USACE / NAVFAC / AFCESA / NASA UFGS-35 20 20 (January 2008)
----------------------------
Preparing Activity: USACE (CW) Superseding
UFGS-35 20 20 (April 2006)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 35 20 20
ELECTRICAL EQUIPMENT FOR GATE HOIST
01/08
NOTE: This guide specification covers the technical requirements for hoist
applications using a squirrel-type induction motor commonly used for control
gates for outlet works; penstock gates, crest gates, spillway tainter gates,
and other similar applications.
Edit this guide specification for project specific requirements by adding, deleting,
or revising text. For bracketed items, choose applicable items(s) or insert
appropriate information.
Remove information and requirements not required in respective project, whether
or not brackets are present.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a Criteria Change Request
(CCR).
PART 1 GENERAL
NOTE: This specification is to be used as a section of a supply specification
for the procurement of hoisting equipment, or, with only minor modification,
it may be used as a section in a general contract specification.
The specification is general and covers all types and ratings of hoist applications
used by the Corps of Engineers on Civil Works structures where a squirrel cage
induction-type hoist motor is used. The specification must be accompanied by
a drawing or drawings showing the schematic wiring diagram of the control system
for the particular application, along with a description of the scheme of operation
and illustrations showing the several items of electrical equipment.
In adapting this specification to any project, the form and phraseology will
be changed as necessary to properly specify the work contemplated. When technical
deviations from this specification are considered necessary and the specification
is not submitted to Headquarters, US Army Corps of Engineers (HQUSACE), for
review, prior approval of (HQUSACE) will be obtained. Instructions for the
preparation and submission of specifications for approval are included in ER 1110-2-1200.
The electrical equipment requirements contained herein are based upon experience
and information gained from similar equipment now in service and are considered
the most suitable for use on hydraulic structures.
1.1 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Also use the Reference Wizard's Check Reference feature
to update the issue dates.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
The publications listed below form a part of this specification to the extent referenced. The publications are
referred to within the text by the basic designation only.
[ASME INTERNATIONAL (ASME)ASME B1.1(2003; R 2008) Unified Inch Screw Threads (UN and UNR Thread Form)][ASTM INTERNATIONAL (ASTM)ASTM A 123/A 123M(2008) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel ProductsASTM A 153/A 153M(2005) Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware][INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)IEEE Std 112(2004) Standard Test Procedure for Polyphase Induction Motors and Generators][NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)NEMA AB 1(2002) Molded-Case Circuit Breakers, Molded Case Switches, and Circuit-Breaker EnclosuresNEMA C80.1(2005) Standard for Electrical Rigid Steel Conduit (ERSC)NEMA FB 1(2007) Standard for Fittings, Cast Metal Boxes, and Conduit Bodies for Conduit, Electrical Metallic Tubing, and CableNEMA ICS 1(2000; R 2005; R 2008) Standard for Industrial Control and Systems General RequirementsNEMA ICS 2(2000; Errata 2002; R 2005; Errata 2006) Standard for Industrial Control and Systems: Controllers, Contractors, and Overload Relays Rated Not More than 2000 Volts AC or 750 Volts DC: Part 8 - Disconnect Devices for Use in Industrial Control EquipmentNEMA ICS 6(1993; R 2006) Standard for Industrial Controls and Systems EnclosuresNEMA MG 1(2007; Errata 2008) Standard for Motors and GeneratorsNEMA ST 1(1988; R 1997) Standard for Specialty Transformers (Except General Purpose Type)][U.S. GENERAL SERVICES ADMINISTRATION (GSA)CID A-A-50553(Basic; Notice 1) Fitting for Conduit, Metal, Rigid (Thick-Wall and Thin-Wall (EMT) Type)][UNDERWRITERS LABORATORIES (UL)UL 44(2005; Rev thru Nov 2005) Thermoset-Insulated Wires and Cables]1.2 SYSTEM DESCRIPTION
All equipment furnished under these specifications will be subjected to [severe moisture] [moderately moist]
conditions, [shall operate over a temperature range of [_____] to [_____] degrees C F,] and shall be designed
to render it resistant to corrosion. The general requirements to be followed are specified below; any additional
special treatment or requirement considered necessary for any individual item is specified under the respective
item.
1.2.1 Fastenings and Fittings
Where practicable, all screws, bolts, nuts, pins, studs, springs, washers, and such other miscellaneous fastenings
and fittings shall be of an approved corrosion-resisting material or shall be treated in an approved manner to
render them resistant to corrosion.
1.2.2 Corrosion-Resisting Materials
Corrosion-resisting steel, copper, brass, bronze, copper-nickel, and nickel-copper alloys are acceptable corrosion-resisting
materials. However, contact between dissimilar metals should be avoided as much as practicable, except where
one of the dissimilar metals is steel or in the case of wiring and connections.
1.2.3 Corrosion-Resisting Treatments
Hot-dip galvanizing shall be in accordance with ASTM A 123/A 123M or ASTM A 153/A 153M as applicable. Other
corrosion-resisting treatments may be used if approved by the Contracting Officer.
1.2.4 Frames, Enclosing Cases, and Housings
All surfaces of the enclosing cases or housings of controllers, brakes, limit switches, control stations, and
other similar equipment, if other than plastic or stainless steel construction, shall be cleaned of rust, grease,
mill scale, and dirt and then treated with an approved iron and zinc phosphate solution followed by rinsing with
a chromic acid solution, bonderizing, or equivalent process. Immediately after rinsing and drying, the inside
and outside surfaces shall be given one coat of a zinc molybdate primer and cured as required. For items of
cast construction, the iron and zinc phosphate treatment may be omitted.
1.2.5 Finish Painting
NOTE: If severely moist conditions exist, a separate paint system should be
specified using Civil Works Guide Specification UFGS Section 09 97 02 PAINTING:
HYDRAULIC STRUCTURES, system 21, epoxy finish or equivalent. When such painting
is specified, care must be taken to specify a paint that will adhere to and
not be injurious to the protective painting provided under these specifications.
A minimum of two coats of paint shall be applied to all equipment in accordance with the manufacturer's standard
process for the conditions specified.
1.3 SUBMITTALS
NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Submittals should be kept to the minimum required for adequate
quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are for [Contractor Quality Control approval.] [information only. When used, a designation following the "G"
designation identifies the office that will review the submittal for the Government.] The following shall be
submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
Controller
[Six] [_____] copies of a description of the operation scheme, if other than herein specified
or shown on the drawings; a dimensioned outline drawings showing specific relationships and
clearances between equipment and their component parts, detailed panel layouts, schematic wiring
diagrams, and a panel wiring diagram dimensioned outline drawings showing specific relationships
and clearances between equipment and their component parts.
Limit Switch
[Interrupter]
[Six] [_____] copies of dimensioned outline drawing of the limit switch [and "Interrupter"
drive]. Show on the Drawings specific relationships and clearances between equipment and their
component parts.
Hoist Motor
Control Station[s]
Brake Enclosing Case
[Six] [_____] copies of dimensioned outline drawings showing specific relationships and clearances
between equipment and their component parts.
SD-03 Product Data
Hoist Motor
[Six] [_____] copies of motor characteristics, curves or tabulated data (tested or calculated),
indicating the speed, power factor, efficiency, current and kilowatt input, all plotted or tabulated
against torque or percent of rated motor load.
[Six] [_____] copies of calculations to determine the required horsepower rating of each motor.
[Six] [_____] copies of detailed descriptive specifications of the motor, with necessary cuts,
photographs, and drawings to clearly indicate the construction of the machine. Place special
emphasis on describing and illustrating features of "Insulated Windings," "Winding Heaters,"
"Bearings and Lubrication," and "Terminal Leads."
Brake
[Six] [_____] copies of detailed descriptive data covering the brake, with necessary cuts,
photographs, and drawings to indicate clearly the construction of the brake and the materials
used. Releasing device specifications and characteristics, including input current minimum
voltage required for brake release.
Limit Switch
[Six] [_____] copies of all limit switch computations used to determine the selection of gear
ratios and calibration for gate travel.
[Six] [_____] copies of complete descriptive data covering the limit switch with necessary
cuts, photographs, and drawings to indicate clearly the construction, materials used in the
parts, rating, accuracy of tripping and reset, method of adjustment, and safeguards.
Overload Relays
[Six] [_____] copies of curves showing the overload relay tripping time versus current characteristics
of the overload relays for the controller.
Controller
[Six] [_____] copies of detailed descriptive data covering all component parts of the controller.
Control Station[s]
[Six] [_____] copies of detailed descriptive data covering the control station[s].
[Interrupter
[Six] [_____] copies of description of "Interrupter" drive.]
Wiring
[Six] [_____] copies of data sufficient to demonstrate that the proposed wire and cable conform
to these specifications.
Conductors
Terminal Leads
Terminal Blocks
Method of identifying conductors, terminal leads, and terminal blocks.
Motor nameplates
Equipment and Door Nameplates
Schedule of nameplates.
SD-06 Test Reports
Tests
[Six] [_____] certified copies of the reports of all complete and routine tests, including
complete test data. Certified copies of the results of a complete test for duplicate equipment
will be accepted in lieu of the requirement of the complete test specified. Reports shall include
analysis and interpretation of test results and shall be properly identified with the test systems
and materials. Provide test reports for "complete tests" on the motor, brake, and controller.
Performance curves indicating the results of the motor tests shall be furnished as follows:
a. Excitation Tests. Volts or percent of rated voltage as abscissa vs. amperes and watts as
ordinates.
b. Impedance Tests. Volts or percent of rated voltage as abscissa vs. amperes and watts as
ordinates.
c. Performance Test. Torque or percent of rated horsepower output as abscissa vs. efficiency,
power factor, amperes watts, and rpm or percent slip as ordinates.
d. Speed-Torque Test. Torque in foot-pounds as abscissa vs. speed in rpm or percent of synchronous
speed as ordinates.
e. Temperature Test. Time in minutes as abscissa vs. temperature rise in degrees C as ordinate.
f. Insulation Resistance Test. Test result values shall be plotted on semilogarithmic graphs,
the insulation resistance values as logarithmic ordinates, and the temperature values as uniform
abscissa.
g. Routine test reports shall include analysis and interpretation of test results and shall
be properly identified with the test systems and materials. No substitute will be accepted
for the routine test. Provide test reports for "routine tests" on the motor, brake, controller,
limit switch, [interrupter,] and wiring.
PART 2 PRODUCTS
2.1 HOIST MOTOR
2.1.1 Motor Type
NOTE: When a single-speed motor or two single-speed motors in lieu of a two-speed
motor is acceptable for the application, the designer will specify NEMA MG 1
standard design letter. The torque requirements listed in paragraph MOTOR LIMITS
must be met, and the designer will verify that the design specified is sufficient.
Design "C" and "B" have a 5 percent or less slip limit and are used where load
inertia is lower. Design "D" has a 5 percent or greater slip and must be used
where inertia is high. Designs "B," "C," and "D" provide progressively higher
torques and get progressively more expensive. Design "B" will generally apply
to motors from 1 to 3 hp, design "C" to motors between 3 and 15 hp, and design
"D" for motors larger than 15 hp. This a general guide according to NEMA minimum
standards and may vary with manufacturer's specific equipment.
At reduced cost, dripproof encapsulated construction may be used in protected
locations. Consult manufacturer's data for information on application of this
type motor to specific environmental conditions.
Provide a motor of the horizontal-shaft, squirrel-cage induction type [two-speed, two-winding, constant [torque]
[horsepower]] [NEMA design [B] [C] [D]], designed for full-voltage starting, [of water-proof, totally enclosed,
fan-cooled or nonventilated frame construction],[dripproof, encapsulated frame construction] and shall conform
to the applicable requirements of NEMA MG 1.
2.1.2 Motor Rating
NOTE: For a two-speed motor, use single-voltage rating. Specify load conditions
when Contractor designed. (Second Option) This specification covers three-phase
motors which are suitable for most applications and shall be used whenever possible.
When utility three-phase power is unavailable and forces use of single-phase
motors, this specification may be modified accordingly. Generally, single-phase
motors used for this application should be below 25 horsepower. The torque
limits should be carefully evaluated, and the testing requirements should be
changed. Please consult Engineering Manual (EM) 1110-2-2703 for further guidance.
[The motor shall be rated [_____] horsepower, [_____] rpm synchronous speed for the machinery design shown on
the drawings or, if the design is changed as permitted by [_____], shall have a horsepower rating as required
by performance requirements specified to [_____].] [The motor shall have a horsepower rating as required by
the load conditions specified in [_____].] The motor shall be rated for continuous full-load operation without
exceeding the standard temperature rise for the class of insulation and frame construction used, and it shall
be wound for [_____] [230/460] [460] volts, three-phase, 60-Hz.
2.1.3 Motor Torque
NOTE: The torque values are those required by design guidance given in EM-1110-2-2702
and EM-1110-2-2703. The gate design must be coordinated with the requirements
of these documents to ensure that torque limits are met. Reducing the upper
limit or raising the lower limit will result in significant cost increase and
should be avoided where ever possible.
2.1.3.1 Motor Limits
The torque limits for each individual winding shall be as follows:
a. Upper Limit: The upper limit of the torque between locked-rotor and breakdown shall be not more
than 280 percent of the rated full-load torque of the motor.
b. Lower Limit: The lower limit of the torque between locked-rotor and breakdown shall be as high as
possible consistent with good design but not less than 150 percent of the rated full-load torque of the
motor.
c. When the characteristics of a motor or the winding of a motor results in a speed torque curve without
a definite value of breakdown torque, the limitations on the minimum value of torque shall apply between
locked-rotor and 75 percent of synchronous speed.
2.1.3.2 [Single-Speed Motor Limits
NOTE: Permit the use of two single-speed motors in lieu of a single two-speed
motor where space is not a concern, and a two-speed motor cannot meet the specifications
requirements.
Two single-speed motors may be used in lieu of a two-speed motor, providing the synchronous speed of the high-speed
motor is not more than 1,800 rpm's and the low-speed motor will conform to the 50 percent over-speed requirements
of the high-speed motor.]
2.1.4 Frames and Shafts
NOTE: Shafts of stainless steel may be specified in lieu of manufacturer's
standard treatment where extremely corrosive atmospheres exist. The use of
stainless steel will change the motor design and increase the shaft diameter
at a significant cost. Manufacturer's should be consulted before specifying
stainless steel in a given application.
Size and dimensions of frames shall conform to NEMA MG 1 and shaft extension shall be as required. Eye bolts
shall be provided on all motors. Each motor shall be provided with a drain-breather which shall be so located
to prevent accumulation of water inside the motor. Frames shall have corrosion prevention in accordance with
the requirements of paragraph CORROSION PREVENTION AND FINISH PAINTING. Exposed portions of shafts shall be
treated with manufacturer's standard primer and two coats of moisture proof varnish in accordance with the manufacturer's
recommendation.
2.1.5 Windings and Insulation
NOTE: Select insulation class based on NEMA temperature requirements as follows:
CLASS LIMITING TEMPERATURE
(in degrees Celsius)
B 130
F 155
H 180
Selection of insulation class should be left to the Contractor when he is also
responsible for motor design, but in no case should it be less than Class B.
Class F is typical.
Designer will provide ambient temperature values where possible.
Insulation shall be Class [B] [F] [H] [B or better as required for design conditions] with special moisture,
[fungus], and oil proof treatment. Motors shall be designed and constructed to withstand the environmental conditions
specified. The following specifications describe the minimum requirements for acceptable insulation and are
not intended to restrict or prohibit the use of materials or methods which will give equal or better performance.
2.1.5.1 Insulated Windings
Insulated windings, unless otherwise approved, shall be completely assembled in the motor core before impregnating
with the insulating compound. Insulating compound shall be 100 percent solid. Impregnation of the windings
with the insulating compound shall be by vacuum impregnation method followed by baking. The procedure shall
be repeated as often as necessary to fill in and seal over the interstices of the winding, but in no case shall
the number of dips and bakes be less than two dips and bakes when the vacuum method of impregnation is used.
2.1.5.2 Magnet Wire
The magnet wire shall have an insulation or combination of insulations with an insulation thickness not less
than that required for the environment specified and the temperature rating as required by the hot-spot temperature
of the motor.
2.1.6 Winding Heaters
NOTE: Delete this paragraph and the requirement for "Winding Heaters," if dripproof
encapsulated motor is used. Additionally, the designer should consider elimination
of winding heaters if possible in other situations, i.e. where the probability
of condensation is low. In the past, heaters have been a maintenance problem
and have been disconnected by project personnel.
A heater or heaters shall be installed in the motor frame or end bells or wrapped around the winding end turns.
Heaters shall meet the requirements of paragraph HEATERS-GENERAL. Heaters installed around the winding end turns
shall consist of the required turns of heating cable wrapped around the end turns and secured in place before
the motor windings are impregnated.
2.1.7 Bearings and Lubrication
NOTE: The use of sealed bearings should be limited to special applications.
Sealed bearings do not require as much maintenance but reduce the overall life
of the motor.
The motors shall be provided with antifriction bearings, and the design of the housing and method of assembly
shall permit ready removal of the end brackets and prevent escape of lubricant and entrance of foreign materials.
Bearings shall be fitted with bronze or other approved bushings to prevent any binding of moving parts. Approved
antifriction bearings of corrosion resisting construction may be used. Bearings [shall be of an approved prelubricated
type requiring no addition or change of lubrication for a period of at least 5 years] [shall have fitted openings
located on the top and bottom of the bearing housing. The openings shall be readily accessible for applying
and draining the lubricant]. Pressure lubrication fittings may be used provided the housings are properly vented
to prevent damage to the seals. When the brake housing or other equipment is to be assembled adjacent to or
bolted to the motor end bell, suitable filler and drain pipe extensions, with the ends properly fitted and easily
accessible, shall be provided. For those applications where the brake wheel is mounted on a shaft extension
on the front end of the motor, the bearing housing, or a suitable flange, shall be furnished to provide a suitable
surface and connecting means to allow the fastening of the brake enclosure to the bearing housing (see paragraph
BRAKE ENCLOSING CASE).
2.1.8 Terminal Leads
Terminals leads shall extend outside the frame; shall have insulation equivalent to that of the motor winding;
shall be terminated in a two-piece, watertight terminal box secured rigidly to the motor frame; and shall be
suitably identified. Leads shall be positioned and sealed where they pass through the frame with a water-resistant
seal of a synthetic rubber material or a synthetic rubber gasket. Terminal box shall have threaded conduit entrances
on a minimum of four sides.
2.1.9 Machine Work
Machine work shall be accurate, of high quality, and in conformity with approved standard practice. Threads
shall be in accordance with ASME B1.1. Thread fittings shall be Class 2. Threads on all body-bound bolts shall
be chased a sufficient length so that when the nut is tightened there will be approximately one and one-half
full threads under the nut. All bolts and cap screws shall be provided with lock washers.
2.1.10 Designation and Markings
Motor nameplates of a suitable corrosion-resisting material shall be attached to the frame of each motor and
shall indicate clearly the motor NEMA temperature and insulation class, continuous amperage rating, voltage rating,
operating frequency, rated RPM, horsepower rating, nominal efficiency, NEMA locked rotor code letter and serial
number. In addition, the nameplate shall show a lead connection diagram. Identification or serial numbers shall
be die stamped on the frame.
2.2 BRAKE
2.2.1 Brake Type
The brakes shall be of the shoe type, spring set, with AC or DC magnet operated release and shall be completely
enclosed in a watertight and dusttight enclosing case arranged for [floor mounting] [motor mounting].
2.2.2 Brake Rating
NOTE: Delete paragraph b. if constant torque two-speed motor or a single-speed
motor is specified.
a. The brake shall have a torque rating not less than 150 percent of the full load torque of the motor when
referred to the shaft on which the brake wheel is mounted, efficiency of speed reducer not being considered.
The torque rating shall be based on open construction, [1-hour] [continuous] duty.
b. [The brake shall have a torque rating of [_____] pound-feet as shown on the plans, or if the design is changed
as permitted by [_____], the brake shall have a torque rating not less than 150 percent of the full-load torque
of the motor when referred to the shaft on which the brake wheel is mounted, efficiency of speed reducer not
being considered.] [For a two-speed motor, the rating shall be computed from the full-load torque of the low-speed
winding of the motor.]
2.2.3 Adjustment
Means shall be provided for varying torque required for holding. Additionally, the brake shall have means of
adjusting the position of the shoes to compensate for wear, unless the design is such that compensation for shoe
wear is automatic.
2.2.4 Release
2.2.4.1 Releasing Magnets and Rectifier
NOTE: Coordinate voltage requirements with paragraph MOTOR RATING.
The releasing magnets shall be of the DC or AC shunt type and of standard stock design, suitable for operation
on [_____] [230] [460]-volt, 60-Hz, AC electrical power. Direct current shall be supplied by means of a self-contained
rectifier unit of proper rating. The complete unit shall be suitable for connection to the control circuit or
the power circuit of the motor with which the brake is used so that the brake will set or release when the motor
is deenergized or energized, respectively. The brake releasing magnet shall be rated in accordance with the
brake rating requirements of paragraph MOTOR RATING, and shall be sufficient to release and hold the brake in
the released position with 85 percent of rated voltage impressed on the incoming terminals. The rectifier, when
required, shall be mounted in the motor controller enclosing case unless otherwise noted.
2.2.4.2 Hand Release
Hand release shall be provided. It shall be operable only when the enclosing case cover is removed and shall
be self-resetting.
2.2.5 Terminal Leads
Connecting leads from the releasing magnet shall be extended outside the enclosing case and shall be terminated
on a terminal block located in a watertight terminal box, which shall be rigidly bolted or equally secured to
and on the outside of the lower or fixed half of the enclosing case. The terminal box shall provide for conduit
entrances on four sides. All conduit entrances to the brake terminal box shall be threaded. The leads inside
the brake enclosing case shall be suitably protected. Enclosing case space heater leads shall be terminated
in the same manner in separate terminal boxes.
2.2.6 Brake Enclosing Case
NOTE: Manufacturers do not generally weld enclosures. Welding required only
where conditions require substantial construction and costs may be justified.
The outdoor NEMA Type 4-watertight enclosing case shall be [welded type] [in accordance with the manufacturer's
standard practice for the conditions indicated]. In order that the brake mechanism will be accessible from above,
when the upper half or cover of the enclosing case is removed, the enclosing case shall be constructed to give
equal accessibility to all portions of the brake. The joint between the two halves shall be made with a synthetic
rubber gasket, not less than 6 mm 1/4 inch in width, and held in place by embedding in a groove or by other equally
effective means. For those applications where the brake wheel is mounted on a shaft extension on the front end
of the motor, the enclosing case shall be arranged to permit bolting to the bearing housing of the motor, the
joint being made watertight with a gasket. For those applications where the brake wheel is mounted on a shaft
of the operating machine or on a flange and shaft extension on the front end of the motor, suitable watertight
seals shall be provided on each part of the housing. The shaft seals shall be arranged for pressure lubrication
and shall be adjustable for alignment relative to the shaft. An automatic drain breather, located in a protected
location, shall be provided in the lower part of the enclosing case. If the drain breather cannot be located
in a protected location, the tapped hole shall be plugged and the drain furnished separately for installation
in the field. Enclosing case space heaters conforming to the applicable part of paragraph HEATERS-GENERAL, shall
be provided. The enclosing case shall be treated to render the steel resistant to corrosion as required by paragraph
CORROSION PREVENTION AND FINISH PAINTING.
2.2.7 Mechanical Construction
Except for brake wheels, shoes, and electrical parts, no cast iron shall be used in brake construction. All
pins, fittings, and other miscellaneous small metal parts shall be of approved corrosion-resisting metal or shall
be treated to render them corrosion-resistant as required by paragraph CORROSION PREVENTION AND FINISH PAINTING.
Bearings shall be fitted with bronze or other approved bushings to prevent any binding of moving parts. Approved
antifriction bearings of corrosion-resisting construction may be used. Approved means for lubrication shall
be provided for all bearings, unless bearings are of an approved self- or prelubricated type. The machine work
shall conform to the requirements for the motor with which the brake is used.
2.2.8 Designation and Markings
A nameplate of suitable corrosion-resisting material shall be provided and attached to a part of the brake which
ordinarily will not be renewed during its service life. The nameplate shall conform to standard practice and
clearly indicate the manufacturer's name, identification symbols, serial number, and salient design features
such as type, frame, torque, rating, voltage, phase, and frequency. If adjustment is required, pertinent information
for making the adjustments is necessary.
2.3 CONTROL SYSTEM
NOTE: The scheme of control shown on the applicable plate at the end of this
document should be retained where possible.
The Plates listed below, containing the related control sequences, are attached
at the end of this spec.
PLATE
NO. SUBJECT
1. Crest Gate, Electrical Control System (With Approximately 300 mm (1.0 Foot)
Increments)
2. Crest Gate, Electrical Control System (With Approximately 150 mm (0.5 Foot0)
Increments)
3. Crest Gate, Electrical Control System (With Remote Control and Approximately
300 mm (1.0 Foot) Increments)
4. Crest Gate, Electrical Control System (With Remote Control and Approximately
150 mm (0.5 Foot) Increments)
5. Outlet Control Gate, Electrical Control System (Single-Speed Motor)
6. Outlet Control Gate, Electrical Control System (Multispeed Motor)
7. Intake Gate, Electrical Control System.
In some instances, where control for a penstock intake gate hoist where the
emergency lower control switch is to be located in the powerhouse, the length
of the connecting circuit may be such that its mutual inductance may render
the circuit susceptible to false operation. In such cases, it will be necessary
to use direct current and interpose an additional control relay. The direct
current can be provided from a rectifier located in the control cabinet or from
a circuit on the power house control battery.
The scheme of operation of the [outlet control gate] [tainter gate] [intake gate] hoist motor control system
shall be as described and indicated. The control system shall include the controller, limit switch, master control
station[s], and such other items as may be required to accomplish the operating features specified. Each item
shall be [installed and] tested as specified and shall be complete and ready for operation [, when installed
under another contract,] in accordance with the scheme of operation.
2.4 CONTROLLER
NOTE: Separate mounting of the controller is usually the preferred practice.
When mounting the controller on the hoist frame is desired, the Contractor will
be required to submit a drawing showing the arrangement of the controller and
other electrical equipment on the hoist frame. In this case, the electrical
equipment should be wired in the shop complete and ready for operation upon
bringing the power connection to the line side of the controller disconnect
switch.
2.4.1 Controller Type
The hoist motor controller shall be of the full magnetic type initiated by the push-button control station and
controlled automatically by a limit switch or limit switches. Limit switch[es] shall be driven by the hoist
mechanism or other auxiliary operating devices as indicated or required to provide the sequence of operation
specified or indicated on the plans.
2.4.2 Protection
The controller shall provide [under-voltage protection,] inverse-time-limit overload protection, or other protection
as indicated or specified. [In addition, the controller shall provide protection from single-phase faults.]
The protection shall be accomplished by suitable relays conforming to the requirements of paragraph RELAYS.
Overload relays shall provide protection during both the starting and running condition, and approved means shall
be provided to manually reset the relays without opening the enclosing case of the controller. All forward and
reversing contactors shall be electrically interlocked. Controller disconnecting circuit breaker[s] shall be
interlocked with the controller enclosing case access door to permit opening or closing the access door only
when the disconnect is in the "OPEN" position.
2.4.3 Enclosure
NOTE: When controller is mounted in a dry room or gallery adjacent to the hoist
equipment adjacent to the hoist equipment, a NEMA Type 12, industrial-use enclosure
should be specified and the drawings and specifications revised accordingly.
Hubs shall be specified for all conduit entrances.
Wall mounting is generally the least costly alternative and should be used whenever
practical.
Designer shall coordinate padlock requirements with local standards.
Enclosing cabinet shall be of the NEMA Type [3R [stainless steel]] [4 watertight [stainless steel] and moisture-resisting]
[12 industrial use] construction with interior dead-front panel meeting the requirements of NEMA ICS 6. Enclosing
cabinet shall be designed for [floor mounting] [mounting on the hoist frame] [wall mounting]. Suitable padlock
eyes shall be provided to allow locking the exterior door in the closed position. Padlocks, conforming to [_____],
shall be provided with each controller and chained to the enclosing case. The chain shall be of a nonferrous
material resistant to corrosion. Only front-connected devices shall be used, and clearances shall be in accordance
with NEMA ICS 1requirements. Threaded hubs for conduit entrance of the welded-in type shall be provided as indicated
on the drawings or as required to make the wiring connections. An automatic breather-drain, not less than 3/8-inch
size and located in a protected location and at the lowest point of the enclosure, shall be provided.
2.4.4 Air Circuit Breakers
Air circuit breakers as shown on the drawings or specified shall be provided and assembled in the housing of
each controller.
2.4.4.1 Circuit Breakers - General
Each air circuit breaker shall conform to the applicable requirements of NEMA AB 1. The circuit breakers shall
be manually operated and shall be of the instantaneous trip type, unless otherwise specified or indicated on
the drawings. All poles of each breaker shall be operated simultaneously by means of a common handle and shall
be enclosed in a common molded plastic case. The contacts of multipole breakers shall open simultaneously when
the breaker is tripped manually or automatically. The operating handles shall clearly indicate whether the breakers
are in "ON," "OFF," or "TRIPPED" position. Each circuit breaker shall be externally operated [and interlocked]
as specified in paragraph PROTECTION. Approved means shall be provided for padlocking the breaker[s] operating
handle in either the "ON" or "OFF" position. A padlock of the same type as specified in paragraph ENCLOSURE,
shall be provided for each breaker and shall be chained to the enclosing case. The circuit breakers shall be
products of only one manufacturer and shall be interchangeable when of the same frame size.
2.4.4.2 Trip Units
Except as otherwise indicated on the drawings, the circuit breakers shall be provided with combination thermal
and instantaneous magnetic trip units. The minimum frame sizes and the trip unit ratings shall also be as required
for the equipment controlled. Nonadjustable instantaneous magnetic trip unit shall be set as approximately 10
times the continuous current ratings of the circuit breakers.
2.4.4.3 480-Volt AC Circuits
Air circuit breakers for 480-volt AC circuits shall be rated 600 volts AC and shall have a minimum NEMA interrupting
capacity of 14,000 symmetrical amperes at 600 volts AC.
2.4.4.4 120-Volt AC Circuits
Air circuit breakers for 120-volt AC circuits shall be rated not less than 120/240 or 240 volts AC and shall
have a minimum NEMA interrupting capacity of 10,000 symmetrical amperes.
2.4.4.5 125-Volt DC Circuits
Air circuit breakers for 125-volt DC circuits shall be two-pole rated 125/250 or 250 volts DC and shall have
a minimum NEMA interrupting capacity of [5,000] [10,000] amperes DC.
2.4.5 Assembly of Controller
Furnish all necessary air circuit breakers, contactors, relays, resistors, interlocks, master switches, limit
switches, or other devices required by the scheme of operation. The panel for mounting the relays and contactors
shall be sheet steel of sufficient thickness to provide rigid support for the equipment mounted thereon. The
steel panel shall be given a corrosion resisting treatment in accordance with the requirements of paragraph CORROSION
PREVENTION AND FINISH PAINTING.
2.4.5.1 Wiring
Insulated wire shall conform to the requirements of paragraph CONDUCTORS. All wiring shall be securely held
in place and arranged in a neat and orderly manner in horizontal and vertical runs. All wiring passing through
steel gutters shall be protected by grommets, unless the openings in the steel gutter are formed to protect the
wiring from damage. [All controllers shall be wired in like manner as to location of parts and phase sequence.]
The wire and terminal numbers shall be neatly and legibly identified in an approved manner. Terminal blocks
shall be used for making all external connections.
2.4.5.2 Terminal Blocks
Terminal blocks for control wiring shall be molded type with barriers, rated not less than 600 volts, and they
shall be provided with covers. The terminals shall be removable, screw type, or of the stud type with contact
and locking nuts. The terminals shall be not less than No. 10 AWG in size and shall have sufficient length and
space for connecting at least two indented terminals on No. 10 AWG conductors to each terminal. The terminal
arrangement shall be subject to the approval of the Contracting Officer.
a. Not less than 10 percent, but in no case less than 2 percent, spare terminals shall be provided on
each block. Terminal blocks for conductors larger than No. 10 AWG or with a capacity of more than 30
amperes shall be adequate for the purpose intended, having length and space for at least two indented
terminals of the size required on the conductors to be terminated.
b. For conductors rated more than 50 amperes, all screws shall have hexagonal heads. For conductors
rated 50 to 99 amperes, the minimum screw size shall be 8 mm 5/16 inch. Conducting parts between connected
terminals shall have adequate contact surface and cross section to operate without overheating.
c. White or other light-colored marking strips, fastened by screws to the molded sections at each block,
shall be provided for circuit designation. Each connected terminal of each block shall have the circuit
designation or wire number placed on the marking strip with permanent marking fluid. One reversible
or one spare marking strip shall be furnished with each block.
2.4.6 Magnetic Contactors
2.4.6.1 Contactor Ratings
All heavy-duty magnetic contactors shall be of the voltage rating indicated on the drawings or otherwise required.
They shall have a horsepower rating not less than the horsepower rating of the motor with which the controller
is to be used, but in no case shall the contactor used be smaller than NEMA, Size 1. The contactors shall meet
the requirements of NEMA ICS 2and have continuous current ratings for the duty indicated. Contactors shall be
suitable for at least 200,000 complete operations under rated load without more than routine maintenance. They
shall operate successfully on 10 percent over-voltage and 15 percent under-voltage. The interrupting capacity
shall conform to NEMA standards. Mechanical interlocking between contactors shall be provided as indicated or
required and shall be accomplished without any mechanical attachment between the interlocking mechanism and the
moving parts of the contactor, unless otherwise approved by the Contracting Officer.
2.4.6.2 Arcing Protection
For each pole, the interruption arc and flame shall be minimized by suitable arc chutes or other means so that
no damage will be done to other portions of the device. The arc chutes, if provided, shall be easily removed
without removing or dismantling other parts.
2.4.6.3 Contactors
All current carrying surfaces shall be of a silver alloy or of copper faced with a silver alloy and shall be
easily accessible and removable for replacement. Contactor shall operate without chatter or perceptible noise
while energized. Coils shall be suitable for continuous operation on the voltage specified.
2.4.6.4 Construction
Each contactor shall be provided with a minimum of three auxiliary contacts, which many be easily changed from
normally open to normally closed. Contactor construction shall be such as to prevent corrosion in accordance
with paragraph CORROSION PREVENTION AND FINISH PAINTING.
2.4.7 Relays
2.4.7.1 Control
Control relay devices shall meet applicable requirements of NEMA ICS 2for Class A600 contacts. All contacts
shall be of a silver alloy or of copper faced with a silver alloy.
2.4.7.2 Overload
Overload relays shall be the adjustable thermal type with normally closed control circuit contacts having a pilot
and control circuit contact rating of A600, in accordance with NEMA ICS 2, and shall have combination manual
and automatic-type reset. They shall have inverse-time tripping characteristics simulating the heating characteristics
of the motor, shall protect the motor with which used against exceeding its specified temperature rise under
any overload, stalled rotor, or single-phase condition, and shall be self-protecting under all conditions, except
short circuit. A relay consisting of an assembly of individual-phase thermal elements actuating a common tripping
bar shall be used. The means of adjustment shall provide a range from 90 percent to 110 percent of the heater
rating and shall be sufficiently accurate to allow setting the relay at the full-load current value of the motor
with which used. Reset mechanism shall be trip free and arranged for manual reset in accordance with paragraph
PROTECTION, unless automatic reset is indicated. Reset mechanism shall be of design that will permit changing
from manual to automatic reset or vice versa without the use of special tools.
2.4.8 Control Transformer
The control transformer shall be a standard, single-phase, 60-Hz, dry-type, [_____] [480]/120 volts, and with
kVA rating sufficient to supply the control [and heater] circuits. Transformer shall meet applicable requirements
of NEMA ST 1.
2.4.9 Control Circuit Breakers
The control circuit breakers shall conform to the requirements of paragraph AIR CIRCUIT BREAKERS, except that
an external operating mechanism is not required. Breakers shall be two-pole, 100-ampere frame, and 20-ampere
continuous current rating.
2.4.10 Indicating Lights
Indicating lights shall be complete with low-voltage lamps, self-contained resistor or transformer units, and
lens or color caps. Lens and lamp shall be removable from the front. They shall operate on 120 volts AC and
be suitable for flush or semiflush mounting to the exterior cabinet door. Exterior mounting of the indication
lights shall meet the requirement for the enclosure NEMA type. Hinge wire shall be used for connections between
the indicator lights and the terminal block.
2.4.11 [Plug Receptacle for Inching Pendant Control Switch
NOTE: Inching pendant control switch in paragraph INCHING STATION, and receptacle
is not required on crest gates. Omit requirement for receptacle on controller
enclosure and mount receptacle on wall of gate inspection room if inspection
room is above maximum flood.
The receptacle body shall be weather resistant with threaded cap and gasket complete with polarized female contact
unit, four-wire, five-pole, grounded through shell and extra pole, and rated 30A, 460 volts.]
2.4.12 Equipment and Door Nameplates
Nameplates shall be provided for the front of the cabinet door and for each item of equipment within the enclosure.
Anodized aluminum, stainless steel, or a laminated plastic sheet with black surface layer and a white bottom
layer not less than 1/16 inch thick shall be used for the nameplate material. Equipment within the enclosure
shall be identified by nameplates or other suitable marking on the equipment unit base or on the panel.
2.4.13 Heater
The heater shall be strip type and meet the requirements of paragraph HEATERS-GENERAL.
2.4.14 Grounding
The ground connection for the controller enclosing cabinet shall be made by a threaded post fitting which extends
through the enclosure wall and which is provided with fittings to connect No. 6 AWG stranded copper ground wire
both inside and outside the enclosure. Inside the enclosure, the ground circuit shall be extended with No. 6
AWG stranded copper wire from the connector to the panel.
2.5 CONTROL STATION[S]
Control station[s] shall be of the rocker handle push-button type and shall provide the number of indicating
lights and individual switches of the type or types required by the scheme of operation. Enclosure shall be
NEMA-Type [3R] [4 watertight [stainless steel]] [12R industrial use] construction. All contacts shall be of
the double-break bridging type and shall have a pilot and control circuit rating designation of A600 in accordance
with NEMA ICS 2. Switch cases shall be provided with threaded bosses for conduit or cable connection and shall
provide ample wiring space for conductors of the size and insulation specified.
2.5.1 Master Station
NOTE: Use padlocked stop switch on all hoists except intake gate hoists provided
with remote lowering. Intake gate hoists may use either padlock or "substantial
metal cover" alternate. If metal cover alternate is used, the emergency lower
contact "ELS" in parallel with the stop switch contact should be deleted.
The master station shall be arranged with the elements stacked vertically and with [_____]-inch conduit entrance
from the bottom. The station shall provide [a red indicating light and] [3] [4] operating rocker handle-type
push buttons. The station shall be arranged starting at top with [a red light followed by] the "RAISE," ["CONDUIT
OPEN,"] "LOWER," and "STOP" push buttons. The station switch elements shall have nameplates with the above designations.
[The "STOP" switch shall be provided with means of padlocking the switch in the stop or in the open position.]
[The station shall be provided with a substantial removable or hinged metal cover which can be locked in the
closed position to prevent operation of the switch elements.] The padlock shall be chained to the enclosing
case with a chain made of nonferrous material.
2.5.2 [Inching Station
The inching station shall be arranged with the elements stacked vertically and with conduit entrance on the top
for a cable clamp. The cable shall be [_____] feet of five-conductor, No. 12 AWG portable cable with extra flexible
conductors, heat and moisture resistant insulation, and outer Neoprene jacket. The station shall have two rocker
handle-type push buttons. The switch elements shall be designated "INCH UP" and "INCH DOWN" from top to bottom,
respectively.]
2.6 LIMIT SWITCH
2.6.1 Normal Operation
The limit switch shall be the linear solid-state programmable type with digital display and shall operate on
120 volts AC. It shall contain all the contacts required for making and breaking all control and interlocking
circuits necessary for the proper control and operation in the manner specified or required.
2.6.2 Construction
The limit switch shall be of compact and rugged construction, totally enclosed in a NEMA Type 13 case, and housed
within the controller enclosure. The digital display shall be visible without opening the enclosure door. This
viewing port in the door shall have a replaceable gasketed piece of clear plastic mounted to maintain the NEMA
rating of the enclosure. The cover shall be provided with cap screws or other approved means for readily breaking
the cover free for removal unless the gasket is so designed that it will not stick. All parts shall be of corrosion-resisting
metal or treated in an approved manner to render it resistant to corrosion. The switch shall permit final adjustment
in the field. Tapped bosses shall be provided for making all conduit connections to the switch. A clamp-type
connector bolted to the outside of the case shall be provided for making ground connections.
2.6.3 Switches
Switches shall be solid state with current rating as required and shall be assembled or combined into operating
units as indicated on the plans. They shall be provided with suitable terminals for connecting the external
conductors and shall provide for one remote digital readout. Each terminal shall be suitably marked or tagged
with the wire number shown on the contract drawings. The tripping mechanism shall be designed for fail-safe
operation and shall reset the contacts when moving in the reverse direction. The switch shall have an operator
lockout feature which permits programming only by authorized personnel.
2.6.4 Transducer
The electromagnetic position sensor shall be single-turn, heavy-duty enclosed in a outdoor NEMA 4 watertight
enclosure. A cable [chain] connector used for the enclosure shall be provided and be suitable for No. 16 AWG
shield twisted pair.
2.6.5 Accuracy of Trip and Reset
NOTE: For installations where water control requires gate travel of over 9
m (30 feet), measurement of gate travel may become nonlinear. This is due to
stretching of the wire rope. The attachment point for measurement of travel
should be as near the switch as possible and need not be at the top of the gate.
The designer shall investigate possible options, including use of chain and
additional limit switches.
The design of the switch elements and operating mechanism of the limit switch shall provide for uniform and accurate
setting. Switch shall be single turn with 1,000 counts per turn and a minimum of 16 set points. The switch
shall accurately transmit position within + 75 mm 3 inches and shall reset gate for drift exceeding 150 mm 6
inches.
2.7 WIRE AND CONDUIT
2.7.1 Conductors
Conductors shall be of annealed copper wire. Copper conductors shall be insulated with polyethylene. Conductors
shall be Class B or Class C stranding, except for hinge wire which shall be Class D or K stranding. Unless otherwise
specified, all wire and cable for power and control shall be single conductor. Insulation thickness shall be
that required for a rated circuit voltage of 0 to 600 volts. Insulation shall be a cross-linked thermosetting
polyethylene insulation type. Over the insulated conductor there shall be applied a moisture resisting thermoplastic
jacket. The method of accomplishment shall be in accordance with the current practice of the industry. Wire
for power and motor circuits shall have a current carrying capacity corresponding to the ampere rating of the
circuit's air circuit breaker and not less than No. 10 AWG and the full-load current of the motor or the circuit.
Wire for control circuits shall not be smaller than No. 12 AWG.
2.7.2 Control Wire
All control wire shall be type SIS switchboard wire meeting the requirements of UL 44.
2.7.3 Conduit
Rigid steel conduit shall conform to NEMA C80.1 and shall, in addition, be zinc-coated (galvanized) both inside
and outside by the hot-dip method.
2.7.4 Fittings
Conduit fittings shall conform to the requirements of NEMA FB 1 and CID A-A-50553.
2.7.5 Assembly
NOTE: For contracts where all conduit and wiring are furnished and installed
by others, use paragraph 'a.'
For contracts where all conduit and wiring are on the hoist and are furnished
and installed under this contract, use paragraph 'b.'
For contracts where the conduit and wiring on the hoist are furnished and installed
under this contract and the connections to remotely located items are made under
a subsequent contract, use paragraph 'c.'
The hoist motor, motor brake, controller, limit switch, and master control station shall be installed on the
[hoist frame] [as shown on contract drawings].
[a. The conduit and wiring connections external to the items of electrical equipment previously mentioned
will not be furnished or installed under this contract.]
[b. The conduit and wiring connections external to these previously mentioned items of electrical equipment
shall be furnished, installed, and connected complete and ready for operation. The conduit, wiring,
and connections for the incoming power will be made by others under a subsequent contract.]
[c. The conduit and wiring connections external to these previously mentioned items of electrical equipment
which are installed on the hoist frame shall be furnished, installed, and connected complete and ready
for operation. The conduit and wiring connections to the remotely located control equipment and the
incoming power connections will be made by others under a subsequent contract.]
d. All wiring shall be installed in rigid hot-dip galvanized metal conduit with threaded-type fittings
(Condulets) and zinc-coated watertight outlet and pull boxes. The conduit shall be securely mounted
and fastened to the hoist framework and shall be installed in a neat and workmanlike manner. Change
of direction of a conduit run shall be made by means of threaded-type fittings (Condulets) or factory
fabricated bends, and the conduit shall be installed to fit close to the hoist framework. Conduit unions
shall be used whenever it is necessary to join conduits that are to be turned right and left. No running
threads will be permitted. Ends of conduits shall be carefully reamed. All threaded connections shall
be made up with electrically conductive colloidal copper rust-inhibiting compound or other suitable compound.
Separate conduit systems shall be provided for power and control circuits. The entire conduit system
shall be grounded and shall be installed so that any moisture will be drained away from terminal boxes
and equipment. All conduit connections to equipment enclosures shall be of the watertight threaded type.
Suitable "drain-breather" devices shall be provided at all low points of the conduit system to prevent
an accumulation of water. All conductors shall be terminated in an approved manner. Indented terminals
shall be used on No. 12 AWG and larger conductors and shall be terminated on screw or stud terminals.
Toothed lock washers shall be used on all screw terminals and locking nuts or lock washers shall be used
on all stud terminals.
2.8 HEATERS - GENERAL
Enclosure heaters shall be strip type constructed with a chrome-nickel heating element embedded in a refractory
insulating material and encased in an approved watertight, corrosion-resisting, nonoxidizing metal sheath. The
rate of heat dissipation shall be uniform throughout the effective length. Watt density shall not exceed 20
watts per square inch for chrome-nickel type.
2.8.1 Heater Ratings
Heaters shall be of such rating that, when energized, the temperature of the windings or enclosure will be held
approximately 10C above ambient. They shall be designed for 120 volts AC and for continuous operation under
the conditions of installation. The rate of heat dissipation shall be uniform throughout their effective length.
2.8.2 Insulation
Insulation for the heating cable (winding wrap around type) heaters shall be suitable for a conductor temperature
of 180C.
2.8.3 Heater Terminals
The terminals of the heater, including the leads, shall be watertight. The leads shall be terminated and sealed
in a watertight terminal box located as selected by the motor manufacturer. The method of sealing shall be as
specified for the motor winding leads.
2.9 TESTS
NOTE: If designer elects to do operational tests of the gate hoist equipment,
in conjunction with testing of the hoist itself, the hoist specification number
must be included.
Each item of equipment furnished, one of each rating and type and selected at random by the Contracting Officer,
shall be given a complete test. The remaining items of equipment shall be given a routine test. All complete
tests required herein shall be witnessed by the Contracting Officer, unless waived in writing, and no equipment
shall be shipped until it has been approved for shipment by the Contracting Officer. Notify the Contracting
Officer sufficiently in advance of the date of the tests, so that arrangements can be made for the Contracting
Officer to be present at the tests. The test equipment and the test methods used shall conform to the applicable
requirements of ANSI, IEEE, and NEMA standards and shall be subject to the approval of the Contracting Officer.
Certified copies of "Complete Tests" on duplicate equipment may be accepted with the approval of the Contracting
Officer. No substitute will be accepted for the routine test. The cost of performing all tests shall be borne
by the Contractor and shall be included in the price bid. [Operational tests shall be made on the equipment
in conjunction with the tests specified in [_____] for the assembled hoist.] [Operational tests shall be made
on equipment after it is installed.]
2.9.1 Motor Tests
All tests shall be performed in accordance with the requirements of IEEE Std 112 for three-phase induction motors.
2.9.1.1 Complete Motor Tests
The complete tests shall include the following:
a. Excitation test.
b. Impedance test.
c. Performance and speed-torque test (Prony brake or other approved method).
d. Temperature test.
e. Insulation resistance tests. Measurements shall be taken following temperature test with readings
taken at approximately 10C intervals. Temperature shall be determined by the resistance method.
f. Dielectric test.
g. Cold and hot resistance measurement.
h. Effectiveness of enclosure.
i. Motor winding heater test.
(1) Successful operation.
(2) Dielectric.
2.9.1.2 Routine Motor Tests
The routine tests shall include the following:
a. Excitation test: (One point - no load, volts, amperes, and watts.)
b. Impedance test: (One point - half-voltage amperes and watts.)
c. General operation.
d. Insulation resistance - temperature test (one point).
e. Resistance measurements.
f. Dielectric.
g. Motor winding heater test.
(1) Successful operation.
(2) Dielectric.
h. [Interrupter].
2.9.2 Brake Tests
2.9.2.1 Complete Brake Tests
The complete tests shall include the following:
a. Check operation of brake release at the specified rated brake torque for rated and 85 percent terminal
voltage.
b. Heat run on release magnet at the specified rated brake torque and voltage.
c. Insulation resistance of release magnet including leads and terminal block.
d. Resistance measurements of release.
e. Dielectric test of release magnet including leads and terminal block.
f. Brake space heater test.
(1) Successful operation.
(2) Dielectric.
2.9.2.2 Routine Brake Tests
The routine tests of the brake shall be the same as specified in paragraph COMPLETE BRAKE TESTS, except that
the heat run tests shall be omitted.
2.9.3 Controller Tests
2.9.3.1 Complete Controller Tests
The complete tests shall include all tests listed in paragraph ROUTINE CONTROLLER TESTS, and the following:
a. Effect of voltage and frequency variation.
b. Temperature Test.
2.9.3.2 Routine Controller Tests
The routine tests shall include the following:
a. Adjustment, fit, and material.
b. Successful operation.
c. Resistance.
d. Dielectric.
e. Insulation Resistance.
f. Enclosure space heater test.
(1) Successful operation.
(2) Dielectric.
2.9.4 Limit-Switch Tests
Each drive shall be tested in the manufacturers shop by suitable means, simulating service conditions, to ascertain
that it will transmit the correct information for the control sequence specified. In addition, the routine tests
shall include the following:
a. Adjustment, fit, and material.
b. Accuracy of trip and reset.
c. Successful operation.
d. Dielectric.
e. Insulation resistance.
2.9.5 Wiring Tests
All wiring shall be given a dielectric test following installation by applying, for 5 minutes, a voltage test
of 1,500 volts to each circuit and ground and between each conductor and all other conductors in the same conduit.
PART 3 EXECUTION [(Not Applicable)]
NOTE: Designer should place any requirements for field installation in this
section.
[_____].
Plate No. 1
CREST GATE
ELECTRICAL CONTROL SYSTEM
(With Approximately 1.0 Foot Increments)
DESCRIPTION OF CONTROL SYSTEM
1. SCHEME OF OPERATION
a. General. The control system for the gate shall be as indicated by the schematic control wiring diagram,
and as specified below.
b. Control Points. The operation of the hoist motor shall be controlled by:
(1) A push button station located on the gate hoist with momentary contacts designated "RAISE,
"LOWER," and "STOP."
(2) A push button station located on the door of the controller cabinet with momentary contacts
designated "BACKOUT FROM RAISE OVER TRAVEL" and "BACKOUT FROM LOWER OVER TRAVEL."
c. Operating Features
(1) Actuation of the "RAISE" and LOWER" contacts shall provide seal-in operation.
(2) A limit switch geared or directly connected to the hoist machine, shall control the incremental
and stopping operations initiated manually from the control station as described under sequence
of operation.
(3) Actuation of the "STOP" contact during any operation shall stop the hoist motor and set
the brake.
2. SEQUENCE OF OPERATION
a. Raising
(1) When the gate is between the closed and the intermediate position, each actuation of the
"RAISE" contact will cause the gate to raise approximately 1 foot and stop.
(2) When the gate is at or above the intermediate position, actuation of the "RAISE" contact
will cause the gate to raise continuously to the raised position.
b. Lowering
(1) When the gate is between the over travel raised position and the intermediate position,
actuation of the "LOWER" contact will cause the gate to lower continuously to the intermediate
position and stop.
(2) When the gate is at or below the intermediate position and is above the closed position,
each actuation of the "LOWER" contact will cause the gate to lower approximately 1 foot and
stop.
c. Over Travel. If during normal operation, the gate motor should fail to stop when the gate reaches
the raised or closed positions, the over travel limit switch contacts shall stop the hoist motor after
over travel by de-energizing the "main" or "line" contactor of the controller. To operate the gate after
an over travel, the appropriate backout switch contact shall be held closed to permit operation of the
gate only in the direction away from the over travel position after operation of either the "RAISE" or
"LOWER" contact on the master control station.
Plate No. 2
CREST GATE
ELECTRICAL CONTROL SYSTEM
(With Approximately 0.5 Foot Increments)
DESCRIPTION OF CONTROL SYSTEM
1. SCHEME OF OPERATION
a. General. The control system for the gate shall be as indicated by the schematic control wiring diagram,
and as specified below.
b. Control Points. The operation of the hoist motor shall be controlled by:
(1) A push button station located on the gate hoist with momentary contacts designated "RAISE,"
"LOWER" and "STOP."
(2) A push button station located on the door of the controller cabinet with momentary contacts
designated "BACKOUT FROM RAISE OVER TRAVEL" and "BACKOUT FROM LOWER OVER TRAVEL."
c. Operating Features
(1) Actuation of the "RAISE" and "LOWER" contacts shall provide seal-in operation.
(2) A limit switch geared or directly connect to the hoist machine, shall control the incremental
and stopping operations initiated manually from the control station as described under sequence
of operation.
(3) Actuation of the "STOP" contact during any operation shall stop the hoist motor and set
the brake.
2. SEQUENCE OF OPERATION
a. Raising
(1) When the gate is between the closed position and the first intermediate position, each
actuation of the "RAISE" contact will cause the gate to raise approximately 0.5 foot and stop.
(2) When the gate is at or above the first intermediate position and is below the second intermediate
position, each actuation of the "RAISE" contact will cause the gate to raise approximately 1
foot and stop.
(3) When the gate is at or above the second intermediate position, actuation of the "RAISE"
contact will cause the gate to raise continuously to the raised position.
b. Lowering
(1) When the gate is between the over travel raised position and the second intermediate position,
actuation of the "LOWER" contact will cause the gate to lower continuously to the second intermediate
position and stop.
(2) When the gate is at or below the second intermediate position and above the first intermediate
position, each actuation of the "LOWER" contact will cause the gate to lower approximately 1
foot and stop.
(3) When the gate is at or below the first intermediate position and is above the closed position,
each actuation of the "LOWER" contact will cause the gate to lower approximately 0.5 foot and
stop.
NOTE:
c. Over Travel. If during normal operation, the gate motor should fail to stop when the gate reaches
the raised or closed positions, the over travel limit switch contacts shall stop the hoist motor after
over travel by de-energizing the "main" or "line" contactor of the controller. To operate gate after
an over travel, the appropriate backout switch contact shall be held closed to permit operation of the
gate only in the direction away from the over travel position after operation of either the "RAISE" or
"LOWER" contact on the master control station.
Plate No. 3
CREST GATE
ELECTRICAL CONTROL SYSTEM
DESCRIPTION OF CONTROL SYSTEM
(With Remote Control and Approximately 1.0 Foot Increments)
1. SCHEME OF OPERATION
a. General. The control system for the gate shall be as indicated by the schematic control wiring diagram,
and as specified below.
b. Control Points. The operation of the hoist motor shall be controlled by:
(1) A push button selector switch station located on the gate hoist with momentary push button
contacts designated "RAISE", "LOWER", and "STOP" and selector switch contacts designated "LOCAL"
and "REMOTE."
(2) A push button station located on the door of the controller cabinet with momentary contacts
designated "BACKOUT FROM RAISE OVER TRAVEL" and "BACKOUT FROM LOWER OVER TRAVEL."
(3) A push button station, located on the spillway gate remote control board with momentary
contacts designated "RAISE", "LOWER", and "STOP."
(4) A synchronous type indicator, located on the spillway gate remote control board to show
the gate position.
c. Operating Features
(1) Actuation of the "RAISE" and "LOWER" contacts of the remote or local control station shall
provide seal-in operation.
(2) The position of the "REMOTE-LOCAL" control switch will determine which station is operative.
(3) The remote control shall utilize direct current interposing relays.
(4) A limit switch geared or directly connected to the hoist machine, shall control the incremental
and stopping operations initiated manually from the control station as described under sequence
of operation.
(5) Actuation of the "STOP" contact during any operation shall stop the hoist motor and set
the brake.
2. SEQUENCE OF OPERATION
a. Raising
(1) When the gate is between the closed position and the intermediate position, each actuation
of the "RAISE" contact will cause the gate to raise approximately 1 foot and stop.
(2) When the gate is at or above the intermediate position, actuation of the "RAISE" contact
will cause the gate to raise continuously to the raised position.
b. Lowering
(1) When the gate is between the over travel raised position and the intermediate position,
actuation of the "LOWER" contact will cause the gate to lower continuously to the intermediate
position and stop.
(2) When the gate is at or below the intermediate position and is above the closed position,
each actuation of the "LOWER" contact will cause the gate to lower approximately 1 foot and
stop.
c. Over Travel. If during normal operation, the gate motor should fail to stop when the gate reaches
the raised or closed positions, the over travel limit switch contacts shall stop the hoist motor after
over travel by de-energizing the "main" or "line" contactor of the controller. To operate the gate after
an over travel, the appropriate backout switch contact shall be held closed to permit operation of the
gate only in the direction away from the over travel position after operation of either the "RAISE" or
"LOWER"contact on the master control station.
Plate No. 4
CREST GATE
ELECTRICAL CONTROL SYSTEM
DESCRIPTION OF CONTROL SYSTEM
(With Remote Control and Approximately 0.5 Foot Increments)
1. SCHEME OF OPERATION
a. General. The control system for the gate shall be as indicated by the schematic control wiring diagram,
and as specified below.
b. Control Points. The operation of the hoist motor shall be controlled by:
(1) A push button selector switch station located on the gate hoist with momentary push button
contacts designated "RAISE", "LOWER", and "STOP" and selector switch contacts designated "LOCAL"
and "REMOTE."
(2) A push button station located on the door of the controller cabinet with momentary contacts
designated "BACKOUT FROM RAISE OVER TRAVEL" and "BACKOUT FROM LOWER OVER TRAVEL."
(3) A push button station, located on the spillway gate remote control board with momentary
contacts designated "RAISE", "LOWER", and "STOP."
(4) A synchronous type indicator, located on the spillway gate remote control board to show
the gate position.
c. Operating Features
(1) Actuation of the "RAISE" and "LOWER" contacts of the remote or local control station shall
provide seal-in operation.
(2) The position of the "REMOTE-LOCAL" control switch will determine which station is operative.
(3) The remote control shall utilize direct current interposing relays.
(4) A limit switch geared or directly connected to the hoist machine, shall control the incremental
and stopping operations initiated manually from the control station as described under sequence
of operation.
(5) Actuation of the "STOP" contact during any operation shall stop the hoist motor and set
the brake.
2. SEQUENCE OF OPERATION
a. Raising
(1) When the gate is between the closed position and the first intermediate position, each
actuation of the "RAISE " contact will cause the gate to raise approximately 0.5 foot and stop.
(2) When the gate is at or above the first intermediate position and is below the second intermediate
position, each actuation of the "RAISE" contact will cause the gate to raise approximately 1
foot and stop.
(3) When the gate is at or above the second intermediate position, actuation of the "RAISE"
contact will cause the gate to raise continuously to the raised position.
b. Lowering
(1) When the gate is between the over travel raised position and the second intermediate position,
actuation of the "LOWER" contact will cause the gate to lower continuously to the second intermediate
position and stop.
(2) When the gate is at or below the second intermediate position and above the first intermediate
position, each actuation of the "LOWER" contact will cause the gate to lower approximately 1
foot and stop.
(3) When the gate is at or below the first intermediate position and is above the closed position,
each actuation of the "LOWER" contact will cause the gate to lower approximately 0.5 foot and
stop.
c. Over Travel. If during normal operation, the gate motor should fail to stop when the gate reaches
the raised or closed positions, the over travel limit switch contacts shall stop the hoist motor after
over travel by de-energizing the "main" or "line" contactor of the controller. To operate the gate after
an over travel, the appropriate backout switch contact shall be held closed to permit operation of the
gate only in the direction away from the over travel position after operation of either the "RAISE" or
"LOWER" contact on the master control station.
Plate No. 5
OUTLET CONTROL DATE
ELECTRICAL CONTROL SYSTEM
DESCRIPTION OF CONTROL SYSTEM
(Single-speed Motor)
1. SCHEME OF OPERATION
a. General. The control system for the gate shall be as indicated by schematic control wiring diagram,
and as specified below.
b. Control Points. The operation of the hoist motor shall be controlled by:
(1) A push button station located on the gate hoist with contacts designated "RAISE," "CONDUIT
OPEN," "LOWER," and "STOP."
(2) A push button station located on the gate hoist with momentary contacts designated "BACKOUT
FROM LOWER OVER TRAVEL" and "BACKOUT FROM RAISE OVER TRAVEL."
(3) A pendant push button station with momentary contacts designated "INCH UP" and "INCH DOWN,"
provided with a portable cable of suitable length to permit operation from the inspection room.
The cable shall terminate in a polarized plug matching receptacle located on motor controller
cabinet or other suitable place.
c. Operating Features
(1) Actuation of the "RAISE", "CONDUIT OPEN", and "LOWER" contacts of the push button station
shall provide seal-in operation.
(2) Actuation of the "INCH UP" and "INCH DOWN" contacts of the pedant push button station shall
not provide seal-in operation.
(3) Actuation of the "STOP" contact during any operation shall stop the hoist motor and set
the brake.
(4) A limit switch geared to directly connected to the hoist machine shall control the incremental
and stopping operations initiated manually from the control station as described under sequence
of operation.
2. SEQUENCE OF OPERATION
a. Raising
(1) When the gate is between the closed position and the raised position, actuation of the
"RAISE" contact will cause the gate to open continuously to the raised position.
(2) When the gate is between the closed position and the conduit open position, actuation of
the "CONDUIT OPEN" contact will cause the gate to open continuously to the conduit open position.
b. Lowering. When the gate is between the over travel raised position and the closed position, actuation
of the "LOWER" contact will cause the gate to lower continuously to the closed position.
c. Inching
(1) To raise the gate above the raised position the "INCH UP" contact shall be held closed.
The gate will be stopped at upper inch position by the limit switch.
(2) To lower the gate when it is above the raised position the "INCH DOWN" contact shall be
held closed. The gate will be stopped at the raised position by the limit switch.
d. Over Travel
(1) Over travel limit switches shall stop the driving motor if it fails to stop at the raised
or closed position on the gate.
(2) The "BACKOUT FROM LOWER OVER TRAVEL" or "BACKOUT FROM RAISE OVER TRAVEL" contact shall
be held closed to operate the gate from over travel closed and over travel raised, respectively.
Plate No. 6
OUTLET CONTROL GATE
ELECTRICAL CONTROL SYSTEM
DESCRIPTION OF CONTROL SYSTEM
(Multispeed Motor)
1. SCHEME OF OPERATION
a. General. The control system for the gate shall be as indicated by the schematic control wiring diagram,
and as specified below.
b. Control Points. The operation of the hoist motor shall be controlled by:
(1) A push button station located on the gate hoist with momentary contacts designated "RAISE",
"CONDUIT OPEN", "LOWER", and "STOP."
(2) A push button station located on the gate hoist with momentary contacts designated "BACKOUT
FROM LOWER OVER TRAVEL" and "BACKOUT FROM RAISE OVER TRAVEL."
(3) A pendant push button station with momentary contacts designated "INCH UP" and "INCH DOWN",
provided with a portable cable of suitable length to permit operation from the inspection room.
The cable shall terminate in a polarized plug matching receptacle located on motor controller
cabinet or other suitable place.
c. Operating Features
(1) Actuation of the "RAISE", "CONDUIT OPEN", and "LOWER" contacts of the push button station
shall provide seal-in operation.
(2) Actuation of the "INCH UP" and "INCH DOWN" contacts of the pedant push button station shall
not provide seal-in operation.
(3) Actuation of the "STOP" contact during any operation shall stop the hoist motor and set
the brake.
(4) A limit switch geared to be directly connected to the hoist machine shall control the incremental
and stopping operations initiated manually from the control station as described under sequence
of operation.
2. SEQUENCE OF OPERATION
a. Raising
(1) When the gate is between the closed position and the raised position, actuation of the
"RAISE" contact will cause the gate to open continuously at low speed to the conduit open position.
(2) When the gate is between the closed position and the conduit open position, actuation of
the "CONDUIT OPEN" contact will cause the gate to open continuously at low speed to the conduit
open position where the limit switch shall cause the gate to open continuously at high speed
to the raised position. (3) When the gate is between the conduit open position and the raised
position, actuation of the "RAISED" contact will cause the gate to open continuously at high
speed to the raised position.
b. Lowering
(1) When the gate is between the over travel raised position and conduit open position, actuation
of the "LOWER" contact will cause the gate to lower continuously at high speed to the conduit
open position where the limit switch shall cause the gate to close continuously at low speed
to the closed position.
(2) When the gate is between the conduit open position and the closed position, actuation of
the "LOWER" contact will cause the gate to lower continuously at low speed to the closed position.
c. Inching
(1) To raise the gate above the raised position the "INCH UP" contact shall be held closed.
The gate will be stopped at upper inch position by the limit switch.
(2) To lower the gate when it is above the raised position the "INCH DOWN" contact shall be
held closed.
(3) The gate will be stopped at the raised position by the limit switch.
d. Over Travel
(1) Over travel limit switches shall stop the driving motor if it fails to stop at the raised
or closed position or the gate.
(2) The "BACKOUT FROM LOWER OVER TRAVEL" or "BACKOUT FROM RAISE OVER TRAVEL" contact shall
be held closed to operate the gate from over travel closed and over travel raised, respectively.
Plate No. 7
INTAKE GATE
ELECTRICAL CONTROL SYSTEM
DESCRIPTION OF CONTROL SYSTEM
1. SCHEME OF OPERATION
a. General. The control system for the gate shall be as indicated by the schematic control wiring diagram,
and as specified below.
b. Control Points. The operation of the hoist motor shall be controlled by:
(1) A push button station located on the gate hoist with momentary contacts designated "RAISE,"
"LOWER," and "STOP."
(2) A push button station located on the door of the controller with momentary contacts designated
"BACKOUT FROM LOWER OVER TRAVEL" and "BACKOUT FROM RAISE OVER TRAVEL."
(3) A pendant push button station with momentary contacts designate "INCH UP" and "INCH DOWN,"
provided with a portable cable of suitable length to permit operation from the inspection room.
The cable shall terminate in a polarized plug matching receptacle located on motor controller
cabinet or other suitable place.
c. Operating Features
(1) Actuation of the "RAISE" and "LOWER" contacts of the push button station shall provide
seal-in operation.
(2) Actuation of the "INCH UP" and "INCH DOWN" contacts of the pendant push button station
shall not provide seal-in operation.
(3) Actuation of the "CLOSE" contact of the emergency lower switch shall provide seal-in operation.
(4) Actuation of the "STOP" contact during any operation shall stop the hoist motor and set
the brake.
(5) A "balanced-pressure switch" with normally closed contact.
(6) A limit switch geared or directly connected to the hoist machine shall control the incremental
and stopping operations initiated manually from the control station as described under sequence
of operation.
(7) Gate position indicating lights as follows:
(a) A red light on push button station and with emergency lower switch indicating gate is in
normal operating position.
(b) A green and blue light with emergency lower switch indicating gate is in closed and raised
position, respectively.
(c) Am amber light with emergency lower switch indicating gate is closing.
2. SEQUENCE OF OPERATION
a. Raising. When the gate is between the closed position and the raised position, actuation of the
"RAISE" contact will cause the gate to open continuously to the raised position. If there is a pressure
difference between the two sides of the gate, the gate will stop at the cracked position. After pressure
is balanced actuation of the "RAISE" contact will cause the gate to open to the raised position.
b. Lowering. When the gate is between the over travel raised position and the closed position, actuation
of the "LOWER" contact will cause the gate to lower continuously to the closed position.
c. Normal Operating Position
(1) The gate is placed in the normal operating position by either the raising or lowering operation
described above.
(2) The red light indicates the gate is in normal position.
(3) Actuation of the "STOP" contact of the push button station stops the gate.
d. Emergency Closing. When the gate is between the normal position and the closed position, actuation
of the "CLOSE" contact of the emergency lower switch will cause the gate to lower continuously to the
closed position.
e. Inching
(1) To raise the gate above the raised position the "INCH UP" contact shall be held closed.
Gate will be stopped at upper inch position by the limit switch.
(2) To lower the gate when it is above the raised position the "INCH DOWN" contacts shall be
held closed. Gate will be stopped at the raised position by the limit switch.
f. Over Travel
(1) over travel limit switches shall stop the driving motor if it fails to stop at the raised
or closed position of the gate.
(2) The "BACKOUT FROM LOWER OVER TRAVEL" or "BACKOUT FROM RAISE OVER TRAVEL" contact shall
be held closed to operate the gate from over travel closed and over travel raised, respectively.