERIC DISPLAY displays message: "SYSTEM READY."

2. System status:

a. Traffic signals GREEN. b. Flashing yellow lights (WARNING DRAWBRIDGE AHEAD) OFF. c. Traffic gates and barrier gates are RAISED. d. Motor and machinery brakes SET. e. Bridge Span Leaf(s) are FULLY SEATED.

3. Indicating Lights status:

STATUS INDICATIONS ON OFF STATUS INDICATIONS ON OFF

Control power X Barrier gate(s) raised X

Traffic lights green X Barrier gate(s) lowered X

Traffic lights yellow X Brakes set X

Traffic lights red X Brakes released X

On-coming traffic gate(s)

raised

X Span fully opened X


lowered

X Span nearly opened X



Off-going traffic gate(s)

raised

X Span nearly closed X


lowered

X Span fully closed X

B. Start opening sequence.

1. Sound Horn by manually depress HORN (PUSH & HOLD) pushbutton.

2. Turn the Traffic Signal “Red” / “Green” Selector Control Switch to “RED” on the

operator control console starts span raise sequence.

3. The early warning light (flashing yellow lights) automatically turn on.

C. Overhead traffic signals automatically transition from “Green” to” YELLOW”.

1. Change to YELLOW immediately after turning the Traffic Signal “Red” / “Green”

Selector Control Switch to “RED”.

2. Start 5 second timer.







raised



lowered


Off-going traffic gate(s) raised X Span nearly closed X


lowered


D. Overhead traffic signals to RED.

1. Traffic lights change to RED automatically after 5 seconds in YELLOW light.

2. Start 15 second traffic gate permissive timer. The Bridge Operator can be activated to

revert to traffic signals GREEN (before traffic gates move off of fully raised).







raised



lowered






lowered


E. Lower On-coming Traffic Gate(s).

1. Automatically activate warning bell(s) and gate arm’s flashing lights of the on-coming

traffic gate(s) after traffic signals turn RED

2. Enabled gate operation only after 15 second traffic signal permissive timer times out.

3. Bridge Operator is required to manual turn the On-coming Traffic Gates “Raise” /

“Lower” Control Switch to “Lower” position and hold switch in “Lower” position for

the On-coming gate(s) to lowers to its final lowered position.

4. Gate(s) can be stopped by the E-STOP button. The gate position (“Raised” or

“Lowered”) indication are “OFF” during mid-travel and are “ON” when it reached its

“Raised” or “Lowered” position.







raised



lowered




lowered


F. Lower Off-going Traffic Gate(s).

1. Enabled off-going gate operation only after 15 second on-coming traffic gate

permissive timer times out.

2. Automatically activate warning bell(s) and gate arm’s flashing lights of the off-coming


3. Bridge Operator is required to manual turn the off-going gate “Raise” / “Lower”

Control Switch to “Lower” position and hold switch in “Lower” position for the off-

going gate(s) to lowers to its final lowered position.












raised



lowered



raised



lowered


G. Lower Barrier Gate(s).

1. Enabled barrier gate operation after received off-going traffic gate permissive.

2. Automatically activate warning bell(s) and gate arm’s flashing lights of the off-coming


3. Bridge Operator is required to manual turn the barrier gate “Raise” / “Lower” Control

Switch to “Lower” position and hold switch in “Lower” position for the off-going

gate(s) to lowers to its final lowered position.




STATUS INDICATIONS ON OF

F

STATUS INDICATIONS ON OFF






raised



lowered



raised



lowered


H. Initiate Span(s) Opening Sequence.

1. Enabled only when the traffic signals are RED, all traffic gate(s) and barrier gate(s) are

lowered.

2. Initiate Span(s) opening cycle by turning the Lift Span “Open” / “Close” Control

Switch on console to the “OPEN” position.



3. Automatically:

a. Enable the selected adjustable drive(s). Active drive indication lights indicated on the Operator Control Console.

b. No system fault(s) and all bridge operation permissive(s) satisfied. c. Issue lift span open direction command to ASD. d. ASD establishes brake opening torque absolute value greater than the

maximum torque required to hole the bridge span in place. e. ASD initiate command to release brake(s) after a set time delay when the

drive has magnetized the motor and increased the motor torque to the level required for brake release.

f. ASD accelerate drive motor(s) to the pre-selected lift span operational speed (100%, 75%, 50%, or 25%).

g. ASD maintain the speed of the drive motor(s) to the pre-selected lift span operational speed.

h. ASD decelerate the speed of the drive motor(s) to programmed creep speed when the lift span reached nearly opened position.

i. ASD maintains the speed of the drive motor(s) to programmed creep speed and decelerate the drive motor to stop when the lift span reached the fully open position.

j. Monitor Span Position and Speed.

• The control system monitors the lift span speed and position, and

automatically correct the out of skew condition throughout the

operation

• Check for high overspeed and low overspeed conditions. Initiate E-

stop (emergency) on overspeed switch trip.

• Check for NEAR OPEN limit switches (A & B), decelerate to creep

speed when first one opens (second one is for redundancy).

• When in creep speed check for FULL OPEN limit switch, stop Span(s) k. Remove direction command (zero speed) when the lift span is in FULLY

OPENED position. Automatically set motor brake(s). l. De-energize drive(s) when brake(s) are set. m. Indicate drive(s) de-energized by energizing DRIVE(S) OFF indicating light

on the operator control console. n. Indicate brakes set by energizing appropriate brake set indicating light on the

operator control console. o. Indicate Span(s) FULL OPEN by energizing span fully opened indicating light

on the operator control console.

4. Span(s) can be stopped at any time by releasing the Lift Span “Open” / “Close” Control

Switch handle to spring return to center off position, or by pressing the E-STOP

pushbutton. Set ALL brake(s) when lift span comes to a stop.

STATUS INDICATIONS

(at start of span opening) ON OFF STATUS INDICATIONS ON OFF








raised

X Span fully opened X X


lowered

X Span nearly opened X X


raised

X Span nearly closed X X


lowered

X Span fully closed X X

*See Span Position Indication Table below

Span Position Indication Table

Span Positions Full

Closed Nearly Closed

Nearly Open

Fully Open

Fully Closed ON OFF OFF OFF

Between Fully Closed & Nearly

Closed

OFF ON OFF OFF

Nearly Closed OFF ON OFF OFF

Between Nearly Closed &-

Nearly Open

OFF OFF OFF OFF

Nearly Open OFF OFF ON OFF

Between Nearly Open & Fully

Open

OFF OFF ON OFF

Fully Open OFF OFF OFF ON

STATUS INDICATIONS

ON OFF STATUS INDICATIONS ON OFF






raised



lowered



raised



lowered



I. Span Position Indication (Navigation Aid Lights).

1. The span position indication light switch to GREEN automatically when lift span is at

FULLY OPEN position. In all other span lift position, the span position indication

lights remain RED.

3.09.03 3.0 LIFT SPAN CLOSING SEQUENCE

A. System ready to continue operation from fully opened position.



1. System status:

a. Traffic signals RED. b. Flashing yellow lights (WARNING DRAWBRIDGE AHEAD) ON. c. Traffic gates and barrier gates are LOWERED. d. Motor and machinery brakes SET. e. Bridge Span Leaf(s) are FULLY OPENED.

2. Indicating Lights as follows:

STATUS INDICATIONS







raised



lowered



raised



lowered



B. Start Closing Sequence.

1. Sound Horn by manually depress HORN (PUSH & HOLD) pushbutton.

2. Initiate Span(s) closing sequence by turning the Lift Span “Open” / “Close” Control

Switch on console to the “CLOSE” position.

3. Automatically:

a. Enable the selected adjustable drive(s). Active drive indication lights indicated on the Operator Control Console.

b. No system fault(s) and all bridge operation permissive(s) satisfied. c. Issue lift span close direction command to ASD. d. ASD establishes brake opening torque absolute value greater than the

maximum torque required to hole the bridge span in place. e. ASD initiate command to release brake(s) after a set time delay when the

drive has magnetized the motor and increased the motor torque to the level required for brake release.

f. ASD accelerate drive motor(s) to the pre-selected lift span operational speed (100%, 75%, 50%, or 25%).

g. ASD maintain the speed of the drive motor(s) to the pre-selected lift span operational speed.

h. ASD decelerate the speed of the drive motor(s) to programmed creep speed when the lift span reached nearly closed position.

i. ASD maintains the speed of the drive motor(s) to programmed creep speed and decelerate the drive motor to stop when the lift span reached the fully close position.



j. Monitor Span Position and Speed.

• The control system monitors the lift span speed and position, and

automatically correct the out of skew condition throughout the

operation

• Check for high overspeed and low overspeed conditions. Initiate E-

stop (emergency) on overspeed switch trip.

• Check for NEARLY CLOSE limit switches (A & B), decelerate to

creep speed when first one opens (second one is for redundancy).

• When in creep speed check for FULLY CLOSED limit switch.

ASD switch to REDUCED TORQUE mode when lift span reached

the FULLY CLOSED position. The drive(s) maintain reduced

torque (approximately 25% of full load torque, zero (0) speed) for a

set time delay (set for 6 seconds).

• Remove direction command (zero speed) when reduced torque time

delay expired, then automatically set brake(s).

4. Span(s) can be stopped at any time by releasing the Lift Span “Open” / “Close” Control

Switch handle to spring return to center off position, or by pressing the E-STOP

pushbutton. Set ALL brake(s) when lift span comes to a stop.

5. De-energize drive(s) after all brake(s) are set. Motor brake(s) are SET after a preset

time delay (10 seconds) initiated by FULLY CLOSED limit switch. The machinery

brake(s) are set after motor brake(s) are set.

a. Indicate drive(s) de-energized by energizing DRIVE(S) OFF indicating on the operator control console.

b. Indicate brakes set by energizing appropriate indicating light on the operator control console.

c. Indicate Span(s) FULLY CLOSED by energizing fully closed indicating light on the operator control console.

STATUS INDICATIONS

(at start of span closing) ON OFF STATUS INDICATIONS ON OFF






raised

X Span fully opened X X


lowered

X Span nearly opened X X


raised

X Span nearly closed X X


lowered

X Span fully closed X X




Span Position Indication Table

Span Positions Full

Closed Nearly Closed

Nearly Open

Fully Open

Fully Closed ON OFF OFF OFF

Between Fully Closed & Nearly

Closed

OFF ON OFF OFF

Nearly Closed OFF ON OFF OFF

Between Nearly Closed &-

Nearly Open

OFF OFF OFF OFF

Nearly Open OFF OFF ON OFF

Between Nearly Open & Fully

Open

OFF OFF ON OFF

Fully Open OFF OFF OFF ON

STATUS INDICATIONS

(lift span at fully closed

position)







raised



lowered



raised



lowered


*See Span Position Indication Table

below

C. Raise Barrier Gate(s).

1. Operator manually initiate raise barrier gate operation after received barrier gate raise

permissive. Bridge Operator is required to manual turn the barrier gate “Raise” /

“Lower” Control Switch to “Raise” position and hold switch in “Raise” position for

the barrier gate(s) to raise to its final raised position.

2. Automatically activate warning bell(s) and gate arm’s flashing lights of the barrier

gate(s) prior to barrier gate movement.












raised



lowered



raised



lowered


D. Raise Off-going Traffic Gate(s).

1. Operator manually initiate raise off-going gate operation after received raise gate raise

permissive. Bridge Operator is required to manual turn the barrier gate “Raise” /













On-coming traffic gate(s) raised X Span fully opened X

On-coming traffic gate(s) lowered X Span nearly opened X


Off-going traffic gate(s) lowered X Span fully closed X



E. Raise On-coming Traffic Gate(s).

1. Operator manually initiate raise barrier gate operation after received on-coming gate

raise permissive. Bridge Operator is required to manual turn the barrier gate “Raise” /














raised



lowered



raised



lowered


F. Operator turns the Traffic Signal “Red”/ “Green” Selector Control Switch on the operator

control console to “GREEN” to release the vehicle and pedestrian traffic.

G. The early warning light (flashing yellow lights) automatically turn off.



METHOD OF MEASUREMENT

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

BASIS OF PAYMENT

The lump sum price bid per bridge shall include the cost of all labor, materials, and equipment required

to complete the work of this item.

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

schedule:

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

drawings.

Thirty percent (30%) of the lump sum price will be paid upon procurement of equipment and

completion of Factory Acceptance Test (FAT).

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

installation.

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

and commissioning.

The remainder ten percent (10%) of the lump sum price will be paid once the punchlist item,

documentation and final approval has been completed.

Payments will be paid under:

Item 599.061801ER – CONTROL SYSTEM REPLACEMENT

ITEM 599.061801ER MOVABLE BRIDGE CONTROL ......ANSI/NETA ATS - Acceptance Testing Specifications for...

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Transcript of ITEM 599.061801ER MOVABLE BRIDGE CONTROL ......ANSI/NETA ATS - Acceptance Testing Specifications for...